This Haynes DIY repair manual covers 1987-2008 Kawasaki EX500 (GPZ500S) and 1997-2007 ER500 (ER-5) models, including:
Kawasaki EX500A (GPZ500S), U.K., U.S. 1987-1993
Kawasaki EX500D (GPZ500S,) U.K. 1994-2001
Kawasaki EX500E (GPZ500S), U.K. 2002-2004
Kawasaki ER500A (ER-5), U.K. 1997-1999
Kawasaki ER500C (ER-5), U.K. 2000-2007
Kawasaki EX500D (Ninja), U.S. 1994-2008
Book Excerpt: 1987-2008 Kawasaki EX500, GPZ500S, ER500 Repair Manual
ROUTINE MAINTENANCE AND SERVICING
COOLING SYSTEM | CHECK
WARNING: The engine must be cool before beginning this procedure.
NOTE: Refer Daily (pre-ride) checks and check the coolant level before performing this check.
The entire cooling system should be checked carefully at the recommended intervals.
Remove the fuel tank (Chapter 4).
Examine each of the rubber coolant hoses along its entire length. Look for cracks, abrasions and other damage. Squeeze each hose at various points.
They should feel firm, yet pliable, and return to their original shape when released. If they are dried out or hard, renew them.
Check for evidence of leaks at each cooling system joint. Tighten the hose clamps carefully to prevent future leaks.
Check the radiator for evidence of leaks and other damage. If leaks are noted, remove the radiator (refer to Chapter 3) and have it professionally repaired.
HAYNES HINT: Leaks in the radiator leave tell-tale scale deposits or coolant stains on the outside of the core below the leak.
ELECTRICAL SYSTEM
JUNCTION BOX CHECKS | EX MODELS
Aside from serving as a mounting for the fuse box, the junction box also houses relays - the fan relay (EX500A1 and A2 only), the starter circuit relay and the headlight relay (US and Canada only).
None of these relays are available individually. If one of them fails, the junction box must be renewed.
In addition to the relay checks, the fuse circuits and diode circuits should be checked also, to rule out the possibility of an open circuit condition or brown diode within the junction box as the cause of an electrical problem.
The terminal pairs given in the following test procedures relate to specific pins on the junction box wiring connectors (see illustrations).
Remove the seat and disconnect the battery negative (-ve) cable (see Section 3).
