Market Position:
The Kawasaki KLE500 is positioned as a versatile dual-sport motorcycle, blending on-road comfort with off-road capability, appealing to riders seeking adventure touring and commuting practicality.
Competitive Analysis:
Competed against other mid-displacement dual-sport motorcycles from manufacturers like Honda (e.g., Transalp), Suzuki (e.g., DR650), and Yamaha (e.g., XT660).
Key Features:
Robust parallel-twin engine, comfortable ergonomics, durable construction, spoked wheels for off-road use, capable suspension.
Engine Systems:
Engine overhaul, lubrication system, cooling system, fuel system, ignition system, starting system, exhaust system, emissions control.
Drivetrain Systems:
Clutch, transmission, gearbox, final drive (chain and sprockets).
Chassis Systems:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires, brakes (front and rear), braking system hydraulics.
Electrical Systems:
Battery, charging system (alternator, regulator/rectifier), ignition system, lighting system, instrumentation, wiring diagrams, switches, sensors.
Bodywork And Trim:
Fairings, body panels, seat, fuel tank, luggage systems (if applicable), trim pieces.
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacements, spark plug service, chain adjustment, brake fluid replacement, coolant flush, tire pressure checks.
Troubleshooting Guides:
Diagnostic procedures for common and uncommon issues, fault finding for electrical and mechanical problems.
Repair Procedures:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly of all major motorcycle systems.
Technical Specifications:
Detailed torque specifications, clearances, fluid capacities, electrical values, engine timing, and dimensional data.
Depth Of Coverage:
In-depth coverage suitable for both professional technicians and experienced DIY enthusiasts, including complete engine rebuilds and complex electrical diagnostics.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Displacement:
498 cc (30.4 cu in)
Bore X Stroke:
74.0 mm x 58.0 mm (2.91 in x 2.28 in)
Horsepower:
Approximately 48-50 HP at 8,500 RPM (manufacturer specific, may vary by market and tune)
Torque:
Approximately 43 Nm (31.7 lb-ft) at 6,000 RPM (manufacturer specific, may vary by market and tune)
Fuel Delivery:
Carburetor (e.g., Keihin CVK34 or similar twin carburetors)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
Approximately 17 liters (4.5 US gallons)
Length:
Approximately 2,170 mm (85.4 in)
Width:
Approximately 840 mm (33.1 in)
Height:
Approximately 1,320 mm (52.0 in)
Wheelbase:
Approximately 1,455 mm (57.3 in)
Dry Weight:
Approximately 185 kg (408 lbs)
Curb Weight:
Approximately 198 kg (436.5 lbs) (fully fueled)
Weight Distribution:
Typically 48% front / 52% rear (rider dependent)
Safety Ratings:
Motorcycle safety is primarily assessed through rider skill and adherence to traffic laws; no formal crash test ratings like automobiles.
Braking System:
Dual hydraulic disc brakes front, single hydraulic disc brake rear. Stainless steel braided lines may be a desirable aftermarket upgrade.
Suspension Features:
Adjustable front forks (pre-load) and adjustable rear shock absorber (preload, rebound damping) for optimal handling and stability.
Lighting:
Halogen headlamp, LED taillight, turn signals for visibility.
Tires:
Spoked wheels with dual-purpose tires suitable for both on-road and light off-road use. Common sizes: Front 90/90-21, Rear 130/80-17.
Infotainment System:
Basic instrumentation including speedometer, odometer, trip meter, tachometer, and warning lights. No advanced infotainment systems.
Driver Assistance Features:
No electronic rider aids such as ABS or traction control typically offered on this model. Rider assistance relies on rider skill and proper maintenance.
Connectivity Features:
No integrated connectivity features like Bluetooth or USB ports.
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,750 miles) or annually, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning Or Replacement:
Every 8,000-12,000 km (5,000-7,500 miles), depending on riding conditions.
Spark Plug Service:
Every 12,000-16,000 km (7,500-10,000 miles).
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles) or as needed based on slack.
Coolant Replacement:
Every 2 years or 24,000 km (15,000 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified (e.g., Motul 5100 10W-40)
Engine Oil Capacity:
Approximately 2.3 liters (2.4 US qt) without filter change, 2.5 liters (2.6 US qt) with filter change.
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water (e.g., Prestone, Engine Ice).
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for specific recommendation)
Fork Oil Type:
SAE 10W or 15W (refer to manual for specific grade and quantity)
Known Issues:
Potential for carburetor synchronization issues, premature wear on the starter clutch, and occasional stator failures. The rear suspension linkage may benefit from regreasing. Some owners report the exhaust headers can discolour due to heat.
Brand Heritage:
Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various categories, including sportbikes, cruisers, and dual-sport models.
Model Evolution:
The KLE500 was introduced in the early 1990s as a successor to models like the KLR650 in some markets, evolving through various updates to its engine, suspension, and styling until its discontinuation in 2007.
Production Years:
1991-2007
Manufacturing Location:
Primarily manufactured in Japan.
