The Kawasaki KLR500 KLR650 1991 All Service Repair Manual offers a comprehensive guide to repairing and maintaining your motorcycle. This manual contains detailed instructions and diagrams covering a wide range of topics, ensuring you have the information you need to tackle any repair job.

Dive deep into the intricacies of your Kawasaki KLR500/KLR650 with this manual. It covers everything from basic maintenance tasks like oil changes and tire rotations to complex repairs involving the engine, transmission, brakes, and electrical system.

The manual provides step-by-step instructions for each repair procedure, making it easy to follow along. You'll find clear illustrations and diagrams to help you visualize the process and ensure you're performing the repairs correctly. Whether you're a seasoned mechanic or a novice, this manual will empower you to handle routine maintenance and tackle more complex repairs with confidence.

Some of the key areas covered in the manual include:

* **General Maintenance:** Learn about essential maintenance procedures, including lubrication, fluid checks, and cleaning.
* **Troubleshooting:** Get expert guidance on diagnosing and resolving common motorcycle problems.
* **Engine Service and Repair:** Gain the knowledge to service and repair your engine, including components like the cylinder head, crankshaft, and valves.
* **Transmission Service and Repair:** Understand how to maintain and repair your transmission, covering topics like gears, clutch, and shifting mechanisms.
* **Brake System:** Learn about brake components, adjustment procedures, and bleeding techniques.
* **Wiring Diagram:** Decode the electrical system with a detailed wiring diagram for easy troubleshooting.
* **Electrical System:** Gain knowledge about the electrical system, including components like the battery, starter, alternator, and lighting.
* **Suspension:** Learn about the suspension components, adjustment procedures, and maintenance techniques.
* **Periodic Lubrication:** Understand the importance of regular lubrication and learn how to lubricate your motorcycle's key components.
* **Steering:** Explore the steering system, including components like the handlebars, steering head, and forks.
* **Cooling System:** Discover the workings of the cooling system, including the radiator, water pump, and thermostat.
* **Fuel Injection/Fuel System:** Gain an understanding of the fuel injection system, including the injectors, fuel pump, and fuel lines.
* **Emission System:** Learn about emissions control components and their role in maintaining clean emissions.
* **Engine Control System:** Get acquainted with the engine control system and its role in regulating engine performance.
* **Chassis/Body:** Explore the chassis and body components, including the frame, swingarm, and body panels.
* **Restraint System:** Understand the components and function of the restraint system, like the seat belts and airbags.
* **Axle:** Learn about the axle components and their role in connecting the wheels to the chassis.

This manual is your comprehensive resource for all things related to your Kawasaki KLR500/KLR650. It empowers you to keep your motorcycle running smoothly and tackle repairs with confidence.

The Kawasaki KLR650, and its predecessor the KLR500, are rugged and versatile dual-sport motorcycles known for their reliability and off-road capabilities. Introduced in 1987, the KLR650 quickly gained a reputation as a capable and affordable adventure bike, attracting riders of all experience levels. The KLR650 is powered by a 651cc, air-cooled, single-cylinder engine that produces a respectable amount of power, making it suitable for both on and off-road riding. The motorcycle features a strong steel frame, long-travel suspension, and a large fuel tank, offering a comfortable ride on both paved roads and rough terrain. The KLR650's simplicity and durability have made it a popular choice for long-distance touring, commuting, and adventure riding.

Despite its age, the KLR650 remains a capable and popular motorcycle, thanks to its blend of off-road performance and touring comfort. While Kawasaki has made some updates to the KLR650 over the years, including fuel injection and a larger fuel tank, the core design has remained largely unchanged. The KLR650's robust construction and relatively straightforward mechanicals make it easy to maintain, and its large aftermarket support network offers countless options for customization and upgrading. The KLR650 is an excellent choice for riders seeking a reliable and capable motorcycle that can handle a variety of riding conditions. Whether you're looking to explore back roads, tackle challenging trails, or embark on a cross-country adventure, the KLR650 has proven its worth as a dependable and versatile motorcycle that can go the distance.