KAWASAKI KLE500 KLE BIKE 1995-2007 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLE500 Nickname: KLE Bike Generation Production Years: 1995-2007 👋 Introduction Market Position Segment: Dual-sport, Adventure-Touring motorcycle Competitive Analysis Key Competitors: Honda Transalp, Suzuki...

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Type: Motorcycle

Vendor:

Sku: 603669

Tags: 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Kawasaki KLE500 Motorcycle Motorcycles Versys

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE500

Nickname:

KLE Bike

Generation

Production Years:

1995-2007

👋 Introduction

Market Position

Segment:

Dual-sport, Adventure-Touring motorcycle

Competitive Analysis

Key Competitors:

Honda Transalp, Suzuki V-Strom (later models), Yamaha XT600/Tenere

Key Features

Features:

Versatile for both on-road commuting and light off-road exploration, robust engine, comfortable ergonomics

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service Repair

Page Count

Estimated Pages:

Approximately 300-400 pages (typical for this era and type of manual)

Manual Type

Type:

Comprehensive Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF), often available as printable

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, disassembly, assembly, tuning, cooling system, lubrication system, ignition system

Fuel System:

Carburetor service, fuel tank, fuel lines, fuel pump (if applicable)

Transmission:

Clutch operation, gearbox disassembly and assembly, shifting mechanism

Chassis:

Frame inspection and repair, suspension (front forks, rear shock absorber), steering system

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake disc maintenance

Electrical System:

Wiring diagrams, lighting system, battery, starter motor, charging system, ignition switch, instruments

Bodywork:

Fairings, body panels, seat, fuel tank mounting, fenders

Wheels And Tires:

Wheel bearing service, tire replacement, spoke tension adjustment (if applicable)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement

Troubleshooting:

Diagnostic charts, common problems and solutions

Repair:

Step-by-step repair instructions for all major components

Disassembly Assembly:

Detailed procedures for component removal and reinstallation

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine and gearbox rebuilds

📊 Manual Specifications

File Format

Digital Format:

PDF (searchable text, high-resolution images)

Print Quality

Print Readability:

Designed for clear printing, ensuring legibility of text and diagrams

Binding Type

Physical Binding:

N/A (Digital Format); if printed, typically coil-bound or saddle-stitched for lay-flat use

Paper Type

Physical Paper:

N/A (Digital Format); if printed, typically glossy or matte paper suitable for technical diagrams

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

498 cc

Bore X Stroke:

74.0 mm x 58.0 mm

Performance

Horsepower:

Approximately 45-50 PS (33-37 kW) @ 8000 rpm (varies slightly by market and year)

Torque:

Approximately 42-45 Nm (31-33 lb-ft) @ 6000 rpm (varies slightly)

Fuel System

Carburetion:

Twin Keihin CVK34 carburetors

Fuel Capacity:

17 Liters (4.5 US gal)

Ignition

Ignition Type:

CDI (Capacitor Discharge Ignition)

Cooling

Cooling System:

Liquid-cooled

🔧 Transmission

Standard

Type:

Constant mesh 6-speed sequential

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Length:

Approximately 2200 mm (86.6 in)

Width:

Approximately 800 mm (31.5 in)

Height:

Approximately 1360 mm (53.5 in)

Wheelbase:

Approximately 1460 mm (57.5 in)

Weights

Dry Weight:

Approximately 175 kg (386 lbs)

Wet Weight:

Approximately 195 kg (430 lbs)

Max Load:

Approximately 200 kg (441 lbs) including rider and luggage

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is primarily based on rider skill and adherence to traffic laws; no formal crash test ratings like cars)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Lighting:

Halogen headlight, LED taillight (in later models), turn signals

Passive Features

Frame Construction:

Steel diamond frame

💡 Technology Features

Infotainment

Infotainment System:

Basic analog instrument cluster: speedometer, tachometer, odometer, trip meter, fuel gauge, engine temperature warning light.

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle)

Connectivity

Connectivity Options:

N/A (Motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000-6,000 km (2,500-3,700 miles) or 6 months, whichever comes first

Chain Adjustment Interval:

Every 1,000-2,000 km (600-1,200 miles) or as needed

Valve Clearance Check:

Every 12,000-16,000 km (7,500-10,000 miles)

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil

Engine Oil Capacity:

Approximately 2.1 Liters (2.2 US qt) with filter change

Coolant Type:

Ethylene glycol-based coolant with anti-corrosion additives (50/50 mix with distilled water)

Brake Fluid Type:

DOT 4

Known Issues

Common Issues:

Carburetor synchronization drift, occasional starter clutch noise, cam chain wear over high mileage, front fork seal leaks.

Electrical Wear:

Wiring harness connectors can corrode over time due to exposure; regulator/rectifier can be a failure point on higher mileage units.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Model Evolution

Introduction Year:

Major Updates:

Minor styling and component updates throughout its production run, with the later models (post-2005) featuring some refinements and possibly updated emission controls.

Production

Production End Year:

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Notable Awards:

While the KLE500 didn't receive specific 'awards' in the automotive sense, it was recognized for its value, reliability, and versatility in the dual-sport segment by motorcycle publications of its era.