Segment:
High-performance Motocross competition bike, known for its power and aggressive off-road capability.
Competitors:
YZ490 (Yamaha), CR500R (Honda), RM490 (Suzuki).
Power Delivery:
Renowned for its torquey and potent 500cc two-stroke engine.
Chassis Design:
Strong, durable chassis optimized for motocross racing and aggressive off-road riding.
Engine Mechanical:
Complete overhaul, disassembly, assembly, troubleshooting, and component inspection.
Fuel System:
Carburetor (Keihin PWK series) tuning, cleaning, and rebuilding; fuel tank, lines, and petcock.
Ignition System:
CDI system, spark plug selection and gap, troubleshooting ignition timing.
Cooling System:
Liquid cooling system, radiator, hoses, water pump, coolant specifications and replacement.
Transmission:
Clutch operation and adjustment, gearbox disassembly, assembly, inspection, and lubrication.
Suspension Front:
Front fork (Kayaba) service, oil change, seal replacement, damping adjustments, spring rates.
Suspension Rear:
Monoshock rear suspension (Kawasaki Uni-Trak), shock absorber service, linkage maintenance, bearing inspection.
Brakes Front:
Hydraulic disc brake system, caliper service, master cylinder overhaul, pad replacement, fluid bleeding, rotor specifications.
Brakes Rear:
Hydraulic disc brake system, caliper service, master cylinder overhaul, pad replacement, fluid bleeding, rotor specifications.
Electrical System:
Lighting system, battery maintenance, wiring diagrams, fuse replacement, switchgear service.
Frame And Bodywork:
Frame inspection, handlebar replacement, footpeg service, plastic body panel removal and installation.
Maintenance:
Routine checks, lubrication, chain adjustment, air filter cleaning, spark plug replacement.
Troubleshooting:
Comprehensive diagnostic flowcharts and common problem identification for engine, electrical, and chassis issues.
Repair:
Step-by-step instructions for all major component repairs and replacements.
Disassembly Assembly:
Detailed procedures for taking apart and reassembling all major vehicle systems.
Adjustments:
Carburetor jetting, clutch, throttle, brake levers, suspension settings.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced diagnostics.
Visual Aids:
Detailed pictorial diagrams, exploded views, and photographs.
Special Tools:
Identification and usage instructions for specialized service tools.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
499 cc (30.45 cu in)
Bore X Stroke:
89.0 x 80.0 mm (3.50 x 3.15 in)
Compression Ratio:
Approx. 6.8:1 (varies slightly by year)
Valvetrain:
Reed valve induction
Carburetor:
Keihin PWK39 (typically)
Horsepower:
Approx. 50-55 HP at peak RPM (estimated, varies by year and tuning)
Torque:
High torque output, particularly in the mid-range.
Fuel Type:
Unleaded gasoline, mixed with 2-stroke oil (typically 32:1 or 40:1 ratio recommended)
Fuel Capacity:
Approx. 2.7 US gallons (10.5 Liters)
Oil Change Engine:
Refer to manual for specific gearbox oil change intervals. Engine oil is mixed with fuel.
Air Filter Cleaning:
Frequent cleaning recommended based on riding conditions (e.g., dusty environments).
Chain Adjustment:
Regular checks and adjustments required to maintain proper slack.
Coolant:
Ethylene glycol-based antifreeze, mixed with distilled water (e.g., 50/50 ratio). Refer to manual for specific Kawasaki coolant type if available.
Transmission Oil:
SAE 10W-30 or SAE 10W-40 API SG, SH, or SJ classification engine oil. (Manual will specify exact type and capacity).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. (Manual will specify)
Engine Power Band:
Known for its aggressive and powerful power band, which can be challenging for inexperienced riders. Requires careful throttle control.
Suspension Setup:
Proper suspension tuning is crucial for optimal handling and rider comfort. The manual provides guidance on this.
Kickstarter Engagement:
Occasional issues with kickstarter engagement or return can occur with wear; manual provides troubleshooting.
Kawasaki Motorsports:
Kawasaki has a long and successful history in motocross and off-road racing.
Kx Lineage:
The KX500 is a descendant of earlier KX models, evolving to become a dominant force in its class.
Production Years:
The KX500 model line was produced for many years, with the 1990-1999 range representing a specific evolution.
Key Updates 1990S:
The 1990s saw refinements in suspension, chassis stiffness, and minor engine tuning for improved performance.
