Motorcycle Segment:
Dual-sport / Adventure touring motorcycle.
Target Audience:
Riders seeking a versatile motorcycle for commuting, light off-road excursions, and touring.
Key Competitors:
Competed against models like the Honda Transalp, Suzuki V-Strom 650 (later generation), and Yamaha XT660R/X.
Engine Configuration:
Parallel-twin engine, known for its smooth power delivery.
Chassis Design:
Combines on-road comfort with sufficient ground clearance and suspension travel for light off-road capability.
Engine Mechanical:
Full overhaul and repair of the engine, including cylinder head, valves, piston, crankshaft, lubrication system, cooling system, and timing components.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel pump operation; fuel tank and lines.
Ignition System:
CDI unit, spark plugs, ignition coils, wiring, and timing checks.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox inspection and repair, chain and sprocket maintenance, final drive.
Brakes:
Front and rear brake system diagnosis, caliper service, master cylinder overhaul, hydraulic lines, bleeding procedures.
Suspension Steering:
Front fork disassembly, service, and tuning; rear shock absorber replacement and adjustment; steering head bearing service.
Electrical System:
Battery, charging system (alternator/stator, rectifier/regulator), lighting (headlight, taillight, indicators), horn, starter motor, wiring diagrams.
Chassis Frame:
Frame inspection, swingarm removal and service, wheel bearing replacement, general chassis components.
Bodywork Fairings:
Removal and installation of body panels, seat, fuel tank, and other cosmetic components.
Preventative Maintenance:
Detailed service intervals for oil changes, filter replacements, spark plug checks, chain lubrication, and valve clearance checks.
Troubleshooting Diagnostics:
Systematic fault finding for common issues related to starting, running, electrical faults, and performance problems.
Complete Overhaul Rebuild:
Step-by-step instructions for complete disassembly and reassembly of major mechanical components.
Technical Specifications:
Torque specifications for all fasteners, clearances, fluid capacities, and performance data.
Wiring Diagrams:
Comprehensive electrical schematic for easy diagnosis and repair of electrical issues.
Level Of Detail:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Procedures:
Includes specific diagnostic steps for various systems and components.
Special Tool Requirements:
Likely specifies any proprietary Kawasaki tools required for specific procedures.
Digital Format Details:
Typically provided as a PDF, ensuring searchability and ease of navigation. High resolution for clear diagrams.
Diagram Clarity:
High-quality diagrams, illustrations, and exploded views for clarity during repairs.
Physical Manual Binding:
If printed, expect a durable binding suitable for workshop use (e.g., spiral-bound or stitched).
Physical Manual Paper:
If printed, often on durable, gloss-coated paper to withstand workshop environments.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
10.8:1 (typical for this generation)
Power Delivery:
Smooth and accessible power band suitable for a range of riding conditions.
Horsepower Peak:
Approx. 49-50 HP (at ~7500 RPM, subject to regional variations)
Torque Peak:
Approx. 45-47 Nm (at ~6000 RPM, subject to regional variations)
Fuel Delivery:
Carburetor (likely dual Keihin CVK carburetors)
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended.
Fuel Tank Capacity:
Approximately 15 Liters (3.96 US gallons)
Gearbox Type:
Constant mesh, 6-speed, return shift
Clutch Type:
Wet, multiple-disc, cable operated
Final Drive:
Sealed O-ring chain drive
Gear Ratios:
Specific gear ratios will be detailed in the manual for performance tuning and diagnosis.
Transmission Fluid Type:
Kawasaki motorcycle gear oil or equivalent API GL-4, SAE 80W-90.
Crash Safety Standards:
As a motorcycle, does not undergo automotive crash test ratings. Safety relies on rider skill and component integrity.
Braking System:
Dual hydraulic disc brakes front, single hydraulic disc brake rear. ABS was not standard on this model.
Lighting:
Halogen headlight, taillight, brake light, and turn signals for visibility.
Frame Integrity:
Robust steel perimeter frame designed for stability and rider protection.
Instrument Cluster:
Analog speedometer and tachometer, LCD display for odometer, trip meter, and basic indicators (fuel level, oil pressure, turn signals, high beam).
ABS Availability:
ABS was not a standard or widely available option on this generation of KLE500.
Connectivity Features:
No modern connectivity features (e.g., Bluetooth, smartphone integration) present.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 12,000 km (7,400 miles) or annually, coinciding with oil changes.
Air Filter Cleaning Replacement:
Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 18,000 km (11,000 miles).
Spark Plug Inspection Replacement:
Inspect every 6,000 km (3,700 miles), replace every 12,000 km (7,400 miles).
Valve Clearance Check:
Every 18,000 km (11,000 miles).
Engine Oil Type:
API SG, SH, SJ or higher, JASO MA, SAE 10W-40.
Engine Oil Capacity:
Approx. 2.8 Liters (2.9 US quarts) with filter change.
Coolant Type:
Mixture of ethylene glycol-based antifreeze and distilled water (50/50 ratio).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Chain and sprockets, brake pads, tires, steering head bearings, fork seals due to general use.
Potential Electrical Issues:
Stator or rectifier/regulator failures can occur over time, as with many motorcycles of this era. Check voltage output.
Carburetor Tuning:
Carburetors may require periodic cleaning and synchronization for optimal performance.
Kawasaki History:
Kawasaki Heavy Industries is a Japanese conglomerate with a long history in motorcycle manufacturing, known for its performance and innovation across various segments.
Kle500 Lineage:
The KLE500 was part of Kawasaki's dual-sport lineup, evolving from earlier models and offering a balance between on-road comfort and off-road versatility. It was popular in Europe and other global markets.
Production Years:
Initially launched in the early 1990s, with this generation (2004-2007) representing a significant update or continued production phase.
Manufacturing Location:
Primarily manufactured in Japan or Thailand.
