🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: KLR500 Year: 1987 Generation First Generation Start: 1987 First Generation End: 2007 👋 Introduction Market Position Target Audience: Professional technicians, DIY mechanics, enthusiasts looking for comprehensive repair information. Competitive Analysis Comparison To Oem: Provides information equivalent to official Kawasaki Service Manuals used by authorized dealers and technicians. Key Features Detail Level: Extremely detailed with numbered steps, notes, cautions, warnings, and enlarged insets for clarity. Illustration Quality: Detailed illustrations, drawings, and photos to guide repair procedures. Organization: Numbered table of contents for quick information retrieval. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Secondary Coverage: Maintenance, Diagnostics, Rebuilding, Refurbishing, Restoration Page Count Estimated Page Count: N/A (Digital Download) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system, exhaust system. Transmission: Clutch, gearbox, drive chain, maintenance, repair, adjustments. Brakes: Front and rear brake systems, hydraulic components, caliper maintenance, pad replacement, bleeding procedures. Electrical: Wiring diagrams, charging system, ignition system, lighting, starter motor, troubleshooting, diagnostic procedures. Suspension: Front forks (oil change, seal replacement), rear shock absorber, linkage maintenance, adjustments. Chassis Frame: Frame inspection, swingarm maintenance, wheel bearing service, steering head bearing service. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel tank, petcock, fuel lines. Cooling System: Radiator, coolant, hoses, thermostat, fan (if applicable). Bodywork Cosmetics: Fairings, seat, fenders, tank removal and installation, minor bodywork repair guidance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustments, lubrication points, spark plug checks, brake fluid checks, tire pressure. Troubleshooting: Detailed symptom-based troubleshooting guides for common mechanical and electrical issues. Rebuild Procedures: Engine rebuild, carburetor rebuild, suspension fork rebuild, brake caliper rebuild. Diagnostic Procedures: Engine performance diagnostics, electrical system diagnostics, ignition timing checks. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for easy fault finding. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine rebuilds and complex electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Searchable: Implied by PDF format, though not explicitly stated as text-searchable. Print Quality Printability: Full Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software: Adobe PDF Reader, WinRAR Compatibility: All Versions of Windows & Mac Delivery Method: Instant Download Cost Savings: No shipping costs, no waiting for physical delivery. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder (for KLR650), dual-cylinder (for KLR500 - though KLR500 models were rare and may refer to an earlier iteration or mislabeling, KLR650 is the dominant model of this era). Engine Displacement: Approx. 651cc (for KLR650) Performance Horsepower: Approx. 47 hp @ 6500 rpm (for KLR650, spec may vary slightly by region/tuning) Torque: Approx. 39 lb-ft @ 5000 rpm (for KLR650, spec may vary slightly by region/tuning) Fuel System Carburetor: Single Keihin CVK40 (for KLR650) Fuel Type: Unleaded gasoline Lubrication Oil Type: API SG, SF 10W-40 (refer to manual for exact specification and capacity) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: 5-speed constant mesh Drive Type: Chain Drive Features Clutch Type: Wet, multi-disc Transmission Fluid: Refer to manual for specific type and capacity (typically engine oil) 📐 Dimensions Exterior Length: Approx. 2,235 mm (88.0 in) (for KLR650) Width: Approx. 855 mm (33.7 in) (for KLR650) Height: Approx. 1,380 mm (54.3 in) (for KLR650) Weights Dry Weight: Approx. 174 kg (384 lbs) (for KLR650) Wet Weight: Approx. 190 kg (419 lbs) (for KLR650, with fluids) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle, no standardized crash test ratings like cars) Active Features Braking System: Front: Dual disc, Rear: Single disc Passive Features Lighting: Halogen headlight, taillight, turn signals. 💡 Technology Features Infotainment Audio System: N/A (Motorcycle) Driver Assistance Electronic Aids: N/A (Motorcycle) Connectivity Features: N/A (Motorcycle) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-6,000 km (1,800-3,700 miles) or 6 months, whichever comes first (refer to manual for precise interval). Air Filter Cleaning: Every 6,000 km (3,700 miles) or annually. Spark Plug Replacement: Every 12,000 km (7,500 miles) or as needed based on inspection. Valve Clearance Check: Every 12,000 km (7,500 miles) or every two years. Fluid Specifications Engine Oil Capacity: Approx. 2.5 liters (2.6 US qt) with filter change (refer to manual for exact capacity). Coolant Type: Ethylene glycol based coolant (50/50 mixture with distilled water). Brake Fluid: DOT 4 recommended (refer to manual for exact specification). Known Issues Common Problems: Starter clutch wear, cam chain noise, carburetor jetting sensitivity to altitude and modifications, fork seal leaks with heavy off-road use. Maintenance Focus: Regular chain lubrication and adjustment, proper engine oil level checks, and carburetor cleaning/adjustment are crucial for longevity. 📚 Vehicle History Brand Heritage Kawasaki Motorcycles: Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and durability. Model Evolution Klr Series: The KLR650 is...