The Kawasaki KLR500 KLR650 1996 All Service Repair Manual is a comprehensive resource for motorcycle enthusiasts and mechanics alike. This manual offers a detailed guide to understanding, maintaining, and repairing your Kawasaki KLR500 or KLR650 motorcycle, specifically for the 1996 model year.

Within its pages, you'll find a vast collection of information covering virtually every aspect of your motorcycle, from basic maintenance procedures to advanced engine and transmission repairs. The manual provides clear and concise instructions, accompanied by detailed illustrations and diagrams, to ensure a successful repair experience.

Some of the key topics covered in the manual include:

* **General Maintenance:** This section covers routine maintenance tasks such as oil changes, filter replacements, and tire pressure checks, ensuring your motorcycle runs smoothly and efficiently.
* **Troubleshooting:** Encountering a problem with your motorcycle? The manual provides comprehensive troubleshooting guides to identify and address various issues.
* **Engine Service / Repair:** Detailed instructions guide you through engine disassembly, repair, and reassembly, covering everything from carburetion to valve adjustments.
* **Transmission Service / Repair:** Learn how to maintain and repair your transmission, including clutch adjustments, gear selection, and chain replacement.
* **Brake System:** The manual outlines procedures for inspecting and maintaining your brake system, ensuring optimal braking performance.
* **Wiring Diagram:** A detailed wiring diagram helps you understand the electrical system and troubleshoot any electrical issues.
* **Electrical System:** Discover how to diagnose and repair problems in your motorcycle's electrical system, covering components such as the starter, alternator, and lights.
* **Suspension:** Find comprehensive instructions for inspecting, adjusting, and repairing your motorcycle's suspension, ensuring a comfortable and controlled ride.
* **Periodic Lubrication:** Learn the proper lubrication points on your motorcycle, ensuring smooth operation and preventing premature wear.
* **Steering:** The manual covers steering system maintenance, including checking and adjusting steering components for optimal handling.
* **Cooling System:** Understand the operation and maintenance of your motorcycle's cooling system, ensuring proper temperature regulation.
* **Fuel Injection / Fuel System:** Detailed information on fuel injection systems and fuel system maintenance, covering components such as fuel pumps, injectors, and filters.
* **Emission System:** Learn how to maintain and repair the emission system, ensuring compliance with environmental regulations.
* **Engine Control System:** Discover the inner workings of the engine control system, covering components such as sensors and actuators.
* **Chassis / Body:** The manual provides instructions for inspecting and repairing the motorcycle's chassis and bodywork.
* **Restraint System:** Information on maintaining and troubleshooting your motorcycle's restraint system.
* **Axle:** Detailed guidance on axle inspection, maintenance, and repair.

This manual is an invaluable tool for any Kawasaki KLR500 or KLR650 owner, empowering you to perform maintenance and repairs confidently and efficiently. It's a comprehensive resource that will help you keep your motorcycle in top condition for years to come.

The Kawasaki KLR650, and its predecessor the KLR500, are renowned dual-sport motorcycles that have captivated riders for decades. These rugged and versatile machines are designed to conquer both paved roads and challenging off-road terrain. The KLR650, introduced in 1987, quickly gained popularity for its robust build, comfortable ergonomics, and impressive off-road capabilities. It features a powerful air-cooled, single-cylinder engine displacing 651cc, known for its torque and reliability. The KLR650 is equipped with a sturdy tubular steel frame, long-travel suspension with adjustable preload, and knobby tires for excellent traction on various surfaces. Its upright riding position provides a commanding view of the road ahead, while the spacious fuel tank ensures ample range for extended adventures.

The KLR500, produced from 1984 to 1986, served as the foundational model for the KLR650. It shared many design elements with its successor, including the sturdy frame, long-travel suspension, and comfortable ergonomics. However, the KLR500 was powered by a smaller 499cc single-cylinder engine, sacrificing some power and torque. Despite its smaller displacement, the KLR500 remained a capable dual-sport motorcycle, offering a rewarding riding experience for both on-road and off-road adventures. Both the KLR500 and KLR650 have earned a loyal following for their durability, ease of maintenance, and affordability. They have proven their worth as reliable and capable companions for everything from daily commuting to long-distance touring and challenging off-road excursions.