🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Year: 1987 Product Type: Repair Service Manual 👋 Introduction Market Position Target Audience: Primarily professional technicians, but also suitable for do-it-yourself mechanics with basic electrical and mechanical knowledge. Purpose: To provide comprehensive guidance for maintaining and repairing the Kawasaki KLR500/KLR650 1987 model. Competitive Analysis Comparison To Paper Manuals: Functionally equivalent to paper manuals, offering the same detailed information with the advantage of instant digital access and searchability. Key Features Instructional Style: Step-by-step procedures designed to teach factory-level knowledge. Visual Aids: Includes illustrations and pictures (as typical for factory manuals). Decision Making Aid: Empowers owners to make informed decisions regarding maintenance and repairs. 📋 Manual Details Coverage Areas Primary Coverage: Kawasaki KLR500 and KLR650 motorcycles Model Year Coverage: 1987 Page Count Estimated Page Count: Refer to factory specifications (typically 300-500 pages for a comprehensive service manual) Manual Type Type: Factory-style Repair Service Manual Language Language: English Format File Format: PDF Digital Delivery: Instant Download 📖 Manual Coverage Systems Covered Engine: Comprehensive engine overhaul, including disassembly, inspection, assembly, and tuning. Fuel System: Carburetor service, fuel pump operation, fuel tank maintenance, and fuel line routing. Ignition System: Ignition timing, spark plug specifications, CDI unit testing, and related components. Transmission: Gearbox disassembly, inspection, lubrication, and clutch service. Drivetrain: Final drive chain and sprocket inspection, adjustment, and replacement procedures. Suspension: Front fork service, rear shock absorber maintenance, spring rates, and damping adjustments. Brakes: Front and rear brake caliper service, master cylinder overhaul, brake fluid specifications, and bleeding procedures. Electrical System: Wiring diagrams, component testing, battery maintenance, lighting systems, and starter motor operation. Cooling System: Radiator service, coolant specifications, fan operation, and thermostat replacement. Chassis And Frame: Frame inspection, steering head bearing service, and wheel bearing maintenance. Bodywork: Fairing removal and installation, seat service, and fender care. Procedures Included Maintenance: Routine maintenance checks, lubrication schedules, filter replacements, and fluid changes. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Troubleshooting: Diagnostic guides and symptom-based troubleshooting for common and uncommon issues. Disassembly Assembly: Detailed instructions for component disassembly and reassembly. Cleaning: Specific cleaning procedures for various engine and chassis components. Reinstalling: Procedures for correctly reinstalling all serviced components. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Quality: High-resolution PDF, allowing for Zoom IN/OUT capability. Print Quality Printability: Full Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, Single-cylinder (KLR650), Single-cylinder (KLR500 - typically a smaller displacement variant sharing architecture) Displacement Klr650: 651 cc (39.7 cu in) Displacement Klr500: Approximately 461 cc (28.1 cu in) - exact specification may vary based on specific market variants. Performance Bore X Stroke Klr650: 100.0 mm x 83.0 mm (3.94 in x 3.27 in) Compression Ratio Klr650: 9.5:1 Horsepower Klr650 Estimated: Approximately 40-45 HP @ 6500 RPM (factory figures may vary). Torque Klr650 Estimated: Approximately 35-40 lb-ft @ 5000 RPM (factory figures may vary). Fuel System Fuel Delivery: Mikuni VM32SS carburetor (typical for KLR650, KLR500 may differ slightly) Fuel Type: Unleaded gasoline, 87 octane (minimum) Lubrication Oil Type: SAE 10W-40 motorcycle oil, API SG or higher. Oil Capacity Klr650: Approximately 2.4 Liters (2.5 US qt) with filter change. 🔧 Transmission Standard Type: Constant-mesh, 6-speed return Optional Availability: N/A (Single transmission option for the model year) Features Clutch: Wet, multi-disc Gear Ratios: Detailed ratios available within the manual, specific to each gear. Transmission Fluid Type: API GL-4, SAE 80W-90 gear oil. 📐 Dimensions Exterior Overall Length Klr650: Approx. 2,235 mm (87.9 in) Overall Width Klr650: Approx. 850 mm (33.5 in) Overall Height Klr650: Approx. 1,455 mm (57.3 in) Weights Dry Weight Klr650 Estimated: Approx. 160 kg (353 lbs) Wet Weight Klr650 Estimated: Approx. 176 kg (388 lbs) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle, not subject to automotive crash testing standards) Active Features Braking System: Dual-piston caliper front, drum brake rear (typical for the era, KLR650 might have disc option). Suspension Stability: Telescopic front fork and Uni-Trak rear suspension designed for stability. Passive Features Lighting: Headlight, taillight, brake light, turn signals. 💡 Technology Features Infotainment Features: Basic instrumentation: speedometer, odometer, tachometer, trip meter, neutral indicator, high beam indicator. Driver Assistance Features: N/A (No electronic driver assistance systems found on this vintage motorcycle). Connectivity Features: N/A (No modern connectivity features). 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. Air Filter Cleaning Replacement: Every 6,000-10,000 km (3,700-6,200 miles) or annually. Spark Plug Replacement: Every 10,000-15,000 km (6,200-9,300 miles). Chain Lubrication Adjustment: Every 500-1,000 km (300-600 miles) or after riding in wet conditions. Fluid...