Market Segment:
Dual-sport motorcycle, targeting riders for off-road adventure and street versatility.
Competitors 1993:
Honda XR650L, Suzuki DR650S, Yamaha XT600E.
Model Identity:
Known for its robust single-cylinder engine, capable suspension, and reliable performance in a variety of conditions.
Manual Value Proposition:
Provides essential information for owners and mechanics to maintain, troubleshoot, and repair the KLX650, extending its lifespan and ensuring optimal performance.
Engine:
Complete engine disassembly, assembly, inspection, and repair procedures for the 651cc single-cylinder, liquid-cooled engine.
Transmission:
Clutch, gearbox, shift mechanism, and final drive (chain) inspection and repair.
Fuel System:
Carburetor (Keihin CVK34) disassembly, cleaning, adjustment, and troubleshooting; fuel tank and lines.
Ignition System:
CDI ignition system, spark plug, ignition coil, and stator testing and replacement.
Cooling System:
Radiator, fan, water pump, hoses, and thermostat inspection and maintenance.
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator), lighting, starter motor, and electrical component testing.
Suspension Front:
Front fork (telescopic, cartridge type) disassembly, oil change, seal replacement, and adjustment procedures.
Suspension Rear:
Uni-Trak rear suspension system, shock absorber, linkage, and swingarm inspection and service.
Brakes Front:
Front disc brake system: caliper, master cylinder, brake lines, and pad replacement and bleeding procedures.
Brakes Rear:
Rear disc brake system: caliper, master cylinder, brake lines, and pad replacement and bleeding procedures.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, and fairing procedures.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug checks.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Engine Rebuild:
Complete engine overhaul, including piston, rings, cylinder, valve train, and crankshaft service.
Suspension Rebuild:
Front fork seal replacement, fork oil changes, rear shock absorber servicing.
Carburetor Tuning:
Detailed instructions for carburetor cleaning, synchronization (if applicable), and jetting adjustments.
Brake Service:
Brake pad replacement, caliper overhaul, master cylinder replacement, and bleeding procedures.
Electrical Diagnostics:
Testing of charging system, ignition system components, and troubleshooting of wiring harness issues.
Wheel And Tire Service:
Tire pressure checks, spoke tensioning, wheel bearing inspection, and rim maintenance.
Depth:
Comprehensive, covering all aspects from basic adjustments to complete engine and chassis overhauls.
Engine Type:
Four-stroke, single-cylinder, DOHC, liquid-cooled
Displacement:
651 cc (39.7 cu in)
Bore X Stroke:
100.0 mm x 82.0 mm (3.94 in x 3.23 in)
Valve Train:
DOHC, 4 valves
Horsepower Estimated:
Approx. 45-50 HP @ 6,500 RPM (Manufacturer data may vary)
Torque Estimated:
Approx. 45-50 lb-ft @ 5,000 RPM (Manufacturer data may vary)
Carburetor Model:
Keihin CVK34
Fuel Capacity:
12.0 L (3.17 US gal)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil
Engine Oil Capacity With Filter:
2.0 L (2.1 US qt)
Engine Oil Capacity Without Filter:
1.8 L (1.9 US qt)
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
With every oil change.
Air Filter Cleaning:
Every 2,000 km (1,250 miles) or more frequently in dusty conditions.
Spark Plug Check:
Every 4,000 km (2,500 miles).
Chain Maintenance Interval:
Lubricate and adjust chain every 1,000 km (600 miles).
Valve Clearance Check:
Every 8,000 km (5,000 miles).
Fork Oil Change Interval:
Recommended every 2 years or 20,000 km (12,500 miles).
Coolant Type:
Permanent type antifreeze, mix 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, carburetor diaphragms can be wear items requiring periodic replacement.
Potential Electrical:
Age-related electrical connector corrosion or starter solenoid issues can sometimes occur.
Carburetor Performance:
Carburetor can become gummed up if the bike sits for extended periods without fuel stabilizer, requiring cleaning.
