Kawasaki KLR650 1987-2002 Service-Reparaturhandbuch

Normaler Preis: $17.99
Verkaufspreis: $17.99
Normaler Preis
Grundpreis: pro

🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Product Name: Kawasaki KLR650 1987-2002 Service Repair Manual Covered Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998,...

19 people are viewing this right now

Typ: Motorräder

Anbieter:

Art.-Nr: 603352

Stichworte: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Kawasaki KLR Series KLR650 Motorcycle Motorcycles

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLR650

Product Name:

Kawasaki KLR650 1987-2002 Service Repair Manual

Covered Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

👋 Introduction

Market Position

Segment:

Dual-sport motorcycle

Target Audience:

Adventure riders, commuters, off-road enthusiasts.

Competitive Analysis

Competitors Of Era:

Honda Transalp, Suzuki DR650, Yamaha Tenere models.

Key Features Of Vehicle

Versatility:

Renowned for its ability to handle both paved roads and light off-road trails.

Durability:

Known for its robust construction and long-term reliability.

Simplicity:

Relatively simple mechanical design, making it accessible for DIY maintenance.

Manual Value Proposition

Diy Support:

Empowers owners to perform a wide range of maintenance and repair tasks, saving on labor costs.

Diagnostic Aid:

Provides essential troubleshooting information for quick problem identification.

Restoration Guide:

Crucial for owners undertaking vintage restorations or major overhauls.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Vehicle Generations Covered:

First Generation KLR650 (KL650-A, KL650-B, KL650-C)

Page Count

Estimated Page Count:

Approximately 400-500 pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, carburetor tuning, valve clearance adjustment, timing chain, lubrication system, cooling system (liquid-cooled).

Transmission:

Clutch operation, gearbox inspection and repair, shift mechanism.

Fuel System:

Carburetor (Mikuni BS40) disassembly, cleaning, adjustment, fuel pump operation.

Electrical System:

Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, fuses.

Suspension:

Front fork (including oil change and seal replacement), rear shock absorber (Uni-Trak system), linkage maintenance.

Brakes:

Front and rear brake system inspection, fluid replacement, caliper and master cylinder overhaul, brake pad replacement.

Chassis And Frame:

Frame inspection, swingarm, steering head bearings.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank, fenders.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, lubrication points.

Troubleshooting:

Diagnostic charts, common problems and their solutions.

Repair And Rebuild:

Complete disassembly and reassembly procedures for major components.

Technical Specifications:

Torque values, clearances, fluid capacities, electrical specifications.

Technical Depth

Depth:

Comprehensive, covering everything from basic tune-ups to complete engine and chassis rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval.

Print Quality

Image Resolution:

High-resolution, clear diagrams and images.

Readability:

Optimized for digital viewing and printing.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, single-cylinder

Displacement:

651 cc (cc)

Bore X Stroke:

100.0 x 83.0 mm (mm)

Cooling System:

Liquid-cooled

Compression Ratio:

9.5:1 (typical for this generation)

Performance

Horsepower:

Approximately 46-48 hp @ 6500 rpm (peak, depending on specific sub-model and market tuning)

Torque:

Approximately 52-54 Nm @ 5000 rpm (peak, depending on specific sub-model and market tuning)

Fuel System

Carburetor Type:

Mikuni BS40 (constant velocity, 40mm) with DFI on later models

Fuel Type:

Unleaded gasoline, minimum octane rating 87 (R+M)/2

Lubrication

Oil Capacity:

2.4 Liters (with filter change) (L)

Recommended Oil Viscosity:

10W-40 API SG or higher

Ignition

Ignition System:

Digital CDI

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Overall Length:

2,275 mm (approx.)

Overall Width:

880 mm (approx.)

Overall Height:

1,370 mm (approx.)

Wheelbase:

1,485 mm (approx.)

Weights

Dry Weight:

176 kg (approx.)

Wet Weight:

196 kg (approx., fully fueled)

Fuel Capacity:

18 Liters (approx.)

Suspension Travel

Front Suspension Travel:

206 mm (approx.)

Rear Suspension Travel:

183 mm (approx.)

🛡️ Safety Features

Ratings

NHTSA Rating:

N/A (Motorcycle safety ratings differ from automotive)

Active Features

Brakes Front:

Single Disc (230mm disc, 2-piston caliper - standard, later models may have optional dual disc)

Brakes Rear:

Drum Brake (or Disc on later models, depending on sub-variant)

Lighting:

Halogen headlamp, LED taillight (on some later models)

Passive Features

Frame Construction:

High-tensile steel semi-double cradle frame.

💡 Technology Features

Infotainment

Display:

Analog speedometer and tachometer, odometer, trip meter, neutral indicator, oil warning light.

Driver Assistance

Not available on models covered by this manual.

Connectivity

Bluetooth:

Not available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 6 months, whichever comes first (check manual for specific model year variations)

Air Filter Cleaning:

Every 6,000 km or 6 months, replacement as needed.

Spark Plug Inspection:

Every 12,000 km or 12 months.

Valve Clearance Check:

Every 24,000 km or 24 months.

Chain Adjustment:

As needed, typically every 1,000-2,000 km.

Fluid Specifications

Engine Oil:

SAE 10W-40, API SG or higher (e.g., Motul 5100 10W-40, Castrol Power 1 10W-40)

Coolant:

50/50 mixture of permanent antifreeze and distilled water (e.g., Kawasaki Genuine Coolant, Prestone All-Season)

Brake Fluid:

DOT 4 (e.g., Castrol DOT 4, Valvoline DOT 4)

Fork Oil:

KHL15-10 (Kawasaki Fork Oil 10W) or equivalent

Known Issues

Doohickey Failure:

The balancer shaft lever (often called 'doohickey') can break, causing timing chain issues. Highly recommended to upgrade to an aftermarket unit.

Carburetor Icing:

Can occur in cold, humid conditions, affecting engine performance. Manual covers carburetor cleaning and adjustment.

Oil Consumption:

Some models may exhibit increased oil consumption with high mileage, requiring monitoring and potential engine work. Manual details engine inspection.

Charging System Issues:

Stator and regulator/rectifier can fail over time. Manual provides testing procedures for these components.

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company.

Model Evolution

Introduction Year:

1984 (globally, initial models) and 1987 (US market launch of the first generation KLR650)

Key Generations Within Covered Period:

First Generation (KL650-A, KL650-B Tengai, KL650-C ADV) - 1987-2007 (with minor updates within this range).

Design Philosophy:

Developed to be a rugged, versatile, and affordable dual-purpose motorcycle.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Popularity:

Consistently praised for its longevity and value in adventure motorcycling communities.

Ratings

Reliability Reputation:

Strong reputation for mechanical robustness and durability.

Certifications

Emissions Compliance:

Meets emissions standards for its respective model years (covered by the manual).