Kawasaki KLX 650 R 1987-2007 Workshop Service Manual

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This manual covers the KLX 650 R, a versatile dual-sport motorcycle produced from 1987 to 2007. Renowned for its robust engineering and reliability, the KLX 650 R is designed for...

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Taper: Motorcycle

Distributeur:

UGS: 84796

Mots clés: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Kawasaki KLX 650 R KLX Series Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the KLX 650 R, a versatile dual-sport motorcycle produced from 1987 to 2007. Renowned for its robust engineering and reliability, the KLX 650 R is designed for both on-road commuting and off-road adventures. Its durable liquid-cooled, 4-stroke, single-cylinder engine, coupled with a 5-speed transmission and chain drive, provides dependable performance across a variety of terrains. The model's extended production run signifies its enduring popularity and capability, reflecting a legacy in producing capable off-road and dual-sport machines. This comprehensive Workshop Service Manual provides detailed instructions for the maintenance, repair, and overhaul of the KLX 650 R. It covers all major systems, including the engine, transmission, fuel system, ignition, brakes, and suspension. The manual includes routine maintenance procedures, diagnostic guides for common issues, and step-by-step repair instructions for component disassembly and reassembly. Essential technical specifications, troubleshooting advice, and safety precautions, including the proper use of tools and equipment, are also detailed. This resource is intended for mechanical technicians and knowledgeable owners seeking to perform professional-quality service.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX 650 R

Vehicle Type:

Dual-sport Motorcycle

Generation

Production Years Covered By Manual:

1987-2007

Codes

Chassis Code Range:

Not specified in provided information, but typically includes variations like KL650A, KL650B for different configurations.

👋 Introduction

Market Position

Target Audience:

Mechanical technicians and knowledgeable motorcycle owners undertaking maintenance and repair.

Competitive Analysis

Manual Advantage:

Provides detailed, OEM-level information enabling professional-quality service and cost savings for DIY repairs.

Key Features

Information Reliability:

Cited as the most reliable information, mirroring authorized dealer service department procedures.

Safety Emphasis:

Highlights the importance of safety equipment and precautions, including the use of a torque wrench.

Document Structure:

Emphasizes important information through WARNING, CAUTION, and NOTE notations.

📋 Manual Details

Coverage Areas

Engine Systems:

Engine overhaul, tune-ups, lubrication system, fuel system, ignition system, exhaust system.

Transmission Systems:

Transmission disassembly and assembly, clutch operation.

Chassis Systems:

Frame, suspension (front and rear), wheels, tires, brakes (front and rear), steering.

Electrical Systems:

Electrical system diagnostics, wiring diagrams, lighting, charging system, ignition.

Bodywork And Accessories:

Body panel removal and installation, fairings, seat, fuel tank, fenders.

Page Count

Estimated Page Count:

Not explicitly stated, but comprehensive workshop manuals typically range from 300-800+ pages depending on the depth of coverage.

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

Delivery Method:

PDF Download (Electronic Delivery via Email)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine repair and overhaul, including top-end and bottom-end procedures. Covers all internal components, timing, and sealing.

Transmission:

Detailed procedures for gearbox removal, disassembly, inspection, repair, and reassembly. Includes gear shift mechanism.

Fuel System:

Carburetor (likely Keihin CVK type for the era) inspection, cleaning, adjustment, and overhaul. Fuel tank and petcock service.

Ignition System:

Ignition timing, spark plug specifications, CDI unit, coil testing, and troubleshooting.

Suspension:

Front fork (telescopic) service, seal replacement, oil level and type, rear shock absorber adjustments and service.

Brakes:

Front and rear brake system servicing, including hydraulic brake fluid replacement, caliper disassembly, pad replacement, and disc inspection.

Electrical:

Comprehensive electrical troubleshooting, wiring diagrams, lighting system (headlight, taillight, indicators), battery maintenance, charging system (stator, regulator/rectifier).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks, air filter cleaning/replacement, brake fluid checks, tire pressure checks.

Diagnostics:

Troubleshooting guides for common problems across all major systems, including engine performance issues, electrical faults, and brake problems.

Repair And Overhaul:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for virtually every part of the motorcycle.

Tune Ups:

Specific procedures for optimizing engine performance, including carburetor adjustments, ignition timing verification, and valve clearance checks.

Special Tools:

Identification and usage instructions for specialized tools required for specific maintenance and repair tasks.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis component overhauls.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printable:

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, single-cylinder (typically a 651cc or similar displacement, though exact spec not provided here).

Bore X Stroke:

Specifics not provided, but typical for this era and displacement.

Compression Ratio:

Specifics not provided, but typically around 9.5:1 to 10.5:1.

Performance

Horsepower:

Estimated 47-50 HP at peak RPM, specific figures not provided.

Torque:

Estimated 37-40 lb-ft at peak RPM, specific figures not provided.

Fuel System

Carburetor Type:

Likely a single Keihin CVK (Constant Velocity Carburetor), with specifications for jetting and settings detailed in the manual.

Fuel Capacity:

Typically around 3.7 gallons (14 liters), but specific to model variations.

Lubrication System

Oil Type Capacity:

Manual will specify recommended oil grade (e.g., SAE 10W-40 motorcycle oil) and capacity. Likely around 2.5-3.0 quarts (2.4-2.8 liters) with filter change.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Transmission Options:

Features

Clutch Type:

Wet multi-disc

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2260 mm (89.0 in), may vary slightly by year.

Overall Width:

Approx. 830 mm (32.7 in), may vary slightly by year.

Overall Height:

Approx. 1195 mm (47.0 in), may vary slightly by year.

Weights

Dry Weight:

Approx. 169 kg (373 lbs), may vary slightly by year.

Curb Weight:

Not explicitly provided, but significantly higher than dry weight.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety ratings are typically not comparable to automotive crash tests).

Active Features

Braking System:

Front: Disc brake, Rear: Disc brake. Manual details proper maintenance and bleeding procedures.

Suspension Stability:

Adjustable front forks and rear shock absorber for optimal handling and stability in off-road conditions.

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals. Manual covers bulb replacement and electrical troubleshooting.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Focus is on mechanical and electrical systems, not typical automotive infotainment).

Driver Assistance

Assistance Features:

N/A (This is a motorcycle from an era predating significant rider assistance technologies).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-6,000 miles (5,000-10,000 km) or annually, with specific guidance in the manual.

Valve Adjustment Interval:

Generally around 10,000-15,000 miles (16,000-24,000 km), but crucial to follow manual's recommended intervals.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment every 500-1000 miles (800-1600 km).

Fluid Specifications

Engine Oil Grade:

Manual will specify: likely SAE 10W-40 or 20W-50 motorcycle-specific oil meeting JASO MA standards.

Fork Oil Type Viscosity:

Manual will specify: typically a light-weight fork oil like SAE 5W or 10W.

Brake Fluid Type:

Manual will specify: typically DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, fork seals, chain and sprockets, wheel bearings, brake pads.

Carburetor Issues:

Can be prone to gumming if fuel is left sitting for extended periods; requires regular cleaning and adjustment.

Engine Longevity:

Generally robust single-cylinder engines, with proper maintenance contributing significantly to longevity.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing robust and capable off-road and dual-sport motorcycles.

Model Evolution

Klx Lineage:

The KLX designation signifies Kawasaki's line of off-road and dual-sport machines, known for their versatility and durability.

Production

Manufacturing Location:

Likely Japan, though specific plant not detailed.

Production Run Length:

The manual covers a significant 21-year production run, indicating a consistently popular and well-regarded model.

🏆 Awards & Recognition

Recognitions

Model Recognition:

While specific awards for the 1987-2007 KLX 650 R are not detailed, the model's extended production run suggests consistent market approval and rider satisfaction for its class.