KAWASAKI KLE500 Motorcycle Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Kawasaki Model: KLE500 Product Type: Service & Repair Manual Format: PDF Codes Vehicle Code Designation: LE500A 👋 Introduction Market Position Motorcycle Segment: Dual-sport / Adventure...

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE500

Product Type:

Service & Repair Manual

Format:

Codes

Vehicle Code Designation:

LE500A

👋 Introduction

Market Position

Motorcycle Segment:

Dual-sport / Adventure touring motorcycle.

Target Demographic:

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

Competitive Analysis

Key Competitors:

Honda Transalp, Suzuki V-Strom, Yamaha TDM series (depending on specific generation).

Key Features

Versatility:

Designed for both on-road comfort and capability on unpaved surfaces.

Engine Configuration:

Parallel-twin engine offers a good balance of power and tractability.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive service and repair procedures for the Kawasaki KLE500 motorcycle.

Page Count

Estimated Page Count:

Refer to actual product for precise page count (typically 300-500+ pages for this type of manual).

Manual Type

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

Likely English (confirm with seller).

Format

File Format Details:

Digital PDF, typically searchable and printable.

📖 Manual Coverage

Systems Covered

Engine Service:

Engine assembly/disassembly, cylinder head, pistons, crankshaft, valve timing, lubrication system, cooling system.

Fuel System Service:

Carburetor(s) adjustment and overhaul, fuel pump, fuel lines, fuel tank maintenance.

Transmission Service:

Gearbox inspection, clutch operation and adjustment, shift mechanism.

Chassis Service:

Frame inspection, suspension fork disassembly and rebuild, rear shock absorber, swingarm maintenance.

Brake System Service:

Front and rear brake caliper service, master cylinder, brake fluid replacement, pad and disc inspection.

Electrical System Service:

Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), lighting, starting system, battery maintenance.

Cooling System Service:

Radiator, coolant hoses, thermostat, fan operation.

Exhaust System Service:

Exhaust pipe and muffler inspection and replacement.

Wheels And Tires:

Wheel bearing service, tire pressure, rim inspection.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank, fenders.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, lubrication points.

Troubleshooting Guides:

Diagnostic procedures for common problems, fault finding charts.

Engine Rebuild:

Detailed steps for complete engine disassembly and reassembly.

Carburetor Tuning:

Idle speed adjustment, mixture control, jetting specifications.

Suspension Setup:

Fork oil level and viscosity, rear shock preload adjustment.

Electrical Diagnostics:

Troubleshooting ignition, charging, and starting system faults.

Clutch Adjustment:

Lever free play and cable adjustment.

Brake Bleeding:

Procedure for bleeding hydraulic brake systems.

Technical Depth

Depth Of Information:

Complete workshop level, covering diagnostics, repairs, and overhauls. Includes detailed diagrams and specifications.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text content.

Print Quality

Print Recommendation:

Optimized for digital viewing; printing recommended for workshop use.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin.

Displacement:

498 cc (approx.)

Bore X Stroke:

Refer to specific model year manual for exact figures (typically around 70mm x 64.8mm).

Compression Ratio:

Refer to specific model year manual for exact figures (typically around 9.1:1).

Performance

Horsepower:

Approximately 46-50 HP (varies by market and year, refer to manual).

Torque:

Approximately 40-45 Nm (varies by market and year, refer to manual).

Fuel System

Fuel Delivery:

Carburetor(s) (e.g., Keihin CVK34 or similar twin carburetors).

Fuel Type:

Unleaded gasoline.

Lubrication

Oil Capacity:

Refer to specific model year manual (typically around 2.2-2.5 liters with filter change).

Oil Type:

Refer to specific model year manual for API service classification and viscosity grade (e.g., SAE 10W-40 or 20W-50).

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed sequential.

Optional

Clutch Type:

Wet, multi-disc.

Features

Final Drive:

Sealed chain drive.

📐 Dimensions

Exterior

Overall Length:

Refer to specific model year manual (typically around 2,175 mm).

Overall Width:

Refer to specific model year manual (typically around 845 mm).

Overall Height:

Refer to specific model year manual (typically around 1,365 mm).

Wheelbase:

Refer to specific model year manual (typically around 1,470 mm).

Ground Clearance:

Refer to specific model year manual (typically around 210 mm).

Seat Height:

Refer to specific model year manual (typically around 830 mm).

Weights

Dry Weight:

Refer to specific model year manual (typically around 182 kg).

Curb Weight:

Refer to specific model year manual (typically around 190-200 kg).

Fuel Tank Capacity:

Refer to specific model year manual (typically around 17 liters).

🛡️ Safety Features

Ratings

Safety Certifications:

Designed to meet relevant national and international motorcycle safety standards of its production era.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake (configurations may vary by market and year).

Suspension Features:

Telescopic front forks, Monoshock rear suspension for stability and control.

Passive Features

Lighting:

Halogen headlight, taillight, turn signals.

Ergonomics:

Upright riding position for rider comfort and control.

💡 Technology Features

Infotainment

Dashboard Layout:

Analog tachometer, speedometer, odometer, trip meter, and warning lights.

Charging Ports:

Typically none standard; aftermarket options available.

Driver Assistance

ABS was not a standard or widely available option on most KLE500 models from its primary production years.

Connectivity

Bluetooth Integration:

Not applicable for the standard vehicle.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-6,000 km or 6-12 months, refer to manual for exact mileage/time intervals and conditions.

Spark Plug Inspection:

Check at intervals like 6,000-12,000 km, replace as needed. Manual will specify type and gap.

Air Filter Service:

Inspect and clean at intervals like 3,000-6,000 km, replace as needed. Manual will specify procedure and filter type.

Chain Lubrication And Adjustment:

Regular intervals, often every 500-1000 km or after riding in wet conditions. Manual will detail slack specification.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze, diluted with distilled water. Refer to manual for exact mixture ratio and type.

Brake Fluid Type:

DOT 4 is common for this era, but manual confirmation is essential.

Fork Oil Type:

Specific viscosity grade (e.g., 10W) and level as per manual. Capacity is crucial.

Known Issues

Carburetor Sync:

Carburetors may require periodic syncing for optimal performance and fuel economy.

Rear Shock ABSorber:

The OEM rear shock can degrade over time; upgrades are common for improved damping.

Charging System:

Regulator/rectifier units can be a failure point on some older Kawasakis; manual assists in diagnosis.

Cam Chain Tensioner:

Some models may benefit from manual cam chain tensioner upgrades to prevent premature wear or noise.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for performance and durability in motorcycles, including their range of versatile dual-sport and adventure bikes.

Model Evolution

Kle500 Introduction:

The KLE500 was introduced in the early 1990s as a mid-size dual-sport option.

Kle500 Updates:

Underwent updates throughout its production run, often involving minor engine tweaks, suspension refinements, and cosmetic changes to align with evolving market demands and emissions standards.

Kle500 Variants:

Different versions or generations exist, particularly with the transition to fuel injection on later models (though the manual's focus is likely carbureted versions unless specified).

Production

Production Period:

Produced from the early 1990s through the late 2000s.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific industry awards for the KLE500 are not prominently documented, it was recognized for its value and versatility in the dual-sport segment during its tenure.

Ratings

User Reviews:

Praised for its ruggedness, comfortable riding position, and affordability for adventure touring.