1979-1985 Kawasaki KZ550 GPZ550 Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 128816

Stichworte: 1979 1980 1981 1982 1983 1984 1985 GPZ Series GPZ550 Kawasaki KZ550 Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the KZ550 and GPz550 models, produced between 1979 and 1985. These mid-size motorcycles, featuring a 4-stroke, DOHC, air-cooled inline-four engine displacing 553cc, were known for their smooth power delivery and versatility. The KZ550 offered a reliable platform for commuting and touring, while the GPz550 variant provided enhanced sportbike performance with a distinctive fairing and tuned engine. Both models utilize a 6-speed transmission and are built on a steel semi-double cradle frame, offering a solid foundation for their respective riding characteristics. This comprehensive service and repair manual provides detailed guidance for maintaining and troubleshooting your KZ550 or GPz550. It covers all essential systems, including engine overhaul, fuel and ignition systems, transmission, electrical components, suspension, brakes, and bodywork. You will find step-by-step procedures for routine maintenance, diagnostics, and repair, along with critical technical specifications and wiring diagrams. This manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance and longevity of these classic motorcycles.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ550 / GPz550

Model Code:

KZ550-A1, A2, A3, A4; GPz550-B1, B2

Generation

Production Years Covered:

1979-1985

Codes

Chassis Codes:

KZ550A1, KZ550A2, KZ550A3, KZ550A4, KZ550B1, KZ550B2

👋 Introduction

Market Position

Vehicle Class:

Mid-size sport touring / naked motorcycle

Target Audience:

Performance-oriented riders, commuters, vintage motorcycle enthusiasts

Competitive Analysis

Key Competitors Era:

Honda CB550/CB650, Yamaha XJ550/XJ650, Suzuki GS550/GS650

Key Features

Kz550 Focus:

Reliable inline-four, versatile for commuting and touring

Gpz550 Focus:

Performance-oriented, faired sportbike variant with enhanced engine tuning and suspension

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair for Kawasaki KZ550 and GPz550 models

Secondary Coverage:

Maintenance, troubleshooting, diagnostics, specifications, wiring diagrams

Page Count

Estimated Page Count:

Approx. 300-400 pages (typical for comprehensive factory-style manuals)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Top end, bottom end, cooling system, lubrication system, timing, valve adjustment

Fuel System:

Carburetor removal, cleaning, adjustment, synchronization, fuel pump, fuel tank

Ignition System:

CDI unit, ignition coils, spark plugs, timing adjustments

Transmission Clutch:

Clutch operation, gearbox disassembly, assembly, lubrication, torque specifications

Electrical System:

Wiring diagrams, charging system (alternator, rectifier/regulator), starting system (starter motor, solenoid), lighting, instruments, switches, fuses

Suspension:

Front forks (oil change, seal replacement, spring replacement), rear shock absorbers, linkage

Brakes:

Front and rear brake systems, caliper overhauls, master cylinders, fluid replacement, bleeding procedures, brake pads, rotors

Wheel Tires:

Wheel bearing replacement, tire mounting, balancing

Frame Bodywork:

Frame inspection, body panel removal and installation, seat, handlebars, footpegs

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement, battery maintenance

Troubleshooting:

Systematic diagnosis of common problems and solutions

Engine Rebuild:

Complete disassembly and reassembly of the engine

Carburetor Tuning:

Jetting, needle adjustments, float bowl levels, idle speed

Electrical Diagnostics:

Testing of electrical components and circuits using multimeters

Fork Rebuild:

Front fork seal replacement and oil service

Brake System Service:

Fluid flushing, caliper and master cylinder rebuilding

Torque Specifications:

Critical torque values for all fasteners

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine rebuilds and complex electrical troubleshooting.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Digital Quality:

High-resolution scans, clear text and diagrams, searchable content

Binding Type

Digital Format Details:

Downloadable, accessible on multiple devices

Paper Type

Digital Format Details:

Printable pages for workshop use

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, inline-four cylinder

Displacement:

553 cc

Bore X Stroke:

58.0 mm x 50.6 mm

Compression Ratio:

9.7:1 (typical, may vary slightly by model year)

Performance

Horsepower:

Approx. 58-65 HP @ 9,000 RPM (GPz variant often slightly higher)

Torque:

Approx. 34-37 lb-ft @ 7,500 RPM

Fuel System

Carburetion:

Four 32mm (or 34mm for GPz) Mikuni VM series carburetors

Fuel Tank Capacity:

Approx. 16 Liters (4.2 US gallons)

Cooling

Cooling System:

Air-cooled

Ignition

Ignition Type:

Electronic (CDI) with breakerless ignition

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Drive Type:

Chain drive

Features

Clutch Type:

Wet multi-plate

📐 Dimensions

Exterior

Overall Length:

Approx. 2,160 mm (85 in)

Overall Width:

Approx. 760 mm (30 in)

Overall Height:

Approx. 1,145 mm (45 in)

Weights

Dry Weight:

Approx. 185-195 kg (408-430 lbs), depending on model/trim

Wet Weight:

Approx. 200-210 kg (441-463 lbs)

🛡️ Safety Features

Ratings

Safety Features Era:

Reflects safety standards of the early 1980s; focus on reliable braking and chassis stability.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake (standard on most models/years)

Passive Features

Frame Construction:

Steel semi-double cradle frame for rigidity

💡 Technology Features

Infotainment

Infotainment Systems:

Not applicable (classic motorcycle era)

Driver Assistance

Rider Aids:

Not applicable (classic motorcycle era)

Connectivity

Connectivity Features:

Not applicable (classic motorcycle era)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-4,000 km (2,000-2,500 miles) or 6 months

Valve Clearance Check:

Every 6,000-8,000 km (4,000-5,000 miles)

Chain Adjustment:

As needed, typically every 1,000-1,500 km (600-1,000 miles)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE or SF (or equivalent motorcycle-specific oil)

Engine Oil Capacity:

Approx. 3.2 Liters (3.4 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Fork Oil Type:

Kawasaki Fork Oil G10 or SAE 10W (specify quantity per leg from manual)

Known Issues

Common Wear Items:

Carburetor synchronization issues, stator/rectifier failures, front fork seal leaks, cam chain wear.

Common Issues

Starting Problems:

Can be related to battery condition, starter motor, or ignition system components.

Fueling Issues:

Clogged carb jets, worn floats, vacuum leaks in fuel lines or intake boots.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing high-performance motorcycles, from the Z1 to modern Ninja models. The KZ series represented their entry into the popular 500-650cc segment.

Model Evolution

Kz550 Development:

Evolved from earlier KZ400 and KZ500 models, offering increased displacement and improved performance. The GPz variant was a sportier iteration with a distinctive fairing and tuned engine.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Market Reception:

Well-regarded for its smooth inline-four engine and reliable performance in its class. The GPz variant was praised for its sportbike capabilities.