🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Code:

LE500 (various sub-codes apply depending on region and specific model year updates)

Year:

2004-2005

Vin Code:

Refer to VIN plate for specific year and manufacturing origin. Typically starts with JKA...

👋 Introduction

Market Position:

The Kawasaki KLE500 was positioned as a versatile adventure touring motorcycle, bridging the gap between street-biased sportbikes and dedicated off-road machines. It offered a comfortable riding position and sufficient capability for light off-road excursions and long-distance touring.

Competitive Analysis:

Competed with other dual-sport or adventure touring motorcycles of its era, such as the Suzuki DR650, Honda Transalp (XL600V/XL650V), and Yamaha XT600/XT660.

Key Features:

Parallel-twin engine, comfortable ergonomics for touring, adjustable suspension, robust chassis, suitable for varied road conditions.

📋 Manual Details

Coverage Areas:

Engine, Fuel System, Carburetion, Ignition, Starting System, Charging System, Lubrication, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Wheels, Tires, Brakes (Front & Rear), Suspension (Front & Rear), Steering, Frame, Bodywork, Electrical System, Lighting, Instruments, Wiring Diagrams, Troubleshooting, Maintenance, Specifications, Torque Values, Special Tools.

Wiring Diagrams:

Detailed and accurate wiring diagrams are a key component of the electrical system coverage, crucial for diagnostics and repairs.

Page Count:

Approximately 400-500 pages (estimated for a comprehensive service manual of this era and type).

Manual Type:

Service Repair Manual

Language:

English

Format:

Digital (PDF) - Searchable and printable

📖 Manual Coverage

Systems Covered:

Comprehensive coverage of all major mechanical and electrical systems including: Engine (disassembly, assembly, inspection), Carburetion (cleaning, adjustment, synchronization), Fuel Delivery, Ignition System (timing, components), Electrical System (charging, starting, lighting, wiring), Drivetrain (transmission, final drive), Braking System (hydraulic, mechanical components), Suspension (forks, rear shock), Steering, Frame and Chassis, Bodywork and Plastics, Cooling System, Lubrication System, Exhaust System.

Procedures Included:

Routine maintenance, scheduled servicing, component inspection, troubleshooting common problems, detailed repair and overhaul procedures for all major systems, electrical diagnostics, wiring harness repair, suspension adjustments and rebuilds, brake bleeding and caliper service, engine tuning, carburetor reassembly, clutch adjustment and replacement, drive chain maintenance.

Troubleshooting Guides:

Includes detailed troubleshooting sections with symptoms, possible causes, and corrective actions for common mechanical and electrical issues.

Technical Depth:

Detailed technical information suitable for professional mechanics and experienced DIY enthusiasts. Includes step-by-step instructions, exploded views, diagnostic flowcharts, specifications, torque values, and service limits for complete engine and component rebuilds.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Searchability:

Fully searchable text allows for quick access to specific information, procedures, and specifications.

Print Quality:

High-resolution scans of original factory manual pages, ensuring clear text and legible diagrams for printing.

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 (30.4 cu. in.)

Bore X Stroke:

74.0 x 58.0 mm

Compression Ratio:

9.8:1

Horsepower Estimated:

Approx. 45-50 HP (varies by market and tuning)

Torque Estimated:

Approx. 40-45 Nm (varies by market and tuning)

Fuel System Type:

Carbureted (typically dual Keihin CVK carburetors, specific sizes vary by region and year)

Fuel Tank Capacity:

Approx. 15 Liters (3.9 US gal)

Lubrication System:

Forced lubrication, wet sump

Cooling System Type:

Liquid-cooled

Ignition System:

Digital CDI

Starting System:

Electric starter

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-disc, cable operated

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

Approx. 2215 mm (87.2 in.)

Overall Width:

Approx. 800 mm (31.5 in.)

Overall Height:

Approx. 1370 mm (53.9 in.)

Wheelbase:

Approx. 1465 mm (57.7 in.)

Ground Clearance:

Approx. 215 mm (8.5 in.)

Seat Height:

Approx. 850 mm (33.5 in.)

Dry Weight:

Approx. 182 kg (401.3 lbs)

Curb Weight:

Approx. 195 kg (430 lbs) (estimated with fluids)

Load Capacity:

Refer to owner's manual for specific load limits, typically around 180-200 kg including rider and luggage.

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA in the same manner as cars).

Active Features:

Disc brakes (front and rear) for effective stopping power, responsive suspension for handling.

Passive Features:

Sturdy frame construction, protective fairing for wind deflection.

💡 Technology Features

Infotainment System:

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

🔧 Maintenance

Oil Change Interval:

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

Air Filter Cleaning:

Every 6,000 km (3,700 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or as per inspection.

Valve Clearance Check:

Every 12,000 km (7,500 miles)

Chain Maintenance:

Lubricate and adjust every 1,000 km (600 miles) or as needed.

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA approved

Engine Oil Capacity:

Approx. 2.4 Liters (2.5 US qt) without filter change, 2.6 Liters (2.7 US qt) with filter change.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol base) mixed with distilled water at a 50/50 ratio.

Brake Fluid Type:

DOT 4

Fork Oil Type:

Refer to manual for specific viscosity (typically around 10W or equivalent).

Fork Oil Capacity:

Refer to manual for specific volume per fork leg.

Common Issues:

Carburetor synchronization can drift over time, leading to rough idling or poor performance. Cam chain tensioner wear can cause rattling noises. Some models may experience stator or regulator/rectifier failures. Rear suspension linkage bearings can require periodic lubrication or replacement.

📚 Vehicle History

Brand Heritage:

Kawasaki Heavy Industries, Motorcycle & Engine division, has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments, including sportbikes, cruisers, and dual-purpose machines.

Model Evolution:

The KLE500 (also known as the KLR600/650 successor in some markets) evolved from Kawasaki's experience with parallel-twin engines and dual-sport design. Introduced in the early 1990s, it received updates over its production run to meet evolving emissions standards and customer preferences. The 2004-2005 models represent a later iteration, likely with minor refinements.

Production Years:

Approx. 1991-2007

Manufacturing Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions:

While not typically receiving specific awards, the KLE500 was recognized for its durability and versatility within the adventure touring segment, particularly for its value proposition.

User Ratings:

Generally positive user reviews for its reliability, comfortable ride, and adaptability to various conditions, though often cited as less powerful than some competitors.

Certifications:

Compliant with emissions standards relevant to its manufacturing and sale regions (e.g., Euro 1, Euro 2 depending on the specific model year and market).