Target Audience:
Kawasaki KLR500/KLR650 owners, DIY mechanics, repair shops
Value Proposition:
Cost savings on repairs and maintenance, empowers owners to perform self-service.
Comparison To Alternatives:
Equivalent to factory service manual, offers same accuracy and detail as paper manuals but with digital convenience.
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.
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
Estimated Page Count:
Hundreds of pages (specific number not provided, typical for comprehensive workshop manuals)
Type:
Workshop Repair Service Manual
Source:
Original Manufacturer (Kawasaki)
Print Quality:
Full Printable
Digital Features:
Zoom IN/OUT functionality
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
General Information:
Included
Engine Lubrication System:
Included
Crankshaft Transmission:
Included
Suspension System:
Included
Steering System:
Included
Electrical System:
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)
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
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)
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 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 Method:
Liquid-cooled
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)
Overall Length:
Refer to manual for specific dimensions
Overall Width:
Refer to manual for specific dimensions
Overall Height:
Refer to manual for specific dimensions
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)
Crash Test Results:
N/A (Motorcycle specific safety features are more relevant)
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)
Lighting:
Halogen headlight, LED taillight (bulb types and specifications in manual)
Windscreen:
Adjustable or fixed windscreen for rider protection
Features:
Basic analogue dashboard with speedometer, tachometer, odometer, tripmeter, and warning lights. No advanced infotainment systems.
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)
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)
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)
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.
Manufacturer History:
Kawasaki Heavy Industries, Ltd., a Japanese multinational corporation known for its motorcycles, heavy equipment, and aerospace components.
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.
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.
