🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Year:

2009

Model Generation:

Second Generation (KL650E)

Chassis Code:

KL650E9F

Engine Code:

KL650AE

👋 Introduction

Motorcycle Segment:

Dual-sport / Adventure touring motorcycle, known for its ruggedness, reliability, and affordability.

Key Competitors:

Honda XR650L, Suzuki DR650SE, Yamaha XT660R (though XT660R was less prevalent in some markets).

Model Strengths:

Versatility for both on-road commuting and off-road exploration, robust single-cylinder engine, long-travel suspension, large fuel tank capacity, low seat height for its class, and a reputation for durability.

📋 Manual Details

General Coverage:

Comprehensive service and repair information for the Kawasaki KLR650 (2009 model year).

Page Count:

Approx. 500+

Manual Type:

Factory Service Manual (FSM)

Language:

English

Format:

Digital (PDF)

Searchability:

Yes, text is searchable.

Illustration Quality:

High-quality, clear line drawings and diagrams.

📖 Manual Coverage

Engine And Drivetrain:

Engine disassembly, assembly, diagnosis, maintenance, internal components, cooling system, lubrication system, ignition system, starting system, fuel system (carburetor, fuel pump, fuel lines), exhaust system, clutch, transmission, final drive (chain).

Chassis And Suspension:

Frame, front fork assembly (disassembly, rebuild, seals, oil), rear suspension (shock absorber, linkage, bearings), swingarm, steering system, wheel and tire maintenance, spoke tensioning.

Brakes And Controls:

Front and rear brake systems (hydraulic lines, calipers, master cylinders, pads, rotors), brake bleeding procedures, control cables (throttle, clutch), levers, footpegs, handlebars.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), ignition coil, starter motor, fuses, relays, switches, instruments, diagnostic codes.

Bodywork And Fittings:

Fairing removal and installation, seat, fuel tank, fenders, luggage racks, mirrors, instrument panel cover, side covers.

Maintenance Procedures:

Routine checks, oil changes, filter replacements, chain adjustment and lubrication, brake pad inspection, tire pressure checks, coolant level checks, spark plug replacement, air filter cleaning/replacement.

Repair Procedures:

Engine rebuilds, transmission overhauls, carburetor tuning and rebuilding, suspension fork seal replacement, wheel bearing replacement, electrical troubleshooting and component replacement, brake system overhauls.

Troubleshooting Guides:

Systematic diagnostic procedures for common performance issues, starting problems, electrical faults, and other malfunctions, often presented with flowcharts or symptom-based solutions.

Specifications And Data:

Includes detailed technical specifications, torque values, clearances, electrical resistance values, diagnostic flowcharts, and component specifications crucial for accurate repair and maintenance.

Depth Of Coverage:

Highly detailed, covering from basic maintenance to full engine and chassis overhauls. Includes torque specifications, clearances, diagnostic values, and step-by-step illustrated instructions.

Rebuild Procedures:

Provides complete step-by-step instructions for engine internal component replacement, transmission gear inspection and replacement, and full carburetor disassembly and reassembly.

📊 Manual Specifications

File Format Details:

Searchable PDF, allowing for quick navigation and text extraction. High-resolution scans ensure readability of diagrams and text.

Print Quality:

N/A (Digital Format)

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, SOHC, four-valve single-cylinder.

Engine Displacement:

651 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

8.3:1

Horsepower Peak:

Approx. 37 hp @ 6000 rpm (Note: Varies slightly by market and tuning).

Torque Peak:

Approx. 39 lb-ft @ 4500 rpm (Note: Varies slightly by market and tuning).

Fuel Delivery:

Mikuni BSR32 CV-type carburetor.

Fuel Type Recommendation:

Unleaded gasoline, minimum octane rating of 87 AKI (Anti-Knock Index).

Coolant Type:

Kawasaki motorcycle coolant or equivalent ethylene glycol-based antifreeze, 50/50 mix with distilled water.

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.

Oil Capacity With Filter:

3.0 US qt (2.8 L)

Oil Filter Part Number:

Kawasaki 16097-0002 (or aftermarket equivalent like K&N KN-111, HiFlofiltro HF111).

🔧 Transmission

Transmission Type:

Constant-mesh 5-speed sequential.

Clutch Type:

Wet, multiple-disc, cable-actuated.

Final Drive Type:

Sealed chain (520 O-ring sealed).

Transmission Oil Type:

Gear oil (not shared with engine oil), typically SAE 80W-90 API GL-4 or GL-5, or dedicated motorcycle transmission fluid.

📐 Dimensions

Overall Length:

2,295 mm (90.4 in)

Overall Width:

910 mm (35.8 in)

Overall Height:

1,365 mm (53.7 in) (with windshield)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

220 mm (8.7 in)

Seat Height:

855 mm (33.7 in)

Curb Weight:

194 kg (428 lbs)

Fuel Capacity:

18 L (4.7 US gal)

Cargo Capacity:

Integrated rear luggage rack with generous tie-down points.

🛡️ Safety Features

Crash Test Ratings:

Not applicable for motorcycles in standard automotive ratings.

Braking System:

Front: Hydraulic disc, Rear: Hydraulic disc. (Note: ABS was not a standard or widely available option for the 2009 KLR650).

Lighting:

Halogen headlight, LED taillight, incandescent turn signals.

Frame Construction:

Semi-double cradle, high-tensile steel for durability and chassis stiffness.

Tire Specification:

Front: 90/90-21, Rear: 130/80-17 (Tubed tires common).

💡 Technology Features

Infotainment System:

N/A (Basic analog gauges: speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light).

ABS Availability:

ABS was not a standard feature on the 2009 model. It became an option on later model years.

Connectivity Features:

N/A (No Bluetooth, USB ports, or smartphone integration).

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Chain Adjustment Interval:

Every 1,000 km (600 miles) or more frequently if subjected to heavy off-road use.

Spark Plug Inspection Interval:

Every 12,000 km (7,500 miles).

Valve Clearance Inspection Interval:

Every 24,000 km (15,000 miles).

Fork Oil Type:

Showas suspension fluid SS-8 or SAE 10W fork oil.

Fork Oil Quantity:

462 ml (15.6 US oz) per fork leg.

Common Wear Items:

Cam chain tensioner (risk of failure leading to engine damage, often replaced with aftermarket manual units), exhaust pipe corrosion (especially header), stator output degradation over time, rear wheel bearings.

Carburetor Quirks:

The BSR32 CV carburetor can be sensitive to altitude changes and may require rejetting for optimal performance in different conditions. It's also known for potential wear on the slide diaphragm.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki has a long history of producing robust and reliable motorcycles, particularly in the dual-sport segment. The KLR lineage itself dates back to the mid-1980s.

Klr650 Generations:

The 2009 model represents the second generation (KL650E), which was a significant update from the first generation (KL650A). Key improvements included a larger fuel tank, improved suspension, and revised bodywork, though the fundamental engine and chassis architecture remained similar.

Manufacturing Location:

Primarily manufactured in Japan. Some later models or variants may have had assembly in other regions.

🏆 Awards & Recognition

Industry Accolades:

Consistently recognized for its value, reliability, and capability as an entry-level to mid-level adventure motorcycle. Often praised in reviews for its 'bang for the buck' factor.

Owner Satisfaction:

Generally high owner satisfaction, particularly for its durability and low cost of ownership compared to more complex adventure bikes.