Kawasaki KLR650 / KLR500 Supplementary Service Manual (1987–1995, 2000–2002)

The Kawasaki KLR650 and KLR500 in this manual belong to Kawasaki's late-1980s single-cylinder dual-purpose family. The manual's application table starts with KL650-A1 and KL500-A1 for 1987, adds KL650-A2 and KL500-A2 for 1988, and then continues with KLR650 A-series model codes through KL650-A9 for 1995. Kawasaki's official Owner Center independently identifies the 1987 KLR650 as KL650-A1, matching the code printed in this factory supplement.

The KLR650 is built around a carbureted 651 cc dual-sport single: a liquid-cooled, four-stroke DOHC four-valve engine with a 100.0 × 83.0 mm bore and stroke and 9.5:1 compression ratio. Fuel is supplied by a Keihin CVK40 carburetor, with CDI ignition and electric starting. The KLR500 shares the same basic service architecture but uses an 89.0 × 80.0 mm bore and stroke for 497 cc displacement. Factory specifications list 35.3 kW (48 PS) for the KLR650 and 29.4 kW (40 PS) for the KLR500 in applicable markets.

Both variants use a wet multi-disc clutch and five-speed constant-mesh return-shift transmission with chain final drive. The KLR650 specification gives a 23 L fuel tank, 890 mm seat height, 153 kg dry weight, 21-inch front and 17-inch rear tube-type tires, and 230 mm of wheel travel at both ends. The frame is a tubular semi-double-cradle design with Uni-Trak rear suspension and single-disc front and rear brakes. The KLR500 shares the listed chassis specification but uses a different 3.133 final-drive reduction ratio versus 2.866 for the KLR650.

This publication is specifically a service-manual supplement and states that it must be used with the KLR600 base Service Manual, P/N 99924-1050-01. Its printed Model Application table covers 1987–1995 and then 2000–2002, ending with KL650-A16 for 2002; it does not list 1996–1999 or 2003–2007. Kawasaki's official 2007 KLR650 manual page points to a later supplement revision, item 99924-1080-64, whereas this uploaded scan is P/N 99924-1080-58. This listing therefore follows the exact application of the uploaded revision. For related manuals, browse the Kawasaki KLR650 manual category.