🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Nickname:

Also known as the Kawasaki ER500 in some markets for the naked variant, though the KLE500 is specifically the dual-sport offering.

Generation:

Second Generation (A-model continued and refined, B-model introduced for later years).

Generation Years:

1991-2007 (with significant updates in 2005 for the B-model).

Chassis Code:

LE500A (for earlier models) / LE500B (for later models like the 2005-2007 range covered).

Engine Code:

EX500E (derived from the Ninja 500 engine).

👋 Introduction

Segment:

Lightweight dual-sport/adventure touring motorcycle.

Target Audience:

Riders seeking an affordable, reliable, and versatile motorcycle for commuting, light off-road exploration, and touring.

Competitors:

Suzuki DR650, Honda Transalp (though larger), Yamaha XT600/XT660.

Versatility:

Ability to handle both paved roads and light off-road conditions.

Engine Reliability:

Proven parallel-twin engine derived from the Ninja 500, known for its robustness.

Affordability:

Positioned as an entry-level to mid-range adventure bike.

📋 Manual Details

Years Covered:

2005, 2006, 2007

Market Focus:

Global, with specific regional variations noted where applicable.

Page Count:

Approximately 300-400 pages (typical for a comprehensive service manual of this era).

Manual Type:

Full Service and Repair Manual

Manual Format:

Likely a comprehensive printed manual or a high-quality PDF scan of the original factory manual.

Language:

English (standard for most global service manuals).

📖 Manual Coverage

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures, including valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod checks.

Fuel System:

Carburetor maintenance, cleaning, and adjustment (dual Keihin CVK34), fuel pump operation, fuel tank and lines inspection.

Ignition System:

CDI unit, ignition coil testing, spark plug specifications and replacement, ignition timing checks.

Transmission And Clutch:

Clutch operation, adjustment, and replacement (wet multi-plate type); gearbox disassembly, inspection, and repair; shift mechanism troubleshooting.

Cooling System:

Radiator, fan, thermostat, water pump maintenance and testing; coolant specifications and flushing procedures.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, emissions control information.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier testing), starter motor operation, lighting, horn, instrumentation.

Suspension:

Front fork overhaul (oil change, seal replacement, spring inspection), rear shock absorber inspection and adjustment, linkage systems.

Brakes:

Front and rear brake system maintenance, caliper disassembly and service, master cylinder inspection, brake fluid replacement and bleeding procedures, pad and disc wear specifications.

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, tire wear inspection, spoke tension (if applicable).

Frame And Bodywork:

Frame inspection, swingarm maintenance, body panel removal and installation, fairing repairs, seat and tank mounting.

Steering:

Headstock bearing inspection and adjustment, handlebar and control lever maintenance.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, lubrication points, air filter cleaning/replacement, spark plug checks, coolant checks.

Troubleshooting:

Diagnostic flowcharts and common problem identification for engine starting issues, running problems, electrical faults, and braking issues.

Component Removal Installation:

Detailed step-by-step instructions for removing and installing major components like the engine, wheels, suspension, body panels, and electrical components.

Torque Specifications:

Comprehensive list of all critical torque values for fasteners throughout the motorcycle.

Rebuild Procedures:

Detailed instructions for rebuilding major sub-assemblies such as carburetors, brake calipers, and water pumps.

Diagnostic Capabilities:

Advanced diagnostic procedures for electrical systems, fuel delivery, and engine performance, including troubleshooting logic.

Special Tools:

Identification and usage of specialized tools required for specific repair and maintenance tasks.

Specifications Tables:

Detailed tables for all technical data, including clearances, pressures, capacities, and measurements.

📊 Manual Specifications

Digital Format:

PDF (if digital), optimized for readability and printing.

Print Quality:

High-resolution scans ensuring clear diagrams, text, and images.

Binding Type:

Perfect bound or spiral bound for ease of use and lay-flat functionality (if printed).

Paper Type:

Durable, coated paper suitable for workshop environments (if printed).

⚙️ Engine Specifications

Engine Type:

Four-stroke, liquid-cooled, DOHC, parallel-twin

Displacement:

498 cc

Bore X Stroke:

74.0 x 58.0 mm

Compression Ratio:

9.7:1

Horsepower:

Approx. 49 HP @ 8000 RPM (varies slightly by market and tuning)

Torque:

Approx. 44 Nm (32.5 lb-ft) @ 6000 RPM

Carburetors:

2 x Keihin CVK34

Fuel Tank Capacity:

18 Liters (4.75 US gal)

Oil Capacity:

3.1 Liters (with filter change), 2.8 Liters (without filter change)

Ignition Type:

Digital CDI

Starter System:

Electric Start

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Gear Ratios:

Specific ratios are detailed within the manual for each gear.

📐 Dimensions

Length:

Approx. 2185 mm (86.0 in)

Width:

Approx. 850 mm (33.5 in)

Height:

Approx. 1385 mm (54.5 in)

Wheelbase:

Approx. 1465 mm (57.7 in)

Ground Clearance:

Approx. 180 mm (7.1 in)

Seat Height:

Approx. 820 mm (32.3 in)

Dry Weight:

Approx. 180 kg (397 lbs)

Curb Weight:

Approx. 198 kg (436.5 lbs) (with all fluids)

Gross Vehicle Weight Rating:

Not typically specified for motorcycles, but payload capacity is implied.

🛡️ Safety Features

Safety Certification:

Complies with relevant international safety standards for motorcycles of its era.

Braking System:

Hydraulic dual-disc front brakes, hydraulic single-disc rear brake. ABS was not standard or commonly available on this model.

Lighting:

Halogen headlamp, LED taillight (on some later models/variants), turn signals.

Frame Construction:

Steel diamond frame for structural integrity.

Ergonomics:

Upright riding position designed for comfort and control.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, and various warning lights (neutral, oil pressure, high beam, turn signals). Modern connectivity features are absent.

ABS:

Not equipped with ABS.

Usb Charging:

Not factory equipped. Aftermarket solutions may be available.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Maintenance:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Replace every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles) or 12 months.

Brake Fluid Change:

Every 24 months, regardless of mileage.

Engine Oil Type:

API SG or higher, SAE 10W-40 recommended. Kawasaki recommends their own brand or equivalent.

Coolant Type:

Permanent type antifreeze coolant, 50% mixture with distilled water.

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (Capacity typically 485-495 ml per leg, refer to manual for exact fill).

Cam Chain Noise:

Some owners report occasional cam chain noise, often related to tensioner wear or a need for adjustment/replacement. The manual will detail checks.

Stator Failure:

While not exceptionally common, stator failures can occur, leading to charging system issues. The manual provides testing procedures.

Carburetor Synchronization:

Carburetors may require periodic synchronization for optimal running, especially after significant mileage or if issues arise. The manual covers this procedure.

Suspension Wear:

As with most bikes of this age and intended use, fork seals and rear shock absorbers can wear over time, impacting ride quality. The manual details fork oil changes and seal replacement.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long history of producing reliable and performance-oriented motorcycles, from sportbikes to cruisers and off-road machines.

Kle500 Lineage:

The KLE500 was first introduced in 1991, drawing heavily from the Ninja 500's parallel-twin engine. It was designed as a more affordable alternative to larger adventure bikes, offering a blend of on-road comfort and light off-road capability. The B-model iteration (relevant to 2005-2007) received updates including a revised front fairing, improved suspension, and slight styling changes to keep it competitive.

Manufacturing Location:

Primarily manufactured in Japan.

Production Years:

1991-2007

🏆 Awards & Recognition

Motorcycle Of The Year:

The KLE500 did not win major 'Motorcycle of the Year' awards, but it was recognized for its value and versatility in its segment by various motorcycle publications during its production run.

Reliability Perception:

Generally perceived as a reliable and durable motorcycle, especially its engine, given proper maintenance.

Emission Standards:

Meets the emissions standards applicable to its model year and region of sale.