KAWASAKI KZ500 KZ550 ZX550 Service Repair Manual 1979-1986

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Taper: Motorcycle

Distributeur:

UGS: 136201

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

Variantes de produits

Description

This manual covers the KZ500, KZ550, and ZX550 series motorcycles, produced between 1979 and 1986. These models, including variants such as the KZ500A, KZ550A, KZ550B, KZ550C (LTD), KZ550D (GP), KZ550F (GP), and ZX550-A (GPz), are known for their robust 4-stroke, DOHC, air-cooled inline-four engines. The KZ500 features a 498cc displacement, while the KZ550 and ZX550 offer 552cc, providing accessible performance and reliable engineering characteristic of the legacy in the sportbike and standard motorcycle segments. This comprehensive Service Repair Workshop Manual provides detailed information for the maintenance, repair, and troubleshooting of your motorcycle. It covers all major systems, including the engine, transmission, chassis, suspension, brakes, and electrical system, with step-by-step instructions, torque specifications, and diagnostic procedures. The manual is designed to assist owners and technicians in performing routine maintenance, complex repairs, and component overhauls, ensuring the longevity and optimal performance of your vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Model Variants:

KZ500A, KZ550A, KZ550B, KZ550C (LTD), KZ550D (GP), KZ550F (GP), ZX550-A (GPz)

Production Years Covered:

1979-1986

Codes

Chassis Codes:

KZ500A, KZ550A, KZ550B, KZ550C, KZ550D, KZ550F, ZX550A

👋 Introduction

Market Position

Target Audience:

Owners and independent mechanics seeking to perform maintenance and repairs on these specific Kawasaki models.

Competitive Analysis

Value Proposition:

Provides essential factory-level repair information, enabling DIY maintenance and reducing reliance on costly dealership services.

Key Features

Key Selling Points:

Factory quality, comprehensive coverage, detailed diagrams, instant download, cost savings on repairs.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive repair and service for the entire vehicle

Page Count

Estimated Page Count:

Approximately 400-600 pages (typical for this era/scope)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, inspection, troubleshooting, tuning, lubrication system, cooling system (air-cooled), fuel system (carburetors), ignition system, exhaust system

Transmission:

Gearbox disassembly, assembly, inspection, lubrication, clutch operation and service

Chassis And Suspension:

Front fork overhaul, rear shock absorber service, swingarm inspection and lubrication, steering head bearing service

Brakes:

Front and rear brake system service (hydraulic disc and drum), caliper and master cylinder overhaul, brake fluid replacement, bleeding procedures

Electrical System:

Wiring diagrams, lighting system, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, ignition coil testing, instrument panel functions

Fuel System:

Carburetor tuning, cleaning, and rebuilding (Mikuni VM series common), fuel tank maintenance, petcock service

Bodywork And Trim:

Fender, seat, fuel tank, side covers, and instrument cluster removal/installation procedures

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake adjustment, valve clearance adjustment

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues

Repair And Rebuild:

Engine top-end and bottom-end rebuild, gearbox overhauls, carburetor rebuilding, suspension component replacement

Inspection:

Torque specifications for all critical fasteners, wear limits for engine and chassis components

Technical Depth

Depth Of Information:

Factory-level detail with step-by-step instructions, torque values, clearances, and exploded diagrams for most components.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (OCR'd if scanned from print)

Print Quality

Printability:

High-resolution, designed for printing specific sections or the entire manual.

Binding Type

Binding Type Original:

N/A (Digital PDF)

Paper Type

Paper Type Original:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, Air-cooled, Inline-Four Cylinder

Displacement Kz500:

498 cc (30.4 cu in)

Displacement Kz550:

552 cc (33.7 cu in)

Bore X Stroke Kz500:

66.0 mm x 72.0 mm (2.60 in x 2.83 in)

Bore X Stroke Kz550:

66.0 mm x 80.0 mm (2.60 in x 3.15 in)

Compression Ratio Kz500:

9.5:1

Compression Ratio Kz550:

9.4:1 (std), 9.1:1 (GPz)

Horsepower Kz500 Approx:

48-50 HP @ 9,000 RPM

Horsepower Kz550 Approx:

50-60 HP @ 9,000 RPM

Torque Kz550 Approx:

32-35 lb-ft @ 7,000 RPM

Fuel System

Carburetor Type:

Twin Keihin CV (Constant Velocity) carburetors (e.g., 34mm VM series)

Fuel Capacity:

Approx. 4.5 - 5.3 US gallons (17 - 20 Liters)

Fuel Type:

Unleaded gasoline, Octane rating 86 or higher (RON+MON)/2

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh, sequential return

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain drive

Fluid Specifications

Transmission Oil Type:

API GL-4, SAE 10W-40 motorcycle gear oil

Fluid Capacities

Transmission Oil Capacity:

Approx. 2.0 - 2.2 US quarts (1.9 - 2.1 Liters)

📐 Dimensions

Exterior

Overall Length Approx:

2.1 - 2.2 meters (83-87 inches)

Overall Width Approx:

0.75 - 0.8 meters (30-31 inches)

Overall Height Approx:

1.1 - 1.2 meters (43-47 inches)

Weights

Dry Weight Approx:

180 - 200 kg (397 - 441 lbs)

Wet Weight Approx:

195 - 215 kg (430 - 474 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is primarily performance and design based)

Active Features

Braking System:

Dual hydraulic disc front, single disc or drum rear (model dependent)

Suspension Features:

Telescopic front forks, adjustable rear shock absorbers (twin or monoshock depending on model/trim)

Passive Features

Lighting:

Halogen headlight, LED taillight/brake light, incandescent turn signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Mechanical motorcycle)

Driver Assistance

Rider Assistance:

N/A (Mechanical motorcycle)

Connectivity

Connectivity:

N/A (Mechanical motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (5,000 km) or 6 months

Valve Clearance Check Interval:

Every 6,000 miles (10,000 km)

Chain Lubrication And Adjustment:

Every 500 miles (800 km) or after washing/rain

Fluid Specifications

Engine Oil Type:

API SE or SF, SAE 10W-40 motorcycle specific oil

Engine Oil Capacity:

Approx. 2.4 - 2.8 US quarts (2.3 - 2.6 Liters) with filter change

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

Cam chain tensioners (can become noisy), carburetor synchronization drift, fork seal leaks, aging electrical connectors.

Typical Problems:

Carburetor gumming if not run regularly, potential for CDI unit failure, general aging of rubber components.

Technical Specifications

Spark Plug Gap:

0.6 - 0.7 mm (0.024 - 0.028 in)

Idle Speed:

Approx. 1000-1200 RPM

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Model Evolution

Kz500 Introduction:

Introduced as a successor to smaller displacement models, offering a balance of performance and manageability in the 500cc class.

Kz550 Development:

Developed from the KZ500 platform, increasing displacement to the 550cc class for enhanced performance. Introduced various sub-models like LTD and GPz variants.

Zx550 Introduction:

The ZX550 designation generally referred to the GPz550, often featuring sportier styling and improved performance components like adjustable suspension and fairings.

Production

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Historical Recognition:

While specific awards for these models may not be widely documented, they were popular and well-regarded in their respective sportbike and standard motorcycle segments of the early to mid-1980s.

Ratings

Performance Reputation:

Praised for their reliable inline-four engines and solid chassis dynamics, making them accessible sportbikes for the era.

Certifications

Certification Standards:

Met all relevant safety and emissions standards for their respective production years and markets.