🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Year:

2005

Engine Type:

Parallel-twin, four-stroke

Chassis Code:

LE500A

👋 Introduction

Motorcycle Segment:

Adventure Touring / Dual-Sport

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.

Key Competitors:

Honda Transalp, Suzuki V-Strom 650, BMW F650GS (early models).

Versatility:

Combines the practicality of a commuter with the capability for longer journeys and mixed terrain.

Engine Character:

Known for its tractable and reliable parallel-twin engine, offering a good balance of power and economy.

Ergonomics:

Generally comfortable seating position for rider and passenger, suitable for extended periods.

📋 Manual Details

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (PDF)

Page Count:

Approx. 300-400 pages (typical for this model and era)

Coverage Scope:

Comprehensive service and repair information for the 2005 Kawasaki KLE500

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, troubleshooting, lubrication, cooling system, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod checks, camshaft and timing chain inspection, torque specifications.

Fuel System:

Carburetor removal, disassembly, cleaning, adjustment, synchronisation, fuel tank, fuel pump, fuel filter inspection and replacement.

Ignition System:

Ignition coil testing, spark plug specifications, ignition timing checks, CDI unit diagnostics, troubleshooting.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlight, taillight, turn signals), horn, fuses, relays, troubleshooting electrical faults.

Transmission:

Clutch inspection and adjustment, gearbox disassembly, inspection and assembly, gear shift mechanism, lubrication specifications.

Drivetrain:

Chain and sprocket inspection, adjustment, lubrication, rear wheel alignment.

Suspension:

Front fork disassembly, seal replacement, oil level and type, rear shock absorber inspection and adjustment, linkage lubrication.

Brakes:

Front and rear brake caliper inspection, pad replacement, disc inspection, brake fluid type and bleeding procedure, master cylinder inspection, troubleshooting brake system issues.

Wheels And Tires:

Tire pressure recommendations, tire wear inspection, wheel bearing inspection, spoke tension adjustment (if applicable), wheel balancing.

Cooling System:

Radiator inspection, coolant type and capacity, thermostat operation, fan operation (if applicable), troubleshooting leaks.

Exhaust System:

Exhaust pipe and muffler inspection for leaks and damage.

Frame And Bodywork:

Frame inspection for damage, fairing removal and installation, seat removal, body panel adjustments, graphics and decals.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake fluid checks, tire pressure checks, general inspection procedures.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues across all systems.

Disassembly And Assembly:

Step-by-step instructions for major component removal, overhaul, and reinstallation.

Calibration And Adjustment:

Carburetor synchronization, valve clearance adjustment, clutch and brake lever adjustments, suspension adjustments.

Wiring Diagram Interpretation:

Detailed electrical schematics with component identification and wire color codes.

Special Tools:

Lists any special tools or equipment required for specific procedures, such as engine timing tools or specialized wrenches.

Depth Level:

Comprehensive: Covers everything from basic rider maintenance to full engine rebuilds and electrical system diagnostics.

Diagnostic Capabilities:

Detailed troubleshooting guides, fault code explanations (if applicable), and component testing procedures.

Specifications Tables:

Includes comprehensive specification tables for all major components, torque values, clearances, and fluid capacities.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-the-go referencing.

Resolution:

High-resolution images and diagrams for clarity.

Print Quality:

N/A (Digital Format)

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Diagrams Illustrations:

Features detailed exploded diagrams, step-by-step illustrations, and clear schematics essential for repair and maintenance.

⚙️ Engine Specifications

Engine Displacement:

498 cc

Engine Bore X Stroke:

74.0 x 58.0 mm

Engine Compression Ratio:

9.7:1

Engine Cooling:

Liquid-cooled

Engine Valves Per Cylinder:

4

Claimed Horsepower:

Approx. 47 hp (35 kW) @ 8000 rpm (Varies slightly by market)

Claimed Torque:

Approx. 43 Nm (31.7 lb-ft) @ 6000 rpm (Varies slightly by market)

Fuel Delivery:

Twin Keihin CVK32 carburetors

Fuel Tank Capacity:

17 Liters (4.5 US gal)

Ignition System:

Digital CDI

Recommended Oil Type:

API SE, SF, SG, SH, SJ, or later, SAE 10W-40 (Refer to manual for specific viscosity and API classification).

Oil Capacity W Filter:

Approx. 2.6 Liters (2.7 US qt)

Oil Capacity Wo Filter:

Approx. 2.3 Liters (2.4 US qt)

🔧 Transmission

Transmission Type:

Constant mesh, 6-speed sequential

Clutch Type:

Wet, multi-plate

Gear Ratios:

1st: 2.571 (36/14), 2nd: 1.867 (28/15), 3rd: 1.421 (27/19), 4th: 1.159 (26/22), 5th: 0.960 (24/25), 6th: 0.815 (26/32) (Typical, verify in manual)

Recommended Fluid Type:

API GL-4, SAE 80W-90 Gear Oil (Refer to manual for specific brand recommendations and capacities).

📐 Dimensions

Length:

Approx. 2185 mm (86.0 in)

Width:

Approx. 810 mm (31.9 in)

Height:

Approx. 1380 mm (54.3 in)

Wheelbase:

Approx. 1465 mm (57.7 in)

Dry Weight:

Approx. 192 kg (423 lbs)

Curb Weight:

Approx. 209 kg (461 lbs) (With all fluids and ready to ride)

Front Suspension Travel:

Approx. 170 mm (6.7 in)

Rear Suspension Travel:

Approx. 170 mm (6.7 in)

Front Tire:

90/90-21 M/C 54S

Rear Tire:

130/80-17 M/C 65S

Front Wheel:

21 inch

Rear Wheel:

17 inch

🛡️ Safety Features

Safety Features General:

ABS was not a standard or widely available option for this model year. Equipped with robust braking system for its class.

Braking System Front:

Dual piston caliper, 300 mm disc

Braking System Rear:

Single piston caliper, 230 mm disc

Lighting:

Halogen headlight, LED taillight, standard turn signals.

Mirrors:

Adjustable mirrors for rear visibility.

💡 Technology Features

Infotainment System:

N/A (This model predates integrated infotainment systems on motorcycles).

ABS:

Typically not available or an optional, rare fitment on this specific model year. Manual would not cover ABS diagnostics if absent.

🔧 Maintenance

Engine Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first (Refer to manual for exact interval).

Oil Filter Change Interval:

Every 6,000 km (3,700 miles) or at every oil change (Recommended).

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles) or inspect annually.

Spark Plug Check Interval:

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

Valve Clearance Check Interval:

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

Chain Lubrication Interval:

Every 1,000 km (600 miles) or after washing/riding in rain.

Brake Fluid Type:

DOT 4 (Refer to manual for confirmation and specific reservoir recommendations).

Coolant Type:

Permanent type anti-freeze coolant (Mixture of 50% ethylene glycol and 50% distilled water). Refer to manual for specific Kawasaki recommendations.

Common Wear Items:

Clutch wear, swingarm bushings, fork seals, exhaust system corrosion.

Electrical Gremlins:

While generally robust, some owners report occasional issues with charging systems or corroded electrical connectors due to exposure. The manual's wiring diagrams are crucial here.

Carburetor Tuning:

Carburetors can require periodic cleaning and synchronization for optimal performance, especially if the bike has sat unused or been subject to poor fuel quality. This manual details the process extensively.

📚 Vehicle History

Manufacturer Origin:

Kawasaki Heavy Industries Motorcycle & Engine Company, Japan.

First Generation Introduction:

The KLE500 was initially introduced in 1991, based on the KLR650 platform but with a different engine and intended use.

Design Philosophy:

Designed to be a practical, comfortable, and capable all-rounder, bridging the gap between street bikes and true off-roaders.

2005 Model Updates:

The 2005 model represents a later iteration of the first generation, likely with minor refinements in suspension, ergonomics, or styling from earlier versions. Significant redesigns occurred with later generations (e.g., the ER6-based Versys). This manual covers a mature and well-tested platform.

Production Period:

The first generation KLE500 was produced from 1991 to approximately 2006/2007.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2005 KLE500 might be scarce, the model was generally well-regarded for its value, reliability, and versatility in the adventure-touring segment during its production run. It often received positive reviews in motorcycle publications for its practical approach.

Reliability Reputation:

Known for its robust and dependable parallel-twin engine, making it a solid choice for commuting and touring with proper maintenance.