Segment:
Dual-sport / Adventure motorcycle
Target Audience:
Riders seeking a reliable, affordable, and versatile motorcycle for commuting, touring, and light off-road use.
Key Competitors Era:
Honda NX650 Dominator, Suzuki DR650S, Yamaha XT600.
Design Philosophy:
Rugged, simple, and dependable. Focus on utility and longevity over outright performance.
Adventure Capability:
Long-travel suspension, upright riding position, and robust construction for varied terrain.
Engine:
Complete engine disassembly, assembly, tuning, troubleshooting, and component specifications.
Fuel System:
Carburetor service, adjustment, fuel tank, fuel pump, and fuel lines.
Ignition System:
CDI ignition, spark plugs, ignition coils, wiring diagrams.
Transmission:
Clutch operation, gearbox disassembly and assembly, gear shift mechanism, lubrication.
Drivetrain:
Final drive chain and sprockets, adjustment, and replacement.
Suspension:
Front fork service (oil changes, seal replacement), rear shock absorber adjustment and removal, linkage maintenance.
Brakes:
Front and rear brake systems, caliper service, master cylinder overhaul, brake pad replacement, hydraulic system bleeding.
Electrical System:
Battery, charging system (stator, rectifier/regulator), lighting system, starter motor, horn, wiring diagrams for all circuits.
Frame And Bodywork:
Chassis components, handlebars, seat, fuel tank removal and installation, body panel repairs and fitment.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid checks, valve clearance adjustments.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Repair:
Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension repairs, electrical component replacement, etc.
Disassembly Assembly:
Comprehensive instructions for removing and reinstalling all major components.
Specifications:
Torque values, clearances, fluid capacities, electrical resistance, etc.
Depth:
Comprehensive, covering from basic owner maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
File Type:
Likely PDF for digital versions.
Searchable:
Typically PDF manuals are searchable, allowing quick access to specific topics.
Image Resolution:
Expect clear line drawings and diagrams, with photographic quality varying depending on the source.
Binding:
For physical copies: Often a comb or spiral binding for lay-flat usability, or stitched/perfect bound.
Paper Quality:
For physical copies: Typically on durable, matte paper suitable for workshop environments.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4-valve
Displacement:
651 cc (651 cubic centimeters)
Bore X Stroke:
100.0 mm x 83.0 mm
Cooling System:
Liquid-cooled
Starting System:
Electric starter
Horsepower:
Approximately 47 HP @ 6500 RPM (claimed, may vary)
Torque:
Approximately 53 Nm (39 lb-ft) @ 5000 RPM (claimed, may vary)
Carburetor Type:
Mikuni BSR32 CV (Constant Velocity)
Fuel Tank Capacity:
17 Liters (approx. 4.5 US gallons)
Oil Capacity:
1.7 Liters (when filter changed)
Recommended Oil Viscosity:
SAE 10W-40 API SG or higher
Safety Standards:
Manufactured to meet relevant national and international motorcycle safety standards for its era.
Braking System:
Front: Dual-piston caliper, 250mm disc. Rear: Single-piston caliper, 203mm disc.
Lighting:
Halogen headlight, LED taillight (common upgrade), turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame for rigidity and durability.
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 4,000 km (2,500 miles).
Spark Plug Replacement:
Every 8,000 km (5,000 miles).
Valve Clearance Check:
Every 8,000 km (5,000 miles).
Chain Adjustment:
Every 2,000 km (1,250 miles), or more frequently if subjected to hard use.
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Type:
Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water).
Doohickey Failure:
The balancer lever ('doohickey') spring can break. A common and recommended preventative upgrade involves replacing it with a hardened aftermarket part and ensuring proper installation.
Countershaft Seal Leaks:
The countershaft seal can sometimes leak. This is a relatively straightforward repair covered in the manual.
Cam Chain Tensioner:
Early models could sometimes have issues with the automatic cam chain tensioner. Manual inspection and adjustment procedures are detailed.
Kawasaki Motorcycles:
Kawasaki Heavy Industries is a long-standing Japanese manufacturer known for a wide range of motorcycles, from sportbikes to cruisers and off-road models.
Klr650 Lineage:
The KLR650 platform, introduced in 1987, has been remarkably consistent, known for its robustness and adaptability. The A-series represents the initial generation.
A4 Designation:
The 'A4' designation typically refers to the fourth major revision or model year of the original KLR650 'A' series. Subtle improvements in suspension, ergonomics, or engine tuning may have been implemented over these early years.
Manufacturing Location:
Primarily manufactured in Japan.
Production Period:
The KLR650 A-series was produced from 1987 through the late 1990s before evolving into later generations (B, C, E, F, G).
