🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Code:

KL650-A14

Year:

2000

👋 Introduction

Positioning:

The Kawasaki KLR650 is a renowned dual-sport motorcycle, celebrated for its ruggedness, reliability, and versatility in both on-road and off-road conditions. It occupies a niche for adventure touring and commuting riders seeking a go-anywhere capability.

Competitors:

Competes with models like the Suzuki DR650, Honda XR650L, and Yamaha XT600/XT660 series in the middleweight dual-sport segment.

Key Features:

Durable single-cylinder engine, long-travel suspension, comfortable ergonomics, substantial fuel range, and robust construction.

📋 Manual Details

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Specifications

Page Count:

Estimated 300-400 pages (typical for this era's comprehensive service manuals)

Manual Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Likely a printed manual, but may be available as a PDF scan.

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the engine and its components.

Fuel System:

Carburetor tuning, cleaning, repair, fuel pump, fuel lines, and tank maintenance.

Ignition System:

Ignition timing, spark plugs, CDI unit, ignition coils, and troubleshooting.

Cooling System:

Radiator, coolant flow, thermostat, fan operation, and coolant specifications.

Exhaust System:

Muffler, exhaust pipes, and catalytic converter (if applicable) inspection and maintenance.

Transmission:

Clutch operation, gearbox disassembly, inspection, repair, and lubrication.

Drivetrain:

Final drive chain and sprockets inspection, adjustment, and replacement.

Chassis Frame:

Frame integrity, steering head bearings, and general chassis inspection.

Suspension Front:

Fork seals, oil levels, spring rates, damping adjustments, and overhaul.

Suspension Rear:

Shock absorber adjustment, linkage maintenance, and bearing inspection.

Brakes Front:

Brake caliper service, pad replacement, rotor inspection, and brake fluid.

Brakes Rear:

Brake caliper service, pad replacement, rotor inspection, and brake fluid.

Wheels Tires:

Wheel bearing service, tire pressure, and mounting.

Electrical System:

Battery, charging system (stator, regulator/rectifier), lighting, horn, and starter motor.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all systems.

Bodywork Fairings:

Removal, installation, and repair of body panels and fairings.

Scheduled Maintenance:

Detailed schedules for oil changes, filter replacements, chain adjustments, and valve checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon faults.

Engine Rebuild:

Complete step-by-step instructions for engine overhauls.

Suspension Overhaul:

Detailed guides for fork and shock absorber servicing.

Brake System Service:

Bleeding procedures, caliper rebuild, and master cylinder service.

Carburetor Cleaning And Synchronization:

Detailed steps for optimizing fuel mixture and delivery.

Electrical Component Testing:

Testing procedures for stator, regulator/rectifier, CDI, and other electrical parts.

Depth:

Comprehensive, covering basic maintenance to full engine and component rebuilds.

📊 Manual Specifications

File Format:

PDF (if scanned), Printed Paper

Print Quality:

High-resolution images and clear text for ease of understanding.

Binding Type:

Likely Saddle-stitched or perfect bound for printed manuals.

Paper Type:

Durable, possibly gloss or semi-gloss paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, single-cylinder, liquid-cooled

Displacement:

651 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

9.5:1

Horsepower:

Approx. 42 hp @ 6,500 rpm (claimed)

Torque:

Approx. 39 lb-ft @ 5,500 rpm (claimed)

Carburetor:

36mm Mikuni BSR36 (CV type) with an accelerator pump

Fuel Tank Capacity:

18 Liters (4.7 US gal)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed sequential

Clutch Type:

Wet, multiple disc, cable operated

Gear Ratios:

Detailed ratios provided in manual (e.g., 1st: 2.500, 2nd: 1.556, 3rd: 1.238, 4th: 1.000, 5th: 0.857)

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Overall Length:

2,240 mm (88.2 in)

Overall Width:

890 mm (35.0 in)

Overall Height:

1,395 mm (54.9 in)

Wheelbase:

1,470 mm (57.9 in)

Ground Clearance:

220 mm (8.7 in)

Seat Height:

890 mm (35.0 in)

Dry Weight:

170 kg (375 lbs)

Curb Weight:

193 kg (425 lbs) (estimated)

🛡️ Safety Features

Crash Safety:

Motorcycles of this era did not undergo standardized crash testing in the same way cars do. Safety features are focused on mechanical integrity and rider control.

Braking System:

Dual piston front caliper with 230mm disc, single piston rear caliper with 230mm disc.

Lighting:

Halogen headlight, LED taillight (typical for the time).

Frame Construction:

High-tensile steel semi-double cradle frame for rigidity and durability.

💡 Technology Features

Infotainment System:

Not applicable for this model year; analog gauges (speedometer, tachometer, odometer, trip meter) and indicator lights.

🔧 Maintenance

Oil Change Interval:

Every 3,000-4,000 miles (4,800-6,400 km) or 6 months.

Valve Check Interval:

Every 7,500-9,500 miles (12,000-15,000 km).

Chain Adjustment:

Check and adjust every 1,500-2,000 miles (2,400-3,200 km).

Engine Oil Type:

API SG, SF, SE, CC or CD classification, SAE 10W-40 viscosity recommended for general use. Refer to manual for temperature-specific recommendations.

Engine Oil Capacity:

3.1 L (3.3 US qt) with filter change; 2.7 L (2.9 US qt) without filter change.

Coolant Type:

Permanent type ethylene glycol antifreeze and distilled water mixture (50:50 ratio).

Brake Fluid Type:

DOT 3 or DOT 4.

Common Issues:

Potential for oil consumption at higher mileage, doohickey failure on the balancer chain tensioner (a common aftermarket upgrade), potential for cam chain rattle if not maintained.

📚 Vehicle History

Kawasaki History:

Kawasaki Heavy Industries, Motorcycle and Engine division, has a long history of producing reliable and performance-oriented motorcycles across various segments.

Klr650 Evolution:

The KLR650 platform, introduced in 1987, is known for its longevity and incremental updates. The 2000 model represents the A-series generation, which was largely unchanged for many years due to its proven design. Significant updates occurred in later generations (e.g., D-series in 2008).

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Industry Recognition:

While not a recipient of specific awards, the KLR650 is widely recognized and respected in the adventure and dual-sport community for its enduring capability and value.