KAWASAKI KZ500 KZ550 ZX550 Motorcycle Service Repair Manual 1979-1985

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Type: Motorcycle

Vendor:

Sku: 134568

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

Product variants

Description

This manual covers the models produced between 1979 and 1985. These motorcycles, including chassis codes KZ500A, KZ550A, KZ550D (Ltd.), KZ550F (Spectre), and ZX550-A, represent a significant era in engineering, blending robust performance with the evolving technology of the time. The KZ500 and KZ550 series featured air-cooled inline-twin engines, while the ZX550 introduced liquid-cooled inline-four power and a fully faired sportbike design. Known for their reliability and dynamic performance, these models were well-regarded for their value and engineering quality, making them popular choices for enthusiasts and everyday riders alike. This comprehensive service repair manual provides detailed information for the maintenance, troubleshooting, and repair of your motorcycle. It covers all essential mechanical and electrical systems, including in-depth engine disassembly and assembly, fuel system overhauls, drivetrain and chassis maintenance, and brake system servicing. The manual includes step-by-step repair instructions, clear diagrams, electrical schematics, and diagnostic procedures to assist DIY mechanics and professional technicians. With its extensive coverage, this workshop manual is an indispensable resource for ensuring the optimal performance and longevity of your KZ500, KZ550, or ZX550.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Product Type:

Service Repair Manual

Generation

Applicable Years:

1979-1985

Codes

Chassis Codes:

KZ500A, KZ550A, KZ550D (Ltd.), KZ550F (Spectre), ZX550-A

👋 Introduction

Market Position

Target Audience:

DIY mechanics, home workshop enthusiasts, and professional motorcycle technicians working on Kawasaki KZ500, KZ550, and ZX550 models.

Competitive Analysis

Manual Advantage:

Specificity to make, model, and year range, offering detailed, factory-level information rather than generic advice.

Key Features

Content Highlight:

Step-by-step repair instructions with diagrams, electrical schematics, fluid capacities, and troubleshooting guides.

Delivery Method:

Instant digital download for immediate access, eliminating shipping delays.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Troubleshooting, Maintenance, Repair

Page Count

Estimated Page Count:

Extensive (Detailed coverage suggests over 500 pages, typical for this era of comprehensive service manuals)

Manual Type

Manual Classification:

Factory Authorized Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF (Printable, Zoomable)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly/assembly, cylinder head, valves, pistons, crankshaft, con-rods, lubrication, cooling (if applicable, though air-cooled typically), timing

Fuel Systems:

Carburetor identification, adjustment, overhaul, fuel tank, fuel lines, fuel pump (if applicable)

Drivetrain Systems:

Clutch operation and overhaul, gearshift linkage, sub-transmission, transmission assembly/disassembly, final drive (chain/sprockets)

Chassis Systems:

Frame inspection, front fork suspension, steering bearings, rear shock absorbers, swingarm, wheels, wheel bearings

Braking Systems:

Hydraulic front and rear brakes, caliper overhaul, master cylinder, brake lines, pads, discs

Electrical Systems:

Battery, charging system (alternator, regulator/rectifier), ignition system (points, CDI, coils, spark plugs), electric starter motor, switches, lighting, wiring diagrams

Procedures Included

Maintenance Procedures:

Oil changes, filter replacement, chain adjustment, lubrication points, spark plug replacement, air filter cleaning/replacement, brake fluid flush

Repair Procedures:

Engine rebuilds (top-end and bottom-end), transmission repair, suspension overhaul, brake system repair, electrical component replacement, carburetor tuning

Diagnostic Procedures:

Troubleshooting guides for common issues, electrical system diagnostics, engine performance troubleshooting

Technical Depth

Diagnostic Capability:

Advanced diagnostics, including electrical system troubleshooting with detailed wiring diagrams and component testing procedures.

Repair Scope:

Comprehensive repair information, covering everything from basic adjustments to complete engine and transmission rebuilds.

Diagram Quality:

Features clear, step-by-step diagrams that are essential for complex repair procedures and component identification.

📊 Manual Specifications

File Format

File Type:

Accessibility:

PC/MAC Compatible for viewing and printing.

Print Quality

Digital Clarity:

High-resolution scans, enabling clear viewing and printing of diagrams and text. Zoom functionality for detailed inspection.

Binding Type

Digital Delivery Method:

Instant Download via Email Link (Tradebit System)

Paper Type

Printable Format:

Printable for physical use in workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, DOHC, Inline-twin (KZ500/550); Liquid-cooled, 4-stroke, DOHC, Inline-four (ZX550)

Bore X Stroke Kz550:

Approx. 58.0 mm x 50.6 mm (refer to specific model for exact figures)

Bore X Stroke Kz500:

Approx. 54.0 mm x 54.0 mm (refer to specific model for exact figures)

Bore X Stroke Zx550:

Approx. 59.0 mm x 50.4 mm (refer to specific model for exact figures)

Engine Cooling Zx550:

Liquid-cooled

Valvetrain Kz550:

DOHC, 8 valves (2 per cylinder)

Valvetrain Zx550:

DOHC, 16 valves (4 per cylinder)

Performance

Compression Ratio Kz550:

Approx. 9.2:1 (refer to specific model for exact figures)

Horsepower Kz550 Approx:

Approx. 48-53 HP @ 8000-8500 RPM (model dependent)

Horsepower Zx550 Approx:

Approx. 65-70 HP @ 9000 RPM (model dependent)

Fuel System

Carburetor Type Kz550:

Twin Constant Velocity (CV) Carburetors (e.g., Mikuni VM22SS, Keihin CVK)

Carburetor Type Zx550:

Four Keihin CVK carburetors (e.g., 26mm or 30mm)

🔧 Transmission

Standard

Gearbox Type:

Constant mesh, 5-speed sequential return (KZ500/550), 6-speed (ZX550)

Features

Clutch Type:

Wet, multiple disc clutch

Final Drive:

Chain drive

📐 Dimensions

Weights

Dry Weight Kz550 Approx:

Approx. 175-185 kg (model dependent)

Dry Weight Zx550 Approx:

Approx. 180-190 kg (model dependent)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear (variations exist across models and years)

Passive Features

Frame Type:

Steel tube frame (e.g., cradle type)

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer, fuel gauge (on some models), and indicator lights. Basic but functional instrumentation typical of the era.

Driver Assistance

ABS Availability:

Anti-lock Braking System (ABS) was not a standard or commonly available feature on these models during their production years.

Connectivity

Electronic Aids:

Limited electronic aids. Focus is on mechanical reliability and performance. Ignition systems may be CDI (Capacitor Discharge Ignition) for improved spark energy.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-4,000 miles or 6 months (refer to specific manual for precise recommendations)

Valve Adjustment Interval:

Typically every 6,000-8,000 miles or annually (model dependent)

Fluid Specifications

Engine Oil Type:

API SE or SF grade, SAE 10W-40 or 20W-50 motorcycle-specific oil (check manual for exact viscosity and API rating requirements)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (ensure it's compatible with rubber seals)

Fork Oil Type:

Specific SAE viscosity fork oil (e.g., SAE 10W) recommended by Kawasaki for optimal damping performance.

Known Issues

Common Wear Items:

Cam chain wear, carburetor synchronization issues, starter clutch wear, aging electrical components (e.g., rectifier/regulator, stator).

Kz550 Specifics:

Potential for valve guide wear, clutch wear, and the need for regular carb cleaning/adjustment due to age.

Zx550 Specifics:

Coolant leaks, aging fairing components, and specific tuning requirements for the inline-four engine.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing high-performance motorcycles, particularly in the sportbike and sport-touring segments.

Model Evolution

Kz550 Development:

The KZ550 series evolved from the earlier KZ500, offering increased displacement and performance enhancements, often incorporating advanced technologies for its time like Uni-Trak rear suspension on some models.

Zx550 Positioning:

The ZX550 (Ninja 550) represented Kawasaki's entry into the fully faired, liquid-cooled sportbike category, competing with Japanese rivals and offering a more aggressive styling and performance profile.

Production

Manufacturing Era:

These models were produced during a dynamic period in motorcycle development, bridging the gap between older air-cooled designs and the more advanced liquid-cooled, fuel-injected sportbikes of the late 80s and 90s.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The KZ550 and ZX550 models were generally well-regarded for their performance, reliability, and value within their respective market segments during the 1980s.