🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: KLR500 Year: 1996 Codes Manual Product Code: KLR500-KLR650-1996-SRM 👋 Introduction Market Position Target Audience: Professional Technicians and DIY Mechanics Value Proposition: Comprehensive repair and maintenance information for a specific model year, delivered instantly and affordably Competitive Analysis Advantage Over Paper: No shipping costs, no waiting time, easily searchable and printable Key Features Instructional Design: Numbered instructions, bold figure numbers for quick reference, detailed illustrations/drawings/photos Diagnostic Tools: Combined troubleshooting and electrical service procedures with detailed wiring diagrams 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Secondary Coverage: Maintenance, Diagnostics, Rebuilding, Refurbishing, Restoration Page Count Estimated Page Count: Varies (typical comprehensive manuals for this era are 300-600 pages) Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Lubrication System, Cooling System, Exhaust System Chassis: Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Drive Chain Electrical: Ignition System, Lighting System, Battery, Charging System, Starter Motor, Instrumentation, Wiring Diagrams Bodywork: Body Panels, Fairings, Seat, Fuel Tank, Luggage Rack Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment, Brake Pad Replacement, Valve Clearance Adjustment Diagnostics: Troubleshooting Guides, Symptom-Based Diagnosis, Electrical System Diagnostics Repair: Engine Overhaul, Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Testing and Replacement Rebuild Refurbish: Complete Engine Rebuild, Carburetor Rebuild, Carburetor Cleaning and Adjustment Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics Detail Level: Detailed sub-steps, critical notes, cautions, and warnings 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if created from digital source or scanned with OCR Print Quality Printability: Full Printable Print Resolution: Depends on source scan quality; aims for clarity of text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements PDF Reader: Adobe PDF Reader Compression Utility: WinRAR (or similar decompression software) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, DOHC, 4-valve Engine Displacement: KLR650: 651 cc (approx.); KLR500: 498 cc (approx.) Bore X Stroke: KLR650: 100.0 x 83.0 mm (approx.); KLR500: Specific to KLR500 model Cooling System: Liquid-cooled Performance Horsepower: KLR650 (1996): Approx. 42-45 HP (at crank); KLR500: Specific to KLR500 model Torque: KLR650 (1996): Approx. 33-35 lb-ft (at crank); KLR500: Specific to KLR500 model Fuel System Fuel Delivery: Carburetor(s) (likely single Keihin CVK) Carburetor Type: Keihin CVK (Constant Velocity Carburetor), size typically 40mm for KLR650 Fuel Type: Unleaded gasoline Fuel Tank Capacity: KLR650 (1996): 6.1 US gal (23 L) Lubrication System Oil Type: SAE 10W-40 Motorcycle Oil (API SG or higher) Oil Capacity: KLR650: 2.4 L (2.5 US qt) with filter change 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain Fluid Specifications Transmission Oil Type: SAE 80W-90 Gear Oil (API GL-4) 📐 Dimensions Exterior Length: KLR650 (1996): Approx. 2,320 mm (91.3 in) Width: KLR650 (1996): Approx. 910 mm (35.8 in) Height: KLR650 (1996): Approx. 1,420 mm (55.9 in) - seat height variable Weights Dry Weight: KLR650 (1996): Approx. 174 kg (383.6 lbs) Curb Weight: KLR650 (1996): Approx. 195 kg (430 lbs) Wheels Tires Front Tire Size: KLR650 (1996): 90/90-21 Rear Tire Size: KLR650 (1996): 130/80-17 Front Wheel Type: Spoked, 21-inch Rear Wheel Type: Spoked, 17-inch 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle) Active Features Brakes Front: Single Disc, Dual-piston caliper Brakes Rear: Single Disc, Single-piston caliper Passive Features Lighting: Halogen Headlight, LED Taillight/Brake Light (typical for era) 💡 Technology Features Infotainment Infotainment System: None (Analog instrumentation) Driver Assistance ABS: Not equipped (ABS was not standard or widely available on this model in 1996) Instrumentation Instrument Cluster: Analog speedometer, tachometer, odometer, trip meter, engine temperature gauge, indicator lights 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles (4,800 km) or 6 months Air Filter Cleaning: Every 3,000 miles (4,800 km) or as needed based on riding conditions Valve Clearance Check: Every 15,000 miles (24,000 km) Spark Plug Replacement: Every 15,000 miles (24,000 km) Fluid Specifications Coolant Type: Kawasaki Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors) Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Clutch plates, wheel bearings, steering head bearings, brake pads, chain and sprockets Potential Engine Concerns: Oil consumption can increase with high mileage; carburetor tuning may be required over time. Electrical Notes: Older wiring harnesses may require inspection for wear or corrosion. 📚 Vehicle History Brand Heritage Manufacturer Heritage: Kawasaki Heavy Industries, Ltd. (Motorcycle and Engine division) established history in motorcycle manufacturing since the 1950s. Model Evolution Klr Lineage: The KLR series is renowned for its dual-sport capability and ruggedness, evolving from earlier models like the KLR250 and sharing lineage with the KLR600. Klr650 Evolution: The...