Segment:
Mid-size Universal Japanese Motorcycle (UJM) segment, positioned as a versatile and approachable performance bike.
Key Competitors:
Honda CB550/CB650, Yamaha XS650/XS650 Special, Suzuki GS550/GS650.
Engine Configuration:
DOHC, inline-four cylinder, air-cooled engine known for its smooth power delivery and reliability.
Handling:
Sporty yet comfortable handling, making it suitable for both commuting and spirited riding.
Design:
Classic UJM styling with a blend of sporty and touring ergonomics.
Target Audience:
DIY enthusiasts, home mechanics, and professional technicians seeking to maintain, repair, or restore the Kawasaki KZ500.
Engine Mechanical:
Complete disassembly, assembly, inspection, and repair of engine components including cylinder head, pistons, crankshaft, connecting rods, camshafts, valves, and timing system.
Fuel System:
Carburetor identification, removal, disassembly, cleaning, adjustment, synchronization, and troubleshooting; fuel tank and fuel line service.
Ignition System:
CDI unit testing, ignition coil specifications, spark plug selection and gap, timing adjustment procedures.
Transmission And Clutch:
Clutch plate inspection and replacement, gearbox disassembly and assembly, gear shift mechanism, transmission fluid specifications and change intervals.
Electrical System:
Wiring diagrams, lighting system, charging system (alternator, rectifier/regulator), starter motor, battery service, fuses, and switches.
Suspension System:
Front fork disassembly, seal replacement, oil level and type specification, rear shock absorber inspection and replacement, swingarm bearing service.
Braking System:
Front and rear brake caliper inspection and overhaul, brake pad replacement, brake fluid type and bleeding procedures, master cylinder service.
Cooling System:
Engine oil cooling (if applicable) and oil filter replacement, oil change intervals and capacity.
Chassis And Bodywork:
Frame inspection, steering head bearing service, wheel bearing inspection, rim runout checks, body panel removal and installation, seat, and fuel tank mounting.
Exhaust System:
Muffler and pipe inspection and replacement, gasket specifications.
Preventive Maintenance:
Detailed periodic maintenance charts, lubrication points, cable adjustments (throttle, clutch), chain adjustment and lubrication.
Troubleshooting Guide:
Systematic diagnostic procedures for common starting, running, and electrical issues, with symptom-based solutions.
Disassembly And Assembly:
Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Repair And Overhaul:
Detailed instructions for rebuilding engine, transmission, carburetors, brake systems, and suspension components.
Adjustments:
Valve clearance adjustments, ignition timing adjustments, carburetor synchronization, brake lever and pedal free play adjustments.
Special Tool Usage:
Identification and recommended usage of specific Kawasaki service tools for various repair operations.
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and electrical system diagnostics.
Diagrams Illustrations:
Abundant pictorial diagrams, exploded views, and photographs to guide users through procedures.
Specifications Data:
Detailed service data including tightening torques, wear limits, clearances, and performance specifications.
Type:
4-stroke, DOHC, parallel-twin cylinder
Displacement:
498 cc (30.4 cu in)
Bore X Stroke:
74.0 mm x 58.0 mm (2.91 in x 2.28 in)
Horsepower:
Approx. 48 HP @ 9,000 rpm (claimed)
Torque:
Approx. 28.5 lb-ft @ 7,000 rpm (claimed)
Carburetion:
Twin Keihin CV carbs, 34mm
Fuel Type:
Unleaded gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Capacity:
Approx. 2.8 L (3.0 US qt) with filter change
Oil Type:
API SE, SF, SG classification, SAE 10W-40 recommended (refer to manual for specific Kawasaki recommendations)
Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first.
Valve Clearance:
Every 6,000-12,000 km (3,700-7,500 miles) or as specified in the manual, with cold engine measurements.
Spark Plug Replacement:
Typically every 10,000-15,000 km (6,000-9,000 miles).
Chain Cleaning Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for specific OEM recommendation).
Fork Oil:
Kawasaki KHL15-10W (or equivalent SAE 10W fork oil), 125-135cc per fork leg (refer to manual for exact quantity and level).
Carburetor Issues:
Common for CV carbs to become gummed up with age, requiring cleaning and synchronization for optimal performance. Idle speed instability.
Electrical Connections:
Corrosion or loose connections in the wiring harness, particularly grounds, can lead to intermittent electrical problems.
Cam Chain Tensioner:
Some models may develop a noisy cam chain tensioner over time, which can be addressed by replacing the unit.
Stator Output:
Voltage regulator/rectifier or stator output issues can lead to charging problems and battery drain.
Engine Bolt Torques:
Critical values for head bolts, main bearing caps, connecting rods, etc., provided in detail within the manual.
Wheel Torque:
Axle nut tightening specifications for front and rear wheels.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long history of producing innovative and performance-oriented motorcycles, from early singles to advanced sportbikes.
Kz Series:
The KZ series was Kawasaki's popular line of motorcycles throughout the 1970s and 1980s, known for their reliability and performance, with the KZ500 building on the success of smaller displacement models.
Kz500 To Kz550 Transition:
The KZ500 was succeeded by the KZ550, featuring a larger displacement and updated styling, though the core engineering remained similar.
Manufacturing Origin:
Japan
