Kawasaki KZ400 KZ500 KZ550 Z400 Z500 Z550 G400 GPZ550 Complete Workshop Service Repair Manual 1979 1980 1981 1982 1983 1984 1985

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Art.-Nr: 157762

Stichworte: 1979 1980 1981 1982 1983 1984 1985 GPZ Series GPZ550 Kawasaki KZ400 KZ500 KZ550 Motorcycle Motorcycles Z400 Z500 Z550

Produktvarianten

Beschreibung

This manual covers a range of motorcycles, including the KZ400, KZ500, KZ550, Z400, Z500, Z550, G400, and GPZ550 models produced between 1979 and 1985. These motorcycles, powered by typically air-cooled parallel-twin engines with displacements around 400cc, 500cc, and 550cc, were known for their reliability and performance in their time. The KZ series represented a strong market presence, evolving to offer a balance of power and manageability, making them popular among riders. This comprehensive workshop service repair manual provides detailed guidance for owners and technicians. It covers essential maintenance procedures, routine adjustments, and component replacements, alongside in-depth engine overhaul instructions, fuel system service, ignition system diagnostics, and transmission and clutch maintenance. The manual also includes troubleshooting guides for common issues, electrical system diagrams, suspension and braking system service, and technical specifications, ensuring the optimal upkeep and repair of these classic machines.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ400, KZ500, KZ550, Z400, Z500, Z550, G400, GPZ550

Codes

Chassis Codes:

Likely variations of KZ400, KZ500, KZ550, Z400, Z500, Z550, G400, GPZ550 designations; specific VIN decoders required for exact model year and sub-model.

👋 Introduction

Market Position

Target Audience:

DIY motorcycle enthusiasts, independent repair shops, and owners seeking to reduce maintenance costs.

Competitive Analysis

Value Proposition:

Provides significant cost savings compared to dealership service or professional repair.

Key Features

Ease Of Use:

Designed for ease of use with step-by-step instructions and clear visuals.

Instant Access:

Instant email delivery upon payment confirmation.

📋 Manual Details

Coverage Areas

Covered Models:

Kawasaki KZ400, KZ500, KZ550, Z400, Z500, Z550, G400, GPZ550.

Covered Years:

1979, 1980, 1981, 1982, 1983, 1984, 1985.

Page Count

Page Count:

Not specified, but described as 'Complete Workshop Service Repair Manual' indicating comprehensive coverage.

Manual Type

Manual Type:

Workshop Service Repair Manual.

Language

Language:

Assumed English, based on product description and typical market availability.

Format

Format:

Downloadable Digital Format (PDF implied).

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Full engine disassembly, inspection, repair, and reassembly procedures for all applicable engine variants.

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel pump service, fuel tank maintenance.

Ignition System:

Ignition timing, coil testing, spark plug specifications, CDI unit diagnostics.

Transmission And Clutch:

Clutch operation, adjustment, replacement; gearbox inspection, repair, and lubrication.

Electrical System:

Wiring diagrams, lighting, starter motor, charging system (alternator/generator), battery, fuses, relays.

Suspension And Steering:

Front fork service, rear shock absorber maintenance, steering head bearing adjustment, swingarm service.

Braking System:

Brake caliper service, master cylinder overhaul, brake fluid replacement, disc and pad inspection/replacement.

Wheel And Tire:

Wheel bearing service, spoke tensioning, tire pressure recommendations, wheel balancing.

Exhaust System:

Exhaust pipe and muffler inspection, replacement, and gasket service.

Frame And Bodywork:

Frame inspection, fairing and panel removal/installation, seat maintenance.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, brake fluid flushes, coolant checks (if applicable).

Troubleshooting Guides:

Diagnostic procedures for common starting, running, and electrical issues.

Routine Adjustments:

Carburetor synchronization, valve clearance adjustment, throttle cable adjustment.

Component Replacement:

Detailed instructions for replacing major and minor components.

Rebuild Procedures:

Comprehensive instructions for rebuilding carburetors, brake master cylinders, and potentially engine components.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to in-depth repairs and diagnostics.

Diagnostic Information:

Includes troubleshooting charts and symptom-based diagnostics.

Torque Specifications:

Essential torque values for all critical fasteners.

Illustrations And Diagrams:

Features step-by-step instructions with pictures and diagrams for clarity.

📊 Manual Specifications

File Format

File Format:

PDF (implied, compatible with Adobe Reader).

Print Quality

Print Quality:

High quality, allowing printing of selected sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download).

Paper Type

Paper Type:

N/A (Digital Download).

Accessibility

Device Compatibility:

Compatible with all PC & MAC Computers, tablets, and mobile phones.

Software Requirements

Required Software:

Adobe Reader (free download if not pre-installed).

⚙️ Engine Specifications

Primary Engine

Engine Types:

Parallel-twin, air-cooled (typical for KZ/Z series of this era).

Engine Displacements

Kz400 Displacement:

Approximately 399 cc.

Kz500 Z500 Displacement:

Approximately 498 cc.

Kz550 Z550 Gpz550 Displacement:

Approximately 553 cc.

G400 Displacement:

Likely a variant of the 400cc engine, specific details may vary.

Performance

Kz400 Horsepower:

Estimated 30-35 HP (varies by year/tuning).

Kz550 Gpz550 Horsepower:

Estimated 50-60 HP (varies by year/tuning).

Fuel System

Carburetor Types:

Mikuni VM or constant velocity (CV) carburetors, typically dual units.

Fuel Delivery:

Gravity feed from fuel tank via petcock to carburetors.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh manual transmission.

Optional

Optional Transmissions:

N/A for these models; all were manual.

Features

Clutch Type:

Wet, multi-plate, cable-actuated.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, generally in the range of 54-57 inches.

Weights

Dry Weight:

Typically between 350-400 lbs (159-181 kg) depending on the specific model.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A for motorcycle safety ratings in the modern sense; relies on rider skill and maintenance.

Active Features

Braking System Features:

Disc brakes front and rear on many models (especially later GPZ variants), drum brakes on some earlier models.

Passive Features

Lighting System:

Headlight, taillight, brake lights, turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Classic motorcycle technology).

Driver Assistance

Assistance Features:

N/A (Classic motorcycle technology).

Connectivity

Connectivity Options:

N/A (Classic motorcycle technology).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,000-3,000 miles (3,000-5,000 km) or 6 months, refer to manual for exact specification.

Valve Adjustment Interval:

Approximately every 6,000-8,000 miles (10,000-12,000 km), crucial for performance and longevity.

Fluid Specifications

Engine Oil Grade:

Typically SAE 10W-40 or 20W-50 motorcycle-specific oil (JASO MA certified recommended).

Brake Fluid Type:

DOT 3 or DOT 4 (check specific model for exact requirement).

Fork Oil Type:

Typically SAE 10W or 15W suspension fluid, quantity specified per fork leg.

Known Issues

Common Issues:

Carburetor gumming/clogging due to old fuel, cam chain noise, fork seal leaks, electrical connector corrosion, worn clutch plates.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycle History:

Kawasaki Heavy Industries has a long history of producing innovative and performance-oriented motorcycles since the 1960s.

Model Evolution

Kz Series Evolution:

The KZ line represented Kawasaki's entry into the multi-cylinder motorcycle market, evolving from smaller displacement models like the KZ400/Z400 to larger, more powerful machines like the KZ1000. The KZ500/550 and GPZ550 models offered a balance of performance and manageability.

Production

Production Period:

These specific models saw significant production from the late 1970s through the mid-1980s.

🏆 Awards & Recognition

Recognitions

Historical Reputation:

The KZ/Z series were known for their reliability, performance, and stylish designs for their era, contributing to Kawasaki's strong market presence.