Segment:
Adventure Touring / Dual-Sport
Target Audience:
Riders seeking a versatile motorcycle for on-road commuting and light off-road excursions.
Key Competitors:
Honda Transalp, Suzuki V-Strom (earlier models), Yamaha Tenere (earlier models)
Versatility:
Designed for both paved roads and unpaved surfaces, offering a balanced riding experience.
Engine Type:
Parallel-twin engine, known for its smoothness and reliability.
Handling:
Comfortable riding position and capable suspension for a variety of conditions.
Engine Mechanical:
Disassembly, inspection, assembly, valve clearance, timing, lubrication, cooling system
Fuel System:
Carburetor(s) tuning, cleaning, inspection, fuel pump, fuel tank, lines
Ignition System:
Ignition timing, spark plugs, coils, CDI unit, troubleshooting
Transmission Drivetrain:
Clutch operation, gearbox overhaul, final drive (chain and sprockets)
Suspension Front:
Front fork disassembly, service, spring rates, damping adjustments
Suspension Rear:
Rear shock absorber service, linkage maintenance, adjustment
Brakes Front:
Brake caliper service, master cylinder overhaul, pad replacement, fluid flush
Brakes Rear:
Brake caliper service, master cylinder overhaul, pad replacement, fluid flush
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instrumentation
Frame Bodywork:
Frame inspection, fairings, body panels, seat, fuel tank mounting, exhaust system
Scheduled Maintenance:
Oil changes, filter replacements, chain lubrication, air filter cleaning/replacement, spark plug checks
Troubleshooting:
Diagnostic guides for common issues, electrical faults, engine performance problems
Component Overhaul:
Detailed step-by-step instructions for major component rebuilds (engine, transmission, suspension)
Adjustments:
Carburetor synchronization, chain tension, brake lever free play, suspension settings
Wiring Diagrams:
Comprehensive electrical schematics for easy fault diagnosis
Depth:
Comprehensive: Covers routine maintenance to full engine and transmission rebuilds, including diagnostic procedures and specifications.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Horsepower:
Approx. 47 hp @ 8000 rpm (subject to regional variations)
Torque:
Approx. 43 Nm @ 6000 rpm (subject to regional variations)
Carburetion:
Two Keihin CVK34 carburetors
Fuel Capacity:
15 Liters (3.9 US gal)
Oil Capacity With Filter:
2.6 Liters (2.7 US qt)
Length:
Approx. 2,195 mm (86.4 in)
Width:
Approx. 845 mm (33.3 in)
Height:
Approx. 1,345 mm (53.0 in)
Wheelbase:
Approx. 1,465 mm (57.7 in)
Dry Weight:
Approx. 180 kg (397 lbs)
Wet Weight:
Approx. 195 kg (430 lbs) (with all fluids)
Front Tire Size:
90/90-21 54S
Rear Tire Size:
130/80-17 65S
Front Brake:
Dual 280 mm discs, hydraulic, 2-piston calipers
Rear Brake:
Single 240 mm disc, hydraulic, 1-piston caliper
Front Suspension Travel:
Approx. 170 mm (6.7 in)
Rear Suspension Travel:
Approx. 173 mm (6.8 in)
Crash Test Results:
N/A (Motorcycles are not typically subject to the same crash testing standards as cars)
Braking System:
Effective dual front disc and single rear disc braking system.
Lighting:
Headlight, tail light, brake lights, turn signals for visibility.
Chassis Design:
Robust frame and suspension designed to handle varied terrain.
Ergonomics:
Comfortable riding posture for extended journeys and better control.
Features:
Basic instrumentation: Speedometer, Tachometer, Odometer, Trip Meter, Neutral Indicator, High-Beam Indicator, Turn Signal Indicators.
Features:
N/A (Motorcycle technology of this era did not typically include advanced rider-assistance systems.)
Features:
N/A (No integrated Bluetooth or smartphone connectivity.)
Oil Change:
Every 6,000 km (3,700 miles) or 6 months.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Engine Oil:
SAE 10W-40 API SG or higher (e.g., Motul 5100 10W-40)
Coolant:
Ethylene glycol based, 50/50 mix with distilled water (e.g., Kawasaki Coolant)
Chain Lube:
Specific motorcycle chain lubricant
Cam Chain Noise:
Some models can develop cam chain noise over time; requires inspection and potential tensioner adjustment/replacement.
Carburetor Synchronization:
Can require periodic synchronization for optimal performance and fuel economy.
Charging System Output:
Occasionally, regulator/rectifier units can fail, leading to charging issues. Diagnosis detailed in manual.
Manufacturer Origin:
Kawasaki Heavy Industries Motorcycle & Engine Company, Japan
Lineage:
The KLE500 was part of Kawasaki's line of dual-purpose motorcycles, building on the success of models like the KLR series. It offered a more street-biased approach compared to some KLR variants.
Production Period:
The KLE500 was produced from the mid-1990s until the late 2000s, with various iterations (A, B series).
Notable Changes For 2004:
The 'B' series typically represented refinements and updates over earlier 'A' series models, though specific changes for the B1 model year would be detailed in the manual itself.
