This comprehensive service repair manual provides the essential information you need to maintain and repair your Kawasaki KLR500 and KLR650 motorcycle, covering models from 2002 to 2006. It equips you with the same level of detail as manuals used by professional mechanics, enabling you to perform a wide range of repairs with confidence. The manual delves into all aspects of your motorcycle, starting with general information and specifications, then guiding you through maintenance procedures, gear and clutch adjustments, engine removal and installation, fuel system troubleshooting, lubrication and cooling system checks, and detailed breakdowns of the combustion, lubrication, and transmission systems. It further covers the intricacies of the cylinder head, valves, alternator, starter clutch, crankshaft, transmission, balancer, and front and rear wheel systems. Explore the manual's explanations of fender and exhaust pipe repair, periodic checks and adjustments, chassis maintenance, cooling system procedures, fuel injection system diagnostics, braking system components, suspension tuning, electrical system analysis, body and fixtures, frame and body panel repair, wheel and tire maintenance, battery and charging system troubleshooting, ignition system analysis, electric starter components, lights, meters, and switches, wiring diagrams, technical information, specifications, and comprehensive troubleshooting guides. This manual serves as your ultimate resource for maintaining and repairing your Kawasaki KLR500 and KLR650, empowering you to save money by performing repairs yourself and ensuring your motorcycle is running at its best.

The Kawasaki KLR650 is a popular dual-sport motorcycle renowned for its rugged reliability and off-road capability. Introduced in 1987 as a successor to the KLR500, the KLR650 boasts a powerful, air-cooled, 651cc single-cylinder engine, known for its smooth power delivery and exceptional torque. This makes it a versatile machine for both road and dirt adventures, easily handling long highway stretches and challenging off-road terrain. The KLR650's standard features include a large 6.1-gallon fuel tank for extended range, a comfortable upright riding position ideal for long days in the saddle, and a durable steel frame designed for off-road durability. While primarily marketed as a dual-sport, its strong points lie in its off-road capabilities, making it a favorite among adventure riders and those seeking to explore remote trails. The KLR650 has undergone several updates throughout its production run, with the 2002-2006 models introducing key changes. These included a revised engine with a larger carburetor and a new exhaust system for improved performance. The suspension was also upgraded with a longer-travel fork and a firmer rear shock for enhanced off-road handling. Other notable enhancements included a redesigned fuel tank with a wider opening for easier filling, a new instrument cluster with a digital speedometer and odometer, and a more comfortable rider seat. These enhancements solidified the KLR650's reputation as a reliable and capable dual-sport motorcycle, further attracting adventure riders and off-road enthusiasts seeking a durable and versatile machine to explore the open road and rugged trails.