🏷️ Basic Information

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Model Codes:

KZ500, KZ550, ZX550

Production Years Covered:

1979-1985

Generation Identifier:

Early to Mid 1980s Sportbike/Standard Lineup

👋 Introduction

Market Segment:

Mid-size sportbike and standard motorcycle segment of the early to mid-1980s.

Target Audience:

DIY motorcycle mechanics, hobbyists, professional technicians, and Kawasaki owners seeking to maintain or repair their vehicles.

Competitors:

Honda CB550/CB650 series, Yamaha XJ550/XJ600 Seca, Suzuki GS550/GS650 series.

Manual Key Features:

Comprehensive step-by-step procedures, detailed illustrations, special service tool references, troubleshooting guides, emphasis on safety precautions.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Secondary Coverage:

Maintenance, Adjustments, Troubleshooting, Diagnostics, Component Removal/Installation

Page Count:

340

Manual Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine Systems:

Engine overhaul, top-end rebuild, bottom-end assembly, cylinder head, valves, pistons, crankshaft, lubrication system, cooling system (if applicable to specific models), ignition system, fuel system (carburetion/fuel injection), exhaust system.

Transmission And Drivetrain:

Gearbox disassembly and assembly, clutch operation and adjustment, chain drive maintenance, final drive.

Chassis And Suspension:

Front fork (telescopic, cartridge type), rear shock absorber (monoshock or twin shock), swingarm, steering head bearings, wheel bearings.

Braking System:

Front and rear brake system (disc or drum), caliper overhaul, master cylinder, brake lines, bleeding procedures.

Electrical System:

Wiring diagrams, battery, charging system (alternator, rectifier/regulator), starter motor, lighting (headlight, taillight, indicators), instrumentation, ignition switch, fuses, relays.

Fuel And Emission Control:

Carburetor settings and overhaul, fuel tank, fuel lines, petcock, (potentially early emission control systems if applicable).

Bodywork And Trim:

Fairings, fuel tank cover, seat, fenders, instrumentation panel, minor body panel removal and installation.

Maintenance Procedures:

Oil change, filter replacement, spark plug inspection/replacement, chain adjustment, brake fluid flush, coolant check (if liquid-cooled), general lubrication.

Troubleshooting And Diagnostics:

Step-by-step diagnostic procedures for common performance issues, electrical faults, starting problems, and running irregularities. Includes special notes, important points, and precautions.

Repair Procedures:

Detailed instructions for removal, disassembly, inspection, repair, assembly, and installation of all major components and systems.

Adjustment Procedures:

Carburetor synchronization and idle adjustment, clutch cable free play, brake lever free play, chain slack, steering head bearing preload.

Technical Data And Specs:

Service data, specifications lists, tightening torques, allowable limits for wear and measurements, reference values.

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and chassis rebuilds, including detailed diagnostic trees and specific tool requirements.

Diagrams And Illustrations:

Pictorial diagrams, exploded views, detailed drawings, and photos guiding through service and repair procedures. Includes illustrations of special service tools.

📊 Manual Specifications

File Format:

PDF

Printability:

Yes, all pages are printable

Digital Viewing:

Viewable on any computer, zoomable

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Required Software:

Adobe Reader

Os Compatibility:

Windows, Mac, Linux OS

Completeness Statement:

100% Complete and Intact, no missing or corrupt pages/sections.

⚙️ Engine Specifications

Engine Type:

Inline-four cylinder, four-stroke, DOHC (typically 8 valves, 2 per cylinder).

Engine Displacement:

Approximately 498cc (KZ500) and 552cc (KZ550/ZX550). Exact displacements vary by specific sub-model. The ZX550 variant often featured a 552cc engine with a focus on sportier performance.

Cooling System:

Air-cooled (common for these models)

Horsepower Range:

Estimated 50-60 HP at peak RPM, depending on specific model and tuning.

Torque Range:

Estimated 30-35 lb-ft at peak RPM.

Fuel Delivery:

Typically multi-carburetor setup (e.g., Mikuni VM series or similar), 24mm-26mm diameter per carburetor. Later models or variations like the ZX550 might have seen enhancements or slightly different carburetor sizes.

Fuel Type:

Unleaded gasoline, Octane rating to be specified in manual.

Ignition Type:

Electronic Ignition (CDI - Capacitor Discharge Ignition) or potentially breaker-point ignition on earliest versions, but CDI became standard for this era.

🔧 Transmission

Transmission Type:

Constant mesh, 6-speed sequential manual transmission.

Optional Transmission:

N/A (Manual transmission was standard)

Clutch Type:

Wet, multiple disc clutch, operated by cable.

Drive Type:

Chain drive to rear wheel.

📐 Dimensions

Wheelbase:

Approximately 1400-1450 mm (55.1-57.1 inches), varies slightly by model.

Dry Weight:

Approximately 170-190 kg (375-420 lbs), depending on specific model and equipment.

Fuel Tank Capacity:

Approximately 14-16 liters (3.7-4.2 US gallons).

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety ratings are not typically published in the same manner as automobiles.)

Active Safety Features:

Responsive braking systems (front and rear disc brakes common), stable chassis geometry.

Passive Safety Features:

Frame integrity, rider positioning for control.

💡 Technology Features

Infotainment Features:

N/A (This era of motorcycles did not feature infotainment systems. Focus is on core mechanical and electrical function.)

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control were available on these models.)

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Recommended every 2,000-3,000 miles or 6 months, refer to manual for exact interval.

Valve Check Interval:

Typically every 6,000-10,000 miles. Manual will specify precise interval and procedure.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment (every 500-1000 miles or as needed).

Engine Oil Type:

API SG or higher, SAE 10W-40 motorcycle specific oil recommended. Refer to manual for exact viscosity and specification.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact type and replacement interval.

Coolant Type:

N/A (These models are typically air-cooled).

Common Issues:

Carburetor gumming/fouling due to infrequent use or stale fuel, stator/regulator issues in some electrical systems, worn steering head bearings, occasional cam chain noise, fork seal leaks. The manual addresses these through proper diagnosis and repair procedures.

Genuine Parts:

Recommended use of genuine Kawasaki parts for reliability and fitment, as emphasized in the manual. Replacement fasteners should match OEM specifications.

📚 Vehicle History

Kawasaki Heritage:

Kawasaki has a long-standing reputation for building reliable and performance-oriented motorcycles, particularly in the sportbike and standard segments since the 1960s.

Kz Series Evolution:

The KZ500 and KZ550 series represented an evolution of Kawasaki's inline-four offerings, bridging the gap between smaller displacement bikes and the larger KZ models. The ZX550 was a sportier iteration, often featuring improvements in handling and engine tuning, and served as a precursor to later 'Ninja' sportbikes.

Production Period:

1979-1985 covers the primary production run for these specific models and their variants.

🏆 Awards & Recognition

Model Recognitions:

These models were generally well-received in their time for their performance, reliability, and value, contributing to Kawasaki's strong market presence.

Motorcycle Publication Ratings:

Contemporary motorcycle reviews from the period would highlight their balance of power, handling, and affordability within the sportbike/standard category.

Manual Certification:

While not a formal certification, the manual's comprehensiveness and detailed nature imply adherence to good service documentation practices.