1979-1985 Kawasaki Kz500-Kz550-Zx550 Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 145175

Tags: 1979 1980 1981 1982 1983 1984 1985 Kawasaki Kz500 Kz550 Motorcycle Motorcycles ZX Models Zx550

Product variants

Description

This workshop service repair manual covers the Kz500, Kz550, and Zx550 models produced between 1979 and 1985. These motorcycles are recognized for their robust parallel-twin engines, DOHC valve trains, and sporty design, making them popular for both daily commuting and spirited riding. 's engineering quality is evident in the reliable performance and enduring appeal of these models, which established a significant presence in the motorcycle market during the early 1980s. This manual provides comprehensive coverage to assist owners and technicians in maintaining these classic machines. The scope of this manual is extensive, offering detailed procedures for all aspects of maintenance, repair, and troubleshooting for the specified models. It includes in-depth guidance on engine overhauls, fuel and ignition system adjustments, transmission and drivetrain service, as well as suspension, brake, and electrical system maintenance. With step-by-step instructions, diagnostic charts, and critical technical specifications, this resource is designed to empower both do-it-yourself enthusiasts and professional mechanics. Its purpose is to ensure the longevity and optimal performance of your Kz500, Kz550, or Zx550.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Kz500 / Kz550 / Zx550

Model Variants:

Kz500, Kz550 (various sub-models), Zx550

Product Name:

1979-1985 Kawasaki Kz500-Kz550-Zx550 Workshop Service Repair Manual

Production Years Covered:

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

👋 Introduction

Market Position

Target Audience:

Do-it-yourself enthusiasts and professional mechanics seeking to maintain, repair, or restore Kawasaki Kz500, Kz550, and Zx550 motorcycles.

Competitive Analysis

Value Proposition:

Provides an inexpensive and efficient way to keep these classic Kawasaki motorcycles in proper working order, saving on labor costs and ensuring longevity.

Key Features

Resource Type:

Primary source for repair and service information.

Ease Of Use:

Printable pages allow for portability in the workshop or garage.

📋 Manual Details

Coverage Areas

Coverage:

Complete service and repair for Kawasaki Kz500, Kz550, and Zx550 models from 1979-1985.

Page Count

Estimated Page Count:

Detailed page count not specified, but described as 'complete' and covering 'every detail'.

Manual Type

Type:

Workshop Service Repair Manual / Factory Service Repair Manual

Language

Language:

English

Format

Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine overhaul, diagnostics, tuning, and component repair for all Kz500/Kz550/Zx550 engine variants.

Fuel System:

Carburetor adjustment, cleaning, rebuilding, fuel pump, fuel tank, and lines.

Ignition System:

CDI, spark plugs, ignition coils, timing checks, and troubleshooting.

Transmission:

Clutch operation, gearbox inspection, rebuild procedures, and shift mechanism.

Drivetrain:

Chain drive maintenance, sprocket inspection, and final drive assembly.

Suspension:

Front fork service (oil changes, seal replacement), rear shock absorber inspection and replacement, linkage maintenance.

Brakes:

Front and rear brake system maintenance, caliper service, master cylinder overhaul, brake fluid replacement, and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator, regulator/rectifier), lighting, starter motor, and switches.

Chassis And Bodywork:

Frame inspection, body panel removal and installation, seat, fuel tank, and fairing details.

Cooling System:

Radiator, fan, hoses, and coolant specifications (where applicable for liquid-cooled variants like some Zx550).

Exhaust System:

Exhaust pipe and muffler inspection and replacement.

Wheels And Tires:

Wheel bearing inspection, tire pressure, and replacement recommendations.

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, chain adjustment, brake checks, and general tune-ups.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting for common mechanical and electrical issues.

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly.

Rebuilds:

Detailed procedures for engine and transmission rebuilds.

Adjustments:

Carburetor synchronization, valve clearance adjustment, ignition timing.

Wiring Diagrams:

Complete electrical schematics for all models and variations.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to advanced engine and transmission overhauls. Suitable for both novice DIYers and experienced mechanics.

Illustrations:

Detailed illustrations and diagrams for clarity.

Specifications:

Includes critical technical specifications for all components and systems.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Fully Printable

Zoom Functionality:

YES (Zoom IN/OUT functionality)

Binding Type

Binding:

Digital (PDF), no physical binding.

Paper Type

Paper Type:

N/A (Digital file)

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, parallel-twin (primarily 500cc and 550cc variants).

Displacement:

Approximately 498cc (Kz500) and 553cc (Kz550/Zx550). Specific displacements may vary slightly by sub-model.

Bore X Stroke:

Varies by specific model. For example, Kz550: 66.0 mm x 81.0 mm (approx.).

Compression Ratio:

Typically around 9.0:1 to 10.0:1 depending on the specific model and tuning.

Performance

Horsepower Range:

Estimated 48-60 HP at the crankshaft, depending on the specific model and state of tune.

Torque Range:

Estimated 28-35 lb-ft, depending on the specific model.

Fuel System

Carburetion:

Typically dual Mikuni VM or BS series carburetors (e.g., VM26, BS30).

Fuel Type:

Unleaded gasoline, typically 87 octane or higher.

Engine Components

Valve Train:

DOHC, 2 valves per cylinder.

Cooling:

Air-cooled, with some Zx550 variants potentially featuring liquid cooling for the cylinder head or block.

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed or 6-speed manual transmission.

Clutch:

Wet, multi-plate clutch.

Features

Gear Ratios:

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

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 56-57 inches (1420-1450 mm).

Weights

Dry Weight:

Approximately 380-430 lbs (172-195 kg), depending on the specific model and equipment.

🛡️ Safety Features

Ratings

Safety Standards:

As with most motorcycles of this era, specific crash test ratings (like modern automotive tests) were not applicable. Safety focus is on rider control, braking, and vehicle stability.

Active Features

Braking System:

Front disc brake, rear drum brake (common configuration). Some later models or variants might have dual front discs.

Passive Features

Frame Construction:

Strong steel frame design for stability and rider confidence.

💡 Technology Features

Infotainment

Features:

N/A. This era of motorcycles is devoid of modern infotainment systems. Focus is on mechanical and electrical function.

Driver Assistance

Features:

N/A. No electronic driver assistance systems.

Connectivity

Features:

N/A. No connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-6,000 miles or annually, depending on riding conditions. Consult manual for specific recommendations.

Valve Adjustment Interval:

Usually around 6,000-12,000 miles. Precision is critical for performance and longevity.

Chain Lubrication And Adjustment:

Regularly, every 500-1000 miles and after washing or riding in wet conditions.

Fluid Specifications

Engine Oil Type:

API SE, SF, or SG classification, SAE 10W-40 or 20W-50 motorcycle specific oil is generally recommended. Always verify with the manual.

Engine Oil Capacity:

Approximately 2.5 - 3.0 liters (with filter change), specific capacity detailed in the manual.

Brake Fluid Type:

DOT 3 or DOT 4 (check master cylinder cap for specification). Always use fresh, high-quality fluid.

Fork Oil Type:

Typically SAE 10W or 15W fork oil. Specific viscosity and quantity are crucial for correct damping.

Known Issues

Carburetor Issues:

Gumming and clogging of carburetors due to fuel degradation over time, requiring cleaning and synchronization.

Electrical Gremlins:

Older wiring harnesses can degrade, leading to intermittent electrical issues. Regulator/rectifier failures are also common on bikes of this age.

Suspension Wear:

Fork seals can leak, and rear shock absorbers may lose damping effectiveness over time.

Engine Seals:

Age-related degradation of engine and transmission seals can lead to oil leaks.

Technical Specifications

Spark Plug Type:

Commonly NGK or Denso plugs, e.g., NGK CR9E or similar. Specific type and gap are detailed in the manual.

Valve Clearance Intake:

Typically a small clearance, e.g., 0.05-0.10 mm. Exact figures are model-specific.

Valve Clearance Exhaust:

Typically a small clearance, e.g., 0.05-0.10 mm. Exact figures are model-specific.

Tire Pressure Front:

Typically 28-32 PSI (cold). Check sidewall for recommendations.

Tire Pressure Rear:

Typically 32-36 PSI (cold). Check sidewall for recommendations.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing powerful and reliable motorcycles, especially in the sportbike and naked bike segments.

Model Evolution

Kz Series Significance:

The Kz500 and Kz550 series were key in Kawasaki's lineup, offering accessible performance and sporty styling. The Zx550 represented an evolution, often with more performance-oriented features.

Production

Manufacturing Period:

1979-1985, establishing these models as influential motorcycles of the early 1980s.

🏆 Awards & Recognition

Recognitions

Industry Impact:

The Kz500/550/Zx550 series were well-regarded in their time for performance, handling, and reliability, contributing to Kawasaki's strong market presence.

Ratings

Modern Appreciation:

These models are often sought after by enthusiasts and collectors for their classic styling and engaging riding experience.

Certifications

Manual Quality:

Described as a complete factory service manual, indicating high adherence to original manufacturer documentation standards.