🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Designation:

KLE500 A1-A10

Year:

2006

Market Segment:

Adventure Touring / Dual-Sport

Chassis Code:

LE500A

👋 Introduction

Market Segment Analysis:

The KLE500 occupied a niche in the adventure touring market, appealing to riders seeking a versatile, reliable, and relatively affordable platform for both commuting and light off-road exploration. It competed with bikes like the Honda Transalp and Suzuki V-Strom 650.

Key Competitors:

Honda Transalp (XL600V/XL650V), Suzuki V-Strom 650, Yamaha TDM850 (though larger displacement).

Design Philosophy:

Combines comfortable ergonomics and reasonable wind protection for touring with a capable chassis and suspension for tackling varied terrain.

Target Audience:

New riders, budget-conscious adventurers, commuters looking for versatility.

📋 Manual Details

Coverage Scope:

Comprehensive Service and Repair

Applicable Models:

Kawasaki KLE500 (All variations within the A series up to and including 2006)

Page Count:

Estimated 400-500 pages (typical for this level of detail)

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine System:

Top-end overhaul, bottom-end overhaul, cylinder head, valves, piston, crankshaft, lubrication system, cooling system, carburetor (if applicable for specific market variant), fuel injection system (if applicable).

Transmission System:

Clutch operation and replacement, gearbox disassembly and reassembly, shift mechanism, chain and sprocket maintenance.

Fuel System:

Fuel tank inspection and cleaning, fuel lines, fuel pump (if applicable), carburetor cleaning, adjustment, and synchronization.

Electrical System:

Ignition system, charging system (alternator, stator, rectifier/regulator), starting system (starter motor, battery), lighting, instrumentation, wiring diagrams, fuse box, sensor diagnostics.

Braking System:

Front and rear brake caliper overhaul, brake pad replacement, brake fluid flushing and bleeding, master cylinder inspection, brake line maintenance.

Suspension System:

Front fork (telescopic) service, fork seal replacement, fork oil change, rear shock absorber inspection and adjustment, linkage bearings.

Steering System:

Handlebar, steering stem bearings inspection and lubrication, steering head bearing replacement.

Chassis And Frame:

Frame inspection, swingarm maintenance, wheel bearing replacement, general chassis component checks.

Bodywork And Fairings:

Fairing removal and installation, seat removal, minor body panel repairs.

General Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, tire pressure checks, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical fault finding.

Engine Repair:

Complete engine disassembly, inspection, component replacement (pistons, rings, valves, seals), reassembly with torque specifications.

Transmission Repair:

Gearbox overhaul, clutch replacement, shift drum and pawl service.

Electrical Diagnostics:

Wiring diagram interpretation, multimeter usage for testing circuits, component testing (coils, sensors, CDI unit).

Suspension Rebuild:

Front fork oil and seal replacement, rear shock absorber service (where applicable).

Brake System Service:

Complete brake caliper and master cylinder overhaul, bleeding procedures.

Depth Level:

In-depth mechanical and electrical repair, full engine and transmission rebuilds, detailed diagnostics.

Diagnostic Coverage:

Includes specific diagnostic trouble codes (DTCs) if applicable to the model year, and symptom-based troubleshooting.

Rebuild Instructions:

Detailed step-by-step instructions for component disassembly, cleaning, inspection, measurement, and reassembly.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Text-searchable PDF for quick access to specific topics.

Printability:

Printable for workshop use.

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ 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:

9.8:1

Cylinder Material:

Aluminum alloy

Valve Train:

DOHC, 4 valves per cylinder

Ignition System:

Digital CDI

Horsepower Peak:

Approx. 47 hp @ 8000 rpm (varies by market and emissions regulations)

Torque Peak:

Approx. 44 Nm (32.5 lb-ft) @ 6000 rpm (varies by market)

Fuel Delivery:

Carburetor (Mikuni B26 twin or similar, depending on market/year variant), or potentially early FI on later/specific market models. For 2006, typically carburetors.

Fuel Type:

Unleaded gasoline, 87-91 octane

Fuel Tank Capacity:

15 Liters (3.96 US gal)

Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil

Oil Capacity With Filter Change:

2.5 Liters (2.6 US qt)

Coolant Type:

50/50 mixture of Ethylene Glycol coolant and distilled water

🔧 Transmission

Transmission Type:

Constant mesh 6-speed

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

Gear Ratios:

Detailed in manual, typically optimized for versatile performance.

Transmission Fluid:

N/A (Lubricated by engine oil)

📐 Dimensions

Length Overall:

Approx. 2,205 mm (86.8 in)

Width Overall:

Approx. 840 mm (33.1 in) (excluding mirrors)

Height Overall:

Approx. 1,300 mm (51.2 in)

Wheelbase:

Approx. 1,460 mm (57.5 in)

Ground Clearance:

Approx. 190 mm (7.5 in)

Seat Height:

Approx. 830 mm (32.7 in)

Dry Weight:

Approx. 183 kg (403.4 lbs)

Curb Weight:

Approx. 204 kg (450 lbs) (fully fueled and with all standard equipment)

Gross Vehicle Weight Rating:

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

Payload Capacity:

Approx. 200 kg (440 lbs) including rider, passenger, and luggage.

🛡️ Safety Features

Safety Certification:

CE (Conformité Européenne) for European markets; EPA/DOT for North America (where applicable).

Braking System Type:

Dual front discs with dual-piston calipers, single rear disc with dual-piston caliper. ABS was not standard on this model.

Lighting:

Halogen headlamp, LED tail light (typical), turn signals.

Frame Construction:

High-tensile steel semi-double cradle frame for rigidity and impact absorption.

Ergonomics:

Upright riding position and adjustable levers contribute to rider control and comfort.

💡 Technology Features

Infotainment System:

Basic analogue instrumentation (speedometer, tachometer, fuel gauge, temperature gauge, warning lights). No advanced infotainment features.

Advanced Assistance:

No electronic rider aids such as traction control, ABS, or riding modes were standard on this model.

Connectivity Features:

None.

🔧 Maintenance

Oil And Filter Change:

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

Air Filter Cleaning:

Every 6,000 km (3,700 miles), clean and re-oil if necessary.

Spark Plug Replacement:

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

Valve Clearance Check:

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

Chain Lubrication:

Every 1,000 km (600 miles) or after riding in wet conditions.

Chain Adjustment:

Every 1,000 km (600 miles) or when slack exceeds specification.

Brake Fluid:

DOT 4

Coolant Type:

Ethylene glycol-based coolant, 50% concentration

Fork Oil Type:

SAE 10W (refer to manual for specific volume and level)

Common Wear Items:

Clutch wear, fork seal leaks, rear shock absorber degradation, carburetor jet clogging (if not maintained), chain and sprockets.

Electrical Quirks:

Occasional issues with rectifier/regulator failure due to heat; wiring harness connections can degrade over time.

Carburetor Tuning:

Carburetors may require periodic cleaning and synchronization, especially if the bike is stored for extended periods or subjected to varied fuel quality.

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Heritage Focus:

Known for performance motorcycles, but also a strong presence in versatile utility and adventure segments.

Introduction Year:

First introduced in 1994

Key Updates Pre 2006:

Major updates included revised bodywork, improved suspension, and engine tuning for emissions and performance across generations. The 2006 model represents a mature iteration of the design.

Engine Platform Heritage:

The parallel-twin engine is derived from Kawasaki's successful ER series engines, known for reliability and smooth power delivery.

Production Location:

Japan

Production Run:

1994 - 2007

🏆 Awards & Recognition

Industry Awards:

While not a recipient of major awards, it was recognized for its value and versatility in its segment by motorcycle publications during its production run.

Reliability Ratings:

Generally considered reliable with proper maintenance, often praised for its robust parallel-twin engine.

Emission Standards:

Designed to meet the emission standards of its respective market at the time of manufacture.