Kawasaki KLR500 KLR650 Motorcycle Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006

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🏷️ Basic Information Identification Make: Kawasaki Model: KLR500/KLR650 Product Name: Kawasaki KLR500 KLR650 Motorcycle Complete Workshop Service Repair Manual 2002-2006 Generation Generation Covered: Second Generation (KL650-A/E) Codes Chassis Codes: KL650-A (earlier models), KL650-E (later models for 2002-2006) 👋 Introduction Market Position Market Position: The Kawasaki KLR650 (and its predecessor the KLR500) has long been a benchmark in the dual-sport motorcycle segment, known for its ruggedness, versatility, and reliability. It appeals to adventure riders, commuters, and those seeking a durable machine for light off-road exploration. Competitive Analysis Competitive Analysis: Competed against motorcycles like the Honda XR650L, Suzuki DR650SE, and Yamaha XT600/XT660. The KLR's unique combination of a large fuel tank, comfortable ergonomics, and robust construction made it a strong contender. Key Features Key Features: Large displacement single-cylinder engine, long-travel suspension, durable chassis, generous fuel capacity, strong aftermarket support, and a reputation for go-anywhere capability. Manual Utility: Enables users to perform all maintenance and repair tasks, saving significant costs associated with dealership or professional mechanic services. High quality images and clear instructions enhance ease of use. 📋 Manual Details Coverage Areas Coverage Areas: All Model Variants, Engine Types, Trim Levels, and Transmission Types within the specified years. Page Count Page Count: Estimated 400-600 pages (typical for comprehensive workshop manuals of this era, specific count not provided but implied by 'Complete Workshop Service Repair Manual') Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, Fuel system (carburetor), Ignition system, Lubrication system, Cooling system, Exhaust system, Clutch, Transmission, Drivetrain (chain drive), Suspension (front forks, rear shock), Brakes (front disc, rear disc), Wheels and Tires, Frame, Electrical system (wiring diagrams, lighting, starting, charging), Bodywork and panels, Special tools, Troubleshooting, Maintenance, Specifications. Electrical System Detail: Comprehensive wiring diagrams, component testing, troubleshooting for lighting, ignition, charging systems (stator, regulator/rectifier), starter motor, battery, and instrumentation. Procedures Included Procedures Included: Routine maintenance (oil change, filter replacement, chain adjustment, brake bleeding), Engine overhaul (top-end, bottom-end rebuild), Carburetor tuning and rebuilding, Ignition system troubleshooting and repair, Suspension servicing (fork seal replacement, shock absorber adjustment), Brake system repair (pad replacement, caliper service), Electrical diagnostics, Wheel bearing replacement, Clutch inspection and adjustment, Transmission gear inspection and replacement, Troubleshooting common problems, Torque specifications, Wiring harness repair. Engine Rebuild Detail: Detailed procedures for piston and ring replacement, cylinder honing, crankshaft and connecting rod inspection and replacement, camshaft timing, and complete engine disassembly/reassembly. Suspension Servicing Detail: Instructions for fork oil replacement, fork seal replacement, fork spring inspection, rear shock absorber adjustment, and overhaul procedures. Brake System Servicing Detail: Procedures for brake pad replacement, caliper servicing and rebuilding, master cylinder inspection and overhaul, brake line replacement, and brake fluid bleeding for both front and rear systems. Technical Depth Technical Depth: Comprehensive, covering all aspects from basic maintenance to complete engine and chassis rebuilds. Includes detailed diagrams, exploded views, specifications, and step-by-step instructions suitable for experienced mechanics and motivated DIY enthusiasts. Diagnostic Procedures: Includes systematic troubleshooting guides for identifying the root cause of various mechanical and electrical problems, often with flowcharts or step-by-step diagnostic sequences. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Accessibility: Downloadable to PC, MAC, tablets, and smartphones. Requires Adobe Reader (free download). Print Quality Print Quality: High quality, suitable for printing individual pages or entire sections. Assumed to contain clear diagrams and legible text. Binding Type Binding Type: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - User Printable) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves Displacement: 500cc (KLR500) / 651cc (KLR650) Bore X Stroke: KLR500: 85.0 x 88.0 mm; KLR650: 100.0 x 83.0 mm Cooling System: Liquid-cooled Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 32-36 HP @ 6000 RPM (KLR650, variations by year and market) Torque: Approx. 32-36 lb-ft @ 5000 RPM (KLR650, variations by year and market) Compression Ratio: Approx. 9.5:1 (KLR650) Fuel System Fuel Delivery: Carburetor (Mikuni BSR32 for KLR650, Mikuni VM34SS for KLR500) Fuel Type: Unleaded gasoline, 87 octane (minimum) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Lubrication System Oil Capacity: Approx. 2.4 L (2.5 US qt) with filter change (KLR650) Oil Type: SAE 10W-40 API SG or higher (motorcycle specific) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Transmissions: N/A (All KLR500/KLR650 models covered feature the standard 5-speed transmission) Features Clutch Type: Wet, multi-disc, manual operation Final Drive: Sealed O-ring chain 📐 Dimensions Exterior Overall Length: Approx. 2,270 mm (89.4 in) (KLR650 2002-2007) Overall Width: Approx. 850 mm (33.5 in) (KLR650 2002-2007) Overall Height: Approx. 1,435 mm (56.5 in) (KLR650 2002-2007) Wheelbase: Approx. 1,470 mm (57.9 in) (KLR650 2002-2007) Weights Dry Weight: Approx. 156 kg (343.9 lbs) (KLR650 2002-2007) Curb Weight: Approx. 173 kg (381.4 lbs) (KLR650 2002-2007, with all fluids) Fuel Tank Capacity: 23...

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLR500/KLR650

Product Name:

Kawasaki KLR500 KLR650 Motorcycle Complete Workshop Service Repair Manual 2002-2006

Generation

Generation Covered:

Second Generation (KL650-A/E)

Codes

Chassis Codes:

KL650-A (earlier models), KL650-E (later models for 2002-2006)

👋 Introduction

Market Position

Market Position:

The Kawasaki KLR650 (and its predecessor the KLR500) has long been a benchmark in the dual-sport motorcycle segment, known for its ruggedness, versatility, and reliability. It appeals to adventure riders, commuters, and those seeking a durable machine for light off-road exploration.

Competitive Analysis

Competitive Analysis:

Competed against motorcycles like the Honda XR650L, Suzuki DR650SE, and Yamaha XT600/XT660. The KLR's unique combination of a large fuel tank, comfortable ergonomics, and robust construction made it a strong contender.

Key Features

Key Features:

Large displacement single-cylinder engine, long-travel suspension, durable chassis, generous fuel capacity, strong aftermarket support, and a reputation for go-anywhere capability.

Manual Utility:

Enables users to perform all maintenance and repair tasks, saving significant costs associated with dealership or professional mechanic services. High quality images and clear instructions enhance ease of use.

📋 Manual Details

Coverage Areas

Coverage Areas:

All Model Variants, Engine Types, Trim Levels, and Transmission Types within the specified years.

Page Count

Page Count:

Estimated 400-600 pages (typical for comprehensive workshop manuals of this era, specific count not provided but implied by 'Complete Workshop Service Repair Manual')

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine mechanical, Fuel system (carburetor), Ignition system, Lubrication system, Cooling system, Exhaust system, Clutch, Transmission, Drivetrain (chain drive), Suspension (front forks, rear shock), Brakes (front disc, rear disc), Wheels and Tires, Frame, Electrical system (wiring diagrams, lighting, starting, charging), Bodywork and panels, Special tools, Troubleshooting, Maintenance, Specifications.

Electrical System Detail:

Comprehensive wiring diagrams, component testing, troubleshooting for lighting, ignition, charging systems (stator, regulator/rectifier), starter motor, battery, and instrumentation.

Procedures Included

Procedures Included:

Routine maintenance (oil change, filter replacement, chain adjustment, brake bleeding), Engine overhaul (top-end, bottom-end rebuild), Carburetor tuning and rebuilding, Ignition system troubleshooting and repair, Suspension servicing (fork seal replacement, shock absorber adjustment), Brake system repair (pad replacement, caliper service), Electrical diagnostics, Wheel bearing replacement, Clutch inspection and adjustment, Transmission gear inspection and replacement, Troubleshooting common problems, Torque specifications, Wiring harness repair.

Engine Rebuild Detail:

Detailed procedures for piston and ring replacement, cylinder honing, crankshaft and connecting rod inspection and replacement, camshaft timing, and complete engine disassembly/reassembly.

Suspension Servicing Detail:

Instructions for fork oil replacement, fork seal replacement, fork spring inspection, rear shock absorber adjustment, and overhaul procedures.

Brake System Servicing Detail:

Procedures for brake pad replacement, caliper servicing and rebuilding, master cylinder inspection and overhaul, brake line replacement, and brake fluid bleeding for both front and rear systems.

Technical Depth

Technical Depth:

Comprehensive, covering all aspects from basic maintenance to complete engine and chassis rebuilds. Includes detailed diagrams, exploded views, specifications, and step-by-step instructions suitable for experienced mechanics and motivated DIY enthusiasts.

Diagnostic Procedures:

Includes systematic troubleshooting guides for identifying the root cause of various mechanical and electrical problems, often with flowcharts or step-by-step diagnostic sequences.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Accessibility:

Downloadable to PC, MAC, tablets, and smartphones. Requires Adobe Reader (free download).

Print Quality

Print Quality:

High quality, suitable for printing individual pages or entire sections. Assumed to contain clear diagrams and legible text.

Binding Type

Binding Type:

N/A (Digital Download - Printable)

Paper Type

Paper Type:

N/A (Digital Download - User Printable)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, DOHC, 4 valves

Displacement:

500cc (KLR500) / 651cc (KLR650)

Bore X Stroke:

KLR500: 85.0 x 88.0 mm; KLR650: 100.0 x 83.0 mm

Cooling System:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 32-36 HP @ 6000 RPM (KLR650, variations by year and market)

Torque:

Approx. 32-36 lb-ft @ 5000 RPM (KLR650, variations by year and market)

Compression Ratio:

Approx. 9.5:1 (KLR650)

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR32 for KLR650, Mikuni VM34SS for KLR500)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication System

Oil Capacity:

Approx. 2.4 L (2.5 US qt) with filter change (KLR650)

Oil Type:

SAE 10W-40 API SG or higher (motorcycle specific)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmissions:

N/A (All KLR500/KLR650 models covered feature the standard 5-speed transmission)

Features

Clutch Type:

Wet, multi-disc, manual operation

Final Drive:

Sealed O-ring chain

📐 Dimensions

Exterior

Overall Length:

Approx. 2,270 mm (89.4 in) (KLR650 2002-2007)

Overall Width:

Approx. 850 mm (33.5 in) (KLR650 2002-2007)

Overall Height:

Approx. 1,435 mm (56.5 in) (KLR650 2002-2007)

Wheelbase:

Approx. 1,470 mm (57.9 in) (KLR650 2002-2007)

Weights

Dry Weight:

Approx. 156 kg (343.9 lbs) (KLR650 2002-2007)

Curb Weight:

Approx. 173 kg (381.4 lbs) (KLR650 2002-2007, with all fluids)

Fuel Tank Capacity:

23 L (6.1 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles typically do not receive standardized crash test ratings like cars. Focus is on rider protection through design and user responsibility.)

Active Features

Active Safety Features:

Strong dual-disc braking system, long-travel suspension for stability over varied terrain, durable frame construction.

Passive Features

Passive Safety Features:

Robust frame and bodywork, integrated handguards (often standard or readily available), positioning for good rider visibility.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (This era of motorcycle does not feature infotainment systems. Focus is on mechanical and electrical function.)

Driver Assistance

Driver Assistance Features:

N/A (Motorcycles of this vintage do not typically feature electronic rider aids like ABS or traction control, although some later KLR650 models might offer ABS as an option not necessarily covered in detail for this specific manual range if introduced later).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-4,000 miles or 6 months, whichever comes first (refer to manual for exact recommendation).

Air Filter Cleaning:

Every 3,000-4,000 miles or as needed based on conditions.

Spark Plug Replacement:

Every 10,000-12,000 miles.

Valve Clearance Check:

Every 7,500-10,000 miles.

Chain Lubrication And Adjustment:

Every 500-1,000 miles.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for specific type and replacement interval).

Coolant:

Ethylene glycol-based coolant, 50/50 mix with distilled water (specific type recommended in manual).

Engine Oil Filter Part Number:

Commonly used filters include Kawasaki P/N 16097-1059, HiFloFiltro HF123, or K&N KN-123 (verify for specific model year).

Known Issues

Known Issues:

Subframe cracking (especially with heavy loads or off-road use), Doohickey failure (torsion spring lever in the clutch basket), Carburetor issues (sticking slides), oil consumption on higher mileage engines, stator failures. The manual will provide detailed troubleshooting and repair procedures for these common concerns.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Kawasaki Heavy Industries has a long and distinguished history in motorcycle manufacturing, known for innovation, performance, and durability across various segments, including sportbikes, cruisers, and off-road/dual-sport motorcycles.

Model Evolution

Model Evolution:

The KLR500 was introduced in the mid-1980s as Kawasaki's answer to the growing dual-sport market. It was later evolved into the KLR650 in 1987, which became an iconic model due to its significant upgrades, including a larger engine, increased fuel capacity, and improved suspension. The 2002-2006 models represent a refined iteration of this highly successful platform, carrying forward its core strengths.

K650 Updates 2002 2006:

The 2002-2006 KLR650 models primarily saw minor updates and color scheme changes, retaining the core robust design. Key components like the engine, chassis, and suspension remained largely consistent with previous generations of the second-generation KLR650.

Production

Production Years:

KLR500: Mid-1980s; KLR650: 1987-Present (with significant updates over time).

Manufacturing Locations:

Japan and Thailand (for later production runs).

🏆 Awards & Recognition

Recognitions

Industry Recognitions:

The KLR650 is widely recognized for its enduring popularity and value as a versatile, long-distance, and go-anywhere motorcycle. It has garnered a loyal following and consistent sales over decades, a testament to its design and capabilities.