{"id":2492,"date":"2024-09-30T21:57:05","date_gmt":"2024-09-30T21:57:05","guid":{"rendered":"https:\/\/www.whitedogbikes.com\/whitedogblog\/?p=2492"},"modified":"2024-12-29T10:40:37","modified_gmt":"2024-12-29T10:40:37","slug":"er5-specs","status":"publish","type":"post","link":"https:\/\/www.whitedogbikes.com\/whitedogblog\/er5-specs\/","title":{"rendered":"Kawasaki ER5 Specs (1996 to 2007)"},"content":{"rendered":"\n
\"Kawasaki<\/figure>\n
\"ER5<\/figure>\n

2004 Kawasaki ER-5 (yes, it’s looking a bit bruised and battered!)<\/strong><\/p>\n

Kawasaki ER5 Specs…..<\/h2>\n

The Kawasaki<\/a> ER5 was a naked, 498cc budget commuter motorcycle produced by Kawasaki in the UK between 1996 and 2007.
The ER-5 used a liquid cooled engine from the GPZ500<\/a> (although the ER-5 was 49bhp while the GPZ was 59bhp) and featured twin rear shocks, 37mm front forks and double cradle frame.
<\/p>\n

The bike was built by Kawasaki on a budget so was very prone to corrosion as well as electrical faults (mainly as they got older and in the wet).<\/p>\n

Need parts for your ER5? Kawasaki ER-5 used parts…<\/a><\/strong><\/p>\n

A little bit about the Kawasaki ER-5…..<\/strong><\/h2>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Basic model info…<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

Manufacturer:<\/strong><\/td>\nKawasaki<\/td>\n<\/tr>\n
Model:<\/strong><\/td>\nER5<\/td>\n<\/tr>\n
Model code:<\/strong><\/td>\nER500<\/td>\n<\/tr>\n
CC:<\/strong><\/td>\n498cc<\/td>\n<\/tr>\n
Engine type:<\/strong><\/td>\nParallel-twin (4 stroke)<\/td>\n<\/tr>\n
Years in production:<\/strong><\/td>\n1996 to 2007<\/td>\n<\/tr>\n
Style of bike:<\/strong><\/td>\nCommuter bike<\/td>\n<\/tr>\n
Insurance:<\/strong><\/td>\nGroup 8 (of 17)<\/td>\n<\/tr>\n
Replaced by:<\/strong><\/td>\nKawasaki ER6<\/a><\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Servicing your bike? You’ll need an ER-5 workshop manual…<\/a><\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Models and years (in the UK)<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

\n
\n

Note: The bike is referred to as the ‘ER500’ in the info below, the ‘ER500’ and ‘ER-5’ are the same bike (ER500 was the model code Kawasaki used for the ER5).<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

ER500 A1 (Sept 1996 to Sept 1997)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nJKAER500AAA00–<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nNaked budget commuter bike with 37mm front forks, 17 inch, 3 spoke wheels, single exhaust silencer and alloy radiator side covers.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nBlack, metallic blue or red<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33695\u00a0<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 A2 (Oct 1997 to Oct 1998)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nJKAER500AAA01–<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nSame as above model with new colours.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nSilver, red or blue<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33695\u00a0<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 A3 (Nov 1998 to Dec 1999)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nJKAER500AAA02–<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nSame as above model with new colours.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nRed, blue or pearl boulogne (kind of a blue\/green colour)<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a32995 to \u00a33095\u00a0<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 A4 (Jan 2000 till Dec 2000)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nJKAER500AAA04–<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nSame as above model with new colours.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nGrey, blue or red<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33250<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 C1 (Jan 2001 to Oct 2002)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nJKAER500ACA0510–<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nRe styled model.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nBlue, black or gold<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33295<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 C3 (Nov 2002 to Jan 2004)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nEX500C3—-<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nSame as above model.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nBlue, black or gold<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33295<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 C4P (Feb 2004 to Oct 2004)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\nEX500C4P—-<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nMinor detail changes.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nBlack or red<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33295<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n
ER500 C5P (Released Nov 2004)…..<\/span><\/strong><\/td>\n<\/tr>\n
Frame number started:<\/strong><\/td>\n<\/td>\n<\/tr>\n
Description:<\/strong><\/td>\nSame as above model.<\/td>\n<\/tr>\n
Available colours:<\/strong><\/td>\nBlack or blue<\/td>\n<\/tr>\n
Price (new):<\/strong><\/td>\n\u00a33345<\/td>\n<\/tr>\n
\u00a0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n
\"ER500<\/figure>\n
\"ER500<\/figure>\n
\"ER500<\/figure>\n
\"ER500<\/figure>\n
\"ER500<\/figure>\n
\"ER500<\/figure>\n

Panoramic view of the ER5 C1<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Engine and gearbox specs…..<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

Displacement:<\/td>\n498 cc<\/td>\n<\/tr>\n
Engine type:<\/td>\nParallel-twin<\/td>\n<\/tr>\n
\n
\n

Note: A parallel twin engine is slightly different to an inline twin engine. In very simple terms, they both have two cylinders placed side by side, but with a parallel twin both the pistons go up and down together (known as a 360 degree crankshaft angle, so they are at the top or bottom of the cylinder together), an inline twin has opposite pistons, so when 1 is at the top of the cylinder the other is at the bottom (known as a 180 degree crankshaft angle).<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Stroke:<\/td>\n4 stroke<\/td>\n<\/tr>\n
Bore\u00d7Stroke:<\/td>\n74x58mm<\/td>\n<\/tr>\n
No. of cylinders:<\/td>\n2<\/td>\n<\/tr>\n
Cam shaft configuration:<\/td>\nDOHC (double overhead cam)<\/td><\/tr>\n
\n
\"ER-5<\/figure>\n

Double overhead cams in an ER5 engine<\/strong><\/p>\n<\/td>\n<\/tr>\n

\n
\n

Note: The term ‘double overhead cams’ (or DOHC for short) refers to the layout and number of camshafts used in the engine.
\nSo ‘double overhead cam’ refers to 2 cam shafts situated in the top of the engine (as in the ER-5 engine pictured above).<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Compression ratio:<\/td>\n9.8:1<\/td>\n<\/tr>\n
Cylinder compression pressure:<\/td>\n9.6 to 14.7 bar (139 to 213 psi)<\/td>\n<\/tr>\n
Valves:<\/td>\n8 valve (4 per cylinder)<\/td>\n<\/tr>\n
Spark plug:<\/td>\nNGK DR9EA<\/a> (x2)<\/td>\n<\/tr>\n
Spark plug gap:<\/td>\n0.6 to 0.7mm<\/td>\n<\/tr>\n
Spark plug torque:<\/td>\n14nm<\/td>\n<\/tr>\n
Spark plug socket size:<\/td>\n18mm<\/td>\n<\/tr>\n
Firing order:<\/td>\n1 – 2<\/td>\n<\/tr>\n
Engine oil:<\/td>\n10w40 API SG\/JASO MA or higher<\/a><\/td>\n<\/tr>\n
\n
\n

Note:<\/strong> You can use any grade oil in the ER5 engine (mineral, semi synthetic or full synthetic). Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a semi synth as it’s a good balance between engine protection and price. More info…<\/a><\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Engine oil capacity:<\/td>\n3.0 litres<\/td>\n<\/tr>\n
Engine oil drain bolt location:<\/td>\nBottom\/underneath of the engine<\/td>\n<\/tr>\n
Oil filter type:<\/td>\nCanister type<\/td>\n<\/tr>\n
Oil filter:<\/td>\nHiflo HF303 \/ Filtrex OIF006<\/a><\/td>\n<\/tr>\n
Oil filter torque:<\/td>\n10nm<\/td>\n<\/tr>\n
Cooling system:<\/td>\nLiquid cooled<\/a><\/td>\n<\/tr>\n
Cooling system capacity:<\/td>\n1.7 litres<\/td>\n<\/tr>\n
Clutch:<\/td>\nWet (oil immersed) multiplate clutch<\/a><\/td>\n<\/tr>\n
Clutch operation:<\/td>\nCable<\/a><\/td>\n<\/tr>\n
Clutch lever free play:<\/td>\n2 to 3mm<\/td>\n<\/tr>\n
\n
\n

Note:<\/strong> You’ll need a clutch holding tool<\/a> for removing it, a clutch lever<\/a> if you’ve dropped it and possibly a clutch cable<\/a> if it’s suddenly stopped working!<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Gearbox:<\/td>\n6 Speed manual (1st gear down, 2nd to 6th gears up, neutral between 1st and 2nd gears)<\/td>\n<\/tr>\n
BHP:<\/td>\n49 bhp<\/td>\n<\/tr>\n
Torque:<\/td>\n33 ft\/lb<\/td>\n<\/tr>\n
Top speed (claimed):<\/td>\n110 mph<\/td>\n<\/tr>\n
0 to 60mph time (claimed):<\/td>\n5.3 seconds<\/td>\n<\/tr>\n
Quater mile time (claimed):<\/td>\n14.9 seconds<\/td>\n<\/tr>\n
\n
\n

Note: Top speed, 0-60 time, 1\/4 mile time etc are all very APPROX!!<\/strong> as it’s not unusual for these figures to be slightly inflated by the manufacturer to help sell more bikes!
\nIt is also worth noting Kawasaki stated the top speed was tested on a flat road with no wind (and probably a rider who weighted slightly more then a cat!) \ud83d\ude00<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Piston ring to cylinder bore clearance:<\/td>\nNew: 0.043mm \/ Max 0.070mm<\/td>\n<\/tr>\n
Valve clearance (inlet):<\/td>\n0.13mm to 0.18mm (when cold)<\/td>\n<\/tr>\n
Valve clearance (exhaust):<\/td>\n0.18mm to 0.23mm (when cold)<\/td>\n<\/tr>\n
Idle speed:<\/td>\n1,200rpm (+\/- 50)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n
\"ER500<\/figure>\n

2004 ER5 cylinder head cover<\/a><\/strong><\/p>\n

\n

Note: The 2004 Kawasaki ER-5 has 2 blanking plates on the cylinder head cover. Earlier models (and some GPZ500 engines on which the ER5 engine was based) had a reed valve and pipes instead of the blanking plate that was used as a crankcase ventilation system (CVS).<\/p>\n<\/blockquote>\n

\"ER5<\/figure>\n

ER5 side and center stands<\/a><\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Final drive stuff…..<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

Final drive:<\/td>\nChain<\/td>\n<\/tr>\n
Front sprocket:<\/td>\n17 teeth<\/a><\/td>\n<\/tr>\n
Engine\/chain sprocket nut tightening torque:<\/td>\n127nm<\/td>\n<\/tr>\n
Rear sprocket:<\/td>\n42 teeth<\/a><\/td>\n<\/tr>\n
Rear sprocket nuts tightening torque:<\/td>\n59nm<\/td>\n<\/tr>\n
Chain pitch\/length:<\/td>\n520 pitch \/ 106 links<\/a><\/td>\n<\/tr>\n
Chain free play:<\/td>\n35 to 40mm<\/td>\n<\/tr>\n
Chain stretch limit:<\/td>\n317.5 to 318.2mm over 20 links<\/td>\n<\/tr>\n
Chain lubrication:<\/td>\nChain lube<\/a><\/td>\n<\/tr>\n
\n
\n

How often should you lube the chain?
Now repeat after me\u2026 \u2018I MUST LUBE MY CHAIN LITTLE AND OFTEN!!\u2019 \ud83d\ude00<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

\"ER5<\/figure>\n

Kawasaki ER-5 Hiflo HF303 oil filter<\/strong><\/p>\n

\"ER500<\/figure>\n

Kawasaki ER-5 inline twin carbs<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Carb, fuel and oil stuff…..<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

Fuel system:<\/td>\nCarburetor<\/a><\/td>\n<\/tr>\n
MPG (average):<\/td>\n46 miles per gallon (very approx)<\/td>\n<\/tr>\n
Fuel tank range (approx):<\/td>\n170 miles<\/td>\n<\/tr>\n
\n
\n

There are variations in MPG and tank range between users, mainly due to different riding styles and areas (e.g. city riding vs open road, weekend blast vs touring etc)<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Fuel tank capacity:<\/td>\n17 litres<\/td>\n<\/tr>\n
Fuel type:<\/td>\nUnleaded petrol (95 octane grade – aka standard petrol from your local garage)<\/td>\n<\/tr>\n
\n
\n

Note: Yes, you can run the ER5 on the newer E10 petrol, but MAKE SURE<\/strong> you drain all the E10 petrol from the tank and carbs if the bikes not being used (e.g. being stored up over winter).
\nE10 grade fuel causes horrendous problems clogging up carb jets and moving parts when left for longer periods!<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Carb make:<\/td>\nKeihin (2x)<\/td>\n<\/tr>\n
Carb type:<\/td>\nCVK 34 (34mm flat-slide carbs)<\/td>\n<\/tr>\n
Pilot screw opening:<\/td>\n1 1\/4 (1 and a quarter) turns<\/td>\n<\/tr>\n
Engine oil:<\/td>\n10w40 API SG\/JASO MA or higher<\/a><\/td>\n<\/tr>\n
\n
\n

Note:<\/strong> You can use any grade oil in the ER-5 engine (mineral, semi synthetic or full synthetic). Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a semi synth as it’s a good balance between engine protection and price. More info…<\/a><\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Engine oil capacity (if just changing the oil and filtet):<\/td>\n3.0 litres<\/td>\n<\/tr>\n
Engine oil capacity (after a complete engine dismantle):<\/td>\n3.4 litres<\/td>\n<\/tr>\n
Engine oil drain bolt location:<\/td>\nBottom\/underneath of the engine<\/td>\n<\/tr>\n
Engine oil drain bolt:<\/td>\n29nm<\/td>\n<\/tr>\n
Oil filter type:<\/td>\nCanister type<\/td>\n<\/tr>\n
Oil filter:<\/td>\nHiflo HF303 \/ Filtrex OIF006<\/a><\/td>\n<\/tr>\n
Oil filter torque:<\/td>\n17nm<\/td>\n<\/tr>\n
\n
\n

Note: As a general rule when tightening oil filters, oil filters should only be tightened with a wrench a QUARTER TURN past finger tight.<\/br>\nThis means do the oil filter up by hand then use a socket\/oil filter pliers or similar to give it an extra quarter turn. More then this can cause damage to and leaks from the rubber seating ring.
\nAlso, always rub some engine oil (old oil if fine) onto the rubber ring before installing the new filter, this stops it becoming stuck to the engine (so makes future oil\/filter changes easier).<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

\"ER5<\/figure>\n

ER-5 exhaust end can<\/strong><\/p>\n

\"ER-5<\/figure>\n

ER5 exhaust downpipes mounted on the bike<\/strong><\/p>\n

\"ER500<\/figure>\n
\"ER500<\/figure>\n

Kawasaki ER5 CDI\/ignitor unit (part no: 21119-1494)<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
\n

Electric stuff…..<\/span><\/strong><\/h3>\n<\/th>\n<\/tr>\n<\/thead>\n

Ignition type:<\/td>\nElectronic CDI<\/td>\n<\/tr>\n
Starter:<\/td>\nElectric start<\/td>\n<\/tr>\n
Electrical system voltage:<\/td>\n12 volts<\/td>\n<\/tr>\n
Battery voltage (fully charged):<\/td>\n13 to 13.2 volts<\/td>\n<\/tr>\n
Battery will need charging if below:<\/td>\n12.6 volts<\/td>\n<\/tr>\n
Regulated voltage:<\/td>\n14 to 15 volts<\/td>\n<\/tr>\n
Spark plug:<\/td>\nNGK DR9EA<\/a> (x2)<\/td>\n<\/tr>\n
Spark plug gap:<\/td>\n0.6 to 0.7mm<\/td>\n<\/tr>\n
Spark plug torque:<\/td>\n14nm<\/td>\n<\/tr>\n
\n
\n

Note: If your not using a torque wrench, spark plugs should be tightened up to a half turn past finger tight.
\nThis means tighten up the plug by hand (being careful not to cross thread the plug into the cylinder head) and then tighten the plug a further half turn using a socket.<\/p>\n<\/blockquote>\n<\/td>\n<\/tr>\n

Spark plug ignition:<\/td>\n2 x coil<\/a><\/td>\n<\/tr>\n
Battery type:<\/td>\nSealed \/ maintenance free<\/a><\/td>\n<\/tr>\n
Battery capacity:<\/td>\n12 volts \/ 10 amp\/hours (12v \/ 10ah)<\/td>\n<\/tr>\n
Battery:<\/td>\nCTX12-BS \/ YTX12-BS \/ GTX12-BS<\/a><\/td>\n<\/tr>\n
\n
\n

Notes: <\/strong><\/p>\n