Positioning:
The Kawasaki KLR650 is a highly regarded dual-sport motorcycle, known for its ruggedness, reliability, and versatility for both on-road commuting and off-road adventuring. The 1991 model falls into the early generation of this iconic platform.
Competitors Era:
Competed with other dual-sport bikes of its era such as the Honda Transalp, Yamaha Tenere, and Suzuki DR650.
Durability:
Renowned for its robust construction and ability to withstand demanding conditions.
Versatility:
Suitable for a wide range of riding environments, from city streets to gravel roads and light trails.
Simplicity:
Relatively simple mechanical design makes it accessible for DIY maintenance and repairs.
Engine:
Detailed disassembly, assembly, troubleshooting, and repair of the 651cc liquid-cooled, four-stroke, single-cylinder engine.
Fuel System:
Carburetor (Mikuni VM26SS) adjustment, cleaning, rebuilding, and troubleshooting. Fuel pump operation and service.
Ignition System:
CDI ignition system testing, troubleshooting, and component replacement.
Transmission:
Clutch operation, adjustment, and replacement. Gearbox disassembly, inspection, and repair. Shift drum and fork service.
Drivetrain:
Chain drive system maintenance, adjustment, and replacement. Rear wheel hub and sprocket service.
Suspension Front:
Front fork disassembly, seal replacement, oil level and viscosity specification, spring preload adjustment, and troubleshooting.
Suspension Rear:
Uni-Trak rear suspension system adjustment, shock absorber service, linkage lubrication, and bearing inspection.
Brakes Front:
Hydraulic disc brake system service, caliper overhaul, pad replacement, fluid bleeding, and master cylinder inspection.
Brakes Rear:
Drum brake system inspection, adjustment, and shoe replacement.
Electrical System:
Wiring diagrams, troubleshooting electrical faults, battery maintenance, charging system (stator, regulator/rectifier), lighting, starting system, and instrument panel.
Cooling System:
Radiator service, fan operation, coolant type and capacity, thermostat testing, and leak detection.
Frame And Bodywork:
Frame inspection, mounting bolt torque specifications, fairing removal and installation, seat and tank maintenance.
Routine Maintenance:
Oil and filter change, air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication and adjustment, brake system checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues related to engine performance, electrical systems, starting problems, and braking.
Engine Rebuild:
Complete engine disassembly, piston and ring inspection/replacement, cylinder honing, valve lapping and adjustment, crankshaft and connecting rod checks.
Suspension Rebuild:
Front fork seal and bushing replacement, rear shock absorber service (if applicable for rebuild), linkage bearing replacement.
Carburetor Tuning:
Idle speed adjustment, mixture screw settings, jetting recommendations for altitude and modifications.
Wheel Service:
Tire removal and installation, spoke tension adjustment, bearing replacement.
Electrical Diagnostics:
Using a multimeter for voltage, resistance, and continuity tests on various circuits.
Depth:
Comprehensive; covers from basic user maintenance to complete engine and component overhauls, including detailed specifications and diagnostic flowcharts.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Displacement:
651 cc (39.7 cubic inches)
Bore X Stroke:
100.0 mm x 83.0 mm (3.94 in x 3.27 in)
Horsepower:
Approximately 47 hp @ 6,500 rpm (manufacturer claimed)
Torque:
Approximately 39 lb-ft @ 5,500 rpm (manufacturer claimed)
Carburetor:
Mikuni VM26SS, constant velocity, single
Fuel Capacity:
19 Liters (5.0 US gal)
Ignition:
Electronic ignition (CDI)
Starter:
Electric starter
Crash Safety:
N/A (Motorcycle safety standards and testing differ significantly from automobiles; emphasis is on rider protection and vehicle stability).
Braking System:
Dual front disc brakes, single rear drum brake. ABS was not a standard feature on this model.
Lighting:
Halogen headlight, taillight, brake light, and turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame for rigidity and durability.
Chassis Design:
Designed for stability and handling across varied terrain.
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Oil Filter Change Interval:
With every oil change.
Air Filter Cleaning Interval:
Every 4,000 km (2,500 miles), clean and re-oil.
Spark Plug Inspection Interval:
Every 8,000 km (5,000 miles).
Valve Clearance Check Interval:
Every 8,000 km (5,000 miles).
Chain Lubrication Adjustment Interval:
Every 1,000 km (600 miles) or after riding in wet conditions.
Engine Oil Type:
SAE 10W-40 API SG or higher (JASO MA recommended).
Engine Oil Capacity:
2.7 Liters (2.9 US qt) without filter change; 3.0 Liters (3.2 US qt) with filter change.
Coolant Type:
Permanent type anti-freeze coolant (ethylene glycol based), 50/50 mix with distilled water.
Coolant Capacity:
Approximately 1.7 Liters (1.8 US qt) including the reservoir.
Brake Fluid Type:
DOT 3 or DOT 4.
Common Wear Item:
Cam chain tensioner (often upgraded to an aftermarket manual tensioner due to potential failure leading to noise or damage).
Carburetor Tuning:
Can require periodic cleaning and adjustment, especially if the bike sits for extended periods or is used with ethanol-blended fuels.
Doohickey:
The balancer shaft lever (commonly called 'doohickey') can fail; inspection and replacement is a common preventative maintenance item.
Shock ABSorber:
The original rear shock absorber may lose damping performance over time due to its age and design; rebuild or replacement is common.
Valve Adjustment:
Requires periodic adjustment using shims, which is a straightforward but necessary maintenance task.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and reliability across various segments, from sportbikes to cruisers and dual-sports.
Klr650 Lineage:
The KLR650 platform, introduced in 1987, has proven exceptionally enduring, with the 'A' series serving as the foundational design. This model has seen relatively minor updates between its introduction and the late 1990s, testament to its successful original engineering.
Manufacturing Location:
Japan (Primary)
Production Years:
The A-series KLR650 was produced from 1987 through 2007 with minimal changes, making the 1991 model representative of this long-running generation.
