1987-2007 Kawasaki KLR 500, KLR 650 motorcycle service manual

Table of Contents

General Information

• Model Identification
• Specifications
• Torque and Locking Agent
• Special Tools
• Service Data

Fuel System

• Fuel Tank
• Carburetor
• Fuel Line
• Fuel Pump
• Fuel System Troubleshooting

Engine Top End

• Cylinder Head
• Valve Clearance
• Camshaft
• Cylinder and Piston
• Top End Troubleshooting

Engine Right Side/Left Side

• Clutch
• Generator
• Starter Clutch
• Ignition System

Cooling System

• Radiator
• Water Pump
• Thermostat
• Cooling Fan
• Cooling System Troubleshooting

Engine Removal/Installation

• Engine Removal Procedures
• Engine Installation Procedures

Engine Bottom End/Transmission

• Crankcase
• Crankshaft
• Transmission Assembly
• Bottom End Troubleshooting

Wheels/Tires

• Wheel Removal
• Tire Replacement
• Wheel Installation
• Tire Troubleshooting

Final Drive

• Drive Chain
• Sprockets
• Final Drive Troubleshooting

Brakes

• Brake Calipers
• Brake Pads
• Brake Discs
• Master Cylinder
• Brake Troubleshooting

Suspension/Steering

• Front Forks
• Rear Shock Absorber
• Steering Stem
• Suspension Troubleshooting

Controls/Instruments

• Handlebar
• Cables
• Instruments
• Control Troubleshooting

Frame

• Frame Inspection
• Frame Maintenance

Electrical System

• Battery
• Charging System
• Lighting System
• Electrical Troubleshooting

Appendix

• Wiring Diagrams
• Maintenance Schedule
• Service Data
• Index

Supplement - 2000 - 2001 Models

• Model Year Changes
• Additional Service Information

Supplement - 2002 Model

• Model Year Changes
• Additional Service Information

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