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Kawasaki KX500 2000-2004 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KX500 Generation Generation Designation: Late Generation (E-series) Codes Engine Family Code: E1-E10 (representative for the model years) 👋 Introduction Market Position Vehicle Segment:...
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类型: Motorcycle
厂商:
斯库: 450591
Kawasaki KX500 2000-2004 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX500
Generation
Generation Designation:
Late Generation (E-series)
Codes
Engine Family Code:
E1-E10 (representative for the model years)
👋 Introduction
Market Position
Vehicle Segment:
High-performance motocross/off-road competition motorcycle.
Competitive Analysis
Key Competitors:
Yamaha YZ450/490, Suzuki RM465/490, Honda CR480/500.
Key Features
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder.
Engine Delivery:
Known for its massive torque and powerful, tractable power delivery, making it formidable in off-road conditions.
Suspension Technology:
Utilized advanced upside-down front forks and a sophisticated monoshock rear suspension for superior handling and control.
📋 Manual Details
Coverage Areas
Model Years Covered:
2000, 2001, 2002, 2003, 2004
Page Count
Total Pages:
330
Manual Type
Type:
Workshop Service Manual for Repair
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, diagnosis, tuning, and repair of the 2-stroke engine.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel tank and petcock servicing.
Ignition System:
CDI system, spark plug selection and gap, timing adjustments.
Cooling System:
Liquid cooling system, radiator, water pump, hoses, and coolant specifications.
Transmission:
Clutch operation and adjustment, gearbox disassembly, assembly, and maintenance.
Suspension:
Front fork (upside-down design) service, adjustment, oil changes, seal replacement; rear shock absorber service and adjustment.
Brakes:
Front and rear hydraulic disc brake systems, caliper service, pad replacement, fluid bleeding, master cylinder overhaul.
Wheels And Tires:
Spoke maintenance, wheel bearing service, tire pressure recommendations.
Electrical System:
Lighting system, wiring diagrams, battery maintenance, troubleshooting guide.
Frame And Bodywork:
Chassis inspection, swingarm maintenance, body panel removal and installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, general inspection procedures.
Troubleshooting:
Comprehensive guides for diagnosing common starting, running, and performance issues.
Disassembly Assembly:
Detailed, step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Repair Overhaul:
Instructions for rebuilding engine components, suspension units, brake systems, and other wear items.
Adjustments:
Carburetor tuning, ignition timing, clutch and throttle cable adjustments, suspension setup.
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced diagnostics.
Diagnostic Capabilities:
Includes specific troubleshooting charts and diagnostic procedures based on symptoms.
Special Tools:
Identifies and illustrates required special service tools for specific procedures.
Pictorial Guidance:
Features detailed illustrations, exploded diagrams, and photographs to guide users.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printable:
Yes
Print Resolution:
High (suitable for clear printing of diagrams and text)
Binding Type
Digital Binding:
N/A (Downloadable Digital File)
Paper Type
Digital Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
Windows, Mac OS, Linux OS
Required Software:
Adobe Reader (or compatible PDF viewer)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
89.0 x 79.0 mm (typical for this generation)
Displacement:
494 cm³ (approx.)
Compression Ratio:
6.7:1 (typical for this generation, for pump gas optimization)
Carburetion:
Keihin PWK39 (typical, with dual-stage power jet)
Performance
Horsepower Estimate:
Approximately 50-55 HP (at crankshaft, depending on tuning and specifics)
Torque Estimate:
Exceptional torque output, a hallmark of the KX500 engine.
Fuel System
Fuel Type:
Unleaded gasoline (with appropriate octane rating specified in manual)
Fuel Premix Ratio:
50:1 (Kawasaki K-Tech 2-stroke oil or equivalent, as specified)
Fuel Tank Capacity:
Typically around 8.5 liters (2.2 gallons)
🔧 Transmission
Standard
Type:
5-speed, constant mesh
Optional
Gear Ratios:
Detailed gear ratios are provided within the manual for each gear.
Features
Clutch Type:
Wet, multi-disc, cable-actuated
Transmission Oil:
Kawasaki Gear Oil 80W or equivalent SAE 80W GL-4 gear oil (refer to manual for exact specification and capacity).
📐 Dimensions
Exterior
Overall Length:
Variable by model year, refer to manual for exact specifications.
Weights
Dry Weight:
Approximately 113 kg (249 lbs)
Curb Weight:
Typically around 119 kg (262 lbs) with all fluids.
🛡️ Safety Features
Ratings
Safety Classification:
Competition Off-Road Motorcycle (not street legal, no safety ratings typical of street vehicles).
Active Features
Handling Dynamics:
Designed for high-speed stability and responsive maneuverability in off-road terrain.
Passive Features
Chassis Design:
Rigid frame designed to withstand the stresses of off-road riding and competition.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (This is a pure performance off-road machine, not equipped with infotainment systems).
Driver Assistance
Rider Assistance:
Focus is on rider control and feedback; no electronic rider aids.
🔧 Maintenance
Service Intervals
Engine Rebuild Interval:
Variable based on usage; the manual provides detailed guidelines for piston ring replacement, top-end rebuilds, and full engine overhauls.
Fork Oil Change:
Recommended every 12-24 months or as per usage intensity, with specific fluid levels and types outlined.
Fluid Specifications
Engine Oil Type:
Kawasaki K-Tech 2-stroke semi-synthetic or fully synthetic oil mixed with gasoline at 50:1 ratio.
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol base) mixed with distilled water in a 50/50 ratio.
Known Issues
Common Wear Items:
Piston, piston rings, clutch plates, wheel bearings, fork seals, and steering head bearings are common wear items requiring periodic inspection and replacement.
Performance Tuning:
The manual provides guidance on jetting, exhaust, and ignition modifications for optimal performance, addressing potential issues with rich or lean running conditions.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross:
Kawasaki has a long and storied history in motocross, with the KX line being a dominant force.
Model Evolution
Kx Line Development:
The KX500 evolved from earlier large-displacement 2-stroke motocross bikes, consistently pushing the boundaries of power and performance.
Production
Kx500 Production Period:
The KX500 had a remarkably long production run, spanning from the mid-1980s through 2004.
🏆 Awards & Recognition
Recognitions
Historical Impact:
The KX500 is widely recognized as one of the most powerful and dominant open-class 2-stroke motocross bikes ever produced, with a cult following among enthusiasts.
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