Description

Kawasaki EX500 Parts Catalog – 1987 to 1993 Factory OEM

I’ve been turning wrenches for 28 years. Every time a kid in my shop pulls a part number off a third-party website, I tell him he’s playing roulette. You want to know what side the oil drain plug washer goes on? You want to know if that carburetor float bowl gasket fits the ’92 EX500-D? You need the factory Kawasaki EX500 Parts Catalog. Not a reprint. Not a scan of a scan. 120 pages of genuine OEM part diagrams and numbers, straight from Kawasaki’s own engineering files.

This catalog covers every EX500 from 1987 through 1993 – the A7, A8, A9, B1, B2, B3, C1, C2, C3, D1, D2, D3 models, including the Ninja 500 variants. I’ve used these parts catalogs to cross-reference gasket sets, brake pads, and even the stupid little rubber plugs that fall out when you sneeze. When you’re rebuilding a cylinder head and the manual says “Cylinder Head Torque: Step 0 – Nuts In sequence: 2.3 kg-m, then 1.0 kg-m, then warm up, retorque cold,” you don’t guess – you pull the page.

General Specifications and Model Identification

Open the catalog and the first two pages give you the core specs: 498 cc, 74.0 x 58.0 mm bore and stroke, 10.8:1 compression, Keihin CVK34 carburetors, transistorized breakerless ignition. Model identification tells you which VIN range matches your bike – for example, ’92 EX500-D JKAEXVD1TA025001 to 035000. If you’re ordering parts for a ’91 and the listing says “EX500-A7,” you’ll know exactly what fits. No guesswork. No calling the dealer to ask if a 1993 coil works on a 1988 frame.

Tuning Specs: Valve Clearance and Spark Plug Gap

Page 2 of the catalog (and yes, I count pages) lists the cold valve clearance: intake 0.15–0.24 mm, exhaust 0.20–0.25 mm. Spark plug NGK D9EA or ND X27ES-U for USA, gap 0.6–0.7 mm. That’s the kind of data aftermarket parts catalogs get wrong half the time. This catalog doesn’t tell you how to adjust – that’s the service manual’s job – but it gives you the factory specs so you know which shims, gaskets, and seals to order. Pair it with a Kawasaki 95 115ZV Training Manual – 420 Pages OEM Specs if you need step-by-step procedures.

Cylinder Head Torque Sequence – Don’t Skip Steps

The OCR excerpt shows the head torque procedure: Step 0, nuts in sequence, 2.3 kg-m first, then 1.0 kg-m, warm up, retorque cold. That sequence matters. You skip the warm-up retorque and you’ll blow a head gasket inside 500 miles. The parts catalog diagrams show every washer, every copper gasket, every stud – you can see the exact part numbers for the head bolts (92001-, 92043-, etc.) and the cylinder head gasket (11004-). No aftermarket website gives you that level of traceability.

7 Systems Exploded in the Parts Catalog

From air cleaner to crankcase, this catalog breaks the EX500 into seven major sections: Air Cleaner, Brake Pedal/Torque Link, Breather Cover/Oil Pan, Cables, Camshafts/Tensioner, Carburetor (1/2 and 2/2), Chassis Electrical Equipment, Clutch, Cowling (1/2 and 2/2), Cowling Lowers, and Crankcase. Each section has an exploded view with callouts linking to the part number list. Need a clutch basket? Flip to the Clutch section. Need the right brake lever? The Brake Pedal/Torque Link page shows the pedal assembly and the torque link with exact bolt lengths. I’ve used these to find obscure parts like the 92066 pin and 92022 washer that hold the shift drum. Nobody stocks those – you order by number.

Why You Want OEM Documentation, Not a Third-Party Copy

Third-party parts catalogs copy the diagrams but omit the fine print – the 92037A washer that’s actually a special lock washer, or the 49002- part that’s a unique Kawasaki gasket. This is a factory PDF from Kawasaki’s own print run, not a reprint from a generic publisher. The Automotive Industry Overview and Internal Combustion Engine articles give you general knowledge, but when you’re holding a part number that starts with 32033, you need to know it’s the front axle nut – not a guess. This catalog gives you that.

Who Needs This Parts Catalog?

If you’re a home garage enthusiast rebuilding a neglected EX500, you need this to order every gasket, seal, and O-ring before you tear the engine open. If you’re a shop owner keeping a customer’s 1990 Ninja 500 running, you need the exploded views to identify which part broke and which part number to give the parts counter. Beginners: this catalog won’t teach you how to rebuild a carburetor – that’s what the service manual is for – but it will keep you from ordering the wrong float bowl gasket. Pair it with a K3V112DT Instruction Manual if you’re working on equipment that uses similar small-displacement engines.

FAQ: Common Questions About This Parts Catalog

Does this catalog include torque specifications for reassembly?

Yes, but only the ones needed for part identification – like cylinder head nut torque listed on page 2. For complete step-by-step torque sequences (crankcase bolts, clutch hub nut, etc.), you need the factory service manual. This catalog is for ordering parts, not for assembly procedures.

Can I use this catalog for a 1986 EX500?

No. The EX500 started in 1987. The 1986 model is a different bike (EX500 predecessor). This catalog covers 1987–1993 only. Check the VIN range table on the model identification page.

You’ve got a 120-page parts breakdown that shows every bolt, gasket, and seal Kawasaki put into the EX500 from ’87 to ’93. Don’t trust a photocopy or a third-party site that pulls part numbers from a forum. Access the Factory Manual and keep it on your tablet or print it out. When the customer asks why the new coil has a different connector, you’ll have the page that shows the supersede part number. That’s what 120 pages of genuine factory data buys you.

Related Manuals:

• K3V112DT Instruction Manual
• Kawasaki 95 115ZV Training Manual – 420 Pages OEM Specs
• Kawasaki Zx7R Rr Workshop Manual – 343-Page Factory OEM