1987-2002 Kawasaki KL650 / KL500 Motorcycle Factory Service Manual (P/N 99924-1080-01)
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
Model 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
- 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, engineered 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
- Provides 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 lays out detailed specifications for engine top and bottom ends. You will find exact transmission gear ratios and valve timing metrics. It thoroughly covers the cooling system, fuel delivery components, and the electrical infrastructure required to maintain the KLR series. Working on the suspension? The text breaks down wheel and tire service, suspension tuning, and frame geometry. It also outlines the exact requirements for Californian emission control systems. Exploded-view part diagrams offer a clear look at assembly sequences for the engine and chassis. Always ensure your workspace is well-ventilated and that you wear appropriate protective gear when handling fuel system components or maneuvering heavy chassis parts.
Specification Highlights
Need torque specs? This document provides comprehensive values in Nm, kg-m, and ft-lb for all major fasteners. Cylinder head bolt torque is laid out in a multi-stage sequence, with final-stage angles specified right in the engine assembly data. You will find the cooling system capacity for the liquid-cooled KLR series listed at 1.3 liters. Moving to the electrical system, the spark plug gap for the NGK DPR8EA-9 is specified at 0.8–0.9 mm. Valve clearance for the intake sits at 0.10–0.20 mm according to the engine top end specification table. This official Kawasaki supplement delivers the technical baselines, torque settings, and wiring diagrams necessary to keep these specific motorcycles running right.
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