Market Position:
The Kawasaki KLR600 was a popular dual-sport motorcycle, known for its ruggedness, versatility for on-road and light off-road use, and reliability, making it a favorite for adventure touring and commuting.
Competitors:
Competed with other dual-sport motorcycles of its era such as the Honda XR600L, Yamaha XT600, and Suzuki DR600/650.
Key Features:
Single-cylinder engine, long-travel suspension, durable construction, often featured a large fuel tank for extended range, capable of handling varied terrain.
Systems Covered:
Engine Mechanical, Fuel System, Ignition System, Lubrication System, Cooling System, Transmission, Clutch, Drivetrain, Suspension, Wheels, Tires, Brakes, Frame, Bodywork, Electrical System, Troubleshooting, Periodic Maintenance, Specifications
Estimated Page Count:
Approximately 250-350 pages (typical for this era and model complexity)
Manual Type:
Service Repair Manual
Format:
Digital (PDF, likely)
Engine System Coverage:
Detailed overhaul procedures, component testing, timing adjustments, valve clearance, piston and cylinder inspection, crankshaft and connecting rod diagnostics.
Fuel System Coverage:
Carburetor (e.g., Keihin CVK) disassembly, cleaning, adjustment, jetting information, fuel pump and line inspection.
Ignition System Coverage:
CDI unit testing, spark plug specifications, timing marks, troubleshooting ignition failures.
Transmission Coverage:
Clutch operation, gear inspection, shifting mechanism, transmission fluid type and capacity, disassembly and reassembly of gearbox components.
Electrical System Coverage:
Wiring diagrams, component testing (stator, rectifier, battery), lighting system, starter motor, horn, troubleshooting electrical faults.
Frame And Bodywork Coverage:
Information on frame inspection, removal and installation of body panels, seat, fuel tank, and fenders, as well as fork and shock disassembly/reassembly procedures.
Maintenance Procedures:
Oil changes, filter replacement, air filter cleaning, chain adjustment, brake pad replacement, cable lubrication, battery maintenance, general inspection.
Repair Procedures:
Engine rebuild, carburetor overhaul, suspension fork seal replacement, brake caliper servicing, wheel bearing replacement, electrical component repair.
Troubleshooting Procedures:
Diagnostic charts for common problems (e.g., hard starting, poor performance, electrical issues), step-by-step fault finding.
Diagnostic Procedures:
Includes detailed troubleshooting guides and flowcharts to identify and resolve various mechanical, electrical, and fuel system issues.
Technical Depth:
Comprehensive; covers routine maintenance to full engine and chassis overhauls, including detailed diagnostic procedures and specifications.
Print Quality:
High-resolution scans, clear diagrams and text (typical for reputable digital manuals).
Binding Type:
N/A (Digital)
Paper Type:
N/A (Digital)
Text Searchability:
Likely searchable (if OCR processed), allowing quick access to specific information.
Manual Completeness:
Likely a complete factory service manual, covering all aspects of maintenance, repair, and troubleshooting for the KLR600 model.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
564cc (actual displacement may vary slightly by specific model year/variant)
Bore X Stroke:
92.0 mm x 84.0 mm (typical)
Compression Ratio:
9.2:1 (typical)
Horsepower:
Approximately 40-45 HP @ 6500-7000 RPM (manufacturer estimates varied)
Torque:
Approximately 45-50 Nm @ 5000-5500 RPM (manufacturer estimates varied)
Carburetor Type:
Keihin CVK32 (typical)
Fuel Capacity:
16 Liters (5.5 US gallons, typical)
Cooling Method:
Liquid-cooled
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific gear ratios detailed in manual (e.g., 1st: 2.642, 2nd: 1.750, 3rd: 1.333, 4th: 1.090, 5th: 0.958, 6th: 0.852 - illustrative, requires manual verification)
Transmission Fluid Type:
API GL-1 SAE 10W-30 or SAE 10W-40 motorcycle gear oil (refer to manual for exact specification)
Length:
2235 mm (typical)
Height:
1270 mm (typical)
Wheelbase:
1450 mm (typical)
Dry Weight:
Approximately 156 kg (344 lbs) (typical)
Curb Weight:
Approximately 174 kg (384 lbs) (typical, with fluids)
Front Suspension Type:
Telescopic fork, spring-loaded, oil-damped
Front Suspension Travel:
230 mm (9.1 inches, typical)
Rear Suspension Type:
Uni-Trak, gas-oil shock, adjustable preload and rebound damping
Rear Suspension Travel:
205 mm (8.1 inches, typical)
Front Tire Size:
80/90-21 48P (typical)
Rear Tire Size:
110/80-18 58P (typical)
Wheel Type:
Spoked wheels
Oil Change Interval:
Every 3,000-5,000 km or annually (refer to manual for precise recommendation based on usage).
Air Filter Cleaning Interval:
Every 2,000-4,000 km or as needed based on conditions.
Valve Clearance Check Interval:
Every 10,000-15,000 km (typical interval, consult manual).
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA (refer to manual for exact specification).
Engine Oil Capacity:
Approximately 2.6 liters (with filter change) (verify in manual).
Coolant Type:
Permanent type ethylene glycol based coolant, 50/50 mix with distilled water.
Coolant Capacity:
Approximately 1.5 liters (verify in manual).
Common Issues:
Carburetor jetting sensitivity to altitude/temperature, potential starter clutch wear, some vibration at higher RPMs, rear shock absorber aging, occasional cam chain tensioner noise.
Preventative Maintenance Focus:
Regular chain maintenance (cleaning and lubrication), carburetor cleaning and synchronization, checking for oil leaks, keeping the air filter clean.
Brand Heritage:
Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and performance-oriented motorcycles, including many successful off-road and dual-sport models.
Model Evolution:
The KLR600 was introduced in the early 1980s as an evolution of Kawasaki's off-road lineage, designed to offer a more practical and versatile package for everyday use and light adventure touring. It was succeeded by the more advanced KLR650.
Production Years:
Approximately 1983-1989 (specific year range may vary by market).
Manufacturing Locations:
Japan
