Original Shop and Service Manual for Kawasaki KZ400, KZ440, KZ500, KZ550 Motorcycle, 1974-1982 edition
Manual Preview
Sample pages from the Original Shop and Service Manual for Kawasaki KZ400, KZ440, KZ500, KZ550 Motorcycle, 1974-1982 edition manual
Purchase & Download
Document Details
- Document Number / Seller:
- 26319 / Nancy Reed
- File Size:
- 73.98 MB
- File Type:
- ZIP
- Language:
- English
- Pages:
- 341
- Printable:
- Yes
- Estimated Download Time:
- 1.52 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Bike
- Brand:
- Kawasaki
- Reviewed and Approved:
- Dec 24, 2025
Models Covered & Key Technical Specifications
- KZ400D (1974–1977)
- KZ400S Special (1975–1977)
- KZ400A Deluxe (1977–1978)
- KZ400B (1978–1979)
- KZ400C (1978)
- KZ440A Ltd (1980–1982)
- KZ440B (1980–1981)
- KZ440C (1980–1981)
- KZ440D Ltd Belt Drive (1980–1982)
- KZ500B (1979–1980)
- KZ550A (1980–1981)
- KZ550C Ltd (1980–1981)
- KZ550D GPz (1981)
Production year(s): 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984
Professional Workshop Service Manual & Technical Specifications
1974-1982 Kawasaki KZ400 KZ440 KZ500 KZ550 Motorcycle Shop & Service Manual
This comprehensive collection provides essential technical data for owners and mechanics working on the legendary Kawasaki KZ series. Whether you are restoring a classic 1974 KZ400D or maintaining a high-performance 1981 GPz550, these manuals offer the deep-dive technical guidance required for professional-grade results.
The KZ400 series, known for its reliable twin-cylinder engine and commuter-friendly design, evolved significantly over its production run. This manual set covers the entire transition from the early drum-brake models to the sophisticated belt-drive Ltd cruisers and the four-cylinder powerhouses like the KZ550.
Detailed Model Coverage
This manual includes technical information for the following models:
- KZ400D (1974–1977): The original commuter twin that started it all.
- KZ400S Special (1975–1977): A budget-friendly variant featuring a drum front brake and simplified trim.
- KZ400A Deluxe (1977–1978): Fully equipped with a front disc brake and electric starter.
- KZ400B (1978–1979) & KZ400C (1978).
- KZ440A Ltd (1980–1982): The popular factory cruiser with stepped seats and chrome accents.
- KZ440B (1980–1981) & KZ440C (1980–1981).
- KZ440D Ltd Belt Drive (1980–1982): Featuring Kawasaki’s low-maintenance final drive system.
- KZ500B (1979–1980): The European-market focused four-cylinder precursor.
- KZ550A (1980–1981): The versatile standard four-cylinder.
- KZ550C Ltd (1980–1981): The custom-styled cruiser version of the 550.
- KZ550D GPz (1981): The high-performance model featuring a bikini fairing and increased horsepower.
Frame and Engine Serial Numbers for Identification
To ensure you are using the correct specifications for your specific bike, refer to these starting serial numbers found within the documentation:
- KZ400D: S3E-000001 (Engine) / KZ400D-000001 (Frame)
- KZ400S: S3E-050001 (Engine) / KZ400S-000001 (Frame)
- KZ400A: K4E-024301 (Engine) / KZ400A-000001 (Frame)
- KZ550A: KZ550AE000001 (Engine) / JKAKZFA1BA000001 (Frame)
What is Inside This Manual
This shop manual is divided into specialized sections to help you navigate complex repairs:
- Engine and Transmission: Complete teardown and reassembly guides for the twin and four-cylinder powerplants. Includes critical data on the balancer mechanism, crankshaft alignment, and primary chain tensioning.
- Fuel System and Carburetion: Detailed adjustment procedures for both the early 1974-1976 carburetors and the updated 1977+ CV models.
- Chassis and Suspension: Service instructions for front forks, rear shock absorbers, and steering head bearing
Manual Access & Delivery Information
FAQ
Is this manual suitable for beginners?
Yes, this Kawasaki manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Bike maintenance and repair.
What file format will I receive?
You will receive this manual as a ZIP file (73.98 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Kawasaki Bike manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
Customer Reviews
Read what our customers say about this Kawasaki Bike manual and share your own experience.
Add a Review
This policy contains information about your privacy. By posting, you are declaring that you understand this policy:
- Your name, rating, website address, town, country, state and comment will be publicly displayed if entered.
- Aside from the data entered into these form fields, other stored data about your comment will include:
- Your IP address (not displayed)
- The time/date of your submission (displayed)
- Your email address will not be shared. It is collected for only two reasons:
- Administrative purposes, should a need to contact you arise.
- To inform you of new comments, should you subscribe to receive notifications.
- A cookie may be set on your computer. This is used to remember your inputs. It will expire by itself.
This policy is subject to change at any time and without notice.
These terms and conditions contain rules about posting comments. By submitting a comment, you are declaring that you agree with these rules:
- Although the administrator will attempt to moderate comments, it is impossible for every comment to have been moderated at any given time.
- You acknowledge that all comments express the views and opinions of the original author and not those of the administrator.
- You agree not to post any material which is knowingly false, obscene, hateful, threatening, harassing or invasive of a person's privacy.
- The administrator has the right to edit, move or remove any comment for any reason and without notice.
Failure to comply with these rules may result in being banned from submitting further comments.
These terms and conditions are subject to change at any time and without notice.
Reviews (1)