Vehicle Market Segment:
Dual-sport / Adventure-Touring motorcycle, known for its reliability, affordability, and go-anywhere capability.
Key Competitors 2009:
Suzuki DR650, Honda XR650L, BMW G 650 GS
Vehicle Key Selling Points:
Robust single-cylinder engine, long-travel suspension, durable construction, fuel efficiency, versatility for both on-road and off-road use.
Manual Benefit To Owner:
Empowers owners to perform routine maintenance, diagnose issues, and undertake repairs, saving on dealership costs and enhancing understanding of their motorcycle's mechanics.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor, fuel pump), ignition system, exhaust system
Drivetrain Systems:
Clutch operation, transmission overhaul, gearshift mechanism, final drive (chain and sprockets)
Chassis Systems:
Frame inspection, suspension (front forks, rear shock), steering system, wheels and tires, braking system (front and rear calipers, master cylinders, hydraulic lines)
Electrical Systems:
Wiring diagrams, lighting system, starting system, charging system (stator, regulator/rectifier), battery maintenance, instrumentation, sensors
Bodywork And Trim:
Fairings, body panels, seat, fuel tank, luggage rack, ergonomics
Maintenance Procedures:
Scheduled maintenance (oil changes, filter replacements, valve adjustments, spark plug replacement), lubrication points, chain maintenance, brake fluid flush, coolant flush
Troubleshooting Guides:
Diagnostic charts for common problems, symptoms, and remedies across all major systems
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul of engine, transmission, suspension, brakes, and electrical components
Technical Specifications And Data:
Torque specifications, clearances, fluid capacities, electrical resistance values, compression test procedures, ignition timing
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds, including detailed troubleshooting and electrical diagnostics.
Digital Format Details:
Searchable PDF, high-resolution diagrams, printable pages
Print Quality Details:
Professionally printed, durable paper stock, clear and legible diagrams
Binding Type Details:
Spiral-bound or perfect-bound for lay-flat usability in a workshop environment
Paper Type Details:
Heavyweight, semi-gloss paper stock to resist grease and dirt
Engine Displacement:
651 cc (39.7 cu in)
Engine Bore X Stroke:
100.0 x 83.0 mm (3.94 x 3.27 in)
Engine Compression Ratio:
9.5:1
Engine Valve Train:
DOHC, 4 valves per cylinder
Engine Horsepower Est:
Approx. 46 hp @ 6,500 rpm (variant dependent)
Engine Torque Est:
Approx. 39 lb-ft @ 5,000 rpm (variant dependent)
Fuel Delivery System:
Keihin CVK-40 carburetor (specific model year configurations may vary)
Fuel Tank Capacity:
18 Liters (4.7 US gal)
Cooling Method:
Liquid-cooled
Safety Ratings:
Motorcycles are not typically assigned standardized crash test ratings like automobiles. Safety depends on rider skill and adherence to maintenance.
Braking System Type:
Front: 280mm petal disc; Rear: 240mm petal disc. Optional ABS available on some global variants.
Lighting System:
Halogen headlight, LED taillight, incandescent turn signals
Instrumentation Type:
Analog tachometer, digital speedometer, odometer, trip meters, clock, coolant temperature gauge, indicator lights.
ABS Availability:
Optional ABS was available on certain models/markets for this year. The manual will cover procedures for both ABS and non-ABS systems if applicable to the covered variants.
Connectivity Features:
N/A for this model year (motorcycle technology focused on core mechanical and electrical systems).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Valve Adjustment Interval:
Every 12,000 km (7,500 miles)
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles) or more frequently in dusty conditions.
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil
Engine Oil Capacity W Filter:
3.0 L (3.2 US qt)
Coolant Type:
Ethylene glycol-based, permanent type antifreeze for motorcycles (e.g., Kawasaki Motorcycle Coolant or equivalent)
Common Klr650 Issues 2008-2009:
Stator failure (rectifier/regulator can be a symptom or cause), potential for oil consumption on higher mileage units, carburetion adjustments for altitude/temperature, subframe fatigue (under heavy load/abuse).
Kawasaki Motorcycle Division Heritage:
Kawasaki Heavy Industries Motorcycle & Engine company has a long history of producing robust and reliable motorcycles across various segments since the mid-20th century, with a strong reputation for engineering prowess.
Klr650 Generations:
The KLR650 platform, first introduced in 1987, is renowned for its longevity and incremental updates. The 2009 model represents a refined version of this established dual-sport legend, featuring a larger fuel tank, improved ergonomics, and updated suspension components compared to earlier generations.
Manufacturing Origin:
Japan (primary production facility, though assembly may occur elsewhere for regional markets).
