Market Position:
The Kawasaki KLR650 is a renowned and long-standing model in the dual-sport motorcycle segment, known for its ruggedness, reliability, affordability, and versatility for both on-road commuting and off-road exploration. It appeals to a wide range of riders, from beginners to experienced adventurers.
Competitive Analysis:
Competes with models like the Honda XR650L, Suzuki DR650SE, and Yamaha XT660R/XT660Z Ténéré in the middleweight dual-sport class. The KLR650 distinguishes itself with its liquid-cooled engine, fuel injection (post-2007), and comfortable ergonomics for longer rides.
Key Features:
Torque-rich 651cc single-cylinder engine, long-travel suspension, robust frame, comfortable seating position, adjustable windscreen, large fuel tank for extended range, luggage rack as standard. The 2008-2014 generation received significant updates including fuel injection and improved suspension.
Covered Years:
2008, 2009, 2010, 2011, 2012, 2013, 2014
Estimated Page Count:
Approx. 400-500 pages (typical for comprehensive service manuals)
Manual Type:
Complete Workshop Service Repair Manual
Engine Systems:
Engine overhaul, top-end rebuild (cylinder head, valves, camshaft), bottom-end rebuild (crankshaft, connecting rods, pistons), lubrication system, cooling system (radiator, fan, coolant), fuel injection system (throttle body, injectors, sensors), ignition system (spark plugs, coils), exhaust system.
Transmission Systems:
Clutch operation and adjustment, gearbox disassembly and assembly, gear selection mechanism, final drive (chain and sprockets).
Chassis Systems:
Frame inspection and repair, suspension system (front forks, rear shock absorber, linkages), steering system (handlebars, steering stem bearings), brake system (front and rear disc brakes, calipers, master cylinders, hydraulic lines, fluid), wheel and tire service (mounting, balancing), electrical system (wiring diagrams, battery, charging system, lighting, instrumentation, starter).
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacement, spark plug replacement, chain adjustment and lubrication, brake bleeding, coolant flush and fill, tire pressure checks.
Repair Procedures:
Engine component replacement (pistons, rings, valves), transmission repairs, suspension fork seal replacement, shock absorber rebuilding, brake caliper overhauls, carburetor cleaning and adjustment (if applicable to specific sub-models, though 2008+ are EFI), electrical component diagnosis and replacement.
Troubleshooting Procedures:
Diagnostic flowcharts for common running problems, electrical faults, starting issues, braking system malfunctions, suspension performance problems.
Installation Procedures:
Guidance on installing aftermarket accessories (if general principles are covered), torque specifications for critical fasteners.
Technical Depth:
Comprehensive, covering from basic rider maintenance to full engine and transmission rebuilds. Includes detailed disassembly and reassembly instructions, torque specifications, and diagnostic procedures.
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve, Single-cylinder
Displacement:
651 cc (39.7 cu in)
Bore X Stroke:
100.0 x 83.0 mm
Horsepower:
Approx. 38-40 hp @ 6000-6500 rpm (claimed)
Torque:
Approx. 34-36 lb-ft @ 4500-5000 rpm (claimed)
Fuel System:
Fuel Injection (DFI) with 40mm throttle body
Ignition:
Digital CDI with electronic advance
Recommended Fuel:
Unleaded gasoline, Octane rating 87 or higher
Valve Lash Adjustment Interval:
Every 15,000 miles (24,000 km) or as per manual
Transmission Type:
5-speed, constant mesh, return type
Clutch:
Wet, multiple disc, cable operated
Final Drive:
O-ring sealed chain
Transmission Oil Type:
API GL-4, SAE 80W-90 Gear Oil (or as specified)
Overall Length:
Approx. 2,245 mm (88.4 in)
Overall Width:
Approx. 910 mm (35.8 in)
Overall Height:
Approx. 1,410 mm (55.5 in)
Wheelbase:
Approx. 1,470 mm (57.9 in)
Ground Clearance:
Approx. 220 mm (8.7 in)
Curb Weight:
Approx. 190 kg (418.9 lbs)
Fuel Capacity:
23.0 L (6.1 US gal)
Oil Capacity:
3.0 L (3.2 US qt) with filter change
Seat Height:
Approx. 855 mm (33.7 in)
Safety Ratings:
N/A (Motorcycle safety is assessed via specific tests rather than general ratings)
Active Safety Features:
Disc brakes front and rear for reliable stopping power, responsive suspension for stability.
Passive Safety Features:
Sturdy frame construction, integrated luggage rack for load stability, upright riding posture for rider visibility.
Infotainment Features:
Basic instrumentation cluster including speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems are present on this model.
Driver Assistance Features:
N/A (Motorcycles do not typically feature driver assistance systems in the automotive sense).
Connectivity Features:
N/A
Engine Management System:
Electronic Fuel Injection (EFI) system managed by the ECU, monitoring various sensors (throttle position, air intake temperature/pressure, engine coolant temperature, etc.) for optimal performance and emissions.
Engine Oil Change Interval:
Every 3,000 miles (4,800 km) or 6 months, whichever comes first.
Air Filter Cleaning Interval:
Every 4,000 miles (6,400 km), replace as needed.
Spark Plug Replacement Interval:
Every 7,500 miles (12,000 km).
Chain Maintenance Interval:
Lubricate and check tension every 600 miles (1,000 km).
Engine Oil Specification:
SAE 10W-40, API SG or SH, JASO MA certified motorcycle oil.
Coolant Type:
Permanent type antifreeze coolant, 50% mixture with distilled water.
Known Issues And Fixes:
Rattling noise from doohickey (balancer lever tensioner arm) on older models, often addressed by aftermarket replacements; potential for oil consumption at higher mileages; occasional issues with the starter relay. Manual will cover inspection and repair procedures for these.
Common Tasks Covered:
Chain adjustment and lubrication, brake pad replacement, tire changes, oil and filter service, coolant replacement, battery maintenance, general cleaning and inspection.
Brand Heritage:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for its performance-oriented motorcycles and robust engineering. The KLR line has been a staple for Kawasaki in the dual-sport market for decades.
Model Evolution:
The KLR650 debuted in 1987 and has undergone continuous refinement. The 2008 model represented a significant update, incorporating fuel injection, a larger front brake, improved suspension, and revised styling, making it more modern and capable. The manual covers this updated generation.
Production Locations:
Primarily manufactured in Japan.
