📚 Vehicle Manual Information

Kawasaki Klr500 Kl500 Klr 650 KL 1987-2004 Service Repair Manual

🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Production Years Covered:

1987-2004

Internal Model Designations:

KL650-A

👋 Introduction

Target Audience:

Kawasaki KLR650 owners and independent repair shops seeking comprehensive service and repair information.

Value Proposition:

Provides both base and supplemental manuals, offering a more complete resource than those selling only supplemental information. Instant download eliminates shipping delays and costs.

Instant Access:

Immediate download post-purchase, crucial for urgent repairs or maintenance.

Digital Flexibility:

Can be saved and accessed on multiple devices (PC/Mac) and printed for workshop use.

📋 Manual Details

Manual Type:

Service Repair Manual (Comprehensive)

Included Manuals:

Base Manual and Supplemental Manuals (as needed)

Estimated Page Count:

Hundreds of pages (specific count not provided, but described as 'complete')

Language:

English

File Format:

PDF

Downloadable:

YES

Operating Systems:

All Versions of Windows & Mac

Required Software:

Adobe PDF Reader & WinZip

📖 Manual Coverage

Engine:

Comprehensive coverage including troubleshooting, general information, tune-up, lubrication system, and the engine itself.

Transmission Drivetrain:

Detailed coverage of the transmission/transaxle and driveline/axle tune-up.

Fuel System:

In-depth information on the fuel system and throttle control.

Electrical Systems:

Complete coverage of all electrical systems.

Suspension Steering:

Detailed information on suspension and steering systems.

Brakes:

Comprehensive coverage of the brake system.

Frame Body:

Detailed information on the frame and bodywork.

Cooling Lubrication:

Specific sections dedicated to the cooling and lubrication systems.

Maintenance:

Step-by-step instructions for periodic maintenance and adjustments.

Troubleshooting:

Extensive troubleshooting guides and procedures.

Repair:

Detailed repair instructions for all major components and systems.

Tune Up:

Specific procedures for engine and driveline tune-ups.

Depth Of Information:

Covers everything from basic servicing to advanced repair and troubleshooting, suitable for professional mechanics and experienced DIY enthusiasts.

Illustrations:

Detailed illustrations accompany step-by-step instructions.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchable Text:

Assumed searchable within PDF format (standard for professional manuals)

Printable Pages:

YES (can be printed)

Illustration Clarity:

Implied high clarity to support step-by-step repair

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, DOHC, 4-valve, Single Cylinder (for KLR650 models)

Displacement:

651 cc (for KLR650)

Cooling System:

Liquid-cooled

Horsepower Range:

Approximately 40-47 HP (varies slightly by year and specific tune)

Torque Range:

Approximately 39-42 lb-ft (varies slightly by year and specific tune)

Carburetor Type:

Often a Keihin CVK carburetor (specific model may vary by year)

Fuel Grade:

Unleaded gasoline (87 octane or higher recommended, specific grade in manual)

Oil Type Recommendation:

Motorcycle-specific 4-stroke engine oil, SAE 10W-40 is common (check manual for exact specification)

🔧 Transmission

Transmission Type:

5-speed constant mesh, return shift

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed chain drive

📐 Dimensions

Length Overall:

Approximately 2,255 mm (88.8 in) for early models, minor variations in later years.

Width Overall:

Approximately 850 mm (33.5 in) for early models.

Height Overall:

Approximately 1,340 mm (52.8 in) for early models.

Dry Weight:

Around 170-175 kg (375-386 lbs) for early models.

Wet Weight:

Around 190-195 kg (419-430 lbs) for early models.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle specific safety ratings differ from automotive; manual covers mechanical safety systems.)

Braking System:

Hydraulic disc brakes front and rear (e.g., single 260mm disc front, 230mm disc rear on early models).

Suspension Design:

Long-travel telescopic front forks and a single rear shock absorber (Uni-Trak system) designed for off-road capability and stability.

Lighting:

Headlight, taillight, brake lights, turn signals (detailed wiring diagrams in manual).

💡 Technology Features

Infotainment System:

N/A (This is a mechanical/service manual for a motorcycle, not an automotive infotainment system.)

Rider Assistance Features:

N/A (Focus is on mechanical systems, not electronic rider aids which were minimal/non-existent in this period for this model).

Connectivity Options:

N/A (This motorcycle predates modern connectivity features.)

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-6,000 km (2,000-4,000 miles) or 6-12 months, whichever comes first (refer to manual for specific intervals).

Air Filter Cleaning:

Recommended every 3,000-6,000 km (2,000-4,000 miles) or annually.

Spark Plug Replacement:

Typically around 12,000-18,000 km (7,500-11,000 miles).

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 brake fluid is a common specification for Kawasaki motorcycles of this era.

Common Wear Items:

Clutch wear, chain and sprockets, wheel bearings, fork seals, and carburetor cleaning are common maintenance items.

Potential Failures:

Early models sometimes experienced doohickey lever failure (a cam chain tensioner component), which is a well-documented upgrade/repair covered in specialized guides often found in supplemental sections or community knowledge bases.

Required Tools:

Standard motorcycle tools, torque wrench, feeler gauges, specialized sockets/wrenches for certain components (detailed in manual).

📚 Vehicle History

Kawasaki Motorcycle Division:

Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and durability.

Klr650 Design Philosophy:

The KLR650 was developed as a dual-purpose motorcycle, blending on-road usability with off-road capability. It became renowned for its ruggedness and versatility.

Major Updates Pre 2004:

While maintaining its core design, the KLR650 saw refinements in suspension, braking, and engine tuning over its early production run, with significant updates occurring later in its lifecycle beyond 2004.

Manufacturing Locations:

Primarily Japan, with some production also in other regions in later years.

🏆 Awards & Recognition

Model Recognition:

The KLR650 is widely recognized as a durable and capable adventure touring motorcycle, particularly popular for its longevity and utility in various conditions.

Customer Satisfaction:

Generally high customer satisfaction for its reliability and value for money as an entry-level adventure bike.

Manual Certification:

N/A (This refers to the quality and completeness of the service manual itself, not a product certification.)