1979-1985 Kawasaki KZ500 KZ550 ZX550 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 131979

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

Product variants

Description

This manual covers the KZ500, KZ550, and ZX550 series motorcycles produced between 1979 and 1985. These models represent a significant era in UJM and sportbike development, featuring DOHC inline-four engines known for their reliable performance and distinctive styling. Popular for both everyday riding and customization, these motorcycles offered accessible performance and straightforward mechanicals, positioning them competitively against other Japanese manufacturers of the period. This comprehensive service and workshop manual provides detailed information essential for maintaining and repairing your KZ500, KZ550, or ZX550. It covers all critical aspects, including mechanical and electrical systems, engine overhaul, transmission servicing, chassis components, and bodywork. Within its pages, you will find step-by-step procedures for routine maintenance, major repairs, troubleshooting common issues, and detailed technical specifications, including torque values and wiring diagrams, empowering owners and technicians to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Year Range:

1979-1985

Codes

Model Codes:

KZ500 series, KZ550 series, ZX550 series (e.g., KZ550-A, KZ550-C, KZ550-D LTD, KZ550-F GPz, ZX550-A GPz)

👋 Introduction

Market Position

Segment:

Mid-size UJM (Universal Japanese Motorcycle) / Sportbike segment

Target Audience:

Owners of Kawasaki KZ500, KZ550, and ZX550 models seeking to perform their own maintenance, repairs, or modifications.

Competitive Analysis

Competitors:

Yamaha XJ550, Honda CB550/CB650 series, Suzuki GS550 series.

Key Features

Model Features:

DOHC inline-four engines, reliable performance, distinctive styling for their era, popular for customization and everyday riding.

Engineering Philosophy:

Focus on reliability, accessible performance, and straightforward mechanicals characteristic of Japanese motorcycles of the era.

Manual Value Proposition

Benefits:

Empowers owners to perform DIY repairs, avoid unnecessary dealership costs, understand their motorcycle's systems, and maintain its performance and longevity. Essential for accurate troubleshooting and correct repair procedures.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Troubleshooting, Maintenance, Repair

Secondary Coverage:

Engine Overhaul, Transmission Servicing, Chassis Components, Bodywork, Wiring Diagrams

Page Count

Estimated Page Count:

400-600 pages (estimated, typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Manual / Workshop Manual

Language

Language:

English

Format

Format:

Accessibility:

Instant download after payment, compatible with various devices (Windows, Mac, iPad, etc.).

📖 Manual Coverage

Systems Covered

Engine:

Top end (cylinder head, valves, camshafts), bottom end (crankshaft, connecting rods, pistons), cooling system (air-cooled), lubrication system (oil pump, oil filter, oil passages), ignition system (CDI, ignition coils, spark plugs), fuel system (carburetors, fuel lines, fuel filter), starting system (starter motor, starter clutch)

Transmission:

Gearbox (gear selection, shift drum, gears), clutch (clutch plates, springs, pressure plate, clutch release mechanism), final drive (chain, sprockets)

Chassis:

Frame, suspension (front forks, rear shock absorbers, linkages), steering system (handlebars, steering head bearings), wheels and tires (rims, spokes, bearings, tire pressures), braking system (front and rear drum or disc brakes, hydraulic lines, master cylinders, calipers, brake pads)

Electrical:

Battery, charging system (alternator/stator, regulator/rectifier), lighting system (headlight, taillight, turn signals), instrumentation (speedometer, tachometer, indicator lights), wiring harness, switches, fuses

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment and lubrication, brake adjustment, tire pressure checks, spark plug inspection and replacement, air filter cleaning/replacement, carburetor synchronization, valve clearance adjustment

Major Repairs:

Engine rebuilds (top-end and bottom-end), transmission overhaul, carburetor overhaul and tuning, fork seal replacement, shock absorber replacement, brake caliper rebuilding, electrical system troubleshooting and repair, clutch replacement

Troubleshooting:

Diagnostic charts for common problems (e.g., no start, poor running, braking issues, electrical faults), specific component testing procedures

Wiring Diagrams:

Detailed electrical wiring diagrams for all model variants, crucial for diagnosing electrical faults.

Frame And Suspension Alignment:

Procedures for checking and adjusting frame alignment and suspension geometry.

Bodywork And Trim Removal:

Instructions on how to safely remove and reinstall body panels, fairings, and trim pieces.

Technical Depth

Depth:

Comprehensive, covering everything from basic adjustments to full engine and transmission rebuilds. Includes detailed disassembly, reassembly, and adjustment procedures with torque specifications.

Diagnostic Procedures:

Includes step-by-step diagnostics for engine, electrical, and fuel system issues. Often features specific troubleshooting flowcharts.

Torque Specifications:

Provides precise torque values for all critical fasteners, essential for proper assembly and preventing damage.

Special Tools:

Lists any specialized tools required for specific maintenance or repair procedures.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Likely searchable text within the PDF, allowing for quick information retrieval.

Print Quality

Printability:

Designed for printing specific pages as needed, offering flexibility for workshop use.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, DOHC, inline-four cylinder

Bore X Stroke Kz500:

54.0 mm x 54.4 mm

Bore X Stroke Kz550:

58.0 mm x 50.6 mm

Displacement Kz500:

498 cc

Displacement Kz550:

553 cc

Valve Train:

DOHC (Double Overhead Camshafts), 2 valves per cylinder

Performance

Horsepower Kz500 Est:

48-50 HP @ 9,000 RPM

Horsepower Kz550 Est:

52-58 HP @ 9,000 RPM

Torque Kz550 Est:

30-33 lb-ft @ 7,500 RPM

Fuel System

Carburetor Type:

Multiple Mikuni VM series or similar side-draft carburetors (e.g., 26mm, 28mm, 32mm depending on model variant)

Fuel Delivery:

Gravity feed from fuel tank

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, foot-shifted

Clutch Type:

Wet multi-plate, cable-actuated

Gear Ratios:

Specific gear ratios are detailed within the manual for each model variant.

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Weights

Dry Weight Kz500 Est:

185-195 kg (408-430 lbs)

Dry Weight Kz550 Est:

190-205 kg (419-452 lbs)

Fuel Capacity Est:

16-18 Liters (4.2-4.7 Gallons)

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, tachometer, odometer, trip meter, high-beam, neutral, oil pressure, turn signal indicators). No modern infotainment or electronic rider aids.

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (2,000-3,000 miles) or 6-12 months, whichever comes first.

Valve Adjustment Interval:

Every 10,000-15,000 km (6,000-9,000 miles) or annually.

Spark Plug Inspection:

Every 5,000-10,000 km (3,000-6,000 miles)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 motorcycle-specific engine oil (API SG or higher recommended).

Engine Oil Capacity Est:

Approx. 2.5-3.0 Liters (2.6-3.2 Quarts) with filter change.

Brake Fluid Type:

DOT 3 or DOT 4 (verify specific model requirement).

Fork Oil Type Est:

10W or 15W fork oil (volume and level specification critical).

Gearbox Oil Type:

Motorcycle-specific transmission oil or API GL-1 gear oil (verify specific recommendation).

Gearbox Oil Capacity Est:

Approx. 1.0-1.2 Liters (1.1-1.3 Quarts).

Known Issues

Carburetor Tuning:

Carburetors can become gummed up or mis-synced over time, leading to poor running conditions. Rebuilds and precise synchronization are often required.

Electrical Connections:

Aging wiring harnesses and connections can lead to intermittent electrical issues. Corrosion on connectors is common.

Valve Clearance:

Valve clearances tend to tighten over time, requiring regular adjustment to maintain performance and prevent damage.

Clutch Wear:

Clutch plates can wear out, leading to slipping. Replacement of plates and springs is a common service item.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing reliable and performance-oriented motorcycles, particularly in the inline-four segment.

Model Evolution

Kz Series:

The KZ500 and KZ550 were part of Kawasaki's highly successful KZ line, evolving from earlier models and paving the way for the GPz series.

Zx Series Introduction:

The ZX550 designation often referred to the GPz550 models, which brought more performance-oriented features like the Uni-Trak rear suspension and sometimes fairings.

Production

Production Period:

1979-1985, with variations and updates within these years across different sub-models.