🏷️ Basic Information Identification Make: Kawasaki Model: KLR500/KLR650 Year: 2000 Product Type: Repair Service Manual Codes Engine Code Klr500: EG500A Engine Code Klr650: EX650A (Note: KLR650 typically uses a 651cc engine, often referred to as 650) 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY motorcycle mechanics with basic electrical and mechanical knowledge. Competitive Analysis Manual Type Comparison: Comparable to OEM factory service manuals in content and detail, offering a digital alternative. Key Features Learning Method: Step-by-step procedures designed to impart factory-trained technician knowledge. Utility: A vital resource for proper maintenance, repair decisions, and ensuring vehicle safety. Accessibility: Instant download availability allows for immediate access to repair information. 📋 Manual Details Coverage Areas Model Coverage: Kawasaki KLR500 and KLR650 models for the 2000 model year. Page Count Estimated Page Count: Estimated 300-500 pages (typical for a comprehensive service manual of this era, precise count not provided) Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, disassembly, assembly, inspection, and repair of engine components (pistons, rings, cylinders, crankshaft, camshaft, valves, timing chain, etc.). Fuel System: Carburetor (model specific, likely Keihin CVK) tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank service. Ignition System: CDI ignition system, spark plug specifications, timing checks, coil testing, and troubleshooting. Cooling System: Liquid cooling system maintenance, coolant specifications, radiator service, fan operation, and water pump. Exhaust System: Exhaust pipe and muffler inspection and replacement. Transmission Gearbox: Clutch operation, disassembly, inspection, and adjustment; gearbox internal inspection and repair; shift mechanism. Drivetrain Final Drive: Chain and sprocket maintenance, adjustment, and replacement; rear suspension linkage lubrication and inspection. Frame And Suspension Front: Front fork disassembly, service, seal replacement, oil specifications, and alignment. Frame And Suspension Rear: Rear shock absorber inspection and adjustment; linkage bearing service; swingarm maintenance. Braking System: Front and rear brake pad inspection/replacement, caliper service, master cylinder overhaul, brake fluid specifications, and bleeding procedures. Wheel And Tires: Spoke wheel maintenance, tire pressure specifications, tire replacement guidelines, and bearing service. Electrical System Charging: Alternator, rectifier/regulator testing and replacement, battery specifications and maintenance. Electrical System Lighting: Headlight, taillight, turn signal bulb specifications and replacement. Electrical System Instruments Controls: Speedometer, tachometer, indicator lamps, switchgear functionality. Bodywork And Trim: Fairing, tank, seat, fenders, and luggage rack removal/installation and maintenance. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting for engine, electrical, and mechanical issues. Procedures Included Routine Maintenance: Oil and filter changes, chain adjustment, air filter cleaning, spark plug replacement, brake inspection. Disassembly And Assembly: Step-by-step instructions for dismantling and reassembling major vehicle components and systems. Cleaning And Lubrication: Specific guidance on cleaning and lubricating various parts and systems. Adjustments: Carburetor idle speed and mixture, clutch free play, throttle cable, chain tension, suspension settings. Component Testing And Diagnosis: Procedures for testing electrical components, engine performance, and mechanical systems. Overhaul Procedures: Detailed instructions for complete engine and transmission rebuilds. Technical Depth Depth: Comprehensive, covering from basic maintenance to advanced engine and transmission overhaul, suitable for professional technicians and skilled DIYers. 📊 Manual Specifications File Format File Format Detail: PDF Print Quality Printable: Yes, full printable Searchability: Likely searchable text content within the PDF, enhancing usability. Zoom Capability Zoom In Out: Yes Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) Software Requirements PDF Reader: Adobe PDF Reader Unzipping Software: WinZip or compatible unzipping software Compatibility Operating Systems: All versions of Windows and Mac Delivery Method Delivery: Instant Download ⚙️ Engine Specifications Primary Engine Klr500 Engine Type: Liquid-cooled, 4-stroke, DOHC, single-cylinder Displacement: 498 cc (30.4 cu in) Primary Engine Klr650 Engine Type: Liquid-cooled, 4-stroke, DOHC, single-cylinder Displacement: 651 cc (39.7 cu in) Performance Klr650 Approx Horsepower: Approx. 42 HP (at crankshaft, model year dependent) Torque: Approx. 39 lb-ft (at crankshaft, model year dependent) Fuel System Carburetor Type: Keihin CVK (Constant Velocity) carburetor, likely 36mm for KLR650 and smaller for KLR500. Fuel Tank Capacity Klr650: 6.1 US gal (23 L) Fuel Type: Unleaded gasoline, minimum 87 octane. Ignition System Ignition Type: Digital CDI with electronic advance 🔧 Transmission Standard Transmission Type: Constant-mesh, 5-speed return type Features Clutch Type: Wet, multi-disc, cable-actuated Final Drive: Sealed O-ring chain 📐 Dimensions Exterior Klr650 Approx Overall Length: Approx. 2,235 mm (87.9 in) Overall Width: Approx. 850 mm (33.5 in) Overall Height: Approx. 1,370 mm (53.9 in) Wheelbase: Approx. 1,470 mm (57.9 in) Weights Klr650 Approx Curb Weight: Approx. 192 kg (423 lbs) Dry Weight: Approx. 174 kg (383.6 lbs) 🛡️ Safety Features Ratings Safety Ratings: No specific crash test ratings available for motorcycles of this era. Safety relies on proper maintenance and operation. Active Features Active Safety Features: Responsive braking system (front disc, rear disc), stable chassis geometry. Passive Features Passive Safety Features: Robust frame construction, integrated lighting system. 💡 Technology Features...