Model Nickname:
A1, A2, A3, A4, A5, A6, A7, A8, A9, A10, A11, A12, A13
Generation Years:
1995-2007
Model Codes:
KLE500-A1 to KLE500-A13
Vehicle Type:
Dual-purpose motorcycle, often categorized as an adventure-touring or trailie.
Target Audience:
Riders seeking a versatile motorcycle capable of on-road touring and light off-road exploration, offering a balance of comfort and capability.
Key Competitors:
Honda Transalp, Suzuki V-Strom 650 (later models), Yamaha TDM850 (in spirit), BMW F650 Funduro.
Versatility:
Designed for both comfortable on-road commuting and touring, as well as handling gravel roads and light trails.
Engine Platform:
Utilizes the robust parallel-twin engine derived from Kawasaki's GPZ500 sportbike, adapted for broader power delivery.
Value Proposition:
Offered a more affordable entry into the dual-purpose segment compared to some European competitors.
Covered Model Years:
1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Covered Engine Variants:
All KLE500 models with the liquid-cooled, four-stroke, parallel-twin engine
Estimated Page Count:
~400-500 Pages (estimated for comprehensive workshop manuals of this era)
Type:
Workshop Manual / Service Manual / Repair Manual
Format:
Digital (PDF) - often digitally scanned from original printed manuals
Engine:
Complete engine overhaul, top-end rebuild, bottom-end assembly, valve clearance adjustment, piston and cylinder inspection, cooling system maintenance, lubrication system.
Fuel System:
Carburetor (CVK) disassembly and cleaning, jetting specifications, fuel pump operation, fuel filter replacement, fuel tank inspection.
Ignition System:
CDI ignition timing, spark plug specifications, ignition coil testing, stator and rotor inspection.
Transmission:
Gearbox disassembly and reassembly, clutch operation, clutch adjustment, transmission bearing inspection, gear shift mechanism.
Suspension:
Front fork overhaul (oil change, seal replacement), rear shock absorber inspection and adjustment, swingarm bearing service, linkage maintenance.
Brakes:
Front and rear brake caliper servicing, hydraulic system bleeding, master cylinder inspection, brake pad replacement, brake disc inspection.
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, indicators), battery maintenance, charging system (alternator), starter motor operation, fuses and relays.
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, general chassis component inspection.
Bodywork:
Fairing removal and installation, seat maintenance, panel fasteners, general body component care.
Cooling System:
Radiator inspection and cleaning, coolant specifications and capacity, water pump inspection, thermostat operation.
Maintenance:
Regular scheduled maintenance tasks, oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug replacement, coolant level checks.
Troubleshooting:
Diagnostic flowcharts for common performance issues, starting problems, electrical faults, and operational anomalies.
Repair:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension fork servicing, brake system repairs, and electrical component replacement.
Assembly Disassembly:
Detailed instructions for component removal and reinstallation, torque specifications for critical fasteners.
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch and throttle cable free play, suspension pre-load and damping settings.
Depth:
Comprehensive from basic rider maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
Engine Type:
Liquid-cooled, four-stroke, parallel-twin, DOHC, 8 valves
Displacement:
498 cc (498cc)
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
10.8:1
Horsepower:
~50 HP @ 8500 RPM (approximate, varies slightly by year/market)
Torque:
~43 Nm @ 6000 RPM (approximate, varies slightly by year/market)
Carburetors:
Dual Keihin CVK34 carburetors
Fuel Capacity:
15 Liters (3.9 US gal)
Ignition Type:
Electronic ignition (CDI)
Lubrication System:
Forced lubrication, wet sump
Cooling Medium:
Liquid (Ethylene Glycol based coolant)
Safety Features:
Disc brakes front and rear, spoke wheels for better off-road durability, adequate lighting for visibility.
Braking System:
Front: 260mm disc with twin-piston caliper. Rear: 230mm disc with twin-piston caliper.
Lighting:
Halogen headlight, LED taillight, amber turn signals.
Frame Construction:
Semi-double cradle frame for stability and robustness.
Oil Change Interval:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 mi).
Valve Clearance Check:
Every 12,000 km (7,500 mi).
Chain Maintenance:
Lubricate and adjust every 1,000 km (600 mi) or after washing/riding in rain.
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified.
Engine Oil Capacity:
2.4 Liters (2.5 US qt) without filter change; 2.6 Liters (2.7 US qt) with filter change.
Coolant Type:
Permanent antifreeze, ethylene glycol based, mixed 50/50 with distilled water.
Fork Oil Type:
Show KHL15-10W or equivalent (refer to manual for exact viscosity and quantity per leg).
Common Wear Items:
Clutch wear, swingarm pivot bearings, steering head bearings, fork seals, charging system output (stator).
Carburetor Idling:
Carburetors can become slightly out of sync over time, affecting smooth idling and low-speed response.
Electrical Connections:
Corrosion or loose connections in the wiring harness, particularly around the ignition and charging circuits, can cause intermittent faults.
