Kawasaki EX 500 Maintenance - Repair Manual

The service manual covers all repair and maintenance procedures. It's simple to use, full of in depth information and specifically written for the kawasaki ex500 motorcycle. Having simple to follow illustrations/diagrams and instructions makes it so much easier, no matter how complex the repair.

Even if you’ve never done any motorcycle maintenance or repair before, you’ll find all the information you need to get started. Professional mechanics and master technicians also use this manual.

Make and Model Year Language Price Rating Instant Download
Kawasaki EX500 1987-1993 £6.99

Supplied in easy to read and print pdf format and works with all operating systems; Windows XP, Vista, 7, MAC, etc. (any device that reads pdf format) plus there's No waiting for delivery!

Example Contents

General Info & Maintenance Fuel & Cooling System
Engine, Clutch & Transmission Electrical System
  • Engine type
  • Model identifications
  • Dimensions
  • Brake fluid
  • Steering system
  • Wheel & tyre
  • Using the workshop manual
  • Clutch fluid change
  • Steering stem bearing lubrication
  • Engine oil & oil filter
  • Air cleaner
  • Emission control information
  • Suspension, fork oil
  • Unit conversion table
  • Clutch hoses & pipe replacement
  • General specifications
  • Wheel bearings
  • Before servicing
  • Lubrication of parts
  • Torque settings, special tools & specifications
  • Fuel system
  • Air pressure & tyre damage & wear
  • Engine valve clearance
  • Fuel hoses
  • Cooling system
  • Spark plug replacement
  • Periodic maintenance chart
  • Maintenance
  • Coolant change
  • Brake maintenance
  • Shock absorber oil
  • Electrical system
  • Drive train lubrication, adjustment & wear
  • Technical information
Wheels & Tyres

  • Balancing
  • Tyres
  • Axle
  • Exploded view
  • Hub bearing
  • Tyre pressure
  • Rear wheel
  • Front wheel
  • Specification & service Information

  • DFI power source
  • Vehicle down sensor
  • Water temperature sensor
  • Main throttle sensor
  • Fuel pump relay
  • Water pump
  • ECU main relay
  • Fuel tank
  • Camshaft position sensor
  • Throttle grip & cables
  • Thermostat
  • Hoses & pipes
  • Exploded view
  • Coolant
  • Fuel pump
  • Inlet air temperature sensor
  • Radiator cap
  • Coolant flow chart
  • Warning Indicator light
  • Atmospheric pressure sensor
  • Sub throttle valve actuator
  • Air line
  • Pressure testing
  • DFI system
  • Stick coils
  • Blank key detection
  • Immobilizer amplifier
  • Fuel Injectors
  • Sub throttle sensor
  • Throttle body
  • Evaporative emission control system
  • Water temperature sensor
  • Self diagnosis
  • Crankshaft sensor
  • ECU
  • Speed sensor
  • Troubleshooting
  • Fuel line
  • Radiator
  • Gear position switch
Brakes & Steering
  • Brake disc & brake pads
  • Brake hoses
  • Steering Inspection & adjustment
  • Calipers
  • Steering stem
  • Exploded view, service Information
  • Brake lever & brake pedal
  • Master cylinder
  • ABS anti-lock braking system
  • Brake fluid

  • Oil pump
  • Shift pedal
  • Exploded view, specifications, special tools & sealant
  • Camshaft chain tensioner
  • Cylinder head & cylinder head cover
  • Oil cooler
  • Crankshaft main bearing
  • Muffler, exhaust pipe
  • Clutch master cylinder
  • Throttle body holder
  • Clean air system
  • Transmission shaft
  • Exhaust system
  • Oil pressure measurement
  • Oil pressure switch
  • Shift fork guide, pin & drum
  • Connecting rod big end bearing
  • Clutch slave cylinder
  • Transmission
  • Piston & piston ring
  • Oil pressure switch
  • Engine oil & oil filter
  • Oil pan
  • Clutch plate
  • Starter motor clutch & torque limiter
  • Clutch fluid
  • Crankshaft & connecting rods
  • Bleeding the clutch
  • Oil pressure relief valve
  • Valves
  • Engine Lubrication System
  • Hoses
  • Compression measurement
  • Crank pin
  • Engine Removal & Installation
  • Balancer
  • Clutch & clutch cover
  • Crankcase splitting
  • Transmission & crankshaft
  • Fenders
  • Side stand
  • Seat
  • Center stand
  • Fairing's
  • Frame
  • Seat cover
  • Charging voltage
  • IC Igniter
  • Spark plug
  • Relay box
  • Starter relay
  • Stick coil
  • Immobilizer system
  • Lighting system
  • Switches & sensors
  • Fuel level sensor
  • ECU
  • Fuse Inspection
  • Headlight
  • Fuses
  • Turn signal lights
  • Water temperature sensor
  • Radiator fan system
  • Electrical wiring
  • Fuel reserve switch
  • Alternator
  • Meter unit
  • Gear position switch
  • Air switching valve
  • Meter, gauge & Indicator unit
  • Camshaft position sensor
  • Battery
  • Brake light timing
  • Starter motor
  • Crankshaft sensor
  • Charging
  • Exploded view & wiring diagram
  • Tail light/brake light
  • Ignition system
  • Regulator
Suspension & Final Drive

  • Front fork
  • Wheel alignment
  • Rebound damper force
  • Rear shock absorber
  • Rear sprocket
  • Specifications, service Information & exploded view
  • Rocker arm & tie arm bearing lubrication
  • Swing arm bearing
  • Chain guard
  • Coupling bearing
  • Swing arm
  • Front sprocket
  • Coupling damper
  • Drive chainElectric starter system

The Kawasaki EX500 Ninja is another great novice rider’s sports bike. With a 50bhp engine, the bike isn’t too powerful, but this lowered horsepower comes as a blessing in terms of providing much better fuel economy. This isn’t to say that the EX500 cannot hold its own and bring out the excitement in your rides, with its 120mph top speed that should keep any novice busy for quite some time. Needless to say, with its relatively low fuel consumption and solid amount of power, the EX500 is the ideal commuting solution. But that’s not to rule out track days from its capabilities, with what it lacks in speed being made up in the corners, giving those new to the track a good means to get acquainted.

If you’ve bought your Kawasaki EX500 second hand, you might be a little concerned with how its looking internally, especially since motorcycles are so exposed to the elements in general. Parts can easily pick up rust and begin to corrode without your knowledge, which can ultimately end up costing you a hefty sum when you get that next garage maintenance check up. Whether your bike requires any parts replacing or not, the fee will still be high due to the overriding expense of the mechanic’s labour. The only way to avoid these obscene fees would be to carry out the maintenance yourself, but how can you go about learning simple servicing techniques?

Well, help is at hand with the EX 500 manual. This guide takes a close up look at your bike’s specific model, allowing you to always have a reference to turn to when something goes wrong on the road. Whether you need to replace one part, or one hundred, there will be a solution and the best part is how much it’ll cost you – nothing. Routine maintenance really isn’t as difficult as you would first imagine, and since all the skills you’ll need are contained within this manual, it should only take you a few hours before you have it mastered.

So how can you benefit from applying the skills within the Kawasaki manual? Well, the obvious answer is the huge savings in cash you’ll be making each year, with expensive garage services being potentially removed for good. What’s more is how efficiently your bike will now be performing under your constant surveillance. By making sure every part is kept in good working order, you can prevent unnecessary malfunctions and damage to parts usually caused by neglect. The manual will also improve the overall safety of the bike, which is essential, especially if the rider is inexperienced. So don’t tempt fate and keep your Ninja at its prime starting today.

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