Target Audience:
Owners, technicians, and hobbyists seeking detailed information for maintaining and repairing Kawasaki KLR500 and KLR650 motorcycles from 1987 to 2002.
Value Proposition:
Provides essential technical data, repair procedures, and specifications necessary for effective and efficient maintenance, reducing reliance on expensive dealership services and ensuring optimal vehicle performance and longevity.
Manual Content Highlight:
Detailed step-by-step instructions, extensive pictorial diagrams, exploded views, troubleshooting guides, service data, and torque specifications for all major mechanical and electrical systems.
Major Systems:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Transmission, Clutch, Chassis, Suspension (Front & Rear), Braking System (Front & Rear), Electrical System (Wiring Diagrams, Charging System, Starting System, Lighting), Frame, Wheels, Tires, Bodywork, Controls, Instrumentation
Chassis And Suspension:
Front forks (telescopic, oil damping), rear suspension (Uni-Trak system, adjustable preload and rebound damping), steering system, wheel bearings, swingarm.
Electrical System Components:
Battery, starter motor, alternator, ignition coil, CDI unit, regulators/rectifiers, fuses, relays, wiring harnesses, sensors, switches (headlight, brake, clutch, sidestand), horn.
Fuel And Emission Control:
Carburetor disassembly, cleaning, adjustment, jetting specifications, fuel tank removal, fuel lines, emission control systems (if applicable per market regulations for the years covered).
Service And Repair:
Routine maintenance, troubleshooting, diagnostics, disassembly, assembly, repair, adjustment, inspection, component testing, replacement procedures, torque specifications, wear limits, special tool recommendations, electrical troubleshooting charts, wiring diagrams
Engine And Transmission Overhaul:
Complete engine teardown, piston and cylinder inspection/replacement, valve job, crankshaft and connecting rod service, clutch plate replacement, gearbox inspection and repair, transmission gear selection mechanism.
Wheel And Tire Service:
Tire pressure checks and adjustments, tire removal and installation, wheel balancing, spoke tensioning (if applicable), wheel bearing maintenance.
Bodywork And Fairings:
Removal and installation procedures for fuel tank, seat, side covers, fenders, headlight and taillight assemblies, and fairings.
Level Of Detail:
Comprehensive, step-by-step procedures with detailed explanations, pictorial diagrams, exploded views, and schematics. Suitable for both professional mechanics and experienced DIY enthusiasts.
Diagnostic Capabilities:
Includes diagnostic procedures for electrical faults, ignition timing issues, fuel delivery problems, and mechanical wear using specified test equipment and methods.
Special Tools:
Lists and illustrates required special tools for specific maintenance and repair tasks, ensuring accuracy and proper procedure execution.
Engine Type:
4-stroke, single-cylinder, DOHC, 4-valve (for KLR650); likely similar architecture for KLR500 but with smaller displacement.
Displacement:
KLR650: 651 cc; KLR500: ~500 cc (specific displacement to be confirmed in manual).
Bore X Stroke:
KLR650: 100.0 mm x 83.0 mm; KLR500: Likely smaller, e.g., 90.0 mm x 78.0 mm (specifics to be confirmed in manual).
Horsepower:
KLR650: Approx. 40-45 HP at 6500 RPM (varies by year and tuning). Manual provides exact figures.
Torque:
KLR650: Approx. 5.2-5.5 kgf-m (37-40 lb-ft) at 5000 RPM. Manual provides exact figures.
Carburetion:
Typically a single Keihin CVK carburetor (e.g., Keihin CVK40 for KLR650, manual will specify exact model and jetting for each year/variant).
Dashboard Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, and warning lights for oil pressure, neutral, turn signals, high beam. Manual covers calibration and troubleshooting.
Rider Aids:
None beyond standard mechanical features. Focus is on reliability and rider control.
Electrical System Features:
Standard 12V electrical system with AC generator for battery charging. Manual provides comprehensive wiring diagrams and component testing for ignition, lighting, and charging circuits.
Recommended Maintenance:
The manual will detail specific intervals for oil changes (e.g., every 3,000-6,000 km), filter changes, valve clearance checks (e.g., every 10,000-12,000 km), spark plug replacement, chain maintenance, and brake fluid flushes. It includes a periodic maintenance chart.
Engine Oil:
API SG or higher, SAE 10W-40 or 20W-50 recommended (specific viscosity may vary with ambient temperature). Manual will list exact specifications and capacity (e.g., 2.7 L with filter change).
Brake Fluid:
DOT 3 or DOT 4 recommended. Manual specifies type and replacement intervals.
Coolant:
Permanent type antifreeze (ethylene glycol based) mixed with distilled water. Manual specifies capacity and change intervals.
Common Wear And Tear Items:
Potential for cam chain noise, clutch wear, carburetor issues (jetting, diaphragm), and rear shock absorber degradation over time. The manual addresses diagnosis and repair for these.
Component Specific Maintenance:
Detailed guidance on air filter cleaning/replacement, spark plug gap and type, chain lubrication and adjustment frequency, and brake pad wear indicators.
Kawasaki Motorcycle Legacy:
Kawasaki has a long history of producing robust and reliable motorcycles, particularly in the dual-sport and off-road segments, building on a reputation for engineering excellence.
Klr Series Development:
The KLR line is known for its go-anywhere capability, blending on-road comfort with off-road prowess. The KLR650, in particular, has seen continuous refinement, becoming a benchmark for adventure touring motorcycles.
Manufacturing Location:
Primarily Japan (e.g., Hyogo Prefecture) for these model years. Manual provides model-specific production details.
