🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Product Name: KAWASAKI KLR500 KLR650 Service Repair Manual 2002-2006 Generation Covered Years: 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Value Proposition: BEST manuals on Tradebit, save money on repairs, professional quality resources Competitive Analysis Comparison To Others: Complete service repair manual, similar to Factory Workshop Manuals or CDROM Manuals, not incomplete cheap versions Key Features Access Method: Instant download upon payment Usage Platform: Viewable on PC, Tablet, or Laptop 📋 Manual Details Coverage Areas Full Vehicle Coverage: Yes (A-Z) Model Variants Covered: All models within the specified year range Page Count Estimated Page Count: Likely 300-600 pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine Removal/Installation, Fuel System (including Fuel Injection), Lubrication, Cooling, Combustion, Crankcase, Piston, Cylinder, Crankshaft, Balancer, Alternator/Starter Clutch, Cylinder Head/Valves Drivetrain Systems: Transmission System, Gearbox, Clutch Chassis Systems: Front Wheel and Steering System, Rear Wheel System, Frame, Body Panels, Exhaust System, Suspension (Front and Rear), Braking System Electrical Systems: Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams Bodywork And Fixtures: Body & Fixtures, Fenders, Exhaust Pipe Procedures Included Maintenance Procedures: Periodic Checks & Adjustments, Routine Maintenance, Scheduled Service Repair Procedures: Step-by-step instructions for all repairs (simple to complicated) Diagnostic Procedures: Troubleshooting section for identifying and resolving issues Technical Depth Depth: Comprehensive (factory workshop manual equivalent) Visuals: Highly detailed exploded pictures and diagrams 📊 Manual Specifications File Format Compatibility: Win/MAC/Linux Searchability: Likely searchable text within PDF Print Quality Printability: Printable (entire manual or specific pages) Binding Type Binding: Not applicable (Digital download) Paper Type Paper Quality: Not applicable (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Single-cylinder, DOHC, 4-valve Engine Displacement Klr650: 651 cc Engine Displacement Klr500: 498 cc (Note: KLR500 is an older model, KLR650 is the focus for 2002-2006) Performance Bore X Stroke Klr650: 100.0 mm x 83.0 mm (typical) Compression Ratio Klr650: 9.5:1 (typical) Fuel System Fuel Delivery: Fuel Injection (for the covered years, typically Keihin CVK40 carburetor on earlier models but the manual covers fuel injection systems) Cooling System Cooling Method: Liquid-cooled Lubrication Lubrication Type: Wet Sump (with oil filter) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Sealed chain drive 📐 Dimensions Exterior Overall Length Klr650: Approx. 2,200 mm (86.6 in) Overall Width Klr650: Approx. 890 mm (35.0 in) Overall Height Klr650: Approx. 1,370 mm (53.9 in) Weights Curb Weight Klr650: Approx. 192 kg (423 lbs) Fuel Tank Capacity Klr650: 23 L (6.1 gal) 🛡️ Safety Features Ratings Safety Certification: CE, EPA (depending on market) Active Features Braking System: Disc brakes front and rear Passive Features Lighting System: Halogen headlight, LED taillight (typical for the era) 💡 Technology Features Infotainment Infotainment System: Not applicable (Motorcycle) Driver Assistance Rider Aids: ABS was not standard or widely available on these models during this period. Manual covers basic operational aspects. Connectivity Connectivity Features: Not applicable (Motorcycle) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals (typically 6,000 km or 3,700 miles for synthetic) Air Filter Cleaning: Refer to manual for specific mileage/time intervals (frequent in dusty conditions) Spark Plug Replacement: Refer to manual for specific mileage/time intervals (e.g., 12,000 km or 7,500 miles) Fluid Specifications Engine Oil Type: API SG or SH, SAE 10W-40 (check manual for exact specification, especially for synthetic) Coolant Type: Permanent type antifreeze coolant (e.g., 50/50 mix of ethylene glycol and distilled water) Brake Fluid Type: DOT 4 (check manual for specific recommendation) Known Issues Common Wear Items: Clutch wear, valve adjustment intervals, countershaft sprocket wear, occasional voltage regulator issues Specific Model Quirks: Early models might have carburetor jetting issues; fuel injected models generally smoother but require proper diagnostic tools. 📚 Vehicle History Brand Heritage Manufacturer: Kawasaki Heavy Industries Motorcycle & Engine Company Model Evolution Klr Lineage: The KLR650 is renowned as a long-running, versatile dual-sport motorcycle, known for its reliability and ability to handle various terrains. The KLR500 was an earlier iteration. Production Production Period Covered: 2002-2006 (with the KLR650 being the primary focus for these years) 🏆 Awards & Recognition Recognitions Model Reputation: The KLR650 is widely recognized for its durability, versatility, and value, often cited as a capable adventure touring and general-purpose motorcycle.