Category:
Dual-Sport / Adventure Touring Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for commuting, light off-road use, and touring. Appeals to budget-conscious adventure riders.
Key Competitors:
Honda Transalp (XL600V/XL650V), Suzuki V-Strom 650 (though larger displacement), Yamaha TDM850 (though larger displacement), other mid-displacement dual-sport bikes of the era.
Versatility:
Designed to handle paved roads and unpaved trails, offering a balance of comfort and capability.
Engine Character:
Known for its reliable and torquey parallel-twin engine, providing usable power across a wide rev range.
Value Proposition:
Offers a compelling blend of performance and practicality at a competitive price point.
Engine:
Complete disassembly, inspection, and reassembly of the 498cc parallel-twin engine, including cylinder head, pistons, crankshaft, camshafts, valves, timing system, lubrication system, and cooling system.
Fuel System:
Carburetor(s) (likely Keihin CVK type) tuning, cleaning, rebuilding, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
Ignition coil testing, spark plug specifications, timing adjustment procedures, CDI unit troubleshooting.
Exhaust System:
Removal and installation of exhaust headers, mufflers, and associated components.
Transmission:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear inspection, shifting mechanism.
Chassis And Frame:
Frame inspection, steering head bearing service, fork disassembly and assembly, rear shock absorber and linkage maintenance, swingarm service.
Wheels And Tires:
Wheel bearing service, spoke tensioning (if applicable), tire replacement, wheel balancing.
Brakes:
Front and rear brake system service, including hydraulic system bleeding, caliper overhaul, master cylinder maintenance, brake pad replacement, and rotor inspection.
Electrical System:
Complete wiring diagrams, component testing (alternator, starter motor, battery), lighting system, switches, fuses, relays, and instrument panel.
Bodywork And Trim:
Fairing removal and installation, seat maintenance, body panel alignment, and accessory fitting.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, brake fluid replacement, coolant checks.
Troubleshooting:
Step-by-step diagnostic procedures for common performance issues, starting problems, electrical faults, and braking system anomalies.
Engine Rebuild:
Detailed instructions for complete engine disassembly, component measurement, wear checks, and reassembly with torque specifications.
Suspension Service:
Fork seal replacement, oil level and type specifications for front forks, rear shock absorber adjustments and potential rebuilding procedures.
Electrical Diagnostics:
Using a multimeter to test electrical components, continuity checks, voltage drop tests, and identifying wiring harness issues.
Brake System Overhaul:
Complete guide to caliper rebuilding, master cylinder replacement, and hydraulic line flushing.
Carburetor Tuning:
Idle speed adjustment, mixture screw settings, and synchronisation procedures.
Depth:
Comprehensive. Covers everything from basic owner maintenance to full engine and transmission rebuilds, including detailed electrical troubleshooting.
Diagnostic Charts:
Includes detailed diagnostic flowcharts for pinpointing problems.
Special Tools:
Lists required special tools and their usage.
Engine Type:
4-stroke, liquid-cooled, parallel-twin
Displacement:
498 cc (30.4 cu in)
Bore X Stroke:
74.0 x 58.0 mm (2.91 x 2.28 in)
Valve Train:
DOHC, 8 valves (4 valves per cylinder)
Horsepower:
Approx. 45-50 HP @ 8,000 RPM (Varies slightly by market and tune)
Torque:
Approx. 43-46 Nm (31.7-33.9 lb-ft) @ 6,000 RPM
Fuel Delivery:
Dual Keihin CVK34 carburetors
Fuel Capacity:
15 Liters (3.96 US gal)
Oil Type Recommendation:
API SG, SF or SH; SAE 10W-40 or 20W-50
Coolant Type:
Ethylene glycol based antifreeze solution (50% mixture with distilled water)
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Brake Fluid Replacement:
Every 2 years.
Engine Oil Capacity:
Approx. 2.6 Liters (2.7 US qt) (without filter change), 2.8 Liters (3.0 US qt) (with filter change).
Coolant Capacity:
Approx. 1.6 Liters (1.7 US qt)
Common Wear Items:
Clutch wear, fork seal leaks, regulator/rectifier failures (common on many Kawasakis of this era), chain and sprockets wear.
Carburetor Performance:
Can sometimes suffer from gumming if not used regularly or properly stored. Tuning might be required over time.
Electrical Charging System:
Early models sometimes had issues with the charging system's regulator/rectifier, leading to battery drain or overcharging.
Kawasaki Legacy:
Kawasaki, a Japanese manufacturer, has a long-standing reputation for producing reliable and performance-oriented motorcycles across various categories, including sportbikes, cruisers, and dual-sport models.
Kle500 Lineage:
The KLE500 series was introduced in the early 1990s as a mid-weight dual-purpose motorcycle, evolving from earlier Kawasaki dual-sport models. The 'B' series represents a refinement and updating of the original concept, with the 2004 model being part of this generation's lifecycle.
Production Years:
The KLE500 was produced roughly from 1991 to 2007, with various 'A' and 'B' series updates.
Manufacturing Location:
Primarily manufactured in Japan by Kawasaki Heavy Industries.