Kawasaki ZL500/ZL600 1986 Service Manual Supplement (P/N 99924-1073-51)

Kawasaki factory service publication P/N 99924-1073-51 covers the 1986 ZL500-A1 European model and ZL600-A1 US and non-US models. It supplies model-specific service information for use with a separate Base Manual, which is not included.

PDF Access and Wiring Diagram Detail

Search, navigation, and small labels: PDF text search and embedded bookmarks are not available. Small wiring labels require magnification, and some fine lettering on the full wiring diagrams remains blurred when enlarged.

The ZIP download contains one printable, English-language 131-page PDF: 129 chapter pages and two unnumbered reference pages covering model application and abbreviations. Both reference pages are already included in the total.

ZL Service Changes and Shaft-Drive Repair

The following selected coverage highlights the main workshop sections. Additional topics include seat and fender removal, general lubrication, and fastener checks.

• Fuel system: Keihin CVK30 calibration differences, throttle-cable adjustment, carburetor-bank removal, surge-tank and air-cleaner service, fuel-tank removal, and California evaporative-emission routing.

• Cooling system: Coolant replacement, radiator and fan removal, thermostat-housing access, hose routing, and model-specific cooling-system changes.

• Engine service: Cylinder-head-cover removal, revised camshaft timing references, valve adjustment, piston-ring installation notes, oil-filter access, and engine removal and installation.

• Clutch repair: Deceleration torque-limiting clutch operation, clutch-pack removal and inspection, spring-plate free-play measurement, steel-plate selection, and damper-cam checks.

• Shaft-drive overhaul: Final and front bevel-gear cases, propeller shaft, bearing preload, shim selection, backlash measurement, tooth-contact adjustment, and bearing and seal work.

• Chassis service: Wheel removal, rear hub bearings, drum-brake repair, fork overhaul, rear-shock adjustment, swingarm alignment, and steering-stem service.

• Electrical diagnosis: Junction-box fuse, relay, and diode tests; tachometer and warning-system checks; harness routing; and separate US/Canadian and other-market wiring diagrams.

Its concise factory procedures, specialty-tool requirements, and frequent cross-references make it suited to experienced motorcycle technicians or advanced owners with proper lifting and measuring equipment and access to the separate Base Manual.

Model Differences and Base-Manual Requirements

The A1-specific specifications and illustrations distinguish the two Eliminator models rather than treating them as interchangeable. Market symbols identify Canadian, California, US, and Swiss variations where applicable.

Entries marked “Refer to Base Manual” direct full carburetor synchronization and overhaul, water-pump repair, most internal engine and transmission work, front-caliper and master-cylinder repair, and numerous electrical component tests to that separate publication. The included pages supply the ZL-specific changes and procedures.

Fuel Calibration and Cooling Changes

The CVK30 tables separate the models’ jetting, jet needles, and pilot settings, including US and California differences. The California emissions diagram identifies the canister, separator/return pump, and associated hose connections.

Cooling-system illustrations show the thermostat-mounted coolant temperature switch that replaces the water temperature sensor. The service material also addresses reservoir-hose routing and clearance around the frame and exhaust.

Engine Access and Torque-Limiting Clutch

The engine instructions account for access around the Eliminator chassis, including cylinder-head-cover clearance and oil-filter removal past the muffler connecting pipe. Revised camshaft-sprocket drawings, valve-clearance measuring positions, and piston-ring cross sections accompany the model-specific notes.

The crankshaft/transmission material identifies the toothed drive-shaft washer and output-shaft damper-cam changes through exploded views and Base Manual references.

Clutch setup connects spring-plate free play with deceleration behavior: insufficient clearance can cause rear-wheel hop, while excessive clearance can produce a spongy or pulsating lever. Pulling the clutch release shaft during cover removal damages the cover oil seal and requires seal replacement.

Named tools include valve-adjusting-screw holder 57001-1217 and clutch holder 57001-305.

Bevel-Gear Setup and Propeller-Shaft Service

Step-by-step procedures cover gear-case removal and disassembly, propeller-shaft inspection, joint lubrication, and reassembly. Bearing-preload checks, shim tables, and drive/coast tooth-contact patterns support gear setup after component replacement.

The ring and pinion are factory-lapped pairs; replacing one gear alone or changing original shim positions can disturb contact and damage the drive. The manual also warns that torch-heating a gear case can warp it.

Pinion-gear holder 57001-1164 and dial-gauge holder 57001-1049 are among the specified measuring and holding tools.

Chassis Adjustment and Electrical Fault Tracing

The tire tables identify Dunlop F17G and K255 applications, with sizes, pressures, tread limits, and market-specific load data. Fork material includes oil service, disassembly, and seal installation using cylinder tools 57001-183 and 57001-1057.

Rear-shock coverage addresses preload, damping, removal, and external inspection; the shocks are sealed units rather than internally rebuildable assemblies. Swingarm material includes pivot alignment and bearing lubrication.

Electrical diagrams distinguish US/Canadian and European headlight circuits. Tachometer and coolant-warning tests accompany junction-box terminal checks, including market differences in the headlight-relay circuit. The engine-oil flow chart and wiring-routing illustrations provide additional component context.

The appendix supplies symptom-based troubleshooting for starting difficulty, poor running, overheating, shifting faults, abnormal noise, handling problems, and charging complaints.

Factory safety notes address secure hoist support, the warning not to place a stand under the exhaust power chamber, fuel and hot-coolant hazards, a radiator fan that can run with the ignition off, and asbestos precautions for rear brake-lining work.

Clutch Clearance and Bevel-Gear Specification Preview

Clutch setup distinguishes spring-plate free play of 0.50–0.95 mm with all new friction plates from 0.50–1.20 mm when the original friction plates are reused. The accompanying steel-plate chart supports thickness selection.

For shaft-drive adjustment, the tables specify 0.08–0.11 mm final bevel-gear backlash and 0.10–0.15 mm front bevel-gear backlash. Separate shim tables and tooth-contact illustrations accompany these measurements.