1986 Kawasaki ZL 600 Service Manual

The 1986 Kawasaki ZL 600 is a 600cc four-cylinder motorcycle featuring a DOHC engine, 6-speed transmission, air cooling system, dual front disc brakes, and shaft drive. This comprehensive service manual covers maintenance procedures, technical specifications, troubleshooting, and repair instructions for proper servicing and upkeep of your motorcycle. Below are key sections for safety, specifications, maintenance, troubleshooting, and repair procedures.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Lubrication System 5. Fuel System 6. Cooling System 7. Electrical System 8. Transmission 9. Brake System 10. Troubleshooting 11. Wiring Diagrams

General Information

Key components: 600cc DOHC inline-four engine, 6-speed constant mesh transmission, shaft final drive, dual front disc brakes with single piston calipers, air cooling system, electronic ignition.

Component	Description
Engine Type	4-stroke, DOHC, air-cooled inline-four
Displacement	592cc
Bore x Stroke	58.0 x 56.0 mm
Compression Ratio	9.5:1
Fuel System	4x Mikuni CV32 carburetors
Ignition System	Battery and coil, electronic advance
Starting System	Electric starter with kick starter backup
Transmission	6-speed, constant mesh
Final Drive	Shaft drive
Frame Type	Double cradle steel frame

Specifications

Overall Length: 2,180 mm
Overall Width: 750 mm
Overall Height: 1,120 mm
Wheelbase: 1,485 mm
Ground Clearance: 140 mm
Seat Height: 780 mm
Dry Weight: 208 kg
Fuel Capacity: 16 liters
Oil Capacity: 3.2 liters (with filter change)
Front Tire: 100/90-18
Rear Tire: 120/90-17
Front Brake: Dual hydraulic disc, 275mm
Rear Brake: Single hydraulic disc, 275mm

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

Every 1,000 km/600 miles: Check engine oil level, tire pressure, chain tension, brake fluid level.
Every 3,000 km/1,800 miles: Change engine oil and filter, check spark plugs, adjust carburetors.
Every 6,000 km/3,600 miles: Clean air filter, check valve clearance, inspect brake pads.
Every 12,000 km/7,200 miles: Replace spark plugs, check wheel bearings, inspect drive shaft.
Every 24,000 km/14,400 miles: Replace air filter, check carburetor synchronization, inspect suspension.

WARNING! Always perform maintenance with engine off and cool. Use proper safety equipment.

Lubrication System

Wet sump lubrication system with gear-type oil pump.

Oil Type: SAE 10W-40 motorcycle oil
Oil Capacity: 3.2 liters (with filter change)
Oil Change Procedure: Warm engine, drain oil, replace filter, refill with new oil
Oil Pressure: 40-55 psi at 3,000 rpm (normal operating temperature)
Oil Filter: Replace every oil change

CAUTION! Do not overfill oil. Check level with motorcycle upright.

Fuel System

Four Mikuni CV32 constant velocity carburetors with manual choke.

Carburetor Settings: Pilot screw: 2 turns out, Float level: 16.5mm
Fuel Filter: Inline filter, replace every 12,000 km
Fuel Pump: Mechanical type, check for leaks and proper operation
Carburetor Synchronization: Use vacuum gauges for balanced operation
Idle Speed: 1,100 ± 100 rpm (warm engine)

Tip: Always use fresh fuel and stabilize if storing for extended periods.

Cooling System

Air-cooled with oil cooler for improved heat dissipation.

Cooling Type: Air cooling with auxiliary oil cooler
Oil Cooler: Located behind front fender
Fins: Keep clean for optimal heat dissipation
Thermal Sensor: Monitors engine temperature

WARNING! Do not cover cooling fins or oil cooler. Ensure proper airflow.

Electrical System

12-volt electrical system with battery and alternator.

Component	Specification
Battery	12V 14Ah
Alternator	Three-phase AC generator
Output	280W at 5,000 rpm
Spark Plugs	NGK D8EA or equivalent
Gap	0.7-0.8 mm
Fuses	Main 30A, Headlight 15A, Signal 10A
Bulbs	Headlight 60/55W, Brake 21W, Turn 21W

Transmission

6-speed constant mesh transmission with wet multi-plate clutch.

Gear Ratios: 1st: 2.571, 2nd: 1.777, 3rd: 1.380, 4th: 1.125, 5th: 0.961, 6th: 0.851
Primary Reduction: 1.719 (77/45)
Final Reduction: 1.095 (23/21)
Clutch Type: Wet multi-plate, cable operated
Clutch Adjustment: Adjust cable free play to 10-15mm

CAUTION! Use motorcycle-specific transmission oil. Do not use automotive gear oil.

Brake System

Hydraulic disc brakes front and rear with dual piston calipers.

Front Brakes: Dual 275mm discs, two-piston calipers
Rear Brake: Single 275mm disc, two-piston caliper
Brake Fluid: DOT 4
Pad Thickness: Replace when less than 1.0mm
Rotor Thickness: Minimum 4.0mm
Bleeding Procedure: Start with farthest caliper from master cylinder

WARNING! Always use fresh brake fluid. Do not reuse old fluid.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel flow, spark plugs, battery voltage, compression
Poor idle	Dirty carburetors, vacuum leak	Clean carbs, check for vacuum leaks, adjust idle mixture
Overheating	Low oil, dirty fins, lean mixture	Check oil level, clean cooling fins, check carburetion
Electrical failure	Battery, alternator, or wiring	Test battery, check alternator output, inspect wiring
Brake fade	Worn pads, contaminated fluid	Replace pads, flush brake system, clean rotors
Transmission noise	Low oil, worn gears	Check oil level, inspect gears for wear

Service Intervals: Follow maintenance schedule strictly for optimal performance.

Wiring Diagrams

Complete electrical schematics available in separate section. Color-coded wiring with connector locations and ground points.

Main Harness: Red - battery positive, Black - ground, Green - ground
Ignition System: Black/White - ignition coil, Orange - CDI unit
Lighting: Blue - high beam, White - low beam, Brown - tail light
Charging System: Three yellow wires - alternator output

Note: Always disconnect battery before working on electrical system.