Market Position:
The KLE500 was positioned as an accessible and versatile dual-sport motorcycle, blending on-road comfort with light off-road capability. It catered to riders seeking a practical and economical option for commuting, touring, and recreational riding.
Competitive Analysis:
Competed with other mid-range dual-sport motorcycles from manufacturers like Honda (Transalp), Suzuki (DL V-Strom series, DR650), and Yamaha (XT600/660).
Key Features:
Reliable parallel-twin engine, comfortable ergonomics for long-distance riding, capable of handling varied terrain, robust construction, relatively simple maintenance.
Coverage Areas:
Complete service, repair, and maintenance for the Kawasaki KLE500 motorcycle.
Page Count:
Approx. 300-400 pages (typical for a comprehensive service manual of this era).
Manual Type:
Factory Service Manual / Workshop Manual
Format:
Digital (PDF), often also available in print.
Systems Covered:
Engine, Drivetrain, Chassis, Electrical System, Fuel System, Cooling System, Lubrication System, Suspension, Brakes, Wheels and Tires, Bodywork, Troubleshooting, Specifications.
Procedures Included:
Engine removal/installation, top-end overhaul (cylinder head, valves, piston), bottom-end overhaul (crankshaft, connecting rods), carburetor service and synchronization, clutch service, transmission inspection and repair, chain drive maintenance, suspension fork service, shock absorber service, brake caliper and master cylinder overhaul, electrical diagnostics and component testing, wiring harness tracing, periodic maintenance (oil changes, filter replacement, spark plug service, air filter cleaning/replacement, valve clearance adjustment), chassis component inspection and replacement.
Technical Depth:
Comprehensive, covering from routine maintenance and adjustments to in-depth engine rebuilds and electrical system diagnostics. Includes torque specifications, clearance measurements, and detailed component diagrams.
File Format:
Searchable PDF, often optimized for digital viewing and printing. May include bookmark navigation.
Print Quality:
High-resolution scans ensuring clarity of diagrams, schematics, and text. Often replicates original factory manual quality.
Binding Type:
N/A for digital; for print versions, typically spiral-bound or perfect-bound for durability and lay-flat usability in a workshop environment.
Paper Type:
N/A for digital; for print versions, usually durable, gloss or semi-gloss paper stock to withstand workshop conditions.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin.
Displacement:
498 cc (498cc).
Bore X Stroke:
74.0 x 58.0 mm.
Compression Ratio:
9.8:1.
Valve Configuration:
DOHC, 4 valves per cylinder.
Horsepower:
Approx. 45-50 HP (varies slightly by year/market).
Torque:
Approx. 43-45 Nm (varies slightly by year/market).
Fuel System Type:
Carburetor (typically Keihin CVK34 twin carbs).
Fuel Tank Capacity:
17 Liters (approx. 4.5 US gallons).
Lubrication Type:
Forced lubrication, wet sump.
Cooling Type:
Liquid-cooled.
Ignition Type:
Electronic ignition (CDI).
Length:
Approx. 2,215 mm (87.2 in).
Width:
Approx. 845 mm (33.3 in).
Height:
Approx. 1,400 mm (55.1 in).
Wheelbase:
Approx. 1,460 mm (57.5 in).
Ground Clearance:
Approx. 180 mm (7.1 in).
Dry Weight:
Approx. 181 kg (399 lbs).
Wet Weight:
Approx. 203 kg (447 lbs).
Front Tire Size:
90/90-21 54S.
Rear Tire Size:
130/80-17 65S.
Wheel Type:
Spoked wheels with tubed tires.
Infotainment System:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, coolant temperature gauge, and indicator lights. No integrated infotainment systems like modern motorcycles.
Driver Assistance Features:
No electronic rider aids (e.g., ABS, traction control) were standard or commonly available on the KLE500.
Connectivity Features:
No connectivity features.
Service Intervals Oil Change:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Service Intervals Filter Replacement:
Oil filter replacement with every oil change. Air filter cleaning/replacement at recommended intervals (e.g., 12,000 km).
Service Intervals Valve Clearance:
Every 12,000 km (7,500 miles) or 12 months.
Service Intervals Spark Plugs:
Check/clean at 8,000 km (5,000 miles), replace as needed. Replacement recommended every 24,000 km (15,000 miles).
Service Intervals Chain Adjustment:
Check and adjust chain slack every 2,000 km (1,250 miles).
Engine Oil Type:
API SG, SF, SE or similar, SAE 10W-40 or 20W-50 (depending on climate). Consult manual for precise recommendation.
Engine Oil Capacity:
2.6 Liters (2.7 US qt) without filter change, 2.9 Liters (3.1 US qt) with filter change.
Coolant Type:
Ethylene glycol based antifreeze and water mixture (50/50 ratio).
Coolant Capacity:
Approx. 1.8 Liters (1.9 US qt).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
KLE type SS-01 or SAE 10W fork oil.
Fork Oil Quantity:
Approx. 430 ml per fork leg.
Known Issues:
Carburetor synchronization can drift over time, requiring periodic adjustment. Potential for stator failure in some models. Rear shock absorber may lose damping capability with age and mileage. Cam chain noise can develop if not properly maintained. Check for fuel line leaks, especially on older models.
Brand Heritage:
Kawasaki has a long and storied history in motorcycle manufacturing, known for its powerful engines, innovative designs, and performance-oriented machines across various categories, including sportbikes, cruisers, and off-road motorcycles.
Model Evolution:
The KLE500 debuted in 1991, sharing its engine and many components with the Kawasaki EN500 Vulcan cruiser. It was designed to fill the gap for an affordable, versatile adventure bike. Over its production run, it received minor updates, primarily in styling and color schemes, but its core engineering remained consistent. Production ceased around 2007.
Production Years:
1991 - 2007 (approximate).
Manufacturing Locations:
Primarily manufactured in Japan.
