🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 Generation Code: A2 Year: 1988 👋 Introduction Market Position Target Audience: Mechanical technicians, motorcycle enthusiasts, owners of Kawasaki KLR500 A2 1988 Competitive Analysis Value Proposition: Provides comprehensive, dealer-level service information for DIY repair and maintenance, saving on labor costs and enabling quality service. Key Features Safety Emphasis: Highlights importance of safety equipment and precautions, including torque wrench usage. Special Tools: Identifies and illustrates recommended or required special tools with Kawasaki part numbers. Accuracy: Endeavors to ensure accuracy of information for reliable repairs. Symbols: Utilizes WARNING, CAUTION, and NOTE symbols to denote critical information. Proprietary Components: Incorporates instructions for proprietary components from their respective manufacturers for comprehensive understanding. 📋 Manual Details Coverage Areas Primary Coverage: Kawasaki KLR500 A2 1988 Page Count Total Pages: 130 Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Full engine overhaul, disassembly, and assembly Transmission: Full transmission overhaul, disassembly, and assembly Fuel System: Carburetor tuning, cleaning, and overhaul; fuel tank and lines Ignition System: Ignition timing, spark plugs, CDI unit Lubrication System: Oil pump, oil filter, oil passages, oil change procedures Exhaust System: Muffler, exhaust pipe inspection and maintenance Electrical System: Wiring diagrams, lighting system, battery, charging system, starter motor Bodywork: Fairings, seat, fenders, fuel tank, body panel removal and installation Frame And Suspension: Frame inspection, fork disassembly/assembly, rear shock absorber adjustments and service Wheels And Tires: Wheel bearing service, spoke tensioning, tire replacement Brakes: Front disc brake caliper service, rear drum brake inspection and adjustment Cooling System: Radiator maintenance, coolant replacement, fan operation Procedures Included Maintenance: Routine servicing, tune-ups, fluid checks and changes Repair: Detailed diagnostic and repair procedures for all major components Disassembly Assembly: Step-by-step instructions for removal and installation of parts and assemblies Troubleshooting: Diagnostic flowcharts and common problem resolution Engine Specifications: Detailed engine component specifications, clearances, and torque values. Troubleshooting Charts: Systematic troubleshooting flowcharts for common issues. Technical Depth Depth: Comprehensive, suitable for professional technicians and knowledgeable DIY mechanics Diagnostic Capabilities: Includes in-depth diagnostic procedures for electrical and mechanical faults. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF, enhancing ease of use. Print Quality Printability: Yes, printable Binding Type Binding: Digital (Not a hard copy) Paper Type Delivery Method: Electronic delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single Cylinder, DOHC, 4 valves Displacement: 498 cc (30.4 cu in) Bore X Stroke: 92.0 x 75.0 mm (3.62 x 2.95 in) Performance Horsepower: Approx. 35 hp @ 6500 rpm (Note: Specific dyno figures may vary) Torque: Approx. 30 lb-ft @ 5000 rpm (Note: Specific dyno figures may vary) Fuel System Carburetor Type: Single Mikuni BS34 Fuel Capacity: 19 L (5.0 US gal) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multiple-disc Fluid Specifications Transmission Oil Type: SAE 10W-40 API SE or SF (Check manual for exact specification) 📐 Dimensions Exterior Overall Length: 2,230 mm (87.8 in) Overall Width: 850 mm (33.5 in) Overall Height: 1,345 mm (53.0 in) Weights Dry Weight: 173 kg (381.4 lbs) Wet Weight: Approx. 190 kg (418.9 lbs) (with fluids) Suspension Front Front Suspension Type: Telescopic fork with adjustable preload Suspension Rear Rear Suspension Type: Uni-Trak system with adjustable preload and damping Wheels Tires Front Tire: 80/90-21 48P Rear Tire: 120/90-17 64P Wheelbase: 1,430 mm (56.3 in) 🛡️ Safety Features Active Features Braking Front: Single 260mm disc with dual-piston caliper Braking Rear: Drum brake Passive Features Lighting: Headlight, taillight, brake lights, turn signals 💡 Technology Features Infotainment Infotainment System: Not applicable to this model; analog instrumentation and basic electrical systems. Driver Assistance Driver Assistance Features: Not applicable to this model. Connectivity Connectivity Options: Not applicable to this model. 🔧 Maintenance Service Intervals Oil Change Interval: Every 4,000 km (2,500 miles) or 6 months (refer to manual for precise intervals) Air Filter Cleaning: Every 2,000 km (1,250 miles) Spark Plug Replacement: Every 8,000 km (5,000 miles) Fluid Specifications Coolant Type: Ethylene glycol-based coolant (50% solution with distilled water) Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for exact specification) Known Issues Common Wear Items: Clutch plates, valve stem seals, rear brake shoes, fork seals. Carburetor Issues: Potential for gumming and clogging if fuel is left standing for extended periods; requires regular cleaning and synchronization. Technical Tips Valve Adjustment: Requires periodic adjustment using shims (detailed procedure in manual). Chain Maintenance: Regular cleaning, lubrication, and tension adjustment is crucial for drivetrain longevity. 📚 Vehicle History Brand Heritage Kawasaki Legacy: Kawasaki has a long-standing reputation for building durable and capable motorcycles, particularly in the dual-sport and adventure segments. Model Evolution Klr Lineage: The KLR500 was an early iteration in the KLR lineage, which later evolved into the highly successful KLR600 and KLR650...