Kawasaki ER-5 (498 cc) — Example photo: lorenzo bolla, CC BY 2.0, Wikimedia Commons

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Kawasaki · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

ER-5 (498 cc)

Library entry covers 1997-2006

32 factory 29 guideline

Published source

Kawasaki ER-5 (ER500-C) Service Manual, Periodic Maintenance Chart pp. 1-9 to 1-10

Factory workshop manual. Covers 2001-2006 (ER500-C service manual; chart in km and mile).

Open the source

61 items for a 2006 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2006 Kawasaki ER-5 (498 cc)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 373 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain - lubricate. Factory: Every 600 km

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 621 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain slack - inspect. Factory: Every 1000 km

Every 1,000 mi or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 3,000 mi or 12 months

4 items

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 1 month

1 item

Brake fluid level - inspect

Brakes

Factory

Factory: Monthly or every column

Every 4,000 mi or 12 months

2 items

Change engine oil

Engine

Factory

Manual: Engine oil - change. Factory: Initial 1 (0.6) x1000 km; columns 1/6/12/18/24/30/36 x1000 km (x1000 mile)
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 4,000 mi

11 items

Air suction valve - inspect

Engine

Factory

Factory: Every column from 6 x1000 km
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug - clean and gap. Factory: Every column from 6 x1000 km
Fuel hoses, connections - inspect

Fuel and air

Factory

Factory: Every column from 6 (4) x1000 km
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch adjust - inspect. Factory: Initial 1,000 km; then every column
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear - inspect. Factory: Every column from 6 x1000 km
Check steering head bearing adjustment

Front end

Factory

Manual: Steering - inspect. Factory: Initial 1,000 km; then every column
Brake light switch - inspect

Brakes

Factory

Factory: Initial 1,000 km; then every column
Brake play - inspect

Brakes

Factory

Factory: Initial 1,000 km; then every column
Check brake pads and discs

Brakes

Factory

Manual: Brake lining or pad wear - inspect. Factory: Every column from 6 x1000 km
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses, connections - inspect. Factory: Every column from 6 x1000 km
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire wear - inspect. Factory: Every column from 6 x1000 km

Every 6,000 mi or 12 months

4 items

Inspect coolant hoses and clamps

Engine

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,500 mi

11 items

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Valve clearance - inspect. Factory: Before 2005 model: 12, 24, 36 x1000 km; after 2005 model: 24 x1000 km
Idle speed - inspect

Engine

Factory

Factory: Initial 1,000 km; then 12, 24, 36 x1000 km
Nut, bolts, and fasteners tightness - inspect

Engine

Factory

Factory: Initial 1,000 km; then 12, 24, 36 x1000 km
Replace oil filter

Engine

Factory

Manual: Oil filter - replace. Factory: Initial 1,000 km; then 12, 24, 36 x1000 km
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle cable - inspect. Factory: Initial 1,000 km; then 12, 24, 36 x1000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - clean. Factory: Marked at 12, 24, 36 x1000 km; more often in severe conditions
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor synchronization - inspect. Factory: Marked at 12, 24, 36 x1000 km
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork oil leak - inspect. Factory: Marked at 12, 24, 36 x1000 km
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm pivot - lubricate. Factory: Marked at 12, 24, 36 x1000 km
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear shock absorber oil leak - inspect. Factory: Marked at 12, 24, 36 x1000 km
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: General lubrication - perform. Factory: Marked at 12, 24, 36 x1000 km

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline

Every 15,000 mi or 2 years

4 items

Replace coolant

Engine

Factory

Manual: Coolant - change. Factory: Marked at 24 (15) x1000 km or 2 years
Change fork oil

Front end

Factory

Manual: Front fork oil - change. Factory: Marked at 24 x1000 km or 2 years
Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearing - lubricate. Factory: Marked at 24 (15) x1000 km or 2 years
Replace brake fluid

Brakes

Factory

Manual: Brake fluid - change. Factory: Marked at 24 x1000 km or 2 years

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Brake master cylinder cup and dust seal - replace

Brakes

Factory

Factory: Every 4 years
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Caliper piston seal and dust seal - replace. Factory: Every 4 years

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.