🏷️ Basic Information Identification Make: Kawasaki Model: GPZ 500 S Product Name: Kawasaki EX 500 GPZ 500 S Service Repair Manual 1987-1993 Codes Chassis Codes: EX500-A1 to EX500-A7 (example, specific model codes may vary) Engine Codes: EX500AE (example, specific engine codes may vary) 👋 Introduction Market Position Target Audience: DIY motorcycle enthusiasts, independent repair shops, owners seeking detailed maintenance information Competitive Analysis Value Proposition: Cost-effective solution for accessing professional-grade repair and maintenance data, saving money on labor Key Features Ease Of Use: Easy-to-follow, step-by-step instructions suitable for any skill level Portability: Printable pages allow for easy on-site use in home, office, or repair shop 📋 Manual Details Coverage Areas Model Years Covered: 1987, 1988, 1989, 1990, 1991, 1992, 1993 Regions Covered: Global (assumed, as specific regional variants are not mentioned) Page Count Estimated Page Count: Extensive (Specific page count not provided, but described as 'complete' and 'extremely detailed') Manual Type Manual Type: Service Repair Manual / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Full Engine Overhaul, Tuning, Troubleshooting, Component Repair Fuel System: Carburetor Tuning, Cleaning, Rebuilding, Fuel Pump Service Ignition System: Ignition Timing, Spark Plug Service, Coil and CDI Unit Testing Clutch: Clutch Plate Replacement, Spring Inspection, Clutch Lever Adjustment Transmission: Gearbox Disassembly, Assembly, Shift Drum and Fork Inspection, Gear Ratio Data Suspension System: Front Fork Overhaul, Rear Shock Absorber Service, Bushing and Seal Replacement Wheels And Tires: Wheel Bearing Service, Tire Mounting and Balancing, Spoke Adjustment (if applicable) Braking System: Brake Caliper Service, Pad Replacement, Brake Fluid Bleeding, Master Cylinder Overhaul Electrical System: Wiring Diagrams, Component Testing, Battery Service, Lighting System Troubleshooting Bodywork: Fairing Removal and Installation, Seat Service, Fuel Tank Removal Air Temperature Control System: Diagnosis and repair related to ambient air temperature sensors affecting engine performance (if applicable) Procedures Included Maintenance: Oil Changes, Filter Replacements, Chain Adjustment, Lubrication Points Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues Repair: Component-level repair and replacement procedures Rebuilding: Complete engine and gearbox rebuilding procedures Installation: Procedures for installing and removing major components Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to full engine rebuilds and advanced diagnostics Diagrams And Illustrations: Detailed step-by-step diagrams, exploded views, and electrical schematics 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within PDF (typical for professional manuals) Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, parallel-twin Displacement: 498 cc (cubic centimeters) Bore X Stroke: 74.0 x 58.0 mm (millimeters) Compression Ratio: 11.3:1 (typical) Power Output Hp: Approximately 55-60 HP (Horsepower) at 9000 RPM (dependent on specific year and market) Torque Ft Lbs: Approximately 32-34 lb-ft (foot-pounds) at 7000 RPM (dependent on specific year and market) Fuel System Fuel Delivery: Dual Keihin CVK34 carburetors Fuel Tank Capacity: Approximately 16 Liters (4.2 US gal) Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Final Drive: O-ring sealed chain Features Clutch Type: Wet, multi-disc 📐 Dimensions Exterior Length: Approximately 2130 mm (83.9 in) (dependent on model year and fairings) Width: Approximately 750 mm (29.5 in) (dependent on model year and fairings) Height: Approximately 1200 mm (47.2 in) (dependent on model year and fairings) Weights Dry Weight: Approximately 170 kg (375 lbs) (dependent on model year) Wet Weight: Approximately 188 kg (414 lbs) (dependent on model year and fluids) 🛡️ Safety Features Ratings Safety Features: Standard motorcycle safety features including dual disc front brakes, single disc rear brake, and durable chassis construction. Active Features Braking System Front: Dual hydraulic discs (e.g., 270 mm diameter) Braking System Rear: Single hydraulic disc (e.g., 230 mm diameter) 💡 Technology Features Infotainment Infotainment Features: N/A (This era of motorcycle did not feature complex infotainment systems; focus is on mechanical and electrical systems). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 4,000-6,000 km (2,500-3,700 miles) or 6-12 months, refer to manual for exact spec. Spark Plug Replacement Interval: Generally around 12,000-24,000 km (7,500-15,000 miles), refer to manual for exact spec and type. Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-40 recommended (specific viscosity may vary with climate). Engine Oil Capacity: Approximately 2.4 Liters (2.5 US qt) with filter change (verify in manual). Coolant Type: Ethylene glycol-based antifreeze with distilled water (50/50 mixture recommended). Brake Fluid Type: DOT 4 recommended (verify in manual). Fork Oil Type And Viscosity: Typically SAE 10W fork oil (refer to manual for exact type and quantity). Known Issues Common Wear Items: Clutch plates, fork seals, brake pads, chain and sprockets, carburetor diaphragms. Potential Electrical Issues: Aging wiring harness insulation, regulator/rectifier failures (common on older bikes). Engine Specific Considerations: Regular valve clearance checks are important for engine longevity and performance. 📚 Vehicle History Brand...