2001-2005 Kawasaki ER-5 / ER500 Service Manual
Diagnostics, removal sequences, and maintenance for ER-5 and ER500 models: fuel system, engine top end, clutch, cooling system, brakes, and more. Part # kawer5er5000105
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Models Covered & Key Technical Specifications
Kawasaki ER-5 / ER500 (kawer5er5000105) - 2001-2005 For ER-5 and ER500 models: diagnostics, service, and parts.
- Calibrated Locking Torques: 45 N
- System Containment Volume: 17 L
- Critical Running Clearance: 0.030-0.071 mm
- Universal Heat Tolerance: 95°C
- Core Weight Data: 179 kg
- Standard Threaded Fastener Data: 11 N
Professional Workshop Service Manual & Technical Specifications
Kawasaki ER-5, ER500 (2001-2005) Service Manual: Unified Shop Hydraulic Manual: Kawasaki ER-5, ER500 service manual, 2005 edition Technical-Guide
Design-Core: ER-5 / ER500 // Application-Range: Motorcycle / Kawasaki Motorcycle & Engine Company Logic // Design-Core: 2001-2005
| Service-Nexus | Rating | Context |
|---|---|---|
| Engine Specifications | Standard | 498 cc Displacement |
| Carburetor Specifications | Standard | KEIHIN CVK34 |
| Valve Specifications | Standard | 0.13-0.18 mm Inlet Clearance |
| Brake Specifications | Standard | Single Disc Front |
| Drive Chain Specifications | Standard | EK520SX-O Drive Chain |
| Oil Capacity | Standard | 3.4 L Total Amount |
Diagnostic procedures address the following systems: Fuel System, Cooling System, Engine Top End, Clutch, Crankshaft/Transmission, Engine Lubrication System, Final Drive, Brakes, Wheels/Tires, and Frame. Specifications are provided for all major components. This manual covers engine overhaul, transmission overhaul, and chassis maintenance. This manual documents torque specifications for the engine mounting bolts to ensure proper gasket sealing.
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