Kawasaki KLE500 (2004) [118/401] 6 engine top end
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Kawasaki KLE500 (2004) [118/401] 6 engine top end

Kawasaki KLE500 (2004) [118/401] 6 engine top end
5-6 ENGINE TOP END
Specifications
Item Standard Service Limit
Clean Air System
Vacuum Switch Valve Closing
Pressure
Open → Close
45 ∼ 53 kPa (340 ∼ 400 mmHg)
–––
Camshafts
Cam Height:
Exhaust 35.416 ∼ 35.530 mm (1.3943 ∼ 1.3988 in.) 35.32 mm (1.3905 in.)
Inlet 35.476 ∼ 35.590 mm (1.3967 ∼ 1.4012 in.) 35.38 mm (1.3929 in.)
Camshaft, Camshaft Cap
Clearance
0.030 ∼ 0.071 mm (0.0012 ∼ 0.0028 in.) 0.16 mm (0.006 in.)
Camshaft Journal Diameter 24.950 ∼ 24.970 mm (0.9823 ∼ 0.9831 in.) 24.92 mm (0.9811 in.)
Camshaft Bearing Inside
Diameter
25.000 ∼ 25.021 mm (0.9843 ∼ 0.9851 in.) 25.08 mm (0.9874 in.)
Camshaft Runout TIR 0.03 mm (0.0012 in.) or less TIR 0.1 mm (0.004 in.)
Rocker Arm Inside Diameter 12.500 ∼ 12.518 mm (0.4921 ∼ 0.4928 in.) 12.55 mm (0.4941 in.)
Rocker Shaft Diameter 12.466 ∼ 12.484 mm (0.4908 ∼ 0.4915 in.) 12.44 mm (0.4898 in.)
Cylinder Head
Cylinder Compression (usable range)
Electric Starter 960 ∼ 1 470 kPa (9.8 ∼ 15.0 kgf/cm², 139
∼ 213 psi) @450 r/min (rpm)
–––
Cylinder Head Warp ––– 0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust 0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.) –––
Inlet 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.) –––
Valve Head Thickness:
Exhaust
0.9 ∼ 1.1 mm (0.0354 ∼ 0.0433 in.) 0.7 mm (0.028 in.)
Inlet
0.4 ∼ 0.6 mm (0.0157 ∼ 0.0236 in.) 0.25 mm (0.01 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less
TIR 0.05 mm
(0.002 in.)
Valve Stem Diameter:
Exhaust 5.455 ∼ 5.470 mm (0.2148 ∼ 0.2154 in.) 5.44 mm (0.2142 in.)
Inlet 5.475 ∼ 5.490 mm (0.2156 ∼ 0.2161 in.) 5.46 mm (0.2150 in.)
Valve Guide Inside Diameter:
Exhaust 5.500 ∼ 5.512 mm (0.2165 ∼ 0.2170 in.) 5.58 mm (0.2197 in.)
Inlet 5.500 ∼ 5.512 mm (0.2165 ∼ 0.2170 in.) 5.58 mm (0.2197 in.)
Valve/valve Guide Clearance
(wobble method):
Exhaust
0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.) 0.27 mm (0.0106 in.)
Inlet
0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.) 0.22 mm (0.0087 in.)
Valve Seat Cutting Angle 45°, 32°, 60° –––
Valve Seat Surface:
Width:
Exhaust
0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
–––
Inlet
0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
–––

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