• Model: KLR Series
  • Manufactured by: Kawasaki
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Kawasaki KLR500 1987-2002



Overview



The Kawasaki KLR500 is a dual-sport motorcycle that was first introduced in 1987. It is powered by a 499 cc (30.4 cu in) single-cylinder, four-stroke engine and has a five-speed transmission. The KLR500 is known for its versatility and off-road capabilities, and it has been used by both recreational riders and adventure travelers.

Engine



The Kawasaki KLR500 engine is a single-cylinder, four-stroke design with a displacement of 499 cc (30.4 cu in). It has a bore and stroke of 83 mm × 80 mm (3.27 in × 3.15 in). The engine is air-cooled and has a compression ratio of 9.0:1. The KLR500 engine is known for its reliability and durability, and it is capable of producing up to 35 horsepower (26 kW) at 5,500 rpm and 29 foot-pounds (39 N⋅m) of torque at 4,500 rpm.

Transmission



The Kawasaki KLR500 transmission is a five-speed unit with a chain final drive. The transmission is smooth and precise, and it provides a good balance of power and fuel economy.

Suspension



The Kawasaki KLR500 suspension is designed to provide a balance of comfort and off-road performance. The front suspension consists of a 43 mm (1.7 in) telescopic fork with 8.3 inches (210 mm) of travel. The rear suspension consists of a single shock with 7.5 inches (190 mm) of travel. The suspension is adjustable for preload and rebound damping.

Brakes



The Kawasaki KLR500 brakes consist of a single 290 mm (11.4 in) disc brake in the front and a single 254 mm (10.0 in) disc brake in the rear. The brakes are powerful and provide good stopping power.

Wheels and Tires



The Kawasaki KLR500 wheels are made of aluminum and are 19 inches (480 mm) in diameter in the front and 17 inches (430 mm) in diameter in the rear. The tires are a 90/90-21 bias-ply tire in the front and a 130/80-17 bias-ply tire in the rear.

Dimensions



The Kawasaki KLR500 has a wheelbase of 58.9 inches (1,495 mm), a seat height of 33.3 inches (845 mm), and a ground clearance of 9.4 inches (238 mm).

Weight



The Kawasaki KLR500 weighs 397 pounds (180 kg) dry.

Fuel Capacity



The Kawasaki KLR500 has a fuel capacity of 6.1 US gallons (23 liters).

Fuel Economy



The Kawasaki KLR500 has a fuel economy of approximately 40 mpg (5.9 L/100 km).

Top Speed



The Kawasaki KLR500 has a top speed of approximately 110 mph (177 km/h).

Price



The Kawasaki KLR500 has a starting price of $6,299.
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Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Workshop Service Manual for Repair.

This PDF service manual contains 130 pages.

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This Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 service manual provides data, characteristics, instructions and methodology to perform repair interventions on the vehicle and its components.

This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
The most detailed, comprehensive step by step procedures, explanations, and pictorial diagrams from bumper to bumper you will ever see for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.

Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service Repair Manual meets all your information needs to repair or make some adjustments to your Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service Repair Manual. This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service Repair Manual.

Adjustment and repair operations include reference to Service tool numbers and the associated illustration depicts the tool for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002. Where usage is not obvious the tool is shown in use.

This Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 service manual can be viewed on any computer, as well as zoomed and printed.
This service manual has been specially prepared so that the explanation is very simple. It has been prepared so that if this manual is thoroughly read, even comparatively new personel can give satisfactory after services to the customers as well as disassemble and maintain the vehicle.

All service and repair instructions included for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.
Where accurate measurements are required, they can only be made using calibrated, precision instruments.
Providing that the service schedules are respected, the customers can be sure of obtaining the maximum satisfaction and best result from his car. This manual provides general descriptions for accomplishing service and repair work with tested, efective tehniques. Following them will help assure reliability.
Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
Information in this manual for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions. They may not show exactly the Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 in your possession.

Adjustment and repair operations also include reference to wear limits for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002. Relevant data, useful assembly details all in this SERVICE MANUAL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with adequate lighting.

Please peruse and utilize this manual for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition.
All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval. The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
This Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 book outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

To maximise the life of your Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002:
Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.
Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002. Rectify all problems as soon as possible (immediately if safety related).
Use only genuine Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 parts as listed in the parts catalogue.
Follow the procedures in this manual carefully and completely. Do not take short cuts.
Keep complete records of all maintenance and repairs with dates and any new parts installed.
Use only approved lubricants, as specified, in the manual of the Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.

This manual for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 has been issued to provide you with technical information regarding the design, function, disassembly, adjusting work and troubleshooting on the components and model of the Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings. All this information is intended to simplify any necessary repair work which can be performed on Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
This manual also contains information about adjusting work and valuable reference data for such adjustment values.
For all maintenance and repair work on Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002, all accident prevention guidelines must be strictly observed. To perform all repairs listed in this manual, a complete set of standard tools, as well as the special tools and fixtures shown and listed are necessary.
No special emphasis is put on replacing sealing components as we assume that these items are replaced during any repair. Unless specific values are given, all threaded connections should be tightened according to the required tightening torques listed on torque charts.
When describing work, which can be dangerous, we have described the required safety measures in this manual and indicated them by special remarks DANGER, CAUTION or NOTE.

This Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service Service Repair Manual QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out!

This Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service manual is known in many names:
Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service service manual.
Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service repair manual.
Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service workshop manual.
Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Service shop manual.

This manual for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.
A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work, satisfactorily.


GENERAL TAGS FOR MOTORCYCLES:

SPECIFICATIONS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
VEHICLE IDENTIFICATION NUMBER (V.I.N.) for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
WHEELS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRONT WHEEL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
REAR WHEEL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
TIRES for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRONT BRAKE MASTER CYLINDER AND HAND LEVER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRONT BRAKE LINE for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRONT BRAKE CALIPER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
BRAKE PEDAL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
REAR BRAKE MASTER CYLINDER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
REAR BRAKE LINE for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
REAR BRAKE CALIPER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FENDERS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRONT FORK for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FORK CLAMPS: UPPER AND LOWER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
STEERING HEAD BEARINGS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
SWINGARM AND BRACE for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FRAME for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
REAR SHOCK ABSORBER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
THROTTLE CONTROL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CLUTCH CONTROL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
HEADLAMP ASSEMBLY AND SUPPORT BRACKET for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FOOTPEG, HEEL GUARD AND MOUNT for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
SPROCKET COVER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
BELT GUARDS. for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
INTAKE COVER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
SIDESTAND for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
SEAT LOCKS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
ENGINE for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
ENGINE REMOVAL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
ENGINE INSTALLATION for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CYLINDER HEAD for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CYLINDER AND PISTON for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
LUBRICATION SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
OIL RESERVOIR AND OIL HOSE ROUTING for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
OIL COOLER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
OIL PRESSURE INDICATOR SWITCH for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CRANKCASE BREATHING SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
OILING SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
OIL PUMP for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
HYDRAULIC LIFTERS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
GEARCASE AND CAM GEARS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CRANKCASE for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
AIR CLEANER ASSEMBLY for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
ELECTRONIC CONTROL MODULE (ECM) for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
THROTTLE POSITION SENSOR (TPS) for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
IGNITION COIL for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FUEL TANK for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
FUEL PUMP for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
THROTTLE BODY for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
EXHAUST SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
STARTER for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
IGNITION SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
IGNITION/HEADLAMP KEY SWITCH for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
SPARK PLUG CABLES for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
CHARGING SYSTEM for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
BATTERY CABLES for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
VOLTAGE REGULATOR for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
ALTERNATOR for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
TURN SIGNAL FLASHER, FRONT TURN SIGNALS, REAR TURN SIGNALS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
HEADLIGHT, TAIL LAMP for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
MAIN FUSE AND FUSES for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
WIRING DIAGRAMS for Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.

AND MORE...

Kawasaki KLR500 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Workshop Service Manual for Repair.