KAWASAKI KZ500 KZ550 ZX550 Digital Workshop Repair Manual 1979-1986

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Taper: Motorcycle

Distributeur:

UGS: 134990

Mots clés: 1979 1980 1981 1982 1983 1984 1985 1986 Kawasaki KZ500 KZ550 Motorcycle Motorcycles ZX Models ZX550

Variantes de produits

Description

This digital workshop repair manual covers the KZ500, KZ550, and ZX550 models produced between 1979 and 1986. These motorcycles, known for their inline-four engines and sporty designs, represent a significant era in performance motorcycle development. The KZ and ZX series were highly regarded for their reliability and performance, making them popular choices for riders and enthusiasts. This manual provides comprehensive information essential for maintaining these classic machines. The purpose of this manual is to offer detailed workshop and repair procedures for all aspects of the KZ500, KZ550, and ZX550. It encompasses everything from routine scheduled maintenance, such as oil changes and chain adjustments, to in-depth engine disassembly, transmission overhauls, carburetor rebuilding, and electrical system troubleshooting. With high-quality photos, illustrations, and diagrams, this English-language resource is designed for owners, DIY enthusiasts, mechanics, and restorers, enabling them to effectively maintain, repair, and preserve these iconic motorcycles.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

ZX550

Years Covered:

1979-1986

👋 Introduction

Market Position

Target Audience:

Owners, DIY enthusiasts, mechanics, restorers of Kawasaki KZ500, KZ550, and ZX550 motorcycles.

Competitive Analysis

Value Proposition:

Provides professional-level repair information at a fraction of dealership service costs. Offers a permanent, clean, and easily accessible resource compared to traditional paper manuals.

Key Features

Content Quality:

High-quality photos, illustrations, and diagrams for clear understanding of procedures.

Availability:

Instant download for immediate access to repair information.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete workshop and repair procedures from A-Z

Page Count

Estimated Page Count:

Extensive (Specific page count not provided, but described as comprehensive for all repairs)

Manual Type

Type:

Digital Workshop Repair Manual

Language

Language:

English

Format

Format:

Digital (Instant Downloadable PDF)

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, tuning, diagnostics, internal components, cooling system, lubrication system.

Fuel System:

Carburetor overhaul, fuel lines, fuel tank, fuel pump (if applicable).

Ignition System:

Ignition timing, CDI unit, spark plugs, coils, wiring.

Transmission:

Gearbox inspection, repair, clutch operation, shift mechanism.

Drivetrain:

Final drive, shaft drive (if applicable), sprocket, chain maintenance.

Suspension:

Front forks (telescopic, cartridge types), rear shock absorbers, swingarm, linkage.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake pads, discs/drums.

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), lighting, indicators, starter motor, horn.

Frame And Bodywork:

Chassis inspection, frame repairs, body panel removal/installation, seat, fairings (if applicable).

Wheels And Tires:

Wheel bearing service, tire replacement, rim maintenance.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustments, lubrication points.

Troubleshooting:

Diagnostic procedures for common problems, fault finding charts.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Rebuild:

Complete engine rebuild, transmission overhaul, carburetor rebuilding.

Restoration:

Guidance on refurbishing and restoring older models.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete overhauls, as used by professional technicians.

📊 Manual Specifications

File Format

File Type:

Print Quality

Print Quality:

High quality, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Usability

Computer Requirements:

Microsoft Windows 95/98/98SE/2000/NT/ME/XP/Vista/7, All Mac Computers

Accessibility:

Easy to view and print, no advanced computer skills required.

⚙️ Engine Specifications

Primary Engine

Engine Type Kz500 Kz550:

4-stroke, DOHC, Inline 4-cylinder (typically)

Engine Displacement Kz500:

498 cc (approximately)

Engine Displacement Kz550:

553 cc (approximately)

Engine Displacement Zx550:

553 cc (approximately - often associated with the GPz550 variant)

Performance

Horsepower Kz500 Kz550:

Varies by year and specific model, typically in the 50-60 HP range.

Torque Kz500 Kz550:

Varies by year and specific model.

Fuel System

Carburetion:

Multiple Carburetors (e.g., 4x Mikuni VM series, or TK carburetors depending on model and year)

Fuel Delivery:

Gravity feed from fuel tank to carburetors, some models might have a fuel pump for higher performance variants.

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed manual transmission

Optional

Clutch Type:

Wet, multi-plate clutch

Features

Gear Ratios:

Specific ratios are detailed within the manual for each model and year.

📐 Dimensions

Exterior

Wheelbase:

Varies by specific model and year (e.g., KZ550 LTD around 1425 mm)

Weights

Dry Weight:

Varies by model, typically in the 190-215 kg range.

🛡️ Safety Features

Ratings

Safety Features:

Focuses on mechanical safety and proper maintenance for safe operation. No electronic safety assists typically found in modern vehicles.

Active Features

Braking System Type:

Front: Disc brake; Rear: Disc or Drum brake depending on model and year.

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals, instrument cluster illumination.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer, fuel gauge, indicator lights for turn signals, high beam, neutral, oil pressure, etc.

Driver Assistance

Anti-lock Braking System (ABS) was not a standard or common feature on these models.

Connectivity

Charging System:

Stator, rectifier/regulator, and battery provide the electrical power. Manual details testing and replacement of these components.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-4,000 miles (4,800-6,400 km) or 6 months, whichever comes first. Consult manual for precise intervals.

Valve Clearance Check:

Usually at 6,000-12,000 mile intervals, critical for engine performance and longevity. Exact interval in manual.

Chain Lubrication Adjustment:

Regularly, every 500-1000 miles (800-1600 km) or after washing/rain. Manual specifies slack.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 or 20W-50 motorcycle oil, API SG or higher. Specific viscosity based on climate.

Engine Oil Capacity:

Approximately 2.4-3.0 liters (with filter change), depending on model variant. Manual specifies exact amount.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil Type:

Specific weight fork oil (e.g., SAE 10W, SAE 15W), quantity per fork leg detailed in manual.

Known Issues

Carburetor Sync And Cleaning:

Carburetors require periodic syncing and cleaning due to age and potential for fuel gumming. Manual provides detailed procedures.

Electrical Connections:

Corrosion and loose connections in the wiring harness can cause intermittent issues. Manual provides wiring diagrams for troubleshooting.

Cam Chain Tensioner:

Some models may have automatic cam chain tensioners that can wear out, leading to rattling noises. Manual details inspection and replacement.

Fork Seals:

Aging fork seals are a common wear item, leading to oil leaks. Manual covers fork seal replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long history of producing performance motorcycles, known for their inline-four engines and sporty designs.

Model Evolution

Kz Series:

The KZ series represented Kawasaki's strong push into the sportbike and sport-touring market during the late 1970s and 1980s, evolving from earlier models with advancements in engine technology and chassis design.

Zx Series Introduction:

The ZX designation began to appear, signaling a move towards more aggressive, sport-focused designs, with the ZX550 often being a variant or precursor to the GPz lineup.

Production

Production Period:

Models covered span from 1979 to 1986, a significant era for Japanese motorcycle development.

🏆 Awards & Recognition

Recognitions

Market Reputation:

Kawasaki's KZ/ZX series from this era were generally well-regarded for their performance, reliability, and value, contributing to the brand's strong market presence.