Category:
Dual-sport motorcycle
Target Audience:
Adventure riders, commuters, off-road enthusiasts seeking versatility.
Key Competitors:
BMW F650GS, Honda Transalp, Suzuki V-Strom, Yamaha Ténéré (though KLR650 often positioned as a more budget-friendly and utilitarian option).
Versatility:
Designed for both on-road touring and light off-road capability.
Durability:
Known for its robust construction and long-term reliability.
Simplicity:
Relatively simple mechanical design makes it easier to maintain and repair.
Engine:
Complete disassembly, inspection, assembly, tuning, and troubleshooting of the 651cc liquid-cooled, four-stroke, single-cylinder engine.
Fuel System:
Carburetor (Mikuni BSR32), fuel pump, fuel tank, fuel lines, and related components.
Ignition System:
CDI ignition, spark plugs, ignition coils, and timing.
Transmission:
5-speed gearbox, clutch assembly (wet multi-plate), gear shift mechanism, lubrication.
Drivetrain:
Chain drive, sprockets, final drive lubrication.
Cooling System:
Radiator, cooling fan, coolant flow, water pump, thermostat.
Suspension:
Front telescopic forks (adjustable preload/damping on some models), rear Uni-Trak monoshock (adjustable preload/rebound damping), linkage system, wheel bearings.
Brakes:
Front hydraulic disc brake (single rotor), rear hydraulic disc brake, brake calipers, master cylinders, brake lines, fluid specifications.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, wiring diagrams.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, footpegs, seat assembly.
Bodywork:
Fairings, fuel tank cover, seat, fenders, skid plate, luggage rack.
Wheels And Tires:
Spoked wheels, tire specifications, inflation pressures, wheel balancing.
Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid changes, coolant flushes, valve clearance checks and adjustments.
Troubleshooting:
Diagnostic procedures for common problems related to starting, running, electrical issues, and braking.
Repair:
Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service, electrical component diagnosis and replacement.
Specifications:
Torque values for critical fasteners, engine clearances, fluid capacities, electrical resistance values, diagnostic parameters.
Depth:
Comprehensive. Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Searchability:
Text-searchable, allowing for quick navigation to specific topics.
Printability:
Printable, with high-resolution diagrams and text for clear reproduction.
Image Resolution:
High-resolution images and diagrams for clarity.
Binding:
N/A (Digital format, no physical binding)
Paper Quality:
N/A (Digital format, no physical paper type)
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Displacement:
651 cc (cubic centimeters)
Bore X Stroke:
100.0 mm x 83.0 mm
Valve Train:
DOHC, 4 valves per cylinder
Horsepower:
Approximately 40-42 hp (at crank) - Actual output can vary.
Torque:
Approximately 39-41 lb-ft (at crank) - Actual output can vary.
Carburetor:
Mikuni BSR32, constant velocity
Fuel Delivery:
Diaphragm-type fuel pump
Oil Type:
SAE 10W-40 API SG or SH motorcycle oil with JASO MA certification
Oil Capacity:
Approx. 2.1 L (2.2 US qt) without filter change; Approx. 2.3 L (2.4 US qt) with filter change.
Transmission Type:
Constant mesh, 5-speed sequential
Clutch Type:
Wet multi-plate, cable-actuated
Gear Ratios:
1st: 2.600, 2nd: 1.750, 3rd: 1.333, 4th: 1.111, 5th: 0.913
Transmission Oil Type:
Same as engine oil (SAE 10W-40 API SG/SH JASO MA)
Transmission Oil Capacity:
Approx. 1.6 L (1.7 US qt)
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Change:
Every 6,000 km (3,700 miles) or 6 months, coinciding with oil changes.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) and before long-distance trips.
Coolant:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Common Wear Items:
Chain and sprockets, brake pads, fork seals, steering head bearings, balancer chain tensioner (later models addressed some of this).
Engine Considerations:
The single-cylinder engine's inherent vibrations can lead to component loosening over time; regular bolt checks are recommended. Some early models had issues with the balancer chain tensioner.
