Kawasaki KLE500
KAWASAKI KLE500 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
KAWASAKI KLE500 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual / Repair Manual and Wiring Diagrams, for motorcycles Kawasaki KLE500. CONTENTS: Foreword General Information - Before starting to perform an inspection service or carry out a - Battery Ground - Edges of Parts - Solvent - Cleaning vehicle before disassembly - Arrangement and Cleaning of Removed Parts - Storage of Removed Parts - Inspection - Replacement Parts - Assembly Order - Tightening Sequence - Tightening Torque - Force - Gasket, O-ring - Liquid Gasket, Locking Agent - Press - Ball Bearing and Needle Bearing - Oil Seal, Grease Seal - Circlips, Cotter Pins - Lubrication - Direction of Engine Rotation - Electrical Wires - KLE500-B1 Left Side View - KLE500-B1 Right Side View - Prefixes for Units: - Units of Temperature: Periodic Maintenance - The scheduled maintenance must be done in accordance with this c - Tighten all bolts and nuts to the proper torque using an accurat - Steering Stem Nut Wrench: - Fuel System - Throttle Cable Inspection - Idle Speed Inspection - Carburetor Synchronization Inspection - Special Tool - - Special Tool - - Coolant Filter Cleaning - Fuel Hoses and Connections Check - Air Cleaner Element Cleaning and Inspection - Cooling System - Coolant Level Inspection - Radiator Hoses and Connections Inspection - Torque - - Engine Top End - Air Suction Valve Inspection - Valve Clearance Inspection - Special Tool - - Torque - - Clutch - Clutch Operation Inspection - Wheels/Tires - Air Pressure Inspection/Adjustment - Tire Tread Wear Inspection - Wheel/Tire Damage Inspection - Wheel Bearing Damage Inspection - Spoke Tightness and Rim Runout Inspection - Torque - - Special Tool - - Final Drive - Drive Chain Slack Inspection - Torque - - Drive Chain Wear Inspection - Drive Chain Lubrication - Brakes - Brake Fluid Leak (Brake Hose and Pipe) Inspection - Brake Hose Damage and Installation Condition Inspection - Torque - - Brake Operation Inspection - Brake Fluid Level Inspection - Special Tool - - Brake Pad Wear Inspection - Brake Light Switch Operation Inspection - Suspension - Front Forks/Rear Shock Absorber Operation Inspection - Front Fork Oil Leak Inspection - Rear Shock Absorber Oil Leak Inspection - Rocker Arm Operation Inspection - Rocker Arm Bearings and Sleeves Lubrication - Tie-rod Operation Inspection - Swingarm Needle Bearing Lubrication - Steering - Steering Play Inspection - Special Tool - - Special Tool - - Torque - - Torque - - Steering Stem Bearing Lubrication - Electrical System - Spark Plug Gap Inspection - Lights and Switches Operation Inspection - Headlight Aiming Inspection - Side Stand Switch Operation Inspection - Engine Stop Switch Operation Inspection - Others - Chassis Parts Lubrication - Pivots: Lubricate with Motor Oil. - Points: Lubricate with Grease. - Cables: Lubricate with Cable Lubricant. - Bolts, Nuts and Fastener Tightness Inspection - Nut, Bolt and Fastener to be checked - Replacement Parts - Fuel Hose Replacement - Air Cleaner Element Replacement - Coolant Change - Torque - - Radiator Hoses and O-ring Replacement - Engine Oil Change - Torque - - Torque - - Oil Filter Replacement - Special Tool - - Torque - - Brake Hose Replacement - Torque - - Brake Fluid Change - Torque - - Bleeding the Brake Line - Torque - - Caliper Rubber Parts Replacement - Master Cylinder Rubber Parts Replacement - Spark Plug Replacement - Torque - Fuel System - Fuel Level Gauge: - Throttle Cable Inspection - Throttle Cable Lubrication - Throttle Cable Removal - Throttle Cable Installation - Choke Cable Free Play Inspection - Choke Cable Free Play Adjustment - Choke Cable Installation - Choke Cable Lubrication - Carburetor Removal - Carburetor Installation - Service Fuel Level Inspection - Special Tool - - Service Fuel Level Adjustment - Fuel System Cleanliness Inspection - Special Tool - - Carburetor Disassembly/Assembly - Torque - - Carburetor Separation/Assembly - Carburetor Cleaning - Carburetor Inspection - Coolant Filter Cleaning - Air Cleaner Element Removal - Air Cleaner Element Installation - Air Cleaner Element Cleaning and Inspection - Air Cleaner Housing Removal - Air Cleaner Housing Installation - Air Cleaner Draining - Fuel Tank Removal - Fuel Tank Installation - Fuel Tap Removal - Fuel Tap Installation - Torque - - Fuel Tank and Tap Cleaning - Fuel Tap Inspection - Fuel Tank and Cap Inspection - Fuel Hose and Connection Inspection Cooling System - Bearing Driver Set: - Permanent type antifreeze is used as a coolant to protect the co - Coolant Deterioration Inspection - Coolant Level Inspection - Coolant Draining - Coolant Filling - Visual Leak Inspection - Cooling System Pressure Testing - Flushing - Coolant Filter Cleaning - Coolant Valve Inspection - Water Pump Removal - Water Pump Installation - Sealant - - Torque - - Torque - - Mechanical Seal Inspection - Water Pump Housing Disassembly - Special Tool - - Water Pump Housing Assembly - Special Tool - - Impeller Assembly - Pump Impeller Inspection - WARNING - Radiator Removal - Radiator Inspection - Radiator Fan Removal - Filler Neck Inspection - Radiator Cap Inspection - Radiator Hose and Connection Inspection - Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installa - Torque - - Thermostat Removal - Thermostat Installation - Thermostat Inspection - CAUTION - Radiator Fan Switch Removal - Water Temperature Switch Removal - Radiator Fan Switch, Water Temperature Switch Installation - Sealant - - Torque - - Radiator Fan Switch, Water Temperature Switch Inspection Engine Top End - Piston Ring Pliers: - Vacuum Switch Valve Removal - Vacuum Switch Valve Installation - Air Suction Valve Removal - Air Suction Valve Installation - Torque - - Air Suction Valve Inspection - Clean Air System Hose Inspection - Vacuum Switch Valve Test - Special Tool - - Cylinder Head Cover Removal - Cylinder Head Cover Installation - Sealant - - Torque - - Camshaft Chain Tensioner Removal - Camshaft Chain Tensioner Installation - Torque - - Torque - - Camshaft Removal - Camshaft Installation - Torque - - Torque - - Camshaft and Sprocket Assembly - Torque - - Camshaft, Camshaft Cap Wear - Torque - - Camshaft Chain Guide Wear - Rocker Shaft, Rocker Arm Removal - Rocker Shaft, Rocker Arm Installation - Torque - - Cylinder Head Oil Pipe Removal - Cylinder Head Oil Pipe Installation - Main Oil Pipe Removal - Main Oil Pipe Installation - Torque - - Compression Measurement - Special Tools - - Cylinder Head Removal - Cylinder Head Installation - Torque - - Cylinder Head Warp - Cylinder Head Cleaning - Valve Clearance Inspection - Valve Removal - Special Tools - - Valve Installation - Special Tools - - Valve Guide Removal - Special Tool - - Valve Guide Installation - Special Tool - - Special Tool - - Valve Seat Inspection - Measuring Valve-to-guide Clearance (Wobble method) - Valve Seat Repair - Cylinder Removal - Cylinder Installation - Special Tool - - Piston Removal - Special Tool - - Special Tool - - Piston Installation - Piston Ring, Piston Ring Groove Wear - Piston Ring End Gap - Cylinder Inside Diameter - Piston Diameter - Boring, Honing - Carburetor Holder Installation - Muffler Removal - Muffler Installation Clutch - Clutch Holder: - Clutch Lever Position Adjustment - Clutch Cable Inspection - Clutch Lever Installation - Cable Lubrication - Clutch Cover Removal - Clutch Cover Installation - Sealant - - Torque - - Clutch Release Removal - Clutch Release Installation - Clutch Removal - Special Tool - - Clutch Installation - Special Tool - - Torque - - Torque - - Clutch Plate Wear, Damage Inspection - Clutch Plate Warp Inspection - Clutch Spring Free Length Measurement - Clutch Housing Finger Inspection - Clutch Hub Spline Inspection Engine Lubrication System - Oil Pressure Gauge, 5 kgf/cm : - WARNING - Engine Oil Level Inspection - Engine Oil Change - Oil Filter Replacement - Oil Pan Removal - Oil Pan Installation - Torque - - Torque - - Relief Valve Removal - Relief Valve Installation - Torque - - Torque - - Relief Valve Inspection - Oil Pump Removal - Oil Pump Installation - Torque - - Torque - - Special Tool - - Oil Pump Disassembly - Oil Pump Assembly - Oil Screen Cleaning and Inspection - Oil Pressure Measurement - Special Tools - - Torque - Engine Removal/Installation - Engine Removal - Engine Installation - Torque - Crankshaft/Transmission - Bearing Puller: - Crankcase Splitting - Crankcase Assembly - Sealant - - Torque - - Torque - - Clutch Housing/Primary Chain Removal - Clutch Housing/Primary Chain Installation - Primary Chain Guide Wear Inspection - Torque - - Crankshaft Removal - Crankshaft Installation - Connecting Rod Removal - Connecting Rod Installation - Torque - - Crankshaft/Connecting Rod Cleaning - Connecting Rod Bend/Twist - Connecting Rod Big End Side Clearance - Connecting Rod Big End Bearing Insert/Crankpin Clearance - Torque - - Torque - - Crankshaft Runout - Crankshaft Main Bearing Insert/Journal Clearance - Torque - - Crankshaft Side Clearance - Balancer Removal - Balancer Installation - Balancer Shaft Bearing Insert/Journal Clearance - Torque - - External Shift Mechanism Removal - External Shift Mechanism Installation - Torque - - Torque - - Sealant - - Torque - - External Shift Mechanism Inspection - Torque - - Transmission Shaft Removal - Transmission Shaft Installation - Transmission Shaft Disassembly - Special Tool - - Special Tools - - Drive Shaft Assembly - Special Tool - - Output Shaft Assembly - Special Tool - - Shift Drum and Fork Removal - Shift Drum and Fork Installation - Torque - - Shift Drum Disassembly - Shift Drum Assembly - Ball and Needle Bearing Wear - Shift Pedal Installation - Torque - Wheels/Tires - Inside Circlip Pliers: - Front Wheel Removal - Special Tool - - Front Wheel Installation - Torque - - Rear Wheel Removal - Special Tool - - Rear Wheel Installation - Torque - - Wheel Inspection - Special Tool - - Spoke Inspection - Rim Inspection - Axle Inspection - Wheel Balance - Balance Inspection - Balance Adjustment - Air Pressure Inspection/Adjustment - Tire Wear Inspection - Tire Removal - Special Tool - - Special Tools - - Tire Installation - Hub Bearing Removal - Special Tool - - Special Tool - - Special Tools - - Hub Bearing Installation - Special Tool - - Special Tool - - Special Tool - - Hub Bearing Inspection - Hub Bearing Lubrication - Disassembly and Assembly - Lubrication Final Drive - Inside Circlip Pliers: - Drive Chain Slack Inspection - Wheel Alignment Inspection/Adjustment - Drive Chain Wear Inspection - Drive Chain Lubrication - Drive Chain Removal - Drive Chain Installation - Torque - - Drive Chain Case and Chain Guide Removal - Drive Chain Replacement - Drive Chain Installation - Engine Sprocket Removal - Engine Sprocket Installation - Torque - - Rear Sprocket Removal - Rear Sprocket Installation - Torque - - Sprocket Wear Inspection - Rear Sprocket Warp Inspection - Coupling Bearing Removal - Special Tool - - Coupling Bearing Installation - Special Tool - - Special Tool - - Coupling Installation - Coupling Bearing Inspection and Lubrication Brakes - Inside Circlip Pliers: - Brake Lever Position Adjustment - Brake Pedal Position Inspection - Brake Pedal Position Adjustment - Brake Pedal and Shaft Removal - Brake Pedal and Shaft Installation - Front Caliper Removal - Front Caliper Installation - Torque - - Rear Caliper Removal - Rear Caliper Installation - Torque - - Caliper Disassembly - Caliper Assembly - Torque - - Caliper Fluid Seal and Dust Seal Inspection - Caliper Dust Boot and Friction Boot Damage - Piston and Cylinder Damage - Caliper Holder Shaft Wear - Brake Pad Removal - Brake Pad Installation - Brake Pad Wear Inspection - Front Master Cylinder Removal - Front Master Cylinder Installation - Torque - - Torque - - Rear Master Cylinder Removal - Rear Master Cylinder Installation - Torque - - Front Master Cylinder Disassembly - Special Tool - - Rear Master Cylinder Disassembly - Special Tool - - Master Cylinder Assembly - Torque - - Master Cylinder Inspection (Visual Inspection) - Brake Disc Removal - Brake Disc Installation - Torque - - Brake Disc Wear - Brake Disc Warp - Special Tool - - Brake Fluid Level Inspection - Brake Fluid Change - Bleeding the Brake Line - Brake Hoses and Connections Inspection - Brake Hose Replacement - Front Brake Hose Removal - Brake Hose Installation Note - Torque - Suspension - Fork Cylinder Holder Handle: - Front Fork Oil Change - Special Tool - - Torque - - Front Fork Removal - Front Fork Installation - Torque - - Front Fork Disassembly - Special Tools - - Special Tool - - Front Fork Assembly - Special Tool - - Special Tool - - Special Tools - - Torque - - Inner Tube, Outer Tube Inspection - Dust Seal Inspection - Spring Tension - Spring Preload Adjustment - Spacial Tool - - Rear Shock Absorber Removal - Special Tool - - Rear Shock Absorber Installation - Torque - - Rear Shock Absorber Wear - Bushing Wear - Rear Shock Absorber Oil Leak Inspection - CAUTION - Swingarm Removal - Swingarm Sleeve and Needle Bearing Wear - Swingarm Installation - Torque - - Torque - - Swingarm Disassembly/Assembly - Special Tool - - Special Tool - - Swingarm Bearing Installation - Special Tool - - Swingarm Needle Bearing Lubrication - Tie-Rod Removal - Special Tool - - Tie-Rod Installation - Torque - - Rocker Arm Removal - Special Tool - - Rocker Arm Installation - Torque - - Rocker Arm Bearing, Sleeve Inspection - Rocker Arm Lubrication Steering - Steering Stem Bearing Driver: - Handlebar Removal - Handlebar Installation - Torque - - Rear View Mirror Removal - Rear View Mirrors (Left and Right) Installation - Steering Play Inspection - Steering Stem Removal - Special Tool - - Steering Stem Installation - Torque - - Torque - - Steering Stem Warp - Stem Bearing Removal - Special Tool - - Special Tools - - Stem Bearing Installation - Special Tools - - Special Tools - - Special Tool - - Torque - - Stem Bearing Lubrication - Stem Bearing Wear, Damage Frame - Jack: - Seat Removal - Seat Installation - Lower Fairings Removal - Lower Fairings Installation - Upper Fairing Removal - Air Duct Removal - Right Side Cover Removal - Right Side Cover Installation - Left Side Cover Removal - Left Side Cover Installation - Front Fender Removal - Rear Fender Removal - Fender Installation Note - Frame Inspection - Engine Guard Removal - Carrier Removal - Carrier Installation - Torque - Electrical System - Outside Circlip Pliers: - There are a number of important precautions that are musts when - Wiring Inspection - Battery Removal/Installation - Battery Activation - Precautions - Interchange - Charging Condition Inspection - Refreshing Charge - Alternator Rotor/Starter Clutch Removal - Special Tool - - Special Tool - - Starter Clutch Sprocket Removal - Starter Clutch Sprocket Installation - Torque - - Alternator Rotor/Starter Clutch Installation - Torque - - Torque - - Special Tool - - Sealant - - Sealant - - Torque - - Alternator Stator Removal - Alternator Stator Installation - Sealant - - Torque - - Alternator Inspection - Special Tool - - Regulator/Rectifier Removal - Regulator/Rectifier Output Voltage Inspection - Special Tool - - Regulator/Rectifier Inspection - Charging System Circuit - Ignition System Circuit - Crankshaft Sensor Removal - Crankshaft Sensor Installation - Torque - - Crankshaft Sensor Inspection - Ignition Coil Removal/Installation - Ignition Coil Inspection - Ignition Timing Inspection - Special Tool - - Spark Plug Removal/Installation - Spark Plug Gap Inspection - IC Igniter Removal - IC Igniter Inspection - Special Tools - - Special Tool - - Special Tool - - Special Tool - - Troubleshooting - Special Tool - - Diodes Inspection - Electric Starter Circuit - Starter Motor Removal - Starter Motor Installation - Torque - - Starter Motor Disassembly - Special Tool - - Starter Motor Assembly - Torque - - Torque - - Brush Inspection - Brush Spring Inspection - Commutator Cleaning and Inspection - Armature Inspection - Brush Plate Inspection - Starter Chain Guide Wear - Starter Relay Inspection - Headlight Circuit - Headlight Beam Horizontal Adjustment - Headlight Beam Vertical Adjustment - Headlight Bulb Replacement - Headlight Unit/Housing Removal - Headlight Unit/Housing Installation - City Light Bulb Replacement - Tail/Brake Light Bulb Replacement - Tail/Brake Light Lens Removal/Installation - Turn Signal Light Bulb Replacement - Turn Signal Relay Inspection - Turn Signal Light Circuit - Fan System Circuit Inspection - Radiator Fan Circuit - Fan Motor Inspection - Meter Unit Removal - Meter Unit Disassembly - Tachometer Inspection - Bulb Replacement - Tachometer Circuit - Water Temperature Warning System Inspection - Water Temperature Warning System - Brake Light Switch Inspection - Switch Inspection - Special Tool - - Neutral Switch Connections - Rear Brake Light Switch Connections - Oil Pressure Switch Connections* - Side Stand Switch Connections* - Radiator Fan Switch Inspection - Water Temperature Switch Inspection - The junction box [A] has fuses [B], relays, and diodes. The rela - Junction Box Fuse Circuit Inspection - Special Tool - - Starter Circuit/Headlight Relay Inspection - Special Tool - - Diode Circuit Inspection - Junction Box Internal Circuit - 30 A Main Fuse Removal - Junction Box Fuse Removal - Junction Box Fuse Installation - Fuse Inspection Appendix - NOTE - Engine Doesn't Start, Starting Difficulty: - Starter motor not rotating: - Starter motor rotating but engine doesn't turn over: - Engine won't turn over: - No fuel flow: - Engine flooded: - No spark; spark weak: - Fuel/air mixture incorrect: - Compression low: - Poor Running at Low Speed: - Spark weak: - Fuel/air mixture incorrect: - Compression low: - Other: - Poor Running or No Power at High Speed: - Firing incorrect: - Fuel/air mixture incorrect: - Compression low: - Knocking: - Miscellaneous: - Overheating: - Firing incorrect: - Fuel/air mixture incorrect: - Compression high: - Engine load faulty: - Lubrication inadequate: - Coolant incorrect: - Cooling system component incorrect: - Over Cooling: - Cooling system component incorrect: - Clutch Operation Faulty: - Clutch slipping: - Clutch not disengaging properly: - Gear Shifting Faulty: - Doesn't go into gear; shift pedal doesn't return: - Jumps out of gear: - Overshifts: - Abnormal Engine Noise: - Knocking: - Piston slap: - Valve noise: - Other noise: - Abnormal Drive Train Noise: - Clutch noise: - Transmission noise: - Drive line noise: - Abnormal Frame Noise: - Front fork noise: - Rear shock absorber noise: - Disc brake noise: - Other noise: - Oil Pressure Warning Light Goes On: - Exhaust Smokes Excessively: - White smoke: - Black smoke: - Brown smoke: - Handling and/or Stability Unsatisfactory: - Handlebar hard to turn: - Handlebar shakes or excessively vibrates: - Handlebar pulls to one side: - Shock absorption unsatisfactory: - Brake Doesn't Hold: - Disc brake: - Battery Trouble: - Battery discharged: - Battery overcharged:
Kawasaki KLE500 - Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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