Market Segment:
Entry-level sportbike / lightweight sport-tourer
Target Audience:
New riders, budget-conscious enthusiasts, commuters seeking sporty performance.
Key Competitors Era:
Suzuki GS500, Honda CB500 (original), Yamaha Seca II
Engine Layout:
Parallel-twin, liquid-cooled, DOHC, 4 valves per cylinder
Chassis Design:
Steel perimeter frame, offering good rigidity for its class.
Styling:
Sportbike fairing (depending on specific sub-model, some were naked), aggressive styling for the era.
Engine Assembly:
Cylinder head, cylinders, pistons, crankshaft, connecting rods, camshafts, valves, timing components
Fuel System:
Carburetors (Keihin CVK), fuel tank, fuel pump, fuel lines, air filter box
Cooling System:
Radiator, cooling fan, coolant hoses, water pump
Ignition System:
CDI unit, ignition coils, spark plugs, wiring harness
Exhaust System:
Exhaust pipes, mufflers, heat shields
Transmission And Drivetrain:
Clutch, gearbox internals, drive chain, sprockets
Frame And Chassis:
Frame, subframe, steering head, swingarm, linkages
Suspension Front:
Front forks, springs, dampers, seals, stanchions, triple clamps
Suspension Rear:
Monoshock absorber, linkage, rear swingarm, bearings
Brake System Front:
Brake calipers, brake discs, master cylinder, brake lines, brake pads
Brake System Rear:
Brake caliper, brake disc, master cylinder, brake lines, brake pads
Wheel And Tire Assembly:
Wheels (spoked or cast), wheel hubs, spokes, bearings, tires
Electrical System:
Wiring harness, battery, starter motor, alternator, regulator/rectifier, lighting (headlight, taillight, turn signals), instrumentation
Bodywork And Trim:
Fairings, fuel tank cover, seat, fenders, logos, decals
Controls And Cables:
Throttle cables, clutch cable, brake levers, shifter linkage, controls assembly
Fasteners And Hardware:
Bolts, nuts, washers, clips, grommets (with diagrams)
Part Identification:
Detailed illustrations of all components with corresponding part numbers and quantities.
Assembly Order:
Implied through the exploded diagrams, showing how parts fit together.
Part Number Lookup:
Essential for ordering replacements and verifying correct fitment.
Subassembly Diagrams:
Breakdown of complex systems into manageable subassemblies for easier understanding.
Technical Depth:
Component-level identification and sourcing. Does not contain diagnostic or repair procedures, but is foundational for them.
Safety Ratings:
Motorcycles of this era typically do not have standardized crash ratings comparable to automobiles. Safety is primarily rider-dependent.
Braking System:
Dual front disc brakes, single rear disc brake. ABS was not commonly available on this model in these years.
Suspension Damping:
Adjustable preload on rear monoshock; front forks typically have limited adjustment (e.g., spring preload only on some later models).
Lighting:
Halogen headlight, taillight, brake light, and turn signals for visibility.
Frame Rigidity:
Perimeter frame contributes to chassis stability.
Infotainment System:
None. Basic analog instrumentation typical for the era.
Driver Assistance Features:
None. Focus on rider control and mechanical feedback.
Connectivity Options:
None. Mechanical systems only.
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, engine temperature gauge (some models), and indicator lights (turn signals, oil pressure, neutral).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Change:
Every 12,000 km (7,500 miles) or 12 months. Recommended at every oil change for best practice.
Air Filter Cleaning Replacement:
Clean every 6,000 km (3,700 miles), replace every 12,000 km (7,500 miles) or as needed.
Spark Plug Replacement:
Inspect every 6,000 km (3,700 miles), replace every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol base) with distilled water. 50/50 mix.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
SAE 10W fork oil. Capacity approximately 330ml per fork leg (specific year dependent).
Carburetor Tuning:
Carburetors can be sensitive to vacuum leaks and require periodic syncing and adjustment, especially after sitting.
Cam Chain Tensioner:
The automatic cam chain tensioner can wear, leading to a rattling noise from the engine. Manual tensioners are often used as replacements.
Fuel Petcock:
Vacuum-operated petcock diaphragm can degrade, leading to fuel leaks or poor fuel flow.
Regulator Rectifier:
Early models could experience regulator/rectifier failures, leading to charging issues.
Kawasaki Legacy:
Kawasaki Heavy Industries, Ltd. has a long history of innovation in motorcycles, known for performance and engineering prowess.
Ex500 Introduction:
Introduced in 1987 as a replacement for the GPZ500S, it aimed to offer a sporty yet practical package.
Ninja Branding:
The EX500 was marketed as the Ninja 500R in many markets, aligning it with Kawasaki's performance image.
Updates 1987-1993:
Minor updates during this period focused on styling refinements, carburetor tuning, and minor mechanical tweaks. The core platform remained consistent.
Manufacturing Location:
Primarily manufactured in Japan.
