Segment:
Dual-sport / Adventure motorcycle, known for its versatility and reliability
Competitors:
Honda Transalp, Suzuki V-Strom (earlier models), Yamaha Ténéré (earlier models)
Versatility:
Capable on pavement and light off-road conditions
Engine Type:
Parallel-twin, liquid-cooled, a robust and proven powerplant
Handling:
Good balance for both commuting and touring
Engine:
Comprehensive engine disassembly, assembly, tuning, and troubleshooting
Fuel System:
Carburetor service, adjustment, and troubleshooting; fuel tank and pump inspection
Cooling System:
Radiator, fan, coolant, and thermostat service and inspection
Ignition System:
Spark plug specifications, ignition timing, CDI unit, and coil testing
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), battery, lighting, and starter motor
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism
Suspension:
Front forks (disassembly, oil change, seal replacement), rear shock absorber, linkage maintenance
Brakes:
Front and rear brake caliper service, master cylinder overhaul, fluid replacement, pad and disc inspection
Wheels And Tires:
Tire pressure, wheel bearing service, spoke tension adjustment (if applicable)
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm pivot bearing maintenance
Bodywork And Fittings:
Fairing removal and installation, seat, fuel tank mounting, and other trim components
Diagnostic Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flushes
Engine Rebuild:
Piston replacement, cylinder inspection, valve clearance adjustment, gasket replacement
Transmission Repair:
Gearbox inspection, seal replacement, clutch plate replacement
Electrical Diagnostics:
Fault finding for charging system, ignition, and lighting circuits
Suspension Overhaul:
Front fork seal replacement, rear shock absorber inspection
Brake System Maintenance:
Bleeding procedures, caliper and master cylinder rebuilds
Carburetor Synchronization:
Detailed steps for balancing multiple carburetors
Wheel Truing And Spoke Maintenance:
Guidance on maintaining wheel integrity
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhaul, including detailed troubleshooting charts
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Bore X Stroke:
72.0 mm x 60.2 mm
Valve Train:
DOHC, 8 valves (4 per cylinder)
Horsepower Approx:
49 hp @ 8000 rpm
Torque Approx:
47 Nm @ 6000 rpm
Carburetors:
Twin Keihin CVK34
Fuel Capacity:
15 Liters (3.3 Gallons)
Oil Type:
API SE, SF or SG, SAE 10W-40 (check manual for specific viscosity)
Oil Capacity W Filter:
2.5 Liters (2.6 US qt)
Ignition System:
Digital CDI with electronic advance
Spark Plug Type:
NGK CR9E or equivalent
Crash Test Results:
Motorcycles are not typically rated by organizations like NHTSA or IIHS; safety relies on rider skill and adherence to road laws.
Braking System:
Dual Disc Front, Single Disc Rear (ABS not standard on this model year)
Suspension Stability:
Provides stable handling characteristics
Lighting:
Halogen headlight, taillight, brake lights, and turn signals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Change Interval:
Every 12,000 km (7,400 miles) or 12 months (coinciding with major service)
Valve Clearance Check:
Every 12,000 km (7,400 miles)
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain
Engine Oil Grade:
SAE 10W-40 (API SE, SF or SG rated)
Coolant Type:
Ethylene glycol based, anti-freeze/anti-corrosion (50/50 mix with distilled water)
Fork Oil Type:
Kawasaki Fork Oil G10 or equivalent (specific viscosity usually 10W, capacity per leg specified in manual)
Carburetor Icing:
Can occur in very cold, humid conditions due to fuel vaporization (less common in warmer climates)
Stator Reliability:
Some owners report stator failures over time; the manual provides testing procedures.
Rear Shock Wear:
As with many bikes of this age, the original rear shock may lose damping effectiveness.
Oil Filter Part Number:
Kawasaki: 16097-1004 (check compatibility for specific model year)
Air Filter Part Number:
Kawasaki: 11013-1207 (check compatibility)
Spark Plug Part Number:
NGK CR9E
Kawasaki Legacy:
Kawasaki Heavy Industries, Ltd. is a well-established Japanese manufacturer with a strong reputation for performance and engineering in motorcycles, powersports, and aerospace.
Kle Series:
The KLE500 is part of Kawasaki's dual-purpose line, evolving from earlier models and offering a balance of on-road comfort and light off-road capability.
Kle500 Generations:
The KLE500 was produced in multiple generations, with the 2001 model representing a refinement of the original concept. It shares its engine architecture with the ER-5 model.
Production Years:
1991-2007 (approximately, with variations)
Manufacturing Location:
Japan
