Category:
Dual-sport motorcycle
Target Audience:
Adventure riders, commuters, off-road enthusiasts
Key Competitors:
BMW F650GS, Suzuki DR650SE, Honda Transalp (variants), Yamaha XT660R
Versatility:
Designed for both on-road touring and off-road capability
Reliability:
Known for its robust engine and durable construction
Value Proposition:
Essential for owners and technicians seeking to maintain, diagnose, and repair the 2008 KLR650 effectively.
Diagnostic Aid:
Provides the necessary technical information to accurately diagnose issues without guesswork.
Primary Coverage:
Complete service and repair for the 2008 Kawasaki KLR650
Secondary Coverage:
Maintenance schedules, troubleshooting, electrical diagnostics, specifications
Page Count:
Approximately 450 pages (estimated for comprehensive service manuals of this era)
Manual Type:
Factory Service Manual / Workshop Manual
Format:
Digital (PDF) - Typically provided as a downloadable file
Engine Systems:
Top end, bottom end, lubrication, cooling, fuel injection, ignition, exhaust
Drivetrain Systems:
Clutch, transmission, final drive (chain and sprockets)
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, tires
Braking Systems:
Front and rear brake caliper service, master cylinder service, brake line maintenance, hydraulic system bleeding
Electrical Systems:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting, ignition system troubleshooting, instrument cluster
Fuel System:
Fuel tank, fuel pump, fuel injectors, throttle body, air filter housing
Routine Maintenance:
Oil change, filter replacement, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid replacement, coolant replacement
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), electrical system diagnostics
Major Repairs:
Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake system overhaul, carburetor/fuel injection system servicing
Component Overhaul:
Detailed instructions for rebuilding engine components, carburetors/injectors, brake calipers, and suspension units
Depth:
Comprehensive; covers all aspects from basic maintenance to complete engine and chassis overhauls.
Detail Level:
Factory-level detail, including torque specifications, measurement tolerances, special tool requirements, and diagnostic data.
Displacement:
651 cc (39.7 cu. in.)
Bore X Stroke:
100.0 mm x 83.0 mm (3.94 x 3.27 in.)
Valve Configuration:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Horsepower Est:
Approx. 37-40 HP at 6,000 RPM (crankshaft)
Torque Est:
Approx. 37-40 lb-ft at 5,000 RPM (crankshaft)
Fuel Delivery:
Fuel Injection (Digital Fuel Injection - EFI)
Throttle Body Size:
40 mm
Fuel Type Recommended:
Unleaded gasoline, 87 octane or higher
Oil Capacity W Filter:
2.3 L (2.4 US qt)
Oil Type Recommended:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR9E or DENSO U27FER9
Spark Plug Gap:
0.8 - 0.9 mm (0.031 - 0.035 in.)
Transmission Type:
5-speed, constant mesh
Clutch Type:
Wet, multi-disc
Final Drive:
Sealed O-ring chain (520)
Transmission Oil Type:
API GL-4, SAE 80W-90 gear oil (Manual specifies motorcycle-specific gear oil)
Transmission Oil Capacity:
Approximately 1.0 L (1.1 US qt) – check level via sight glass or filler plug
Display Type:
Analog speedometer and tachometer, digital odometer, trip meter, clock, coolant temperature gauge
Instrumentation:
Standard dashboard indicators for turn signals, high beam, neutral, oil pressure, and FI warning light.
ABS:
Not available on the 2008 model.
Bluetooth:
Not available.
Headlight Type:
Single Halogen 12V 60/55W
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Air Filter Cleaning:
Every 6,000 km (3,700 miles)
Spark Plug Inspection:
Every 6,000 km (3,700 miles)
Chain Adjustment Lubrication:
Every 1,000 km (600 miles) or more frequently under dusty/wet conditions
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Brake Fluid Replacement:
Every 24 months
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with distilled water (50:50 mix)
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, rear shock spring (over time/heavy use)
Fuel System Notes:
While FI improved reliability, early fuel pumps could be a point of failure. Throttle body cleaning is important for smooth operation.
Electrical Notes:
Regulator/rectifier can be a failure point on some models; check voltage output regularly.
Manufacturer:
Kawasaki Heavy Industries, Ltd.
First Generation Introduction:
The KLR650 platform was originally introduced in 1987.
2008 Model Year Updates:
The 2008 model saw significant updates including fuel injection, a revised fairing for improved wind protection, and suspension improvements, marking a substantial revision from previous generations.
Manufacturing Location:
Primarily manufactured in Japan.
