Segment:
Dual-sport / Adventure motorcycle.
Target Audience:
Riders seeking a versatile motorcycle for both on-road commuting and light off-road exploration.
Key Competitors:
Honda Transalp, Suzuki V-Strom, Yamaha XT660Z Tenere (in its era).
Versatility:
Designed for a balance of on-road comfort and off-road capability.
Engine Type:
Parallel-twin engine offering a good blend of power and torque.
Design Philosophy:
Practical and reliable dual-purpose motorcycle with accessible maintenance.
General Coverage:
Comprehensive service and repair for Kawasaki KLE500-B1 model.
Specific Systems:
Engine, fuel system, ignition, cooling, lubrication, transmission, drivetrain, chassis, suspension, steering, brakes, electrical system, bodywork, troubleshooting.
Page Count:
Approximately 400-500 pages (estimated for a typical service manual of this scope).
Manual Type:
Service and Repair Manual
Engine Mechanical:
Engine disassembly, inspection, assembly, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod checks, lubrication system servicing.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump service, fuel filter replacement.
Ignition System:
Ignition timing checks, spark plug specifications, CDI unit testing, coil inspections.
Cooling System:
Radiator and fan inspection, coolant replacement, thermostat testing, water pump servicing.
Transmission Drivetrain:
Gearbox disassembly and assembly, clutch inspection and adjustment, chain and sprocket wear checks, lubrication.
Suspension Steering:
Front fork servicing (oil change, seal replacement), rear shock absorber inspection, steering bearing maintenance, linkage lubrication.
Brake System:
Brake caliper overhaul, brake pad replacement, brake fluid flush and bleed, master cylinder inspection, rotor measurements.
Electrical System:
Wiring diagrams, battery testing and maintenance, lighting system checks, starter motor and alternator testing, fuse and relay identification.
Bodywork Chassis:
Fairing removal and installation, seat adjustment, luggage rack mounting, general chassis inspection.
Maintenance Procedures:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid replacement, coolant replacement, tire pressure checks.
Repair Procedures:
Complete engine rebuild, transmission repair, carburetor tuning, suspension fork overhaul, brake system repair, electrical component replacement.
Troubleshooting:
Step-by-step diagnostic guides for common performance issues, starting problems, electrical faults, and braking irregularities.
Torque Specifications:
Detailed torque values for all critical fasteners across various systems.
Depth:
Comprehensive, covering everything from basic rider maintenance to advanced engine and transmission overhauls.
Engine Type:
Liquid-cooled, four-stroke, parallel-twin
Bore X Stroke:
70.0 mm x 64.8 mm
Valve Train:
DOHC, 8 valves (4 per cylinder)
Horsepower:
Approx. 48-50 HP @ 8,000 RPM (manufacturer claimed, may vary slightly)
Torque:
Approx. 45 Nm @ 6,000 RPM (manufacturer claimed, may vary slightly)
Fuel Delivery:
Dual Keihin CVK carburetors (likely 34mm or similar)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
17 Liters (approx. 4.5 US gallons)
Ignition System:
Digital CDI with electronic advance
Lubrication System:
Wet sump with oil cooler
Oil Capacity With Filter:
Approx. 2.5 Liters (check manual for precise spec)
Oil Type:
API SG or SH, SAE 10W-40 motorcycle oil (consult manual for specific grades)
Transmission Type:
Constant mesh, 6-speed sequential
Clutch Type:
Wet, multi-plate, cable-operated
Final Drive:
Sealed O-ring chain
Gear Ratios:
Refer to manual for specific gear ratios.
Transmission Oil Capacity:
Refer to manual for specific spec (typically around 1.5-2.0 liters).
Transmission Oil Type:
API GL-1, SAE 80W-90 hypoid gear oil (consult manual for specific grades).
Overall Length:
Approx. 2,220 mm (87.4 in)
Overall Width:
Approx. 850 mm (33.5 in)
Overall Height:
Approx. 1,365 mm (53.7 in)
Wheelbase:
Approx. 1,465 mm (57.7 in)
Ground Clearance:
Approx. 210 mm (8.3 in)
Seat Height:
Approx. 835 mm (32.9 in)
Dry Weight:
Approx. 180 kg (397 lbs)
Curb Weight:
Approx. 195 kg (430 lbs) (with all fluids and full tank)
Gross Vehicle Weight Rating:
Refer to manual (typically around 350-380 kg).
Cargo Capacity:
Not explicitly designed for significant cargo, but accessory luggage racks are common.
Safety Certification:
N/A (Motorcycle safety standards vary by region; manual covers mechanical safety).
Braking System Front:
Dual disc brakes with hydraulic calipers.
Braking System Rear:
Single disc brake with hydraulic caliper.
Lighting:
Halogen headlight, taillight, brake lights, turn signals.
Frame Construction:
Steel semi-double cradle frame for stability and rigidity.
Infotainment System:
Basic analog instrumentation; no integrated infotainment system.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, and warning lights.
ABS:
ABS was typically an optional feature on some versions or markets, not standard on all 2005 models. Check specific vehicle VIN or market designation.
Connectivity Features:
None.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (refer to manual for exact recommendation).
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or 6 months (cleaning/replacement).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Chain Adjustment Lubrication:
Every 1,000 km (600 miles) or after washing/rain.
Engine Oil Grade:
SAE 10W-40 API SG or SH (specific grade as per manual).
Coolant Type:
Permanent type antifreeze coolant (50% solution of ethylene glycol).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
Refer to manual, typically a light-grade fork oil (e.g., Showa SS-10 or equivalent).
Common Wear Item Clutch:
Clutch plates can wear over time, especially with spirited riding or heavy touring.
Common Wear Item Suspension:
Front fork seals can leak; rear shock absorber may lose damping effectiveness with age.
Carburetor Performance:
Carburetors may require periodic cleaning and adjustment due to fuel varnish build-up.
Electrical Connections:
Corrosion in electrical connectors can sometimes lead to intermittent issues, especially in humid environments.
Chain Sprockets:
Regular maintenance is crucial to prevent premature wear on the drive chain and sprockets.
Brand Focus:
Kawasaki is a renowned Japanese manufacturer known for its performance motorcycles, including sportbikes, cruisers, and off-road models.
Kle500 Lineage:
The KLE500 line was introduced in the early 1990s as a versatile dual-purpose machine, evolving through several iterations. The 'B' series represents a later generation with updated styling and components.
Engine Basis:
The 498cc parallel-twin engine was also used in other Kawasaki models, such as the ER-5.
Production Period:
The KLE500 was produced from the early 1990s until around 2007. The 2005 model is part of the second generation (B series).
Manufacturing Location:
Typically manufactured in Japan.
