Kawasaki ER5 Specs (1996 to 2007)

2004 Kawasaki ER-5 (yes, it’s looking a bit bruised and battered!)

Kawasaki ER5 Specs…..

The Kawasaki 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 (although the ER-5 was 49bhp while the GPZ was 59bhp) and featured twin rear shocks, 37mm front forks and double cradle frame.

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).

Need parts for your ER5? Kawasaki ER-5 used parts…

A little bit about the Kawasaki ER-5…..

Basic model info…
Manufacturer:	Kawasaki
Model:	ER5
Model code:	ER500
CC:	498cc
Engine type:	Parallel-twin (4 stroke)
Years in production:	1996 to 2007
Style of bike:	Commuter bike
Insurance:	Group 8 (of 17)
Replaced by:	Kawasaki ER6

Servicing your bike? You’ll need an ER-5 workshop manual…

Models and years (in the UK)
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).
ER500 A1 (Sept 1996 to Sept 1997)…..
Frame number started:	JKAER500AAA00–
Description:	Naked budget commuter bike with 37mm front forks, 17 inch, 3 spoke wheels, single exhaust silencer and alloy radiator side covers.
Available colours:	Black, metallic blue or red
Price (new):	£3695
ER500 A2 (Oct 1997 to Oct 1998)…..
Frame number started:	JKAER500AAA01–
Description:	Same as above model with new colours.
Available colours:	Silver, red or blue
Price (new):	£3695
ER500 A3 (Nov 1998 to Dec 1999)…..
Frame number started:	JKAER500AAA02–
Description:	Same as above model with new colours.
Available colours:	Red, blue or pearl boulogne (kind of a blue/green colour)
Price (new):	£2995 to £3095
ER500 A4 (Jan 2000 till Dec 2000)…..
Frame number started:	JKAER500AAA04–
Description:	Same as above model with new colours.
Available colours:	Grey, blue or red
Price (new):	£3250
ER500 C1 (Jan 2001 to Oct 2002)…..
Frame number started:	JKAER500ACA0510–
Description:	Re styled model.
Available colours:	Blue, black or gold
Price (new):	£3295
ER500 C3 (Nov 2002 to Jan 2004)…..
Frame number started:	EX500C3—-
Description:	Same as above model.
Available colours:	Blue, black or gold
Price (new):	£3295
ER500 C4P (Feb 2004 to Oct 2004)…..
Frame number started:	EX500C4P—-
Description:	Minor detail changes.
Available colours:	Black or red
Price (new):	£3295
ER500 C5P (Released Nov 2004)…..
Frame number started:
Description:	Same as above model.
Available colours:	Black or blue
Price (new):	£3345

Panoramic view of the ER5 C1

Engine and gearbox specs…..
Displacement:	498 cc
Engine type:	Parallel-twin
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).
Stroke:	4 stroke
Bore×Stroke:	74x58mm
No. of cylinders:	2
Cam shaft configuration:	DOHC (double overhead cam)
Double overhead cams in an ER5 engine
Note: The term ‘double overhead cams’ (or DOHC for short) refers to the layout and number of camshafts used in the engine. So ‘double overhead cam’ refers to 2 cam shafts situated in the top of the engine (as in the ER-5 engine pictured above).
Compression ratio:	9.8:1
Cylinder compression pressure:	9.6 to 14.7 bar (139 to 213 psi)
Valves:	8 valve (4 per cylinder)
Spark plug:	NGK DR9EA (x2)
Spark plug gap:	0.6 to 0.7mm
Spark plug torque:	14nm
Spark plug socket size:	18mm
Firing order:	1 – 2
Engine oil:	10w40 API SG/JASO MA or higher
Note: 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…
Engine oil capacity:	3.0 litres
Engine oil drain bolt location:	Bottom/underneath of the engine
Oil filter type:	Canister type
Oil filter:	Hiflo HF303 / Filtrex OIF006
Oil filter torque:	10nm
Cooling system:	Liquid cooled
Cooling system capacity:	1.7 litres
Clutch:	Wet (oil immersed) multiplate clutch
Clutch operation:	Cable
Clutch lever free play:	2 to 3mm
Note: You’ll need a clutch holding tool for removing it, a clutch lever if you’ve dropped it and possibly a clutch cable if it’s suddenly stopped working!
Gearbox:	6 Speed manual (1st gear down, 2nd to 6th gears up, neutral between 1st and 2nd gears)
BHP:	49 bhp
Torque:	33 ft/lb
Top speed (claimed):	110 mph
0 to 60mph time (claimed):	5.3 seconds
Quater mile time (claimed):	14.9 seconds
Note: Top speed, 0-60 time, 1/4 mile time etc are all very APPROX!! as it’s not unusual for these figures to be slightly inflated by the manufacturer to help sell more bikes! It 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!) 😀
Piston ring to cylinder bore clearance:	New: 0.043mm / Max 0.070mm
Valve clearance (inlet):	0.13mm to 0.18mm (when cold)
Valve clearance (exhaust):	0.18mm to 0.23mm (when cold)
Idle speed:	1,200rpm (+/- 50)

2004 ER5 cylinder head cover

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).

ER5 side and center stands

Final drive stuff…..
Final drive:	Chain
Front sprocket:	17 teeth
Engine/chain sprocket nut tightening torque:	127nm
Rear sprocket:	42 teeth
Rear sprocket nuts tightening torque:	59nm
Chain pitch/length:	520 pitch / 106 links
Chain free play:	35 to 40mm
Chain stretch limit:	317.5 to 318.2mm over 20 links
Chain lubrication:	Chain lube
How often should you lube the chain? Now repeat after me… ‘I MUST LUBE MY CHAIN LITTLE AND OFTEN!!’ 😀

Kawasaki ER-5 Hiflo HF303 oil filter

Kawasaki ER-5 inline twin carbs

Carb, fuel and oil stuff…..
Fuel system:	Carburetor
MPG (average):	46 miles per gallon (very approx)
Fuel tank range (approx):	170 miles
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)
Fuel tank capacity:	17 litres
Fuel type:	Unleaded petrol (95 octane grade – aka standard petrol from your local garage)
Note: Yes, you can run the ER5 on the newer E10 petrol, but MAKE SURE you drain all the E10 petrol from the tank and carbs if the bikes not being used (e.g. being stored up over winter). E10 grade fuel causes horrendous problems clogging up carb jets and moving parts when left for longer periods!
Carb make:	Keihin (2x)
Carb type:	CVK 34 (34mm flat-slide carbs)
Pilot screw opening:	1 1/4 (1 and a quarter) turns
Engine oil:	10w40 API SG/JASO MA or higher
Note: 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…
Engine oil capacity (if just changing the oil and filtet):	3.0 litres
Engine oil capacity (after a complete engine dismantle):	3.4 litres
Engine oil drain bolt location:	Bottom/underneath of the engine
Engine oil drain bolt:	29nm
Oil filter type:	Canister type
Oil filter:	Hiflo HF303 / Filtrex OIF006
Oil filter torque:	17nm
Note: As a general rule when tightening oil filters, oil filters should only be tightened with a wrench a QUARTER TURN past finger tight. This 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. Also, 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).

ER-5 exhaust end can

ER5 exhaust downpipes mounted on the bike

Kawasaki ER5 CDI/ignitor unit (part no: 21119-1494)

Electric stuff…..
Ignition type:	Electronic CDI
Starter:	Electric start
Electrical system voltage:	12 volts
Battery voltage (fully charged):	13 to 13.2 volts
Battery will need charging if below:	12.6 volts
Regulated voltage (GPZ500 A – Up to Jan 1994):	14 to 15 volts
Spark plug:	NGK DR9EA (x2)
Spark plug gap:	0.6 to 0.7mm
Spark plug torque:	14nm
Note: If your not using a torque wrench, spark plugs should be tightened up to a half turn past finger tight. This 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.
Spark plug ignition:	2 x coil
Battery type:	Sealed / maintenance free
Battery capacity:	12 volts / 10 amp/hours (12v / 10ah)
Battery:	CTX12-BS / YTX12-BS / GTX12-BS
Notes: The YTX12-BS battery is a 12 volt, 10 amp/hour battery and is length: 151mm width: 87mm height: 130mm in size (more info…). The 1st letter(s) of the battery reference code are a manufacturers reference mark and may vary between different battery makes (different battery manufacturers use different 1st letters), so CTX12-BS, YTX12-BS and DTX12-BS (etc) are all the same battery just from different manufacturers (more info…). Also…… Avoid buying the cheapest of the cheap type batteries online as they have a horrendous failure rate (and they can be a bug!er to post back when it fails).

 

Kawasaki ER-5 battery (CTX12-BS).

Under the ER-5 seat showing the battery compartment and CDI / ignitor unit

ER5 front wheel with 110/70-17 tyre

ER5 drum brake rear wheel with 130/70-17 tyre

Shocks, brakes and wheel specs…..
Front wheel type:	3 spoke cast wheel
Front tyre size:	110/70-17
Front tyre pressure:	32psi (2.2 bar)
Front wheel spindle torque:	88nm
Front wheel spindle clamp bolt torque:	20nm
Rear wheel type:	3 spoke cast wheel
Rear tyre size:	130/70-17
Rear tyre pressure up to 97.5kg load (rider and luggage):	36psi (2.5 bar)
Rear tyre pressure over 97.5kg load (rider and luggage):	41psi (2.8 bar)
Rear wheel spindle torque:	98nm
Front brake:	Single hydraulic disc brake with 2 piston caliper
Front brake disc:	280mm single solid disc. Part no: EBC MD4016 (1x)
Front brake pad (1997 to 2000, A1/A2/A3/A4 models):	EBC FA129 (1x)
Front brake pad (2001 to 2007, C1/C3/C4P/C5P models):	EBC FA229 (1x)
Brake fluid (front):	DOT 4 brake fluid
Rear brake:	160mm drum brake
Rear drum brake pad:	EBC K706
Front suspension:	Telescopic forks
Front fork stanchion diameter:	37mm
Recommended fork oil:	10w fork oil
Fork oil volume (1997 to 2000, A1/A2/A3/A4 models):	295 cm3 (per fork)
Fork oil volume (2001 to 2007, C1/C3/C4P/C5P models):	298 cm3 (per fork)
Fork length:	79.5cm
Rear Suspension:	Twin rear shock absorbers

Kawasaki ER5 rear brake plate

ER-5 back drum brake on bike showing activator and torque arms

Weights, measures ‘n stuff…..
Overall length:	2070mm
Overall width:	730mm
Overall height:	1070mm
Wheelbase:	1,430mm
Seat height:	800mm
Ground clearance:	125mm
Dry weight:	179kg
Turning radius:	2.5 meters

ER5 handlebar controls showing starter button, light and indicator controls

Useful torque settings…..
Camshaft cap bolts:	12nm
Cylinder head cover bolts:	10nm
Cylinder head bolts (10mm):	51nm
Cylinder head bolts (6mm):	10nm
Spark plugs:	14nm
Front wheel spindle bolt:	88nm
Front wheel spindle clamp bolts:	20nm
Rear wheel spindle bolt:	98nm
Engine/chain sprocket nut:	127nm
Rear sprocket nuts:	59nm
Magneto / flywheel:	69nm
Camshaft sprocket:	15nm
Clutch hub:	132nm
Oil filter torque:	17nm
Engine oil drain plug:	29nm
Front brake caliper mounting bolts:	34nm
Front brake disc mounting bolts:	27nm
Front fork yoke upper stanchion allen bolts:	20nm
Front fork yoke lower stanchion allen bolts:	35nm
Front fork stanchion bottom allen bolt:	20nm
Rear shock absorber bolts:	34nm
Handlebar clamp bolts:	25nm
Footpeg hanger bracket mounting bolts:	34nm
Side stand bolt:	44nm
Center stand bolts:	44nm

ER-5 seat and helmet lock location (in the left side panel, just below the seat)

Service stuff…..
Servicing your bike? You’ll need an ER5 workshop manual…
Engine oil
Engine oil change frequency:	Every 6,000km (approx 3,728 miles) or 6 months
Engine oil:	10w40 API SG/JASO MA or higher
Engine oil capacity (if just changing the oil and filtet):	3.0 litres
Engine oil capacity (after a complete engine dismantle):	3.4 litres
Engine oil drain bolt location:	Bottom/underneath of the engine
Engine oil drain bolt:	29nm
Oil filter type:	Canister type
Oil filter:	Hiflo HF303 / Filtrex OIF006
Oil filter torque:	17nm
Chain drive
Chain lubrication:	Chain lube
How often should you lube the chain? Now repeat after me… ‘I MUST LUBE MY CHAIN LITTLE AND OFTEN!!’ 😀
Chain and sprocket size:	106 link / 520 Pitch chain 17 Tooth front sprocket 42 Tooth rear sprocket
Hydraulic brake system (front)
Brake fluid change frequency:	Change every 24 months or 24,000km (approx 14,912 miles)
Brake fluid:	DOT 4 brake fluid
Fork oil
Front fork oil check:	12,000km (approx 7,456 miles) or 24 months
Front fork oil change:	24,000km (approx 14,912 miles) or 24 months
Recommended fork oil:	10w fork oil
Fork oil volume (1997 to 2000, A1/A2/A3/A4 models):	295 cm3 (per fork)
Fork oil volume (2001 to 2007, C1/C3/C4P/C5P models):	298 cm3 (per fork)
Cooling system
Change every:	24,000km (approx 14,912 miles) or 24 months
Cooling system:	Liquid cooled
Cooling system capacity:	1.7 litres

ER-5 clocks showing main light beam light, neutral gear light, speedo and rev counter

Frame number location…..

The frame number is usually stamped onto the right side of the headstock (the front part of the frame just below the handle bars).

ER5 fuse box diagram showing the positions of different fuses in the fuse box

Useless stuff…..

Loved by commuters, couriers and motorcycle training schools the Kawasaki ER5 was a twin cylinder 500cc naked bike released in the UK between 1996 and 2007.
The bike was marketed as a ‘budget’ bike (with an initial retail price of £3695 in 1996, the Honda CB500 retailed for £4085) and didn’t come equipped with many (any?) luxury features.
The bike was aimed at the urban (city) and extra urban commuter and was ideal as a winter hack for owners who like to keep their pride and joy wrapped up over the winter months.

The ER-5 engine was based on the tried and tested GPZ500 engine (although it did have lower power, 49bhp opposed to 59bhp from the GPZ) and was meant as a rival for bikes like the Honda CB500.
The ER5 was economical on fuel, got good tyre life and was fairly cheap to insure making it a cheap way of commuting or for younger riders getting into biking.

Buying advice…..

There are a few things to bare in mind if your thinking of getting one of these bikes. The bike was built on a budget by Kawasaki so metal parts and other bits will be fairly corroded if it’s been used all year round or stored outside (especially without a cover).
Also, there are plenty of ex bike training school and courier bikes around which will have had a hard life and are probably best avoided.
As with alot of older Kawasaki bikes, the electrics can be a bit problematic, especially in the wet weather and the ER5 rear drum brake wheel suffered from ‘ovulation’ of the drum (where, over time, the drum wears to an ‘oval’ shape) which can cause pad rubbing or MOT failure (in a worst case scenario).

Obviously, being as the youngest of these bikes will be 17 years old now, they can suffer from the usual problems related to age (corroded fork stanchions, rusted/holed exhausts and worn rear shocks).
However, due to Kawasaki selling absolutely loads of these there are plenty of spares around in breakers and, as it shared alot of engine parts with the GPZ500S there are alot of new parts for sale.

Happy biking 🙂

Sources / Thanks to / Useful ER-5 / ER500 sites:

ER5 article on MCN
Rock oil for the servicing info
ER5 article on Wikipedia

If you’ve got any questions, comments or suggestions please feel free to leave them below 🙂

Disclaimer: The information on this page is correct to the best of our knowledge. But the info should NOT be taken as 100% accurate as we can, occasionally make mistakes!