🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Year:

2011

Product Type:

Repair Service Manual

👋 Introduction

Vehicle Segment:

Dual-sport motorcycle, known for its versatility in both on-road commuting and off-road adventure touring.

Key Attributes:

Reliability, durability, strong aftermarket support, rider-friendly ergonomics, capable for various terrains.

Direct Competitors:

BMW F650GS, Honda Transalp, Suzuki DR650S, Yamaha XT660R/Tenere.

Engine Design:

Robust single-cylinder engine providing tractable power delivery, good low-end torque, and excellent fuel efficiency.

Suspension Capability:

Long-travel suspension offering compliance over rough terrain and comfort on pavement.

Fueling System:

Electronic Fuel Injection (EFI) for improved throttle response, fuel economy, and easier starting in various conditions.

Build Quality:

Kawasaki's reputation for building durable and long-lasting motorcycles, making this manual essential for long-term ownership.

📋 Manual Details

Manual Type:

Factory Authorized Service Manual

Language:

English

Format:

Digital (PDF)

Page Count:

Approximately 350 pages (estimated based on typical KLR650 service manuals)

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for the 651cc liquid-cooled, four-stroke, single-cylinder engine, including disassembly, inspection, repair, and reassembly of all internal components (crankshaft, connecting rod, pistons, cylinders, valves, camshafts).

Fuel System:

Comprehensive coverage of the fuel injection system, including carburetor (if applicable to specific models, though 2011 is FI), fuel pump, injectors, throttle body, ECU diagnostics, and fuel tank.

Ignition System:

Detailed information on the electronic ignition system, including ignition coil, spark plug, CDI unit, and troubleshooting procedures.

Transmission Drivetrain:

Complete service information for the 5-speed constant mesh transmission, including clutch operation, gear inspection, shift mechanism, and final drive (chain and sprockets).

Cooling System:

Instructions for servicing the liquid cooling system, including radiator, fan, coolant hoses, water pump, and thermostat.

Exhaust System:

Details on the exhaust system components, including mufflers and catalytic converter (if equipped), with inspection and replacement guidelines.

Suspension Front:

In-depth coverage of the telescopic front fork, including disassembly, seal replacement, oil levels, fork spring specifications, and adjustment procedures.

Suspension Rear:

Service information for the Uni-Trak rear suspension system, including shock absorber overhaul, linkage maintenance, and spring pre-load adjustments.

Braking System Front:

Complete service procedures for the hydraulic front disc brake, including caliper overhaul, pad replacement, fluid bleeding, master cylinder inspection, and rotor specifications.

Braking System Rear:

Detailed service information for the hydraulic rear disc brake, including caliper overhaul, pad replacement, fluid bleeding, master cylinder inspection, and rotor specifications.

Wheels Tires:

Guidance on wheel bearing maintenance, spoke tension adjustment (if applicable), tire mounting, and specifications.

Electrical System Charging:

Information on the charging system, including stator, rectifier/regulator, battery testing, and maintenance.

Electrical System Lighting:

Service procedures for headlights, tail lights, turn signals, and instrument panel lighting.

Electrical System Starting:

Coverage of the electric starter motor, starter solenoid, and associated wiring.

Electrical System Wiring Diagrams:

Detailed wiring diagrams for all electrical components, including troubleshooting pathways.

Frame Chassis:

Information on frame inspection, steering head bearing service, and swingarm maintenance.

Bodywork:

Procedures for removal and installation of body panels, including fairings, fuel tank, seat, and fenders.

Routine Maintenance:

Oil changes, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection/replacement, brake fluid checks, coolant level checks.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault codes (if applicable), and symptom-based troubleshooting guides.

Engine Overhaul:

Complete step-by-step instructions for engine disassembly, component inspection (wear limits), piston ring replacement, valve adjustments, cylinder head service, and engine reassembly.

Suspension Rebuild:

Detailed instructions for fork seal replacement, fork oil change, rear shock absorber servicing, and linkage lubrication.

Brake System Service:

Brake pad replacement, caliper overhaul, brake fluid flush and bleeding, master cylinder rebuild, and rotor inspection.

Electrical Diagnostics:

Troubleshooting electrical circuits, testing components (stator, regulator, starter), and following wiring diagrams.

Carburetor Tuning Or Fi Adjustment:

Information on adjusting fuel mixture, idle speed, and potentially electronic fuel injection system parameters.

Wheel Bearing Replacement:

Guidance on proper removal and installation of wheel bearings.

Steering Head Service:

Procedures for cleaning, lubricating, and adjusting steering head bearings.

Depth:

Comprehensive rebuild and repair manual, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and chassis overhauls.

Diagnostic Level:

Advanced diagnostic procedures, including voltage, resistance, and continuity testing of electrical components, and interpretation of system behavior.

Specification Detail:

Detailed torque specifications for all fasteners, clearance specifications for engine components, fluid capacities, and electrical system data.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Fully searchable text content, allowing quick access to specific information.

Printability:

Printable pages, allowing for convenient use during physical repairs.

Resolution:

High-resolution images and diagrams for clarity.

Quality Notes:

Digital format optimized for clarity on screen and in print.

Binding Notes:

N/A (Digital Format)

Paper Notes:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, DOHC, four-valve single-cylinder

Displacement:

651 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

8.8:1

Valve Clearance Intake:

0.08 - 0.13 mm (cold)

Valve Clearance Exhaust:

0.13 - 0.18 mm (cold)

Horsepower Approx:

Approx. 46 hp @ 6,000 rpm (manufacturer's claim varies by market)

Torque Approx:

Approx. 42 lb-ft @ 5,000 rpm (manufacturer's claim varies by market)

Fuel Delivery:

Digital Fuel Injection (DFI) with 40mm throttle body

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

6.1 US gallons (23 Liters)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multiple-disc

Final Drive:

Sealed chain

Gear Ratios:

Refer to manual for specific gear ratios (typically 1st: 2.750, 2nd: 1.944, 3rd: 1.471, 4th: 1.174, 5th: 0.955)

Transmission Oil Type:

API GL-1 Gear Oil SAE 80W-90 (check manual for precise specification)

Transmission Oil Capacity:

Approx. 1.9 L (Refer to manual for precise capacity with filter change)

📐 Dimensions

Length:

Approx. 88.2 inches (2240 mm)

Width:

Approx. 34.1 inches (865 mm)

Height:

Approx. 50.0 inches (1270 mm)

Wheelbase:

Approx. 58.3 inches (1480 mm)

Ground Clearance:

Approx. 9.1 inches (230 mm)

Seat Height:

Approx. 35.0 inches (890 mm)

Curb Weight:

Approx. 430 lbs (195 kg)

Gross Vehicle Weight Rating:

Refer to vehicle identification plate

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety ratings are not typically standardized in the same way as automobiles. Focus is on rider protection through design and equipment.)

Braking System:

Dual hydraulic disc brakes (front and rear) for reliable stopping power.

Lighting:

Halogen headlight, taillight, and LED turn signals for visibility.

Chassis Design:

Strong tubular semi-double cradle frame designed for stability and rigidity.

Ergonomics:

Comfortable riding position for long distances and control in varied terrain.

💡 Technology Features

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, clock, fuel gauge, and indicator lights.

ABS:

ABS was an optional feature on some KLR650 models, including potentially the 2011. This manual will cover ABS system components and troubleshooting if equipped.

Charging Port:

Accessory charging ports (e.g., 12V power outlet) may be factory-fitted or a common aftermarket addition. Manual may cover wiring for such accessories.

🔧 Maintenance

Engine Oil Change:

Every 3,700 miles (6,000 km) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 7,400 miles (12,000 km) or 12 months, or with every oil change.

Air Filter Cleaning:

Every 3,700 miles (6,000 km) or 6 months. Replacement recommended every 7,400 miles (12,000 km).

Spark Plug Inspection:

Every 3,700 miles (6,000 km). Replacement as needed.

Valve Clearance Check:

Every 7,400 miles (12,000 km) or 12 months.

Drive Chain Inspection Lubrication:

Every 600 miles (1,000 km) or after riding in rain/dusty conditions.

Brake Fluid Replacement:

Every 2 years or as needed based on fluid condition.

Engine Oil:

SAE 10W-40 API SG or SH with JASO MA certification (check manual for specific approval codes).

Coolant:

High-quality ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with distilled water. (Kawasaki Coolant KAF2901-001 recommended).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Doohickey Failure:

The balancer shaft tensioner (often called 'doohickey') can be a weak point. While not a guaranteed failure, it's a common upgrade/check item for KLR owners. This manual will detail its inspection and replacement.

Carburetor Vibration (Pre-Efi):

Older models (pre-2011) sometimes experienced issues with carburetor mounting vibrations. The 2011's EFI system avoids this specific issue.

Valve Stem Seals:

Over time, valve stem seals can degrade, leading to increased oil consumption or smoke on startup. This manual provides the procedure for their replacement.

📚 Vehicle History

Kawasaki Motorsports:

Kawasaki Heavy Industries, Motorcycle & Engine division, has a long history in motorcycle manufacturing, renowned for performance, innovation, and durability across various segments including sportbikes, cruisers, and dual-sports.

Klr650 Lineage:

The KLR650 platform has a distinguished history dating back to the mid-1980s, evolving with technological updates while retaining its core identity as a rugged, go-anywhere adventure motorcycle. The 2011 model represents a significant update with the introduction of Fuel Injection.

Manufacturing Location:

Primarily manufactured in Japan.

Production Years Covered:

This specific manual covers the 2011 model year, which saw the introduction of major updates like EFI.

🏆 Awards & Recognition

Model Reputation:

The KLR650 is consistently lauded in motorcycle media and rider forums for its value, durability, and adventure capability. It's often called the 'workhorse' of the dual-sport world.

Longevity Reviews:

Many KLR650 owners report high mileage with proper maintenance, attesting to the model's robust engineering. This manual is key to maintaining that longevity.