🏷️ Basic Information

Make:

Kawasaki

Model:

KLE500

Year:

2004

Engine Type:

Parallel-twin, 4-stroke

Chassis Code:

LE500A

👋 Introduction

Segment:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Owners and independent repair shops seeking comprehensive guidance for maintaining and repairing the KLE500

Competitors 2004:

Honda Transalp, Suzuki V-Strom (early models), BMW F650GS (single cylinder models)

Model Identity:

Known for its accessible performance, comfortable ergonomics for longer rides, and ability to handle light off-road conditions

Manual Value Proposition:

Provides factory-level diagnostic and repair information, enabling DIY maintenance and reducing reliance on expensive dealership services

📋 Manual Details

Primary Coverage:

Mechanical and Electrical Systems, Maintenance, Repair, Troubleshooting

Specific Systems:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Suspension, Brakes, Wheels & Tires, Electrical System, Lighting, Bodywork, Chassis

Estimated Pages:

Approximately 400-500 pages (typical for a workshop manual of this type)

Type:

Workshop Repair Manual / Service Manual

Language:

English

Format:

Digital (PDF) - Searchable and Printable

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, inspection, assembly, cylinder head, valves, camshafts, crankshaft, pistons, connecting rods, lubrication system, oil pump, oil filter replacement

Fuel System:

Carburetor (Mikuni BSR34) disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines

Ignition System:

Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams

Cooling System:

Radiator, cooling fan, thermostat, coolant replacement, hoses

Exhaust System:

Muffler, exhaust pipes, gaskets

Transmission Drivetrain:

Gearbox disassembly and assembly, gear selection, clutch operation, primary drive, final drive (chain and sprockets), chain adjustment, lubrication

Suspension Steering:

Front fork (telescopic, cartridge type) overhaul, rear shock absorber, swingarm, steering head bearings, wheel bearing replacement

Brakes:

Front and rear brake system, brake fluid replacement, caliper maintenance, pad replacement, disc inspection, master cylinder overhaul

Wheels Tires:

Tire replacement, wheel balancing, spoke tension adjustment (if applicable), wheel bearing service

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, fuses, relays, wiring diagrams

Bodywork Chassis:

Fairing removal and installation, seat, fuel tank removal, frame inspection, minor body panel repairs

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake fluid flushes, coolant replacement, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments

Troubleshooting:

Diagnostic procedures for common faults and symptoms across all major systems, fault code interpretation (if applicable)

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly, torque specifications for critical fasteners

Technical Specifications:

Detailed specifications for all components, wear limits, clearances, tolerances

Level Of Detail:

Comprehensive, covering everything from routine maintenance to major component overhauls and troubleshooting

Diagnostic Capability:

Detailed fault finding charts and diagnostic flowcharts for electrical and mechanical issues

Rebuild Procedures:

Includes detailed procedures for engine rebuild, gearbox overhaul, and carburetor rebuilding

📊 Manual Specifications

Digital Features:

Searchable text, bookmark navigation, clickable links within PDF for quick access

Printability:

High-resolution images and clear diagrams suitable for home printing of specific sections

Physical Format If Printed:

N/A (Digital PDF)

Physical Format If Printed:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

LE500AE

Displacement:

498 cc (cubic centimeters)

Bore X Stroke:

74.0 mm x 58.0 mm

Compression Ratio:

9.7:1

Valve Train:

DOHC, 8 valves (4 per cylinder)

Cooling Method:

Liquid-cooled

Horsepower:

Approx. 47 hp @ 7,500 rpm (Varies slightly by region and tuning)

Torque:

Approx. 45 Nm (33 lb-ft) @ 6,000 rpm

Carburetor Type:

Twin Mikuni BSR34 flat-slide carburetors

Fuel Grade:

Unleaded gasoline, minimum 87 octane (RON+MON)/2

Oil Capacity With Filter:

2.6 Liters (2.7 US qt)

Oil Type Specification:

API SG or SH, JASO MA certified, SAE 10W-40 or 10W-50 (depending on ambient temperature)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Primary Drive:

Gear reduction

Final Drive:

O-ring sealed chain

📐 Dimensions

Length:

2,195 mm (86.4 in)

Width:

840 mm (33.1 in)

Height:

1,320 mm (52.0 in)

Wheelbase:

1,455 mm (57.3 in)

Ground Clearance:

220 mm (8.7 in)

Dry Weight:

190 kg (419 lbs)

Curb Weight:

Approx. 210 kg (463 lbs) (fully fueled)

Max Load Capacity:

Approx. 190 kg (419 lbs) including rider, passenger, and luggage

Luggage Capacity:

Designed for aftermarket luggage racks and panniers (not integrated)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety ratings not typically provided in a comparable format to cars)

Braking System:

Dual disc front brakes, single disc rear brake

ABS:

Not available on 2004 models

Lighting:

Halogen headlight, LED taillight, standard turn signals

Frame Construction:

Steel diamond frame

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle instrumentation)

Dashboard:

Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators, high beam indicator

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first

Oil Filter Replacement Interval:

Every 12,000 km (7,500 miles) or 12 months

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles)

Spark Plug Replacement Interval:

Every 12,000 km (7,500 miles)

Valve Clearance Check Interval:

Every 18,000 km (11,000 miles)

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet/dusty conditions

Coolant Type:

Ethylene glycol-based antifreeze, mixed 50/50 with distilled water

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W

Fork Oil Capacity:

452 ml (15.3 US fl oz) per fork leg (check manual for precise amount)

Common Wear Items:

Fork seals, rear shock absorber, steering head bearings, wheel bearings, clutch plates, chain and sprockets

Carburetor Issues:

Can become slightly difficult to synchronize over time, potential for clogged jets if fuel is not clean

Electrical Reliability:

Generally reliable, but regulator/rectifier can be a point of failure in older units, as with many bikes of this era

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Introduction Year:

1991

Generations:

First Generation (1991-2007), Second Generation (2008 onwards with significant updates)

Key Changes Prior To 2004:

Minor styling updates, some internal engine component revisions over its lifecycle

Manufacturing Location:

Japan (primarily)

Production Run:

1991-2007 (First Generation)

🏆 Awards & Recognition

Industry Awards:

N/A (No specific widely publicized industry awards for this model)

Owner Satisfaction General:

Generally good for its segment, appreciated for its reliability and versatility, though often overshadowed by more premium offerings

Emissions Compliance:

Meets the emissions standards applicable in its primary markets at the time of manufacture.