🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: KLR500/KLR650 Year: 1991 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, and owners seeking to maintain and repair their Kawasaki KLR500/KLR650. Competitive Analysis Value Proposition: Provides essential, detailed information to empower owners to perform repairs, saving time and money compared to dealership service. Key Features Accessibility: Instant download allows immediate access to repair information. Comprehensiveness: Covers a vast array of systems and procedures, offering a complete reference. Cost Effectiveness: Significantly reduces the cost of repairs and maintenance by enabling DIY work. 📋 Manual Details Coverage Areas Primary Coverage: All Service and Repair Page Count Estimated Page Count: Varies by specific manual edition; typically 400-700 pages for this era of Kawasaki service manuals. Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive Engine Service/Repair, including disassembly, reassembly, tuning, and diagnostics. Transmission: Detailed Transmission Service/Repair, covering clutch, gearbox, and related components. Brakes: Brake System: Inspection, repair, and maintenance of hydraulic and mechanical brake components. Electrical: Electrical System: Diagnosis, repair, and component testing of lighting, ignition, charging, and starting systems. Wiring Diagrams: Complete Electrical Wiring Diagrams for all circuits. Suspension: Suspension System: Front forks, rear shock absorber, linkage, and adjustment procedures. Steering: Steering System: Handlebar, cables, and steering head bearing service. Cooling: Cooling System: Radiator, coolant, fan, and associated components for liquid-cooled models. Fuel System: Fuel Injection/Fuel System: Carburetor or injection system service, fuel pump, filter, and tank maintenance. Emission Control: Emission System: Components and procedures related to emissions control. Engine Control: Engine Control System: Diagnosis and troubleshooting of ECU and related sensors (if applicable to the specific 1991 model). Chassis Body: Chassis and Bodywork: Frame, subframe, body panels, seat, and mounting hardware. Restraint System: Restraint System: Primarily seat belt systems (if applicable) and general safety component checks. Axle: Axle and Wheel Service: Front and rear axle inspection, wheel bearings, and related components. Procedures Included Maintenance: General Maintenance, Periodic Lubrication, Fluid Changes, Filter Replacements. Troubleshooting: Extensive Troubleshooting Guides for common and uncommon issues. Repair: Step-by-step repair procedures for all major and minor components. Rebuilding Refurbishment: Procedures for disassembly, cleaning, inspection, and reassembly of engine and other major components. Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and chassis adjustments. 📊 Manual Specifications File Format File Format: PDF Compatibility: Compatible with all Windows and Mac operating systems. Software Requirements: Adobe PDF Reader and WinZip (or equivalent unzipping software) required. Print Quality Print Quality: High Resolution - suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, Four-stroke, Single-cylinder, DOHC, 4 valves Displacement: KLR650: 651 cc (40 cu in); KLR500: ~498 cc (Note: KLR500 designation is less common for this era, likely referring to early versions or a typo, KLR600 was a precursor) Performance Bore X Stroke: KLR650: 100.0 x 83.0 mm (approx.) Compression Ratio: KLR650: 9.5:1 (approx.) Horsepower: KLR650: Approximately 40-46 HP at 6000-6500 RPM (varies by market and exact configuration) Torque: KLR650: Approximately 36-40 lb-ft at 5000 RPM (varies) Fuel System Fuel Delivery: Carburetor (e.g., Keihin CVK40 for KLR650), potentially fuel injection on later models but not typical for 1991. Fuel Type: Unleaded Gasoline Fuel Tank Capacity: KLR650: 6.1 US gallons (23 Liters) (approx.) 🔧 Transmission Standard Transmission Type: Constant-mesh 5-speed Features Clutch: Wet, multi-plate Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: KLR650: ~84.1 inches (2135 mm) (approx.) Width: KLR650: ~33.1 inches (840 mm) (approx.) Height: KLR650: ~50.0 inches (1270 mm) (approx.) Weights Dry Weight: KLR650: ~337 lbs (153 kg) (approx.) Wet Weight: KLR650: ~377 lbs (171 kg) (approx.) 🛡️ Safety Features Active Features Braking System: Front: Single Disc Brake; Rear: Disc Brake. Specific caliper types and rotor diameters will be detailed in the manual. Lighting: Halogen headlight, taillight, brake light, and turn signals. Passive Features Frame Construction: High-tensile steel semi-double cradle frame, providing robust support. 💡 Technology Features Infotainment Instrumentation: Analog speedometer, tachometer, odometer, trip meter, and indicator lights. Driver Assistance ABS: Anti-lock Braking System (ABS) was not a standard or widely available option on the 1991 KLR650. Connectivity Charging Port: Not typically equipped with a factory-installed charging port for accessories; aftermarket options are available. 🔧 Maintenance Service Intervals Oil Change: Recommended every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on riding conditions. Air Filter Cleaning: Recommended every 3,000-6,000 miles (4,800-9,600 km) or more frequently in dusty conditions. Spark Plug Replacement: Recommended around 10,000-15,000 miles (16,000-24,000 km). Fluid Specifications Engine Oil Type: API SG, SF or SE, SAE 10W-40 viscosity recommended. Specific Kawasaki oil grades might be listed. Engine Oil Capacity: KLR650: 2.4 Liters (2.5 US qt) without filter change, 2.6 Liters (2.7 US qt)...