Motorcycle Segment:
Dual-sport / Adventure touring motorcycle.
Target Demographic:
Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.
Key Competitors:
Honda Transalp, Suzuki V-Strom, Yamaha TDM series (depending on specific generation).
Versatility:
Designed for both on-road comfort and capability on unpaved surfaces.
Engine Configuration:
Parallel-twin engine offers a good balance of power and tractability.
Manual Coverage Scope:
Comprehensive service and repair procedures for the Kawasaki KLE500 motorcycle.
Estimated Page Count:
Refer to actual product for precise page count (typically 300-500+ pages for this type of manual).
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language:
Likely English (confirm with seller).
File Format Details:
Digital PDF, typically searchable and printable.
Engine Service:
Engine assembly/disassembly, cylinder head, pistons, crankshaft, valve timing, lubrication system, cooling system.
Fuel System Service:
Carburetor(s) adjustment and overhaul, fuel pump, fuel lines, fuel tank maintenance.
Transmission Service:
Gearbox inspection, clutch operation and adjustment, shift mechanism.
Chassis Service:
Frame inspection, suspension fork disassembly and rebuild, rear shock absorber, swingarm maintenance.
Brake System Service:
Front and rear brake caliper service, master cylinder, brake fluid replacement, pad and disc inspection.
Electrical System Service:
Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), lighting, starting system, battery maintenance.
Cooling System Service:
Radiator, coolant hoses, thermostat, fan operation.
Exhaust System Service:
Exhaust pipe and muffler inspection and replacement.
Wheels And Tires:
Wheel bearing service, tire pressure, rim inspection.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, lubrication points.
Troubleshooting Guides:
Diagnostic procedures for common problems, fault finding charts.
Engine Rebuild:
Detailed steps for complete engine disassembly and reassembly.
Carburetor Tuning:
Idle speed adjustment, mixture control, jetting specifications.
Suspension Setup:
Fork oil level and viscosity, rear shock preload adjustment.
Electrical Diagnostics:
Troubleshooting ignition, charging, and starting system faults.
Clutch Adjustment:
Lever free play and cable adjustment.
Brake Bleeding:
Procedure for bleeding hydraulic brake systems.
Depth Of Information:
Complete workshop level, covering diagnostics, repairs, and overhauls. Includes detailed diagrams and specifications.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin.
Displacement:
498 cc (approx.)
Bore X Stroke:
Refer to specific model year manual for exact figures (typically around 70mm x 64.8mm).
Compression Ratio:
Refer to specific model year manual for exact figures (typically around 9.1:1).
Horsepower:
Approximately 46-50 HP (varies by market and year, refer to manual).
Torque:
Approximately 40-45 Nm (varies by market and year, refer to manual).
Fuel Delivery:
Carburetor(s) (e.g., Keihin CVK34 or similar twin carburetors).
Fuel Type:
Unleaded gasoline.
Oil Capacity:
Refer to specific model year manual (typically around 2.2-2.5 liters with filter change).
Oil Type:
Refer to specific model year manual for API service classification and viscosity grade (e.g., SAE 10W-40 or 20W-50).
Overall Length:
Refer to specific model year manual (typically around 2,175 mm).
Overall Width:
Refer to specific model year manual (typically around 845 mm).
Overall Height:
Refer to specific model year manual (typically around 1,365 mm).
Wheelbase:
Refer to specific model year manual (typically around 1,470 mm).
Ground Clearance:
Refer to specific model year manual (typically around 210 mm).
Seat Height:
Refer to specific model year manual (typically around 830 mm).
Dry Weight:
Refer to specific model year manual (typically around 182 kg).
Curb Weight:
Refer to specific model year manual (typically around 190-200 kg).
Fuel Tank Capacity:
Refer to specific model year manual (typically around 17 liters).
Safety Certifications:
Designed to meet relevant national and international motorcycle safety standards of its production era.
Braking System:
Dual front disc brakes, single rear disc brake (configurations may vary by market and year).
Suspension Features:
Telescopic front forks, Monoshock rear suspension for stability and control.
Lighting:
Halogen headlight, taillight, turn signals.
Ergonomics:
Upright riding position for rider comfort and control.
Dashboard Layout:
Analog tachometer, speedometer, odometer, trip meter, and warning lights.
Charging Ports:
Typically none standard; aftermarket options available.
ABS:
ABS was not a standard or widely available option on most KLE500 models from its primary production years.
Bluetooth Integration:
Not applicable for the standard vehicle.
Oil Change Interval:
Typically every 3,000-6,000 km or 6-12 months, refer to manual for exact mileage/time intervals and conditions.
Spark Plug Inspection:
Check at intervals like 6,000-12,000 km, replace as needed. Manual will specify type and gap.
Air Filter Service:
Inspect and clean at intervals like 3,000-6,000 km, replace as needed. Manual will specify procedure and filter type.
Chain Lubrication And Adjustment:
Regular intervals, often every 500-1000 km or after riding in wet conditions. Manual will detail slack specification.
Coolant Type:
Ethylene glycol-based antifreeze, diluted with distilled water. Refer to manual for exact mixture ratio and type.
Brake Fluid Type:
DOT 4 is common for this era, but manual confirmation is essential.
Fork Oil Type:
Specific viscosity grade (e.g., 10W) and level as per manual. Capacity is crucial.
Carburetor Sync:
Carburetors may require periodic syncing for optimal performance and fuel economy.
Rear Shock ABSorber:
The OEM rear shock can degrade over time; upgrades are common for improved damping.
Charging System:
Regulator/rectifier units can be a failure point on some older Kawasakis; manual assists in diagnosis.
Cam Chain Tensioner:
Some models may benefit from manual cam chain tensioner upgrades to prevent premature wear or noise.
Kawasaki Legacy:
Kawasaki has a long-standing reputation for performance and durability in motorcycles, including their range of versatile dual-sport and adventure bikes.
Kle500 Introduction:
The KLE500 was introduced in the early 1990s as a mid-size dual-sport option.
Kle500 Updates:
Underwent updates throughout its production run, often involving minor engine tweaks, suspension refinements, and cosmetic changes to align with evolving market demands and emissions standards.
Kle500 Variants:
Different versions or generations exist, particularly with the transition to fuel injection on later models (though the manual's focus is likely carbureted versions unless specified).
Production Period:
Produced from the early 1990s through the late 2000s.
