🏷️ Basic Information Identification Make: Kawasaki Model: KLE500 Year: 2006 Motorcycle Type: Dual-Sport / Adventure Touring Product Name: Kawasaki KLE500 KLE 500 2006 Repair Service Manual 👋 Introduction Market Position Target Audience: Professional motorcycle technicians and experienced do-it-yourself enthusiasts. Key Features Instructional Methodology: Step-by-step guidance, teaching factory-trained technician knowledge. Value Proposition: Enables owners to make informed decisions regarding maintenance and repair, promoting self-sufficiency. Manual Comparison: Offers similar content to factory service and owner's manuals, with the convenience of digital access. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair and maintenance for the Kawasaki KLE500 (2006 model year). Page Count Page Count: Not specified, but implied to be comprehensive like a factory service manual. Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF Digital Delivery: Instant Download 📖 Manual Coverage Systems Covered Engine Service: Detailed procedures for engine disassembly, assembly, inspection, troubleshooting, and repair, including valve adjustments, piston and cylinder inspection, crankshaft and connecting rod checks. Fuel System: Carburetor maintenance, cleaning, adjustment, and troubleshooting; fuel pump inspection and replacement; fuel tank and line servicing. Ignition System: Spark plug inspection and replacement, ignition coil testing, CDI unit diagnostics, timing verification. Cooling System: Radiator, fan, thermostat, and water pump maintenance and repair; coolant specifications and flushing procedures. Transmission And Drivetrain: Clutch operation, adjustment, and component replacement; gearbox disassembly, inspection, and reassembly; chain and sprocket maintenance and replacement. Chassis And Suspension: Front fork disassembly, seal replacement, and oil level adjustment; rear shock absorber inspection and service; swingarm and linkage lubrication and bearing checks. Wheel And Tire Service: Tire inspection, inflation, and replacement; wheel bearing maintenance; spoke tension adjustment (if applicable to spoked wheels). Brake System: Front and rear brake caliper servicing, pad replacement, hydraulic fluid bleeding, master cylinder inspection, and rotor checks. Electrical System: Wiring diagrams, component testing (battery, starter, alternator, lights, instrumentation), troubleshooting electrical faults. Bodywork And Frame: Fairing removal and installation, seat servicing, fuel tank removal, frame inspection for damage. Procedures Included Maintenance: Regular maintenance tasks, lubrication points, filter changes, fluid level checks, bolt torque specifications. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts. Disassembly And Assembly: Step-by-step instructions for taking apart and reassembling various motorcycle components. Repair: Detailed instructions for fixing or replacing worn or damaged parts. Cleaning And Reinstalling: Procedures for cleaning components during disassembly and proper reinstallation techniques. Technical Depth Depth Of Coverage: Designed for professional technicians and capable DIY mechanics with basic electrical and mechanical knowledge. Covers fundamentals to advanced repair procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT available Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: Not Applicable (Digital) Requirements Software Requirements: Adobe PDF Reader, WinZip (for decompression if applicable) Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, parallel-twin Displacement: 498 cc Bore X Stroke: 74.0 x 58.0 mm Compression Ratio: 9.5:1 Performance Horsepower Approximate: Approx. 48 PS (35 kW) @ 8000 rpm (European spec, may vary by market) Torque Approximate: Approx. 46 Nm (34 lb-ft) @ 6000 rpm (European spec, may vary by market) Fuel System Fuel Delivery: Carburetor (likely Keihin CVK twin carburetors) Fuel Type: Unleaded gasoline Lubrication Oil Capacity With Filter: Approx. 2.4 L (2.5 US qt) Oil Type Recommendation: API SG or SH, SAE 10W-40 recommended (refer to manual for exact specs) 🔧 Transmission Standard Transmission Type: Constant-mesh, 6-speed return Clutch Type: Wet, multiple-disc Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length Overall: Approx. 2195 mm (86.4 in) Width Overall: Approx. 870 mm (34.3 in) Height Overall: Approx. 1370 mm (53.9 in) Wheelbase: Approx. 1460 mm (57.5 in) Weights Dry Weight: Approx. 180 kg (397 lbs) Wet Weight: Approx. 197 kg (434 lbs) Fuel Tank Capacity: Approx. 17 L (4.5 US gal) 🛡️ Safety Features Ratings Safety Features Overview: Standard motorcycle safety features including reliable braking, adequate lighting, and stable chassis design for its class. Active Features Braking System Type: Dual disc front, single disc rear (hydraulic disc brakes) Passive Features Lighting: Halogen headlight, taillight, brake lights, turn signals. 💡 Technology Features Infotainment Infotainment System: Basic instrumentation (speedometer, tachometer, odometer, trip meter, coolant temperature warning light). No advanced infotainment features expected. Driver Assistance Rider Assistance: No electronic rider aids such as traction control or ABS typically found on this model. Connectivity Connectivity Features: No integrated connectivity features (e.g., Bluetooth, smartphone integration). 🔧 Maintenance Service Intervals Oil And Filter Change: Typically every 6,000 km (3,700 mi) or 6 months (refer to manual for exact interval). Valve Clearance Check: Typically every 12,000 km (7,500 mi) or 12 months (refer to manual for exact interval). Air Filter Cleaning: Recommended every 6,000 km (3,700 mi), or more frequently under dusty conditions. Chain Maintenance: Lubricate and adjust chain tension...