Market Segment:
Entry-level to mid-range sportbike / sport-touring motorcycle
Target Audience:
New riders, commuters, budget-conscious sportbike enthusiasts
Key Competitors:
Honda CBR500F/CBR500R (later models), Suzuki GS500E, Yamaha FZR500/EXUP
Competitive Advantages:
Reliability, accessible performance, cost-effectiveness, comfortable ergonomics for its class
Key Features Vehicle:
Parallel-twin engine, comfortable riding position, full fairing (GPZ500S/Ninja 500R), reliable performance
Key Features Manual:
Detailed technical procedures, comprehensive troubleshooting, clear diagrams, essential for DIY maintenance and repair
Engine Mechanical:
Engine disassembly, inspection, assembly, cylinder head, pistons, crankshaft, timing system, valve train
Fuel System:
Carburetor identification, removal, disassembly, cleaning, adjustment, fuel tank, fuel pump, fuel lines
Ignition System:
CDI unit, ignition coils, spark plugs, wiring diagrams
Cooling System:
Radiator, coolant hoses, thermostat, water pump, coolant type and capacity
Exhaust System:
Exhaust pipes, mufflers, mounting
Transmission Drivetrain:
Gearbox, clutch operation, primary drive, final drive chain and sprockets
Suspension Front:
Front forks (telescopic), oil type, levels, seals, spring rates
Suspension Rear:
Monoshock rear suspension, linkage, swingarm, shock absorber adjustment
Brakes Front:
Brake calipers, discs, master cylinder, brake fluid type and specifications
Brakes Rear:
Brake caliper, disc, master cylinder, brake fluid type and specifications
Wheels Tires:
Wheel bearing inspection, tire pressures, tire sizes, wheel specifications
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instruments, horn
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems
Frame Chassis:
Frame inspection, steering head bearings, general chassis components
Bodywork Fairings:
Fairing removal and installation, seat, fuel tank cover, fenders
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, brake adjustments, spark plug replacement, air filter cleaning/replacement
Troubleshooting Diagnostics:
Diagnostic charts for common problems, identifying causes and solutions
Engine Rebuild:
Complete engine overhaul procedures, including torque specifications and clearances
Suspension Overhaul:
Front fork seal replacement, rear shock absorber inspection/replacement procedures
Brake System Service:
Brake pad replacement, caliper service, bleeding procedures
Carburetor Tuning:
Carburetor synchronization, idle speed adjustment, jetting information
Electrical Component Testing:
Testing of stator, rectifier/regulator, starter motor, and other electrical parts
Special Tool Requirements:
Identification of specific tools needed for various repair procedures
Technical Depth:
Comprehensive: Covers everything from basic owner maintenance to complete engine and chassis rebuilds
Diagnostic Capabilities:
Detailed fault diagnosis and troubleshooting guides
Part Identification:
Exploded diagrams for component identification and assembly order
Engine Type:
Liquid-cooled, four-stroke, parallel-twin
Displacement:
498 cc (30.4 cu. in.)
Bore X Stroke:
74.0 mm x 58.0 mm (2.91 in x 2.28 in)
Compression Ratio:
10.5:1
Valve Configuration:
DOHC, 8 valves (2 per cylinder)
Horsepower Estimated:
Approx. 50-60 HP @ 8500 RPM (depending on market and tuning)
Torque Estimated:
Approx. 30-35 lb-ft @ 7000 RPM (depending on market and tuning)
Carburetion:
Twin Keihin CVK32 carburetors
Fuel Capacity:
17 liters (4.5 US gal)
Ignition System:
Digital CDI with electronic advance
Lubrication Type:
Wet sump
Oil Capacity W Filter:
Approx. 2.8 Liters (3.0 US qt)
Recommended Oil:
API SG, JASO MA certified, SAE 10W-40 or 20W-50 (refer to manual for exact spec)
Oil Change Interval:
Every 3,000-5,000 km (2,000-3,000 miles) or 6 months
Air Filter Cleaning:
Every 6,000 km (4,000 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Brake Fluid Flush:
Every 2 years
Coolant Flush:
Every 2 years or 24,000 km (15,000 miles)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation)
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50% mixture with distilled water
Fork Oil Type:
Kawasaki KHL15-10 or equivalent (SAE 10W fork oil)
Fork Oil Quantity:
Approx. 350-360 cc per fork leg (check manual for exact specification and level)
Common Issues:
Carburetor jetting can be lean from factory, leading to potential bogging; weak regulator/rectifier; occasional cam chain noise; fork seal leaks.
Wear Items:
Chain and sprockets, brake pads, tires, fork seals, clutch plates
Brand Heritage:
Kawasaki Heavy Industries has a long history of motorcycle manufacturing, known for performance and reliability.
Model Introduction:
The EX500 was introduced in 1987 as a sportier alternative to the GS500E, evolving into the Ninja 500R in North America.
Model Updates Within Period:
Minor cosmetic updates and potential tuning adjustments between 1987-1993. The GPZ500S designation was used in some markets.
Production Period Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993
Manufacturing Location:
Japan (primarily)
