Vehicle Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for commuting, light off-roading, and touring.
Key Competitors Era:
Honda Transalp, Suzuki V-Strom, Yamaha TDM series.
Model Characteristics:
Known for its robust parallel-twin engine, comfortable riding position, and balance between on-road and light off-road capability. Practical for everyday use and light adventure touring.
Engine Systems:
Engine disassembly, assembly, overhaul, valve clearance adjustment, ignition system, lubrication system, cooling system, fuel system (carburetor, fuel pump), exhaust system.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, final drive (chain and sprockets inspection and replacement), shift mechanism.
Chassis Suspension:
Front fork (oil change, seal replacement, disassembly/assembly), rear shock absorber (adjustment, removal/installation), swingarm and linkage maintenance, wheel bearing inspection and replacement.
Braking System:
Front and rear brake caliper inspection and overhaul, brake pad replacement, brake fluid bleeding and replacement, master cylinder inspection, brake hose inspection.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system components, lighting system (headlight, taillight, turn signals), starter motor, horn, instrument cluster, fault diagnosis.
Fuel System Components:
Carburetor identification, disassembly, cleaning, adjustment, jetting information, fuel tank removal/installation, fuel lines, fuel filter replacement.
Bodywork Trim:
Fairing removal and installation, seat removal, body panel care, sticker/decal application guidance.
Maintenance Procedures:
Routine servicing, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake adjustments, fluid level checks, lubrication points.
Diagnostic Procedures:
Troubleshooting common issues, electrical system diagnostics, engine performance diagnostics, identifying causes of starting problems, running issues, and noise.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly, including critical torque specifications and alignment procedures.
Component Overhaul:
Detailed instructions for complete rebuilds of major components such as the engine, gearbox, and suspension forks.
Diagnostic Level:
Advanced (includes wiring diagrams, component testing specifications, and fault code interpretations if applicable)
Repair Depth:
Comprehensive (covers everything from routine maintenance to complete engine and transmission rebuilds)
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Displacement:
498 cc (498cm3)
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
10.8:1
Max Power:
Approx. 50 PS (37 kW) @ 8,000 rpm (figures may vary slightly by region)
Max Torque:
Approx. 48 Nm (35 lb-ft) @ 6,000 rpm (figures may vary slightly by region)
Fuel Delivery:
Carburetor; twin Keihin CVK34
Fuel Type:
Unleaded gasoline, minimum 90 octane
Ignition System:
Digital CDI
Lubrication Type:
Forced lubrication, wet sump
Cooling System:
Liquid-cooled
Dashboard:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, neutral indicator, oil pressure warning light, turn signal indicators, high beam indicator.
ABS Availability:
Not equipped with ABS.
Connectivity Features:
No modern connectivity features (e.g., Bluetooth, smartphone integration) present.
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 12,000 km (7,500 miles) or 12 months, usually at the same time as oil change.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or 6 months; replacement if damaged.
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after riding in rain/wet conditions.
Engine Oil Type:
API SG, SH, SJ, SL or similar; SAE 10W-40 viscosity recommended for general use. Check manual for temperature-specific recommendations.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Fork Oil Type:
SAE 10W (specific volume per leg listed in manual)
Common Wear Items:
Rear shock absorber bushings, wheel bearings, stator output (can degrade over time), clutch plates (depending on usage).
Carburetor Synchronization:
May require periodic synchronization for smooth engine operation, especially after high mileage.
Stator Failure:
Some owners report premature stator failure, leading to charging system issues. Regular voltage checks are advisable.
Fork Seal Leaks:
Front fork seals can develop leaks over time, necessitating replacement.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Generation Introduction:
The KLE500 was first introduced in 1991, evolving from Kawasaki's experience with its parallel-twin engines. It was designed to fill the gap for a versatile, mid-weight dual-sport machine.
Key Updates Prior 2004:
The model received updates over the years, including revised styling, improved suspension components, and engine tuning tweaks to meet emissions standards. The 2004 model represents a later iteration of the original design.
Manufacturing Location:
Primarily manufactured in Japan.
Production Run:
1991-2007 (Globally, though market availability varied)
