Positioning:
The Kawasaki KLE500 is a versatile dual-sport motorcycle, often categorized as an adventure-touring or all-road bike, offering a balance of on-road comfort and off-road capability. It appeals to riders seeking a practical and rugged machine for commuting, touring, and light off-pavement exploration.
Competitors:
Competed against models like the Honda Transalp, Suzuki V-Strom 650, and Yamaha TDM series, though the KLE500 offered a more utilitarian and less performance-oriented approach compared to some rivals.
Features:
Durable parallel-twin engine, comfortable ergonomics for touring, capable suspension for mixed terrain, relatively simple and reliable mechanicals.
Engine:
Detailed disassembly, assembly, inspection, and repair procedures for the 498cc liquid-cooled parallel-twin engine, including top end, bottom end, cooling system, lubrication system.
Fuel System:
Carburetor system, fuel pump, fuel tank, fuel lines, inspection and adjustment of Keihin carburetors.
Ignition System:
CDI ignition system, spark plugs, ignition coils, troubleshooting ignition faults.
Transmission:
6-speed constant mesh gearbox, clutch operation and adjustment, transmission disassembly, inspection, and reassembly.
Drivetrain:
Chain drive system, sprockets, chain inspection and replacement, rear suspension alignment.
Brakes:
Hydraulic front and rear disc brakes, brake caliper maintenance, master cylinder overhaul, brake pad replacement, bleeding procedures, brake fluid specifications.
Suspension:
Front telescopic forks (fork oil type, level, seal replacement), rear monoshock suspension, shock absorber adjustment and overhaul, linkage maintenance.
Steering:
Handlebar replacement, steering stem bearing inspection and adjustment, troubleshooting steering play.
Electrical System:
12V electrical system, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams, troubleshooting electrical circuits.
Frame And Bodywork:
Chassis inspection, frame straightening information, body panel removal and installation, seat, fuel tank, fairings, fenders.
Wheels And Tires:
Wheel bearing maintenance, tire inspection and replacement, recommended tire pressures, wheel balancing.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug service, chain lubrication and adjustment, brake system inspection, fluid level checks.
Troubleshooting:
Systematic diagnostic procedures for common problems, fault finding charts for engine, electrical, and mechanical issues.
Repair:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.
Specifications:
Torque specifications for all fasteners, critical component clearances, fluid capacities, electrical tolerances.
Wiring Diagrams:
Detailed color-coded wiring diagrams for comprehensive electrical system diagnosis and repair.
Depth:
Comprehensive; covers routine maintenance to complete engine and transmission rebuilds, electrical diagnostics, and chassis component repair.
Format Details:
High-resolution PDF with searchable text, allowing easy navigation and printing. Optimized for digital viewing.
Quality:
Professional grade, designed for clarity of diagrams, text, and images. For printed versions: durable paper stock, clear printing.
Binding:
N/A for PDF. For printed: typically spiral-bound or comb-bound for lay-flat usability in a workshop environment.
Paper:
N/A for PDF. For printed: high-quality, durable paper to withstand workshop conditions.
Engine Type:
4-stroke, liquid-cooled, DOHC, parallel-twin
Displacement:
498 cc (30.4 cu. in.)
Bore X Stroke:
74.0 x 58.0 mm
Valve Train:
DOHC, 8 valves (4 per cylinder)
Horsepower:
Approx. 48 HP @ 8,000 RPM (varies slightly by market)
Torque:
Approx. 45 Nm (33.2 lb-ft) @ 6,000 RPM (varies slightly by market)
Fuel Delivery:
Two Keihin CVK32 constant velocity carburetors
Fuel Tank Capacity:
15 Liters (3.96 US gal)
Oil Capacity:
3.2 Liters (3.4 US qt) with filter change
Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or 6 months; replacement as needed.
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in rain.
Chain Adjustment:
Check slack every 6,000 km (3,700 miles) or 6 months.
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Coolant:
50/50 mixture of ethylene glycol based antifreeze and distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Kawasaki KHL15-10 (or equivalent SAE 10W fork oil).
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, steering head bearings due to mileage and usage.
Electrical Gremlins:
Occasional issues with regulator/rectifier failure or wiring harness degradation over time if exposed to harsh conditions.
Carburetor Tuning:
Carburetors may require periodic synchronization and cleaning to maintain smooth running, especially after extended storage.
Heritage:
Kawasaki Heavy Industries has a long history of producing motorcycles, known for their robust engineering and performance across various segments, from sportbikes to cruisers and dual-sports.
Kle500 Development:
The KLE500 was introduced in the early 1990s as a budget-friendly, versatile dual-sport motorcycle. It evolved through several iterations, with the 'B' series, including the 2005 model, featuring updates and refinements to its styling and components, drawing inspiration from Kawasaki's larger adventure bikes.
Production Period:
The KLE500 was produced from 1991 until 2007, making the 2005 model a representative of the later iterations of this platform.
