🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Model Code:

KLE500-B1

Year:

2004

Engine Code:

All models covered by this manual are equipped with the 'B' series engine designation.

👋 Introduction

Category:

Dual-Sport / Adventure Touring Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, light off-road use, and touring. Appeals to budget-conscious adventure riders.

Key Competitors:

Honda Transalp (XL600V/XL650V), Suzuki V-Strom 650 (though larger displacement), Yamaha TDM850 (though larger displacement), other mid-displacement dual-sport bikes of the era.

Versatility:

Designed to handle paved roads and unpaved trails, offering a balance of comfort and capability.

Engine Character:

Known for its reliable and torquey parallel-twin engine, providing usable power across a wide rev range.

Value Proposition:

Offers a compelling blend of performance and practicality at a competitive price point.

📋 Manual Details

Primary Coverage:

Full Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Component Overhaul, Electrical Schematics

Estimated Pages:

350-450

Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Digital (likely PDF), potentially printable.

📖 Manual Coverage

Engine:

Complete disassembly, inspection, and reassembly of the 498cc parallel-twin engine, including cylinder head, pistons, crankshaft, camshafts, valves, timing system, lubrication system, and cooling system.

Fuel System:

Carburetor(s) (likely Keihin CVK type) tuning, cleaning, rebuilding, fuel pump, fuel lines, and fuel tank maintenance.

Ignition System:

Ignition coil testing, spark plug specifications, timing adjustment procedures, CDI unit troubleshooting.

Exhaust System:

Removal and installation of exhaust headers, mufflers, and associated components.

Transmission:

Clutch operation and adjustment, gearbox disassembly and reassembly, gear inspection, shifting mechanism.

Chassis And Frame:

Frame inspection, steering head bearing service, fork disassembly and assembly, rear shock absorber and linkage maintenance, swingarm service.

Wheels And Tires:

Wheel bearing service, spoke tensioning (if applicable), tire replacement, wheel balancing.

Brakes:

Front and rear brake system service, including hydraulic system bleeding, caliper overhaul, master cylinder maintenance, brake pad replacement, and rotor inspection.

Electrical System:

Complete wiring diagrams, component testing (alternator, starter motor, battery), lighting system, switches, fuses, relays, and instrument panel.

Bodywork And Trim:

Fairing removal and installation, seat maintenance, body panel alignment, and accessory fitting.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, brake fluid replacement, coolant checks.

Troubleshooting:

Step-by-step diagnostic procedures for common performance issues, starting problems, electrical faults, and braking system anomalies.

Engine Rebuild:

Detailed instructions for complete engine disassembly, component measurement, wear checks, and reassembly with torque specifications.

Suspension Service:

Fork seal replacement, oil level and type specifications for front forks, rear shock absorber adjustments and potential rebuilding procedures.

Electrical Diagnostics:

Using a multimeter to test electrical components, continuity checks, voltage drop tests, and identifying wiring harness issues.

Brake System Overhaul:

Complete guide to caliper rebuilding, master cylinder replacement, and hydraulic line flushing.

Carburetor Tuning:

Idle speed adjustment, mixture screw settings, and synchronisation procedures.

Depth:

Comprehensive. Covers everything from basic owner maintenance to full engine and transmission rebuilds, including detailed electrical troubleshooting.

Diagnostic Charts:

Includes detailed diagnostic flowcharts for pinpointing problems.

Special Tools:

Lists required special tools and their usage.

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Likely text-searchable, allowing for quick location of specific information.

Digital Quality:

High-resolution scans or original factory digital files ensuring clarity of text and diagrams.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, parallel-twin

Displacement:

498 cc (30.4 cu in)

Bore X Stroke:

74.0 x 58.0 mm (2.91 x 2.28 in)

Valve Train:

DOHC, 8 valves (4 valves per cylinder)

Horsepower:

Approx. 45-50 HP @ 8,000 RPM (Varies slightly by market and tune)

Torque:

Approx. 43-46 Nm (31.7-33.9 lb-ft) @ 6,000 RPM

Fuel Delivery:

Dual Keihin CVK34 carburetors

Fuel Capacity:

15 Liters (3.96 US gal)

Oil Type Recommendation:

API SG, SF or SH; SAE 10W-40 or 20W-50

Coolant Type:

Ethylene glycol based antifreeze solution (50% mixture with distilled water)

🔧 Transmission

Transmission Type:

Constant-mesh 6-speed return

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Length:

Approx. 2,180 mm (85.8 in)

Width:

Approx. 810 mm (31.9 in)

Height:

Approx. 1,380 mm (54.3 in) (at windshield)

Wheelbase:

Approx. 1,455 mm (57.3 in)

Ground Clearance:

Approx. 195 mm (7.7 in)

Seat Height:

Approx. 830 mm (32.7 in)

Dry Weight:

Approx. 180 kg (397 lbs)

Curb Weight:

Approx. 190 kg (419 lbs) (with fluids)

Front Tire Size:

90/90-21 54S

Rear Tire Size:

130/80-17 65S

Wheel Bolt Pattern:

N/A (Spoked wheels with axle nuts)

🛡️ Safety Features

Safety Features:

Standard motorcycle safety features, including reliable braking and lighting. No electronic rider aids beyond standard ABS on some later/different models, but not typical for this specific 2004 B1 variant.

Active Safety:

Responsive braking system, stable chassis geometry.

Passive Safety:

Sturdy frame construction, protective fairing and windscreen.

💡 Technology Features

Infotainment System:

Basic analog instrumentation including speedometer, tachometer, odometer, trip meter, and indicator lights. No infotainment system.

Rider Assistance Features:

None (This model predates widespread electronic rider aids on motorcycles).

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Inspection:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Chain Lubrication:

Every 1,000 km (600 miles) or after riding in wet conditions.

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Brake Fluid Replacement:

Every 2 years.

Engine Oil Capacity:

Approx. 2.6 Liters (2.7 US qt) (without filter change), 2.8 Liters (3.0 US qt) (with filter change).

Brake Fluid Type:

DOT 4

Coolant Capacity:

Approx. 1.6 Liters (1.7 US qt)

Common Wear Items:

Clutch wear, fork seal leaks, regulator/rectifier failures (common on many Kawasakis of this era), chain and sprockets wear.

Carburetor Performance:

Can sometimes suffer from gumming if not used regularly or properly stored. Tuning might be required over time.

Electrical Charging System:

Early models sometimes had issues with the charging system's regulator/rectifier, leading to battery drain or overcharging.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki, a Japanese manufacturer, has a long-standing reputation for producing reliable and performance-oriented motorcycles across various categories, including sportbikes, cruisers, and dual-sport models.

Kle500 Lineage:

The KLE500 series was introduced in the early 1990s as a mid-weight dual-purpose motorcycle, evolving from earlier Kawasaki dual-sport models. The 'B' series represents a refinement and updating of the original concept, with the 2004 model being part of this generation's lifecycle.

Production Years:

The KLE500 was produced roughly from 1991 to 2007, with various 'A' and 'B' series updates.

Manufacturing Location:

Primarily manufactured in Japan by Kawasaki Heavy Industries.

🏆 Awards & Recognition

Industry Awards:

Specific awards for the 2004 KLE500 are not widely documented, but the model was generally well-regarded for its value and versatility in the dual-sport market.

User Reviews:

Often praised for its reliability and suitability for adventure touring on a budget.

Emissions Compliance:

Compliant with relevant emissions standards for its production year (specific regional standards apply).