Target Audience:
DIY enthusiasts, independent repair shops, and professional mechanics working on Kawasaki KLR500 motorcycles.
Value Proposition:
Provides essential, detailed information for maintaining and repairing the KLR500, enabling cost-effective ownership and reliable operation. Offers a comprehensive alternative to dealership services.
Content Highlight:
Bumper-to-bumper coverage, step-by-step procedures, detailed illustrations, exploded diagrams, crucial service data, and troubleshooting guides.
Download Method:
Instant PDF download after secure payment, eliminating shipping costs and wait times.
Primary Coverage:
Repair and maintenance of the Kawasaki KLR500 for model years 1987 and 1988.
Secondary Coverage:
Diagnostic procedures, component removal/installation, adjustments, technical specifications, and troubleshooting.
Type:
Workshop Service Manual / Repair Manual
Engine Systems:
Engine top-end (cylinder head, valves, camshaft), cylinder block, piston, crankshaft, lubrication system, cooling system (if applicable), fuel system (carburetor, fuel lines), ignition system.
Drivetrain Systems:
Clutch, transmission, final drive (chain/sprocket).
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, brakes (front and rear), wheels, tires, electrical system (lighting, ignition, battery, charging system).
Bodywork And Trim:
Body panels, seating, controls, exhaust system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad inspection/replacement, tire pressure checks, lubrication points.
Repair And Overhaul:
Complete disassembly and reassembly of engine components, transmission, suspension, brakes, and electrical systems. Detailed repair procedures for common wear items and failures.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical faults. Includes symptom-based troubleshooting guides.
Adjustments:
Carburetor tuning, valve clearance adjustment, clutch and throttle cable adjustment, brake lever and pedal adjustment, suspension adjustments.
Depth Of Information:
Comprehensive, covering from basic checks to complete engine and component overhauls. Includes detailed explanations and pictorial diagrams.
Engine Configuration:
Single-cylinder, four-stroke (typical for KLR series, exact configuration TBC from manual).
Displacement:
Approximately 498cc (typical for KLR500).
Bore X Stroke:
Specifics will be detailed within the manual. (e.g., typical KLRs might have around 92mm x 90.3mm)
Compression Ratio:
Specifics will be detailed within the manual. (e.g., typically around 8.9:1 to 9.5:1 for this era of KLR).
Horsepower:
Specifics will be detailed within the manual. (Expected to be in the range of 30-40 HP).
Torque:
Specifics will be detailed within the manual. (Expected to be in the range of 30-35 lb-ft).
Carburetor Type:
Likely a single Keihin carburetor (e.g., CVK40 or similar), specifics in manual.
Fuel Type:
Unleaded gasoline (Octane rating to be specified in manual).
Oil Capacity:
Specifics will be detailed within the manual. (typically around 1.7 - 2.0 liters for KLR models).
Oil Type:
Motorcycle-specific 4-stroke engine oil, viscosity and API service classification will be specified in the manual (e.g., SAE 10W-40, API SG or higher).
Cooling Method:
Air-cooled (typical for KLR500).
Overall Length:
Specifics will be detailed within the manual. (KLR models typically around 2180mm or 85.8 inches).
Overall Width:
Specifics will be detailed within the manual. (KLR models typically around 800mm or 31.5 inches).
Overall Height:
Specifics will be detailed within the manual. (KLR models typically around 1200mm or 47.2 inches).
Dry Weight:
Specifics will be detailed within the manual. (KLR500 models typically around 150-160 kg or 330-350 lbs).
Wet Weight:
Specifics will be detailed within the manual. (including fluids).
Fuel Tank Capacity:
Specifics will be detailed within the manual. (KLR models typically around 14-17 liters or 3.7-4.5 gallons).
Safety Standards:
Adherence to relevant motorcycle safety standards of the era. Manual will detail specific safety precautions and warnings.
Braking System:
Hydraulic disc brakes front and rear (typical for KLR500), with specific caliper and rotor details in manual.
Lighting System:
Headlight, taillight, brake light, turn signals, instrument panel illumination. Bulb types and specifications will be in the manual.
Chassis Design:
Robust frame construction designed for durability and stability. Manual will detail frame inspection and repair.
Warning Labels:
Manual contains 'DANGER', 'CAUTION', and 'NOTE' remarks to highlight critical safety procedures and potential hazards.
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights (turn signals, neutral, oil pressure, high beam). Specific layout detailed in manual.
Rider Aids:
Basic rider aids typical for the era, primarily focused on mechanical systems. No advanced electronic rider aids like ABS or traction control.
Oil Change Interval:
Specifics will be detailed in the periodic maintenance chart within the manual. Typically every 3,000-6,000 km or 6-12 months.
Valve Clearance Check:
Specifics will be detailed in the periodic maintenance chart within the manual. Typically every 6,000-12,000 km.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment will be detailed. Intervals depend on riding conditions, typically every 500-1,000 km.
Brake Fluid Type:
DOT 3 or DOT 4 (specific recommendation in manual).
Coolant Type:
N/A (Likely air-cooled).
Common Wear Items:
Based on KLR lineage: potential for carburetor issues (clogging), brake wear, chain and sprocket wear, suspension seal leaks, and exhaust system corrosion. Manual will guide diagnosis and repair.
Recommended Practices:
Strict adherence to maintenance schedules, using correct fluids and parts, and addressing minor issues promptly to prevent larger problems.
Kawasaki Motorsports:
Kawasaki has a long and storied history in motorcycle manufacturing, known for performance and reliability across various segments.
Klr Lineage:
The KLR series is renowned for its dual-sport capabilities, blending on-road comfort with off-road versatility. The KLR500 is an earlier iteration in this successful lineage.
Production Period:
1987-1988. The KLR500 was succeeded by the more technologically advanced KLR650.
