🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Variant:

KLR500 / KLR650

Model Years Covered:

2002, 2003, 2004, 2005, 2006

👋 Introduction

Target Audience:

DIY motorcycle enthusiasts, independent repair shops, and Kawasaki KLR owners seeking to perform maintenance, repairs, and diagnostics themselves.

Value Proposition:

Provides factory-level information at a fraction of the cost of professional shop manuals, offering significant savings on maintenance and repair expenses. Its lifetime access and multi-device compatibility enhance its value.

Professional Quality:

Designed for professional mechanics, ensuring accuracy, detail, and completeness equivalent to official Kawasaki workshop manuals.

Visual Aids:

Hundreds of pages featuring detailed photos, illustrations, and exploded diagrams to guide users through complex procedures.

📋 Manual Details

Covered Regions:

Global (standard specifications)

Estimated Page Count:

500+

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, lubrication, cooling, fuel system (carburetion, fuel pump), ignition system, exhaust system, starting system, charging system (alternator, regulator/rectifier)

Drivetrain Systems:

Clutch (operation, adjustment, replacement), transmission (gearbox disassembly, assembly, inspection), final drive (chain, sprockets)

Chassis Systems:

Frame, front suspension (forks, steering head bearings), rear suspension (shock absorber, linkage, swingarm), wheels, tires, brakes (front and rear systems, hydraulic components, pad replacement), steering

Electrical Systems:

Wiring diagrams, lighting, instrumentation, battery, fuses, relays, starter motor, ignition coil, electronic control unit (ECU) (if applicable), diagnostic troubleshooting

Bodywork And Accessories:

Fairings, body panels, seats, luggage systems (mounting points, compatibility), controls (levers, pedals)

Maintenance Procedures:

Oil changes, filter replacements, chain lubrication and adjustment, brake pad inspection and replacement, tire pressure checks, battery maintenance, coolant checks, air filter cleaning/replacement

Repair Procedures:

Engine rebuilds, carburetor tuning and overhaul, fork seal replacement, shock absorber replacement, brake caliper overhaul, wheel bearing replacement, electrical component testing and replacement

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon issues, electrical system faults, engine performance problems, braking system malfunctions

Technical Specifications:

Torque specifications for all fasteners, engine clearances, valve timings, fluid capacities, electrical system voltages and resistances

Depth:

Comprehensive: Covers routine maintenance, advanced diagnostics, major repairs, and complete engine/transmission overhauls. Includes detailed exploded diagrams for component identification and reassembly.

📊 Manual Specifications

Digital Format:

PDF

Print Capability:

Printable: Individual pages or the entire manual can be printed. High-resolution images and diagrams.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Usage License:

Lifetime use on multiple devices/computers. No expiry or renewal fees.

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, DOHC, 4-valve, single-cylinder

Displacement Cc:

651 (for KLR650) / 498 (for KLR500 variants)

Bore X Stroke Mm:

100.0 x 83.0 (KLR650) / 90.0 x 78.0 (KLR500)

Compression Ratio:

9.5:1 (KLR650)

Horsepower Hp:

Approx. 48-50 HP (KLR650, at crank, depending on market and tuning)

Torque Lb-Ft:

Approx. 37-39 lb-ft (KLR650, at crank)

Carburetor Type:

Keihin CVK40 (KLR650)

Fuel Delivery:

Carburetor

Oil Capacity Liters:

Approx. 2.5 L (with filter change, KLR650)

Cooling Type:

Liquid-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc, manual

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-1 SAE 80W-90 (or equivalent motorcycle transmission oil)

📐 Dimensions

Overall Length Mm:

2,275 (KLR650)

Overall Width Mm:

870 (KLR650)

Overall Height Mm:

1,365 (KLR650)

Wheelbase Mm:

1,470 (KLR650)

Curb Weight Kg:

Approx. 194 kg (KLR650, wet)

Fuel Tank Capacity Liters:

23.0 (KLR650)

🛡️ Safety Features

Safety Features Overview:

The KLR series is known for its robust construction and predictable handling. Specific crash ratings are not typically issued for motorcycles in the same way as cars.

Braking System:

Front: Single 260mm disc with dual-piston caliper. Rear: 240mm disc with single-piston caliper. ABS was not standard on these models.

Lighting:

Halogen headlight for improved nighttime visibility, LED tail light.

💡 Technology Features

Infotainment Systems:

N/A (This era of KLR is focused on function over infotainment. No integrated audio or navigation.)

Driver Assistance Features:

N/A (No electronic rider aids like traction control or rider modes are present.)

Connectivity Features:

N/A (No Bluetooth or Wi-Fi connectivity.)

Ignition System:

Digital CDI with electronic ignition timing advance.

🔧 Maintenance

Oil Change Interval Km:

Every 6,000 km or 6 months, whichever comes first.

Air Filter Cleaning Km:

Every 6,000 km or annually. Replacement as needed.

Valve Adjustment Interval Km:

Every 24,000 km.

Chain Maintenance Interval Km:

Every 1,000 km or after washing/riding in rain.

Engine Oil Type And Grade:

API SG, SF or SE, SAE 10W-40 motorcycle oil. Semi-synthetic or synthetic recommended.

Coolant Type:

Permanent antifreeze (ethylene glycol base) with distilled water (50/50 mixture)

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, cam chain tensioner (early models), carburetor diaphragm.

Typical Failures:

Stalling at idle (carburetor cleaning), rear shock absorber wear (leaks or reduced damping), excessive chain slap due to worn cam chain tensioner.

Carburetor Tuning:

The CVK40 carburetor requires precise adjustment for optimal performance, especially at altitude or with aftermarket exhausts/air filters. The manual details the correct procedure.

Suspension Tuning:

Front forks and rear shock have adjustment capabilities (preload, damping). Proper setup is crucial for handling and comfort, detailed in the manual.

📚 Vehicle History

Kawasaki History:

Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and innovative motorcycles, including the KLR line, known for its dual-sport capabilities.

Klr Series Evolution:

The KLR650 has a long production run, originating from the KLR600. The 2002-2006 models represent a significant iteration of the popular adventure/dual-sport platform, known for its touring comfort and off-road versatility. The KLR500 was an earlier variant based on the KLR600. This manual covers the lineage bridging these models.

Manufacturing Origin:

Japan (primarily)

🏆 Awards & Recognition

Model Recognition:

The Kawasaki KLR650 is widely recognized as a benchmark in the adventure touring segment for its durability, affordability, and go-anywhere capability, often cited in motorcycle publications for its 'legendary' status among owners.

Owner Satisfaction:

Consistently high owner satisfaction ratings due to reliability and low running costs.

Manual Certification:

Factory authorized information.