🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 / KLR500 Year: 1991 Codes Chassis Code: KL650-A10 (for KLR650) Engine Code Common: KL650E (typical for KLR650 series) 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics for Kawasaki KLR500/KLR650 1991. Value Proposition: Provides comprehensive repair and maintenance information equivalent to factory service manuals, enabling cost-effective DIY repairs. Competitive Analysis Comparison To Oem: Covers the same information as professional technicians use, implying OEM-level detail but presented in a user-friendly digital format. Key Features Accessibility: Instant download eliminates shipping costs and wait times. Usability: Numbered tables of contents, bold figure numbers, and detailed illustrations enhance ease of use. 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: PDF Delivery: Instant Download Page Count Estimated Page Count: Comprehensive (Specific count not provided, but stated as 'very detailed') 📖 Manual Coverage Systems Covered Engine: Full overhaul, carburetor tuning, ignition system, cooling system, lubrication, starting system, exhaust system. Transmission: Clutch operation, gear shifting mechanisms, transmission internals, lubrication, troubleshooting. Fuel System: Carburetor (Mikuni BSR32 for KLR650), fuel pump, fuel lines, fuel tank inspection and maintenance. Electrical System: Ignition system, charging system (stator, regulator/rectifier), lighting, battery, starter motor, fuses, wiring diagrams. Brakes: Front and rear brake systems (hydraulic disc), brake fluid, brake lines, caliper maintenance, master cylinder overhaul. Suspension: Front telescopic forks (with adjustable preload/damping on some variants), rear Uni-Trak monoshock system, fork oil, shock absorber service. Chassis And Frame: Frame inspection, steering head bearings, swingarm, wheel bearings, general chassis component checks. Bodywork: Fairings, fenders, seat, fuel tank, controls, instrumentation, plastics, fasteners. Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, valve clearance checks, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, electrical faults, engine noises, braking concerns. Repair: Complete disassembly and reassembly instructions for all major components, component-specific repair guides. Rebuilding: Detailed instructions for engine rebuilds, carburetor overhauls, suspension component rebuilding, brake caliper rebuilding. Restoration: Guidance on refurbishing and restoring components to original specifications, often implying thoroughness in repair steps. Technical Depth Diagnostic Procedures: Includes detailed diagnostic steps, often referencing specific symptoms and causes. Electrical Service: Combined with detailed wiring diagrams for ease of diagnosis and repair of electrical systems. Illustrations: Detailed illustrations, drawings, and photos guide users through procedures. Enlarged insets for detailed part examination. Instruction Format: Numbered step-by-step instructions, detailed sub-steps, notes, cautions, and warnings. 📊 Manual Specifications File Format File Format: PDF Print Quality: Full Printable Compatibility: All Versions of Windows & Mac Software Requirements: Adobe PDF Reader, WinRAR Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, 4-valve single-cylinder Displacement Klr650: 651 cc (652 cc in some references) Displacement Klr500: 498 cc (Note: The KLR500 was primarily a pre-cursor or different market variant. Manual covers both, suggesting shared components or variations documented.) Bore X Stroke Klr650: 100.0 mm x 83.0 mm Cooling System: Liquid-cooled Performance Horsepower Klr650 Approx: Approx. 40-45 HP (at crankshaft, depending on market and tuning) Torque Klr650 Approx: Approx. 37-40 lb-ft (at crankshaft, depending on market and tuning) Fuel System Carburetor Type Klr650: Mikuni BSR32 (Single Carburetor) Fuel Grade Recommendation: Regular Unleaded Gasoline (Manual will specify octane rating, typically 87-90 AKI) 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed sequential return Clutch Type: Wet, multiple-disc Features Drive System: Chain drive 📐 Dimensions Exterior Length Klr650 Approx: Approx. 88.2 inches (2240 mm) Width Klr650 Approx: Approx. 34.1 inches (865 mm) Height Klr650 Approx: Approx. 53.0 inches (1345 mm) Weights Dry Weight Klr650 Approx: Approx. 388 lbs (176 kg) Wet Weight Klr650 Approx: Approx. 427 lbs (194 kg) Fuel Capacity Klr650: 6.1 US gallons (23 Liters) 🛡️ Safety Features Ratings Safety Equipment: Headlight, taillight, brake light, turn signals, mirrors, horn. Reflectors are standard. Active Features Braking System Features: Dual piston front caliper, single piston rear caliper for hydraulic disc brakes. Manual covers proper brake bleeding and pad replacement. Passive Features Frame Construction: High-tensile steel, semi-double cradle frame provides stability and durability for dual-purpose riding. 💡 Technology Features Infotainment Instrumentation: Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light, turn signal indicators. Driver Assistance Traction Control ABS: Not applicable for this model year and type of motorcycle. Focus is on mechanical systems. Connectivity Charging System: Standard alternator (stator) and regulator/rectifier for battery charging. Manual covers troubleshooting and component testing. 🔧 Maintenance Service Intervals Oil Change Interval Engine: Recommended every 3,000-6,000 miles or 6-12 months (exact interval specified in manual). Valve Clearance Check Interval: Typically every 6,000-12,000 miles (manual will provide precise interval). Spark Plug Replacement Interval: Varies, but typically inspected at major services and replaced as needed or at intervals like 12,000-20,000 miles. Fluid Specifications Engine Oil Type: Kawasaki recommends specific motorcycle-specific 4-stroke engine oil, typically SAE...