zr550 in bits

[pj1960]

Hi BCF.

Newbie here

just wondering I have a Zr550 zephyr, frame with engine in and wheels on now. but have lots of other parts in boxes. I'm led to believe all parts are present. wondering if there is any one that could help in locating where other parts like electrics are to be located.
do you think a Haynes manual would help me see where other parts go.
Cheers PJ

[Easy-X]

Um... have you reassembled many bikes or has the Covid-boredom finally got to you?

A Haynes manual would definitely be worth getting but I'd have a look at some parts diagrams for that model. For example:

https://www.cmsnl.com/kawasaki-zr550a2-1984-europe-uk-wg_model12709/partslist/
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]

If you can get hold of a copy of a proper kawasaki workshop manual for it, they usually have the wiring, hose and cable layouts in them.

Your haynes/clymer manual will have a lot of pictures in but also detailed descriptions of dissassembly/reassembly.

The manufacturers manuals have all the details you would need to service the bike but assume you know how to do things because they are designed for professional mechanics. So it'll list clearances, tolerances, torque ratings and suchlike and has detailed diagrams of how the parts fit together but the actual doing of the servicing is largely left to your own devices.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Bhud]

Hi

The Haynes manual for the Kawasaki 550s (called "Kawasaki 400, 500 and 550 Fours") has everything you need in it. The electrics diagrams are in black and white but they're labelled up with the correct colours.

As far as Haynes manuals go, they're 1980s Haynes manuals (lousy formatting, bad photos, etc.) but complete. If you have any specific questions, state them here (I'll fill you in if I have the answer) or on kzrider.com.

The mechanicals of the 550s are mostly interchangeable (check first) although not the same, but the ignition systems aren't.

[stinkwheel]

[redeem ouzzer]

The Haynes manual is as useless as tits on a fish. If you need to find out where things mount or how stuff routes get the Kawasaki shop manual.
____________________
Be a REAL MAN!

[Bhud]

OK, it's not going to help you put every part in the right place, but it does show where and how to locate and attach the indicator relay, diode pack, IC igniter and coils. Not much, sure, and the owner's manual would probably be a better bet (I don't have one) if the question is where to put the electrics. It's well worth having anyway for the detailed blow-ups of mechanical parts: all sorts of things from the brake master cylinder, brake calipers, forks, frame, fork yoke, engine components (all), swingarm, shocks, etc. You won't miss out a spacer or a washer if you've got the Haynes.

[pj1960]

Thank you for your replies, think I'll send off for a manual.
Then hopefully soon it'll be back together unless theres something missing.
Cheers

[Easy-X]

While you're waiting for the manual to turn up may I suggest you start looking at those parts diagrams and gather all the bits up - a box for each parts page, for example.
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter