Model:
KZ400/500/550 Series
Model Years Covered:
1979, 1980, 1981
Engine Codes:
KZ400 (e.g., KZ400A, KZ400B, KZ400C, KZ400D, KZ400E, KZ400K), KZ500 (e.g., KZ500B), KZ550 (e.g., KZ550A, KZ550C, KZ550D, KZ550F)
Frame Codes:
Typically prefixed with KZ400, KZ500, or KZ550 followed by model variant identifiers.
Segment:
Mid-range motorcycles, popular for commuting, sport touring, and general riding in the late 70s and early 80s.
Target Audience:
Owners of Kawasaki KZ400, KZ500, and KZ550 motorcycles seeking to perform their own maintenance and repairs, as well as independent workshops.
Competitors:
Honda CB series (e.g., CB400, CB550), Yamaha XS series (e.g., XS400, XS500), Suzuki GS series.
Engine Layout:
Inline-twin cylinder (KZ400, KZ500) and inline-four cylinder (KZ550) configurations.
Design Philosophy:
Emphasis on reliability, accessible performance, and a balance of sporty handling and comfortable ergonomics.
Primary Coverage:
Comprehensive mechanical and electrical repair and maintenance for Kawasaki KZ400, KZ500, and KZ550 motorcycles.
Specific Models Covered:
Includes variants such as KZ400 Standard, KZ400 Deluxe, KZ400 Custom, KZ400 Special, KZ400 LTD, KZ500, KZ550 LTD, KZ550 Standard, KZ550 GPz.
Estimated Pages:
~300-400 pages (variable based on specific edition and content)
Type:
Workshop Repair Manual / Service Manual
Format:
Print (Paperback/Bound)
Engine Mechanical:
Engine disassembly, assembly, inspection, lubrication, cooling system (air-cooled), top end (cylinder head, valves, camshafts), bottom end (crankshaft, connecting rods, pistons), timing chain, starters.
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment, synchronization, fuel tank, fuel pump (if applicable), fuel lines, filters.
Ignition System:
CDI ignition system, ignition coils, spark plugs, timing inspection and adjustment, electronic ignition components.
Transmission Drivetrain:
Gearbox disassembly, assembly, inspection, shifting mechanism, clutch (wet multi-plate), primary drive, final drive (chain drive).
Chassis Frame:
Frame inspection, steering head bearings, front fork (telescopic), rear suspension (swingarm, shock absorbers), wheel bearings, axle alignment.
Brakes:
Front brake (disc brake system: caliper, master cylinder, brake lines, brake fluid), rear brake (drum brake system), brake adjustment and bleeding.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), horn, starter motor, instrumentation.
Bodywork Trim:
Fender removal and installation, seat, fuel tank removal, side covers, handlebars, control cables.
Scheduled Maintenance:
Regular service checks, oil changes, filter replacements, spark plug maintenance, chain lubrication and adjustment, brake inspection, tire pressure checks.
Engine Repair:
Complete engine rebuilds, piston ring replacement, valve seat grinding, camshaft bearing inspection, crankshaft runout checks.
Carburetor Tuning:
Detailed procedures for jetting, idle speed adjustment, mixture screw settings, and synchronization for optimal performance.
Troubleshooting Diagnostics:
Step-by-step guides for diagnosing common problems related to starting, running, electrical issues, and braking.
Wiring Diagram Interpretation:
Detailed, often color-coded wiring diagrams with component identification for electrical troubleshooting.
Suspension Rebuild:
Fork seal replacement, fork oil change, shock absorber inspection and replacement.
Depth Of Coverage:
Comprehensive, suitable for professional mechanics and skilled DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission overhauls.
Diagnostic Capability:
High. Includes detailed specifications for measurements, tolerances, and diagnostic procedures.
Engine Type:
Four-stroke, air-cooled, DOHC (Double Overhead Camshaft)
Cylinders:
Inline-twin (KZ400, KZ500), Inline-four (KZ550)
Displacement:
KZ400: approx. 398cc; KZ500: approx. 498cc; KZ550: approx. 553cc
Horsepower:
Varies by model: KZ400 (~30-35 HP), KZ500 (~40-45 HP), KZ550 (~45-50 HP)
Torque:
Varies by model: KZ400 (~25-28 lb-ft), KZ500 (~30-33 lb-ft), KZ550 (~35-38 lb-ft)
Carburetion:
Dual Mikuni carburetors (KZ400, KZ500), Quad Mikuni carburetors (KZ550)
Fuel Type:
Unleaded gasoline, octane rating as specified by manufacturer (typically 87 or higher)
Oil Type:
SAE 10W-40 or 20W-40 motorcycle specific engine oil, API SG or equivalent.
Oil Capacity:
Refer to manual; typically 2.0-3.0 liters (approx. 2.1-3.2 US quarts) with filter change.
Cooling Method:
Air-cooled
Oil Change Interval:
Every 3,000 km (2,000 miles) or 6 months, whichever comes first.
Filter Change Interval:
With every oil change.
Spark Plug Replacement Interval:
Every 6,000 km (4,000 miles) or as per manual specifications.
Valve Clearance Check Interval:
Every 12,000 km (8,000 miles) or annually.
Chain Lubrication Adjustment Interval:
Every 1,000 km (600 miles) or as needed based on slack.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
Typically SAE 10W motorcycle fork oil, specific viscosity detailed in manual.
Common Problems:
Carburetor wear and jetting issues, clutch wear, cam chain noise, front fork seal leaks, electrical connector corrosion.
Recommended Upgrades:
Electronic ignition conversion for improved reliability, braided stainless steel brake lines for better feel.
Kawasaki History:
Kawasaki Heavy Industries, Motorcycle and Engine Division has a long history of producing reliable and performance-oriented motorcycles across various segments, from lightweight commuters to powerful sportbikes and cruisers.
Kz Series Introduction:
The KZ series represented Kawasaki's entry into the mid-displacement segment, offering a blend of performance, reliability, and modern styling that competed directly with Japanese and European manufacturers.
Kz400 Development:
Introduced in the mid-1970s as a versatile, user-friendly motorcycle, evolving through various configurations like standard, custom (LTD), and sport variants.
Kz500 Development:
A step up in performance from the KZ400, often featuring a more potent inline-twin engine.
Kz550 Development:
The KZ550 range, often featuring inline-four engines, provided enhanced performance and smoother power delivery, including sportier variants like the KZ550 GPz.
Production Period:
The KZ400/500/550 models were primarily produced from the mid-1970s through the early to mid-1980s, with the specific 1979-1981 period covered by this manual representing a significant phase of their development and popularity.
Manufacturing Location:
Primarily Japan
