This manual covers the Kawasaki GPZ550 and Z550F models produced between 1983 and 1985. These motorcycles represent a significant part of Kawasaki's legacy in performance-oriented bikes, evolving from the earlier Z series. Known for their inline 4-cylinder, DOHC engines with a displacement of 553cc, these models offered approximately 60-65 horsepower, making them capable machines for their time. They feature a 6-speed transmission, wet multi-plate clutch, and chain drive, providing a dynamic riding experience. The GPZ550 and Z550F were designed to be versatile, suitable for both spirited riding and longer journeys, reflecting Kawasaki's commitment to engineering quality and rider satisfaction.
This comprehensive Workshop Service Repair Manual provides in-depth guidance for maintaining and repairing your Kawasaki GPZ550 or Z550F. It covers all essential systems, including the engine, transmission, fuel system, ignition, lubrication, exhaust, and electrical systems, as well as bodywork, suspension, brakes, and wheels. Within its 124 pages, you will find detailed procedures for routine maintenance, component overhaul, tune-ups, and troubleshooting, along with specific Kawasaki special tool requirements and safety precautions. This manual is designed for mechanical technicians and motorcycle owners with mechanical aptitude, offering dealer-level information to ensure the longevity and optimal performance of your motorcycle.
Model Code:
GPZ550 (KZ550-H1, KZ550-H2), Z550F (KZ550-C3, KZ550-C4)
Production Years Covered:
1983, 1984, 1985
Target Audience:
Mechanical technicians, motorcycle owners with mechanical aptitude.
Value Proposition:
Provides dealer-level information for DIY repair, saving on labor costs and enabling informed maintenance.
Accuracy:
Endeavored accuracy, aiming to be the most reliable information source.
Completeness:
Aims to be a complete service manual covering all necessary repair instructions.
Safety Warnings:
Highlights safety information using WARNING, CAUTION, and NOTE designations.
Ignition System:
Included
Lubrication System:
Included
Electrical System:
Included
Suspension:
Implied by general repair and overhaul
Brakes:
Implied by general repair and overhaul
Wheels And Tires:
Implied by general repair and overhaul
Type:
Workshop Service Repair Manual
Primary Language:
English
Delivery Method:
Electronic (Email)
Engine And Transmission:
Detailed disassembly and reassembly procedures, including advanced repairs.
Fuel And Ignition:
Comprehensive coverage for tune-ups, diagnostics, and component servicing.
Electrical System:
Wiring diagrams, component testing, and troubleshooting.
Lubrication And Cooling:
Maintenance, capacity specifications, and component function.
Body And Frame:
Procedures for body panel removal, installation, and general maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues.
Component Overhaul:
Detailed instructions for rebuilding major components like the engine and transmission.
Tune Ups:
Carburetor synchronization, ignition timing adjustments, valve clearance checks.
Assembly Disassembly:
Step-by-step guides for taking apart and reassembling various vehicle sub-systems.
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics.
Diagnostic Focus:
Emphasizes understanding functions to judge performance and troubleshoot issues.
Special Tooling:
Identifies and illustrates specific Kawasaki special tool numbers where required.
Proprietary Components:
Incorporates instructions from proprietary component manufacturers for proper understanding.
Safety Emphasis:
Highlights safety precautions and the importance of using correct tools like torque wrenches.
Resolution Suitability:
High enough for clear printing of diagrams and text.
Binding:
Not Applicable (Digital PDF)
Paper Type:
Not Applicable (Digital PDF)
Engine Type:
Inline 4-cylinder, DOHC
Bore X Stroke:
Refer to manual for specific values
Compression Ratio:
Refer to manual for specific values
Horsepower:
Approximately 60-65 HP (Varies slightly by specific model/tuning)
Torque:
Refer to manual for specific values
Carburetion:
Mikuni VM26SS carburetors (typically 4 x 26mm downdraft)
Fuel Type:
Unleaded gasoline
Transmission Type:
6-speed constant mesh
Optional Transmission:
N/A
Clutch Type:
Wet multi-plate
Overall Length:
Refer to manual for specific values
Overall Width:
Refer to manual for specific values
Overall Height:
Refer to manual for specific values
Dry Weight:
Approximately 188 kg (414 lbs)
Wet Weight:
Refer to manual for specific values
Safety Ratings:
Not applicable for this era of motorcycle in modern crash test formats.
Braking System:
Front: Disc brake (single or dual depending on variant); Rear: Disc brake.
Lighting:
Halogen headlight, taillight, turn signals.
Infotainment System:
N/A (Mechanical motorcycle of its era)
Driver Assistance Features:
N/A (Mechanical motorcycle of its era)
Connectivity Features:
N/A (Mechanical motorcycle of its era)
Oil Change Interval:
Refer to manual for specific mileage/time interval (typically every 3,000-5,000 km or annually).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment required (interval depends on conditions).
Valve Clearance Check:
Refer to manual for specific mileage interval (typically around 10,000-12,000 km).
Engine Oil Type:
API SE or SF, SAE 10W-40 recommended (confirm with manual for exact specs).
Engine Oil Capacity:
Refer to manual for specific capacity with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 (confirm with manual).
Carburetor Synchronization:
Can drift over time, requiring periodic synchronization for smooth running.
Cam Chain Tensioner:
May require inspection or replacement due to wear on older models.
Electrical Connections:
Corrosion or loose connections can lead to intermittent electrical issues.
Fork Seals:
Can degrade over time, leading to oil leaks.
Kawasaki Legacy:
Kawasaki has a long history of producing performance motorcycles, including the successful Z and GPZ series.
Gpz Z Lineage:
The GPZ550 was part of Kawasaki's push into the sport-touring and performance motorcycle market, evolving from the earlier Z models.
Manufacturing Location:
Japan
Historical Acclaim:
The GPZ line was generally well-received for its performance and styling in its contemporary market.
