Vehicle Segment:
Dual-sport motorcycle, known for its versatility for commuting, touring, and light off-road use.
Key Competitors During Era:
BMW F650GS, Suzuki DR650, Honda Transalp (depending on market).
Vehicle Reputation:
Robust, reliable, affordable, and highly customizable adventure-touring motorcycle.
Benefit To Owner:
Empowers owners to perform a wide range of maintenance and repair tasks, reducing reliance on dealerships and saving costs.
Digital Format Advantage:
Instant download for immediate access to repair information, searchable text, and digital convenience.
General Coverage:
Comprehensive repair and maintenance for the Kawasaki KLR650 model years 2008-2012.
Target Audience:
Professional technicians and experienced DIY mechanics.
Estimated Page Count:
Typically 400-600 pages for a full factory service manual equivalent. Specific count not provided, but described as comprehensive.
Type:
Service Manual, Repair Manual, Workshop Manual
Engine:
Engine disassembly, assembly, overhaul, tuning, lubrication, cooling system, fuel system (carburetor), exhaust system.
Transmission:
Clutch, gearbox, shift mechanism, lubrication.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, swingarm, wheels, tires.
Brakes:
Hydraulic disc brake systems (front and rear), brake fluid specifications, bleeding procedures, caliper and master cylinder service.
Electrical:
Ignition system, charging system (alternator, battery, regulator/rectifier), lighting, starting system, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Carburetor (CVK40), fuel tank, fuel lines, fuel filter.
Bodywork:
Fairing, plastics, seat, fuel tank cover, fenders.
Maintenance:
Routine maintenance, oil changes, filter replacements, spark plug service, chain adjustment, lubrication points.
Repair:
Step-by-step instructions for component repair and replacement across all systems.
Disassembly Assembly:
Detailed procedures for taking apart and putting back together vehicle components.
Troubleshooting:
Diagnostic procedures for identifying and resolving common and complex issues.
Depth:
Covers fundamental to advanced repair procedures, including engine rebuilds and detailed electrical diagnostics.
Engine Type:
4-stroke, liquid-cooled, DOHC, 4-valve single-cylinder
Displacement:
652 cc (cubic centimeters)
Bore X Stroke:
100.0 x 83.0 mm
Horsepower:
Approximately 45-48 HP (actual figures can vary slightly by year and market). Manual will contain precise specifications.
Torque:
Approximately 40-43 lb-ft (actual figures can vary slightly by year and market). Manual will contain precise specifications.
Carburetor Model:
Mikuni BSR40 flat slide, CV (Constant Velocity) type
Fuel Capacity:
6.1 US gallons (23.1 Liters) - a key feature for touring.
Cooling Method:
Liquid-cooled
Oil Type Recommendation:
Likely a SAE 10W-40 motorcycle specific oil, API SG or higher. Manual will specify exact grade and API classification.
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves per cylinder.
Type:
Constant mesh 5-speed
Clutch Type:
Wet, multi-disc, manual operation
Final Drive:
Sealed O-ring chain
Gear Ratios:
Specific gear ratios will be detailed in the manual for each gear.
Transmission Oil Type:
Motorcycle specific transmission oil, likely same as engine oil, but manual will confirm.
Overall Length:
Approx. 88.2 in (2,240 mm) - varies slightly by year.
Overall Width:
Approx. 34.1 in (865 mm)
Overall Height:
Approx. 52.6 in (1,335 mm)
Curb Weight:
Approx. 430 lbs (195 kg) - varies slightly by year.
Weight Distribution:
Manual will likely provide detailed weight distribution figures.
Wheelbase:
Approx. 58.3 in (1,480 mm)
Ground Clearance:
Approx. 9.1 in (230 mm)
Crash Safety Standards:
Motorcycle safety is primarily focused on rider protection and vehicle stability, not traditional crash ratings. Manual will cover safety best practices.
Braking System:
Dual disc front, single disc rear. ABS was not standard on this generation, but manual will detail braking system components and maintenance.
Lighting System:
Halogen headlight, LED tail light, turn signals. Manual will detail bulb types and replacement.
Infotainment System:
Not applicable for this model. This is a utilitarian motorcycle focused on function.
ABS Availability:
Anti-lock Braking System (ABS) was an option on some later models within this range but not standard. Manual will cover braking system details regardless of ABS presence.
Dashboard Features:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, clock, indicator lights. Manual will explain their function and troubleshooting.
Oil Change Interval:
Typically every 3,000-4,000 miles (4,800-6,400 km) or 6 months, whichever comes first. Manual will provide exact interval.
Air Filter Cleaning Interval:
Depends on riding conditions, but typically inspected every 3,000 miles and cleaned/replaced as needed. Manual will specify.
Spark Plug Replacement Interval:
Typically around 7,500-10,000 miles. Manual will specify the correct plug type and gap.
Engine Oil Grade:
SAE 10W-40, API SG or higher (confirm with manual).
Coolant Type:
Kawasaki Motorcycle Coolant or equivalent ethylene glycol-based antifreeze. Manual will detail mixture ratio.
Brake Fluid Type:
DOT 4 recommended (confirm with manual for exact specification).
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings are common wear items requiring periodic inspection and replacement.
Potential Issues:
Some models might experience 'doohickey' lever failure (a known issue with earlier KLRs that was improved but still worth inspecting) and potential oil consumption with high mileage. Manual will guide on inspection and potential solutions.
Engine Bolt Torques:
Manual provides precise torque specifications for critical engine components (e.g., cylinder head bolts, crankcase bolts) to ensure proper assembly and prevent damage.
Carburetor Adjustment:
Detailed instructions for carburetor idle speed, mixture adjustment, and cleaning are included.
Kawasaki Legacy:
Kawasaki has a long history of producing reliable and performance-oriented motorcycles across various categories, including off-road and sport-touring.
Klr650 Lineage:
The KLR650 platform has been in production for decades, with the 2008 model year representing a significant update over previous generations, including fuel injection (though this manual covers the carbureted model), improved suspension, and revised styling. The 2008-2012 generation is highly regarded for its durability and go-anywhere capability.
Manufacturing Location:
Primarily manufactured in Japan.
