🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Code:

LE500

Years Covered:

2004, 2005

Engine Code:

LE500AE

👋 Introduction

Segment:

Adventure Touring/Dual-Sport Motorcycle.

Target Audience:

Riders seeking a versatile motorcycle capable of both on-road commuting and light off-road exploration, with an emphasis on practicality and reliability.

Competitors:

Competed against models like the Honda Transalp, Suzuki V-Strom (early generations), and Yamaha TDM in its class.

Engine Configuration:

Parallel-twin engine known for its tractable power delivery and reliability.

Ergonomics:

Comfortable, upright riding position suitable for long distances.

Versatility:

Balanced performance for commuting, touring, and light adventure riding.

📋 Manual Details

Overall Scope:

Comprehensive service, repair, and maintenance for the Kawasaki KLE500 (2004-2005 models).

Total Pages:

Approximately 300-400 pages (estimated for a typical workshop manual of this scope).

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Engine overhaul, top-end, bottom-end, cylinder head, pistons, crankshaft, camshafts, valve timing, lubrication system, cooling system.

Fuel System:

Carburetor assembly, fuel pump, fuel lines, fuel tank, fuel filter replacement, carburetor synchronization and adjustment.

Ignition System:

Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams for ignition system.

Transmission:

Clutch operation, gearbox overhaul, gear shift mechanism, transmission lubrication, clutch lever adjustment.

Suspension:

Front fork service, rear shock absorber replacement, swingarm inspection and lubrication, suspension adjustments.

Brakes:

Front and rear brake system diagnosis, brake pad replacement, brake fluid flushing and bleeding, caliper service, brake hose replacement.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, starter motor, alternator, electrical component testing, fuse box layout.

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearing replacement, spoke tensioning, rim inspection.

Bodywork And Trim:

Fairing removal and installation, seat maintenance, panel replacement, decal application.

Maintenance:

Routine inspections, oil changes, filter replacements, chain adjustment and lubrication, brake checks, tire pressure checks, bolt torque checks.

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides, electrical fault finding.

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly across all major systems.

Adjustments:

Carburetor idle speed and mixture adjustment, clutch lever free play, throttle cable free play, chain slack.

Special Tools:

Identification and usage of specialized tools required for specific maintenance and repair tasks.

Depth:

Detailed, professional level coverage suitable for certified technicians and experienced home mechanics, including full engine rebuilds and complex electrical diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text content for quick access to information.

Printability:

Printable pages, allowing for physical reference.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Type:

Four-stroke, liquid-cooled, DOHC, parallel-twin.

Displacement:

498 cc (30.4 cubic inches).

Bore X Stroke:

74.0 mm x 58.0 mm (2.91 in x 2.28 in).

Compression Ratio:

9.7:1.

Valve Train:

DOHC, 8 valves (4 per cylinder).

Cooling System:

Liquid-cooled with fan assist.

Horsepower Est:

Approximately 47 hp @ 8,000 rpm (specifications may vary slightly by region).

Torque Est:

Approximately 44 Nm (32.5 lb-ft) @ 6,000 rpm (specifications may vary slightly by region).

Carburetors:

Twin Keihin CVK34 carburetors.

Fuel Capacity:

18 liters (4.75 US gal).

Type:

Wet sump.

Oil Capacity W Filter:

2.2 liters (2.3 US qt) when filter is changed.

Ignition Type:

Electronic ignition (CDI).

Spark Plugs:

NGK CR9E or DENSO U27ESR-N (refer to manual for specific gap settings).

🔧 Transmission

Type:

Constant mesh, 6-speed sequential.

Gear Ratios:

Refer to manual for specific gear ratios (typically: 1st: 2.43, 2nd: 1.71, 3rd: 1.31, 4th: 1.08, 5th: 0.91, 6th: 0.77).

Clutch Type:

Wet, multiple-disc.

Final Drive:

Chain drive.

Clutch Operation:

Cable-actuated clutch.

Transmission Oil Capacity:

Refer to manual (typically around 1.2 liters of API SG 10W-40 motorcycle oil).

📐 Dimensions

Length:

2,220 mm (87.4 in).

Width:

815 mm (32.1 in).

Height:

1,450 mm (57.1 in) at screen.

Wheelbase:

1,465 mm (57.7 in).

Ground Clearance:

205 mm (8.1 in).

Dry Weight:

Approx. 188 kg (414.5 lbs).

Curb Weight:

Approx. 205 kg (452 lbs) (fully fueled).

Max Load:

Refer to manual (typically for rider and passenger).

Gvwr:

Refer to manual.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS).

Braking System:

Disc brakes front and rear for effective stopping power.

Suspension Stability:

Dual-purpose suspension designed to handle various road surfaces.

Lighting:

Halogen headlamp for improved visibility.

Tire Selection:

Tubeless tires for reduced risk of sudden deflation.

💡 Technology Features

System:

Basic analog instrumentation cluster including speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment systems are present on this model.

Features:

No electronic rider aids such as ABS, traction control, or ride modes are standard on this model.

Features:

No integrated connectivity features (e.g., Bluetooth, smartphone integration).

🔧 Maintenance

First Service:

1,000 km (600 miles) - includes oil change, filter check, chain adjustment, general inspection.

Subsequent Service:

Every 6,000 km (3,750 miles) or annually, whichever comes first - includes oil & filter change, spark plug inspection/replacement, air filter cleaning/replacement, valve clearance check, brake fluid flush, coolant check, chassis lubrication.

Chain Maintenance:

Check and lubricate chain every 1,000 km (600 miles).

Engine Oil:

API SG or higher, SAE 10W-40 motorcycle specific oil.

Coolant:

Ethylene glycol-based permanent antifreeze, mixed with distilled water in a 50:50 ratio.

Brake Fluid:

DOT 4.

Fork Oil:

SAE 10W or equivalent (specific volume per fork leg detailed in manual).

Transmission Oil:

API GL-1 or GL-4 SAE 80W-90 gear oil (check manual for confirmation as some models may use engine oil for shared lubrication).

Carburetor Tuning:

Carburetors can sometimes require periodic cleaning and synchronization, especially after prolonged storage or with fuel quality variations.

Charging System:

The charging system (stator/regulator-rectifier) can be a potential failure point on some older Kawasaki models, requiring careful diagnosis.

Suspension Seals:

Front fork seals can wear over time, leading to oil leaks and requiring replacement. The manual provides instructions for this procedure.

Chain And Sprockets:

Regular maintenance of the chain and sprockets is crucial to prevent premature wear and ensure smooth operation. The manual details proper adjustment and lubrication.

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company, a globally recognized manufacturer with a long history of producing reliable and performance-oriented motorcycles.

Initial Release:

The KLE500 model was first introduced in the early 1990s as a middleweight dual-purpose motorcycle, evolving over its production run.

Updates For 2004-2005:

The 2004-2005 models represent a later iteration, potentially featuring minor styling updates, suspension refinements, or emissions control improvements over earlier versions. Detailed changes would be documented in the original service bulletins and the manual itself.

Manufacturing Location:

Typically manufactured in Japan.

Production Years:

The KLE500 was produced from the early 1990s until around 2007, making the 2004-2005 models part of its mature production lifecycle.

🏆 Awards & Recognition

Industry Acclaim:

The KLE500 was generally well-received for its blend of utility, comfort, and value in the dual-sport segment. Specific awards are not prominently documented for this particular model year.

Reliability Ratings:

Often cited for its robust and reliable parallel-twin engine, characteristic of Kawasaki's reputation.

Emissions Compliance:

Compliant with applicable emissions standards for the model years 2004-2005 in its primary markets.