🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Year:

2004, 2005, 2006, 2007

Engine Code:

Likely to be the EX500 variant engine, specific code not provided in product info

Chassis Code:

LE500A

👋 Introduction

Market Position:

The Kawasaki KLE500 is a versatile dual-sport motorcycle, blending on-road comfort with off-road capability, targeting riders seeking adventure and everyday utility. This manual serves owners and mechanics of this specific model range.

Competitive Analysis:

Competes with other middleweight adventure-touring bikes like the Suzuki V-Strom, Honda Transalp, and Yamaha TDM series, offering a balance of performance, reliability, and ruggedness.

Key Features:

Rugged construction, comfortable riding position, tractable engine, dual-purpose wheels (spoked front, cast rear likely), wind protection, and ample suspension travel. The manual supports maintaining these aspects.

📋 Manual Details

Coverage Areas:

Complete service and repair for Kawasaki KLE500 2004-2007 models.

Page Count:

400

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine (disassembly, assembly, repair, adjustment), Fuel System, Ignition System, Cooling System, Lubrication System, Transmission, Clutch, Drive Train, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Electrical System (Wiring Diagrams, Lighting, Ignition, Starting, Charging), Frame, Bodywork, Controls, Instruments.

Procedures Included:

Routine Maintenance, Troubleshooting, Diagnostic Procedures, Removal and Installation of Components, Disassembly and Assembly of Mechanical Parts, Adjustments, Specifications, Torque Values, Wear Limits, Electrical System Diagnostics, Repair Interventions.

Technical Depth:

Comprehensive, step-by-step procedures, detailed explanations, pictorial diagrams, exploded views, and photos covering basic to advanced repairs and diagnostics. Suitable for both professional mechanics and DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable, high-resolution pages

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Compatibility:

Windows, Mac, Linux OS

Requirements:

Adobe Reader

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin

Displacement:

498 cc (Derived from EX500 engine)

Bore X Stroke:

74.0 x 58.0 mm (typical for EX500 engine)

Compression Ratio:

9.7:1 (typical for EX500 engine)

Horsepower:

Approx. 48-50 HP (at the crank, varies slightly by region/tune)

Torque:

Approx. 42-44 Nm (at the crank, varies slightly by region/tune)

Fuel System:

Carbureted (likely dual Keihin CVK carburetors, e.g., 34mm)

Fuel Type:

Unleaded gasoline (Octane rating as per Kawasaki recommendations)

Valve Clearance Intake:

0.08 - 0.13 mm (Cold)

Valve Clearance Exhaust:

0.13 - 0.18 mm (Cold)

Oil Capacity With Filter:

Approx. 2.7 Liters (refer to manual for exact figure)

Recommended Oil Viscosity:

10W-40 or 20W-50 (based on ambient temperature, refer to manual)

Oil Filter Part Number:

Kawasaki genuine part number varies, commonly used filters include K&N KN-111, Hiflofiltro HF111

🔧 Transmission

Transmission Type:

Constant mesh 6-speed sequential

Clutch Type:

Wet, multi-plate

Final Drive:

Sealed chain drive

Gear Ratios:

Specific ratios available in manual (e.g., 1st: 2.750, 2nd: 2.056, 3rd: 1.619, 4th: 1.333, 5th: 1.160, 6th: 1.042)

📐 Dimensions

Length:

Approx. 2220 mm

Width:

Approx. 840 mm

Height:

Approx. 1365 mm

Wheelbase:

Approx. 1450 mm

Dry Weight:

Approx. 180 kg

Wet Weight:

Approx. 194 kg (fully fueled)

Fuel Capacity:

17 Liters

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety is assessed differently than cars, emphasis on rider skill and protective gear)

Active Features:

Disc brakes front and rear, responsive suspension, stable chassis geometry.

Passive Features:

Sturdy frame construction, rider ergonomics designed for control.

💡 Technology Features

Infotainment System:

Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, coolant temperature gauge, warning lights). No advanced infotainment features.

Driver Assistance Features:

None (primarily rider-controlled systems).

Connectivity Options:

None.

Headlight Type:

Halogen (dual bulbs likely, for high and low beam)

Starting System:

Electric starter motor

🔧 Maintenance

Oil Change Interval:

Every 6,000 km or 6 months, whichever comes first.

Chain Lubrication Inspection:

Every 1,000 km or after riding in the rain/off-road.

Spark Plug Inspection Replacement:

Every 12,000 km.

Air Filter Cleaning Replacement:

Inspect every 6,000 km, clean or replace as needed.

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol based antifreeze, 50% mixture with distilled water

Known Issues:

Cam chain tensioner noise (can be addressed with aftermarket upgrades), potential carburetor synchronization issues, clutch wear over time. The manual provides guidance for diagnosing and resolving these.

Common Wear Items:

Brake pads, chain and sprockets, tires, fork seals, clutch plates.

📚 Vehicle History

Brand Heritage:

Kawasaki Heavy Industries has a long history of building robust and performance-oriented motorcycles, known for their parallel-twin engines and innovative designs.

Model Evolution:

The KLE500 is an evolution of Kawasaki's successful EX500 platform, adapting its sporty engine and chassis for a more adventure-oriented role. It benefited from continuous minor updates throughout its production run.

Production Period:

1991 - 2007

Manufacturing Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions:

While specific awards for the KLE500 might not be widely documented, it's recognized as a capable and durable motorcycle within its segment, praised for its value and versatility.

User Ratings:

Generally well-regarded by owners for its reliability and suitability for touring and commuting, particularly in budget-conscious segments.