Model:
KZ500 / KZ550 / ZX550
Product Name:
Kawasaki KZ500 KZ550 And ZX550 1979-1985 Service Repair Manual
Production Years Covered:
1979, 1980, 1981, 1982, 1983, 1984, 1985
Target Audience:
Owners, mechanics, and enthusiasts of Kawasaki KZ500, KZ550, and ZX550 motorcycles
Motorcycle Segment:
Sportbikes and Standard/Naked motorcycles of their era.
Value Proposition:
Provides essential information for cost-effective repairs and maintenance, empowering users to service their own vehicles.
Benefit 1:
Enables DIY repairs and maintenance, saving money on professional services.
Benefit 2:
Improves understanding of vehicle systems for preventative maintenance and problem prevention.
Benefit 3:
Serves as a reliable reference for all aspects of vehicle care.
General Information:
Included
Periodic Maintenance:
Included
Engine:
Covered in detail
Fuel System:
Covered in detail (including carburetion, fuel pump)
Cooling System:
Covered (likely air-cooled based on era and model lineage)
Electrical System:
Covered in detail (ignition, lighting, charging, starting)
Chassis:
Covered in detail (frame, suspension, steering, wheels, brakes)
Emission Control Information:
Included
Repair Procedures:
Comprehensive for all covered systems
Troubleshooting:
Implicitly covered within repair procedures and diagnostics
Engine Rebuild:
Likely covers piston removal/installation, ring replacement, cylinder honing, valve adjustments, and cam chain replacement.
Electrical Diagnostics:
Includes troubleshooting for starting, charging, ignition systems, and component testing with wiring diagrams.
Chassis Adjustment:
Covers steering head bearing adjustment, swingarm bearing maintenance, and wheel bearing service.
Brake Service:
Includes caliper overhaul, pad replacement, fluid flush, and master cylinder service.
Depth:
Covers routine maintenance, diagnostics, component repair, and likely some disassembly/reassembly
Diagnostic Charts:
Expected to contain diagnostic flowcharts or tables for common problems.
Torque Specifications:
Critical torque values for engine, chassis, and fasteners are typically provided.
Wiring Diagrams:
Essential for electrical system troubleshooting and repairs.
Assembly Disassembly:
Step-by-step instructions for major component removal and installation.
Engine Type Kz500 Kz550:
4-stroke, DOHC, Inline 4-cylinder
Engine Type Zx550:
4-stroke, DOHC, Inline 4-cylinder (Sport variant, potentially higher performance tune)
Cooling Method:
Air-cooled (common for these models)
Displacement Kz500:
498 cc (Approx.)
Displacement Kz550:
553 cc (Approx.)
Bore X Stroke Kz500:
Typically around 66.0 mm x 72.0 mm (Requires manual confirmation)
Bore X Stroke Kz550:
Typically around 70.0 mm x 72.0 mm (Requires manual confirmation)
Fuel Delivery:
Carbureted (Likely Mikuni VM or BS series twin carburetors)
Fuel Type:
Unleaded gasoline
Oil Change Interval:
Typically every 3,000-6,000 km or annually (Consult manual for exact interval and oil type)
Spark Plug Replacement:
Typically every 10,000-20,000 km (Consult manual for specific type and gap)
Engine Oil Type:
API SE, SF, or SG classification, SAE 10W-40 or 20W-50 recommended (Verify in manual)
Engine Oil Capacity:
Approx. 2.8-3.0 liters without filter, 3.0-3.2 liters with filter (Verify in manual)
Brake Fluid Type:
DOT 3 or DOT 4 (Verify in manual)
Fork Oil Type:
Specific viscosity grade (e.g., 10W) and quantity per fork leg (Consult manual)
Chain Lube:
Regular lubrication with appropriate chain lubricant is essential.
Carburetor Issues:
Common with age; may require cleaning, synchronization, and jetting adjustments.
Charging System:
Stator and rectifier/regulator can be points of failure over time.
Suspension Wear:
Fork seals and rear shock absorbers may require rebuilding or replacement.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long-standing reputation for performance and engineering in motorcycles.
Kz Series:
The KZ500 and KZ550 were part of Kawasaki's popular KZ line, known for their inline-four engines and performance.
Zx Variant:
The ZX550 designation often indicated a sportier or faired version, building upon the base KZ platform.
Kz500 Origin:
The KZ500 was introduced to offer a more accessible performance machine, often serving as a successor to smaller displacement KZ models.
Kz550 Development:
The KZ550 represented an increase in displacement and often tuning, providing enhanced power and torque.
Manufacturing Era:
Late 1970s to mid-1980s, a significant period for Japanese motorcycle development.