KAWASAKI KZ500 KZ550 ZX550 Full Service & Repair Manual 1979-1986

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Type: Motorcycle

Vendor:

Sku: 150734

Tags: 1979 1980 1981 1982 1983 1984 1985 1986 Kawasaki KZ500 KZ550 Motorcycle Motorcycles ZX Models ZX550

Product variants

Description

This manual covers the motorcycle models produced between 1979 and 1986. These motorcycles are powered by air-cooled, 4-stroke, DOHC inline-4 cylinder engines, with displacements of 498 cc for the KZ500 and 553 cc for the KZ550 and ZX550 variants. Known for their robust engineering and performance, these bikes offered a blend of sport and standard riding capabilities, with the GPz models, in particular, representing a significant step towards modern sportbike design. The series was well-regarded for its reliability and handling during its production run. This comprehensive Factory Service Repair Workshop Manual provides detailed information essential for the maintenance, diagnosis, and repair of your motorcycle. It covers all major systems, including the engine, transmission, drivetrain, chassis, suspension, brakes, and electrical systems. Within its extensive pages, you will find step-by-step repair instructions, critical technical specifications, torque values, wiring diagrams, and troubleshooting guidance for common issues. This manual is an invaluable resource for owners, independent mechanics, and technicians seeking to maintain the performance and longevity of their KZ500, KZ550, or ZX550.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Common Nickname:

KZ550 LTD, GPz550

Codes

Chassis Code Range:

KZ500-B1, KZ550-A1-A4, KZ550-D1 (GPz), KZ550-H1 (GPz), ZX550-A1-A3 (GPz)

👋 Introduction

Market Position

Target Audience:

Kawasaki KZ500/KZ550/ZX550 owners, independent repair shops, aspiring mechanics

Competitive Analysis

Value Proposition:

Provides professional-level repair and maintenance information at a fraction of the cost of official dealerships, with lifetime access and no limitations.

Key Features

Features:

Detailed photos & diagrams, step-by-step instructions, comprehensive coverage, lifetime usage, cross-platform compatibility.

📋 Manual Details

Coverage Areas

Years Covered:

1979-1986

Page Count

Estimated Pages:

Hundreds (exact count not specified, but described as extensive)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English (implied by product description and common practice for such manuals)

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (all components, top end, bottom end), Transmission (gearbox, clutch, shift mechanism), Final Drive (chain, sprockets)

Chassis:

Frame, suspension (front forks, rear shocks), steering, wheels, brakes (front and rear disc, caliper, master cylinder), exhaust system

Electrical:

Ignition system, charging system (stator, alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, wiring diagrams, fuses, relays

Fuel System:

Carburetors (cleaning, adjustment, synchronization), fuel tank, fuel lines, fuel pump (if applicable)

Bodywork:

Body panels, fairings, seat, tank, fenders, minor trim components

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacement, chain adjustment, spark plug replacement, valve clearance checks), lubrication points, inspections

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting for engine, electrical, and mechanical issues

Repair:

Step-by-step instructions for disassembly, assembly, and repair of all major vehicle components

Technical Data:

Specifications, tolerances, torque values, wiring schematics, diagnostic charts

Technical Depth

Depth:

Comprehensive (covers basic to advanced repairs and rebuilds, suitable for professional mechanics)

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (standard for professional PDF manuals, but not explicitly stated)

Print Quality

Printability:

Printable (individual pages or entire manual)

Binding Type

Binding:

Digital (No physical binding)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, DOHC, Inline-4 Cylinder

Displacement Kz500:

498 cc

Displacement Kz550:

553 cc

Bore Stroke Kz500:

62.0 x 41.2 mm

Bore Stroke Kz550:

66.0 x 41.2 mm

Compression Ratio:

9.2:1 (typical, may vary slightly by model year/variant)

Performance

Horsepower Kz550 Gpz:

~60-65 HP @ 9000 RPM (approximate for GPz models)

Torque Kz550 Gpz:

~35-38 lb-ft @ 7500 RPM (approximate for GPz models)

Fuel System

Carburetion:

Inline 4 x Mikuni VM20SS or VM22SS (common, exact model may vary)

Fuel Capacity:

~3.7 - 4.2 US gal (14 - 16 L) (typical, varies by model)

Engine Cooling

Cooling System:

Air-Cooled

🔧 Transmission

Standard

Type:

6-speed constant mesh

Optional

Type:

N/A (all models typically featured the 6-speed)

Features

Clutch Type:

Wet, multi-disc, cable-actuated

Final Drive:

Chain Drive

📐 Dimensions

Exterior

Wheelbase:

Approx. 57.7-58.3 inches (1465-1480 mm) (varies by model)

Weights

Dry Weight:

Approx. 440-470 lbs (200-213 kg) (varies by model)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety standards and testing differ significantly from automobiles)

Active Features

Braking System:

Dual front disc brakes, single rear disc brake (GPz models often had dual front discs)

Passive Features

Lighting:

Halogen headlight, taillight, turn signals

💡 Technology Features

Infotainment

System:

N/A (Analog gauges only: speedometer, tachometer, fuel gauge, indicator lights)

Driver Assistance

Features:

N/A (No electronic rider aids)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 2,000-3,000 miles or 6 months (typical, refer to specific model section in manual)

Valve Clearance:

Every 6,000-8,000 miles (typical, crucial for engine health)

Chain Adjustment:

Regularly, especially after washing or riding in wet conditions

Fluid Specifications

Engine Oil:

API SE, SF, or SG rated motorcycle oil, SAE 10W-40 or 20W-50 (viscosity depending on ambient temperature). Capacity approx. 2.4-2.7 liters (2.5-2.9 US qt) with filter change.

Brake Fluid:

DOT 3 or DOT 4 (check specific caliper/master cylinder recommendations)

Fork Oil:

Typically SAE 10W or 15W (check specific model for exact type and quantity)

Known Issues

Carburetor Issues:

Gumming and clogging of carburetors due to ethanol in modern fuel, leading to poor running. Needs regular cleaning and synchronization.

Electrical Gremlins:

Age-related issues with wiring insulation, regulator/rectifier failures, and stator output degradation.

Cam Chain Noise:

Loose or worn cam chain tensioner can lead to rattling noise from the engine.

Suspension Wear:

Worn fork seals and aged rear shock absorbers can impact handling and ride quality.

Recommended Filters

Oil Filter Part Number:

e.g., Hiflofiltro HF131, K&N KN-131 (cross-reference specific to model year needed)

Recommended Spark Plugs

Spark Plug Type:

e.g., NGK DPR8EIX-9 (Iridium IX) or DPR8EA-9 (Standard) (verify for specific model and year)

📚 Vehicle History

Brand Heritage

Kawasaki History:

Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing high-performance motorcycles, particularly in the 4-cylinder sportbike and standard categories.

Model Evolution

Kz Series Context:

The KZ500/KZ550 series represented Kawasaki's mid-range offerings in the late 70s and early 80s, evolving from the earlier KZ400 and paving the way for more advanced sportbikes like the GPz line.

Gpz Variant:

The KZ550 GPz (later ZX550) variant introduced sportier styling, improved suspension, and a more potent engine tune, marking a significant step towards the modern sportbike era.

Production

Production Period:

1979-1986

🏆 Awards & Recognition

Recognitions

Period Accolades:

These models were well-regarded in their time for their performance, reliability, and handling within their respective classes, often receiving positive reviews from motorcycle publications.