Question about 2005 kawasaki KLE 500

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2005 Kawasaki KLE 500 downshifting difficult to impossible

My bike has milage of about 13.000 suddenly last year it became difficult to reach the right gear, going down from 6 to 5 was almost impossible. But also other levels gave problems. We've already changed the oil, checked the rest, nothing has damaged, what could be the cause of this and how possibly to solve this. It's becoming dangerous since you don't know what gear you're driving and you can't react in the correct way.

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  • kawasaki Master
  • 40,816 Answers

Hi, Pierre and the usual suspects are:
1. Clutch not adjusted properly.!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
2. Primary chaincase overfilled with lubricant.
3. Corners wore off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. A loose shift lever on shifter shaft.
7. Shifter forks sprung.
8. Shifter pawl needs adjusting.
9. Heel/toe shifter coming in contact with the floorboard.
10. Transmission oil too heavy.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Downshifting problem
cant get into neutral or even first gear sometimes
Kawasaki KLE500 Service Manual
OEM Parts for Kawasaki

Posted on Jun 19, 2017

6 Suggested Answers

  • 2 Answers

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Posted on Jan 02, 2017

  • 2653 Answers

SOURCE: When I change the oil

I've got a service manual if you want it?

That should have all your answers.

Let me know.

Posted on Feb 28, 2009

  • 6966 Answers

SOURCE: Having trouble with the clutch/gears

Hi and welcome to FixYa,

To my knowledge, the engine and the gear/transmission share the same oil in the crankcase. Clutch cable adjustment on most bikes could be done 2 ways:

  • after the clutch lever itself. There would be an adjustable end of the cable. It is locked in place by a coin like nut with grooved edge. This locked must be loosed before the cable end could be adjusted.
  • similarly at the bottom end of the cable that attaches to the clutch arm, the cable end would also have a thread end. There would be 2 lock nuts that must be loosened up.
You can experiment clutch play/slack to your personal preference. Soon as you are satisfied (number of tries clutching/engaging gears), then the locks could be tightened in place.

Good luck and thank you for using FixYa.

Posted on Mar 07, 2009

  • 2 Answers

SOURCE: 2003 vulcan 750-how/where to check engine oil level / noisy

there should be a little window just below the oil fill area that says high and low, that's where you gauge the level of oil you have. it's not a dipstick, and not very precise, but that's it.

Posted on May 05, 2009

  • 3567 Answers

SOURCE: kawasaki en 500 c1Im having problems changing up and down gears

The bike has some bent shift forks. Bent shift forks do not move the slider gears properly when changing gears. Expensive to fix.

Posted on Sep 15, 2009

  • 376 Answers

SOURCE: 2000 Vulcan Nomad 1500 FI - Bike was sitting for 6

You need to remove the carbs and dismantle them completly and adjust them to spec. Also change the fuel filter.

Posted on Oct 28, 2009

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