Category:
Dual-sport / Adventure Motorcycle
Target Audience:
Riders seeking a versatile machine for commuting, touring, and light off-road use.
Key Competitors:
Honda Transalp, Suzuki V-Strom, Yamaha XT660R/Tenere.
Versatility:
Designed for a balance of on-road comfort and off-road capability.
Engine Architecture:
Reliable parallel-twin engine providing a good blend of torque and horsepower.
Comfort:
Ergonomic riding position suitable for longer journeys.
Engine:
In-depth coverage of the liquid-cooled, DOHC, parallel-twin engine, including disassembly, assembly, valve clearance adjustment, piston/ring replacement, and cylinder head overhaul.
Fuel System:
Detailed procedures for carburetor synchronization, cleaning, jetting, fuel pump, fuel filter replacement, and fuel tank maintenance.
Ignition System:
Covers ignition timing, spark plug specifications, coil testing, CDI unit diagnostics, and electrical troubleshooting related to ignition.
Transmission Drivetrain:
Comprehensive instructions for clutch inspection and replacement, gearbox disassembly and reassembly, shift mechanism repair, and final drive chain/sprocket maintenance.
Suspension:
Front fork overhaul, including oil and seal replacement, spring specifications, and rear shock absorber adjustment and service.
Brakes:
Front and rear brake system servicing, including hydraulic fluid replacement, caliper overhaul, pad replacement, master cylinder inspection, and bleeding procedures.
Electrical System:
Extensive wiring diagrams, component testing (alternator, starter motor, battery), lighting system diagnostics, and switchgear troubleshooting.
Cooling System:
Radiator maintenance, coolant specifications, fan operation, thermostat testing, and water pump service.
Exhaust System:
Inspection, repair, and replacement of exhaust components, including mufflers and pipes.
Frame Bodywork:
Frame inspection, fairing removal and installation, seat maintenance, and general body panel repair.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, and general inspection points.
Troubleshooting:
Systematic diagnostic guides for common problems, including no-start conditions, erratic running, electrical faults, and braking issues.
Disassembly Reassembly:
Step-by-step instructions for dismantling and reassembling major vehicle components.
Component Overhaul:
Detailed rebuild procedures for the engine, transmission, suspension, and braking systems.
Electrical Diagnostics:
Troubleshooting electrical circuits, testing sensors, and repairing wiring harness issues using provided diagrams.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine rebuilds and advanced electrical diagnostics.
Type:
Constant mesh 6-speed sequential
Clutch:
Wet multi-disc, cable operated
Final Drive:
Sealed O-ring chain, 525 pitch
Engine Oil Type:
API SG or SH SAE 10W-40 (recommendation based on common practice, consult manual for specific Kawasaki spec)
Engine Oil Capacity:
2.4 Liters (2.5 US qt) with filter change
Crash Test Data:
N/A (Motorcycle specific safety features and rider protection are emphasized)
Braking System:
Dual front discs, single rear disc.
Tire Specifications:
Front: 90/90-21, Rear: 130/80-17 (typical for this model, confirm in manual)
Lighting:
Halogen headlight, LED tail light.
Instrumentation:
Analogue tachometer, speedometer, odometer, trip meters, warning lights.
Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first (typical interval, refer to manual for exact specification).
Valve Adjustment:
Every 12,000 km (7,500 miles) or annually (typical interval, refer to manual for exact specification).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (typical interval, refer to manual for exact specification).
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or annually (typical interval, refer to manual for exact specification).
Brake Fluid:
DOT 4 (recommended, consult manual for precise specification).
Coolant:
Ethylene glycol based coolant, 50% mixture with distilled water (typical, consult manual for Kawasaki specific formulation).
Fork Oil:
Kawasaki KHL15-10 (or equivalent 10W fork oil), 478 ml per fork leg (typical specification, confirm in manual).
Carburetor Sync:
Carburetors can drift out of sync over time, leading to rough idling or poor performance. Regular synchronization is key.
Cam Chain Tensioner:
Some owners report potential wear or failure of the cam chain tensioner, leading to rattling noises. The manual will detail inspection and replacement.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can cause intermittent electrical issues. The manual's wiring diagrams are crucial for diagnosis.
Rear Shock ABSorber:
The stock rear shock may become less effective over time or with high mileage, potentially requiring service or replacement.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Reputation:
Known for reliable and performance-oriented motorcycles across various segments.
Generation Start:
The KLE500 was introduced in the early 1990s as a mid-displacement dual-sport offering.
Updates For 2000:
The 2000 model likely received minor updates or refinements from earlier iterations, such as revised graphics or minor component enhancements. Specific changes should be detailed in the manual.
Production Location:
Primarily manufactured in Japan.
Production Run:
The KLE500 was produced for an extended period, with the model evolving over its lifespan until its discontinuation, often replaced by newer adventure-oriented models.
