🏷️ Basic Information Identification Make: Kawasaki Model: KLE500 Year: 2003 👋 Introduction Market Position Target Audience: Professional motorcycle technicians, experienced DIY enthusiasts, and owners seeking comprehensive repair and maintenance resources Competitive Analysis Advantage: Provides the same detailed information as official factory service manuals, often at a more accessible price point, with the convenience of instant digital delivery. Key Features Feature 1: Instant download for immediate access. Feature 2: Printable pages for on-the-job use. Feature 3: Detailed illustrations, diagrams, and photos. Feature 4: Comprehensive troubleshooting and electrical diagnostics. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Page Count Estimated Page Count: Varies (typical for this type of manual is 300-600 pages) Manual Type Type: Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, top-end rebuild, bottom-end rebuild, cylinder head service, piston and ring installation, crankshaft and connecting rod service, valve timing, lubrication system Fuel System: Carburetor(s) overhaul and adjustment, fuel pump, fuel lines, fuel tank maintenance Ignition System: Ignition timing, spark plugs, ignition coils, CDI unit, troubleshooting Cooling System: Radiator, coolant, thermostat, water pump, fan operation Transmission Drivetrain: Clutch operation and adjustment, gear shifting mechanism, output shaft, drive chain maintenance and adjustment Electrical System: Wiring diagrams, lighting system, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, instrument panel functions, diagnostic procedures Chassis Suspension: Front fork overhaul and adjustment, rear shock absorber service, swingarm lubrication and bearing service Braking System: Front and rear brake caliper service, brake pad replacement, brake fluid replacement and bleeding, master cylinder service Wheels Tires: Wheel bearing service, tire pressure recommendations, tire replacement procedures Bodywork Frame: Fairing removal and installation, seat, fuel tank mounting, frame inspection Procedures Included Maintenance Schedule: Detailed recommended service intervals for all major components and systems Troubleshooting: Comprehensive diagnostic guides for common and uncommon issues, symptom-based troubleshooting flowcharts Repair Procedures: Step-by-step instructions for virtually all mechanical and electrical repairs, including detailed disassembly and reassembly sequences Rebuild Procedures: Complete guides for engine, transmission, and suspension component rebuilds Technical Depth Depth: Expert-level, suitable for professional technicians and advanced DIY mechanics seeking complete overhaul capabilities 📊 Manual Specifications File Format Compatibility: All versions of Windows & Mac Print Quality Printability: Full Printable Binding Type Binding: Digital (PDF download) Paper Type Paper Type: N/A (Digital) ⚙️ 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 Performance Horsepower: Approx. 45-50 HP (varies slightly by region and specific model tuning) Torque: Approx. 42-46 Nm (varies slightly) Fuel System Carburetion: Twin Keihin CVK34 carburetors Fuel Tank Capacity: 17 Liters (approx.) Lubrication Oil Type: SAE 10W-40 API SG or higher, JASO MA recommended Oil Capacity: Approx. 2.4 Liters with filter change 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed return Features Clutch Type: Wet, multi-disc Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2215 mm Width: Approx. 820 mm Height: Approx. 1440 mm Weights Dry Weight: Approx. 174 kg Wet Weight: Approx. 192 kg (fully fueled and ready to ride) 🛡️ Safety Features Ratings Safety Features: Dual disc front brakes, single disc rear brake, sturdy frame construction, integrated lighting system. Active Features Braking System: Hydraulic disc brakes front and rear 💡 Technology Features Infotainment Infotainment System: N/A (basic motorcycle instrumentation) Driver Assistance Assistance Features: N/A (mechanical and basic electrical systems) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 6 months Air Filter Cleaning: Every 6,000 km Spark Plug Replacement: Every 12,000 km Valve Clearance Check: Every 12,000 km Fluid Specifications Coolant Type: Ethylene glycol-based coolant, 50/50 mixture with distilled water Brake Fluid Type: DOT 4 Known Issues Issue 1: Carburetor synchronization can drift over time, affecting smooth running. Issue 2: Regulator/rectifier can be prone to failure under heavy load or heat, leading to charging system issues. Issue 3: Front fork seals may wear, causing leaks. Issue 4: Cam chain tensioner wear can lead to rattling noises. 📚 Vehicle History Brand Heritage Manufacturer: Kawasaki Heavy Industries Motorcycle & Engine Company Model Evolution Model Lineage: The KLE500 is part of Kawasaki's dual-sport or 'adventure touring' segment, known for versatility. It shares components and design philosophy with other Kawasaki models of its era. Production Production Period: 1991-2007 (with various updates) 🏆 Awards & Recognition Recognitions Recognition Status: The KLE500 is generally recognized as a reliable and versatile middleweight dual-sport, popular for its value and capability in mixed riding conditions, though specific individual awards are not widely documented.