Positioning:
The Kawasaki KLE500 is an adventure touring motorcycle known for its versatility, capable of handling both on-road and light off-road conditions. It appeals to riders seeking an accessible and practical dual-purpose machine.
Competitors:
Competes with other mid-displacement adventure bikes of its era, such as the Suzuki DR650, Honda Transalp series, and BMW F650GS.
Features:
Parallel-twin engine, comfortable ergonomics for long-distance riding, durable construction, capable suspension for varied terrain.
Coverage:
Comprehensive service, repair, troubleshooting, and maintenance for the 2005 Kawasaki KLE500-B1.
Pages:
Refer to product details for exact page count, typically 300-500 pages for this type of manual.
Type:
Factory Authorized Service Repair Manual
Engine:
Full engine disassembly, inspection, assembly, tuning, fuel injection system, ignition system, cooling system, lubrication system.
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, shift mechanism.
Drivetrain:
Final drive, chain and sprockets inspection and replacement, wheel bearings.
Chassis:
Frame inspection, suspension system (front forks, rear shock absorber), steering system, wheel assembly.
Brakes:
Front and rear brake systems, hydraulic components, caliper service, disc inspection, brake fluid specifications.
Electrical:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system, lighting system, ignition coils, sensors, fault codes.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, instrumentation.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, chain maintenance, brake system checks, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics.
Repair:
Step-by-step repair instructions for all major components, engine rebuilds, suspension overhaul, electrical system repairs.
Specifications:
Detailed technical specifications for all components, torque values, clearances, fluid capacities, electrical values.
Depth:
Comprehensive from basic user maintenance to full engine and electrical system overhauls, suitable for professional mechanics and experienced DIY enthusiasts.
Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Horsepower:
Approx. 49 HP @ 8,500 RPM (Varies by market and specific configuration)
Torque:
Approx. 43 Nm @ 5,500 RPM (Varies by market and specific configuration)
Carburetion:
Twin Keihin CVK34 carburetors
Fuel Tank Capacity:
15 Liters (3.96 US gal)
Oil Type:
SAE 10W-40 API SG or higher (Check manual for specific classification and viscosity)
Oil Capacity:
Approx. 2.6 Liters (with filter change)
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water (Refer to manual for specific Kawasaki coolant specification)
Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,450 miles) or as needed based on inspection.
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in the rain.
Brake Fluid:
DOT 4 (Refer to manual for exact specification and replacement interval)
Coolant:
Kawasaki Coolant (KAC) or equivalent, 50/50 mix with distilled water.
Common Problems:
Cam chain noise (can be normal or indicate wear), clutch wear, potential for electrical connector issues, carburetor synchronization.
Oil Filter:
Kawasaki 16097-0004 (Equivalent aftermarket filters available from HiFloFiltro HF123, K&N KN-123, etc.)
Air Filter:
Kawasaki 11013-1235 (Equivalent aftermarket filters available from HiFloFiltro HFA2606, K&N KA-5002, etc.)
