Kawazaki EX 500 User Manual

Despiece EX500 desde el ´87 al 

´93.



www.ex500.com.ar



ex500@ciudad.com.ar

General Specifications

Model Identification

Engine

Engine Type 4-stroke, Inline, 2-cylinder, DOHC, Liquid cooled,

8-Valve Displacement 498 cc Bore x Stroke 74.0 x 58.0 mm Compression Ratio 10.8:1 Maximum Torque 4.7 kg-m at 8,500 rpm Carburetor Keihin CVK34 (2) Constant velocity, Diaphragm-type Ignition System 12 V Battery & Coil, Transistorized Breakerless Ignition Advance Electronic Crankshaft Rotation Clockwise from ignition (RH side) Cylinder Number Method Left to Right: 1-2 Firing Interval/Order 180° Cylinder Material Aluminum alloy with ferrous sleeves Fuel Min 91 Research/87 Avg. Oct. Unleaded OK Coolant 50% distilled water /50% ethylene glycol base antifreeze.

—Capacity 1.8 liter —Level Level with radiator filler neck.

Transmission

Clutch Type Wet, Multi-disc, Manual Transmission 6-speed, Constant mesh, Return shift

Shift Pattern (Bottom up) 1-N-2-3-4-5-6 (w/Neutral Finder) Gear Ratios —1st 2.57 (36/14)

—2nd 1.78 (32/18) —3rd 1.38 (29/21) —4th 1.13 (27/24) —5th 0.96 (25/26)

—6th 0.85 (23/27) Primary Ratio 2.65 (27/23 x 63/28) Final Ratio 2.63 (39/15) Overall Ratio (Top Gear) 5.93

Chassis

Wheelbase 1440 mm Seat Height 770 mm Ground Clearance 120 mm Dry Weight 169 kg (US) 169.5 kg (CA) Curb Weight 190 kg (US) 195.5 kg (CA) Max Recom Load 186 kg Fuel Tank Capacity 4.8 U.S. gal. Tire Size —Front 110/70 17

—Rear 130/70 17 Brake Type —Front Single Disc

—Rear Single Disc Brake Size —Front 252 mm Effective Diameter

—Rear 203 mm Effective Diameter Wheel Travel —Front 140 mm

— Rear 140 mm

Year & Model '92 EX500-D:Ninja 500 Colors ① Candy Wine Red (H3)

② Metallic Blue Violet (SD) VIN Range JKAEXVD1TA025001 - 035000 Engine No. Range EX500AE018001 -

Tuning Specifications

Engine

Cylinder Head Torque 0 = Step — Nuts In sequence: ① 2.3 kg-m

② 1.0 kg-m ③ Warm up ④ Retorque cold Valve Clearance (Cold) Intake: 0.15-0.24 mm

Exhaust: 0.20-0.25 mm

— Adjustment Method Rocker arm screw Compression Pressure 18.8 kg/m2 at 440 rpm Spark Plug NGK D9EA or ND X27ES-U (USA)

NGK D8ES or NDX24ES-U (Canada)

—Gap 0.6-0.7 mm

Ignition Timing —Idle 10° BTDC at 1,200 rpm (US)

10° BTDC at 1,300 rpm (CA)

—Full 37.5° BTDC at 10,000 rpm (US)

37.5° BTDC at 10,000 rpm (CA) Air Screw Sealed—not adjustable Idle Speed 1,050 ±50 rpm (US,CN)

1,250 ±50 rpm (CA)

Engine Oil SE Class SAE 10W40, 10W50, 20W40, 20W50

—w/Filter Change 3.4 liter —No Filter Change 2.4 liter —Level On center stand, wait 5 min, middle of window

Chassis

Fork Oil SAE 10W20

—Capacity 349.5-354..5 cc

Tire Pressure (Cold)

—Front 33 psi —Rear 36 psi

Drive Chain Slack 34-45 mm (STD)

EX500-A7

AIR CLEANER BRAKE PEDAL/TORQUE LINK BREATHER COVER/OIL PAN CABLES CAMSHAFTS/TENSIONER CARBURETOR (1/2) CARBURETOR PARTS (1/2) CHASSIS ELECTRICAL EQUIPMENT CLUTCH COWLING (1/2)(EX500-A7) COWLING LOWERS (1/2)(EX500-A7) CRANKCASE (1/2) CRANKCASE BOLT PATTERN CRANKSHAFT CYLINDER HEAD CYLINDER HEAD COVER CYLINDER/PISTONS DECALS (EX500-A7)(BLUE/WHITE) DECALS (EX500-A7)(GREEN/WHITE) ELECTRO BRACKET ENGINE COVERS FENDERS FOOTRESTS FRAME FRAME FITTINGS FRONT BRAKE FRONT FORK FRONT MASTER CYLINDER FRONT WHEEL FUEL EVAPORATIVE SYSTEM FUEL TANK (1/4)(EX500-A7) GEAR CHANGE DRUM/SHIFT FORKS GEAR CHANGE MECHANISM GENERATOR HANDLEBAR HEADLIGHT IGNITION SWITCH/LOCKS/REFIECTORS

IGNITION SYSTEM LABELS METERS MUFFLERS OIL PUMP/OIL FILTER OWNER'S TOOLS RADIATOR/FAN/WATER PUMP (1/2) REAR SUSPENSION REAR WHEEL/CHAIN/COUPLING ROCKER ARMS/VALVES SEAT (1/2)(EX500-A7) SHOCK ABSORBER SIDE COVERS (2/2)(EX500-A7) STANDS STARTER MOTOR SWINGARM TAILLIGHT TIRES TRANSMISSION TURN SIGNALS WATER PUMP