🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Year:

2006

Model Code Variant:

Likely A17 or similar, specific to MY2006

👋 Introduction

Vehicle Segment:

Dual-sport / Adventure Touring motorcycle, positioned as an accessible and versatile option for riders looking for on-road comfort and light off-road capability.

Competitors:

Competed against other mid-weight dual-sport bikes of its era such as the Suzuki DR650, Honda Transalp (though often positioned slightly above), and Yamaha XT660R/Tenere.

Features:

Parallel-twin engine, comfortable ergonomics for long distances, capable suspension for varied terrain, adequate wind protection, utilitarian styling, and a reputation for reliability and affordability.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch, Transmission, Drive Chain, Frame, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Electrical System (Lighting, Ignition, Starting, Charging, Instruments), Bodywork, Troubleshooting, Periodic Maintenance, Specifications, Torque Values

Page Count:

Estimated 350-450 pages (typical for comprehensive service manuals of this era)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (likely PDF), potentially available as a printed copy

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, repair, and reassembly of all engine components including cylinder head, valves, pistons, rings, connecting rods, crankshaft, camshafts, timing system, oil pump, and oil seals.

Fuel System:

Carburetor (likely Keihin CVK twin) disassembly, cleaning, adjustment, jetting, float level, vacuum operation, fuel pump, fuel filter, and fuel lines.

Ignition System:

CDI ignition system, spark plugs (type, gap), ignition timing, troubleshooting of ignition coil, pickup coil, and ECU.

Cooling System:

Radiator, cooling fan, thermostat, water pump, hoses, coolant specifications, and bleeding procedures.

Transmission And Drivetrain:

Clutch operation, clutch plates, springs, gearbox disassembly and reassembly, gear inspection, shift drum and forks, drive chain adjustment and maintenance, sprockets.

Suspension And Steering:

Front fork (oil type, level, seals, springs, damping adjustments), rear shock absorber (preload adjustment, damping), linkage system (if applicable), steering head bearings (adjustment, replacement), swingarm bearings.

Braking System:

Front and rear brake caliper disassembly, piston seals, brake pads (replacement), brake discs (thickness, runout), master cylinders, brake lines, brake fluid type (DOT 4), bleeding procedures.

Electrical System:

Wiring diagrams, battery specifications, charging system (stator, rectifier/regulator), starter motor, lighting (headlight, taillight, indicators), horn, instruments (speedometer, tachometer), fuses, relays, troubleshooting using a multimeter.

Bodywork And Chassis:

Fairing removal and installation, seat, fuel tank, fenders, exhaust system removal and installation, frame inspection, center stand, side stand.

Maintenance:

Regular scheduled maintenance checks, oil changes, filter replacement, chain lubrication and adjustment, brake fluid changes, coolant flushes, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments, carburetor synchronization.

Troubleshooting:

Systematic diagnostic procedures for common problems such as starting issues, poor running, electrical faults, braking problems, and suspension issues, often with symptom-based flowcharts.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, part replacement, and reassembly for major systems.

Technical Specifications:

Comprehensive listing of all critical torque values, clearances, fluid capacities, fluid types, electrical resistance values, and performance specifications.

Diagnostics:

Includes systematic troubleshooting guides and diagnostic procedures for common issues across all major systems, utilizing electrical schematics and mechanical specifications.

Assembly Disassembly:

Detailed, step-by-step instructions with accompanying diagrams for the removal, installation, and overhaul of all motorcycle components and systems.

Depth:

Comprehensive coverage suitable for professional mechanics and experienced DIY enthusiasts. Includes detailed component breakdown, diagnostic procedures, and specifications for complete engine and chassis overhauls.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable if a high-quality scan or digital native file.

Print Readability:

High-resolution images and clear text for easy reading and reference when printed.

Binding:

N/A (for digital); if printed, typically spiral-bound or saddle-stitched for lay-flat usability.

Paper Quality:

N/A (for digital); if printed, typically durable, semi-gloss paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, DOHC, parallel-twin

Displacement:

498 cc

Bore X Stroke:

74.0 mm x 58.0 mm

Compression Ratio:

9.7:1

Valve Actuation:

DOHC, 8 valves (4 per cylinder)

Horsepower Output:

Approximately 48-50 hp @ 8000 rpm (varies slightly by market/tuning)

Torque Output:

Approximately 45-47 Nm (33-35 lb-ft) @ 6000 rpm

Carburetion:

Twin Keihin CVK34 constant-velocity carburetors

Fuel Tank Capacity:

15 liters (approx. 4.0 US gal)

Oil Capacity With Filter:

2.4 Liters

Oil Type:

API SG or higher, SAE 10W-40 or 20W-50 motorcycle oil recommended

🔧 Transmission

Transmission Type:

6-speed constant-mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Sealed O-ring chain drive

Gear Ratios:

Detailed ratios available within the manual.

📐 Dimensions

Length:

2,220 mm (87.4 in)

Width:

820 mm (32.3 in)

Height:

1,270 mm (50.0 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

220 mm (8.7 in)

Seat Height:

840 mm (33.1 in)

Dry Weight:

180 kg (397 lbs)

Wet Weight:

Approx. 199 kg (439 lbs)

Gross Vehicle Weight Rating:

Not explicitly stated, but typical limits apply for rider + luggage.

Front Tire Size:

90/90-21 54S

Rear Tire Size:

130/80-17 65S

Front Wheel Type:

Spoked

Rear Wheel Type:

Spoked

Front Wheel Size:

21 x 1.85

Rear Wheel Size:

17 x 3.00

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subject to the same standardized crash test ratings as automobiles.

Braking System Type:

Dual hydraulic disc brakes (front and rear)

ABS:

Not typically equipped with ABS on this model.

Lighting:

Halogen headlight, LED taillight, standard amber incandescent turn signals.

Instrumentation:

Analog speedometer, tachometer, fuel gauge, coolant temperature warning light, neutral indicator, oil pressure warning light, high beam indicator.

💡 Technology Features

Infotainment System:

Basic analog and digital instrumentation. No advanced infotainment or connectivity features.

Driver Assistance Features:

None.

Connectivity Options:

None.

🔧 Maintenance

Oil Change Interval:

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.

Air Filter Inspection Cleaning:

Every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles) or 12 months.

Brake Fluid Change:

Every 24,000 km (15,000 miles) or 24 months.

Coolant Flush:

Every 24,000 km (15,000 miles) or 24 months.

Engine Oil Specification:

API SG or higher, SAE 10W-40 or 20W-50 Motorcycle Oil

Brake Fluid Specification:

DOT 4

Coolant Specification:

Permanent type anti-freeze, ethylene glycol based, mixed with distilled water (50/50 ratio recommended).

Fork Oil Type:

SAE 10W (refer to manual for specific type and level)

Common Wear Items:

Clutch plates, brake pads, fork seals, wheel bearings, steering head bearings, drive chain and sprockets. Regulator/rectifier failures can occur on some Kawasaki models of this era.

Carburetor Issues:

Carburetor synchronization can drift, requiring periodic adjustment for smooth engine operation. Diaphragms can degrade over time.

Electrical Issues:

Corrosion in connectors, regulator/rectifier failure, and starter solenoid issues are sometimes reported. Wiring diagrams in the manual are crucial for diagnosis.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and performance-oriented motorcycles, known for their innovation in engine technology and sporting prowess.

Kle500 Lineage:

The KLE500 was part of Kawasaki's dual-sport lineup, evolving from earlier models and sharing some DNA with the GPz500/Ninja 500 series. It was designed to offer a balance of street comfort and off-road capability, with a focus on affordability and versatility.

Production Period:

The KLE500 was produced from the early 1990s through to the late 2000s (around 2007-2008), with the 2006 model representing a mature iteration of the design.

Manufacturing Location:

Primarily manufactured in Japan by Kawasaki Heavy Industries.

🏆 Awards & Recognition

Market Reception:

Generally well-received as a practical and affordable middleweight adventure bike, praised for its versatility and comfortable ride.

Reliability Reputation:

Good reputation for mechanical reliability when properly maintained. The parallel-twin engine is known for its durability.

Emissions Standards:

Complies with emissions standards relevant to its production year and market (e.g., Euro 2 or equivalent for 2006).