This comprehensive service repair manual supplement is designed for Kawasaki KLR650 and KLR500 motorcycles manufactured between 1987 and 1995, and 2000 to 2002. It provides detailed instructions and diagrams to guide you through every aspect of repair, maintenance, rebuild, refurbishment, or restoration of your motorcycle.

You'll find complete tear-down and rebuild procedures, comprehensive part diagrams, precise torque specifications, essential maintenance tips, troubleshooting guides, and much more. This manual is a valuable resource for both novice and experienced mechanics, offering an inexpensive way to keep your KLR running smoothly.

The manual is structured to guide you through each service and repair procedure with a level of detail that's unmatched. Hundreds of photos and illustrations accompany step-by-step instructions, ensuring clarity and ease of understanding.

The content covers a wide range of topics, including:

* **General Information:** Provides an overview of the motorcycle, its components, and essential safety precautions.
* **Fuel System:** Covers fuel tank, fuel lines, carburetor, fuel pump, and related components.
* **Cooling System:** Includes information on the radiator, coolant, hoses, and cooling fan.
* **Engine Top End:** Details on the cylinder head, valves, camshaft, and other components.
* **Engine Lubrication System:** Covers oil pump, oil filter, and oil lines.
* **Engine Removal/Installation:** Provides instructions for removing and installing the engine.
* **Crankshaft/Transmission:** Covers the crankshaft, transmission, and related components.
* **Wheels/Tires:** Includes information on wheel bearings, tire maintenance, and tire replacement.
* **Final Drive:** Details on the final drive system, including the chain or shaft drive.
* **Brakes:** Covers front and rear brakes, including calipers, rotors, and hydraulic systems.
* **Suspension:** Includes information on forks, shocks, and related components.
* **Steering:** Covers steering head, handlebar, and related components.
* **Frame:** Provides information on the motorcycle frame and its components.
* **Electrical System:** Covers the battery, starter, alternator, ignition system, and wiring.
* **Appendix:** Provides additional information, such as wiring diagrams, specifications, and troubleshooting charts.
* **Supplement - 2000-2001 Model:** Includes specific information for the 2000 and 2001 model years.
* **Supplement - 2002 Model:** Includes specific information for the 2002 model year.

This manual is designed to be your comprehensive guide for keeping your Kawasaki KLR650 or KLR500 in optimal condition.

The Kawasaki KLR650 and KLR500 are dual-sport motorcycles renowned for their versatility and rugged reliability. These machines are designed to handle a wide range of riding conditions, from paved roads to challenging off-road terrain. The KLR650, introduced in 1987, features a powerful 651cc air-cooled, single-cylinder engine known for its torque and durability. It boasts a robust steel frame, long-travel suspension, and a large fuel tank, making it ideal for long-distance adventures. The KLR500, produced from 1990 to 1995, was a smaller, more manageable version with a 499cc engine. Both models offer a comfortable riding position and a high level of ground clearance, allowing riders to confidently tackle obstacles.

The KLR series has garnered a loyal following among adventure riders and commuters alike. Their simplicity of design, ease of maintenance, and low cost of ownership have contributed to their popularity. The KLR650, in particular, has become a staple for riders seeking a dependable machine for exploring remote areas. The motorcycle's ability to handle both on-road and off-road conditions, coupled with its comfortable riding experience, has made it a favorite for long-distance touring. The KLR650's reputation for reliability and durability, along with its aftermarket support, has fostered a strong community of enthusiasts who share their knowledge and experiences.