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Kawasaki KLR650 1987-1995 Workshop Service Manual for Repair

$16.99
$16.99
🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Variant: Dual-Sport Motorcycle Generation Generation Designation: First Generation Codes Chassis Code Range: KL650-A1 through KL650-A10 👋 Introduction Market Position Category: Adventure...
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Taper: Motorcycle
Distributeur:
Kawasaki
UGS: 450970
Mots clés: 1987 1988 1989 1990 1991 1992 1993 1994 1995 Kawasaki KLR Series KLR650 Motorcycle Motorcycles
Kawasaki KLR650 1987-1995 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLR650
Model Variant:
Dual-Sport Motorcycle
Generation
Generation Designation:
First Generation
Codes
Chassis Code Range:
KL650-A1 through KL650-A10
👋 Introduction
Market Position
Category:
Adventure Touring / Dual-Sport Motorcycle
Target Audience:
Owners, DIY mechanics, professional motorcycle technicians
Competitive Analysis
Competitors Era:
Honda Transalp, Suzuki DR650, Yamaha Tenere (contemporary competitors in the dual-sport segment)
Key Features
Manual Strength:
Comprehensive coverage, detailed diagrams, step-by-step procedures, diagnostic information
Download Benefit:
Instant access, no shipping costs, immediate usability
📋 Manual Details
Coverage Areas
Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Page Count
Total Pages:
130
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, troubleshooting, tuning, specifications
Fuel System:
Carburetor (Mikuni BS40), fuel pump, fuel tank, fuel lines, troubleshooting, cleaning, adjustment
Transmission:
Gearbox disassembly, assembly, inspection, lubrication, shifting mechanism
Clutch:
Clutch plate replacement, pressure plate, springs, operation, adjustment
Drivetrain:
Chain and sprocket inspection, adjustment, replacement, rear shock linkage lubrication
Suspension Front:
Fork disassembly, assembly, oil change, seal replacement, spring inspection, adjustments
Suspension Rear:
Monoshock (Uni-Trak) inspection, adjustment, linkage lubrication, bearing inspection
Brakes Front:
Hydraulic disc brake system, caliper, master cylinder, pad replacement, fluid flush, bleeding, rotor inspection
Brakes Rear:
Drum brake system, shoe inspection, adjustment, replacement
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, troubleshooting
Cooling System:
Radiator, hoses, thermostat, fan operation, coolant specifications, bleeding
Frame And Bodywork:
Frame inspection, fairing removal/installation, seat, fuel tank mounting, fenders, luggage rack system
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, adjustments
Troubleshooting:
Systematic fault diagnosis, common issues, diagnostic flowcharts
Repair:
Step-by-step instructions for component repair and replacement
Disassembly Assembly:
Complete breakdown and reassembly procedures for all major components
Adjustments:
Carburetor synchronization, valve clearance, chain tension, brake adjustments, clutch lever free play
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds)
Detail Level:
Detailed step-by-step procedures with explanatory text and diagrams
Illustrations:
Pictorial diagrams, exploded views, detailed drawings, and photos
Special Tools:
Identification and usage of specific service tools required for certain operations
Torque Specifications:
Comprehensive list of torque values for fasteners across all systems
Wear Limits:
Specifications for component wear limits to ensure proper function and longevity
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Implied by PDF format, but not explicitly stated as text-searchable.
Print Quality
Printable:
Yes
Print Resolution:
Assumed to be standard for PDF, suitable for home/workshop printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
Windows, Mac, Linux OS
Software Requirement:
Adobe Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
651 cc
Bore X Stroke:
100.0 x 83.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Approx:
Approx. 46 HP @ 6,000 RPM (varied slightly by year/tuning)
Torque Approx:
Approx. 53 Nm @ 5,000 RPM
Fuel System
Carburetor:
Mikuni BS40 (Constant Velocity)
Fuel Delivery:
Mechanical Fuel Pump
Cooling System
Cooling Method:
Liquid-cooled (radiator and fan)
Ignition
Ignition System:
Digital CDI with electronic advance
Lubrication
Lubrication System:
Forced lubrication (wet sump)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Optional Transmissions:
N/A (Single standard transmission)
Features
Clutch Type:
Wet multi-disc
Final Drive:
Sealed O-ring chain
📐 Dimensions
Exterior
Overall Length:
Approx. 2,230 mm (91.7 in)
Overall Width:
Approx. 860 mm (33.9 in)
Overall Height:
Approx. 1,370 mm (53.9 in)
Wheelbase:
Approx. 1,480 mm (58.3 in)
Ground Clearance:
Approx. 220 mm (8.7 in)
Weights
Dry Weight:
Approx. 163 kg (359 lbs)
Wet Weight Approx:
Approx. 175 kg (386 lbs)
Fuel Capacity:
23 Liters (6.1 US gal)
Oil Capacity With Filter:
3.0 L (3.2 US qt)
🛡️ Safety Features
Ratings
Safety Features Era:
Reflective elements on tires and bodywork, basic lighting systems. ABS and advanced rider aids not standard for this era.
Active Features
Active Safety Systems:
Effective braking systems (disc front, drum rear), stable chassis design, good ground clearance for varied terrain.
Passive Features
Passive Safety Features:
Robust frame construction, rider ergonomics designed for control.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals, typically every 3,000-5,000 km (1,800-3,000 miles) or annually.
Valve Clearance Interval:
Refer to manual, usually at 6,000-12,000 km (3,700-7,500 miles) or as specified.
Chain Tension Check:
Regularly, e.g., every 1,000 km (600 miles) or as part of pre-ride checks.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 (refer to manual for ambient temperature recommendations)
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based) with sufficient water (50/50 mix recommended)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch plates, front fork seals, brake pads, rear shock bushings, carburetor diaphragms (age-related degradation).
Typical Problems:
Potential for valve seat recession (less common in later versions), carburetor issues if not maintained, electrical connections can corrode over time, countershaft seal leaks.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long history in motorcycle racing and production, known for performance and reliability.
Model Evolution
Klr650 Lineage:
The KLR650 line is renowned for its longevity and consistent design philosophy, emphasizing ruggedness and versatility. The 1987-1995 models represent the foundational generation of this highly successful platform.
Production
Production Period:
The first generation KLR650 (KL650-A) was produced from 1987 through 2007, with minor updates throughout its run.
🏆 Awards & Recognition
Recognitions
Model Reputation:
The KLR650 is widely recognized for its durability, go-anywhere capability, and affordability, making it a popular choice for adventure touring and commuting.
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