🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Code:

KLE500 A1-A10

👋 Introduction

Category:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Enthusiast riders, independent repair shops, service technicians

Competitors:

Honda Transalp, Suzuki DR650, Yamaha XT600/XT660

Vehicle Attributes:

Versatile, reliable, long-distance touring capability with off-road potential.

Purpose:

To provide comprehensive guidance for maintaining, diagnosing, and repairing the Kawasaki KLE500 motorcycle, enabling owners and technicians to perform all necessary service operations.

📋 Manual Details

Coverage Years:

1991-2007 (Likely covers primary production years of the A-series model, specific years should be verified based on manual edition)

Regions Covered:

Global (Designed for international markets, may include regional variations where applicable)

Estimated Page Count:

300-500 (Typical for a comprehensive service manual of this era)

Type:

Service Repair Manual

Language:

English (Primary language, may be available in others)

Format:

Digital (PDF) / Printed (Specify based on product offering)

📖 Manual Coverage

Engine:

Detailed engine disassembly, assembly, inspection, tuning, and troubleshooting. Includes carburetor systems, cooling system, lubrication system.

Transmission:

Clutch inspection and replacement, gearbox inspection, maintenance, and repair procedures. Gear ratios and specifications.

Chassis And Suspension:

Front fork (telescopic) disassembly, inspection, and rebuild. Rear shock absorber and linkage maintenance. Swingarm service. Wheel bearing service.

Brakes:

Front and rear brake system maintenance, including hydraulic lines, calipers, master cylinders, and pad replacement. Bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, ignition system troubleshooting, lighting system, starter motor, and charging system (alternator/stator).

Fuel System:

Carburetor disassembly, cleaning, adjustment, and synchronization. Fuel tank and petcock maintenance.

Cooling System:

Radiator and fan inspection, coolant replacement, thermostat service.

Exhaust System:

Exhaust pipe and muffler inspection and replacement.

Bodywork And Frame:

Fairing removal and installation, seat service, fuel tank removal, frame inspection.

Preventative Maintenance:

Regularly scheduled maintenance, lubrication points, filter replacement intervals.

Troubleshooting Diagnostics:

Step-by-step troubleshooting guides for common issues, symptom analysis.

Repair And Rebuild:

Detailed instructions for component disassembly, inspection, repair, and reassembly.

Electrical Troubleshooting:

Fault finding for ignition, charging, lighting, and starting systems using wiring diagrams.

Carburetor Tuning:

Jetting information, idle speed adjustment, mixture screw settings, synchronization procedures.

Suspension Setup:

Fork oil viscosity and level, rear shock adjustments.

Engine Rebuild:

Full engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), cylinder head reconditioning, and reassembly.

Carburetor Overhaul:

Detailed steps for disassembling, cleaning, replacing worn parts (jets, needles, seals), and reassembling carburetors.

Depth:

Comprehensive (Covers routine maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values)

Specifications Included:

Torque specifications, clearances, fluid capacities, wear limits, electrical resistance values, diagnostic codes (if applicable).

📊 Manual Specifications

Digital Quality:

High-resolution scans, searchable text (if OCR'd), bookmark navigation.

Print Quality:

Professional printing, clear diagrams and text (for physical copies)

Binding:

Spiral-bound or perfect-bound (typical for workshop manuals, allows flat opening)

Paper Type:

Durable, high-gloss or matte finish paper suitable for workshop environments (for printed copies)

Manual Completeness:

Factory Original or equivalent comprehensive coverage of all mechanical and electrical systems.

⚙️ Engine Specifications

Type:

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

Displacement:

498 cc (498 cm³)

Bore X Stroke:

74.0 mm x 58.0 mm

Compression Ratio:

9.0:1

Horsepower:

Approx. 48-50 HP (35-37 kW) @ 8000 RPM (Varies slightly by year/market)

Torque:

Approx. 45 Nm (33 lb-ft) @ 6000 RPM (Varies slightly by year/market)

Carburetion:

Twin Keihin CVK34 carburetors

Fuel Capacity:

15 Liters (3.96 US gal)

Ignition System:

CDI (Capacitor Discharge Ignition)

Oil Capacity:

2.6 Liters (with filter change)

Oil Type:

API SG or SH, SAE 10W-40 motorcycle specific oil

🔧 Transmission

Type:

Constant mesh 6-speed

Clutch:

Wet multi-plate, cable operated

Final Drive:

Sealed chain drive

Gear Ratios:

Detailed ratios provided in manual for each gear

Transmission Oil Type:

API GL-4, SAE 80W-90 Gear Oil (Check manual for specific Kawasaki recommendation)

📐 Dimensions

Length:

Approx. 2215 mm (87.2 in)

Width:

Approx. 850 mm (33.5 in)

Height:

Approx. 1310 mm (51.6 in)

Wheelbase:

Approx. 1460 mm (57.5 in)

Ground Clearance:

Approx. 180 mm (7.1 in)

Dry Weight:

Approx. 185 kg (408 lbs)

Curb Weight:

Approx. 202 kg (445 lbs) (with all fluids)

Frame Type:

Semi-double cradle, steel tube

Front Tire Size:

90/90-21 M/C 54S

Rear Tire Size:

130/80-17 M/C 65S

Front Suspension:

Telescopic fork, 41 mm stanchion diameter, 200 mm travel

Rear Suspension:

Monoshock, linkage system, 185 mm rear wheel travel

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subject to standard automotive crash testing)

Braking System:

Dual hydraulic disc front, single hydraulic disc rear.

ABS:

Not typically equipped on this model

Lighting:

Halogen headlight, LED tail light (on later models), front and rear turn signals.

Frame Material:

Steel

💡 Technology Features

Features:

Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, fuel gauge, warning lights). No advanced infotainment systems.

Features:

None (Focus is on mechanical and electrical systems, not electronic rider aids)

Features:

None (No Bluetooth, GPS integration, or smartphone connectivity)

🔧 Maintenance

Oil Change:

Every 6,000 km (3,700 miles) or 6 months

Air Filter Cleaning:

Every 6,000 km (3,700 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

Every 12,000 km (7,500 miles)

Coolant Type:

Permanent type antifreeze, mixture of 50% ethylene glycol and 50% distilled water

Brake Fluid Type:

DOT 4

Carburetor Synchronization:

Can become slightly out of sync over time, affecting smooth running. Manual covers syncing procedures.

Stator Failure:

While not exceptionally common, stators can fail, impacting the charging system. Manual provides testing procedures.

Fork Seals:

Like many bikes of this era, fork seals can degrade over time and leak. Manual details seal replacement.

Chain And Sprockets:

Wear items that require regular inspection and adjustment of chain tension. Manual provides guidance.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long history of producing high-performance motorcycles, known for innovation and reliability in various racing and street categories.

Kle500 Development:

The KLE500 was developed as a more accessible and lighter alternative to larger adventure bikes, targeting riders seeking versatility for commuting and light touring. It shared its engine with the popular KLR650 but in a detuned, twin-cylinder configuration.

Key Updates:

Minor cosmetic updates and color scheme changes throughout its production run. The fundamental mechanical design remained largely consistent.

Production Years:

1991-2007

Manufacturing Location:

Japan (Likely Kawasaki's primary motorcycle manufacturing facilities)

🏆 Awards & Recognition

Industry Awards:

The KLE500 was well-regarded in its segment for its balance of capability and affordability, often praised for its reliability and touring comfort for its class.

Long Term Reliability:

Generally considered a reliable motorcycle with good longevity when properly maintained, as detailed in this manual.

Emissions Standards:

Complies with emissions standards relevant to its production years (e.g., Euro 1/2 depending on market and year).