🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: KLR500 KLR650 Year: 1999 Codes Chassis Code Prefix: KL650-A 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY enthusiasts. Competitive Analysis Value Proposition: Provides same information as professional technicians, accessible for DIY, instant download saves time and shipping costs. Key Features Features: Comprehensive coverage, detailed procedures, diagnostic focus, high-quality illustrations, instant availability. 📋 Manual Details Coverage Areas Primary Coverage: 1999 Kawasaki KLR650 / KLR500 Page Count Estimated Page Count: High (Specific number not provided, but described as comprehensive) Manual Type Type: Full Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Printability: Full Printable Requirements Software Requirements: Adobe PDF Reader, WinRAR Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, troubleshooting, diagnostics, rebuild procedures, component analysis. Fuel System: Carburetor (CVK) service, fuel tank, fuel pump, fuel lines, troubleshooting. Cooling System: Radiator, fan, coolant circulation, thermostat, troubleshooting. Ignition System: CDI, ignition coil, spark plug, wiring, troubleshooting. Transmission: Clutch operation, gearbox inspection and repair, lubrication, troubleshooting. Electrical System: Wiring diagrams, charging system, starting system, lighting, battery, fuses, relays, troubleshooting. Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, disc service, troubleshooting. Suspension: Front fork service (oil change, seal replacement), rear shock absorber, linkage maintenance, troubleshooting. Wheels And Tires: Wheel bearing service, spoke adjustment, tire replacement, rim inspection. Frame And Bodywork: Frame inspection, fairings, fuel tank removal/installation, seat, fenders, graphics. Controls: Throttle control, clutch lever, brake lever, footpegs, handlebar setup. Exhaust System: Muffler, header pipe inspection and replacement. Procedures Included Maintenance: Regular service schedules, oil changes, filter replacements, chain adjustment, lubrication points. Troubleshooting: Comprehensive diagnostic procedures for various systems, common problems and solutions. Repair: Detailed step-by-step repair instructions for all major components and systems. Rebuild: Complete engine and component rebuild procedures. Diagnostics: Electrical system diagnostics, engine performance troubleshooting. Refurbishment Restoration: Guidance for bringing the motorcycle back to original specifications. Technical Depth Depth: Professional technician level, with adequate data for DIY mechanics. Detail Level: Detailed sub-steps, notes, cautions, and warnings for critical information. Illustrations: Detailed illustrations, drawings, and photos, with enlarged inset views. Navigation: Numbered table of contents for quick information retrieval. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: Full Printable Binding Type Binding: Digital (Downloadable, can be printed and bound) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, Single Cylinder, DOHC, 4 valves Displacement: 500cc (for KLR500 variant), 651cc (for KLR650 variant) Performance Bore X Stroke: Approx. 85.0 mm x 86.0 mm (KLR650) Compression Ratio: Approx. 9.5:1 (KLR650) Horsepower: Approx. 30-35 HP (KLR650 - actual varies by market and tuning) Torque: Approx. 30-35 lb-ft (KLR650 - actual varies by market and tuning) Fuel System Carburetor: Keihin CVK40 (likely for KLR650) Fuel Capacity: Approx. 6.1 US gal (23 L) for KLR650 Lubrication Oil Type: SAE 10W-40 API SG or SH recommended Oil Capacity: Approx. 2.5 L (2.6 US qt) with filter change (KLR650) 🔧 Transmission Standard Type: Constant mesh, 5-speed Clutch: Wet, multiple disc Drive Type: Chain drive Features Gear Ratios: Detailed ratios provided within the manual. Transmission Oil Type: API GL-1 Gear Oil (e.g., SAE 80) Transmission Oil Capacity: Approx. 1.3 L (1.4 US qt) (KLR650) 📐 Dimensions Exterior Overall Length: Approx. 88.2 in (2240 mm) (KLR650) Overall Width: Approx. 34.8 in (885 mm) (KLR650) Overall Height: Approx. 53.7 in (1365 mm) (KLR650) Weights Dry Weight: Approx. 397 lb (180 kg) (KLR650) Curb Weight: Approx. 430 lb (195 kg) (KLR650 - with fluids) Wheels And Tires Front Tire Size: 80/90-21 48P (KLR650) Rear Tire Size: 130/80-17 65P (KLR650) Wheelbase: Approx. 57.7 in (1465 mm) (KLR650) 🛡️ Safety Features Ratings Crash Safety: Not applicable to motorcycle manual coverage in traditional sense, but manual covers brake system integrity. Active Features Braking System: Front: Single 260mm disc; Rear: 230mm disc (KLR650 - models may vary slightly, ABS not standard) Passive Features Lighting: Headlight, tail light, brake lights, turn signals. 💡 Technology Features Infotainment Features: N/A (Basic motorcycle functionality, no modern infotainment systems). Driver Assistance Features: N/A (No electronic rider aids like ABS, traction control, or ride modes). 🔧 Maintenance Service Intervals Oil Change: Every 3,000 miles or 6 months, whichever comes first (typical for this era). Air Filter Cleaning: Every 3,000 miles or as needed based on conditions. Chain Lubrication Adjustment: Every 500-1000 miles or as needed. Valve Clearance Check: Every 12,000 miles (typical for KLR650). Fluid Specifications Engine Oil Spec: SAE 10W-40 API SG or SH Brake Fluid Spec: DOT 3 or DOT 4 Coolant Spec: Ethylene glycol based coolant, 50/50 mix with distilled water. Known Issues Common Problems: Potential for oil consumption with high mileage, cam chain tensioner (if not replaced with upgraded aftermarket), carburetor jetting for altitude, minor electrical gremlins if neglected. 📚 Vehicle History Brand...