Segment:
Mid-size dual-sport motorcycle
Target Audience:
Owners, mechanics, and enthusiasts seeking in-depth maintenance and repair information
Competitors Era:
Honda XR series, Yamaha XT series, Suzuki DR series
Versatility:
Designed for both on-road and off-road riding, contributing to its dual-sport classification
Durability:
Known for robust construction and reliability, making it a popular choice for adventure and commuting.
Engine:
Complete overhaul, top-end, bottom-end, valve adjustment, timing, lubrication, cooling system
Fuel System:
Carburetor (cleaning, adjustment, rebuilding, jetting, mixture screw, pilot jet, main jet), fuel tank, fuel pump, fuel lines
Drivetrain:
Clutch operation and adjustment, transmission gears, shift mechanism, primary reduction gear, drive shaft
Suspension:
Front forks (oil change, seal replacement, spring replacement), rear shock absorber, linkage, swingarm
Brakes:
Front and rear brake system inspection, maintenance, caliper overhaul, pad replacement, fluid flush, hydraulic system troubleshooting
Electrical System:
Ignition system (spark plug, coil, magneto), charging system (stator, rectifier, battery), lighting system, starter motor, switches
Bodywork And Frame:
Frame inspection, plastic panel removal and installation, fenders, seat, handlebars, triple tree
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication points, tire pressure checks
Troubleshooting:
Diagnosing common problems (no spark, starting issues, poor performance), error code interpretation (if applicable to the era, though EFI not typical for 84-86 KLR600)
Repair:
Complete tear-down and rebuild procedures for all major components, component-specific repair instructions
Installation:
Instructions for installing specific parts or accessories (though primary focus is on factory configuration)
Depth:
Comprehensive (from basic maintenance to full engine rebuild)
Visual Aids:
Includes pictures and part diagrams
Data Tables:
Includes torque specifications, fluid specifications, and general data
Type:
Four-stroke, single-cylinder, DOHC
Displacement:
564 cc (34.4 cubic inches)
Bore X Stroke:
90.0 mm x 44.0 mm (3.54 in x 1.73 in)
Horsepower Estimate:
Approximately 38-40 hp (at crank, estimates vary by source)
Torque Estimate:
Approximately 32-34 lb-ft (at crank, estimates vary by source)
Carburetor:
Keihin CVK36 (Constant Velocity Carburetor)
Fuel Type:
Unleaded gasoline
Cooling Method:
Liquid-cooled
Length Overall:
Approximately 2225 mm (87.6 in)
Width Overall:
Approximately 845 mm (33.3 in)
Height Overall:
Approximately 1235 mm (48.6 in)
Dry Weight:
Approximately 151 kg (333 lbs)
Wet Weight:
Approximately 170 kg (375 lbs)
Front Tire Size:
3.00-21 4PR
Rear Tire Size:
4.60-17 4PR
Front Wheel Size:
21 inch
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first
Air Filter Cleaning:
Every 1,500 km (930 miles) or 3 months
Valve Clearance Check:
Every 6,000 km (3,730 miles) or 12 months
Spark Plug Replacement:
Every 6,000 km (3,730 miles) or 12 months
Engine Oil Type:
API SE, SF, SG or SH; SAE 10W-40 (recommended)
Engine Oil Capacity:
2.0 L (2.1 US qt) without filter change; 2.2 L (2.3 US qt) with filter change
Coolant Type:
Permanent type antifreeze (ethylene glycol based) mixed with distilled water, 50/50 ratio
Coolant Capacity:
Approximately 1.8 L (1.9 US qt)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Idling:
Can sometimes develop an unstable idle or require frequent adjustment due to wear on the throttle shaft or mixture screw.
Stator Reliability:
While generally reliable, stators can fail over time, impacting charging system performance.
Fork Seals:
Fork seal leaks are common with age and use, requiring periodic replacement.
