Market Position:
The Kawasaki KLR650 has long been established as a reliable and versatile dual-sport motorcycle, appealing to a broad spectrum of riders from commuters to adventure touring enthusiasts. Its robust construction and manageable power delivery have made it a popular choice for both new and experienced riders seeking a go-anywhere capability without the complexity of larger adventure bikes.
Competitive Analysis:
In 1990, the KLR650 competed in a segment with models like the Honda Transalp, Suzuki DR650, and Yamaha Tenere. The KLR650 distinguished itself with its balance of on-road civility and off-road prowess, often being praised for its affordability and long-term reliability compared to some European counterparts. This service manual provides the essential documentation for owners to maintain and repair this enduring platform.
Key Features:
The 1990 KLR650 (KL650-A4) is characterized by its liquid-cooled, single-cylinder engine, robust steel tube frame, long-travel suspension, and substantial fuel tank, enabling extended range. Its distinctive fairing offers wind protection, and its upright riding position contributes to rider comfort on varied terrain. This manual addresses the specific engineering of this model year.
Coverage Areas:
Complete service, repair, maintenance, troubleshooting, diagnostics, electrical systems, engine, transmission, chassis, bodywork, fuel system, cooling system, exhaust system, suspension, brakes, wheels, tires, and more.
Page Count:
Approximately 400+
Manual Type:
Factory Service Manual / Repair Manual
Systems Covered:
Engine disassembly and assembly, carburetor tuning and repair, ignition system diagnostics, cooling system maintenance, lubrication system service, transmission operation and repair, clutch service, braking system overhaul, suspension fork and shock absorber service, electrical wiring diagrams, lighting system repair, chassis and frame inspection, fuel tank and petcock service, exhaust system inspection and replacement, wheel and tire maintenance, and general tune-up procedures.
Procedures Included:
Step-by-step repair instructions, detailed troubleshooting guides for common and uncommon faults, diagnostic procedures for electrical and mechanical systems, routine maintenance schedules and procedures, torque specifications for all fasteners, internal engine component specifications, carburetor adjustment procedures, valve clearance checks and adjustments, clutch adjustment and replacement, brake bleeding procedures, suspension setup and repair, and wiring harness repair.
Technical Depth:
Comprehensive from basic maintenance and troubleshooting to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics. Includes detailed exploded views and diagrams for all major components.
File Format:
Searchable PDF with high-resolution diagrams and text.
Print Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type:
Digital (N/A for physical binding, but designed for easy navigation).
Paper Type:
Digital (N/A for physical paper type).
Engine Type:
Liquid-cooled, four-stroke, single-cylinder, DOHC, 4 valves
Bore X Stroke:
100.0 mm x 83.0 mm
Horsepower Est:
Approx. 40-45 HP @ 6,000 RPM (claimed)
Torque Est:
Approx. 40-45 lb-ft @ 5,000 RPM (claimed)
Fuel Delivery:
Carburetor (likely dual Keihin CVK32)
Fuel Type:
Unleaded gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled
Overall Length:
Approx. 87.6 inches (2225 mm)
Overall Width:
Approx. 33.1 inches (840 mm)
Overall Height:
Approx. 51.2 inches (1300 mm)
Wheelbase:
Approx. 57.7 inches (1465 mm)
Dry Weight:
Approx. 368 lbs (167 kg)
Wet Weight:
Approx. 403 lbs (183 kg)
Fuel Capacity:
6.1 US gallons (23 liters)
Front Tire Size:
80/90-21 M/C 48S
Rear Tire Size:
130/80-17 M/C 65S
Front Suspension Travel:
8.7 inches (220 mm)
Rear Suspension Travel:
7.3 inches (185 mm)
Safety Ratings:
N/A (Motorcycle safety ratings not standardized like cars; relies on rider skill and component integrity addressed in the manual).
Active Features:
Disc brakes front and rear, effective suspension system for stability.
Passive Features:
Robust frame construction, protective fairing for rider wind deflection.
Infotainment Features:
Basic analog instrument cluster (speedometer, tachometer, odometer, trip meter, coolant temperature gauge, neutral indicator, turn signal indicators).
Driver Assistance Features:
None (standard for motorcycles of this era).
Connectivity Features:
None (standard for motorcycles of this era).
Lighting System:
Halogen headlight, incandescent taillight and turn signals.
Oil Change Interval:
Every 3,000-4,000 miles or 6 months, whichever comes first (refer to manual for exact recommendation).
Air Filter Cleaning:
Every 3,000-6,000 miles, depending on riding conditions.
Valve Clearance Check:
Every 7,500-10,000 miles (critical for engine health).
Spark Plug Replacement:
Every 7,500-10,000 miles.
Engine Oil Type:
API SE, SF, or SG classification, SAE 10W-40 motorcycle oil recommended (check manual for specific viscosity and JASO MA rating).
Coolant Type:
Permanent type ethylene glycol based antifreeze (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation).
Transmission Oil Capacity:
Approx. 2.0 L (1.9 US qt) when disassembled, 1.7 L (1.8 US qt) for normal change (verify in manual).
Known Issues:
Oil consumption can increase with mileage, potential for cam chain tensioner noise, starter clutch wear, carburetor jetting sometimes requires adjustment for altitude or modifications, and general wear and tear on suspension components and bearings over time. The manual provides troubleshooting for these common wear items.
Common Tasks Covered:
Oil and filter changes, chain adjustment and lubrication, tire pressure checks, brake pad inspection and replacement, coolant checks, spark plug replacement, air filter cleaning/replacement, carburetor cleaning and adjustment, battery maintenance, and general bolt torque checks.
Brand Heritage:
Kawasaki Heavy Industries has a long-standing reputation for building durable and performance-oriented motorcycles across various segments, from sportbikes to cruisers and dual-purpose machines. The KLR series is a testament to their commitment to versatile and reliable transportation.
Model Evolution:
The KLR650 platform was introduced in 1987 and underwent significant revisions over its lifespan. The KL650-A4 represents an early iteration of this highly successful model, establishing the core attributes that would define the KLR650 for decades. Subsequent generations introduced fuel injection, revised suspension, and aesthetic updates.
Production Span For Model Code:
The KL650-A chassis code generally covers the early generation KLR650s from their introduction through the early 1990s, with the 'A4' designating the fourth model year of production (1990).
Recognitions:
While specific awards for the 1990 model may not be widely documented, the KLR650 platform as a whole has been consistently recognized for its durability, value, and versatility in numerous motorcycle publications and owner surveys throughout its production run.
Owner Satisfaction Ratings:
Generally high owner satisfaction due to its reliability and low cost of ownership, as documented by various motorcycle enthusiast forums and long-term reviews.
