Kawasaki KLE500 Motorcycle Service Manual – PDF DOWNLOAD

Description

Kawasaki KLE500 Motorcycle Service Manual – PDF DOWNLOAD

FILE DETAILS:

Kawasaki KLE500 Motorcycle Service Manual – PDF DOWNLOAD 

Language : English
Pages : 401
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Kawasaki KLE500 Motorcycle Service Manual – PDF DOWNLOAD 

tables 1
LIST OF ABBREVIATIONS 6
Units of Mass: 19
Units of Volume: 19
Units of Force: 19
Units of Length: 19
Units of Torque: 19
Units of Pressure: 19
Units of Speed: 19
Units of Power: 19
Periodic Replacement Parts 25
Basic Torque for General Fasteners 30
Throttle Grip Free Play 34
Idle Speed 35
Valve Clearance Measuring Position 40
Valve Clearance Measuring Position 40
Valve Clearance (when cold) 41
Clutch Lever Free Play 41
Air Pressure (when cold) 42
Tread Depth 43
Rim Runout (with tire installed) 44
Chain Slack 45
Drive Chain 20-link Length 46
Recommended Disc Brake Fluid 49
Pad Lining Thickness 49
Brake Light Timing 50
Spark Plug Gap 54
Sidestand Switch Operation 57
Water and Coolant Mixture Ratio (when shipping) 63
Engine Oil 65
Choke Cable Free Play 79
Fuel Level 82
Float Height 83
Valve Closing Temperature (for reference) 103
Radiator Cap Relief Pressure 108
Thermostat Valve Opening Temperature 111
Vacuum Switch Valve Closing Pressure (open → close) 124
Camshaft Journal, Camshaft Cap Clearance 130
Cylinder Compression (Usable Range) 133
Cylinder Head Warp 136
Valve Seating Surface Outside Diameter 138
Valve Seating Surface Width 138
Valve/Valve Guide Clearance (Wobble Method) 139
Special Tools – 139
Piston Ring/Groove Clearance 146
Piston Ring End Gap 146
Cylinder Inside Diameter 146
Piston Diameter 147
Friction Plate Thickness 162
Friction and Steel Plate Warp 162
Clutch Spring Free Length 163
Oil Pressure 179
Torque Value for 8 mm Bolts 198
Connecting Rod Bend 204
Connecting Rod Twist 204
Connecting Rod Big End Side Clearance 204
Connecting Rod Big End Bearing Insert/Crankpin Clearance 205
Crankpin Diameter 205
Crankpin Diameter Marks 205
Connecting Rod Big End Bore Diameter Marks 206
Connecting Rod Big End Bearing Insert Selection 206
Crankshaft Runout 206
Crankshaft Main Bearing Insert/Journal Clearance 207
Crankshaft Main Journal Diameter 207
Crankshaft Main Journal Diameter Marks 207
Crankcase Main Bearing Bore Diameter Marks 208
Crankshaft Main Bearing Insert Selection 208
Crankshaft Side Clearance 208
Balancer Shaft Bearing Insert/Journal Clearance 209
Balancer Shaft Journal Diameter 209
Balancer Shaft Diameter Marks 210
Crankcase Bearing Bore Diameter Marks 210
Balancer Shaft Bearing Insert Selection 210
Axle Runout/100 mm (3 94 in ) 228
Balance Weight 229
Recommended Tool 241
Link Pin Outside Diameter 242
Link Plates Outside Width 242
Rear Sprocket Warp 244
Pedal Position 254
Disc Thickness 267
Disc Runout 267
Front Fork Oil Level (Fully compressed without fork spring) 278
Spring Free Length 282
Spring Preload Adjustment 283
Kawasaki-recommended chargers: 335
Battery Terminal Voltage 336
Terminal Voltage: 11 5 ∼ less than 12 8 V 337
Terminal Voltage: less than 11 5 V 337
Voltage 342
Table 2 Stator Coil Resistance 342
Regulator/Rectifier Output Voltage 343
Rectifier Circuit Inspection 344
Crankshaft Sensor Resistance 348
Ignition Coil Arcing Distance 349
Ignition Coil Winding Resistance 350
Ignition Timing 350
Connect 353
Ignition Coil Primary Peak Voltage 353
Connect 355
Crankshaft Sensor Peak Voltage 355
Starter Motor Brush Length 360
Commutator Diameter 360
Testing Relay 362
Testing Turn Signal Relay 366
Wire Connectors 368
Radiator Fan Switch Resistance 374
Water Temperature Switch Connections 375
Fuse Circuit Inspection 376
Relay Circuit Inspection (with the battery disconnected) 377
Relay Circuit Inspection (with the battery connected) 377
Diode Circuit Inspection 377
toc 1
Read OWNER’S MANUAL before operating 6
Foreword 7
General Information 9
Before starting to perform an inspection service or carry out a 10
Battery Ground 10
Edges of Parts 10
Solvent 10
Cleaning vehicle before disassembly 10
Arrangement and Cleaning of Removed Parts 11
Storage of Removed Parts 11
Inspection 11
Replacement Parts 11
Assembly Order 11
Tightening Sequence 12
Tightening Torque 12
Force 12
Gasket, O-ring 12
Liquid Gasket, Locking Agent 12
Press 13
Ball Bearing and Needle Bearing 13
Oil Seal, Grease Seal 13
Circlips, Cotter Pins 13
Lubrication 14
Direction of Engine Rotation 14
Electrical Wires 14
KLE500-B1 Left Side View 15
KLE500-B1 Right Side View 15
Prefixes for Units: 19
Units of Temperature: 19
Periodic Maintenance 21
The scheduled maintenance must be done in accordance with this c 23
Tighten all bolts and nuts to the proper torque using an accurat 26
Steering Stem Nut Wrench: 33
Fuel System 34
Throttle Cable Inspection 34
Idle Speed Inspection 35
Carburetor Synchronization Inspection 36
Special Tool – 36
Special Tool – 36
Coolant Filter Cleaning 37
Fuel Hoses and Connections Check 37
Air Cleaner Element Cleaning and Inspection 37
Cooling System 38
Coolant Level Inspection 38
Radiator Hoses and Connections Inspection 39
Torque – 39
Engine Top End 39
Air Suction Valve Inspection 39
Valve Clearance Inspection 39
Special Tool – 40
Torque – 41
Clutch 41
Clutch Operation Inspection 41
Wheels/Tires 42
Air Pressure Inspection/Adjustment 42
Tire Tread Wear Inspection 42
Wheel/Tire Damage Inspection 43
Wheel Bearing Damage Inspection 44
Spoke Tightness and Rim Runout Inspection 44
Torque – 44
Special Tool – 44
Final Drive 45
Drive Chain Slack Inspection 45
Torque – 45
Drive Chain Wear Inspection 46
Drive Chain Lubrication 47
Brakes 47
Brake Fluid Leak (Brake Hose and Pipe) Inspection 47
Brake Hose Damage and Installation Condition Inspection 48
Torque – 48
Brake Operation Inspection 48
Brake Fluid Level Inspection 48
Special Tool – 48
Brake Pad Wear Inspection 49
Brake Light Switch Operation Inspection 50
Suspension 50
Front Forks/Rear Shock Absorber Operation Inspection 50
Front Fork Oil Leak Inspection 51
Rear Shock Absorber Oil Leak Inspection 51
Rocker Arm Operation Inspection 51
Rocker Arm Bearings and Sleeves Lubrication 51
Tie-rod Operation Inspection 52
Swingarm Needle Bearing Lubrication 52
Steering 52
Steering Play Inspection 52
Special Tool – 52
Special Tool – 53
Torque – 53
Torque – 53
Steering Stem Bearing Lubrication 53
Electrical System 54
Spark Plug Gap Inspection 54
Lights and Switches Operation Inspection 54
Headlight Aiming Inspection 56
Side Stand Switch Operation Inspection 57
Engine Stop Switch Operation Inspection 58
Others 58
Chassis Parts Lubrication 58
Pivots: Lubricate with Motor Oil 58
Points: Lubricate with Grease 59
Cables: Lubricate with Cable Lubricant 59
Bolts, Nuts and Fastener Tightness Inspection 59
Nut, Bolt and Fastener to be checked 60
Replacement Parts 60
Fuel Hose Replacement 60
Air Cleaner Element Replacement 61
Coolant Change 61
Torque – 62
Radiator Hoses and O-ring Replacement 64
Engine Oil Change 64
Torque – 64
Torque – 65
Oil Filter Replacement 65
Special Tool – 65
Torque – 65
Brake Hose Replacement 65
Torque – 66
Brake Fluid Change 66
Torque – 66
Bleeding the Brake Line 67
Torque – 68
Caliper Rubber Parts Replacement 68
Master Cylinder Rubber Parts Replacement 68
Spark Plug Replacement 69
Torque – 69
Fuel System 71
Fuel Level Gauge: 77
Throttle Cable Inspection 78
Throttle Cable Lubrication 78
Throttle Cable Removal 78
Throttle Cable Installation 78
Choke Cable Free Play Inspection 79
Choke Cable Free Play Adjustment 79
Choke Cable Installation 79
Choke Cable Lubrication 79
Carburetor Removal 80
Carburetor Installation 80
Service Fuel Level Inspection 81
Special Tool – 82
Service Fuel Level Adjustment 82
Fuel System Cleanliness Inspection 83
Special Tool – 84
Carburetor Disassembly/Assembly 84
Torque – 85
Carburetor Separation/Assembly 85
Carburetor Cleaning 87
Carburetor Inspection 88
Coolant Filter Cleaning 88
Air Cleaner Element Removal 89
Air Cleaner Element Installation 89
Air Cleaner Element Cleaning and Inspection 89
Air Cleaner Housing Removal 89
Air Cleaner Housing Installation 90
Air Cleaner Draining 90
Fuel Tank Removal 91
Fuel Tank Installation 92
Fuel Tap Removal 92
Fuel Tap Installation 92
Torque – 92
Fuel Tank and Tap Cleaning 92
Fuel Tap Inspection 93
Fuel Tank and Cap Inspection 93
Fuel Hose and Connection Inspection 94
Cooling System 95
Bearing Driver Set: 99
Permanent type antifreeze is used as a coolant to protect the co 100
Coolant Deterioration Inspection 102
Coolant Level Inspection 102
Coolant Draining 102
Coolant Filling 102
Visual Leak Inspection 102
Cooling System Pressure Testing 102
Flushing 103
Coolant Filter Cleaning 103
Coolant Valve Inspection 103
Water Pump Removal 104
Water Pump Installation 104
Sealant – 104
Torque – 104
Torque – 105
Mechanical Seal Inspection 105
Water Pump Housing Disassembly 105
Special Tool – 105
Water Pump Housing Assembly 105
Special Tool – 105
Impeller Assembly 106
Pump Impeller Inspection 106
WARNING 107
Radiator Removal 107
Radiator Inspection 107
Radiator Fan Removal 108
Filler Neck Inspection 108
Radiator Cap Inspection 108
Radiator Hose and Connection Inspection 109
Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installa 109
Torque – 109
Thermostat Removal 110
Thermostat Installation 110
Thermostat Inspection 110
CAUTION 112
Radiator Fan Switch Removal 112
Water Temperature Switch Removal 112
Radiator Fan Switch, Water Temperature Switch Installation 112
Sealant – 112
Torque – 112
Radiator Fan Switch, Water Temperature Switch Inspection 112
Engine Top End 113
Piston Ring Pliers: 120
Vacuum Switch Valve Removal 123
Vacuum Switch Valve Installation 123
Air Suction Valve Removal 123
Air Suction Valve Installation 123
Torque – 123
Air Suction Valve Inspection 123
Clean Air System Hose Inspection 123
Vacuum Switch Valve Test 124
Special Tool – 124
Cylinder Head Cover Removal 125
Cylinder Head Cover Installation 126
Sealant – 126
Torque – 126
Camshaft Chain Tensioner Removal 127
Camshaft Chain Tensioner Installation 127
Torque – 127
Torque – 127
Camshaft Removal 128
Camshaft Installation 128
Torque – 129
Torque – 129
Camshaft and Sprocket Assembly 129
Torque – 129
Camshaft, Camshaft Cap Wear 130
Torque – 130
Camshaft Chain Guide Wear 130
Rocker Shaft, Rocker Arm Removal 131
Rocker Shaft, Rocker Arm Installation 131
Torque – 131
Cylinder Head Oil Pipe Removal 132
Cylinder Head Oil Pipe Installation 132
Main Oil Pipe Removal 132
Main Oil Pipe Installation 132
Torque – 132
Compression Measurement 133
Special Tools – 133
Cylinder Head Removal 134
Cylinder Head Installation 135
Torque – 135
Cylinder Head Warp 136
Cylinder Head Cleaning 136
Valve Clearance Inspection 137
Valve Removal 137
Special Tools – 137
Valve Installation 137
Special Tools – 137
Valve Guide Removal 137
Special Tool – 137
Valve Guide Installation 138
Special Tool – 138
Special Tool – 138
Valve Seat Inspection 138
Measuring Valve-to-guide Clearance (Wobble method) 139
Valve Seat Repair 139
Cylinder Removal 144
Cylinder Installation 144
Special Tool – 144
Piston Removal 144
Special Tool – 144
Special Tool – 145
Piston Installation 145
Piston Ring, Piston Ring Groove Wear 146
Piston Ring End Gap 146
Cylinder Inside Diameter 146
Piston Diameter 147
Boring, Honing 147
Carburetor Holder Installation 148
Muffler Removal 149
Muffler Installation 149
Clutch 151
Clutch Holder: 157
Clutch Lever Position Adjustment 158
Clutch Cable Inspection 158
Clutch Lever Installation 158
Cable Lubrication 158
Clutch Cover Removal 159
Clutch Cover Installation 159
Sealant – 159
Torque – 159
Clutch Release Removal 159
Clutch Release Installation 160
Clutch Removal 161
Special Tool – 161
Clutch Installation 161
Special Tool – 161
Torque – 161
Torque – 162
Clutch Plate Wear, Damage Inspection 162
Clutch Plate Warp Inspection 162
Clutch Spring Free Length Measurement 163
Clutch Housing Finger Inspection 163
Clutch Hub Spline Inspection 163
Engine Lubrication System 165
Oil Pressure Gauge, 5 kgf/cm : 172
WARNING 173
Engine Oil Level Inspection 173
Engine Oil Change 173
Oil Filter Replacement 173
Oil Pan Removal 174
Oil Pan Installation 174
Torque – 174
Torque – 174
Relief Valve Removal 174
Relief Valve Installation 175
Torque – 175
Torque – 175
Relief Valve Inspection 175
Oil Pump Removal 176
Oil Pump Installation 177
Torque – 177
Torque – 177
Special Tool – 177
Oil Pump Disassembly 177
Oil Pump Assembly 178
Oil Screen Cleaning and Inspection 178
Oil Pressure Measurement 179
Special Tools – 179
Torque – 179
Engine Removal/Installation 181
Engine Removal 184
Engine Installation 186
Torque – 186
Crankshaft/Transmission 187
Bearing Puller: 195
Crankcase Splitting 196
Crankcase Assembly 197
Sealant – 197
Torque – 198
Torque – 199
Clutch Housing/Primary Chain Removal 200
Clutch Housing/Primary Chain Installation 200
Primary Chain Guide Wear Inspection 201
Torque – 201
Crankshaft Removal 202
Crankshaft Installation 202
Connecting Rod Removal 202
Connecting Rod Installation 203
Torque – 203
Crankshaft/Connecting Rod Cleaning 203
Connecting Rod Bend/Twist 204
Connecting Rod Big End Side Clearance 204
Connecting Rod Big End Bearing Insert/Crankpin Clearance 205
Torque – 205
Torque – 206
Crankshaft Runout 206
Crankshaft Main Bearing Insert/Journal Clearance 206
Torque – 207
Crankshaft Side Clearance 208
Balancer Removal 209
Balancer Installation 209
Balancer Shaft Bearing Insert/Journal Clearance 209
Torque – 209
External Shift Mechanism Removal 211
External Shift Mechanism Installation 211
Torque – 211
Torque – 211
Sealant – 211
Torque – 212
External Shift Mechanism Inspection 212
Torque – 212
Transmission Shaft Removal 212
Transmission Shaft Installation 212
Transmission Shaft Disassembly 213
Special Tool – 213
Special Tools – 214
Drive Shaft Assembly 214
Special Tool – 214
Output Shaft Assembly 215
Special Tool – 215
Shift Drum and Fork Removal 216
Shift Drum and Fork Installation 217
Torque – 217
Shift Drum Disassembly 218
Shift Drum Assembly 218
Ball and Needle Bearing Wear 219
Shift Pedal Installation 219
Torque – 219
Wheels/Tires 221
Inside Circlip Pliers: 225
Front Wheel Removal 226
Special Tool – 226
Front Wheel Installation 226
Torque – 226
Rear Wheel Removal 227
Special Tool – 227
Rear Wheel Installation 227
Torque – 227
Wheel Inspection 228
Special Tool – 228
Spoke Inspection 228
Rim Inspection 228
Axle Inspection 228
Wheel Balance 229
Balance Inspection 229
Balance Adjustment 229
Air Pressure Inspection/Adjustment 230
Tire Wear Inspection 230
Tire Removal 230
Special Tool – 230
Special Tools – 231
Tire Installation 231
Hub Bearing Removal 232
Special Tool – 232
Special Tool – 232
Special Tools – 232
Hub Bearing Installation 232
Special Tool – 232
Special Tool – 232
Special Tool – 232
Hub Bearing Inspection 233
Hub Bearing Lubrication 233
Disassembly and Assembly 234
Lubrication 234
Final Drive 235
Inside Circlip Pliers: 239
Drive Chain Slack Inspection 240
Wheel Alignment Inspection/Adjustment 240
Drive Chain Wear Inspection 240
Drive Chain Lubrication 240
Drive Chain Removal 240
Drive Chain Installation 240
Torque – 240
Drive Chain Case and Chain Guide Removal 241
Drive Chain Replacement 241
Drive Chain Installation 242
Engine Sprocket Removal 243
Engine Sprocket Installation 243
Torque – 243
Rear Sprocket Removal 244
Rear Sprocket Installation 244
Torque – 244
Sprocket Wear Inspection 244
Rear Sprocket Warp Inspection 244
Coupling Bearing Removal 245
Special Tool – 245
Coupling Bearing Installation 245
Special Tool – 245
Special Tool – 245
Coupling Installation 245
Coupling Bearing Inspection and Lubrication 245
Brakes 247
Inside Circlip Pliers: 253
Brake Lever Position Adjustment 254
Brake Pedal Position Inspection 254
Brake Pedal Position Adjustment 254
Brake Pedal and Shaft Removal 254
Brake Pedal and Shaft Installation 255
Front Caliper Removal 256
Front Caliper Installation 256
Torque – 256
Rear Caliper Removal 256
Rear Caliper Installation 257
Torque – 257
Caliper Disassembly 257
Caliper Assembly 259
Torque – 259
Caliper Fluid Seal and Dust Seal Inspection 260
Caliper Dust Boot and Friction Boot Damage 260
Piston and Cylinder Damage 260
Caliper Holder Shaft Wear 261
Brake Pad Removal 262
Brake Pad Installation 262
Brake Pad Wear Inspection 262
Front Master Cylinder Removal 263
Front Master Cylinder Installation 263
Torque – 263
Torque – 263
Rear Master Cylinder Removal 263
Rear Master Cylinder Installation 264
Torque – 264
Front Master Cylinder Disassembly 264
Special Tool – 264
Rear Master Cylinder Disassembly 265
Special Tool – 265
Master Cylinder Assembly 265
Torque – 265
Master Cylinder Inspection (Visual Inspection) 266
Brake Disc Removal 267
Brake Disc Installation 267
Torque – 267
Brake Disc Wear 267
Brake Disc Warp 267
Special Tool – 267
Brake Fluid Level Inspection 268
Brake Fluid Change 268
Bleeding the Brake Line 268
Brake Hoses and Connections Inspection 269
Brake Hose Replacement 269
Front Brake Hose Removal 269
Brake Hose Installation Note 269
Torque – 269
Suspension 271
Fork Cylinder Holder Handle: 277
Front Fork Oil Change 278
Special Tool – 278
Torque – 278
Front Fork Removal 279
Front Fork Installation 279
Torque – 279
Front Fork Disassembly 280
Special Tools – 280
Special Tool – 280
Front Fork Assembly 281
Special Tool – 281
Special Tool – 281
Special Tools – 281
Torque – 281
Inner Tube, Outer Tube Inspection 282
Dust Seal Inspection 282
Spring Tension 282
Spring Preload Adjustment 283
Spacial Tool – 283
Rear Shock Absorber Removal 283
Special Tool – 283
Rear Shock Absorber Installation 284
Torque – 284
Rear Shock Absorber Wear 284
Bushing Wear 284
Rear Shock Absorber Oil Leak Inspection 284
CAUTION 285
Swingarm Removal 285
Swingarm Sleeve and Needle Bearing Wear 285
Swingarm Installation 286
Torque – 286
Torque – 286
Swingarm Disassembly/Assembly 286
Special Tool – 286
Special Tool – 286
Swingarm Bearing Installation 286
Special Tool – 286
Swingarm Needle Bearing Lubrication 286
Tie-Rod Removal 287
Special Tool – 287
Tie-Rod Installation 287
Torque – 287
Rocker Arm Removal 287
Special Tool – 287
Rocker Arm Installation 288
Torque – 288
Rocker Arm Bearing, Sleeve Inspection 288
Rocker Arm Lubrication 288
Steering 289
Steering Stem Bearing Driver: 292
Handlebar Removal 294
Handlebar Installation 294
Torque – 294
Rear View Mirror Removal 295
Rear View Mirrors (Left and Right) Installation 295
Steering Play Inspection 296
Steering Stem Removal 297
Special Tool – 297
Steering Stem Installation 297
Torque – 298
Torque – 298
Steering Stem Warp 299
Stem Bearing Removal 300
Special Tool – 300
Special Tools – 300
Stem Bearing Installation 300
Special Tools – 300
Special Tools – 300
Special Tool – 301
Torque – 301
Stem Bearing Lubrication 301
Stem Bearing Wear, Damage 301
Frame 303
Jack: 307
Seat Removal 308
Seat Installation 308
Lower Fairings Removal 309
Lower Fairings Installation 309
Upper Fairing Removal 309
Air Duct Removal 309
Right Side Cover Removal 310
Right Side Cover Installation 310
Left Side Cover Removal 310
Left Side Cover Installation 310
Front Fender Removal 311
Rear Fender Removal 311
Fender Installation Note 312
Frame Inspection 313
Engine Guard Removal 314
Carrier Removal 314
Carrier Installation 314
Torque – 314
Electrical System 315
Outside Circlip Pliers: 326
There are a number of important precautions that are musts when 330
Wiring Inspection 332
Battery Removal/Installation 333
Battery Activation 333
Precautions 335
Interchange 336
Charging Condition Inspection 336
Refreshing Charge 337
Alternator Rotor/Starter Clutch Removal 338
Special Tool – 338
Special Tool – 338
Starter Clutch Sprocket Removal 339
Starter Clutch Sprocket Installation 339
Torque – 339
Alternator Rotor/Starter Clutch Installation 340
Torque – 340
Torque – 340
Special Tool – 340
Sealant – 340
Sealant – 340
Torque – 340
Alternator Stator Removal 340
Alternator Stator Installation 341
Sealant – 341
Torque – 341
Alternator Inspection 341
Special Tool – 341
Regulator/Rectifier Removal 342
Regulator/Rectifier Output Voltage Inspection 342
Special Tool – 343
Regulator/Rectifier Inspection 343
Charging System Circuit 346
Ignition System Circuit 347
Crankshaft Sensor Removal 348
Crankshaft Sensor Installation 348
Torque – 348
Crankshaft Sensor Inspection 348
Ignition Coil Removal/Installation 349
Ignition Coil Inspection 349
Ignition Timing Inspection 350
Special Tool – 350
Spark Plug Removal/Installation 350
Spark Plug Gap Inspection 350
IC Igniter Removal 351
IC Igniter Inspection 351
Special Tools – 351
Special Tool – 352
Special Tool – 352
Special Tool – 353
Troubleshooting 354
Special Tool – 355
Diodes Inspection 355
Electric Starter Circuit 357
Starter Motor Removal 358
Starter Motor Installation 358
Torque – 358
Starter Motor Disassembly 358
Special Tool – 358
Starter Motor Assembly 359
Torque – 359
Torque – 360
Brush Inspection 360
Brush Spring Inspection 360
Commutator Cleaning and Inspection 360
Armature Inspection 361
Brush Plate Inspection 361
Starter Chain Guide Wear 361
Starter Relay Inspection 362
Headlight Circuit 363
Headlight Beam Horizontal Adjustment 363
Headlight Beam Vertical Adjustment 363
Headlight Bulb Replacement 364
Headlight Unit/Housing Removal 364
Headlight Unit/Housing Installation 365
City Light Bulb Replacement 365
Tail/Brake Light Bulb Replacement 365
Tail/Brake Light Lens Removal/Installation 366
Turn Signal Light Bulb Replacement 366
Turn Signal Relay Inspection 366
Turn Signal Light Circuit 367
Fan System Circuit Inspection 368
Radiator Fan Circuit 368
Fan Motor Inspection 368
Meter Unit Removal 369
Meter Unit Disassembly 369
Tachometer Inspection 370
Bulb Replacement 370
Tachometer Circuit 371
Water Temperature Warning System Inspection 371
Water Temperature Warning System 372
Brake Light Switch Inspection 373
Switch Inspection 373
Special Tool – 373
Neutral Switch Connections 373
Rear Brake Light Switch Connections 373
Oil Pressure Switch Connections* 373
Side Stand Switch Connections* 373
Radiator Fan Switch Inspection 374
Water Temperature Switch Inspection 375
The junction box [A] has fuses [B], relays, and diodes The rela 376
Junction Box Fuse Circuit Inspection 376
Special Tool – 376
Starter Circuit/Headlight Relay Inspection 376
Special Tool – 376
Diode Circuit Inspection 377
Junction Box Internal Circuit 378
30 A Main Fuse Removal 379
Junction Box Fuse Removal 379
Junction Box Fuse Installation 379
Fuse Inspection 379
Appendix 381
NOTE 396
Engine Doesn’t Start, Starting Difficulty: 396
Starter motor not rotating: 396
Starter motor rotating but engine doesn’t turn over: 396
Engine won’t turn over: 396
No fuel flow: 396
Engine flooded: 396
No spark; spark weak: 396
Fuel/air mixture incorrect: 396
Compression low: 396
Poor Running at Low Speed: 396
Spark weak: 396
Fuel/air mixture incorrect: 396
Compression low: 396
Other: 397
Poor Running or No Power at High Speed: 397
Firing incorrect: 397
Fuel/air mixture incorrect: 397
Compression low: 397
Knocking: 397
Miscellaneous: 397
Overheating: 397
Firing incorrect: 397
Fuel/air mixture incorrect: 397
Compression high: 397
Engine load faulty: 397
Lubrication inadequate: 397
Coolant incorrect: 398
Cooling system component incorrect: 398
Over Cooling: 398
Cooling system component incorrect: 398
Clutch Operation Faulty: 398
Clutch slipping: 398
Clutch not disengaging properly: 398
Gear Shifting Faulty: 398
Doesn’t go into gear; shift pedal doesn’t return: 398
Jumps out of gear: 398
Overshifts: 398
Abnormal Engine Noise: 398
Knocking: 398
Piston slap: 398
Valve noise: 398
Other noise: 398
Abnormal Drive Train Noise: 398
Clutch noise: 398
Transmission noise: 399
Drive line noise: 399
Abnormal Frame Noise: 399
Front fork noise: 399
Rear shock absorber noise: 399
Disc brake noise: 399
Other noise: 399
Oil Pressure Warning Light Goes On: 399
Exhaust Smokes Excessively: 399
White smoke: 399
Black smoke: 399
Brown smoke: 399
Handling and/or Stability Unsatisfactory: 399
Handlebar hard to turn: 399
Handlebar shakes or excessively vibrates: 399
Handlebar pulls to one side: 399
Shock absorption unsatisfactory: 399
Brake Doesn’t Hold: 399
Disc brake: 399
Battery Trouble: 400
Battery discharged: 400
Battery overcharged: 400

DESCRIPTION:

Kawasaki KLE500 Motorcycle Service Manual – PDF DOWNLOAD 

FOREWORD:

• This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance andrepair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry outmaintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
• In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures  before starting work, and then do the work carefullyin a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
• For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

S.V 16/03/2025