Market Segment:
Versatile dual-purpose motorcycle catering to both on-road commuting and light off-road adventure touring
Competitors:
Suzuki V-Strom 650, Honda Transalp XL650V, Yamaha TDM850
Key Features Vehicle:
Robust parallel-twin engine, long-travel suspension, upright riding position, durable construction
Manual Value:
Essential resource for maintaining optimal performance, diagnosing issues, and executing repairs for the KLE500
Engine Systems:
Engine overhaul, carburetor tuning, ignition system diagnostics, cooling system, lubrication system
Transmission Systems:
Clutch operation, gearbox disassembly and assembly, shift mechanism
Chassis Systems:
Frame inspection, suspension fork overhaul, rear shock absorber service, steering system maintenance
Brake Systems:
Front and rear brake caliper service, hydraulic system bleeding, pad replacement
Electrical Systems:
Wiring diagrams, starter system, charging system, lighting, instrumentation
Fuel System:
Fuel tank service, fuel pump operation, carburetor identification and adjustment
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, and mechanical problems
Major Repairs:
Engine rebuilds, transmission repairs, carburetor synchronization, suspension component replacement
Special Tools:
Identification of specialized tools required for specific procedures
Depth Level:
Detailed, in-depth coverage suitable for professional mechanics and experienced DIY enthusiasts
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
70.0 mm x 64.8 mm
Valve Clearance Intake:
0.06 - 0.10 mm (cold)
Valve Clearance Exhaust:
0.08 - 0.12 mm (cold)
Horsepower Rating:
Approx. 47 hp @ 8000 rpm (manufacturer-specified)
Torque Rating:
Approx. 45 Nm @ 6000 rpm (manufacturer-specified)
Fuel Delivery:
Dual Keihin CVK34 carburetors
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified
Oil Capacity W Filter:
3.1 L
Coolant Type:
Ethylene glycol based coolant (50% solution with distilled water)
Ignition Timing:
ECU controlled, refer to manual for specifications
Safety Ratings:
N/A (Motorcycles typically do not receive standardized crash ratings like cars)
Braking System:
Dual disc front, single disc rear
Suspension Front:
41 mm telescopic fork
Suspension Rear:
Monoshock with adjustable preload
Lighting:
Halogen headlight, LED tail light
Infotainment System:
Basic instrumentation: speedometer, odometer, trip meter, tachometer, fuel gauge, coolant temperature warning light
Driver Assistance Features:
None (standard motorcycle features)
First Service:
1000 km or 1 month (whichever comes first)
Subsequent Service:
Every 6000 km or 6 months
Engine Oil Change:
Every 6000 km or 6 months, or more frequently under severe use
Spark Plug Check:
Every 6000 km
Valve Clearance Check:
Every 12000 km
Engine Oil Specification:
SAE 10W-40, API SG or higher, JASO MA
Coolant Type:
Ethylene glycol based, 50% solution with distilled water
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals
Carburetor Sync:
May require periodic synchronization for optimal performance, especially after extensive use or modifications
Electrical Connections:
Some owners report potential issues with corrosion in electrical connectors over time, particularly in humid climates.
Brand Origin:
Kawasaki Heavy Industries Motorcycle & Engine Company, Japan
First Generation:
Introduced in the early 1990s as the KLE500, building on Kawasaki's experience with dual-purpose bikes
Updates By 2005:
The 2005 model features refinements from earlier iterations, often including minor aesthetic changes and potentially internal engine tuning
Production Period:
Mid-1990s to late 2000s (specific end date varies by market)
