🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Year:

2004

Engine Type:

Parallel-twin, Four-stroke

Vin Code:

Typically starts with JKB

Engine Code:

EX500D

👋 Introduction

Market Position:

The Kawasaki KLE500 is positioned as a versatile dual-sport motorcycle, capable of handling both on-road commuting and light off-road adventures. It appeals to riders seeking a practical and rugged machine with a relaxed riding posture.

Competitive Analysis:

Competes with other mid-weight adventure touring motorcycles and dual-sports, offering a balance of performance, comfort, and affordability. Key competitors include models like the Suzuki V-Strom 650, Honda Transalp, and Yamaha Tenere series.

Key Features:

Robust parallel-twin engine, long-travel suspension, durable construction, comfortable seating for rider and passenger, ample fuel range, and a capable chassis for mixed terrain.

📋 Manual Details

Systems Covered:

Engine, Chassis, Electrical System, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Suspension, Brakes, Wheels and Tires, Frame, Bodywork, Troubleshooting

Page Count:

Approximately 500+

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, piston and ring inspection, cylinder head removal and inspection, crankshaft and connecting rod checks, valve timing and adjustment, oil pump operation, lubrication system

Fuel System:

Carburetor disassembly, cleaning, and adjustment (CVK34), fuel pump, fuel filter, fuel lines, fuel tank servicing

Ignition System:

Ignition coil testing, spark plug specifications, CDI unit troubleshooting, pickup coil inspection

Cooling System:

Radiator and fan inspection, thermostat operation, coolant specifications and capacity

Transmission:

Clutch operation and adjustment, gear shifting mechanism, gearbox disassembly and assembly, transmission fluid specifications

Brakes:

Hydraulic brake system (front and rear), brake fluid specifications and bleeding procedures, caliper inspection and overhaul, brake pad replacement, brake disc specifications

Suspension:

Front fork (telescopic) disassembly, inspection, and oil change; rear shock absorber inspection and adjustment; linkage lubrication

Electrical System:

Wiring diagrams, battery specifications and maintenance, charging system (alternator, rectifier/regulator), starter motor, lighting system (headlight, taillight, indicators), horn, instrument cluster troubleshooting

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid flush, coolant change, valve clearance checks

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides for engine performance, electrical faults, and braking issues

Repair Overhaul:

Detailed step-by-step instructions for major component disassembly, repair, and reassembly, including engine rebuilds, transmission overhauls, and suspension component replacement

Technical Depth:

Comprehensive, covering everything from basic user maintenance to complete engine and chassis rebuilds, including detailed torque specifications and diagnostic procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, clear text and diagrams, suitable for printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Searchability:

Fully searchable PDF for quick access to specific topics and components.

⚙️ Engine Specifications

Engine Description:

Liquid-cooled, four-stroke, DOHC, parallel-twin cylinder

Displacement:

498 cc

Bore X Stroke:

74.0 x 58.0 mm

Compression Ratio:

9.0:1

Horsepower:

Approx. 45-48 HP @ 8,000 rpm (specifications may vary by market)

Torque:

Approx. 42 Nm @ 6,000 rpm (specifications may vary by market)

Carburetion:

Dual Keihin CVK34 carburetors

Fuel Capacity:

15 Liters (3.9 US gal)

Oil Type:

API SG or SH, SAE 10W-40 motorcycle oil

Oil Capacity:

2.6 Liters (with filter change)

🔧 Transmission

Transmission Type:

Constant mesh, 6-speed return

Final Drive:

O-ring sealed chain

Clutch Type:

Wet, multiple disc, cable operated

Transmission Oil:

API GL-4, SAE 80W-90

📐 Dimensions

Overall Length:

2,220 mm (87.4 in)

Overall Width:

820 mm (32.3 in)

Overall Height:

1,370 mm (53.9 in)

Wheelbase:

1,460 mm (57.5 in)

Ground Clearance:

210 mm (8.3 in)

Seat Height:

835 mm (32.9 in)

Dry Weight:

182 kg (401.2 lbs)

Curb Weight:

Approx. 200 kg (441 lbs) with all fluids

Front Tire:

90/90-21 M/C 54S

Rear Tire:

130/80-17 M/C 65S

Wheel Type:

Spoked wheels

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety ratings are not standardized like automobiles. Focus is on mechanical integrity and rider aids.)

Active Safety:

Disc brakes front and rear, responsive suspension, good rider visibility

Passive Safety:

Sturdy frame, protective fairing for wind deflection, handguards

💡 Technology Features

Infotainment System:

Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment features typically found on modern motorcycles.

Driver Assistance:

No electronic rider aids such as ABS or traction control on standard models.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Service:

Every 12,000 km (7,500 miles) or 12 months. Clean and re-oil foam element.

Spark Plug Replacement:

Every 18,000 km (11,000 miles). Check and adjust gap every 6,000 km.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km (600 miles) and before long trips.

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Brake Fluid:

DOT 4 (or specified equivalent)

Coolant:

Permanent type antifreeze coolant, 50% solution in distilled water

Common Issues:

Carburetor synchronization can drift over time, requiring periodic adjustment. Some owners report the clutch lever feel can become heavy. Chain and sprockets wear relatively quickly if not properly maintained. Rear suspension linkage may require periodic greasing.

📚 Vehicle History

Brand Heritage:

Kawasaki Heavy Industries has a long-standing reputation for producing robust and performance-oriented motorcycles across various segments, including sportbikes, cruisers, and off-road machines.

Model Evolution:

The KLE500, introduced in 1991, evolved from Kawasaki's successful EN500 Vulcan and ER-5 models, adapting the parallel-twin engine and chassis for adventure touring. The 2004 model represents a refinement of this platform.

Production Years:

1991-2007 (in most markets)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions:

While the KLE500 did not receive specific 'awards' in the traditional sense, it was widely recognized by motorcycle publications and riders for its reliability, versatility, and value for money in the dual-sport segment.