🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Code:

KL650-A

Generation:

First Generation (A-Series)

Production Years:

1987-2002

👋 Introduction

Market Segment:

Dual-sport motorcycle, known for its reliability, versatility, and long-distance touring capability.

Competitors:

Honda Transalp, Suzuki DR650, Yamaha XT600 (though the KLR650 distinguished itself with its robust build and utilitarian design).

Key Features:

Durable single-cylinder engine, large fuel tank, long-travel suspension, robust chassis, comfortable ergonomics for rider and passenger.

📋 Manual Details

Coverage Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

Page Count:

130

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine:

Engine disassembly, assembly, inspection, repair, troubleshooting, engine specifications, internal components

Fuel System:

Carburetor (Mikuni BS40), fuel tank, fuel pump, fuel lines, fuel filter

Ignition System:

CDI ignition system, spark plugs, ignition timing, electrical components

Transmission:

Clutch operation, transmission gear inspection and repair, shift mechanism, transmission lubrication

Cooling System:

Liquid cooling system, radiator, water pump, thermostat, coolant specifications

Exhaust System:

Exhaust pipe, muffler, exhaust gasket replacement

Suspension:

Front fork (telescopic, conventional), rear shock absorber (monoshock), suspension adjustments, fork oil specifications and replacement

Brakes:

Front disc brake, rear disc brake, brake fluid specifications, brake pad replacement, caliper overhaul, brake line inspection

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), wiring diagrams, fuses, relays

Frame And Bodywork:

Frame inspection, fairings, body panels, seat, fuel tank removal and installation, handlebars, footpegs

Wheels And Tires:

Wheel bearing inspection, tire replacement, wheel balancing, spoke tensioning

Controls:

Throttle control, clutch lever, brake levers, shifter operation

Procedures:

Routine maintenance, periodic inspections, troubleshooting guide, component removal and installation, disassembly and assembly procedures, adjustments, repairs, diagnostics

Depth Of Coverage:

Comprehensive step-by-step procedures with pictorial diagrams, exploded views, and detailed explanations for all repair interventions.

Diagnostic Information:

Includes troubleshooting sections, diagnostic data, checking procedures, and service specifications.

Special Tools:

Reference to special service tool numbers and illustrations of tools in use.

Specifications:

Detailed service data, tightening torques, wear limits, and allowable tolerances.

📊 Manual Specifications

File Type:

PDF

Printability:

Printable pages

Resolution:

High-resolution, suitable for clear printing and viewing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Software Requirement:

Adobe Reader

Operating Systems:

Windows, Mac, Linux OS

⚙️ Engine Specifications

Engine Type:

4-stroke, DOHC, 4-valve, Single Cylinder, Liquid-Cooled

Displacement:

651 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

9.5:1

Horsepower:

Approx. 40-45 HP (at crankshaft, varies slightly by year and specific tune)

Torque:

Approx. 38-40 lb-ft (at crankshaft, varies slightly by year)

Carburetor:

Mikuni BS40 (constant velocity, single).

Fuel Tank Capacity:

6.1 US gal / 23 L

Oil Capacity With Filter Change:

2.5 US qt / 2.4 L

Engine Oil Type:

SAE 10W-40 API SE, SF, or SG with Energy Conserving designation.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc, manual

Final Drive:

O-ring sealed chain

📐 Dimensions

Overall Length:

88.2 in / 2240 mm

Overall Width:

35.4 in / 900 mm

Overall Height:

52.2 in / 1325 mm

Dry Weight:

Approx. 364 lbs / 165 kg

Wet Weight:

Approx. 401 lbs / 182 kg (fully fueled)

Wheelbase:

58.7 in / 1490 mm

Ground Clearance:

10.4 in / 265 mm

Seat Height:

35.0 in / 890 mm

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety is typically assessed by independent agencies and crash test data is not as standardized as for cars).

Active Safety:

Strong braking system, stable chassis, large fuel tank for extended range.

Passive Safety:

Robust frame construction, integrated bodywork offering some rider protection.

💡 Technology Features

Infotainment Features:

N/A (This era of motorcycle did not feature advanced infotainment systems. Focus is on mechanical and electrical function).

Driver Assistance Features:

N/A (No electronic rider aids were standard on this model).

Connectivity Options:

N/A (No digital connectivity features).

🔧 Maintenance

Oil And Filter Change:

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

Air Filter Cleaning:

Every 3,700 miles (6,000 km), replace if damaged.

Spark Plug Inspection And Replacement:

Inspect every 7,500 miles (12,000 km), replace as needed.

Valve Clearance Check:

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

Brake Fluid Change:

Every 2 years or as needed, depending on usage and conditions.

Coolant Type:

High-quality ethylene glycol-based antifreeze coolant mixed with distilled water (50/50 ratio recommended).

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues:

Some models may experience doohickey failure (cam chain tensioner lever), potential for oil consumption with high mileage, and occasional issues with the starter solenoid. The manual would detail inspection and repair for these.

📚 Vehicle History

Kawasaki Heritage:

Kawasaki Heavy Industries has a long history of producing reliable and performance-oriented motorcycles, including legendary models like the Ninja and Z series.

Klr650 Evolution:

The KLR650 was introduced in 1987 as a successor to the KLR600. It was designed to be a more capable and versatile dual-sport machine, offering improved comfort and range. The first generation (A-series) remained largely unchanged in its core design and engine for its entire production run, a testament to its effective engineering.

Production Period:

1987-2002 (First Generation/A-Series)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Industry Recognition:

While not typically receiving 'awards' in the automotive sense, the KLR650 is widely recognized within the motorcycling community for its exceptional durability, value, and go-anywhere capability. It's a long-standing favorite for adventure touring and commuting.