🏷️ Basic Information Identification Make: Kawasaki Model: KLR500 / KLR650 Model Variant: Dual-Sport Motorcycle Product Name: KAWASAKI KLR500 KLR650 Full Service & Repair Manual 1987-2002 Codes Chassis Codes Klr500: KL600 Chassis Codes Klr650: KL650-A1, KL650-A2, KL650-A3, KL650-A4, KL650-A5, KL650-A6, KL650-A7, KL650-A8, KL650-A9, KL650-A10, KL650-A11, KL650-A12, KL650-A13, KL650-A14, KL650-A15, KL650-A16, KL650-A17, KL650-A18 👋 Introduction Market Position Motorcycle Segment: Dual-sport / Adventure touring motorcycle. Known for its ruggedness, versatility, and long-distance capability. Competitive Analysis Key Competitors: Honda Transalp, Suzuki DR650, Yamaha XT600/XT660, BMW F650 Funduro. Key Features Durability: Renowned for its bulletproof engine and robust construction, making it a favorite for long-distance touring and off-road excursions. Versatility: Capable of handling a wide range of conditions, from commuting to exploring unpaved roads and light off-roading. Aftermarket Support: Strong aftermarket community and parts availability, contributing to its longevity and customizability. 📋 Manual Details Coverage Areas Applicable Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Page Count: Hundreds of pages (Specific count not provided, but descriptor implies comprehensive depth) Manual Type Manual Type: Full Service & Repair Workshop Manual Language Language: English (Presumed based on product description and typical market) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, tuning, troubleshooting, and repair for all variants. Fuel System: Carburetor (CVK) system overhaul, adjustment, fuel pump, fuel lines, and tank maintenance. Ignition System: Ignition timing, spark plugs, CDI unit, ignition coils, troubleshooting electrical faults. Transmission: Clutch operation, gearbox inspection, maintenance, and repair of all components. Drivetrain: Chain and sprockets maintenance, rear shock absorber, swingarm, and linkage lubrication and adjustment. Braking System: Front and rear brake systems, including hydraulic lines, calipers, master cylinders, brake pads, discs, and bleeding procedures. Suspension: Front fork (telescopic) disassembly, service, oil changes, seal replacement, and rear suspension unit maintenance. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, horn, starter motor, and instrumentation. Cooling System: Coolant levels, radiator, hoses, and thermostat operation (for liquid-cooled models if applicable, though KLR650 is typically air/oil-cooled). Check for specific cooling system coverage for KLR500 if it differs. Exhaust System: Exhaust pipe and muffler inspection and replacement. Frame And Bodywork: Frame inspection, fairings, body panels, seat, fuel tank removal and installation, and general chassis maintenance. Procedures Included Preventative Maintenance: Detailed schedules for oil changes, filter replacements, chain adjustments, brake fluid flushes, and general inspections. Routine Servicing: Step-by-step instructions for all routine checks and adjustments required to keep the motorcycle in optimal condition. Troubleshooting: Diagnostic procedures for common and uncommon problems, including electrical issues, engine performance, and starting problems. Engine Rebuild: Comprehensive guidance on engine disassembly, component measurement (e.g., piston ring gap, cylinder bore), reassembly, and break-in procedures. Carburetor Overhaul: Detailed instructions for cleaning, rebuilding, and tuning the Keihin CVK carburetor. Suspension Service: Front fork seal replacement, oil level adjustments, and rear shock absorber inspection. Electrical Diagnostics: Using multimeters, testing components, and interpreting wiring diagrams to diagnose electrical faults. Brake System Maintenance: Brake fluid replacement, caliper servicing, and bleeding the hydraulic system. Wheel And Tire Service: Tire replacement, wheel balancing, and spoke tensioning (if applicable). Technical Depth Depth Of Information: Factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic checks to complete engine rebuilds. Diagrams And Illustrations: Hundreds of detailed photos and exploded diagrams to guide every step of the repair or maintenance process. Diagnostic Codes: Likely includes diagnostic procedures but may not list specific OBD-II codes as this is pre-OBD-II era for motorcycles. Specifications Data: Includes torque values, clearances, fluid types and capacities, electrical resistance values, and other critical technical data. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely searchable text within the PDF (depends on PDF creation process, but common for professional manuals). Print Quality Printable: Yes, allows printing of individual pages or the entire manual. Resolution: High-resolution images and diagrams suitable for clear viewing and printing. Binding Type Binding: N/A (Digital Download - no physical binding) Paper Type Paper Type: N/A (Digital Download - no physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type Klr650: 4-stroke, Liquid-cooled, DOHC, Single Cylinder Engine Type Klr500: 4-stroke, Single Cylinder, SOHC (typically air/oil cooled) Displacement Klr650: 651 cc (39.7 cu in) Displacement Klr500: 498 cc (30.4 cu in) Performance Bore X Stroke Klr650: 100.0 mm x 83.0 mm (3.94 in x 3.27 in) Bore X Stroke Klr500: 92.0 mm x 76.0 mm (3.62 in x 2.99 in) Horsepower Klr650: Approx. 42-46 hp (at crankshaft, depending on specific model year and tuning) Torque Klr650: Approx. 39-42 lb-ft (at crankshaft, depending on specific model year and tuning) Fuel System Carburetor Type: Keihin CVK40 (Constant Velocity) or similar for both models. Fuel Tank Capacity Klr650: 18 Liters (4.7 US gal) Fuel Tank Capacity Klr500: 12 Liters (3.2 US gal) 🔧...