1979-1985 Kawasaki Kz500 Kz550 Zx550/gpz550 Workshop Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 153532

Stichworte: 1979 1980 1981 1982 1983 1984 1985 GPZ Series Kawasaki Kz500 Kz550 Motorcycle Motorcycles Zx550/gpz550

Produktvarianten

Beschreibung

This manual covers the Kz500, Kz550, Zx550, and Gpz550 models manufactured between 1979 and 1985. These motorcycles are part of a renowned series, celebrated for their performance and engineering during a key period of Japanese motorcycle development. The GPz variants, in particular, often featured sportier styling and advanced systems like Uni-Trak rear suspension. Known for their smooth inline-four engines, these models offered a compelling blend of power and handling, making them popular choices for riders seeking a spirited and reliable machine. This comprehensive workshop service repair manual provides detailed information for maintaining and repairing your motorcycle. It covers all major systems, including complete engine disassembly, assembly, and tuning; fuel system servicing; ignition system diagnostics; transmission and clutch operation; chassis components such as suspension and steering; braking systems; and the electrical system. The manual includes step-by-step procedures for maintenance, repairs, adjustments, and troubleshooting, supported by factory-level detail, numerous illustrations, and photos, making it an essential resource for both DIY enthusiasts and professional mechanics.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Kz500 / Kz550 / Zx550 / Gpz550

Model Variant:

Kz500, Kz550, Zx550, Gpz550

Model Years Covered:

1979-1985

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts and professional mechanics

Competitive Analysis

Value Proposition:

Inexpensive way to maintain and repair vehicles, saving on labor costs

Key Features

Completeness:

100% complete and intact factory service information

Illustration Quality:

Detailed illustrations and hundreds of photos

Ease Of Use:

Written for both novice and experienced mechanics

📋 Manual Details

Coverage Areas

Primary Regions Covered:

Global (based on factory specifications)

Language:

English

Page Count

Estimated Page Count:

Refer to actual manual for exact count

Manual Type

Type:

Workshop Service Repair Manual

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, tuning, troubleshooting

Fuel System:

Carburetor servicing, fuel pump, fuel lines

Ignition System:

Ignition timing, coil testing, spark plug specifications

Transmission:

Clutch operation, gearbox disassembly and assembly, lubrication

Chassis:

Frame inspection, suspension servicing (front forks, rear shock), steering components

Brakes:

Disc brake servicing, hydraulic system bleeding, pad replacement

Electrical System:

Wiring diagrams, starter motor, alternator, battery maintenance, lighting

Cooling System:

Air-cooled engine specifics, heat dissipation

Exhaust System:

Component inspection and replacement

Wheels And Tires:

Tire pressure, wheel bearing maintenance, rim specifications

Bodywork:

Panel removal and installation, fairing components (where applicable)

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, spark plug checks

Repair:

Engine rebuilds, transmission overhauls, brake system repairs, electrical diagnostics and repair

Troubleshooting:

Diagnostic flowcharts, common problems and solutions

Disassembly Assembly:

Complete step-by-step procedures for major components

Adjustments:

Carburetor synchronization, valve clearance adjustments, chain tension, clutch and brake levers

Technical Depth

Depth:

Comprehensive: From basic maintenance to full engine and transmission rebuilds

Detail Level:

Factory-level detail with hundreds of photos and illustrations

📊 Manual Specifications

File Format

Searchability:

Likely searchable text within PDF

Print Quality

Printability:

All pages printable

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, Inline-4 Cylinder (typically)

Displacement Kz500:

498cc (approx.)

Displacement Kz550:

553cc (approx.)

Cooling System:

Air-cooled

Performance

Horsepower Kz500:

Approx. 48-52 HP (varies by year/tune)

Horsepower Kz550:

Approx. 54-60 HP (varies by year/tune)

Torque Kz550:

Approx. 33-35 lb-ft (varies by year/tune)

Fuel System

Carburetion:

Typically 4 x Mikuni VM series carburetors (specific model varies)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Type:

6-speed constant mesh

Optional

Transmission Options:

N/A (Standard 6-speed)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Wheelbase Kz550:

Approx. 57.1 inches (1450 mm)

Weights

Dry Weight Kz550:

Approx. 445 lbs (202 kg)

Fuel Capacity:

Approx. 4.0 US gallons (15 Liters)

🛡️ Safety Features

Ratings

Safety Standards:

Reflects period safety standards for motorcycles

Active Features

Braking System:

Front and rear disc brakes (later models may feature dual front discs)

Passive Features

Frame Construction:

High-tensile steel frame

💡 Technology Features

Infotainment

Infotainment System:

N/A (No electronic infotainment systems typical for this era)

Driver Assistance

Rider Aids:

N/A (No electronic rider aids)

Connectivity

Connectivity Features:

N/A (No electronic connectivity)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-4,000 miles or 6 months (refer to manual for exact recommendation)

Valve Clearance Interval:

Typically every 6,000-8,000 miles (crucial for performance and longevity)

Spark Plug Replacement:

Refer to manual, typically around 6,000-12,000 miles depending on plug type

Fluid Specifications

Engine Oil Type:

API SE or SF, SAE 10W-40 or 20W-40 (verify in manual for exact specification)

Engine Oil Capacity:

Approx. 2.4-2.6 Liters with filter change (verify in manual)

Brake Fluid Type:

DOT 3 or DOT 4 (verify in manual)

Fork Oil Type:

Refer to manual, typically SAE 10W or 15W

Known Issues

Carburetor Issues:

Clogging due to fuel varnish, synchronization drift, idle speed instability.

Electrical Gremlins:

Corroded connections, failing rectifier/regulator, intermittent charging system issues.

Cam Chain Tensioner:

Wear or failure leading to rattling noise, especially on higher mileage units.

Suspension Wear:

Fork seals leaking, rear shock absorber degradation.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki's reputation for performance and engineering in the sportbike and motorcycle market.

Model Evolution

Kz Series:

Part of the popular KZ series, known for its performance and reliability during the late 70s and early 80s.

Gpz Variant:

The GPz designation often indicated sportier styling and performance enhancements, including the Uni-Trak rear suspension.

Production

Production Era:

1979-1985 marked a significant period for Japanese motorcycle development.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The KZ550 series was generally well-received for its performance, handling, and value in its class.

Ratings

Magazine Reviews:

Period motorcycle magazines often praised their smooth four-cylinder engines and balanced chassis.