Segment:
Dual-purpose / Adventure Touring motorcycle
Target Audience:
Riders seeking an affordable, versatile motorcycle capable of both on-road commuting and light off-road exploration.
Competitors:
Honda Transalp, Suzuki DR650 (comparable segment, though different engine configurations), Yamaha XT660R.
Versatility:
Designed to handle varied road conditions, from highways to unpaved tracks.
Engine Basis:
Shares engine architecture with the popular Kawasaki Ninja 500 and GPZ500 models, offering proven reliability and parts availability.
Affordability:
Represents a cost-effective entry into the dual-sport category.
Engine:
Complete disassembly, inspection, repair, and reassembly of the 498cc parallel-twin engine, including cylinder head, pistons, crankshaft, lubrication system, and cooling system.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel tank, fuel pump, and fuel lines.
Transmission:
Gearbox operation, maintenance, repair, and overhaul; clutch operation, adjustment, and replacement.
Drivetrain:
Chain drive system maintenance, adjustment, and replacement; rear hub and sprocket servicing.
Chassis:
Frame inspection and repair; front fork overhaul and adjustment; rear shock absorber servicing; steering head bearing maintenance.
Suspension:
Front and rear suspension component specifications, maintenance, and repair procedures, including fork oil change and seal replacement.
Brakes:
Front and rear brake system maintenance, including hydraulic fluid replacement, caliper overhaul, pad replacement, and disc inspection.
Electrical System:
Ignition system troubleshooting and repair; charging system (stator, regulator/rectifier); lighting system; starter motor; battery maintenance; wiring diagrams.
Wheels And Tires:
Tire pressure specifications, tire replacement, wheel bearing maintenance, spoke tensioning (if applicable).
Bodywork And Trim:
Fairing removal and installation, seat servicing, body panel repair and maintenance.
Preventative Maintenance:
Scheduled maintenance intervals, lubrication points, fluid checks and changes, filter replacement, chain adjustment.
Troubleshooting:
Diagnostic procedures for common issues, fault finding charts, troubleshooting electrical problems.
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly for all major systems.
Technical Specifications:
Torque specifications for fasteners, clearances, fluid capacities, electrical values, engine timing.
Depth:
Comprehensive, covering from basic rider maintenance to complete engine and chassis rebuilds. Suitable for experienced DIY mechanics and professional technicians.
Engine Type:
Four-stroke, liquid-cooled, DOHC, parallel-twin
Displacement:
498 cc (30.4 cu in)
Bore X Stroke:
74.0 x 58.0 mm (2.9 x 2.3 in)
Valve Train:
DOHC, 8 valves
Horsepower Estimated:
Approx. 45-50 HP @ 8000 RPM
Torque Estimated:
Approx. 40-45 Nm @ 6000 RPM
Carburetion:
Twin Keihin CVK34 carburetors
Fuel Tank Capacity:
15 liters (3.96 US gal)
Oil Capacity W Filter:
2.5 L (2.6 US qt)
Recommended Oil Viscosity:
10W-40 (for general use, check manual for specific ambient temperature ranges)
Length:
Approx. 2,155 mm (84.8 in)
Width:
Approx. 850 mm (33.5 in)
Height:
Approx. 1,370 mm (53.9 in)
Wheelbase:
Approx. 1,460 mm (57.5 in)
Dry Weight:
Approx. 182 kg (401.2 lbs)
Wet Weight Estimated:
Approx. 200 kg (440.9 lbs)
Load Capacity Estimated:
Approx. 200 kg (440 lbs) including rider and luggage
Front Suspension Travel:
170 mm (6.7 in)
Rear Suspension Travel:
170 mm (6.7 in)
Front Tire Size:
90/90-21 M/C 54S
Rear Tire Size:
130/80-17 M/C 65S
Front Wheel Type:
Spoked, 21-inch
Rear Wheel Type:
Spoked, 17-inch
Crash Test Results:
Not applicable for motorcycles in the same way as cars; refer to owner's manual for safe riding practices.
Braking System:
Disc brakes front and rear. Front: Dual discs. Rear: Single disc.
Brake Disc Diameter Front:
230 mm (9.1 in)
Brake Disc Diameter Rear:
240 mm (9.4 in)
Lighting:
Halogen headlamp, tail lamp, turn signals.
Audio System:
No integrated audio system. Provisions for aftermarket accessory installation.
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights.
Connectivity Features:
No integrated connectivity features such as Bluetooth or GPS.
Oil And Filter Change:
Every 6,000 km (3,750 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,750 miles)
Spark Plug Inspection:
Every 6,000 km (3,750 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles) or after riding in rain/wet conditions
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water.
Carburetor Icing:
Can be susceptible to icing in cold, humid conditions, potentially leading to rough idling or stalling. Manual will cover adjustment and cleaning.
Voltage Regulator Failure:
As with many bikes of this era, voltage regulators can be a point of failure. Manual covers testing and replacement.
Suspension Wear:
After significant mileage, fork seals and rear shock absorber may require servicing or replacement. Manual details these procedures.
Kawasaki Motorcycles:
Kawasaki Heavy Industries, Ltd. has a long and storied history in motorcycle manufacturing, known for performance and innovation across various segments.
Kle500 Origin:
The KLE500 was introduced in the early 1990s as Kawasaki's answer to the growing dual-purpose motorcycle market. It evolved from the ER500 platform, adapting its parallel-twin engine for adventure touring.
Kle500 Generations:
The KLE500 saw several updates throughout its production life, with the 2000 model representing a refinement of the earlier designs, featuring improved styling and component updates.
Production Period:
1991 - 2007
Manufacturing Location:
Japan
