🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: KLR500 Year: 1994 Codes Engine Code Primary: KL650A 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY mechanics, Kawasaki KLR owners Competitive Analysis Comparison To Alternatives: Equivalent to factory service manual, offering in-depth repair and maintenance data Key Features Content Highlight: Step-by-step repair procedures, critical specifications, illustrations/pictures Benefit To Owner: Enables informed maintenance and repair decisions, teaches factory technician knowledge Benefit To Owner Availability: Instant PDF download for immediate use 📋 Manual Details Coverage Areas Geographic Coverage: Global (English Language) Model Year Coverage: 1994 Variant Coverage: KLR650, KLR500 Page Count Estimated Page Count: Likely over 300 pages (typical for factory service manuals) Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (or equivalent unzipping software) Compatibility Operating System Compatibility: All versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, assembly, tuning, lubrication Fuel System: Carburetor, fuel pump, fuel lines, fuel tank inspection and service Ignition System: CDI unit, ignition coils, spark plugs, timing Cooling System: Radiator, fan, coolant, hoses, thermostat Exhaust System: Muffler, pipes, heat shields Transmission: Gearbox, clutch, shifting mechanism, lubrication Drivetrain: Final drive chain and sprockets, adjustment, lubrication, replacement Suspension Front: Fork assembly, oil seals, springs, damping adjustments Suspension Rear: Shock absorber, linkage, swingarm, bearings Braking System Front: Caliper, disc, master cylinder, brake lines, fluid replacement Braking System Rear: Caliper, disc, master cylinder, brake lines, fluid replacement Electrical System: Wiring diagrams, battery, charging system, starter, lighting, fuses, relays Frame And Bodywork: Chassis inspection, body panel removal and installation, seat, fairings Wheels And Tires: Tire pressure, wheel balancing, spoke tension, rim inspection Procedures Included Preventative Maintenance: Scheduled checks, lubrication points, fluid changes, filter replacements Troubleshooting: Diagnostic charts for common problems and their solutions Disassembly: Step-by-step guides for component removal Assembly: Detailed instructions for reassembling components Cleaning: Procedures for cleaning specific parts and systems Reinstallation: Instructions for correctly refitting components Adjustment Procedures: Carburetor, chain tension, brake levers, suspension preload Engine Rebuild: Complete engine overhaul, piston replacement, valve adjustments, bearing services Electrical Diagnostics: Testing of charging system, ignition, lighting, and accessories Technical Depth Depth: Comprehensive (suitable for professional technicians and advanced DIYers) Detail Level: Factory-level detail, including specifications, torque values, and diagrams 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable (depending on PDF conversion quality) Print Quality Printability: Full Printable Zoom Capability: YES (Zoom IN/OUT) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 4-valve Displacement Cc: 651 cc (for KLR650), 500cc (for KLR500 variant) Bore X Stroke Mm: 100.0 x 83.0 mm (KLR650 - indicative, requires manual confirmation) Compression Ratio: 9.5:1 (KLR650 - indicative, requires manual confirmation) Cooling Method: Liquid-cooled Performance Horsepower Ps: Approx. 47 PS @ 6000 rpm (KLR650 - indicative, requires manual confirmation) Torque Nm: Approx. 57 Nm @ 5000 rpm (KLR650 - indicative, requires manual confirmation) Fuel System Fuel Delivery: Carburetor (e.g., Keihin CVK40 for KLR650 - requires manual confirmation) Fuel Type: Unleaded gasoline Fuel Tank Capacity Liters: 23 Liters (KLR650 - indicative, requires manual confirmation) 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed sequential Features Clutch Type: Wet, multi-disc Final Drive: Sealed chain 📐 Dimensions Exterior Overall Length Mm: Approx. 2185 mm (KLR650 - indicative, requires manual confirmation) Overall Width Mm: Approx. 875 mm (KLR650 - indicative, requires manual confirmation) Overall Height Mm: Approx. 1330 mm (KLR650 - indicative, requires manual confirmation) Wheelbase Mm: Approx. 1450 mm (KLR650 - indicative, requires manual confirmation) Weights Curb Weight Kg: Approx. 194 kg (KLR650 - indicative, requires manual confirmation) Gross Vehicle Weight Rating Kg: Not specified, but typically higher than curb weight 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not have automotive safety ratings like NCAP) Active Features Active Safety Features: Disc brakes (front and rear), responsive suspension Passive Features Passive Safety Features: Sturdy frame, rider ergonomics 💡 Technology Features Infotainment Infotainment System: N/A (Motorcycle of this era does not feature infotainment systems) Driver Assistance Driver Assistance Features: N/A (Motorcycle of this era does not feature driver assistance systems) Connectivity Connectivity Features: N/A (Motorcycle of this era does not feature connectivity features) 🔧 Maintenance Service Intervals Oil Change Interval Km: Every 6,000 km or 6 months (indicative, refer to manual for precise intervals) Valve Adjustment Interval Km: Every 12,000 km or 12 months (indicative, refer to manual for precise intervals) Chain Maintenance Interval: Clean and lubricate every 1,000 km or after riding in wet/dusty conditions Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (indicative, confirm with manual) Engine Oil Capacity Liters: Approximately 2.5 Liters with filter change (KLR650 - indicative, confirm with manual) Coolant Type: Ethylene glycol based antifreeze, mixture...