🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Code:

A1/A2 (depending on region, typically refers to generation)

Years Covered:

2008, 2009, 2010, 2011, 2012

Vehicle Type:

Dual-sport Motorcycle

👋 Introduction

Vehicle Segment:

Adventure Touring / Dual-Sport

Key Selling Points:

Reliability, versatility for both on-road and off-road use, affordability, strong aftermarket support.

Primary Competitors:

BMW F650GS (pre-2008), Suzuki V-Strom 650, Honda Transalp (earlier models).

Versatility:

Designed for commuting, touring, and light off-road excursions.

Durability:

Known for its robust construction and longevity.

Fuel Capacity:

Large fuel tank providing extended range.

📋 Manual Details

Manual Type:

Workshop Service Manual (WSM)

Language:

English

Format:

PDF Download

Manual Completeness:

Full Professional Quality, In-Depth

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, inspection, and repair of all internal components (pistons, rings, cylinders, crankshaft, connecting rods, camshaft, valves, valve train).

Engine Fuel System:

Carburetor (CVK40) tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank maintenance.

Engine Cooling System:

Radiator, cooling fan, coolant flow, thermostat, and related components.

Engine Ignition System:

CDI unit, ignition coil, spark plug specifications, timing, and troubleshooting.

Engine Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable), and emissions control.

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, shifting mechanism, final drive (chain and sprockets).

Chassis Frame:

Frame inspection, steering head bearing service, and general chassis integrity.

Suspension Front:

Front fork disassembly, seal replacement, oil levels and type, spring rates, and damping adjustments.

Suspension Rear:

Rear shock absorber servicing, linkage inspection, and swingarm maintenance.

Braking System Front:

Front brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul, disc inspection.

Braking System Rear:

Rear brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul, disc inspection.

Electrical System Lighting:

Headlight, taillight, turn signals, brake lights, and accessory lighting.

Electrical System Instruments:

Speedometer, tachometer, odometer, indicator lights, and dashboard assembly.

Electrical System Charging:

Alternator, stator, rectifier/regulator, battery specifications, and charging system testing.

Electrical System Starting:

Starter motor, starter solenoid, and battery testing.

Electrical System Wiring Harness:

Wiring diagrams, component identification, troubleshooting electrical faults.

Bodywork Fairings:

Fairing removal and installation, plastic component repair, body panel alignment.

Wheels Tires:

Wheel bearing service, tire pressure specifications, wheel balancing, spoke tensioning (if applicable).

Scheduled Maintenance:

Detailed procedures for routine checks and servicing at specified intervals (oil changes, filter replacements, chain lubrication, brake checks).

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon mechanical and electrical issues.

Disassembly Reassembly:

Step-by-step instructions for removing, overhauling, and reinstalling major components and systems.

Adjustments:

Procedures for adjusting clutch, throttle cables, idle speed, valve clearances, and chain slack.

Specifications Torque:

Comprehensive list of torque specifications for all critical fasteners and bolts.

Component Testing:

Instructions for testing the functionality of electrical components like the stator, rectifier, and starter.

Diagnostic Capabilities:

Advanced diagnostic routines, including electrical system testing and carburetor tuning.

Repair Depth:

Covers everything from basic fluid changes to full engine and transmission rebuilds.

Special Tools:

Identifies any specialized tools required for specific procedures.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (typically, dependent on scan quality)

Printable:

Yes

Image Resolution:

High Resolution (professional quality)

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, DOHC, four-valve

Displacement:

652 cc

Bore X Stroke:

100.0 x 83.0 mm

Compression Ratio:

8.8:1

Horsepower:

Approx. 47 hp @ 6,000 rpm (specifications may vary slightly by region)

Torque:

Approx. 41.7 lb-ft @ 4,500 rpm (specifications may vary slightly by region)

Fuel Delivery:

Carburetor: Keihin CVK40

Fuel Type:

Unleaded gasoline

Oil Type:

SAE 10W-40 API SG or SH, SE, SF classification

Oil Capacity With Filter Change:

3.4 US qt (3.2 L)

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh

Final Drive:

Sealed chain

Clutch Type:

Wet, multi-disc

📐 Dimensions

Overall Length:

89.6 in (2,275 mm)

Overall Width:

34.3 in (870 mm)

Overall Height:

52.0 in (1,320 mm)

Wheelbase:

59.3 in (1,505 mm)

Ground Clearance:

9.3 in (235 mm)

Seat Height:

34.0 in (865 mm)

Curb Weight:

440.9 lb (200 kg) (approximate, varies with equipment)

Fuel Tank Capacity:

6.1 US gal (23 L)

🛡️ Safety Features

Crash Test Data:

N/A for motorcycles in traditional automotive sense. Manual covers safe operating procedures.

Braking System:

Dual hydraulic disc brakes (front), Single hydraulic disc brake (rear).

Lighting:

Halogen headlight, LED taillight.

Frame Construction:

High-tensile steel semi-double cradle frame designed for stability.

💡 Technology Features

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, clock, and indicator lights.

ABS:

Not available on this model year.

Charging Port:

Not typically factory-equipped; aftermarket options exist.

🔧 Maintenance

Engine Oil Change:

Every 4,000 miles (6,000 km) or 6 months.

Oil Filter Replacement:

Every 4,000 miles (6,000 km) or 6 months.

Air Filter Cleaning Replacement:

Clean every 4,000 miles (6,000 km), replace as needed.

Spark Plug Inspection Replacement:

Inspect every 8,000 miles (12,000 km), replace as needed.

Valve Clearance Check:

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

Chain Lubrication Adjustment:

Lubricate every 600 miles (1,000 km), check tension every 1,200 miles (2,000 km).

Coolant:

Permanent type radiator coolant (50% solution with distilled water).

Brake Fluid:

DOT 4

Fork Oil:

SAE 10W (refer to manual for exact type and quantity).

Water Pump Seal:

Some models may experience leaks from the water pump seal over time, often due to wear or seal degradation.

Doohickey Failure:

The balancer shaft tensioner ('doohickey') can be a point of failure on some earlier KLR models; though less common on this generation, it's a known area for inspection and potential upgrade.

Carburetor Jetting:

Depending on modifications (e.g., aftermarket exhaust), the carburetor may require re-jetting for optimal performance.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles.

Klr650 Lineage:

The KLR650 has been in continuous production since 1987, making it one of the longest-running motorcycle models. This generation (2008-2012) received significant updates, including a larger fuel tank, improved fairing for better wind protection, and a slightly revised engine for increased torque.

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Longevity Award:

The KLR650 platform is often recognized for its remarkable longevity and reliability, contributing to its enduring popularity.

Adventure Magazine Reviews:

Consistently praised in adventure riding publications for its value and capability in its class.