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New member, KZ500 project 14 Sep 2020 17:49 #835034

  • GregAxi
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Hello to all,
Recently picked up a KZ500 as a project bike in need of some serious TLC, joined the forum to learn more as I'm new to the Kawasaki brand.
It's in need of a top end rebuild which the PO started but in the current climate didn't have the funds to progress. I know its the wrong color but I do intend to fix that shortly, there is a hint of red in a number of spots. From what I've looked into these seem to be pretty hard to come by here in Australia

Any assistance on where to buy a top end rebuild kit for the Z500 would be great as a starting point, also I'm in need of an instrument panel (km/h) to replace the crappy cafe racer gauges it has. Located in Melbourne, Australia

Cheers, Greg
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New member, KZ500 project 17 Sep 2020 00:32 #835202

  • GregAxi
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Anyone have a copy of the KZ500B parts diagrams in PDF?
Thanks Greg

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New member, KZ500 project 17 Sep 2020 05:57 #835208

  • TexasKZ
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So far as I know, the Z500 was never sold in North America, so there is very little info on it around here. The Z designation (rather than KZ) suggests a Euro spec bike, but I see that CMSNL does not show parts diagrams for it. Weird. Also, from what I can tell, it was only made for two years. Finding parts and information may take some serious sleuthing.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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New member, KZ500 project 17 Sep 2020 06:06 #835209

  • TexasKZ
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I did stumble across this, though I have no idea if the book is in Dutch or Japanese or Swahili or ......


www.cmsnl.com/products/ond-boek-z500b1b3_z500b13/#.X2NeWV48KK0
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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New member, KZ500 project 17 Sep 2020 06:16 #835210

  • 650ed
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Welcome aboard! Do NOT use Phillips screwdrivers on the Kawasaki. Those screws that look like Phillips are actual Japanese Industrial Standard (JIS) and using a Phillips screwdriver on them will damage the screw heads. If you need more info just ask, but Phillips screwdrivers can very easily be modified so they are JIS shaped. Ed




MODIFIED PHILLIPS SCREWDRIVER BIT
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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New member, KZ500 project 17 Sep 2020 07:28 #835216

  • scubaanders
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Check out www.kawasaki.com
Owner center -> Parts
There you find high resolution pdf parts diagrams. You should look for KZ550A model, same same just 50cc more displacement.

m.kawasaki.com/Parts/PartsDiagrams/1980/KZ550-A1


/A

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New member, KZ500 project 17 Sep 2020 17:17 #835241

  • GregAxi
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Thanks, i'll give that a shot.

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New member, KZ500 project 17 Sep 2020 19:09 #835247

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Thanks, i'll give that a shot.

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New member, KZ500 project 18 Sep 2020 06:51 #835258

  • TexasKZ
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I saw a post in another thread that mentioned some KZ400 and 500 info in the 550 factory service manual. I think it might have been Lou (loudhvx).
There is a 400/550 factory service manual in the Articles section.. It will not help with part numbers, but it may be invaluable in procedures and identifying common parts.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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New member, KZ500 project 18 Sep 2020 09:45 #835284

  • loudhvx
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In my signature there is a link to other links for several service manuals. There are at least 3 that pertain to your 500 specifically.
There is also a link to a carb website for your specific TK22 (or possibly Tk21) carbs.

Last but not least, you will want to read the valve train warning in my sig.

Like Scubaabders said, most Kz550A or even D parts will be similar if not identical. The brake's disk diameter and fork mounting points for the calipers might be different.

A Kz550 engine from any chain-drive bike would most likely be a direct swap if you wanted to get that extra 50cc.
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New member, KZ500 project 18 Sep 2020 10:52 #835296

  • linuxrob
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Have the european part book for B1 to B4 your looks like a B3 or B4 you can tell from the engine and frame numbers, download the manual from loudvx site and look at the back page it gives the models and corrisponding engine and frame numbers. The Z500 B3 and 4 share alot more parts from the 550, mine is a B2 with the early type calipers and point ignition and does not have air forks. My guess is that the GPZ550 D will ahve the same calipers as the Z550 only had a drum at the back. there are a lot of folk in Aus with the Z500 and a lot are on this facebook group

www.facebook.com/groups/1884835178398402

My part book should be ideal to fill in the gaps from the CMSL site bits

www.cmsnl.com/kawasaki-kz550_model12595/

feel free to message me and i can scan the pages that you require.

Rob B
UK
1980 Z500 B2 owned from new 78260 miles
1980 Z500 B2 in bits since 1982 23000 miles
2004 GSF1200S Bandit K4
2000 GS125 ESD
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New member, KZ500 project 28 Sep 2020 17:15 #835813

  • GregAxi
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Thanks for the info gents, great time to start the clean up while still in lockdown.
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