Category:
Dual-sport motorcycle
Target Audience:
Adventure touring, commuting, light off-road
Competitors Example:
BMW F650GS, Honda Transalp, Suzuki V-Strom (early models)
Engine Type:
Parallel-twin, liquid-cooled
Fuel Delivery:
Fuel Injection (EFI)
Design Philosophy:
Versatile and reliable for mixed terrain riding
Engine:
Complete engine overhaul, top-end, bottom-end, cooling system, lubrication system, fuel injection, ignition system
Transmission:
Clutch operation and adjustment, gearbox disassembly and assembly, shift drum and forks, internal lubrication
Chassis:
Frame inspection, suspension (front fork and rear shock absorber) disassembly, service, and adjustment, steering system
Brakes:
Front and rear brake system service, hydraulic system bleeding, caliper maintenance, master cylinder service, disc and pad replacement
Electrical:
Wiring diagrams, battery service, charging system (alternator, regulator/rectifier), starting system (starter motor, starter clutch), lighting system, instrumentation, diagnostic codes
Fuel System:
Fuel tank, fuel pump, fuel injectors, throttle body service, fuel pressure testing
Exhaust System:
Exhaust pipe and muffler inspection and replacement, gasket service
Cooling System:
Radiator service, coolant specifications, fan operation, thermostat service
Wheels And Tires:
Wheel bearing service, tire pressure recommendations, spoke tensioning (if applicable)
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes, coolant changes
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault diagnosis flowcharts
Repair:
Step-by-step repair instructions for all major components and systems
Disassembly Assembly:
Detailed procedures for dismantling and reassembling all motorcycle systems
Adjustments:
Valve clearance adjustments, carburetor synchronization (if applicable), throttle cable adjustments, clutch cable adjustments
Special Tools:
Identification and usage of specialized tools required for specific procedures
Depth:
Comprehensive, from basic owner maintenance to full engine rebuilds and complex electrical diagnostics
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 x 58.0 mm
Compression Ratio:
11.0:1
Valve Train:
DOHC, 8 valves (4 per cylinder)
Horsepower Peak:
Approx. 47 hp @ 8000 rpm
Torque Peak:
Approx. 45 Nm (33 lb-ft) @ 6000 rpm
Fuel Delivery System:
Electronic Fuel Injection (EFI), Twin Keihin throttle bodies (e.g., 36mm)
Fuel Type:
Unleaded gasoline, minimum 91 RON (Octane Rating)
Fuel Tank Capacity:
18 Liters (4.75 US gal)
Oil Capacity With Filter:
Approx. 2.6 Liters
Oil Type Specification:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil
Ignition System:
Digital CDI with electronic advance
Cooling Method:
Liquid-cooled, forced circulation
Coolant Type:
Ethylene glycol-based coolant, 50/50 mixture with distilled water
Safety Features Design:
Designed with rider visibility and stability in mind
Braking System:
Dual disc front brakes, Single disc rear brake
ABS Availability:
Not typically equipped with ABS on this model year range
Lighting:
Halogen headlight, LED taillight
Frame Construction:
Steel diamond frame for rigidity
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature indicator, neutral indicator
ABS:
Generally not equipped on this model year.
Connectivity Features:
None (standard for its class and era)
Oil Change Interval:
Every 6,000 km (3,750 miles) or 6 months, whichever comes first
Oil Filter Change Interval:
Every 6,000 km (3,750 miles) or 6 months, with oil change
Air Filter Cleaning Replacement:
Inspect every 6,000 km (3,750 miles), clean/replace as needed
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Chain Adjustment Lubrication:
Inspect and lubricate every 1,000 km (620 miles) or after riding in wet conditions; adjust chain slack as needed
Engine Oil Specification:
SAE 10W-40, API SG/SH/SJ, JASO MA
Brake Fluid Specification:
DOT 4 (or DOT 3 for older specifications if compatible)
Coolant Specification:
50/50 mixture of ethylene glycol and distilled water
Fork Oil Specification:
SAE 10W (check manual for exact type and quantity)
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, wheel bearings
Potential Engine Issues:
Cam chain wear (leading to rattling noise), potential oil consumption at high mileage
Electrical Notes:
Regulator/rectifier failure is a known concern on some Kawasaki models of this era; check charging system voltage regularly.
Manufacturer:
Kawasaki Heavy Industries, Motorcycle & Engine Company
Introduction Year Kle500:
1991
Key Updates 2004 2005:
Likely refinements in fuel injection mapping, minor styling tweaks, and potentially improved suspension settings compared to earlier models.
Production Period:
1991 - 2007 (Global Market)
Manufacturing Locations:
Primarily Japan (Kawasaski Motors Ltd.)
