Target Audience:
Owners of the Kawasaki KLE500 2006 seeking to perform maintenance, repairs, or understand their motorcycle's technical aspects.
Value Proposition:
Provides comprehensive, accurate, and detailed information necessary for efficient and effective servicing, saving time and money compared to dealership service or less complete manuals.
Accessibility:
Digital PDF format allows for instant download and access on multiple devices.
Support:
Includes customer support for download issues and satisfaction guarantee.
Systems Covered:
General Information, Specifications, Maintenance, Engine, Fuel System, Cooling System, Lubrication System, Clutch, Transmission, Drive Train, Wheels, Tires, Suspension (Front & Rear), Brakes (Front & Rear), Frame, Bodywork, Electrical System, Wiring Diagrams, Troubleshooting
Estimated Page Count:
300+
Type:
Service Repair Manual
Engine:
Detailed disassembly, assembly, inspection, and repair of all engine components including cylinders, pistons, crankshaft, camshafts, valves, timing chain, and lubrication system.
Fuel System:
Carburetor adjustment and overhaul (likely Keihin CVK), fuel pump operation, fuel filter replacement, fuel tank inspection.
Cooling System:
Radiator, fan operation, coolant flow, thermostat testing, hose inspection, and coolant replacement procedures.
Transmission:
Gearbox disassembly and assembly, clutch operation and adjustment, shift drum and fork inspection, transmission fluid specifications and change procedures.
Brakes:
Front and rear brake system maintenance, including caliper overhaul, brake pad replacement, brake fluid bleeding, master cylinder inspection, and hydraulic line inspection.
Suspension:
Front fork (telescopic) disassembly, service, and oil change procedures. Rear shock absorber inspection and replacement. Swingarm and linkage maintenance.
Electrical System:
Comprehensive wiring diagrams, ignition system testing (spark plugs, coils, CDI unit), charging system analysis (stator, regulator/rectifier, battery), lighting system troubleshooting, starter motor operation, and instrument cluster functions.
Maintenance:
Periodic maintenance schedules, oil changes, filter replacements (oil, air, fuel), chain adjustment and lubrication, tire pressure checks, brake inspections, coolant checks, and spark plug replacement.
Troubleshooting:
Systematic diagnostic procedures for common issues such as hard starting, poor running, electrical faults, brake fade, and suspension problems, with symptom-based troubleshooting charts.
Repair:
Detailed step-by-step instructions for component disassembly, repair, replacement, and reassembly for all major motorcycle systems.
Depth:
Comprehensive, covering everything from basic rider maintenance to advanced engine and electrical system diagnostics and repairs. Suitable for both amateur and professional mechanics.
Engine Code:
LE500AE (example, specific code may vary slightly)
Displacement:
498 cc (30.4 cu. in.)
Bore X Stroke:
74.0 x 58.0 mm (2.9 x 2.3 in.)
Horsepower Claimed:
Approx. 45 hp (33.1 kW) @ 7500 rpm (varies by market)
Torque Claimed:
Approx. 46 Nm (34 lb-ft) @ 5500 rpm (varies by market)
Carburetor Type:
Dual Keihin CVK36 carburetors
Fuel Capacity:
18 Liters (4.8 US gal)
Oil Type Recommendation:
SAE 10W-40 API SG or higher (specific Kawi recommendations to be detailed in manual)
Oil Capacity With Filter:
Approx. 2.2 Liters (2.3 US qt)
Instrument Cluster:
Analog speedometer and tachometer, odometer, trip meter, neutral indicator, oil pressure warning light, turn signal indicators.
ABS:
Not standard on most 2006 KLE500 models.
Gps Integration:
No built-in GPS integration.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (as per typical recommendations, exact interval in manual).
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) (as per typical recommendations, exact interval in manual).
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles) (as per typical recommendations, exact interval in manual).
Fork Oil Type:
Specific grade SAE 10W fork oil recommended (manual will detail type and quantity).
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, front fork seals, and brake pads are common wear items addressed in maintenance schedules.
Potential Faults:
Carburetor synchronization issues, charging system component failure (regulator/rectifier), and electrical connection corrosion can occur over time.
Kawasaki Motorcycles:
Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and performance-oriented motorcycles across various segments.
Kle500 Development:
The KLE500 was part of Kawasaki's dual-sport line, designed to offer versatility for on-road and light off-road use. It often shared its engine with other Kawasaki models, providing a balance of power and reliability.
Production Years:
Originally introduced in the early 1990s, with continuous updates through the 2000s, including the 2006 model.
