Target Audience:
Owners of Kawasaki KLR500 and KLR650 motorcycles from 1987-2002 seeking to perform their own maintenance and repairs.
Advantage:
Provides the same comprehensive information as professional technicians, enabling significant savings on labor costs.
Content Authenticity:
Official full factory service repair manual, ensuring accuracy and completeness.
Usability:
Easy to navigate with a numbered table of contents and search functionality for quick information retrieval. Print out only what you need.
Empowerment:
Empowers owners to understand their motorcycle's systems, make informed repair decisions, and communicate effectively with mechanics.
Supported Models:
Kawasaki KLR500, Kawasaki KLR650
Supported Model Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Estimated Page Count:
Hundreds of pages (Printable)
Type:
Factory Service Repair Manual
Engine Systems:
General Information, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Crankshaft/Transmission, Engine Removal/Installation
Chassis Systems:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System, Wiring Diagrams
Component Systems:
Clutch
Diagnostic Systems:
Troubleshooting, Engine Fault Symptom Diagnosis
Maintenance Procedures:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Tune-ups
Repair Procedures:
Step-by-step repair instructions for all covered systems, Component Overhaul, Reassembly
Diagnostic Procedures:
Troubleshooting guides, Fault symptom analysis, Part testing techniques
Electrical Procedures:
Wiring diagram analysis, Electrical system troubleshooting, Component testing
Tuning Procedures:
Engine tuning and adjustment (carburetion, timing)
Depth:
Comprehensive factory-level detail, suitable for both novice DIY mechanics and experienced technicians.
Detail Level:
Includes detailed substeps, critical notes, cautions, and warnings.
Illustration Quality:
Detailed illustrations, drawings, photos, and enlarged insets for precise part identification.
Troubleshooting Scope:
Advanced troubleshooting guide for diagnosing and correcting a wide range of problems.
Documentation Type:
Actual genuine factory repair service manual, not a third-party publication.
Compatibility:
Compatible with all PC-based Windows operating systems and Mac.
Printability:
Fully printable, allowing for individual page or full manual printing without restriction.
Binding Style:
N/A (Digital Download - Printable)
Paper Quality:
N/A (Digital Download - Printable)
Delivery Method:
Instant download link provided on checkout page after payment.
Software Requirements:
Adobe PDF Reader
Engine Type:
4-stroke, single-cylinder, DOHC, 4 valves (specific configuration varies slightly between KLR500 and KLR650 models)
Displacement:
KLR500: Approx. 461cc, KLR650: Approx. 651cc
Horsepower:
KLR650: Approx. 42-48 HP (model dependent)
Torque:
KLR650: Approx. 30-33 lb-ft (model dependent)
Carburetion:
Single Keihin carburetor (e.g., CVK34 for KLR650)
Fuel Type:
Unleaded gasoline
Length:
Varies by model year (e.g., KLR650 Gen 1: ~2,150 mm)
Width:
Varies by model year (e.g., KLR650 Gen 1: ~820 mm)
Height:
Varies by model year (e.g., KLR650 Gen 1: ~1,220 mm)
Dry Weight:
KLR650: Approx. 153 kg (dry)
Wet Weight:
KLR650: Approx. 176 kg (wet)
Safety Compliance:
Meets relevant motorcycle safety standards for its production era.
Braking System:
Disc brakes front and rear (dual-piston caliper front, single-piston caliper rear typical)
Lighting:
Halogen headlight, LED taillight (later models)
Instrumentation:
Analog speedometer, tachometer, odometer, trip meters, and indicator lights.
ABS:
Anti-lock Braking System (ABS) was not a standard or widely available feature on this generation KLR650.
Charging System:
Stator and rectifier/regulator for battery charging.
Oil Change Interval:
Typically every 3,000-6,000 miles or 6-12 months (refer to manual for precise interval and oil type).
Air Filter Maintenance:
Inspect and clean/replace at specified intervals (e.g., every 6,000-12,000 miles, more frequently in dusty conditions).
Spark Plug Replacement:
Recommended replacement around 7,500-15,000 miles, depending on plug type.
Engine Oil Type:
API SG, SF or SE, SAE 10W-40 (check manual for specific viscosity recommendations based on temperature).
Engine Oil Capacity:
Approx. 2.0-2.4 liters (with filter change) - check manual.
Coolant Type:
Permanent type anti-freeze coolant (50/50 mix with distilled water).
Common Wear Items:
Clutch wear, valve stem seals, countershaft seal leaks, cam chain tensioner wear, and fork seal leaks are common as mileage increases.
Dovetail Rocker Arm Wear:
Early models were known for potential wear in the dovetail rocker arm assembly, which is addressed by the manual's comprehensive engine overhaul sections.
Doohickey Failure:
The balancer drive chain tensioner (often called the 'doohickey') is a known failure point that can lead to catastrophic engine damage if not addressed. This manual provides instructions for inspection and replacement.
Kawasaki Motorsports:
Kawasaki is a long-standing manufacturer known for its robust and reliable motorcycles, with a history in off-road and dual-sport segments.
Klr Series Introduction:
The KLR series, starting with the KLR600 in the early 1980s, established itself as a durable, go-anywhere adventure touring motorcycle.
Klr650 Development:
The KLR650, introduced in 1987, built upon the KLR600's platform with a larger engine, improved suspension, and a larger fuel tank, becoming an icon in the dual-sport category.
Production Run:
The models covered (1987-2002) represent the first generation of the KLR650, characterized by its iconic utilitarian design and legendary reliability.
