Segment:
High-performance open-class motocross bike.
Competitors:
Honda CR500R, Yamaha YZ490, Suzuki RM465/RM464.
Engine Performance:
Renowned for its torquey and powerful liquid-cooled 499cc two-stroke engine, delivering exceptional off-the-line acceleration and top-end power.
Chassis Design:
Typically featured a robust steel frame and advanced suspension systems for its era, designed for competitive motocross racing.
Durability:
The KX500 has a reputation for being a robust and durable machine, capable of withstanding demanding off-road conditions when properly maintained.
Covered Years:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Type:
Workshop Service Manual
Delivery Method:
Instant Download
Engine:
Engine overhaul, disassembly, assembly, troubleshooting, tuning, lubrication, cooling system (liquid-cooled).
Fuel System:
Carburetor (Mikuni VM series typically), fuel tank, fuel lines, fuel pump (if applicable).
Ignition System:
CDI, spark plug, wiring, troubleshooting.
Transmission:
Gearbox, clutch, shifting mechanism, lubrication, troubleshooting.
Suspension:
Front forks (upside-down models common), rear shock absorber, linkages, adjustment, service, seal replacement.
Brakes:
Front and rear disc brakes, hydraulic system, caliper service, pad replacement, bleeding.
Electrical System:
Wiring diagrams, lighting, charging system (if applicable), battery, troubleshooting.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, wheel bearings, maintenance.
Bodywork:
Fairings, fenders, seat, fuel tank removal and installation.
Maintenance:
Routine maintenance, oil changes, filter replacement, chain adjustment, spark plug inspection/replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts.
Repair:
Detailed step-by-step instructions for disassembly, repair, and reassembly of all major components.
Adjustment:
Carburetor adjustment, suspension sag, clutch and throttle cable free play.
Installation:
Component installation and removal procedures.
Depth:
Comprehensive, from basic user maintenance to complete engine rebuilds and chassis overhauls.
Visual Aids:
Pictorial diagrams, exploded views, detailed illustrations, and photographs.
Special Tools:
Identification and usage instructions for specialized service tools.
Bore X Stroke:
Approx. 89.0 mm x 80.0 mm (varies slightly by year)
Cooling System:
Liquid-cooled
Compression Ratio:
Varies by year, typically around 6.8:1 to 7.4:1
Horsepower:
Estimated 40-50+ HP (at the crank, varies by year and tuning)
Torque:
Significant low-to-mid range torque, characteristic of large displacement two-strokes.
Carburetor:
Typically Mikuni VM series (e.g., VM34 or VM36) with variable jetting recommendations based on altitude and conditions.
Fuel Type:
Unleaded gasoline (91+ octane recommended) mixed with 2-stroke oil.
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Length:
Approx. 86.4 inches (2195 mm) (varies by year)
Width:
Approx. 32.1 inches (815 mm) (varies by year)
Height:
Approx. 50.2 inches (1275 mm) (varies by year)
Dry Weight:
Approx. 238 lbs (108 kg) (varies by year)
Wet Weight:
Approx. 254 lbs (115 kg) (with fluids, varies by year)
Fuel Capacity:
Approx. 2.5 gallons (9.5 L) (varies by year)
Off Road Specific:
Safety is paramount in off-road riding. Proper gear (helmet, boots, gloves, body armor) is essential. The manual emphasizes the use of correct safety procedures and tools to prevent injury.
Handling:
Designed for aggressive off-road handling, with responsive steering and stable suspension.
Frame Rigidity:
Sturdy frame construction contributes to overall stability and rider confidence.
Oil Change Engine:
Refer to the manual for specific intervals, typically after a set number of riding hours or mileage, depending on riding conditions.
Air Filter Cleaning:
Recommended after every few rides or as conditions dictate, essential for engine longevity in dusty environments.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment are critical for performance and drivetrain life.
2-Stroke Oil:
Use a high-quality, reputable brand of 2-stroke premix oil specifically designed for air-cooled or liquid-cooled racing engines. Recommended mix ratio will be detailed in the manual.
Coolant:
A 50/50 mixture of ethylene glycol-based antifreeze and distilled water is typically recommended for the liquid-cooled engine.
Gear Oil:
Specific gear oil (e.g., SAE 80W or 90W) is required for the transmission. Refer to manual for exact specification and capacity.
Engine Seizure:
Can occur due to improper fuel/oil mixture, lean jetting, or overheating. Proper maintenance is key.
Carburetor Fouling:
Can lead to poor running. Regular cleaning and proper jetting are important.
Suspension Leaks:
Fork seals and rear shock seals can wear over time, requiring replacement and fluid service.
Clutch Wear:
Clutch plates can wear with hard use, leading to slippage. Replacement is a common service item.
Kawasaki Off Road:
Kawasaki has a long and successful history in off-road racing, particularly with its KX line, building a reputation for powerful and competitive machines.
Kx Line Progression:
The KX500 evolved from earlier Kawasaki open-class two-stroke motocross bikes, incorporating advancements in suspension, chassis design, and engine technology throughout its production run.
Production Period:
The KX500 was produced from 1983 to 2004, making this manual cover a significant portion of its lifespan.
Racing Success:
The KX500 has a strong racing pedigree, achieving numerous victories in professional motocross and desert racing events.
