Segment:
Adventure Touring / Dual-Sport Motorcycle
Target Audience:
Owners and technicians seeking in-depth maintenance and repair knowledge
Competitors:
Honda Transalp, Suzuki V-Strom (earlier models), Yamaha Ténéré (earlier models)
Model Positioning:
Accessible and reliable adventure bike with a focus on versatility
Primary Coverage:
Comprehensive service and repair for the 2001 Kawasaki KLE500
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, specifications, electrical diagrams, torque values
Page Count:
Approx. 300-400 pages (estimated for a full service manual of this era)
Manual Type:
Full Service & Repair Manual
Engine:
Engine overhaul, top-end, bottom-end, lubrication, cooling, fuel injection, ignition
Transmission:
Clutch, gearbox, shifting mechanism, lubrication
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires
Brakes:
Front and rear brake systems, hydraulic components, pads, discs, bleeding procedures
Electrical:
Battery, charging system, ignition system, lighting, starting system, instrumentation, wiring diagrams
Bodywork:
Fairings, body panels, seat, fuel tank, exhaust system
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, air filter service
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation
Adjustments:
Carburetor synchronization, idle speed, clutch lever free play, brake lever adjustments
Depth:
Complete overhaul and rebuild procedures, advanced diagnostics
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Displacement:
498 cc (498cm3)
Bore X Stroke:
72.0 x 61.0 mm
Horsepower Output:
Approx. 48 PS (35 kW) at 8000 rpm (unrestricted)
Torque Output:
Approx. 45 Nm (33 lb-ft) at 6000 rpm (unrestricted)
Fuel Delivery:
Carburetor (Dual Keihin CVK32)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Oil Type:
API SG, JASO MA certified 10W-40 or 20W-50
Oil Capacity:
Approx. 2.8 liters (with filter change)
Safety Standards:
Compliant with relevant motorcycle safety regulations for the period
Braking System:
Dual piston front caliper, single piston rear caliper with disc brakes
Suspension:
Stable and compliant suspension for various road conditions
Lighting:
Halogen headlamp, LED tail lamp
Instrument Cluster:
Analog speedometer and tachometer, digital odometer, trip meters, fuel gauge, coolant temperature gauge, warning lights
ABS:
Not available on the 2001 model
Charging Port:
Not standard, aftermarket options may exist
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Air Filter Service:
Every 12,000 km (7,500 miles)
Spark Plug Replacement:
Every 18,000 km (11,200 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based), 50/50 mix with distilled water
Chain Lube:
High-quality motorcycle chain lubricant
Common Wear Items:
Chain and sprockets, brake pads, fork seals, exhaust gasket
Potential Issues:
Carburetor wear (less common), charging system regulator (on some earlier models), rear shock absorber wear
Kawasaki Legacy:
Kawasaki is renowned for its performance-oriented motorcycles, including sportbikes, cruisers, and off-road machines.
Kle500 Lineage:
The KLE500 was introduced in 1991 as Kawasaki's entry into the mid-size dual-sport adventure market, evolving over its production run with updates to styling and features.
Production Period:
1991-2007
Manufacturing Location:
Japan
