Market Segment:
Adventure Touring / Dual-Sport
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.
Key Competitors:
Honda Transalp, Suzuki V-Strom, BMW F650GS (early models).
Model Philosophy:
Affordable, reliable, and capable dual-purpose motorcycle with a focus on usability and versatility.
Distinctive Attributes:
Parallel-twin engine, comfortable ergonomics, significant wind protection, capable on and off-road.
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, and troubleshooting of internal components (pistons, rings, valves, camshafts, crankshaft, etc.).
Fuel System:
Carburetor service, adjustment, troubleshooting, fuel pump, fuel lines, and related components.
Ignition System:
Ignition timing, spark plugs, coils, CDI unit, and troubleshooting.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanisms, transmission disassembly and assembly, final drive (chain and sprockets) maintenance and replacement.
Cooling System:
Radiator, cooling fan, thermostat, coolant flow, and maintenance.
Suspension System:
Front fork (telescopic) disassembly, seal replacement, oil levels, and rear shock absorber adjustment and service.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, and troubleshooting.
Wheel And Tire Service:
Wheel bearing inspection and replacement, tire mounting and balancing, spoke tensioning.
Electrical System:
Wiring diagrams, lighting system, starter motor, battery maintenance, charging system (alternator), and instrument panel.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders, and other cosmetic components.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.
Troubleshooting Guides:
Detailed diagnostic procedures for common and uncommon problems across all major systems.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Adjustment Procedures:
Carburetor synchronization, clutch and throttle cable free play, suspension sag.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Depth Of Information:
Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic servicing to complete engine and gearbox rebuilds.
Oil Change Interval:
Every 6,000 km or 6 months, whichever comes first (typical, refer to manual for exact specs).
Spark Plug Check Interval:
Every 6,000 km (typical).
Valve Clearance Check Interval:
Every 12,000 km or 24,000 km (refer to manual for exact specs).
Chain Maintenance:
Lubricate and adjust chain every 1,000 km or more frequently in dusty/wet conditions.
Engine Oil Type:
SAE 10W-40 API SG or higher (typical, verify with manual).
Engine Oil Capacity:
Approx. 2.4 L (without filter change), 2.6 L (with filter change).
Coolant Type:
Ethylene glycol based coolant with de-ionized water (50/50 mix) (typical).
Brake Fluid Type:
DOT 4 (typical, verify with manual).
Fork Oil Type:
SAE 10W (typical, refer to manual for specific viscosity and quantity).
Common Wear Items:
Clutch wear, rear shock absorber damping (over time), front fork seals, wheel bearings.
Engine Characteristics:
Engine can be a little vibey at higher RPMs. Carburetor tuning can be critical for optimal performance.
Electrical Notes:
As with many bikes of this era, check battery terminals and ground connections for corrosion.
Kawasaki Heritage:
Kawasaki Heavy Industries, Ltd. is a renowned Japanese public company known for its motorcycles, heavy equipment, aerospace, and defense products.
Kle500 Lineage:
The KLE500 debuted in 1991, evolving from Kawasaki's off-road heritage and aiming to offer a more road-biased alternative to its KLR models. The 2005 model represents a mature iteration of this platform, likely with refinements from earlier generations.
Key Updates Prior To 2005:
Likely included minor styling updates, carburetor tuning adjustments, and potentially suspension refinements over its production run.
Production Period:
1991-2007
Manufacturing Location:
Japan (primary)
