1983-1985 Kawasaki GPZ 400-500-550 Service & Repair Manual

QUICK REFERENCE GUIDE To use, bend the manual back and match the desired section below against the black spot showing at the edge of these pages. Specifications 1 Adiustment 1 Introduction Disassembly I Chassis Engine r Maintenance & Chassis Theory Electrical Troubleshooting Appendix - Supplement Index

4 MODEL IDENTIFICATION Model ldentification KZ500-B1 Left Side View KZ500-B1 Right Side View

SPECIFICATIONS 5 Specifications Table of Contents SPECIFICATIONS .......................................... 6 ENGINE PERFORMANCE CURVES ........................... 8 RUNNING PERFORMANCE CURVES ......................... 9 ........................... PERIODIC MAINTENANCE CHART 10

6 SPECIFICATIONS SPEC1 FICATIONS Dimensions Overall length Overall width Overall height Wheel base Road clearance Dry weight Fuel tank capacity Performance Climbing ability Braking Distance Minimum turning radius Engine TY pe Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Valve timing Inlet Open Close Duration Exhaust Open Close Duration Carburetors Lubrication system Engine oil TY pe Capacity Starting system Ignition system Cylinder numbering method Firing order Ignition timing Spark plugs Transmission TY pe Clutch Gear ratio: 1 st 2nd 3rd 4th 5th 6th DOHC, 4-cylinder, 4-stroke, air-cooled 55.0 x 52.4 mm 497 cc 9.5 52 HP (99,000 rpm 4.5 kg-m @7,500 rpm 20" BTDC 48" ABDC 248" 48" BBDC 20" ATDC 248" TK K22P-2A Forced Lubrication (wet sump) SE class SAE 10W40, 10W50, 20W40, or 20W50 3.0 a Electric starter Battery and coil Left to right 1-2-3-4 1-2-4-3 From 10" BTDC (91,050 rpm to 35" BTDC (93,200 rpm NGK D8EA or ND X24ES-U 6-speed, constant mesh, return shift Wet rnulti disc 2.57 (36114) 1.78 ( W l 8 ) 1.38 (29121 ) 1.13 (27124) 0.96 (25126) 0.85 (23127)

Primary reduction ratio Final reduction ratio Overall drive ratio Electrical Equipment Alternator Regulator/Rectifier Ignition coils Battery Starter Motor Headlight TailIBrake light City light Turn signal lights Meter lights Indicator lights Horn Frame TY pe Steering angle Castor Trail Tire size Suspension Suspension stroke Front fork oil Brakes TY pe TY pe Bulb Front Rear Front Rear Front Rear TY pe Capacity (each fork) Oil level Front Rear Effective disc diameter Front Rear KZ500-61 2.94 (27123 x 65/26) 2.50 (40116) 6.25 (Top gear) Nippon Denso 037000-1400 Mitsubishi TSIOBRI K-L Toyo Denso ZC004-12V Furukawa FB12A-A (12V 12AH) Mitsuba SM-227K Semi-sealed 12v 45/40w @ @l 1 2 v 50140W 12V 5/21 W 0 12V 8/27W 12v 4W @ 0 12v 3.4W 12V21W @@12V23W 12v 3.4W 12v 3.4W 12V 2.5A Tubular, double cradle 37" to either side 26" 98 mm 3.25H-19 4PR 3.75H-18 4PR Telescopic fork Swing arm 180 mm 100 mm SAE 5W20 220 cc 505 mm (From top of inner tube with spring removed) Dual disc brakes 0 Single disc brake Disc brake 232 mm @I 250 mm 237 mm @ : European model @ : Australian model 0 : Other than European and Australian model Specifications subject to change without notice, and may not apply to every country.

8 SPECIFICATIONS ENGINE PERFORMANCE CURVES Crankshaft rprn

SPECIFICATIONS 9 RUNNING PERFORMANCE CURVES I:' 1 I I I 4 0 80 120 160 201 Vehicle Speed kph

ADJUSTMENT.. ENGINE 11 Adjustment-Engine Table of Contents SPARK PLUGS ............................................ 12 IGNITION TIMING ......................................... 12 Point Gap Adjustment (using a thickness gauge) ................. 13 Point Gap Adjustment (using a dwell angle tester) ................ 13 ....................................... Timing Test (Static) 13 .................................... Timing Test (Dynamic) 14 ...................................... VALVE CLEARANCE 15 THROTTLE CABLES ....................................... 18 ........................................... CARBURETORS 19 ........................... Initial Synchronization-Mechanical 19 ........................................ Idling Adjustment 21 ...................................... Fine Synchronization 21 CLUTCH ................................................ 22 ENGINE OIL .............................................. 24 ....................................... Oil Level Inspection 24 ................................... Oil and Oil Filter Change 24 ............................................ FUEL SYSTEM 24

12 ADJUSTMENT-ENGINE SPARK PLUGS Correct ignition timing is achieved by first obtaining Neglecting the spark plug eventually leads to difficult starting and poor performance. If the spark plug is used for a long period, the electrodes gradually burn away and carbon builds up along the insulator. In accordance with the Periodic Maintenance Chart (Pg. lo), the plug should be removed for inspection, cleaning and to reset the gap. @Remove the spark plugs using a spark plug wrench. @Clean the spark plug preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard plug or its equivalent. @Measure the gap with a wire-type thickness gauge. If the gap is incorrect, carefully bend the outer electrode, with a suitable tool to obtain the correct gap. Spark Plug Gap m Table B1 Spark Plug I Type I NGK D ~ E A . ND ~ 2 m @Tighten the spark plugs in the cylinder head to 1.4 kg-m (1 0.0 ft-lbs). Tightening Toraue IGNITION TIMING Incorrect ignition timing can cause poor performance, knocking, overheating, and serious engine damage. Peri- odic adjustment will be necessary to compensate for wear of parts, and the ignition timing must be check whenever ignition related parts have been disassembled or replaced. 1.4 kg-m (1 0.0 ft-lbs) the correct contact breaker point gaps (this can also be achieved by adjusting the dwell angles to the specified amount) and then changing the position of the mounting plate. Setting the points often returns the timing very close to the correct original setting. Once the timing has been adjusted, it may be checked for accuracy by the use of a strobe light. There are two sets of contact breaker points, the left set marked "L" fires spark plugs 1 and 4 simultaneously, and the right set marked "R" fires plugs 2 and 3 180' later. The gap for each set of points must be adjusted separately. NOTE: Spark plugs and cylinders are numbered consecutively, starting from the left. A. "L" contact breaker B. "R" contact breaker There are two sets of timing marks on the timing advancer, which can be viewed through the inspection window by turning the crankshaft. One set is marked "1 4" and the other one is marked "2 3". The "F" mark of each set is for checking the timing before advancing, and the "advanced timing marks" (a pair of lines) are for checking the timing it has advanced. Timing Advancer R m 1. #1, 4 Cylinder Advanced Timing Marks 2. #1, 4 Cylinder Timing Mark 3. #I, 4 Cylinder TDC Mark 4. #2, 3 Cylinder TDC Mark 5. #2, 3 Cylinder Timing Mark 6. #2, 3 Cylinder Advanced Timing Marks

1983-1985 Kawasaki GPZ 400-500-550 Service & Repair Manual

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