Motorcycle Type:
Adventure Touring / Dual-Sport
Target Audience:
Riders seeking a versatile machine for commuting, touring, and light off-road use
Competitors Era:
Honda Transalp, Suzuki V-Strom (later models), Yamaha XT660R/Tenere
Engine Configuration:
Parallel-twin, liquid-cooled
Design Philosophy:
Combining touring comfort with dual-purpose capability
Engine Mechanical:
Engine disassembly, assembly, cylinder head, pistons, crankshaft, timing, lubrication system, cooling system
Fuel System:
Carburetor system (cleaning, adjustment, overhaul), fuel pump, fuel filter, fuel tank
Ignition System:
Ignition timing, CDI unit, spark plugs, ignition coils
Transmission:
Gearbox inspection, repair, clutch assembly, shifting mechanism
Drivetrain:
Chain drive system, sprockets, lubrication
Suspension:
Front fork (oil, seals, spring replacement), rear shock absorber, swingarm, linkage
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, pads, discs, bleeding procedures
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, indicators, starter motor, horn
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, footpegs, fairing components
Wheels And Tires:
Wheel bearing maintenance, tire pressure, tire replacement
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, valve clearance checks
Troubleshooting:
Diagnostic charts for common problems, fault finding procedures
Repair Procedures:
Step-by-step instructions for component removal, disassembly, repair, and reassembly
Overhaul:
Detailed procedures for engine and major component overhauls
Depth Level:
Comprehensive (from basic maintenance to complete engine rebuilds)
Diagnostic Capabilities:
Includes diagnostic procedures and specifications for electrical and mechanical systems
Searchability:
Likely text-searchable if properly scanned/created
Print Recommendation:
High-resolution, suitable for printing individual sections or the entire manual
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Manual Completeness:
Complete Factory Service Manual covering all aspects of maintenance, repair, and diagnostics for the 2004 Kawasaki KLE500 B1.
Engine Type:
Four-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 x 58.0 mm
Horsepower Peak Est:
Approx. 45-50 HP (at 8000 rpm)
Torque Peak Est:
Approx. 45 Nm (at 6000 rpm)
Fuel Delivery:
Carburetor
Carburetor Type:
Dual Keihin CVK34 carburetors
Fuel Capacity:
15 Liters (3.96 US gal)
Oil Capacity W Filter Change:
2.2 Liters (2.3 US qt)
Cooling Type:
Liquid-cooled
Safety Ratings:
N/A (Motorcycle safety ratings vary by jurisdiction and are often not standardized like cars)
Braking System:
Dual hydraulic disc front, single hydraulic disc rear
ABS:
Not standard on this model
Lighting:
Halogen headlight, LED taillight (typical)
Windscreen:
Adjustable height windscreen for rider comfort and protection
Infotainment System:
Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights).
Driver Assistance Features:
None (basic motorcycle design of the era)
Headlight Type:
12V 60/55W Halogen
Battery Type:
12V, YTX9-BS (or equivalent)
First Service Mileage:
600 miles (1,000 km)
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months
Oil Filter Change Interval:
With every oil change
Air Filter Inspection Interval:
Every 3,750 miles (6,000 km)
Valve Clearance Interval:
Every 7,500 miles (12,000 km)
Engine Oil Grade:
SAE 10W-40, API SG or higher (or JASO MA compliant)
Coolant Type:
Ethylene glycol based, anti-freeze/anti-corrosion coolant (50/50 mix with distilled water)
Fork Oil Type And Level:
Kawasaki KHL15-10 or equivalent (e.g., Showa SS-10), 500cc per leg (check manual for precise level/quantity)
Common Wear Items:
Cam chain tensioner (can become noisy), clutch wear, suspension seals (forks), wheel bearings
Electrical Quirks:
Occasional regulator/rectifier failures (common on many bikes of this era)
Carburetor Maintenance:
Carburetors can require periodic cleaning and synchronization due to age and potential fuel gumming.
Kawasaki Heritage:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and reliability across various segments.
Kle500 Generation:
The KLE500 was introduced in 1991 and received updates, with the B series representing the later iteration. The 2004 model is part of the B1 variant.
Previous Model Features:
Early models had simpler suspension and styling; later models like the 2004 received minor updates to styling and components.
Production Period:
1991-2007 (globally)
Manufacturing Location:
Japan (primarily)
