1993 kawasaki GPZ 500 S - GPX 500 R - Answered Questions & Fixed issues
Wont get 23456 gear just 1st and neutral
That indicates a bent shift fork in the transmission. This is a costly repair and is not recommended for the novice. Some special tools are required. A bent fork will not slide freely to change gears. Contact a dealer to confirm my diagnosis. Please rate my answer. Thanks.
Wich mark is tdc
the tdc mark is the C mark. turn the engine clockwise until the right cylinder is at the top and both cams are facing away from the rocker arms.The C mark should be line up with the notch in the upper hole.
Turn slowly as the piston comes up as it will spin past quickly and you will have to go all the way around again.
hope this helps.
GPZ 500 - starter chain spins on cogs
First may I say I don't know for sure your bike model that well (In- line 4 cylinder or water cooled twin?) BUT I am very experienced with motorcycles ( I am a qualified motorcycle mechanic & have owned GPZ 550, Z650, ZIR-II ).
For starters Kwasaki have used two different methods of delivering drive from the starter motor to the engine. Gear driven & chain driven. The chain driven type ( like GPZ 900 R ) were equiped with a tensioner. If yours has a tensioner be sure to change it with a new one also.
Both of the styles of drives ( chain & gear ) incorporate what is called a starter clutch mechanism.
This is what allows drive from the starter motor to be applied only when the starter motor is activated & free wheel when the engine runs. It is a one way clutch mechanism.
I am explaining this because a verry common fault on all electric start bikes is the starter clutch. ( except Moto-Guzzi, BMW, Harley which use a car style starter with a sliding pinion ).
When the starter clutch is faulty it displays a very distinct symptom.
When the starter motor is activated, you will hear a "whizz" followed by a crunching noise rather reminicent of a chain jumping teeth on a sprocket.
If this is the case with your bike & is what is what led you to change the chain, plus is what your continueing problem is, I would suggest you check the starter clutch.
The starter clutch comprises of a drive gear(the one that the chian, or startor motor output shaft drives), 3 rollers, three springs with guide pins, & the housing plate for the rollers & springs with guides.
To effectivly repair a starter clutch it is necessary to replace the gear, the 3 rollers, the 3 springs, sometimes the housing plate if it is also worn (from the rollers moveing)
I am hopefull this may shed some light as to the cause of your problem.
If not please post a comment & I'll try to help you further.
Regards Andrew porrelli
Starter motor
Check the battery is fully charged for a start. Secondly i would test the starter solenoid usually found under the seat, it is identified as a square box with 2 large leads and 2 smaller wires. one of the large leads go down to starter, the other goes up to battery. very carefully cross these out, ensuring the bike is in NEUTRAL before hand. The engine should turn. If all this still fails, replace starter.
Change fork seals Kawasaki GPZ 400
If you are not VERY mechanically inclined...and have the special tools required... .please take this to a professional!! it will be less expensive in the long run.!!
It takes some special tools that only dealers have.
I lost my key to
Before you attempt to take out the ignition, call a dealer and ask him if they can get you a key for your bike by using the VIN as reference. Harley and some metrics can do it this way.
No fire to the motor
check coil or wire from coil. could be blown fuse or bad brain...aka CDI in which case you could open it after locating it and possibly discover a bloated capacitor which you can snip off and solder in a new one for 2 bucks. at a radio shack or electronics parts store
Motorbike wont move
sidestand lockout switch is sticking...bike thinks that you're trying to ride away with the stand down so it kills the sparks.
How do u no if ur coil packs are fireing
If you have a wiring diagram, trace out the ignition system this way you trace problems. But you could pull the plugs and put them in the wire and ground it against the head, away from the spark plug hole, turn the engine over and see if it fires, i use a spark tester, but a known good plug will do. If there is no spark then check to see if you have volts at the primary side of coil "the little wires that hook to it test them with the ignition on" if no volts there then begin your volt chace checking all wire and connectors. You will need a multi meter ok. let me know how it goes, just takes patience and time k.
It drives great 1st gear
The cakey, white oil color is water emulsified with the oil. Rainwater, car wash spray, condensation in the tranny, rain water or sprinklers have contaminated the oil. If the tranny will not shift into a higher gear, there is a bent shift fork or two creating the problem. This can be a costly repair and is not recommended for the novice mechanic. Below is a diagram showing how the shift drum rotates to move shift forks left and right to change gears.
Took the carbs off toclean
I would say if you have not messed with the adjutments on your carbs , they are prob ok.
It sounds like if you drain your fuel, tank, all filters, what is left in the carbs
will work it self out, you can remove and drain either way. Go buy new spark plugs and filters
Charge your battery to full charge slow trickle while you working on the other . I am confident that you will be happy with the results .
How can i start a
boost it, it should stay running if the charging system is good, then you can check charging rate
Not finding what you are looking for?
In the above picture inside the rectangular box area to the left of the push rod do you see the many actuator parts that the clutch has to push the rod and disengage the clutch? One of these is broken or has come loose and jammed the clutch release mechanism, you will need to pull the assembly apart and see what has gone wrong, no matter what it has to come apart for inspection. Here is the factory parts site where I got the diagram.
