Vehicle Segment:
Dual-sport motorcycle, known for its versatility and ruggedness.
Key Competitors:
BMW F650GS (earlier models), Honda Transalp, Suzuki DR650.
Vehicle Purpose:
Adventure touring, commuting, light off-road capability.
Manual Benefit:
Empowers owners and technicians to perform comprehensive maintenance and repairs, extending the lifespan and performance of the KLR650.
Engine Service:
Complete engine disassembly, assembly, inspection, tuning, and component replacement.
Fuel System Service:
Carburetor (Keihin CVK40) overhaul, adjustment, fuel pump, fuel tank, and lines.
Transmission Service:
Clutch operation, gearbox disassembly, inspection, and reassembly, shift drum and forks.
Drivetrain Service:
Final drive chain maintenance, adjustment, and sprocket replacement.
Suspension Service:
Front fork (conventional telescopic) and rear shock absorber (linkage type) service, adjustment, and component replacement.
Braking System Service:
Front and rear disc brake caliper service, hydraulic lines, master cylinders, and pad replacement.
Electrical System Service:
Ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, battery, and wiring diagrams.
Cooling System Service:
Radiator, cooling fan, water pump, thermostat, and coolant specifications.
Chassis And Frame Service:
Frame inspection, steering head bearing service, and general chassis components.
Bodywork And Fittings Service:
Fairing removal, installation, instrument panel, and seat assembly.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake checks.
Troubleshooting Guides:
Diagnostic charts for common running problems, starting issues, and electrical faults.
Component Rebuilds:
Detailed step-by-step instructions for overhauling engine, transmission, and suspension components.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Wiring Diagrams:
Comprehensive electrical schematics for the entire motorcycle.
Diagnostic Capabilities:
Advanced diagnostic procedures, symptom analysis, and fault finding for mechanical and electrical issues.
Repair Procedures:
Detailed, illustrated procedures for repairs ranging from minor adjustments to major component overhauls.
Part Identification:
Clear identification of all major components and sub-assemblies.
Engine Type:
4-stroke, DOHC, 4-valve, single-cylinder
Bore X Stroke:
100.0 x 83.0 mm
Cooling System:
Liquid-cooled
Horsepower Approx:
39.5 HP @ 6000 rpm (rear wheel estimate)
Torque Approx:
39.1 lb-ft @ 4500 rpm (rear wheel estimate)
Carburetor Type:
Keihin CVK40, constant velocity carburetor with diaphragm
Fuel Capacity:
6.1 US gal (23 L)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, clock, coolant temperature gauge, and indicator lights.
ABS:
Available as an option on some 2012 KLR650 models.
Usb Charging:
Not factory standard; aftermarket integration possible.
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months
Oil Filter Change:
With every oil change
Spark Plug Inspection:
Every 7,500 miles (12,000 km)
Valve Clearance Check:
Every 15,000 miles (24,000 km)
Engine Oil Type:
API SG or SH, SAE 10W-40, SE or SF or SG classified petroleum product
Engine Oil Capacity:
2.0 US qt (1.9 L) at oil change, 2.3 US qt (2.2 L) after filter replacement
Coolant Type:
Kawasaki All Season Motorcycle Coolant (or equivalent ethylene glycol-based coolant with distilled water, 50:50 mix)
Common Wear Items:
Clutch plates, drive chain and sprockets, fork seals, valve stem seals, voltage regulator (in earlier models).
Doohickey Failure:
The balancer shaft lever (commonly called 'doohickey') can fail, leading to noise and potential engine damage. Regular inspection and replacement with an improved aftermarket unit is recommended by many owners.
