🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Year: 2001 Codes Product Code: KLR500KLR650-2001-Service-Repair-Manual 👋 Introduction Market Position Segment: Dual-sport motorcycle Target Audience: Owners and independent mechanics seeking comprehensive repair and maintenance information Competitive Analysis Competitor Manuals: Factory service manuals, Haynes, Clymer (this PDF aims to consolidate or exceed their coverage) Key Features Accessibility: Instant download, accessible on multiple devices Comprehensiveness: Covers all major systems and procedures for the specified model year Cost Effectiveness: Saves money on professional repair services Empowerment: Enables users to perform their own maintenance and repairs with confidence 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: 500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, assembly, overhaul, component testing, timing, valve adjustment Fuel System: Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel filter replacement Ignition System: Ignition coils, spark plugs, CDI unit, timing inspection Cooling System: Radiator, coolant pump, thermostat, hoses, fan operation, coolant flush and refill Transmission: Clutch inspection and replacement, gearbox disassembly and assembly, shift mechanism, lubrication Brake System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, hydraulic lines Suspension Front: Front fork service, seal replacement, oil levels, spring inspection, steering head bearing adjustment Suspension Rear: Rear shock absorber inspection and replacement, swingarm bearings, linkage lubrication Steering: Handlebar, steering stem, bearings, and linkage inspection and adjustment Electrical System: Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), lighting, starter motor, fuses, relays Chassis Body: Frame inspection, body panel removal and installation, seat, fuel tank, fenders, fairings Emission System: Emissions control components, exhaust system, catalytic converter (if applicable), evaporative emission control Engine Control: ECU diagnostics, sensor testing (e.g., TPS, MAP), idle control, fault codes Restraint System: N/A for this model (motorcycle) Axle: Front and rear wheel axle inspection and maintenance, bearing checks Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication points Troubleshooting: Diagnostic charts, common problems and solutions, symptom-based troubleshooting Repair: Step-by-step instructions for all major component repairs and replacements Rebuilds: Comprehensive instructions for engine and transmission rebuilds Adjustments: Carburetor (if applicable to specific variants), clutch, throttle, brakes, suspension Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format Type: PDF Readability Software: Adobe PDF Reader File Compression: Requires WinZip or similar for extraction Print Quality Quality: High-resolution, suitable for printing Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, DOHC, 4-stroke Displacement Klr500: 461 cc (28.1 cu in) Displacement Klr650: 651 cc (39.7 cu in) Bore X Stroke Klr500: 81.0 x 90.6 mm (3.19 x 3.57 in) Bore X Stroke Klr650: 100.0 x 83.0 mm (3.94 x 3.27 in) Performance Horsepower Klr650 Approx: 42-48 hp @ 6500 rpm Torque Klr650 Approx: 36-40 lb-ft @ 5000 rpm Fuel System Type: Electronic Fuel Injection (EFI) - Keihin DFI Fuel Type: Unleaded gasoline, 87 octane (minimum) Lubrication Oil Type: SAE 10W-40 API SG or higher, JASO MA certified Oil Capacity W Filter: Approx. 2.3 Liters (2.4 US qt) 🔧 Transmission Standard Type: 5-speed constant mesh Clutch: Wet, multi-plate Features Drive System: Chain drive Fluid Type Transmission Oil: SAE 80W-90 API GL-4 or GL-5 gear oil 📐 Dimensions Exterior Overall Length Klr650: 2220 mm (87.4 in) Overall Width Klr650: 880 mm (34.6 in) Overall Height Klr650: 1300 mm (51.2 in) Weights Dry Weight Klr650 Approx: 172 kg (379 lbs) Wet Weight Klr650 Approx: 190 kg (419 lbs) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle safety standards apply, not automotive crash ratings) Active Features Brakes: Disc brakes front and rear Passive Features Lighting: Halogen headlight, LED taillight, turn signals 💡 Technology Features Infotainment Features: Basic motorcycle instrumentation: speedometer, odometer, trip meter, tachometer, coolant temperature warning light, neutral indicator. 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000 miles or 6 months, whichever comes first Oil Filter Change: Every engine oil change Air Filter Cleaning: Every 3,000 miles; replace as needed Spark Plug Replacement: Every 15,000 miles Valve Clearance Check: Every 15,000 miles Fluid Specifications Brake Fluid: DOT 4 Coolant: Kawasaki genuine coolant or equivalent ethylene glycol-based coolant, 50/50 mix with distilled water Known Issues Cam Chain Tensioner: Early models sometimes had issues with automatic cam chain tensioners failing; manual tensioner conversion is a common upgrade. Check for rattling noise. Doo-Hickey: Refers to the balancer chain tensioner lever. A common failure point, often replaced with an aftermarket upgrade (often called the 'doohickey'). Fuel Pump Reliability: Occasional reports of early fuel pump failures, particularly with ethanol-blended fuels. 📚 Vehicle History Brand Heritage Manufacturer: Kawasaki Heavy Industries Motorcycle & Engine Company Model Evolution Klr Lineage: The KLR650...