Kawasaki KLR500 KLR650 1987-2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Product Type: Repair Service Manual Format: PDF Download Generation Covered Generations: First Generation (A1-A30) Codes Engine Codes: Likely KG650A for...

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Type: Motorcycle

Vendor:

Sku: 439246

Tags: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Kawasaki KLR Series KLR500 KLR650 Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLR500 / KLR650

Product Type:

Repair Service Manual

Format:

PDF Download

Generation

Covered Generations:

First Generation (A1-A30)

Codes

Engine Codes:

Likely KG650A for KLR650, KLR500 variant designation if applicable

👋 Introduction

Market Position

Target Audience:

Kawasaki KLR500/KLR650 owners, DIY mechanics, repair shops

Value Proposition:

Cost savings on repairs and maintenance, empowers owners to perform self-service.

Competitive Analysis

Comparison To Alternatives:

Equivalent to factory service manual, offers same accuracy and detail as paper manuals but with digital convenience.

Key Features

Accessibility:

Instant download for immediate access.

Comprehensiveness:

Covers all aspects of repair, maintenance, and troubleshooting.

Accuracy:

Written by manufacturer, providing precise technical information.

Usability:

Step-by-step instructions, clear diagrams, and organized table of contents.

📋 Manual Details

Coverage Areas

Manufacturers:

Kawasaki

Model Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

Engine Variants:

All engine types (specifically KLR500 and KLR650)

Trim Levels:

All trim levels

Transmission Types:

All transmission types

Page Count

Estimated Page Count:

Hundreds of pages (specific number not provided, typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Repair Service Manual

Source:

Original Manufacturer (Kawasaki)

Language

Language:

English

Format

File Format:

Print Quality:

Full Printable

Digital Features:

Zoom IN/OUT functionality

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

General Information:

Included

Fuel System:

Included

Cooling System:

Included

Engine Top End:

Included

Clutch System:

Included

Engine Lubrication System:

Included

Crankshaft Transmission:

Included

Wheels Tires:

Included

Final Drive:

Included

Brakes System:

Included

Suspension System:

Included

Steering System:

Included

Frame:

Included

Electrical System:

Included

Appendix:

Included

Procedures Included

Maintenance Procedures:

Included (e.g., lubrication, fluid changes, filter replacements, adjustments)

Troubleshooting:

Included (diagnostic procedures, common issue identification)

Repair Procedures:

Included (step-by-step instructions for component repair)

Disassembly Assembly:

Included (detailed instructions for taking apart and putting back together)

Cleaning:

Included (as part of disassembly/assembly and repair)

Reinstallation:

Included (procedures for correctly reassembling components)

Engine Removal Installation:

Included

Electrical Troubleshooting:

Included (combined with wiring diagrams)

Technical Depth

Depth:

Comprehensive (covers basic maintenance to complete rebuilds, diagnostics, and electrical systems)

Detail Level:

Detailed substeps, notes, cautions, and warnings

Illustrations:

Detailed illustrations, drawings, photos, and enlarged insets

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Full Printable

Zoom:

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, 4-valve, Single Cylinder (for KLR650, KLR500 likely similar)

Displacement:

Approx. 651cc (KLR650), specific displacement for KLR500 not detailed but implied to be close or a variant

Bore X Stroke:

Refer to manual for specific values (typical for this era would be around 100mm x 83mm for KLR650)

Compression Ratio:

Refer to manual for specific values (likely around 9.5:1)

Performance

Horsepower:

Refer to manual for specific values (estimated 40-50 HP at the crank)

Torque:

Refer to manual for specific values (estimated 35-40 lb-ft)

Fuel System

Fuel Delivery:

Carburetor (specific model like Keihin CVK likely)

Carburetor Size:

Refer to manual for specific size (typically 40mm for KLR650)

Fuel Type:

Unleaded gasoline

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Type:

Refer to manual for specific SAE viscosity and API classification (e.g., SAE 10W-40, API SG or higher)

Oil Capacity:

Refer to manual for specific capacity (typically around 2.5-3.0 liters with filter change)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Clutch Type:

Wet multi-plate clutch

Final Drive Type:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Refer to manual for specific dimensions

Overall Width:

Refer to manual for specific dimensions

Overall Height:

Refer to manual for specific dimensions

Weights

Dry Weight:

Refer to manual for specific weight (approx. 180-190 kg for KLR650)

Curb Weight:

Refer to manual for specific weight

Fuel Tank Capacity:

Refer to manual for specific capacity (typically 17-18 liters)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle specific safety features are more relevant)

Active Features

Braking System:

Front: Disc brake, Rear: Disc brake (specific caliper configurations and rotor sizes in manual)

Suspension Front:

Telescopic forks (specific travel and damping adjustments in manual)

Suspension Rear:

Uni-Trak single shock (adjustable preload and rebound damping typically)

Passive Features

Lighting:

Halogen headlight, LED taillight (bulb types and specifications in manual)

Windscreen:

Adjustable or fixed windscreen for rider protection

💡 Technology Features

Infotainment

Features:

Basic analogue dashboard with speedometer, tachometer, odometer, tripmeter, and warning lights. No advanced infotainment systems.

Electrical System

Ignition System:

CDI (Capacitor Discharge Ignition) with electronic advance

Charging System:

Alternator with AC output, rectified and regulated

Battery:

12V system, refer to manual for specific battery type and capacity (e.g., YTX14-BS)

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual for specific mileage/time intervals (typically every 3,000-5,000 miles or 6 months)

Air Filter Cleaning:

Refer to manual for specific intervals (often tied to operating conditions)

Spark Plug Replacement:

Refer to manual for specific intervals (e.g., every 6,000-10,000 miles)

Valve Clearance Check:

Refer to manual for specific intervals (crucial for engine longevity, typically around 10,000-15,000 miles)

Fluid Specifications

Coolant Type:

Refer to manual for specific antifreeze type and mixture ratio (e.g., ethylene glycol-based, 50/50 mix)

Brake Fluid:

Refer to manual for DOT specification (e.g., DOT 3 or DOT 4)

Known Issues

Common Wear Items:

Cam chain tensioner (potential for noise/failure), doohickey upgrade is a common modification, clutch wear, suspension seals.

Engine Reliability:

Generally robust and reliable engine, but regular maintenance is key.

Electrical Component Reliability:

Can be prone to rectifier/regulator failures or stator issues over time, especially on higher mileage units. Detailed diagnostics in the manual are crucial.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Kawasaki Heavy Industries, Ltd., a Japanese multinational corporation known for its motorcycles, heavy equipment, and aerospace components.

Model Evolution

Klr Series Origin:

The KLR series began with the KLR600 in the early 1980s, evolving into the KLR650 in 1987, renowned for its dual-purpose capability and legendary reliability.

Klr500 Context:

The KLR500 likely represents a regional variant or an earlier iteration of the KLR platform, sharing many components and design principles with the KLR650.

Production

Manufacturing Period:

1987-2002 (for the specific models covered by this manual)

Key Markets:

North America, Europe, Australia, and other global markets where dual-sport motorcycles are popular.

🏆 Awards & Recognition

Recognitions

Model Acclaim:

The KLR650 is widely recognized for its adventure-touring capabilities, durability, and value, earning it a loyal following among riders who tackle diverse terrain.

Certifications

Standards:

Manual adheres to industry standards for technical documentation.