Segment:
Versatile dual-sport motorcycle, appealing to riders seeking adventure and commuter capabilities.
Competitors:
Competes with models like the Honda Transalp, Suzuki V-Strom 650 (though the KLE500 is generally simpler and less touring-focused).
Design Philosophy:
Blends on-road comfort with light off-road capability, emphasizing reliability and accessible performance.
Target Audience:
Commuters, touring riders, adventure enthusiasts looking for a capable and affordable dual-sport.
Engine System:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, starting system, charging system.
Fuel System:
Carburetor system (including jetting, float levels, idle speed), fuel pump, fuel lines, fuel tank.
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams.
Transmission System:
Clutch operation and adjustment, gearbox inspection and repair, gear shifting mechanism.
Chassis System:
Frame, front fork (suspension, damping), rear shock absorber, swingarm, steering system.
Braking System:
Front and rear brake mechanisms, hydraulic system, brake fluid specifications, pad replacement, caliper service.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, fuses, relays, instrument panel, starter motor, alternator.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Cooling System:
Radiator, coolant, thermostat, fan operation.
Scheduled Maintenance:
Detailed schedules for oil changes, filter replacements, chain adjustment, spark plug checks, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting charts.
Engine Rebuild:
Complete engine disassembly, component inspection, measurement, and reassembly procedures.
Suspension Overhaul:
Front fork seal replacement, rear shock absorber service procedures.
Brake Servicing:
Brake caliper rebuild, master cylinder service, bleeding procedures.
Electrical Diagnostics:
Fault finding for electrical circuits, component testing, wiring repair.
Carburetor Tuning:
Synchronization, idle speed adjustment, jet replacement, float adjustment.
Depth:
In-depth technical repair and maintenance, suitable for professional technicians and experienced DIY mechanics.
Type:
Liquid-cooled, four-stroke, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Valve Train:
DOHC, 8 valves (4 per cylinder)
Horsepower Est:
45 hp (approx. at 7500 rpm)
Torque Est:
46 Nm (approx. at 5500 rpm)
Carburetors:
Two Keihin CVK34 carburetors
Fuel Capacity:
18 Liters (4.8 US gal)
Oil Type:
SAE 10W-40, API SG or higher motorcycle oil
Coolant Type:
Ethylene glycol based coolant with distilled water (50/50 mix)
Safety Certifications:
Meets relevant national and international motorcycle safety standards.
Braking System:
Dual disc front brakes, single disc rear brake. ABS was not commonly available on this model.
Suspension:
Long-travel front forks and rear monoshock for handling varied terrain.
Lighting:
Halogen headlight, taillight, turn signals.
Ergonomics:
Upright riding position for comfort and control.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first.
Chain Lubrication Inspection:
Every 1,000 km (600 miles) or after riding in rain/off-road.
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Spark Plug Replacement:
Recommended every 12,000 km (7,500 miles)
Engine Oil Capacity W Filter:
2.6 Liters (2.7 US qt)
Engine Oil Capacity Wo Filter:
2.4 Liters (2.5 US qt)
Coolant Capacity:
1.3 Liters (1.4 US qt)
Common Wear Items:
Chain and sprockets, brake pads, fork seals, clutch plates (depending on usage).
Engine Quirks:
Carburetors can require synchronization and cleaning for optimal performance; potential for cam chain noise if not maintained.
Electrical Considerations:
Check wiring harness connections, especially around the headstock and under the seat, for corrosion or damage.
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.
Kle500 Development:
The KLE500 line, introduced in the early 1990s, aimed to bridge the gap between street bikes and off-roaders, evolving with styling and minor mechanical updates over its production run.
2005 Updates:
The B1 model generally reflects the later iterations of the KLE500, often featuring revised bodywork and improved suspension components compared to earlier models.
Production Period:
Approximately 1991-2007
Manufacturing Location:
Japan (primarily)
