🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Year: 1994 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics for Kawasaki KLR500/KLR650. Purpose: To provide comprehensive repair, maintenance, rebuilding, refurbishment, and restoration guidance. Competitive Analysis Advantage: Instant download, no shipping costs, detailed information mirroring professional technician resources. Key Features Content Focus: Detailed diagnostic, repair, and maintenance procedures. Usability: Numbered table of contents, clear instructions, and helpful cross-referencing. 📋 Manual Details Coverage Areas Covered Models: Kawasaki KLR500, Kawasaki KLR650 Covered Years: 1994 Manual Type Type: Full Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Printability: Full Printable 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, troubleshooting, lubrication system, cooling system. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel pump, fuel filter replacement, fuel tank maintenance. Ignition System: Ignition timing, spark plugs, ignition coils, CDI unit testing and replacement. Transmission: Clutch operation, gear shifting mechanisms, transmission disassembly and assembly, gear oil specifications. Drivetrain: Chain adjustment, sprockets, rear drive unit maintenance and overhaul. Suspension: Front forks (inspection, seal replacement, oil change), rear shock absorber adjustment and overhaul. Brakes: Front and rear brake system diagnosis, pad replacement, caliper service, master cylinder overhaul, bleeding procedures. Electrical System: Wiring diagrams, battery testing, charging system (stator, regulator/rectifier), lighting, instrumentation, starter system. Frame And Bodywork: Frame inspection, fairings, seat, handlebars, footpegs, mounting hardware. Procedures Included Maintenance: Regular service schedules, oil changes, filter replacements, chain lubrication, brake adjustments, tire pressure checks. Troubleshooting: Comprehensive diagnostic flowcharts for common starting, running, and electrical issues. Repair: Step-by-step instructions for component removal, installation, and repair. Rebuild: Detailed procedures for engine, transmission, and suspension component rebuilds. Diagnostics: Electrical diagnostics, ignition system testing, carburetor diagnostics. Technical Depth Depth: Full rebuilds, advanced diagnostics, professional technician level. Illustrations: Detailed illustrations, drawings, and photos for each procedure. Instructions: Numbered step-by-step instructions with sub-step expansions. Critical Information: Notes, cautions, and warnings to pinpoint critical information. Wiring Diagrams: Detailed and easy-to-use wiring diagrams integrated with electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows & Mac Software Requirements: Adobe PDF Reader, WinRAR Print Quality Printability: High-quality, full pages printable. Binding Type Binding: Digital (N/A for print) Paper Type Paper Type: Digital (N/A for print) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, DOHC (likely for KLR650, KLR500 may have differences or be a precursor) Cooling System: Liquid-cooled (typical for KLR650) Performance Displacement Klr650: 651 cc (approx.) Displacement Klr500: 500 cc (approx.) Fuel System Carburetion Klr650: Likely Mikuni BSR32 carburetor (specifics in manual) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Type: Constant mesh, 5-speed, return shift Features Clutch: Wet, multiple disc 📐 Dimensions Exterior Wheelbase: Refer to specific model data in manual (typical KLR650 ~1465 mm) Weights Curb Weight Klr650: Refer to specific model data in manual (typical KLR650 ~170 kg dry) 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators, oil pressure warning light. Driver Assistance ABS: Not typically available on this model year. Manual does not cover ABS systems. Connectivity Connectivity Features: None (basic mechanical and electrical systems). 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific intervals based on mileage or time (e.g., every 3,000-5,000 km or annually). Air Filter Cleaning: Refer to manual for frequency (e.g., every 3,000-6,000 km or based on operating conditions). Valve Clearance Check: Refer to manual for initial and subsequent intervals (e.g., every 10,000-12,000 km). Fluid Specifications Engine Oil Type: Refer to manual for viscosity grade (e.g., SAE 10W-40) and API classification (e.g., SF, SG, SH). Coolant Type: Permanent type antifreeze (ethylene glycol based) mixed with distilled water (50/50 ratio). Brake Fluid Type: DOT 4 recommended (refer to manual for exact specification). Fork Oil Type: Refer to manual for viscosity grade (e.g., 10W) and quantity. Known Issues Oil Consumption: Can occur with high mileage, piston ring wear, or valve stem seal degradation. Manual details checks and replacements. Carburetor Issues: Pilot jet clogging, float bowl contamination leading to rough idling or poor fuel delivery. Manual covers cleaning and adjustment. Doohickey: A known failure point on some KLR models is the balancer drive chain tensioner arm (often called the 'doohickey'). Manual provides guidance on inspection and replacement. Rear Shock Oil Leaks: Can occur with age and mileage. Manual details shock disassembly and seal replacement procedures. 📚 Vehicle History Brand Heritage Manufacturer: Kawasaki Heavy Industries Motorcycle & Engine division. Model Evolution Klr Lineage: The KLR series is known for its dual-sport versatility, blending on-road comfort with off-road capability, a lineage dating back to the KLR250 and evolving into the popular KLR650. Production Manufacturing Region: Japan 🏆 Awards & Recognition Recognitions Model Recognition: The KLR series is recognized for its ruggedness, reliability, and value in the dual-sport and adventure touring market.