1987-2002 Kawasaki KL650 / KL500 Motorcycle Service Manual
Field service reference for Kawasaki KL650 and KL500 models, covering years 1987-2002. This manual details maintenance and repair procedures.
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Sample pages from the 1987-2002 Kawasaki KL650 / KL500 Motorcycle Service Manual manual
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Kawasaki Models Covered & Key Technical Specifications
Models: KL650-A1, KL650-A2, KL650-A3, KL650-A4, KL650-A5, KL650-A6, KL650-A7, KL650-A8, KL650-A9, KL500-A1, KL500-A2
Sub-models / Variants: 2WD, Californian Model, U.S. Model, Swiss Model, Australian Model, Austrian Model, Canadian Model, French Model, West German Model, Italian Model, South African Model, Spanish Model, Greek Model
Trade Names: KLR650, KLR500
Build Years: 1987–2002
Technical Data:
- Engine displacement: 651 mL (KL650), 497 mL (KL500)
- Engine type: 4-stroke, DOHC, 4-valve, 1-cylinder
- Cooling system: Liquid cooled
- Transmission type: 5-speed, constant mesh, return shift
- Clutch type: Wet multi disc
- Fuel delivery: Keihin CVK40 carburetor
- Ignition system: CDI with electronic timing advance
Kawasaki Manual Features & Content Preview
Kawasaki KLR650 and KLR500 1987–2002 Technical Documentation
- Covers the 1987–2002 Kawasaki KL650 and KL500 motorcycles, including US, European, and Californian emissions-compliant variants
- Official Kawasaki publication P/N 99924-1080-01 supplement, designed to work alongside the base KLR600 workshop documentation
- Contains 14 detailed exploded-view mechanical diagrams and 5 electrical schematic reference guides for the charging and ignition systems
- Accessible from your device as soon as the order is placed
- Suitable for printing individual sections for shop-floor use
- Indexed PDF search covers every chapter and appendix
- This specific supplement contains essential engine, chassis, and cooling system data unique to the 500cc and 650cc liquid-cooled architecture
What the Manual Documents:
The 1987–2002 Kawasaki KL650 and KL500 service manual supplement provides detailed specifications for the engine top and bottom ends, including transmission gear ratios and valve timing. This technical publication covers the cooling system, fuel delivery components, and electrical infrastructure required for the KLR series maintenance. Detailed sections on wheel and tire service, suspension tuning, and frame geometry are also provided. The document outlines the specific requirements for the Californian emission control systems and provides exploded-view part diagrams to assist in identifying assembly sequences for the engine and chassis.
Specification Highlights:
This manual provides comprehensive torque values in Nm, kg-m, and ft-lb for major fasteners. Cylinder head bolt torque is documented in a multi-stage sequence, with final-stage angles specified in the engine assembly data. The cooling system capacity for the liquid-cooled KLR series is 1.3 liters. Spark plug gap for the NGK DPR8EA-9 is specified at 0.8–0.9 mm in the electrical system reference table. Valve clearance for the intake is listed at 0.10–0.20 mm in the engine top end specification table. For more details on maintaining your machine, see how factory workshop documentation is structured. This official Kawasaki supplement covers the 1987–2002 KL650 and KL500 models, providing technical specifications, torque settings, and wiring diagrams necessary for service and maintenance of the KLR series motorcycle.
Document Reference: Kawasaki P/N 99924-1080-01
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