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KAWASAKI KZ500 KZ550 ZX550 Service Repair Manual 1979-1986

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This manual covers the models produced between 1979 and 1986. These motorcycles, including variants such as the LTD, Spectro, CSR, GP, and Shaft models, were known for their inline-twin, four-stroke,...
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Tipo: Motorcycle
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SKU: 144441
KAWASAKI KZ500 KZ550 ZX550 Service Repair Manual 1979-1986
This manual covers the models produced between 1979 and 1986. These motorcycles, including variants such as the LTD, Spectro, CSR, GP, and Shaft models, were known for their inline-twin, four-stroke, air-cooled engines, offering a balance of performance and reliability for their era. The engineering quality of these bikes, with displacements around 498cc for the KZ500 and 552cc for the KZ550/ZX550, positioned them as competitive options in the mid-size sport and standard motorcycle segment. The legacy in performance motorcycle development is evident in the progression from the KZ500 to the more advanced KZ550 and ZX550 series. This comprehensive service and repair workshop manual provides detailed instructions for all aspects of maintenance and repair for these models. It covers engine systems, drivetrain and transmission, chassis and suspension, braking systems, and the electrical system, including troubleshooting guides for common issues like carburetor wear and electrical faults. The manual is designed for enthusiast owners, independent repair shops, and restorers, offering extensive procedures for periodic checks, adjustments, fluid changes, component replacement, and in-depth diagnostics. Its professional quality ensures users can effectively maintain and repair their vehicles, offering significant value and cost savings.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KZ500 / KZ550 / ZX550
Model Variants:
Includes standard KZ500, KZ550 LTD, KZ550 Spectro, KZ550 CSR, KZ550 GP, KZ550 Shaft, ZX550 (Ninja 550)
Generation
Production Years:
1979-1986
👋 Introduction
Market Position
Target Audience:
Enthusiast owners seeking to perform their own maintenance and repairs, independent repair shops, and classic motorcycle restorers.
Competitive Analysis
Value Proposition:
Presents itself as the 'BEST' and 'COMPLETE' manual, offering superior value compared to incomplete or lower-quality alternatives, enabling significant cost savings on repairs.
Key Features
Delivery Method:
Instant download, no shipping costs or waiting for physical delivery.
Usability:
Easy to use on PC, tablet, or laptop; allows selective printing of pages or sections.
📋 Manual Details
Coverage Areas
Manual Coverage Summary:
Comprehensive service and repair for all aspects of the Kawasaki KZ500, KZ550, and ZX550 models from 1979 to 1986.
Page Count
Estimated Page Count:
Likely 300-600+ pages (typical for factory-level service manuals covering this range of models and detail).
Manual Type
Manual Format Type:
Service Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine removal/installation, fuel system (carburetor troubleshooting and adjustment, potential injection systems for later models), lubrication system, cooling system (air-cooled designs), combustion system, cylinder head/valves, crankcase, piston, cylinder, crankshaft, transmission, balancer assembly.
Drivetrain And Transmission:
Gearbox, clutch (wet multi-plate), transmission system components, gear ratios, output shaft, final drive (chain or shaft drive depending on specific model variant).
Chassis And Suspension:
Front wheel and steering system (forks, steering bearings), rear wheel system (swingarm, shock absorbers), frame structure, body panels, exhaust system.
Braking System:
Front and rear brake mechanisms (drum or disc, depending on model and year), hydraulic systems, brake fluid specifications, bleeding procedures.
Electrical System:
Alternator, starter clutch, battery/charging system, ignition system (CDI, points/condenser variations), electric starter motor, lights, meters, switches, wiring diagrams for all electrical components.
Procedures Included
Maintenance Procedures:
Periodic checks, adjustments (valve clearance, chain tension, carburetor synchronization), fluid changes (oil, brake fluid), filter replacements, spark plug service, battery maintenance.
Repair Procedures:
Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension repairs, brake system servicing, electrical diagnostics, bodywork repair, and component replacement.
Troubleshooting:
Comprehensive diagnostic guides for identifying and resolving common and uncommon issues across all vehicle systems.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics for engine performance, electrical faults, and mechanical issues, suitable for both enthusiast and professional mechanics.
📊 Manual Specifications
File Format
File Quality:
Professional quality, high-resolution PDF with clear, legible text and diagrams. Likely searchable text for ease of use.
Print Quality
Printability:
Fully printable, allowing users to print specific sections or the entire manual as needed.
Binding Type
Digital Binding:
N/A (Digital format, instant download via PDF)
Paper Type
Digital Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-twin cylinder, four-stroke, air-cooled (majority of models).
Engine Displacement:
Approximately 498cc (KZ500) and 552cc (KZ550/ZX550).
Performance
Horsepower Range:
Estimated 48-55 hp (varies by model and year).
Torque Range:
Estimated 30-35 lb-ft (varies by model and year).
Fuel System
Carburetor Type:
Typically dual Mikuni VM series carburetors, with specific sizes varying by model (e.g., 34mm).
Fuel Injection:
May be present on later ZX550 variants, requiring specific diagnostics covered in the manual.
🔧 Transmission
Standard
Gearbox Type:
Constant mesh, 5-speed sequential manual transmission.
Optional
Clutch Type:
Wet, multi-plate, cable-actuated.
Features
Final Drive Options:
Chain drive on most models; some variants may have had shaft drive options, though less common for this specific platform.
📐 Dimensions
Exterior
Wheelbase Range:
Approximately 57.5 inches (1460 mm) for KZ550 models.
Weights
Dry Weight Range:
Approximately 390-430 lbs (177-195 kg) depending on model.
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for this era of motorcycle; safety focus is on mechanical integrity and rider control systems.
Active Features
Braking Systems:
Disc front brake, drum or disc rear brake (depending on model and year). Manual covers inspection, maintenance, and repair of these.
Passive Features
Frame Construction:
Steel tube frame for rigidity and rider safety.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights (neutral, oil pressure, turn signals, high beam). Manual details their function and troubleshooting.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was not a standard or widely available feature on these models from this era.
Connectivity
Diagnostic Ports:
N/A. Diagnostics rely on visual inspection, multimeter testing, and understanding of mechanical/electrical principles, all detailed in the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (4,800-8,000 km) or annually, whichever comes first. Manual will specify exact interval and oil type.
Valve Adjustment Interval:
Commonly every 6,000-10,000 miles (9,600-16,000 km). Manual provides detailed procedures.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 10W-30 API SE or SF motorcycle oil. Manual will confirm exact viscosity and API classification.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify.
Fork Oil Type:
Specific weight and viscosity (e.g., 10W) fork oil. Manual will provide details.
Known Issues
Common Wear Items:
Carburetor wear (jets, diaphragms), clutch plate wear, fork seal leaks, ignition coil failure, charging system issues (stator/regulator-rectifier), and aging wiring harnesses.
Carburetor Issues:
Clogged jets, worn needle valves, vacuum leaks leading to poor idle and performance. Manual offers extensive carburetor troubleshooting and rebuilding guides.
Electrical Faults:
Corroded connectors, failed relays, weak charging systems. Detailed wiring diagrams in the manual are crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Legacy:
Kawasaki has a long history of producing performance-oriented motorcycles, known for their inline-four engines and innovative designs. The KZ series represented a significant step in their motorcycle development in the late 70s and early 80s.
Model Evolution
Kz500 To Kz550 Transition:
The KZ500 was a precursor that evolved into the more powerful and refined KZ550 series, which then laid the groundwork for the sporty ZX550 (Ninja 550), showcasing Kawasaki's progression towards sportbike technology.
Production
Manufacturing Focus:
These models were primarily produced in Japan, reflecting Kawasaki's core manufacturing base during this period.
🏆 Awards & Recognition
Recognitions
Model Reputation:
The KZ/ZX series were well-regarded for their performance, reliability, and handling in their class during the early 1980s, often competing against Yamaha Seca, Honda CB, and Suzuki GS models.
Ratings
Performance Classification:
Mid-size sport/standard motorcycles known for a good balance of power, handling, and everyday usability.
Certifications
Manual Certification:
The manual is presented as a 'Professional Quality' resource, analogous to factory workshop manuals, implying a high standard of technical accuracy and completeness.
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