Kawasaki KL650 Motorcycle Complete Workshop Service Repair Manual 2008 2009 2010 2011 2012

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Mots clés: 2008 2009 2010 2011 2012 Kawasaki KL650 Misc Motorcycle Motorcycles

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Description

This manual covers the KL650, also known as the KLR650, specifically the Second Generation (KL650E) models produced between 2008 and 2012, including chassis codes KL650E8F through KL650ECF. Renowned for its ruggedness, reliability, and versatility, the KL650 is a capable dual-sport motorcycle, equally adept at on-road commuting and off-road exploration. This generation features a 651cc liquid-cooled, four-stroke single-cylinder engine with fuel injection, a five-speed transmission, and robust suspension and braking systems, making it a popular choice for adventure touring. This comprehensive Workshop Service Repair Manual in English provides detailed procedures for all aspects of the KL650's maintenance and repair. It covers engine overhaul, fuel system servicing, transmission and drivetrain maintenance, suspension and brake system work, and electrical system diagnostics, including full wiring diagrams. The manual also includes routine maintenance schedules, troubleshooting guides for common issues, and precise technical specifications and tolerances. Its thoroughness ensures that owners and technicians have the necessary information to keep the motorcycle in optimal condition, ensuring its legendary durability and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KL650

Model Alias:

KLR650

Generation

Generation Identifier:

Second Generation (KL650E)

Codes

Chassis Code Range:

KL650E8F, KL650E9F, KL650EAF, KL650EBF, KL650ECF

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure-touring motorcycle

Target Audience:

Owners and technicians requiring in-depth knowledge for maintenance, repair, and customization of the KL650 motorcycle.

Competitive Analysis

Competitors:

BMW F650GS, Honda XR650L, Suzuki DR650S, Yamaha XT660R

Key Features

Vehicle Reputation:

Known for its ruggedness, reliability, versatility for both on-road and off-road use, and affordability.

Manual Value Proposition:

Provides comprehensive, factory-level repair information to enable owners and mechanics to maintain and repair the motorcycle effectively, saving on dealership service costs.

📋 Manual Details

Coverage Areas

Vehicle Years:

2008, 2009, 2010, 2011, 2012

Page Count

Estimated Pages:

Approximately 600-750 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

All aspects of the 651cc liquid-cooled four-stroke single-cylinder engine, including disassembly, assembly, inspection, and tuning.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel tank, and related components.

Transmission:

Five-speed constant mesh transmission, clutch operation, lubrication, and disassembly/assembly.

Drivetrain:

Final drive system (chain and sprockets), inspection, and replacement procedures.

Suspension:

Front telescopic fork (including oil change, seal replacement, and spring inspection), rear Uni-Trak suspension, shock absorber, and linkage inspection.

Brakes:

Front and rear disc brake systems, hydraulic lines, master cylinders, calipers, pads, fluid replacement, and bleeding procedures.

Electrical System:

Ignition system, starting system (starter motor, battery), charging system (alternator, regulator/rectifier), lighting, instrumentation, and wiring diagrams.

Cooling System:

Radiator, cooling fan, water pump, coolant fluid specifications, and replacement procedures.

Exhaust System:

Exhaust pipes, muffler, and heat shields inspection and replacement.

Frame And Bodywork:

Frame inspection, fairings, body panels, seat, fuel tank removal/installation, and related hardware.

Wheels And Tires:

Wheel bearing inspection, tire pressure, and replacement.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, brake fluid checks, and general lubrication.

Troubleshooting:

Diagnostic procedures for common issues related to engine performance, electrical faults, starting problems, and braking concerns.

Component Overhaul:

Detailed step-by-step instructions for engine rebuild, transmission overhaul, carburetor/fuel injection system servicing, and suspension component refurbishment.

Electrical Diagnostics:

Testing and repair of electrical circuits, ignition timing, charging system output, and sensor diagnostics.

Specifications And Tolerances:

Precise torque values, clearance specifications, fluid capacities, and other critical measurements for all components.

Wiring Diagrams:

Comprehensive, color-coded wiring diagrams for easy electrical system diagnosis and repair.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and troubleshooting.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Readability:

High-resolution, ensuring clear text and legible diagrams. Optimized for digital viewing and printing.

Binding Type

Format Description:

Digital download (PDF). No physical binding.

Paper Type

Format Description:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, SOHC, two-valve single-cylinder

Displacement:

651 cc (39.7 cu in)

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

9.5:1

Performance

Horsepower Est:

Approx. 40-45 HP @ 6500 RPM (figures vary slightly by market and specific tuning)

Torque Est:

Approx. 45-50 Nm (33-37 lb-ft) @ 5500 RPM

Fuel System

Fuel Delivery:

Fuel Injection (EFI)

Throttle Body Size:

40 mm

Ignition:

Digital CDI

Spark Plug Type:

NGK CR9EIA-9 (Iridium IX)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Clutch Type:

Wet multi-disc, manual

Features

Final Drive:

Sealed chain

Transmission Oil Spec:

API GL-4, SAE 80W-90 (manual specifies Kawasaki Genuine Gear Oil or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 2,275 mm (89.6 in)

Width:

Approx. 905 mm (35.6 in)

Height:

Approx. 1,465 mm (57.7 in)

Wheelbase:

Approx. 1,465 mm (57.7 in)

Weights

Curb Weight:

Approx. 192 kg (423 lbs) (fully fueled, with oil and coolant)

Fuel Capacity:

18 Liters (4.7 US gal)

Ground Clearance:

Approx. 210 mm (8.3 in)

🛡️ Safety Features

Ratings

ABS Availability:

Not standard; typically not available on this model year range for KL650

Active Features

Braking System Type:

Hydraulic disc brakes front and rear

Front Brake Spec:

260 mm petal disc

Rear Brake Spec:

240 mm petal disc

Passive Features

Lighting:

Halogen headlight, LED taillight

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, clock, fuel gauge, and warning lights.

Driver Assistance

ABS System:

ABS was not a standard or commonly offered option for the KL650 during these model years.

Connectivity

Charging Ports:

Not typically equipped with factory USB or 12V power outlets; aftermarket options are common.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 6,000 km (3,700 miles) or 6 months, at each oil change.

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or 6 months. Replace if damaged.

Spark Plug Inspection:

Every 6,000 km (3,700 miles) or 6 months. Replace as needed.

Chain Adjustment:

Every 1,000 km (600 miles). Check for wear and tension.

Brake Fluid Replacement:

Every 12,000 km (7,500 miles) or 12 months, whichever comes first. Bleed system during replacement.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher, conforming to JASO MA specification.

Engine Oil Capacity:

2.2 L (2.3 US qt) without filter change; 2.4 L (2.5 US qt) with filter change.

Coolant Type:

Permanent type antifreeze coolant mixed with distilled water (50:50 ratio).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, valve stem seals (potential oil consumption at higher mileage), fork seals.

Efi System Notes:

While EFI generally improves reliability, potential issues might involve sensor malfunctions (e.g., TPS, MAP) or fuel pump issues if not properly maintained.

Charging System:

The regulator/rectifier can be a point of failure on some Kawasaki models; regular voltage checks are recommended.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries, Ltd. has a long-standing reputation for producing high-performance and durable motorcycles across various segments.

Model Evolution

Kl650 Lineage:

The KL650 platform, particularly the KLR650 variant, has a significant history dating back to the late 1980s, known for its continuous refinement and unwavering appeal as a go-anywhere dual-sport machine.

Second Generation Update:

The 2008 model year marked a significant update (KL650E generation), introducing fuel injection (EFI) which replaced the previous carburetor system, along with revised bodywork, suspension tuning, and other enhancements for improved performance and emissions compliance.

Production

Manufacturing Location:

Typically manufactured in Japan (Hyogo Prefecture) by Kawasaki Heavy Industries.

🏆 Awards & Recognition

Recognitions

Model Reputation:

Consistently recognized for its durability, value for money, and versatility in the dual-sport segment. Often lauded in adventure motorcycling communities for its ability to cover long distances and various terrains reliably.