Kawasaki KZ500 KZ550 ZX550 1979-1985 Best Service Repair Manual

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This manual covers the Kawasaki KZ500, KZ550, and ZX550 models produced between 1979 and 1985. These motorcycles represent a significant era for Kawasaki, with the KZ series known for its...

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Type: Motorcycle

Vendor:

Sku: 156119

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

Product variants

Description

This manual covers the Kawasaki KZ500, KZ550, and ZX550 models produced between 1979 and 1985. These motorcycles represent a significant era for Kawasaki, with the KZ series known for its blend of performance and everyday usability, while the ZX550 evolved towards a sportier design. The KZ500 features a 498 cc parallel-twin engine, the KZ550 offers a 553 cc parallel-twin, and the ZX550 utilizes a 553 cc inline-four engine, all paired with a 5-speed transmission and wet, multi-plate clutch. These models are recognized for their robust engineering and have contributed to Kawasaki's reputation for producing reliable and capable motorcycles. This comprehensive service repair manual provides detailed, step-by-step instructions and illustrations for all maintenance, diagnostic, and repair procedures. It covers essential systems including the engine, fuel system, clutch, transmission, brakes, suspension, steering, and electrical components, with specific attention to wiring diagrams for electrical troubleshooting. The manual is designed for owners and independent repair shops, empowering them with the knowledge to perform routine checks, oil changes, component rebuilds, and complex fault diagnosis, ultimately ensuring optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500/KZ550/ZX550

Product Name:

Kawasaki KZ500 KZ550 ZX550 1979-1985 Best Service Repair Manual Download PDF

Generation

Generation Covered:

First Generation KZ/KZ-derived models

Codes

Engine Codes:

KZ500A, KZ550A, KZ550C, KZ550D, KZ550F, KZ550H, ZX550A

👋 Introduction

Market Position

Target Audience:

Kawasaki KZ500, KZ550, ZX550 owners and independent repair shops

Competitive Analysis

Value Proposition:

Provides professional-level repair and maintenance knowledge for DIY enthusiasts and mechanics, offering cost savings.

Key Features

Key Feature 1:

Comprehensive coverage of all models and years (1979-1985).

Key Feature 2:

Detailed, step-by-step instructions with illustrations for all repair and maintenance tasks.

Key Feature 3:

Advanced troubleshooting guide for diagnosing and resolving common and complex issues.

Key Feature 4:

Includes essential wiring diagrams for electrical system diagnosis.

Key Feature 5:

Empowers owners to understand their motorcycle and communicate effectively with mechanics.

📋 Manual Details

Coverage Areas

Years Covered:

1979, 1980, 1981, 1982, 1983, 1984, 1985

Page Count

Estimated Page Count:

Hundreds of pages (Specific count not provided, but described as comprehensive)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Delivery Format:

PDF Download

File Format:

Platform Compatibility:

Windows, Mac OS

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top end, crankshaft, transmission, lubrication, cooling, fuel system

Chassis Components:

Wheels, tires, final drive, brakes, suspension, steering, frame

Electrical System:

Wiring diagrams, troubleshooting, diagnostics

Fuel System:

Carburetor systems, fuel delivery, fuel tank

Cooling System:

Radiator, coolant flow, fan operation (where applicable)

Clutch System:

Clutch operation, adjustment, replacement

Transmission System:

Gearbox internals, shifting mechanisms, lubrication

Brake System:

Hydraulic systems, caliper service, pad replacement, fluid specifications

Suspension System:

Front forks, rear shocks, adjustment, service

Steering System:

Handlebar assembly, steering head bearings

Electrical Component Coverage:

Ignition system, lighting, battery, charging system, starter motor

Procedures Included

Maintenance Procedures:

Routine checks, oil changes, filter replacements, chain adjustment

Diagnostic Procedures:

Engine fault symptom diagnosis, troubleshooting guides, part testing

Repair Procedures:

Step-by-step instructions for all covered systems and components

Rebuild Procedures:

Complete engine and component rebuild instructions

Troubleshooting Electrical:

Detailed wiring diagrams, fault finding for electrical issues

General Information:

Vehicle specifications, identification, model variations

Engine Removal Installation:

Detailed steps for engine removal and reinstallation

Technical Tips:

Advice for preventing issues and common fixes

Technical Depth

Depth Of Coverage:

Comprehensive (from basic maintenance to complete rebuilds)

Detail Level:

Detailed substeps, notes, cautions, and warnings

Illustrations:

Includes detailed illustrations, drawings, and photos

Diagnostic Tools:

Guidance on testing suspected parts and understanding systems

📊 Manual Specifications

File Format

PDF Quality:

High quality, printable without restriction

Print Quality

Print Option:

Print entire manual or specific pages

Binding Type

Binding Type:

Not applicable (Digital Download)

Paper Type

Paper Type:

Not applicable (Digital Download)

Delivery Method

Delivery Method:

Instant download via link after purchase

Requirements

Software Requirement:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, Parallel-Twin (for KZ500/KZ550), 4-stroke, DOHC, Inline-Four (for ZX550)

Performance

Kz500 Displacement:

498 cc

Kz550 Displacement:

553 cc

Zx550 Displacement:

553 cc

Kz500 Horsepower:

Approximately 48-50 HP (Varies by specific model and year)

Kz550 Horsepower:

Approximately 55-60 HP (Varies by specific model and year)

Zx550 Horsepower:

Approximately 65-70 HP (Varies by specific model and year)

Fuel System

Fuel Delivery:

Dual Carburetors (e.g., Mikuni VM26SS for KZ500/KZ550, potentially larger for ZX550)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh sequential gearbox

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Overall Length:

Varies by model (Consult specific model data if available)

Weights

Dry Weight:

Approx. 170-190 kg (Varies significantly by model, e.g., KZ500 vs. KZ550 vs. ZX550)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically assessed via specific component performance and rider skill)

Active Features

Active Safety Features:

Responsive braking system, stable chassis dynamics

Passive Features

Passive Safety Features:

Robust frame construction, protective bodywork (fairings on some variants)

💡 Technology Features

Infotainment

Infotainment Features:

N/A (These models predate modern infotainment systems; focus is on mechanical and electrical operation).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids common on modern motorcycles).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or 6 months (Refer to specific manual for precise intervals).

Valve Clearance Check:

Typically around 6,000-10,000 km (Crucial for performance and longevity).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher recommended (Specific viscosity and API rating as per manual).

Brake Fluid Type:

DOT 3 or DOT 4 (Consult manual for exact specification).

Fork Oil Type:

Specific grade fork oil, typically SAE 10W or 15W (Capacity also critical).

Known Issues

Common Issue 1:

Carburetor synchronization and cleaning (especially on older, less-maintained units).

Common Issue 2:

Wear on steering head bearings leading to notchy steering.

Common Issue 3:

Charging system issues (stator or regulator/rectifier failure).

Common Issue 4:

Fork seal leaks.

Common Issue 5:

Cam chain noise on some engines if not properly tensioned or worn.

📚 Vehicle History

Brand Heritage

Brand Focus:

Kawasaki is renowned for its high-performance motorcycles, including sportbikes and standards.

Model Evolution

Kz Series Significance:

The KZ500 and KZ550 models were part of Kawasaki's successful line of motorcycles that offered a blend of performance and everyday usability, bridging the gap between smaller displacement bikes and larger machines.

Zx Series Introduction:

The ZX550 marked an evolution towards more sport-oriented designs, often featuring sportbike fairings and a more aggressive riding posture.

Production

Production Period:

1979-1985

🏆 Awards & Recognition

Recognitions

Historical Recognition:

While specific awards for these models are rare in contemporary terms, they were critically acclaimed in their era for performance, reliability, and value, contributing to Kawasaki's strong market presence.