This comprehensive service and repair manual is your go-to resource for maintaining and repairing your Kawasaki KLR500 or KLR650 motorcycle, covering model years 2002 through 2006. This manual is packed with detailed information, including step-by-step instructions, high-resolution diagrams, and clear photographs, making even complex repairs accessible. It covers all aspects of servicing and troubleshooting, from basic maintenance like oil changes and filter replacements to more advanced tasks like engine rebuilds and electrical system repairs. This manual is designed to be used by both professional mechanics and DIY enthusiasts, providing the same level of detailed information used by technicians at dealerships. This manual is a valuable investment for any KLR500 or KLR650 owner, providing you with the knowledge and tools to keep your motorcycle running smoothly for years to come.

The Kawasaki KLR650, and its predecessor the KLR500, are rugged dual-sport motorcycles renowned for their versatility and durability. These motorcycles are designed to handle a wide range of riding conditions, from paved roads to challenging off-road trails. The KLR650, introduced in 2008, inherited the legacy of the KLR500 and became a popular choice for adventure touring and long-distance travel. Both models feature an air-cooled, four-stroke, single-cylinder engine that provides ample power for on and off-road riding. The KLR650 boasts a larger displacement engine, resulting in more torque and power, making it suitable for both solo and two-up riding. Both models are known for their reliability, with a simple design and proven mechanical components contributing to their longevity.

The KLR650 and KLR500 are equipped with a high-ground clearance, long-travel suspension, and a rugged chassis, making them capable of handling rough terrain. The KLR650 features a larger fuel tank, allowing for extended range, while the KLR500 may require more frequent fuel stops. These motorcycles are designed for comfort and ease of use, with a spacious riding position, large windshields, and optional luggage systems. The KLR650, despite its large size and rugged design, is relatively light, making it agile and manageable on the road and off. The KLR500, though smaller, shares similar handling characteristics. The KLR650 and KLR500 are popular choices for riders seeking a reliable and versatile machine for adventure, touring, or daily commutes. Their durability, ease of maintenance, and wide range of aftermarket parts and accessories make them attractive options for a diverse group of riders.