manual kawasaki kle 500
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manual kawasaki kle 500Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done. General Specifications.Unit Conversion Table.1-11. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Specifications. 2-11 Special Tools. 2-13 Maintenance Procedure.2-14 Fuel System. 2-14 Throttle Cable Inspection.2-14 Idle Speed Inspection. 2-15 Carburetor Synchronization Inspection. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. Use this table for only the bolts and nuts which do not require a specific torque value. If the free play is improper, adjust the throttle cable. Throttle Grip Free Play Standard: 3 mm (0.08. Visually inspect the hoses for signs of deterioration. Valve Clearance (when cold) Inlet 0.13 0.18 mm (0.0051 0.0071 in.) Exhaust 0.18 0.23 mm (0.0070 0.0090 in.) A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.http://watersns.com/userData/board/brother-sx-4000-typewriter-manual.xml
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WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser- voir are unidentified. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection) or shock absorber clamps. If the steering is too loose, tighten the stem nut a fraction of a turn. Turning the adjuster clockwise moves the headlight beam to the left. Also, if there is a brake in the element material or any other damage to the element, replace the element with a new one. First turn the cap counterclockwise to the first stop and wait there for a few seconds.Engine Oil Grade: API SE, SF, SG or API SH or SJ with JASO MA Viscosity: SAE 10W40. Air, however, is easily compressed. Choke Cable Free Play Adjustment. Main Jet 11. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. If the dampers are damaged or deteriorated, replace them. Cooling System Pressure Testing.Flushing. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. If the coolant is brown, iron or steel parts are rusting. In either case flush the cooling system. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system. The radiator fan may start even if the ignition switch is off.Avoid sharp bending, kinking, flattening, or twisting. MO: Apply molybdenum disulfide oil. R: Replacement Parts.http://kythuatviet.vn/uploads/userfiles/federal-styles-manual.xml The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. The rings should fit perfectly parallel to the groove sur- faces.If the measurement is under the service limit, replace the piston. WARNING Install the clamp screws horizontally. M: Apply molybdenum disulfide grease. R: Replacement Parts. EO: Apply engine oil. G: Apply grease. HG: Apply high temperature grease. Clutch Release Installation CAUTION Always install a new oil seal when the clutch release. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspection. Engine Oil and Oil Filter.Engine Oil Level Inspection.Engine Oil Change.Oil Filter Replacement. Oil Pan and Relief Valve. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it. Note the follow- ing. If these parts are assembled in the wrong position, the neutral indicator light will not light when the gears are in neutral. HG: Apply high temperature grease. L: Apply a non-permanent locking agent. R: Replacement Parts. Tire Removal CAUTION Do not lay the front wheel on the ground with the disc facing down. Special Tools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 CAUTION Take care not to insert the tire irons so deeply that. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc.https://ayurvedia.ch/e-scooter-wiring-manual Place blocks under the wheel so that the disc does not touch the ground. If any bear- ings are removed, they will need to be replaced with new ones. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts. If the seal is torn or is leaking, replace the bearing. If this seal is not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence. G: Apply grease. Top Bolt and O-ring Spacer Fork Spring Seat Fork Spring. Push or pull the pivot shaft while turn- ing the shaft. Tapping on the shaft could damage the needle bearings in the swingarm.G: Apply grease. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it. Sidestand Switch 2. Radiator Fan 14. Horn 3. Radiator Fan Switch 15.Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under condi- tions other than given above. WARNING This battery is sealed type.The measured resistance should be small in one direc- tion and 10 or more times in the other direction. Neutral Switch 3. Starter Button 11. Main Fuse 30 A 4. Spark Plugs 12. Battery 12 V 10 AH 5. Ignition Coils 13. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running. CAUTION When handling the quartz-hologen bulb, never touch the glass portion with bare hands. The relays and diodes can not be removed.It Ignition or engine stop switch shorted is meant simply as a rough guide to assist Wiring shorted or open the troubleshooting for some of the more Fuse blown. Cables: Lubricate with Cable Lubricant.The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. First Edition (1): Dec. 10, 2004 (K) However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourse lf with the procedures before starting work, and then do the work care- fully in 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 ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. A ny owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special T ool Catalog or Manual. How to Use This Manual In this manual, the product is divided into its major systems and these systems ma ke up the manual’s cha pters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive T able of Contents. For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the T able of Contents on the first page of the chap- ter to find the ignition coil section. Whenever you see these W ARNING and CAUTION symbols, heed their instructions. Always follow safe operating and maintenance practices. W ARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, o r loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to W ARNING and CAUTION) which will help you distinguish different types of informa- tion. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the T able of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly. T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each c hapter wherever necessary. This section explains the items that r equire particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Battery Ground Before completing any service on the motorcycle, discon- nect the battery wires from the battery to prevent the engine from accidentally turning over. Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer. Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during ve- hicle disassembly can cause excessive wear and decrease performance of the vehicle. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage o f Removed P arts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious ac- cident. Visually inspect removed parts for corrosion, discol- oration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part i s be- yond its service limit. Replacement Parts Replacement Parts must be KA W ASAKI genuine or recommended by KA WASAKI. G askets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Assembly Order In most cases assem bly order is the reverse of disa ssem- bly, however, if assembly order is provided in this Service Manual, follow the procedures given. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar- ter turn and them remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening T orque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. T ighten fasteners to the specified torque using a good quality torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam- age. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing per- formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling. Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains be- fore applying liquid gasket or locking agent. Do no t apply them excessively. Excessive application can clog oil pas- sages and cause serious damage. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Sea l Do not remove pressed oil or grease seals unless removal is necessary. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to lip of seal before installing the seal. Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. T ake c are not to open the clip excessively when in- stalling to prevent deformation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. The initial maintenance is vitally important and must not be neglected.An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the majo r bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket. When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten it to the specified torque. L: Apply a non-permanent locking agent to the threads. LG: Apply liquid gasket to the threads. Lh: Left-hand threads. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1) R: Replacement parts. S: T ighten the fasteners following the specified sequence. SS: Apply silicone sealant to the threads. St: Stake the fasteners to prevent loosening.All of the values are for use with dry solvent-cleaned threads.If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage. If the idle speed increase, check the throttle cable free play and the cable routing.WA R N I N G Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding.Special T ool - V acuum Gauge: 57001-1369 Synchronization Adjustment 0 The pilot screw is set at the factory and should not be removed. This is to set the screw to its original (correct) position when assembling. When setting the pilot screw, do not refer to the specifi- cations which show mean opening of the pilot screws. Replace the hose if it has been sharply bent or kinked. Air Cleaner Element Cleaning and Inspection NOTE 0 In dusty areas, the element should be cleaned more frequently than the recommended interval. 0 After riding through rain or on muddy roads, the element should be cleaned immediately. WA R N I N G Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. CAUTION For refilling, add the specified mixture of coolant and soft water. Adding water alone dilute s the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum en- gine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often, or the reserve tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks (see V isual Leak Inspection, and Cooling System Pressure T esting). Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.If the clutch operation is insuf ficiency, inspect the clutch system. WA R N I N G When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust the clutch. Clutch Lever Free Play Standard: 2 ? 3 mm (0.08 ? 0.12 in.) An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life (90 worn). Since the tire may wear unevenly, take measurement at several places. NOTE 0 Check and balance the wheel when a tire is replaced with a new one. If any damage is found, replace the wheel if necessary. A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break. Rim Runout (with ti re installed) Standard: Axial Runout 0.5 mm (0.02 in.) Radial Runout 0.8 mm (0.03 in.) Service Lim it: Axial Runout 1.5 mm (0.06 in.) Radial Runout 1.5 mm (0.06 in.) If rim runout exceeds the service limit, inspect the hub bearings. If the problem is not due to the bearings, retighten the spokes. W ARNING Never attempt to repair a damaged wheel part. If the wheel part is damaged, it must be replaced with a new part. NOTE 0 Wheel alignment can also be checked using the straightedge or string method. W ARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. If there is any irregularity, replace the drive chain. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. Drive Chain 20-link Length Standard: 317.5 ? 318.2 mm (12.50 ? 12.53 i n.) Service Limit: 323 mm (12.7 in.) A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safely, use only the standard chain. It is an end- less type and should not be cut for installation. T o avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules: Use only kerosene or diesel oil for cleaning an O -ring drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring. Blow the chain dry with compressed air immedi- ately after cleaning. If the brake fluid leaked from any position, inspect or re- place the problem part. T ighten any loose fittings and any banjo bolts. If any brake hose routing is incorrect, route the brake hose according to Cable, Wire and Hose Routing Section in the Appendix chapter. If the brake operation is insuf ficiency, inspect the brake system. W ARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety. NOTE 0 Hold the reservoirs horizontal by raising the motorcycle perpendicular to the ground when checking brake fluid level.After changing the fluid, use only the same type and brand of fluid thereafter.If it does not, adjust the brake light timing. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter). You've come to the right place! It all starts here. Read our stories from the road. Informative and entertaining DVDs to help get you on the road! Inspirational stories by veteran travellers Greg Frazier (5 times RTW), Peter and Kay Forwood (193 countries), Tiffany Coates (Mongolia Mayhem) and Rene Cormier (University of Gravel Roads). From the HU Annual photo contest! This section will help you to plan your trip, whether it's to the next state, country or all the way around the world. Start here! That includes the bike, riding gear, etc. etc. Which bike is right for me. How do I prepare the bike. What do I need - riding gear, clothing, camping gear, first aid kit, tires, maps, GPS. What don't I need? How do I pack it all.This section is about staying healthy, happy and secure on your motorcycle adventure. And crossing borders, war zones or oceans! Security tips and questions. Also available for download on Vimeo! Start your blog here! People who want to meet travellers - yes that's YOU - and can provide local assistance, and may be your new best friends! For the first time ever, a motorcycle travel DVD made for women, by women. These intrepid women share their tips to help you plan your own motorcycle adventure. They also answer the women-only questions, and entertain you with amazing tales from the road.They will encourage you, share their experiences and advice on how to do it! To get a sense of what goes on, watch the meetings trailer here! You get additional privileges on the HUBB, access to the Members Private Store, and more to come as we roll out new systems. Of course, you get our sincere thanks, good karma and knowing you're helping to keep the motorcycle travel dream alive.:-) Become a Contributing or Gold Member here! Great conversation starter when you meet people on the road! New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps! Meet some of your fellow travellers. See the trailer! We reach a dedicated, worldwide group of real travellers, and are the only website focusing exclusively on long distance motorcycle travellers. If you sell motorcycles or motorcycle accessories, riding gear, camping equipment and clothing, transport motorcycles, organize motorcycle tours, or have motorcycles to rent, you should be advertising with us! Help keep your favorite website going and get additional HUBB privileges. Already have an account. Become a Contributing Member here. Use Site Search to search everywhere. Or maybe haven't checked out the FAQ ? It's also helpful to all to put your location in your profile, so when you ask a question that's geographically dependent, people know where you are and can give a MUCH better answer. It is almost 8 MB, so will have to try compressing with RAR. Also have an illustrated parts breakdown file with part numbers. PM an email address, if file is too big to email comfortably I can put it on google share. Regards, ShaunALL the information you need to get inspired to travel anywhere in the world, and be READY to GO when it's time! We did too - and now here's the list of Circumnavigators. Check it out now, and add your information if we didn't find you. ALL Dates subject to change. New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps! To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB. Please try your request again later. Why did this happen. This page appears when Google automatically detects requests coming from your computer network which appear to be in violation of the Terms of Service. The block will expire shortly after those requests stop. This traffic may have been sent by malicious software, a browser plug-in, or a script that sends automated requests. If you share your network connection, ask your administrator for help — a different computer using the same IP address may be responsible. Learn more Sometimes you may see this page if you are using advanced terms that robots are known to use, or sending requests very quickly. Top Tips to Prepare Your Vehicle for an Off-Road Adventure July 11, 2021 5 Helpful Tips for Buying a Car for First-Timers July 10, 2021 8 Advantages of PDR Training July 10, 2021 How to Become a Truck Driver: A Simple Guide July 9, 2021 Debunking the Most Common Myths About Junk Car Removal July 5, 2021 5 of the Best Trailer Tires for 2021 July 3, 2021 Search Motor Era. Clunky gear box and the engine sounds clunky on cold start up to is this normal for these engines. The manual tells me to pull clutch in and kawasaki kle 500 manual use the choke if temp below 35c. It does sound better if i do that. Temp means i will always have to use choke even in summer unless the bike is warmed. 4 cu in) parallel- twin engine. As a dual- sport motorcycle, it can be used both on roads and in light off- road conditions. Manual de servicio en ingles. ) 181 kg ( 399 lb. ) 95 kg ( 209 lb. ) 105 kg kawasaki kle 500 manual ( 232 lb. Free pdf download kawasaki kle 500 manual kawasaki kawasaki kle 500 manual versys kawasaki kle 500 manual online service repair manual pdf by just give me the damn manual. Kawasaki kle 500 kawasaki kle 500 manual manual: 6. 62 kawasaki kle 500 manual mb 46683 kawasaki kle 500 parts list: 1. 73 mb 15256 kawasaki klf 250 kawasaki kle 500 manual aservice manual: 5. 45 mb 10485 kawasaki klr 250 kl 250 d service manual: 42.