Kawasaki KLR650 2008-2012 Workshop Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 65910

Etiquetas: 2008 2009 2010 2011 2012 Kawasaki KLR Series KLR650 Motorcycle Motorcycles

Variantes de producto

Descripción

The Kawasaki KLR650, specifically the Second Generation (KL650E) models produced between 2008 and 2012, is a renowned dual-sport motorcycle celebrated for its exceptional durability, versatility, and user-friendly design. This model is engineered to excel in a wide range of conditions, from daily commuting and long-distance adventure touring to challenging off-road excursions. Its reputation for a robust engine and chassis makes it a reliable companion, appealing to both seasoned riders and those new to the dual-sport segment, offering a balance of performance and practicality. This comprehensive workshop service and repair manual provides in-depth guidance for the maintenance and overhaul of your Kawasaki KLR650. It covers all essential systems, including detailed procedures for engine mechanical and electrical aspects, fuel system, transmission, drivetrain, suspension, brakes, steering, and bodywork. Whether you are performing routine service checks, replacing wear items, or undertaking complex diagnostic and repair tasks, this manual offers step-by-step instructions and technical specifications to ensure your motorcycle remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLR650

Years Covered:

2008, 2009, 2010, 2011, 2012

Generation

Generation Designation:

Second Generation (KL650E)

👋 Introduction

Market Position

Model Segment:

Dual-sport motorcycle, known for its ruggedness, versatility, and affordability

Competitive Analysis

Key Competitors:

BMW F650GS (early models), Suzuki V-Strom 650, Honda Transalp (if available in market)

Key Features

Durability:

Renowned for its bulletproof engine and chassis, capable of handling rough terrain and long-distance touring

Versatility:

Suitable for commuting, adventure touring, off-road excursions, and daily riding

Ease Of Maintenance:

Designed with user-serviceability in mind, making it a popular choice for DIY mechanics

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop Service and Repair

Scope:

Comprehensive overhaul and maintenance

Page Count

Estimated Page Count:

Varies by specific version, but typically 500+ pages for a complete factory service manual

Manual Type

Type:

Factory Service Repair Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of engine components (pistons, cylinders, valves, crankshaft, etc.)

Engine Electrical:

Ignition system, charging system, starting system, sensor diagnostics, ECU troubleshooting

Fuel System:

Carburetor overhaul and adjustment, fuel pump, fuel lines, emission control systems

Transmission:

Clutch system, manual transaxle (gearbox) service, lubrication

Drivetrain:

Final drive (chain and sprockets), wheel bearings, swingarm service

Suspension:

Front fork service (seals, oil, springs), rear shock absorber inspection and replacement, linkage lubrication

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, hydraulic system bleeding

Steering:

Handlebar replacement, steering stem bearing service and adjustment

Bodywork:

Fairing removal and installation, seat service, fender replacement, plastic component repair

Electrical System:

Wiring diagrams, lighting systems, instrument cluster, battery maintenance, starter motor, alternator

Restraint Systems:

Not applicable for this motorcycle model (typically relates to seatbelts in cars)

Procedures Included

Maintenance:

Regular service checks, oil changes, filter replacements, chain adjustment, tire pressure checks

Troubleshooting:

Detailed diagnostic procedures for common and uncommon problems, fault codes (if applicable)

Repair:

Step-by-step instructions for virtually all repair tasks, from minor adjustments to major component overhauls

Diagnostics:

Guidance on diagnosing electrical and mechanical issues using specified procedures

Technical Depth

Depth:

Complete, covering everything from routine maintenance to full engine rebuilds and electrical system diagnosis

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Fully Printable

Zoom Functionality:

Yes (Zoom IN/OUT)

Binding Type

Binding:

Digital Download (PDF) - User printable

Paper Type

Paper Type:

N/A (Digital)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for extraction if compressed)

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, DOHC, 4 valves

Displacement:

652 cc

Bore X Stroke:

100.0 x 83.0 mm

Cooling System:

Liquid-cooled

Performance

Horsepower Approx:

Approx. 46 hp @ 6,000 rpm (Varies slightly by market and tuning)

Torque Approx:

Approx. 38 lb-ft @ 5,000 rpm (Varies slightly by market and tuning)

Fuel System

Fuel Delivery:

Carburetor (Keihin CVK40)

Ignition:

Electronic ignition (CDI)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

N/A (Manual transmission only)

Features

Clutch:

Wet, multi-disc

Final Drive:

Sealed chain (525 O-ring sealed)

📐 Dimensions

Exterior

Length:

Approx. 88.0 in (2,235 mm)

Width:

Approx. 34.1 in (865 mm)

Height:

Approx. 50.2 in (1,275 mm)

Wheelbase:

Approx. 58.3 in (1,480 mm)

Weights

Curb Weight:

Approx. 430 lbs (195 kg)

Fuel Capacity:

6.1 US gal (23 L)

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Motorcycle safety is assessed differently than automobiles; focus is on rider protection and vehicle stability)

Active Features

Braking System:

Front: Dual-piston caliper, 260mm petal disc; Rear: Single-piston caliper, 240mm petal disc. ABS was not standard or commonly available on this generation.

Passive Features

Lighting:

Halogen headlight, LED taillight

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic analog instrumentation)

Driver Assistance

Not standard on this generation

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,700 miles (6,000 km) or 6 months, whichever comes first (check manual for specifics)

Air Filter:

Inspect every 3,700 miles (6,000 km), clean or replace as needed

Spark Plug:

Replace every 7,500 miles (12,000 km) or annually (check manual for specifics)

Valve Clearance:

Inspect every 14,500 miles (23,000 km)

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ or SL, SAE 10W-40 or 20W-50 (consult manual for precise recommendation and ambient temperature suitability)

Engine Oil Capacity:

Approx. 2.7 US qt (2.5 L) without filter change, 2.9 US qt (2.7 L) with filter change

Coolant Type:

Kawasaki Motorcycle Coolant or equivalent ethylene glycol based antifreeze (50/50 mix with distilled water)

Brake Fluid:

DOT 4

Known Issues

Common Wear Item:

Clutch wear, especially under heavy use; some models may experience occasional starter solenoid issues.

Maintenance Tip:

Regular chain lubrication and adjustment is crucial for drivetrain longevity.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.

Model Evolution

Klr650 Lineage:

The KLR650 platform has been in continuous production since 1987, evolving with minor updates. The 2008 model year marked the introduction of the second generation, which brought significant styling and some mechanical refinements.

Production

Manufacturing Location:

Japan (and potentially other Kawasaki global facilities)

🏆 Awards & Recognition

Recognitions

Market Recognition:

Consistently praised for its value, reliability, and go-anywhere capability in motorcycle publications and rider forums.