This comprehensive service and repair manual is a must-have for any owner of a Kawasaki KLR500 KL500 or KLR 650 KL model from 1987-2004. It contains hundreds of pages of detailed information covering all aspects of your motorcycle's maintenance and repair, ensuring you have the knowledge and guidance for any task.

The manual includes step-by-step instructions and clear illustrations for troubleshooting common issues, performing routine maintenance, and tackling complex repairs. You'll find detailed information on the cooling and lubrication systems, general information, periodic maintenance schedules, driveline/axle tune-up, engine rebuilds, transmission/transaxle adjustments, fuel system and throttle tuning, electrical system diagnostics, suspension and steering adjustments, brake maintenance, frame repair, bodywork restoration, periodic inspections, and all necessary specifications.

This manual provides both the Base and Supplemental manuals, giving you a complete resource for all your Kawasaki KLR needs.

The Kawasaki KLR 500 and KLR 650 are dual-sport motorcycles, a class of motorcycles designed for both on and off-road riding. They were produced by Kawasaki from 1987 to 2004, earning a reputation for reliability and ruggedness, making them popular among adventure riders and commuters alike. The KLR 500 was the first model, introduced in 1987, featuring a 499cc single-cylinder, air-cooled engine. It quickly gained popularity for its simplicity, versatility, and affordability. In 1991, the KLR 650 was introduced, featuring a larger 651cc engine. This larger displacement offered more power and torque, making it ideal for longer trips and heavier loads. Both models shared a similar design, featuring a steel frame, telescopic forks, and a monoshock rear suspension. They also included a 17-inch front and 17-inch rear wheel setup, along with a large fuel tank for extended range.

The KLR 500 and KLR 650 were praised for their robust construction and ease of maintenance. The simple, air-cooled engine was known for its reliability and durability, while the rest of the bike offered a straightforward design with few complex components. These features made them popular among riders who desired a bike that could handle anything thrown at it, from daily commutes to long-distance adventures, with minimal fuss. However, both models were criticized for their relatively heavy weight and basic suspension, lacking the agility and sophistication of more modern dual-sport motorcycles. Despite this, the KLR series remained popular throughout its production run, attracting a loyal following of riders who appreciated their ability to tackle diverse terrains without breaking the bank. The KLR 500 and KLR 650 remain a popular choice for adventure riders and commuters, readily available on the used market and praised for their simplicity and durability.