Segment:
Dual-sport/Adventure touring motorcycle, offering a blend of on-road comfort and off-road capability. Positioned as an accessible and reliable option for riders seeking versatility.
Competitors:
Competed against models like the BMW F650GS, Suzuki V-Strom 650 (later years), and Honda Transalp (though the KLE500 generally offered a more budget-friendly entry point).
Defining Characteristics:
Parallel-twin engine, comfortable riding position, robust construction, long-travel suspension for handling varied terrain, large fuel tank for extended range, and a generally understated yet functional design.
Covered Sections:
Engine, Fuel System, Carburetion, Ignition, Cooling System, Exhaust System, Clutch, Transmission, Gearshifting, Drive Train, Frame, Suspension (Front and Rear), Wheels, Tires, Brakes (Front and Rear), Electrical System, Lighting, Instruments, Switches, Wiring Diagrams, Bodywork, Maintenance, Troubleshooting, Specifications, Torque Values, Special Tools
Estimated Pages:
Approximately 300-400 pages (typical for a comprehensive service manual of this era)
Type:
Service and Repair Manual
Engine And Powertrain:
Detailed coverage of the 498cc parallel-twin engine, including top-end rebuilds, bottom-end work, valve clearance adjustments, carburetor synchronization and tuning, ignition system diagnosis, cooling system maintenance, and exhaust system repair.
Chassis And Suspension:
Comprehensive sections on front fork overhaul and adjustment, rear shock absorber inspection and replacement, swingarm bearing service, wheel bearing replacement, and tire mounting/balancing.
Brakes:
In-depth procedures for front and rear brake caliper maintenance, brake pad replacement, brake fluid bleeding, master cylinder inspection, and hydraulic line servicing.
Electrical And Ignition:
Extensive coverage of the electrical system, including starter motor, alternator, battery maintenance, lighting circuits, ignition timing, troubleshooting of electrical faults using wiring diagrams, and instrument cluster diagnostics.
Routine Maintenance:
Step-by-step instructions for oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake adjustments, and coolant checks.
Troubleshooting:
Systematic diagnostic procedures for common running problems, starting issues, electrical malfunctions, and mechanical failures, often presented in a flow-chart format.
Major Repairs:
Detailed instructions for engine disassembly and reassembly, transmission component replacement, carburetor overhauls, suspension rebuilds, and bodywork repairs.
Wiring Diagrams:
Clear and detailed wiring schematics for all electrical components, essential for diagnosing electrical issues and performing modifications.
Special Tools:
Lists recommended special tools required for specific repair procedures, aiding in efficient and correct servicing.
Depth:
Comprehensive, covering everything from basic owner-level maintenance to advanced engine and transmission rebuilds, suitable for both amateur and professional mechanics.
Diagnostic Capabilities:
Includes guidance on diagnosing engine performance issues, electrical faults, and chassis problems using common tools and logical troubleshooting steps.
Format Details:
Digital PDF format, typically searchable, allowing for quick access to specific information. Designed for easy viewing on computers, tablets, and smartphones. Potentially printable.
Quality:
High-resolution scans or original digital files ensuring clarity of text, diagrams, and photographs.
Binding:
Not Applicable (PDF format)
Paper:
Not Applicable (PDF format)
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Engine Mounting:
Transverse
Horsepower:
Approximately 48 HP (35.8 kW) @ 8000 rpm (claimed)
Torque:
Approximately 42 Nm (31 lb-ft) @ 5500 rpm (claimed)
Fuel Delivery:
Carburetor (Dual Keihin CVK34)
Fuel Type:
Unleaded gasoline, minimum octane rating 87 (RON+MON)/2
Coolant Type:
Kawasaki Motorcycle Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Crash Safety:
N/A (Motorcycles typically do not have formal crash test ratings like cars. Safety depends heavily on rider skill and adherence to safety protocols.)
Braking System:
Front: Dual disc brakes. Rear: Single disc brake. ABS was not a standard or common option for this model year.
Lighting:
Halogen headlight, LED taillight, turn signals.
Ergonomics:
Upright riding posture designed for comfort and control over various terrains.
Features:
Basic instrumentation cluster including speedometer, tachometer, odometer, trip meter, and indicator lights. No modern infotainment systems like touchscreens or integrated audio were standard.
Features:
No electronic rider aids such as traction control or ABS (typically). Relies on rider skill and mechanical grip.
Features:
No digital connectivity features. Focus is on mechanical reliability and rider interaction.
Oil Change:
Every 3,000 - 5,000 km (1,800 - 3,100 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 4,000 - 6,000 km (2,500 - 3,700 miles), depending on operating conditions.
Spark Plug Replacement:
Every 12,000 - 16,000 km (7,500 - 10,000 miles).
Valve Clearance Check:
Every 12,000 - 16,000 km (7,500 - 10,000 miles).
Chain Lubrication And Adjustment:
Check and lubricate every 500 - 800 km (300 - 500 miles); check tension at every service.
Engine Oil:
SAE 10W-40 API SG or higher, JASO MA certified.
Coolant:
Kawasaki Motorcycle Coolant or equivalent mixture of distilled water and ethylene glycol-based coolant (50/50 ratio).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Fork Oil Type:
SAE 10W (or as specified by Kawasaki for front suspension)
Common Wear Items:
Rear shock absorber can lose damping over time, requiring rebuild or replacement. Clutch plates can wear, especially under hard use. Cam chain tensioner can become noisy, necessitating replacement.
Carburetor Issues:
Carburetors may require periodic cleaning and synchronization due to vacuum diaphragm wear or jet clogging, especially with varied fuel quality.
Electrical Connections:
Corrosion or loosening of electrical connectors, particularly in the headlight or taillight areas, can lead to intermittent function.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company is a renowned Japanese manufacturer known for its high-performance motorcycles across various segments, including sportbikes, cruisers, and dual-sport models.
Kle Series:
The KLE500 is part of Kawasaki's lineage of dual-purpose motorcycles, building on the KLR series' off-road prowess while emphasizing a more road-biased touring capability. The KLE500 was developed as a more street-oriented alternative to the KLR650.
Production Period:
The KLE500 was produced from 1991 to 2007. The 2004-2005 models represent a mature iteration of the original design, likely with minor refinements over the years.
Manufacturing Location:
Primarily manufactured in Japan.
