🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Years Covered:

2008, 2009, 2010, 2011, 2012

👋 Introduction

Segment:

Dual-sport motorcycle, adventure touring

Competitors:

BMW G 650GS, Honda XR650L, Suzuki DR650SE, Yamaha XT660R

Versatility:

Capable of handling both on-road commuting and off-road exploration

Reliability:

Known for its robust and dependable single-cylinder engine

Value:

Offers a balance of performance and affordability in its class

Riders:

Commuters, adventure riders, touring enthusiasts, beginner to intermediate riders

📋 Manual Details

Overall Coverage:

Comprehensive workshop service and repair

Estimated Pages:

500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Top end, bottom end, cylinder head, piston, crankshaft, connecting rod, valve train, lubrication system

Engine Fuel System:

Carburetor (CVK40), fuel injection (for later models if applicable, though this range is primarily carbureted), fuel pump, fuel lines, tank

Engine Ignition System:

CDI, ignition coil, spark plug, wiring

Cooling System:

Radiator, fan, thermostat, coolant hoses, water pump

Transmission Drivetrain:

Clutch, gearbox, shift mechanism, final drive (chain and sprockets)

Chassis Suspension:

Front forks (conventional telescopic), rear shock absorber, swingarm, linkages, bearings

Brakes:

Front disc brake system, rear disc brake system, master cylinders, calipers, lines, pads, fluid specifications

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, tail light, signals), instrumentation, wiring diagrams, fuses, relays

Body Frame:

Frame construction, fuel tank, seat, fenders, fairing, body panels, handlebars, footpegs

Wheels Tires:

Spoked wheels, tire types, pressures, wheel bearing maintenance

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake pad inspection, tire pressure checks, air filter cleaning/replacement

Engine Rebuild:

Complete engine disassembly, inspection, repair, and reassembly procedures

Carburetor Service:

Removal, cleaning, adjustment, jetting (if applicable), reinstallation

Suspension Service:

Fork seal replacement, fork oil change, shock absorber servicing, linkage lubrication

Brake System Repair:

Caliper rebuild, master cylinder servicing, bleeding procedures, line replacement

Electrical Troubleshooting:

Wiring diagram interpretation, diagnostic procedures for common electrical faults

Torque Specifications:

Detailed torque values for all critical fasteners

Diagnostic Charts:

Troubleshooting guides for various symptoms

Depth:

Full workshop-level detail suitable for professional technicians and experienced DIY mechanics

📊 Manual Specifications

Digital Format:

PDF

Image Resolution:

High resolution, clear schematics and diagrams

Binding:

Not applicable (Digital)

Paper:

Not applicable (Digital)

Text Search:

Searchable text for quick information retrieval

Print Option:

Printable pages

⚙️ Engine Specifications

Type:

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

Displacement:

651 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

8.3:1

Horsepower:

~45-50 HP @ 6,500 RPM (approximate, varies slightly by source)

Torque:

~39-42 lb-ft @ 5,000 RPM (approximate)

Carburetor Type:

Keihin CVK40 constant velocity carburetor

Fuel Capacity:

18 Liters (4.7 US gal)

Oil Capacity With Filter:

2.3 Liters (2.4 US qt)

Cooling Method:

Liquid-cooled

Starter:

Electric

🔧 Transmission

Type:

5-speed constant mesh

Final Drive:

O-ring sealed chain drive

Transmission Oil Type:

API GL-4, SAE 80W-90 gear oil (refer to manual for specific Kawasaki recommendation)

📐 Dimensions

Length:

2,275 mm (89.6 in)

Width:

905 mm (35.6 in)

Height:

1,400 mm (55.1 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

210 mm (8.3 in)

Seat Height:

890 mm (35.0 in)

Curb Weight:

192 kg (423.3 lbs)

Max Load:

Refer to manual (typically rider + cargo limit)

🛡️ Safety Features

Crash Test Ratings:

Not applicable to motorcycles in the same way as cars

Braking System:

Disc brakes front and rear

Lighting:

Halogen headlight, LED tail light

Frame Construction:

Semi-double cradle, high-tensile steel

💡 Technology Features

Infotainment System:

Not applicable (basic motorcycle instrumentation)

ABS:

Optional ABS available on some late models within this range, but not standard.

Dashboard Features:

Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators, water temperature warning light, fuel gauge (on some models).

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months

Air Filter Cleaning:

Every 12,000 km (7,500 miles) or 12 months

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

Every 24,000 km (15,000 miles)

Engine Oil Type:

API SG, SF or SH, SAE 10W-40 motorcycle oil (synthetic or mineral, consult manual for specific recommendations)

Coolant Type:

High-quality ethylene glycol-based coolant, pre-diluted 50/50 with distilled water

Brake Fluid Type:

DOT 4

Common Wear Items:

Clutch plates, countershaft bearing, doohickey (shift lever arm spring/tab washer), wheel bearings

Vibration:

Single-cylinder engines are prone to vibration; some owners add aftermarket dampeners.

Doohickey Failure:

The stock doohickey can fail; often replaced with a stronger aftermarket unit during maintenance.

Countershaft Bearing:

Can wear prematurely, leading to clutch drag or difficulty shifting. Early detection and replacement are key.

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries, Ltd.

Generations:

The KLR650 has been in continuous production since 1987, with significant updates in 2008 that introduced fuel injection (on some models, but the 08-12 range is primarily carbureted), a larger fuel tank, and revised bodywork.

Manufacturing Location:

Japan

Sales Figures:

Consistently one of Kawasaki's best-selling motorcycles globally due to its value and versatility.

🏆 Awards & Recognition

Industry Awards:

While not typically receiving specific 'awards' in the automotive sense, the KLR650 is widely recognized for its durability and value retention in the adventure and dual-sport segments.