🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 / KLR500 Product Name: Kawasaki KLR650 KLR500 Motorcycle Service Repair Manual Supplement 1987-1995 2000-2002 Generation Klr650 A Series Generation: First Generation (A Series) Codes Frame Prefix Klr650: JKAKLEA1□ Vin Identifier Klr650 A1: HA000001 Frame Identifier Klr650 A1: KL650A-000001 Vin Identifier Klr500 A1: KL500A-000001 👋 Introduction Market Position Value Proposition: Inexpensive way to keep your vehicle working properly, save money on repairs Competitive Analysis Uniqueness: Comprehensive coverage for a wide range of early KLR models including specific supplements for later years Key Features Completeness: 100 percent complete and intact, no missing/corrupt pages/sections Visual Aids: Hundreds of photos and illustrations 📋 Manual Details Coverage Areas Applicable Model Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 2000, 2001, 2002 Covered Models: Kawasaki KLR650 (A1-A9, A14-A16), Kawasaki KLR500 (A1-A2) Page Count Total Pages: 130 Manual Type Type: Service Repair Manual Supplement Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine Top End, Engine Lubrication System, Crankshaft/Transmission Fuel And Cooling: Fuel System, Cooling System Chassis And Drivetrain: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame Electrical: Electrical System Supplements: Supplement-2000-2001 Model, Supplement-2002 Model Procedures Included Major Repair: Complete tear down and rebuild, Engine Removal/Installation Maintenance And Diagnostics: Maintenance, Troubleshooting, Diagnostic procedures Restoration: Refurbish or restore procedures Technical Depth Detail Level: Detailed illustrations, diagrams, wiring schematics, step-by-step instructions Target Audience: Do-it-yourselfer and experienced mechanic 📊 Manual Specifications File Format Digital Delivery: Instant Download Compatibility: All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android etc. Print Quality Searchability: Searchable Bookmarking: Bookmarked Binding Type Physical Format Implication: Can be burned to CD-ROM Paper Type Printability: Printable ⚙️ Engine Specifications Primary Engine Engine Type Klr650: Four-stroke, DOHC, 4-valve, Single-cylinder Engine Type Klr500: Four-stroke, DOHC, 4-valve, Single-cylinder Performance Displacement Klr650: 651 cc (39.7 cu in) Displacement Klr500: 498 cc (30.4 cu in) Fuel System Carburetion Klr650: Keihin CVK40 carburetor Carburetion Klr500: Keihin CVK36 carburetor Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: Constant mesh, 5-speed Features Clutch: Wet, multi-disc 📐 Dimensions Weights Dry Weight Klr650 Approx: 388 lbs (176 kg) Dry Weight Klr500 Approx: 344 lbs (156 kg) Exterior Ground Clearance Klr650 Approx: 9.3 inches (235 mm) Seat Height Klr650 Approx: 35.0 inches (889 mm) 🛡️ Safety Features Ratings Safety Features Coverage: Brake system details, tire information, suspension setup guidance 💡 Technology Features Infotainment Infotainment Features: N/A (basic motorcycle electronics) Driver Assistance Rider Aids: N/A (basic motorcycle electronics) Connectivity Connectivity Features: N/A (basic motorcycle electronics) 🔧 Maintenance Service Intervals Oil Change Interval Approx: Every 4,000 miles or 6 months (refer to manual for precise intervals) Valve Clearance Check Interval Approx: Every 8,000 miles or 12 months (refer to manual for precise intervals) Fluid Specifications Engine Oil Type Recommendation: API SG, SF or SE, SAE 10W-40 (refer to manual for exact specifications) Coolant Type Recommendation: Kawasaki Coolant or equivalent, ethylene glycol-based antifreeze (refer to manual for exact specifications) Known Issues Common Wear Item: Doohickey (balancer lever spring and tab), often recommended for replacement/upgrade to prevent catastrophic failure. Clutch plates can wear over time. Cam chain tensioner can become noisy. Fuel System Consideration: Carburetor jetting may need adjustment for altitude or modifications. Fuel petcock can leak. 📚 Vehicle History Brand Heritage Kawasaki Motorcycle Legacy: Kawasaki has a long history of producing robust and versatile motorcycles, with the KLR line being a prime example of dual-sport capability. Model Evolution Klr650 A Series Design: The A-series KLR650 established the platform's reputation for durability and adventure touring, featuring a large fairing, ample fuel capacity, and long-travel suspension. Production Klr650 A Series Production Span: 1987-2005 (with model year variations covered in this manual) Klr500 Production Span: Approximately 1987-1990 (covered by this manual's earlier years) 🏆 Awards & Recognition Recognitions Model Reputation: The KLR650 is widely recognized for its reliability, versatility, and ability to tackle diverse terrains, making it a favorite among adventure and dual-sport riders.