Kawasaki EX500, GPZ500S, Ninja 500R 1987 - 2002

Clymer Owners Service & Repair Manual

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Front Cover
Stock image only. Actual cover art may differ.
Kawasaki EX500, GPZ500S, Ninja 500R 1987 - 2002 Clymer Owners Service & Repair Manual Covers the following models:
● Kawasaki EX500 A1 through A7, 1987-1993 (U.S., Canada)
● Kawasaki Ninja 500R D1 through D9, 1994-2002 (U.S., Canada)
● Kawasaki GPZ500S E1-on, 1994-on (Germany, Norway, Greece)
● Kawasaki GPZ500S F1-on 1994-on (U.K. and Sweden)

Contents:
Quick Reference Data

General Information
Manual Organization / Notes, Cautions And Warnings / Safety First / Service Hints / Torque Specifications / Fasteners / Lubricants / Parts Replacement / Basic Hand Tools / Test Equipment / Mechanic's Tips / Specifications

Troubleshooting
Operating Requirements / Troubleshooting Instruments / Engine Starting / Engine Performance / Engine Noises / Engine Lubrication / Clutch / Transmission / Charging System / Starting System / Electrical Problems / Ignition System / Electronic Ignition Troubleshooting / Excessive Vibration / Front Suspension And Steering / Brake Problems / Carburetor Troubleshooting

Periodic Lubrication, Maintenance And Tune-Up
Routine Checks / Maintenance Intervals / Tyres / Battery / Periodic Lubrication / Engine Oil Change / Fork Oil Change / Ultra-Trak Linkage Lubrication / Periodic Maintenance / Drive Chain Adjustment / Throttle Adjsutment / Steering Head Adjustment / Air Filter / Coolant Change / Timing / Tune-Up / Valve Clearance / Compression Test / Spark Plugs / Electronic Ignition / Carburetor / Idle Speed / Carb Synchronization /

Engine
Engine Removal Installation / Cylinder Head And Camshafts / Rocker Arm Assemblies / Cam Chain Tensioner / Valves And Valve Components / Cylinder / Pistons And Piston Rings / Oil Pump / Oil Pressure Relief Valve / Oil Level Switch / Neutral Switch / Alternator, Starter Drive Mechanism And Starter / Crankcase / Crankshaft And Connecting Rods / Balancer Shaft

Clutch And Primary Chain
Clutch And Primary Chain

Transmission
Shift Mechanism / Transmission

Fuel, Emission Control And Exhaust System
Fuel Tank / Carburetor / Carburetor Adjustment / Emission Control (California Models) / Exhaust System

Electrical Systems
Charging System / Transistorized Ignition / Ic Igniter Removal/Installation / Ic Igniter Test / Electric Starter / Lighting System / Switches / Horn / Wiring And Connectors / Thermostatic Fan Switch / Water Temperature Sensor / Junction Box And Fuses / Wiring Diagrams

Cooling System
Cooling System Inspection / Radiator And Fan / Thermostat / Water Pump / Hoses / Thermostatic Fan Switch And Water Temperature Sensor

Front Suspension And Steering
Front Wheel / Front Hub / Wheel Balance / Tubeless Tyres / Tubeless Tyre Changing / Handlebars / Steering Head / Front Forks

Rear Suspension
Rear Wheel / Rear Hub / Rear Wheel Coupling / Drive Chain / Cleaning / Wheel Balancing / Tyre Changing / Rear Shock Absorber / Uni-Trak Preload Adjustment / Rear Swing Arm

Brakes
Front Disc Brakes / Front Brake Pad / Front Caliper / Front Master Cylinder / Front Brake Hose / Front Brake Disc / Bleeding The System / Rear Drum Brake

Fairing

Supplement / 1994 And Later Service Information

Wiring Diagrams

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

Publisher
Clymer Publications
ISBN
0892878428
ISBN-13
9780892878420
Format
Paperback, 244 pages
Published
September 2002

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