Segment:
Light-to-midweight adventure touring motorcycle, also known as a 'dual-sport' or 'all-rounder'.
Target Audience:
Riders seeking a versatile machine for commuting, touring, and light off-road excursions.
Competitors:
Honda Transalp (XL600V/XL650V), Suzuki V-Strom (DL650), Yamaha XT660R/X, BMW F650GS.
Engine Layout:
Parallel-twin, liquid-cooled, 4-stroke
Suspension:
Long-travel telescopic front forks and adjustable rear monoshock
Wheel Configuration:
Spoked wheels with larger front rim (e.g., 19-inch or 21-inch) for off-road capability
Wind Protection:
Integrated fairing and windscreen for improved rider comfort on longer journeys.
Engine:
Complete overhaul, disassembly, reassembly, troubleshooting, performance tuning
Fuel System:
Carburetor identification, cleaning, adjustment, jetting, fuel pump, fuel tank, fuel lines
Ignition System:
CDI unit, ignition coils, spark plugs, wiring, timing
Cooling System:
Radiator, cooling fan, coolant flow, thermostat, water pump
Transmission:
Gearbox inspection, clutch operation, shift mechanism, maintenance, repair
Frame And Suspension:
Frame inspection, front fork overhaul, rear shock absorber maintenance, linkage systems
Brakes:
Hydraulic system, front and rear brake calipers, master cylinders, brake pads, rotors, bleeding procedures
Electrical System:
Wiring diagrams, battery, charging system, lighting, indicators, starter motor, fuses, relays
Wheel And Tires:
Wheel bearing replacement, tire mounting, wheel balancing, spoke tension
Bodywork And Fairings:
Panel removal, installation, plastic repair, decal application
Diagnostics And Troubleshooting:
Symptom-based diagnostics, common fault finding, diagnostic charts
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication, spark plug checks
Scheduled Maintenance:
Service intervals, inspections, adjustments as per factory recommendations
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement
Component Disassembly And Reassembly:
Detailed step-by-step guides for all major components
Torque Specifications:
Precise torque values for all fasteners
Wiring Diagrams:
Comprehensive, color-coded wiring schematics
Depth:
Comprehensive: Covers basic maintenance to full engine and chassis rebuilds, including electrical system diagnostics.
Digital Format Details:
Searchable text, printable pages, bookmark support (typical for high-quality PDFs)
Print Quality Details:
High-resolution diagrams and illustrations, clear text reproduction
Binding Type:
N/A (if digital), Spiral-bound or Perfect-bound (if printed)
Paper Type:
Durable, shop-grade paper (if printed) to withstand workshop conditions
Engine Type:
Parallel-twin, liquid-cooled, DOHC, 8-valve
Bore X Stroke:
74.0 x 58.0 mm
Horsepower:
Approximately 45-50 PS (33-37 kW) at 8000 rpm (varies slightly by market and tuning)
Torque:
Approximately 45-48 Nm (33-35 lb-ft) at 6000 rpm
Carburetor Type:
Twin Keihin CVK34 carburetors
Fuel Capacity:
15 Liters (3.96 US gallons)
Overall Length:
Approx. 2215 mm (87.2 in)
Overall Width:
Approx. 845 mm (33.3 in)
Overall Height:
Approx. 1335 mm (52.6 in)
Wheelbase:
Approx. 1455 mm (57.3 in)
Ground Clearance:
Approx. 215 mm (8.5 in)
Seat Height:
Approx. 850 mm (33.5 in)
Dry Weight:
Approx. 180 kg (397 lbs)
Curb Weight:
Approx. 190 kg (419 lbs) (with all fluids)
Gross Vehicle Weight Rating:
Not explicitly specified, but typically around 380-400 kg for this class
Crash Test Ratings:
N/A (Motorcycles are not subject to standard automotive crash testing)
Braking System:
Front: Dual piston caliper with disc, Rear: Single piston caliper with disc
Tire Specification:
Front: 90/90-21, Rear: 130/80-17 (typical for dual-sport)
Lighting:
Halogen headlight, LED taillight, turn signals
Frame Construction:
Steel, semi-double cradle frame for rigidity and impact absorption.
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, warning lights (oil pressure, neutral, high beam, turn signals).
ABS:
Not typically available on this model for the specified years.
Usb Charging:
Not standard. Aftermarket options may exist.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Change Interval:
Every 12,000 km (7,500 miles) or 12 months (concurrent with oil change)
Air Filter Cleaning:
Every 6,000 km (3,700 miles), replace as needed
Spark Plug Inspection:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Engine Oil Type:
SAE 10W-40 API SG or higher (or specified by Kawasaki, e.g., KAWASAKI SCOOTER OIL 10W-40)
Engine Oil Capacity:
2.4 Liters (2.5 US qt) without filter change, 2.6 Liters (2.7 US qt) with filter change
Coolant Type:
Ethylene glycol-based antifreeze (50% solution with distilled water)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Chain Lube Type:
High-quality motorcycle chain lubricant
Common Wear Items:
Clutch plates (due to usage patterns), regulator/rectifier (common on many Japanese bikes of the era), wheel bearings, swingarm bearings.
Potential Faults:
Carburetor synchronization issues, occasional electrical connector corrosion if poorly maintained, slight vibration at certain RPMs.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company, a long-standing Japanese manufacturer renowned for performance and reliability.
Initial Release:
The KLE500 was first introduced in 1991, evolving from Kawasaki's successful ER5 platform, and was designed to fill the dual-sport niche.
Generation Details:
The 2004-2005 models represent a later iteration, benefiting from refinements in suspension, styling, and engine tuning over its production life. Significant updates were made around 2005 with a revised front suspension and aesthetics.
Production Period:
1991 - 2007 (in most markets)
