Kawasaki KZ500 KZ550 ZX550 1979-1985 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 146327

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, known for their robust parallel-twin engines and reliable performance, represent a significant era in Japanese motorcycle engineering. The KZ series offered dependable air-cooled power, while the ZX550 introduced liquid cooling and enhanced sporty characteristics, making them popular choices for both daily commuting and spirited riding. 's legacy in building performance-oriented machines is evident in the design and capabilities of these models. This comprehensive service and repair manual provides detailed instructions for maintaining and repairing your motorcycle. It covers all essential systems, including engine diagnostics and rebuilds, fuel and ignition systems, transmission, electrical components, suspension, brakes, and frame. The manual includes step-by-step procedures for disassembly, assembly, cleaning, and troubleshooting, offering the same depth of information as original factory manuals. It is designed to assist professional technicians and experienced DIY mechanics in keeping these classic machines in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ500 / KZ550 / ZX550

Product Name:

Kawasaki KZ500 KZ550 ZX550 1979-1985 Service Repair Manual

Product Description:

Service Manual Repair PDF Download

Generation

Applicable Years:

1979, 1980, 1981, 1982, 1983, 1984, 1985

👋 Introduction

Market Position

Target Audience:

Professional technicians and experienced DIY mechanics with basic electrical and mechanical knowledge.

Competitive Analysis

Comparison To Print:

Offers the same information as a printed factory manual, with the convenience of instant digital access.

Key Features

Delivery Method:

Instant Download

Learning Curve:

Designed to teach users what factory-trained technicians know through step-by-step guidance.

Manual Value:

Enables informed decisions regarding maintenance and repairs for owners.

📋 Manual Details

Coverage Areas

Covered Models:

Kawasaki KZ500, Kawasaki KZ550, Kawasaki ZX550

Coverage Scope:

Comprehensive Service and Repair

Page Count

Estimated Page Count:

Refer to original factory manual (typically 300-600 pages)

Manual Type

Type:

Service Repair Manual / Factory Service Manual Equivalent

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, disassembly, assembly, tuning, and troubleshooting for all engine variants.

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel pump, fuel lines, and tank maintenance.

Ignition System:

CDI unit, coils, spark plugs, wiring diagrams, troubleshooting.

Transmission:

Gearbox inspection, maintenance, repair, clutch operation and adjustment.

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter, switches, and troubleshooting.

Suspension:

Front fork maintenance, seals, oil, rear shock absorber adjustment and replacement.

Brakes:

Front and rear brake system maintenance, hydraulic lines, caliper service, pad replacement, bleeding.

Cooling System:

Radiator, fan, coolant, hoses, and thermostat for liquid-cooled models (ZX550).

Frame And Bodywork:

Frame inspection, fairings, seats, handlebars, and minor bodywork repairs.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication.

Disassembly:

Step-by-step instructions for dismantling various components.

Assembly:

Step-by-step instructions for reassembling components.

Troubleshooting:

Diagnosis of common problems with symptom-based guidance.

Cleaning:

Proper procedures for cleaning engine parts, carburetors, and other components.

Reinstallation:

Correct procedures for reinstalling serviced or replaced parts.

Technical Depth

Depth:

Comprehensive, from basic maintenance to advanced diagnostics and complete engine rebuilds.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all versions of Windows and Mac.

Software Requirements:

Adobe PDF Reader, WinZip (for extraction if zipped).

Print Quality

Printability:

Full Printable specifications.

Zoom Functionality:

Zoom IN/OUT capability for detailed viewing.

Binding Type

Binding Type Digital:

N/A (Digital PDF Download)

Paper Type

Paper Type Digital:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Kz500 Engine Type:

Air-cooled, four-stroke, DOHC, parallel-twin

Kz550 Engine Type:

Air-cooled, four-stroke, DOHC, parallel-twin

Zx550 Engine Type:

Liquid-cooled, four-stroke, DOHC, parallel-twin

Kz500 Displacement:

498 cc (30.4 cu in)

Kz550 Displacement:

553 cc (33.7 cu in)

Zx550 Displacement:

552 cc (33.7 cu in)

Performance

Kz500 Horsepower Est:

~48 hp @ 9000 rpm

Kz550 Horsepower Est:

~55 hp @ 9000 rpm

Zx550 Horsepower Est:

~65 hp @ 9000 rpm

Fuel System

Carburetion Kz500 Kz550:

Dual Mikuni VM26SS or similar (depending on market/year)

Carburetion Zx550:

Dual Mikuni BS32 or similar (depending on market/year)

Fuel Capacity Est:

~14-17 liters (3.7-4.5 gallons)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Gear Ratios:

Specific ratios detailed within the manual.

Features

Clutch Type:

Wet multi-disc

📐 Dimensions

Exterior

Wheelbase Est:

~1400-1450 mm (55.1-57.1 inches)

Weights

Dry Weight Est Kz500:

~180 kg (397 lbs)

Dry Weight Est Kz550:

~185 kg (408 lbs)

Dry Weight Est Zx550:

~190 kg (419 lbs)

🛡️ Safety Features

Ratings

Safety Features Era:

Standard safety features for motorcycles of the era: robust braking systems, stable chassis design.

Active Features

Active Braking:

Hydraulic disc front brake, drum or disc rear brake (depending on model/variant).

Passive Features

Frame Construction:

Strong steel frame providing stability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (These are classic motorcycles without modern infotainment systems).

Driver Assistance

Driver Assistance Features:

N/A (These are classic motorcycles without modern driver assistance features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or 6 months, refer to manual for exact specification.

Spark Plug Replacement:

Refer to manual for specific mileage or time interval.

Valve Clearance Check:

Typically every 6,000-12,000 km (3,700-7,500 miles), refer to manual for exact specification.

Fluid Specifications

Engine Oil Type:

API SE, SF, or SG, SAE 10W-40 or 20W-50 (specific viscosity depends on climate, refer to manual).

Fork Oil Type:

SAE 10W or 15W fork oil (specific grade and quantity detailed in manual).

Coolant Type Zx550:

Permanent antifreeze solution (ethylene glycol based, typically 50/50 mix with distilled water).

Known Issues

Common Wear Items:

Carburetor synchronization issues, worn fork seals, aging electrical components, cam chain wear.

Fuel Delivery:

Clogged carburetors due to old fuel or debris are a common issue, requiring cleaning and rebuilding.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing reliable and performance-oriented motorcycles.

Model Evolution

Kz Series Impact:

The KZ series were popular and influential motorcycles, representing a significant step in Japanese motorcycle technology and performance.

Zx550 Distinction:

The ZX550, particularly the GPz550 variant, introduced liquid cooling and more sporty performance characteristics.

🏆 Awards & Recognition

Recognitions

Model Era Acclaim:

The KZ and GPz series were highly regarded for their performance and handling in their respective production years.