🏷️ Basic Information Identification Make: Kawasaki Model: KLE500 Model Variants: KLE500-A1, KLE500-A2, KLE500-A3, KLE500-A4, KLE500-A5, KLE500-A6, KLE500-A7, KLE500-A8, KLE500-A9, KLE500-A10, KLE500-A11, KLE500-A12, KLE500-A13 Generation Generation: First Generation (LE500A) Codes Chassis Code: LE500A Engine Code: LE500AE (typically) 👋 Introduction Market Position Target Audience: Professional motorcycle technicians, experienced DIY enthusiasts, and owners seeking in-depth knowledge of their KLE500. Competitive Analysis Manual Value Proposition: Provides factory-level diagnostic and repair information, bridging the gap between basic owner's manuals and specialized workshop manuals, at an accessible digital format. Key Features Digital Advantage: Instant access, searchable content, printable for workshop use, cost-effective compared to physical manuals. 📋 Manual Details Coverage Areas Applicable Years: 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Refer to actual manual for precise count; typically 300-600 pages for comprehensive factory service manuals. Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, lubrication, cooling, ignition system, fuel system (carburetor tuning and overhaul), exhaust system. Transmission: Clutch system, gearbox inspection and repair, final drive (chain and sprockets). Chassis: Frame, suspension (forks, rear shock), steering system, wheel and tire servicing. Brakes: Front and rear brake system maintenance, caliper overhaul, hydraulic system bleeding, disc and pad replacement. Electrical: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting system, ignition coils, starting motor, fuses, relays, instrument cluster. Bodywork: Fairing removal and installation, seat, fuel tank, fenders, side covers, general body panel maintenance. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, coolant checks, spark plug replacement. Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major systems. Troubleshooting: Diagnostic flowcharts and procedures for identifying and resolving common mechanical and electrical faults. Disassembly: Detailed instructions for taking components apart safely and efficiently. Assembly: Guidance on reassembling components, including proper torque specifications and procedures. Cleaning And Reinstalling: Procedures for cleaning parts during service and correctly reinstalling them. Technical Depth Depth: Comprehensive: Covers routine maintenance to major overhauls and diagnostics. Suitable for both experienced professionals and skilled DIY mechanics. 📊 Manual Specifications File Format File Format Details: PDF (Portable Document Format) Print Quality Printability: Full Printable: Designed for printing specific sections or the entire manual. Zoom Functionality Zoom Quality: Zoom IN/OUT Enabled: Allows for close inspection of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Method Delivery: Instant Download Software Requirements Requirements: Adobe PDF Reader, WinZip (or equivalent decompression software) Compatibility Operating Systems: Compatible with all versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, Parallel-twin Displacement: 498 cc Bore X Stroke: 70.0 x 64.8 mm Performance Horsepower: Approx. 47.7 HP @ 7500 RPM (Varies slightly by market/tuning) Torque: Approx. 46 Nm @ 6000 RPM (Varies slightly by market/tuning) Fuel System Carburetion: 2 x Keihin CVK34 Carburetors Fuel Type: Unleaded Gasoline (91-98 RON recommended) Lubrication Oil Type: SAE 10W-40 API SG or SH with JASO MA specification recommended. Refer to manual for exact specifications. Cooling Coolant Type: Permanent Antifreeze (Ethylene Glycol based) with demineralized water (50/50 mix recommended). Refer to manual for exact specifications. 🔧 Transmission Standard Type: Constant mesh, 6-speed return Features Clutch Type: Wet, multi-disc Final Drive: Sealed chain, 525 VS-X 📐 Dimensions Exterior Overall Length: Approx. 2,215 mm (87.2 in) Overall Width: Approx. 800 mm (31.5 in) Overall Height: Approx. 1,375 mm (54.1 in) Wheelbase: Approx. 1,460 mm (57.5 in) Weights Dry Weight: Approx. 180 kg (397 lbs) Curb Weight: Approx. 198 kg (437 lbs) (Wet weight, with fluids) Fuel Tank Capacity: 17 Liters (4.5 US gal) 🛡️ Safety Features Ratings Crash Test Information: Motorcycles of this era are not typically subjected to standardized crash testing like automobiles. Safety is primarily addressed through design and component reliability. Active Features Braking System: Front: Dual Disc; Rear: Single Disc. ABS was not standard or widely available on this model. Passive Features Lighting: Halogen headlight, LED taillight (typical), turn signals. Frame Design: Steel perimeter frame designed for stability and rider comfort. 💡 Technology Features Infotainment Infotainment System: Not applicable for this model year. Focus is on essential motorcycle functionality. Driver Assistance ABS Availability: ABS (Anti-lock Braking System) was not a standard feature for the 2004-2007 KLE500 models. Connectivity Connectivity Features: No integrated connectivity features (e.g., Bluetooth, GPS) are present on this model. Ancillary charging ports might be added aftermarket. Instrumentation Dashboard Features: Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator, high beam indicator, turn signal indicators. 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km (3,700 miles) or 6 months, whichever comes first. Refer to manual for precise intervals and conditions. Spark Plug Replacement: Typically at 12,000 km (7,500 miles). Refer to manual for specific plug type and gap. Chain Lubrication Adjustment:...