Model:
KZ500 / KZ550 / ZX550
Product Type:
Full Service & Repair Workshop Manual
Product Format Digital:
Downloadable
Digital Compatibility:
Windows & MAC Computers, Tablets, Smartphones
Chassis Codes Kz500:
KZ500A
Chassis Codes Kz550:
KZ550A, KZ550B, KZ550C, KZ550D, KZ550E, KZ550F, KZ550H
Chassis Codes Zx550:
ZX550-A
Target Audience:
Kawasaki KZ500, KZ550, and ZX550 owners and independent mechanics seeking a comprehensive factory-level resource.
Value Proposition:
Provides professional-grade repair and maintenance information equivalent to dealership manuals, at a fraction of the cost, with perpetual access.
Content Breadth:
Covers all repair, servicing, and troubleshooting procedures for the specified models and years.
User Experience:
Detailed photos and diagrams, step-by-step instructions, and digital format for broad accessibility.
Engine Variants Covered:
All engine variants for KZ500, KZ550, and ZX550 models within the specified years.
Geographic Markets:
Assumed to cover specifications and procedures relevant to major global markets where these models were sold, including North America, Europe, and Japan.
Estimated Pages:
Hundreds (Exact number not specified but described as 'very detailed' with 'hundreds of pages')
Type:
Factory Service Repair Workshop Manual
Purpose:
Comprehensive guide for repairs, servicing, and troubleshooting.
Language:
English (Implied by product description and typical professional manual language)
Digital File Format:
PDF (Implied by downloadable nature and compatibility with various devices)
Engine:
Engine assembly, disassembly, overhaul, tuning, ignition system, cooling system (air-cooled), lubrication system, fuel system (carburetion).
Transmission:
Gearbox operation, clutch system (dry or wet clutch depending on model variant), shift mechanism, lubrication.
Drivetrain:
Final drive (chain drive), sprocket and chain maintenance, wheel hub and bearing servicing.
Brakes:
Front and rear brake systems (disc or drum depending on model/year), hydraulic components, brake fluid specifications, caliper and master cylinder overhaul.
Suspension:
Front forks (telescopic), rear shock absorbers, fork oil specifications, seals, bushings, and adjustments.
Electrical:
Wiring diagrams, lighting systems, charging system (alternator/stator, rectifier/regulator), battery maintenance, starter system, ignition coils, CDI unit.
Frame And Body:
Frame inspection, front and rear wheel removal/installation, steering head bearings, bodywork component removal and installation, seat, fuel tank, fenders.
Controls:
Throttle controls, clutch lever, brake lever, gear shift linkage, kickstart mechanism (if applicable).
Maintenance:
Routine service checks, oil changes, filter replacements, chain adjustments, brake adjustments, tire pressure, spark plug replacement, carburetor synchronization.
Troubleshooting:
Diagnostic procedures for common and uncommon issues related to engine performance, electrical systems, starting problems, and braking.
Repair:
Step-by-step instructions for component disassembly, overhaul, and reassembly, including engine rebuilds, transmission repairs, and electrical system fixes.
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance tasks.
Torque Specifications:
Detailed torque values for critical fasteners throughout the motorcycle.
Depth:
Comprehensive, covering basic maintenance to complete engine and component overhauls. Suitable for both amateur enthusiasts and professional mechanics.
Illustrations:
Hundreds of detailed photos and exploded diagrams to visually guide repair and maintenance procedures.
Information Source:
Factory-level documentation, reflecting the same information used by authorized service centers.
Searchability:
Likely searchable text within the PDF, enhancing user experience.
Printability:
Printable on demand, either single pages or the entire manual.
Binding:
Not applicable (digital product)
Paper Type:
Not applicable (digital product)
Usage License:
Lifetime usage, unlimited installations across multiple devices.
Updates:
No expiry dates, no renewal fees, full manual access for life.
Engine Type Kz500:
4-stroke, DOHC, air-cooled, inline-twin cylinder
Engine Type Kz550 Standard:
4-stroke, DOHC, air-cooled, inline-four cylinder
Engine Type Kz550 Sport:
4-stroke, DOHC, air-cooled, inline-four cylinder (often with sportier tuning or camshafts)
Engine Type Zx550:
4-stroke, DOHC, air-cooled, inline-four cylinder (often with a focus on sport performance, potentially different bore/stroke or valve timing)
Displacement:
498 cc (approximate, depending on exact variant)
Displacement:
553 cc (approximate, depending on exact variant)
Horsepower Estimated:
Approx. 48-50 HP
Horsepower Estimated:
Approx. 55-60 HP (depending on variant and tuning)
Fuel Delivery:
Carbureted (typically dual Mikuni VM or similar, 26mm-32mm depending on model)
Fuel Type:
Unleaded gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled
Lubrication Method:
Wet sump
Features:
Basic motorcycle instrumentation: speedometer, tachometer, odometer, turn signal indicators, high beam indicator, neutral indicator. No advanced infotainment features typical of modern motorcycles.
Features:
No electronic driver assistance systems. Relies on rider skill and mechanical systems.
Features:
No connectivity features. Purely mechanical and basic electrical systems.
Oil Change Interval:
Typically every 3,000-4,000 km or 6 months, whichever comes first (refer to manual for exact specifications).
Valve Clearance Interval:
Recommended at initial break-in and then every 6,000-8,000 km or annually.
Spark Plug Replacement Interval:
Typically every 10,000-12,000 km or as needed based on condition.
Engine Oil Type:
API SE or SF, SAE 10W-40 or 20W-50 motorcycle-specific oil (manual will specify exact grades and capacities).
Fork Oil Type:
SAE 10W or 15W fork oil (refer to manual for specific viscosity and quantity per fork leg).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification and reservoir fill levels).
Carburetor Issues:
Carburetor synchronization drift, jetting issues due to age or modifications, float bowl leaks.
Electrical Issues:
Corroded wiring connectors, failing rectifier/regulator, stator coil degradation, aging battery terminals.
Engine Wear:
Cam chain tensioner wear, potential for valve guide wear on high-mileage examples.
Suspension Wear:
Worn fork seals, tired fork oil, worn rear shock absorber damping.
Kawasaki Motorcycles:
Kawasaki Heavy Industries, Ltd. has a long history in motorcycle manufacturing, known for performance and innovation in the 1970s and 1980s.
Kz Series:
The KZ series represented Kawasaki's popular line of motorcycles, evolving from smaller displacement bikes to larger fours and twins, including sportier variants.
Kz500 Introduction:
Introduced as a modern twin-cylinder sportbike, offering a balance of performance and handling.
Kz550 Introduction:
The 550cc inline-four models offered increased power and a smoother engine character, often available in standard, cruiser (CSR), and sportier configurations.
Zx550 Introduction:
The ZX550 designation often pointed towards a more sport-oriented version of the 550cc platform, possibly with a different fairing or tuning.
Production Period:
1979-1985
