Segment:
Lightweight/Mid-weight Naked Sportbike, Commuter
Target Audience:
New riders, commuters, riders seeking an affordable and reliable motorcycle for everyday use and light sporty riding.
Key Competitors:
Suzuki SV650, Honda CB500, Yamaha FZ6N (in later years), Ducati Monster 600/750.
Strengths:
Reliability, affordability, ease of maintenance, nimble handling, forgiving power delivery, low running costs.
Design Philosophy:
Simple, functional, and robust design focused on user-friendliness and cost-effectiveness.
Engine:
Complete engine overhaul, top-end and bottom-end components, valve timing, lubrication system, cooling system.
Transmission:
Clutch operation, gearbox disassembly and reassembly, gear shift mechanism, lubrication.
Fuel System:
Carburetor adjustment and overhaul (Keihin CVK), fuel tank, fuel pump, fuel lines.
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams.
Electrical System:
Battery, charging system (stator, rectifier/regulator), starter motor, lighting, indicators, horn, wiring diagrams for all circuits.
Suspension:
Front forks (disassembly, oil change, seal replacement), rear shock absorber, swingarm, linkage.
Brakes:
Front and rear brake systems, caliper overhaul, brake pad replacement, brake fluid flush, master cylinder service.
Cooling System:
Radiator, cooling fan, coolant, thermostat, hoses.
Exhaust System:
Muffler, exhaust pipes, mounting.
Frame And Bodywork:
Frame inspection, fairings, seat, handlebars, footrests, fenders.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, lubrication points, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common problems, identifying and rectifying issues with engine, electrical, and chassis components.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Technical Specifications:
Detailed torque values, clearance specifications, fluid capacities, performance data.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams with component identification.
Depth:
Comprehensive: Covers everything from routine maintenance and basic adjustments to full engine and gearbox rebuilds, electrical diagnostics, and component-level repairs.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
10.8:1
Horsepower:
Approx. 50 PS (36.8 kW) @ 9000 rpm (specifications may vary slightly by market)
Torque:
Approx. 42 Nm (31 lb-ft) @ 7500 rpm (specifications may vary slightly by market)
Fuel Delivery:
Carburetor: Keihin CVK34 (dual)
Fuel Tank Capacity:
17 Liters (approx. 4.5 US gallons)
Recommended Fuel:
Unleaded gasoline, octane rating 91 or higher
Oil Type:
SAE 10W-40 API SG or higher (or as specified in manual for specific climates)
Oil Capacity:
Approx. 3.4 Liters (with filter change)
Crash Safety:
N/A (Motorcycle safety ratings differ from automotive; emphasis on rider protection and vehicle stability.)
Braking System:
Front: Disc brake; Rear: Disc brake. ABS was not a standard or common option for this model.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame Construction:
Steel diamond frame for rigidity and stability.
Ergonomics:
Upright riding position for rider comfort and control.
Oil Change Interval:
Every 6,000 km or 6 months, whichever comes first (refer to manual for precise interval).
Air Filter Replacement:
Every 12,000 km or 12 months (or as needed based on operating conditions).
Spark Plug Replacement:
Every 12,000 km (check and clean at 6,000 km).
Valve Clearance Check:
Every 24,000 km.
Brake Fluid Flush:
Every 2 years or as recommended by manufacturer.
Engine Oil Specification:
SAE 10W-40 API SG or higher.
Coolant Type:
Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water.
Fork Oil Type:
Refer to manual for specific viscosity and type (e.g., Showa SS-01 or equivalent).
Common Wear Items:
Clutch wear, fork seals, exhaust pipe corrosion, chain and sprockets.
Carburetor Issues:
Occasional carburetor synchronization issues or clogging if not maintained; requires proper cleaning and adjustment.
Electrical Connections:
Corrosion on electrical connectors, especially in humid climates, can lead to intermittent faults. Regular inspection and protection recommended.
Rear Shock ABSorber:
Over time, the original rear shock absorber can lose its damping effectiveness, requiring replacement or refurbishment.
Kawasaki Motorsports:
Kawasaki Heavy Industries has a long and successful history in motorcycle manufacturing, known for performance and reliability across various segments, including sportbikes, cruisers, and off-road vehicles.
Er5 Development:
The ER5 was developed as a practical, accessible, and economical motorcycle, building on Kawasaki's parallel-twin engine technology. It replaced earlier models like the ER-250 and was designed to be a versatile machine for daily commuting and general motorcycling.
Production Period:
The ER5 was produced from 1997 to 2006. This manual specifically covers the later ER500A variants from 2001-2005.
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other global locations.
