Target Audience:
Professional Technicians and DIY Mechanics
Value Proposition:
Comprehensive repair and maintenance information for a specific model year, delivered instantly and affordably
Advantage Over Paper:
No shipping costs, no waiting time, easily searchable and printable
Instructional Design:
Numbered instructions, bold figure numbers for quick reference, detailed illustrations/drawings/photos
Diagnostic Tools:
Combined troubleshooting and electrical service procedures with detailed wiring diagrams
Powertrain:
Engine, Fuel System, Lubrication System, Cooling System, Exhaust System
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Drive Chain
Electrical:
Ignition System, Lighting System, Battery, Charging System, Starter Motor, Instrumentation, Wiring Diagrams
Bodywork:
Body Panels, Fairings, Seat, Fuel Tank, Luggage Rack
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment, Brake Pad Replacement, Valve Clearance Adjustment
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnosis, Electrical System Diagnostics
Repair:
Engine Overhaul, Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Testing and Replacement
Rebuild Refurbish:
Complete Engine Rebuild, Carburetor Rebuild, Carburetor Cleaning and Adjustment
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics
Detail Level:
Detailed sub-steps, critical notes, cautions, and warnings
Searchability:
Likely text-searchable if created from digital source or scanned with OCR
Printability:
Full Printable
Print Resolution:
Depends on source scan quality; aims for clarity of text and diagrams
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
PDF Reader:
Adobe PDF Reader
Compression Utility:
WinRAR (or similar decompression software)
Operating Systems:
All Versions of Windows & Mac
Engine Type:
4-stroke, single-cylinder, DOHC, 4-valve
Engine Displacement:
KLR650: 651 cc (approx.); KLR500: 498 cc (approx.)
Bore X Stroke:
KLR650: 100.0 x 83.0 mm (approx.); KLR500: Specific to KLR500 model
Cooling System:
Liquid-cooled
Horsepower:
KLR650 (1996): Approx. 42-45 HP (at crank); KLR500: Specific to KLR500 model
Torque:
KLR650 (1996): Approx. 33-35 lb-ft (at crank); KLR500: Specific to KLR500 model
Fuel Delivery:
Carburetor(s) (likely single Keihin CVK)
Carburetor Type:
Keihin CVK (Constant Velocity Carburetor), size typically 40mm for KLR650
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
KLR650 (1996): 6.1 US gal (23 L)
Oil Type:
SAE 10W-40 Motorcycle Oil (API SG or higher)
Oil Capacity:
KLR650: 2.4 L (2.5 US qt) with filter change
Length:
KLR650 (1996): Approx. 2,320 mm (91.3 in)
Width:
KLR650 (1996): Approx. 910 mm (35.8 in)
Height:
KLR650 (1996): Approx. 1,420 mm (55.9 in) - seat height variable
Dry Weight:
KLR650 (1996): Approx. 174 kg (383.6 lbs)
Curb Weight:
KLR650 (1996): Approx. 195 kg (430 lbs)
Front Tire Size:
KLR650 (1996): 90/90-21
Rear Tire Size:
KLR650 (1996): 130/80-17
Front Wheel Type:
Spoked, 21-inch
Rear Wheel Type:
Spoked, 17-inch
Crash Test Ratings:
N/A (Motorcycle)
Brakes Front:
Single Disc, Dual-piston caliper
Brakes Rear:
Single Disc, Single-piston caliper
Lighting:
Halogen Headlight, LED Taillight/Brake Light (typical for era)
Infotainment System:
None (Analog instrumentation)
ABS:
Not equipped (ABS was not standard or widely available on this model in 1996)
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, engine temperature gauge, indicator lights
Oil Change Interval:
Every 3,000 miles (4,800 km) or 6 months
Air Filter Cleaning:
Every 3,000 miles (4,800 km) or as needed based on riding conditions
Valve Clearance Check:
Every 15,000 miles (24,000 km)
Spark Plug Replacement:
Every 15,000 miles (24,000 km)
Coolant Type:
Kawasaki Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, brake pads, chain and sprockets
Potential Engine Concerns:
Oil consumption can increase with high mileage; carburetor tuning may be required over time.
Electrical Notes:
Older wiring harnesses may require inspection for wear or corrosion.
Manufacturer Heritage:
Kawasaki Heavy Industries, Ltd. (Motorcycle and Engine division) established history in motorcycle manufacturing since the 1950s.
Klr Lineage:
The KLR series is renowned for its dual-sport capability and ruggedness, evolving from earlier models like the KLR250 and sharing lineage with the KLR600.
Klr650 Evolution:
The KLR650 model, introduced in the mid-1980s, underwent gradual updates. The 1996 model represents a mature iteration of the design, prior to significant overhauls in later years.
Production Location:
Japan (typically)
Klr650 Production Span:
1987 - Present (with various updates and regional variations)
