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Kawasaki KX500 1983-2004 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KX500 Year Range: 1983-2004 Vehicle Type: Motocross Motorcycle 👋 Introduction Market Position Market Segment: High-performance motocross competition bike Competitive Analysis Key Competitors: Honda...
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类型: Motorcycle
厂商:
Kawasaki
斯库: 412325
标签: 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Kawasaki KX Series KX500 Motorcycle Motorcycles
Kawasaki KX500 1983-2004 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX500
Year Range:
1983-2004
Vehicle Type:
Motocross Motorcycle
👋 Introduction
Market Position
Market Segment:
High-performance motocross competition bike
Competitive Analysis
Key Competitors:
Honda CR500, Yamaha YZ490, Suzuki RM465/RM490
Key Features
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Power Delivery:
Known for its broad, tractable powerband and significant torque
Handling:
Stable and predictable handling characteristics
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual / Repair Manual
Page Count:
570
Language:
English
Format:
PDF
Delivery Method:
Instant Download
Printability:
Yes
Software Requirement:
Adobe Reader
Operating System Compatibility:
Windows, Mac, Linux OS
📖 Manual Coverage
Systems Covered
Engine Service:
Complete overhaul, internal components, cooling system, lubrication system
Fuel System:
Carburetor service, fuel tank, fuel lines, petcock
Ignition System:
CDI unit, ignition coil, spark plug, timing
Transmission Service:
Clutch, gearbox, shift mechanism, lubrication
Suspension Front:
Fork assembly, seals, springs, damping adjustments
Suspension Rear:
Monoshock, linkage, shock absorber, spring preload
Brakes Front:
Disc brake caliper, master cylinder, brake lines, pads, fluid
Brakes Rear:
Disc brake caliper, master cylinder, brake lines, pads, fluid
Cooling System:
Radiator, hoses, coolant, water pump
Electrical System:
Lighting, charging system, wiring diagrams, battery
Exhaust System:
Muffler, expansion chamber, mounting
Frame And Bodywork:
Frame, subframe, seat, fenders, plastics
Wheels And Tires:
Spokes, rims, hubs, tire installation, balancing
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment
Troubleshooting:
Diagnosis of common problems, electrical issues, engine performance issues
Disassembly And Assembly:
Step-by-step instructions for component removal and installation
Adjustments:
Carburetor tuning, suspension settings, clutch engagement, brake levers
Repair:
Detailed repair procedures for all major components and systems
Special Tool Usage:
Identification and illustration of required special service tools
Wiring Diagrams:
Comprehensive electrical schematics for troubleshooting and repair
Technical Depth
Depth:
Comprehensive (Bumper-to-Bumper Coverage)
Target Audience:
Mechanics and DIY enthusiasts
Illustrations:
Detailed pictorial diagrams, exploded views, photographs, and drawings
Specifications:
Service data, factory specifications, allowable limits, torque values
📊 Manual Specifications
File Details
File Type:
PDF
Searchability:
Likely text-searchable due to PDF format
Print Quality:
High quality, printable at home or professionally
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF, printable on various paper types)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
494cc (approximately)
Bore X Stroke:
86.0 mm x 86.0 mm (typical for later models)
Compression Ratio:
Varies by year, typically around 6.8:1 to 7.4:1
Performance
Horsepower:
Estimated 50-60+ HP (depending on year and tune)
Torque:
Strong low-to-mid range torque
Fuel System
Carburetor Size:
Typically 36mm or 38mm Keihin PWK
Fuel Type:
Unleaded gasoline with appropriate two-stroke oil pre-mix
Premix Ratio:
Refer to manual for specific recommendations (typically 40:1 or 50:1)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-disc
Transmission Oil Type:
Kawasaki specified 10W-40 or equivalent motorcycle-specific transmission oil
Transmission Oil Capacity:
Refer to manual (typically around 0.7 - 1.0 liters)
📐 Dimensions
Exterior
Wheelbase:
Approximately 57.5 - 58.3 inches (1460 - 1480 mm), varies by year
Seat Height:
Approximately 37.6 - 38.4 inches (955 - 975 mm), varies by year
Weights
Dry Weight:
Approximately 238 - 247 lbs (108 - 112 kg), varies by year
🛡️ Safety Features
Ratings
Safety Certification:
Off-road use, not typically road-legal without modifications and registration
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Frame Construction:
Steel perimeter frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Competition motocross bike, no infotainment features)
Driver Assistance
Rider Aids:
N/A (Designed for pure performance, no electronic rider aids)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically after every few races or a set number of riding hours for motocross use.
Air Filter Cleaning:
Frequent cleaning and oiling recommended, especially in dusty conditions.
Spark Plug Replacement:
Refer to manual; periodic replacement based on usage.
Piston Ring Replacement:
Recommended during top-end rebuilds, interval dependent on riding conditions.
Fluid Specifications
Engine Oil:
Refer to manual for specific grade and viscosity (e.g., SAE 10W-40, API SG or higher).
Coolant:
Permanent type anti-freeze coolant (e.g., ethylene glycol based) mixed with distilled water.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Power Valve Sticking:
Carbon buildup can cause the power valve to stick, affecting engine performance. Requires regular cleaning.
Clutch Wear:
Heavy use can lead to clutch plate wear and potential slippage. Proper adjustment and timely replacement are key.
Suspension Seals:
Fork and shock seals can wear over time, leading to leaks. Regular inspection and replacement are necessary.
Kickstarter Engagement:
Some models may experience issues with the kickstarter engagement mechanism if not properly maintained.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long and successful history in motocross and off-road racing.
Model Evolution
Kx500 Development:
The KX500 was a dominant force in open-class motocross for many years, evolving through various chassis and engine updates.
Chassis Updates:
Significant chassis changes occurred, including the adoption of larger diameter forks and improved suspension components over the years.
Production
Production Run:
1983-2004, with significant technological advancements and minor cosmetic updates during this period.
🏆 Awards & Recognition
Recognitions
Motocross Championships:
The KX500 platform has been a successful platform for numerous professional motocross and supercross championships.
Ratings
Rider Reviews:
Highly regarded by riders for its power and reliability in its class.
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