Target Audience:
Kawasaki KX500 owners, DIY mechanics, professional repair shops
Kx500 Reputation:
Renowned for its raw power and torque, making it a formidable machine for experienced riders and in specific off-road applications like desert racing or hauling.
Manual Value Proposition:
Enables owners to perform service, maintenance, and repairs, saving significant costs and providing comprehensive diagnostic and repair information as used by professional technicians.
Digital Format Advantage:
Printable sections allow for clean workspace, easy portability, and cost savings over physical manuals. Instant download eliminates shipping delays.
Competitors:
Other open-class motocross bikes of the era such as Yamaha YZ490/495, Suzuki RM490/500, and Honda CR500.
Systems Covered:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Engine Lubrication System:
Detailed coverage including oil pump operation, oil filter, and oil level checks.
Crankshaft Transmission:
In-depth information on gearbox components, gear engagement, bearings, seals, and transmission oil.
Wheels Tires:
Wheel bearing maintenance, tire pressure recommendations, rim strip and tube service, spoke tension checks.
Brakes:
Front and rear brake system servicing, including caliper maintenance, pad replacement, fluid bleeding, and master cylinder inspection.
Suspension:
Front fork (USD type typically) and rear shock absorber maintenance, including oil changes, seal replacement, spring preload, and damping adjustments.
Steering:
Headset bearing inspection and lubrication, steering stem adjustment.
Frame:
Frame inspection for cracks or damage, swingarm pivot bearing service, footpeg and mounting hardware checks.
Electrical System:
Detailed wiring diagrams, lighting system troubleshooting, ignition system components, charging system (if applicable), CDI unit diagnostics.
Procedures Included:
Service, Maintenance, Troubleshooting, Diagnostic, Repair, Disassembly, Assembly, Cleaning, Reinstallation, Wiring Diagrams, Bulletins
Engine Removal Installation:
Step-by-step guide for removing and reinstalling the engine from the chassis.
Engine Top End:
Piston, ring, cylinder, and cylinder head servicing, including decarbonizing and compression testing.
Clutch Service:
Clutch plate replacement, spring inspection and replacement, clutch lever adjustment.
Troubleshooting:
Comprehensive troubleshooting guides for common and uncommon issues across all systems, including starting problems, poor performance, and electrical faults.
Fuel System Maintenance:
Carburetor removal, cleaning, rebuilding, jetting, float adjustment, and fuel line inspection.
Cooling System Maintenance:
Radiator cleaning, coolant flush and replacement, hose inspection, thermostat testing (if applicable).
Final Drive Maintenance:
Sprocket inspection and replacement, chain wear checks, lubrication, and adjustment.
Frame Maintenance:
Swingarm bearing service, linkage lubrication, frame integrity checks.
Technical Depth:
Comprehensive, Professional-grade, detailed substeps, notes, cautions, and warnings
Engine Type:
Two-stroke, Single-cylinder (typically liquid-cooled, based on KX500 lineage)
Displacement:
499cc (approximate, varies slightly by year revision)
Bore X Stroke:
Refer to manual for specific year details, typically around 86mm x 86mm
Horsepower Estimate:
Estimated 50-60+ HP (at the crank), actual figures vary by year and tuning.
Torque Estimate:
Significant torque output, providing strong pulling power.
Carburetor Type:
Mikuni VM Series (e.g., VM34SS or similar, specific model to be confirmed in manual)
Fuel Requirement:
High-octane gasoline mixed with 2-stroke oil (specific ratio provided in manual)
Cooling Method:
Liquid-cooled
Oil Type:
High-quality 2-stroke engine oil (specific API/JASO ratings in manual)
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Replacement Interval:
Refer to manual, typically every 10-20 hours of riding
Air Filter Cleaning Interval:
Frequent cleaning recommended, especially in dusty conditions (daily or every few rides)
Chain Lubrication And Adjustment:
Regularly, based on riding conditions (refer to manual for specific checks)
Coolant Type:
Permanent type antifreeze with a low silicate content, mixed with distilled water (50/50 ratio)
Fork Oil Type And Level:
Specific fork oil weight (e.g., Showa SS-01 or similar) and level measurements are critical and detailed in the manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (as specified by Kawasaki)
Engine Oil Capacity:
Capacity for clutch and transmission lubrication (refer to manual for specific fill amount)
Common Kx500 Issues:
Knee-grinding on the tank/shroud, potential for overheating if cooling system is not maintained, clutch wear, carburetor jetting sensitivity to altitude and temperature.
Carburetor Issues:
Carburetor cleaning and rebuilding, jetting adjustments for different altitudes and temperatures.
Kawasaki Motocross Legacy:
Kawasaki has a long and successful history in motocross, with the KX line being a dominant force.
Kx500 Evolution:
The KX500 was a dominant open-class motocross bike, known for its powerful torque and aggressive performance. While the core design remained consistent for many years, minor revisions to suspension, ergonomics, and engine tuning occurred throughout its production run.
Suspension Updates:
Evolved from conventional forks to USD (Upside-Down) forks during its production life, offering improved rigidity and performance.
Production Period:
1983-2004 (with the covered years being the latter half of its life)
