Model Code:
KZ550-A1, A2, A3, A4; GPz550-B1, B2
Production Years Covered:
1979-1985
Chassis Codes:
KZ550A1, KZ550A2, KZ550A3, KZ550A4, KZ550B1, KZ550B2
Vehicle Class:
Mid-size sport touring / naked motorcycle
Target Audience:
Performance-oriented riders, commuters, vintage motorcycle enthusiasts
Key Competitors Era:
Honda CB550/CB650, Yamaha XJ550/XJ650, Suzuki GS550/GS650
Kz550 Focus:
Reliable inline-four, versatile for commuting and touring
Gpz550 Focus:
Performance-oriented, faired sportbike variant with enhanced engine tuning and suspension
Primary Coverage:
Complete service and repair for Kawasaki KZ550 and GPz550 models
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, specifications, wiring diagrams
Estimated Page Count:
Approx. 300-400 pages (typical for comprehensive factory-style manuals)
Type:
Service Repair Manual
Engine:
Top end, bottom end, cooling system, lubrication system, timing, valve adjustment
Fuel System:
Carburetor removal, cleaning, adjustment, synchronization, fuel pump, fuel tank
Ignition System:
CDI unit, ignition coils, spark plugs, timing adjustments
Transmission Clutch:
Clutch operation, gearbox disassembly, assembly, lubrication, torque specifications
Electrical System:
Wiring diagrams, charging system (alternator, rectifier/regulator), starting system (starter motor, solenoid), lighting, instruments, switches, fuses
Suspension:
Front forks (oil change, seal replacement, spring replacement), rear shock absorbers, linkage
Brakes:
Front and rear brake systems, caliper overhauls, master cylinders, fluid replacement, bleeding procedures, brake pads, rotors
Wheel Tires:
Wheel bearing replacement, tire mounting, balancing
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, footpegs
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement, battery maintenance
Troubleshooting:
Systematic diagnosis of common problems and solutions
Engine Rebuild:
Complete disassembly and reassembly of the engine
Carburetor Tuning:
Jetting, needle adjustments, float bowl levels, idle speed
Electrical Diagnostics:
Testing of electrical components and circuits using multimeters
Fork Rebuild:
Front fork seal replacement and oil service
Brake System Service:
Fluid flushing, caliper and master cylinder rebuilding
Torque Specifications:
Critical torque values for all fasteners
Depth:
Comprehensive: Covers everything from basic scheduled maintenance to complete engine rebuilds and complex electrical troubleshooting.
Engine Type:
4-stroke, DOHC, inline-four cylinder
Bore X Stroke:
58.0 mm x 50.6 mm
Compression Ratio:
9.7:1 (typical, may vary slightly by model year)
Horsepower:
Approx. 58-65 HP @ 9,000 RPM (GPz variant often slightly higher)
Torque:
Approx. 34-37 lb-ft @ 7,500 RPM
Carburetion:
Four 32mm (or 34mm for GPz) Mikuni VM series carburetors
Fuel Tank Capacity:
Approx. 16 Liters (4.2 US gallons)
Cooling System:
Air-cooled
Ignition Type:
Electronic (CDI) with breakerless ignition
Oil Change Interval:
Every 3,000-4,000 km (2,000-2,500 miles) or 6 months
Valve Clearance Check:
Every 6,000-8,000 km (4,000-5,000 miles)
Chain Adjustment:
As needed, typically every 1,000-1,500 km (600-1,000 miles)
Engine Oil Type:
SAE 10W-40 API SE or SF (or equivalent motorcycle-specific oil)
Engine Oil Capacity:
Approx. 3.2 Liters (3.4 US qt) with filter change
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Fork Oil Type:
Kawasaki Fork Oil G10 or SAE 10W (specify quantity per leg from manual)
Common Wear Items:
Carburetor synchronization issues, stator/rectifier failures, front fork seal leaks, cam chain wear.
Starting Problems:
Can be related to battery condition, starter motor, or ignition system components.
Fueling Issues:
Clogged carb jets, worn floats, vacuum leaks in fuel lines or intake boots.
