Market Segment:
Dual-sport motorcycle, adventure touring, commuting.
Competitors:
BMW F650GS, Honda Transalp, Suzuki V-Strom 650.
Vehicle Strengths:
Reliability, affordability, ruggedness, versatility for both on-road and light off-road use.
Manual Benefit:
Empowers owners and technicians to perform all necessary maintenance and repairs, ensuring longevity and optimal performance of the KLR650.
Model Years:
2008, 2009, 2010, 2011, 2012
Vehicle Variants:
Covers all KLR650 models produced within the specified years, regardless of minor cosmetic or regional variations.
Page Count:
Over 400 pages (estimated for comprehensive service manuals of this era)
Manual Type:
Service and Repair Manual
Engine Systems:
Engine overhaul, lubrication, cooling system, fuel system (carburetor, fuel pump), ignition system, exhaust system, starting system, charging system.
Transmission Drivetrain:
Clutch operation and inspection, gearbox disassembly and assembly, chain drive maintenance and adjustment.
Chassis Suspension:
Frame inspection, front fork disassembly, rear shock absorber and linkage maintenance, wheel bearing service, steering system.
Brakes:
Front and rear brake system service, hydraulic system bleeding, pad replacement, caliper overhaul.
Electrical:
Wiring diagrams, lighting system, instrument panel, battery service, fuse identification, ignition switch.
Bodywork Plastics:
Fairing removal and installation, seat maintenance, fender service.
Maintenance Procedures:
Regular maintenance checks, oil and filter changes, air filter cleaning/replacement, spark plug service, chain lubrication and adjustment, valve clearance adjustment.
Repair Procedures:
Complete engine rebuild, carburetor tuning and overhaul, clutch replacement, transmission gear inspection, fork seal replacement, brake caliper rebuilding, electrical component testing.
Troubleshooting:
Diagnostic flowcharts for common issues, symptom-based problem solving.
Torque Specifications:
Detailed torque specifications for all critical fasteners, including engine bolts, suspension components, and brake system fasteners.
Special Tools:
Identification of specific Kawasaki or equivalent tools required for certain repair procedures, such as valve spring compressors or bearing pullers.
Technical Depth:
Comprehensive, covering everything from basic routine maintenance to full engine and transmission overhauls, including detailed specifications, torque values, and diagnostic procedures.
Diagnostic Charts:
Inclusion of comprehensive diagnostic flowcharts to systematically identify and resolve mechanical and electrical issues.
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single-cylinder
Displacement:
652cc (39.8 cu in)
Bore X Stroke:
100.0 x 83.0 mm (3.94 x 3.27 in)
Compression Ratio:
11.3:1
Horsepower:
Approx. 35-40 hp @ 6000 rpm (varies slightly by market and tuning)
Torque:
Approx. 35-40 lb-ft @ 4500 rpm (varies slightly by market and tuning)
Engine Design Philosophy:
Single-cylinder, long-stroke design optimized for torque and reliability over peak horsepower, ideal for touring and varied terrain.
Fuel Delivery:
Keihin CVK40 carburetor (specific model may vary)
Fuel Type:
Unleaded gasoline, 87 octane (AKI) / 91 RON minimum recommended.
Oil Type:
SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil.
Oil Capacity:
Approx. 2.1 L (2.2 US qt) without filter change; 2.3 L (2.4 US qt) with filter change.
Coolant Type:
High-quality ethylene glycol based coolant with demineralized water (50:50 mixture).
Overall Length:
Approx. 2,255 mm (88.8 in)
Overall Width:
Approx. 910 mm (35.8 in)
Overall Height:
Approx. 1,390 mm (54.7 in)
Wheelbase:
Approx. 1,470 mm (57.9 in)
Ground Clearance:
Approx. 210 mm (8.3 in)
Seat Height:
Approx. 855 mm (33.7 in)
Curb Weight:
Approx. 194 kg (427.7 lbs)
Fuel Tank Capacity:
23 L (6.1 US gal)
Crash Test Ratings:
N/A (Motorcycle safety is assessed differently than automobiles, typically focusing on design and handling characteristics).
Braking System:
Front: 2-piston caliper with 230mm petal disc. Rear: 1-piston caliper with 203mm petal disc. Optional ABS not available for these model years.
Lighting:
Halogen headlight, LED tail light.
Frame Design:
High-tensile steel semi-double cradle frame for durability and impact absorption.
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, clock, coolant temperature gauge, neutral indicator, oil pressure indicator, turn signal indicators.
ABS:
Not available on models produced between 2008 and 2012.
Connectivity Features:
N/A (This era of motorcycle focuses on mechanical and functional aspects rather than electronic connectivity).
Oil Change Interval:
Every 4,000 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Cleaning:
Inspect every 4,000 miles (6,000 km), clean/replace as needed.
Spark Plug Replacement:
Recommended replacement every 12,000 miles (20,000 km). Check gap at 4,000 miles (6,000 km).
Valve Clearance Check:
Every 12,000 miles (20,000 km).
Chain Lubrication:
Every 600 miles (1,000 km) and after washing or riding in the rain.
Coolant:
50/50 mixture of high-quality ethylene glycol coolant and demineralized water.
Common Wear Items:
Cam chain tensioner (potential for rattling, often addressed with aftermarket upgrades), exhaust pipe welds (prone to cracking), clutch plates (wear with heavy use).
Carburetor Tuning:
Pilot jet can become clogged with age/disuse, affecting idle and low-speed performance.
Subframe Cracks:
In rare instances, particularly with heavily loaded bikes used off-road, subframe cracks can develop. The manual will detail inspection points.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long-standing reputation for producing reliable and robust motorcycles, particularly in the dual-sport and off-road segments. The KLR line has been a cornerstone of their adventure touring offerings.
Klr650 Lineage:
The KLR650 was first introduced in 1987 and has undergone evolutionary rather than revolutionary changes, a testament to its successful and enduring design. The 2008-2012 models represent a significant update from the previous generation, featuring a larger fuel tank, improved suspension, and revised bodywork, while retaining the core utilitarian ethos. This generation bridges the gap before the introduction of fuel injection in later models.
Manufacturing Location:
Japan (primary manufacturing for this era)
