Models Covered:
KZ500, KZ550, ZX550
Years Covered:
1979, 1980, 1981, 1982, 1983, 1984, 1985
Product Name:
1979-1985 Kawasaki KZ500 KZ550 ZX550 Service Repair Manual Download
Product Description Summary:
Comprehensive downloadable service and repair manual for 1979-1985 Kawasaki KZ500, KZ550, and ZX550 motorcycles, featuring high-quality diagrams and instructions.
Manual Identifier:
1979-1985 Kawasaki KZ500 KZ550 ZX550 Service Repair Manual
Engine Family Codes:
KZ500/KZ550/ZX550 series
Target Audience:
Enthusiasts and DIY mechanics seeking detailed guidance for maintaining and repairing their Kawasaki KZ500, KZ550, and ZX550 motorcycles.
Historical Context:
These models were popular in the early to mid-1980s, competing in the increasingly competitive 500cc-600cc motorcycle segment, offering a balance of performance, reliability, and affordability.
Value Proposition:
Offers the most complete service and repair information for the specified models, providing a cost-effective alternative to professional servicing through its detailed instructions and diagrams.
Manual Highlights:
Instant download, high-quality diagrams, comprehensive coverage, printable pages, wide model and year range.
Diagnostic Focus:
Emphasis on practical diagnosis and repair for home mechanics, covering common failure points and solutions.
Primary Coverage:
Service and Repair
Specific Sections Detailed:
General Information, Troubleshooting, Periodic Maintenance, Lubrication and Tune-Up, Engine, Clutch, Transmission, Fuel and Exhaust, Electrical System, Wheels Tires and Brakes, Chassis, 1982 And Later Service Information, Index, Wiring Diagrams.
Estimated Page Count:
High (Comprehensive, specific number not provided but implied by 'Most Complete')
Type:
Service Repair Manual
Digital Format:
PDF (Downloadable)
Major Systems:
General Information, Troubleshooting, Periodic Maintenance, Lubrication, Tune-Up, Engine, Clutch, Transmission, Fuel System, Exhaust System, Electrical System, Wheels, Tires, Brakes, Chassis, 1982 and Later Service Information, Wiring Diagrams
Electrical Components:
Ignition system, lighting, battery, starter, charging system (alternator/stator, regulator/rectifier).
Braking System:
Front and rear brake mechanisms (disc or drum depending on model variant), hydraulic system (if applicable), pad/shoe replacement, fluid bleeding.
Chassis Components:
Frame, swingarm, steering system, suspension components (forks, shocks), wheel alignment, and related hardware.
Repair Maintenance:
Servicing, Repair, Troubleshooting, Tune-up, Lubrication, Electrical Diagnostics, Brake Servicing, Chassis Adjustments, Engine Overhaul (implied)
Engine Procedures:
Engine removal/installation, cylinder head service, piston and ring inspection/replacement, crankshaft inspection, valve inspection/adjustment, oil pump service.
Transmission Clutch Procedures:
Clutch assembly removal/installation, gearshift mechanism service, transmission component inspection, clutch adjustment.
Suspension Steering Procedures:
Front fork disassembly/reassembly, rear shock absorber service, steering head bearing service, wheel bearing replacement.
Electrical Procedures:
Wiring harness inspection, component testing (coils, regulators, etc.), lighting system repair, battery charging system diagnostics.
Wheel Tire Brake Procedures:
Tire inspection and replacement, wheel truing, brake caliper service, master cylinder overhaul, brake bleeding, pad/shoe replacement.
Depth Of Information:
Comprehensive, including high-quality diagrams and detailed instructions suitable for DIYers and experienced mechanics.
Troubleshooting Guidance:
Detailed troubleshooting charts and diagnostic procedures for common problems across all major systems.
Engine Type:
4-stroke, DOHC, Inline-4 Cylinder (Typical for KZ550/ZX550, KZ500 likely similar)
Bore X Stroke:
Varies by specific model (e.g., KZ550 commonly had around 58.0 mm x 50.6 mm - exact figures require specific model lookup).
Compression Ratio:
Typically around 9.5:1 to 10.0:1 (Refer to manual for specific variants).
Valve Actuation:
Double Overhead Camshafts (DOHC) with mechanical tappets/shims for adjustment.
Typical Displacement:
Approximately 500cc and 550cc (specific values vary by sub-model)
Typical Horsepower:
KZ550: 45-50 HP; KZ500: 40-45 HP (approximate, varies by year/tune)
Fuel Delivery:
Carbureted (Typically Dual Keihin carburetors, e.g., 28mm or 32mm)
Carburetor Details:
Dual carburetors, likely Keihin CV or VM series, with specific jetting and adjustment procedures detailed.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Display Type:
Analog gauges (Speedometer, Tachometer, Fuel Gauge, Warning Lights)
Dashboard Indicators:
Includes neutral indicator, oil pressure warning light, high beam indicator, turn signal indicators, and engine trouble indicator (if equipped).
ABS Availability:
Not typically available on these models.
Traction Control:
Not available on these models.
Connectivity Features:
N/A (No modern electronic connectivity features).
Oil Change Interval:
Typically every 3,000-5,000 km (1,800-3,000 miles) or 6-12 months, whichever comes first (Refer to manual for specific recommendation).
Valve Clearance Check:
Typically around 10,000-15,000 km (6,000-9,000 miles) (Refer to manual for specific recommendation).
Spark Plug Replacement:
Every 6,000-10,000 km (3,700-6,000 miles) or as specified by the manual for optimal combustion.
Air Filter Cleaning:
Recommended at approximately 3,000-6,000 km (1,800-3,700 miles) or more frequently in dusty conditions.
Engine Oil Type:
API SE or SF, SAE 10W-40 motorcycle specific oil recommended (Refer to manual for precise specification).
Brake Fluid Type:
DOT 3 or DOT 4 (Refer to manual for specific recommendation).
Fork Oil Type:
Specific viscosity (e.g., SAE 10W) and quantity per fork leg provided in the manual.
Coolant Type:
These models are typically air-cooled, so coolant specifications are not applicable.
Common Wear Items:
Carburetor synchronization and cleaning, cam chain tensioner wear, fork seal leaks, aging electrical connectors, petcock diaphragm failure.
Electrical Reliability:
Aging wiring insulation and connectors can lead to intermittent faults; manual provides wiring diagrams for troubleshooting.
Fuel System Maintenance:
Carburetor jet clogging from old fuel, aging rubber fuel lines and petcock seals are common and addressed by the manual's repair sections.
Chassis Wear:
Steering head bearing looseness, swingarm bearing wear, and worn suspension bushings can affect handling; manual details inspection and replacement.
Tune Up Components:
Spark plug replacement, air filter cleaning/replacement, ignition timing check, carburetor adjustment/cleaning, chain lubrication and adjustment.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles, particularly in the sportbike and standard motorcycle segments.
Kz550 Lineage:
The KZ550 series evolved from earlier KZ400 and KZ500 models, representing a step up in performance and features, often positioned as a versatile standard or sport-touring motorcycle. The ZX550 variant often indicated a more performance-oriented or faired version.
Zx550 Designation:
The 'ZX' prefix typically denoted a sportier variant, possibly with fairings, improved suspension, or a more aggressive engine tune compared to the standard KZ models.
Production Era:
The 1979-1985 period was a significant era for Japanese motorcycles, with advancements in engine technology, chassis design, and performance.
