Category:
Adventure Touring / Dual-Sport Motorcycle
Target Audience:
Owners, mechanics, DIY enthusiasts seeking detailed repair information
Competitors Of Vehicle:
Honda Transalp, Suzuki DR650, Yamaha XT600 (contemporary competitors in the dual-sport segment)
Comprehensiveness:
Highly comprehensive, 'bumper to bumper' coverage
Clarity:
Simple, easy-to-read explanations, suitable for novice mechanics
Visual Aids:
Detailed illustrations, exploded diagrams, drawings, and photos
Accessibility:
Instant download for immediate access
Applicable Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Type:
Workshop Service Manual / Repair Manual
Delivery Method:
Instant Download
Engine:
Full engine disassembly, assembly, inspection, repair, and adjustments
Fuel System:
Carburetor tuning, cleaning, rebuilding, fuel tank, lines, and petcock
Ignition System:
CDI, spark plugs, ignition timing, stator, and coils
Transmission:
Clutch operation, gearbox disassembly, assembly, inspection, and maintenance
Cooling System:
Liquid cooling system maintenance, radiator, hoses, water pump, and thermostat
Exhaust System:
Muffler, header pipes, and emission controls
Frame And Body:
Frame inspection, fairings, seat, fuel tank, and body panel removal/installation
Suspension:
Front forks (disassembly, seal replacement, oil levels), rear shock absorber, linkage, and adjustments
Brakes:
Front and rear brake systems, caliper service, pad replacement, fluid bleeding, master cylinders
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter motor, switches
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, spoke tensioning
Controls:
Throttle, clutch, and brake lever adjustments, cable maintenance
Cooling Fan:
Fan operation, motor, and thermostatic switch
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment
Troubleshooting:
Diagnosis of common problems, fault finding, electrical system troubleshooting
Repair:
Step-by-step repair procedures for all major components and systems
Disassembly Assembly:
Detailed instructions for removing and reinstalling parts and assemblies
Adjustments:
Carburetor synchronization, valve clearance adjustments, brake lever free play
Special Tools:
Identification and usage of required special service tools
Depth:
Comprehensive, covering from basic checks to complete engine rebuilds
Detail Level:
Detailed step-by-step explanations, pictorial diagrams, and exploded views
Diagnostic Information:
Included, with specifications and testing procedures
Factory Specifications:
Includes service specifications, tightening torques, and allowable limits
Engine Type:
4-stroke, Single-cylinder, Liquid-cooled, DOHC
Displacement:
464 cc (Approximate, based on KLR lineage)
Bore X Stroke:
Specific values not provided, but typical for this class
Compression Ratio:
Specific values not provided
Horsepower:
Estimated 30-35 HP (typical for this engine size and era)
Torque:
Estimated 25-30 lb-ft (typical for this engine size and era)
Carburetor:
Single Mikuni carburetor (likely CV type, specific model not stated but common for KLR)
Fuel Type:
Unleaded gasoline
Oil Capacity:
Specific values require consultation within the manual
Oil Type:
As specified in the manual (likely SAE 10W-40 or 20W-50 motorcycle specific oil)
Overall Length:
Specific dimensions not provided, typical for dual-sport
Overall Width:
Specific dimensions not provided, typical for dual-sport
Overall Height:
Specific dimensions not provided, typical for dual-sport
Dry Weight:
Approximate 160-170 kg (350-375 lbs) - Varies by year/spec
Wet Weight:
Specific values not provided, will be higher than dry weight
Fuel Capacity:
Approximate 17-18 Liters (4.5-4.8 Gallons)
Front Suspension Travel:
Approximate 230 mm (9.1 inches)
Rear Suspension Travel:
Approximate 220 mm (8.7 inches)
Crash Test Ratings:
N/A (Motorcycle specific safety is paramountly based on rider skill and equipment)
Braking System:
Disc brakes front and rear (dual piston front, single piston rear typical)
Tires:
Dual-purpose (on-road/off-road) tires
Lighting:
Headlight, tail light, brake light, turn signals
Manual Emphasis:
Manual provides DANGER, CAUTION, and NOTE remarks for safe operation and service
Oil Change Interval:
Refer to manual's periodic maintenance chart (typically 3,000-6,000 km or 2,000-4,000 miles)
Valve Clearance Check:
Refer to manual's periodic maintenance chart (typically every 6,000-12,000 km or 4,000-8,000 miles)
Chain Lubrication Adjustment:
Check every 1,000 km (600 miles) or as needed based on riding conditions
Coolant Type:
Ethylene glycol based coolant (50/50 mix with distilled water), specific type as per manual
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation)
Common Wear Items:
Clutch plates, fork seals, carburetor diaphragms, exhaust gaskets, chain and sprockets
Engine Performance:
Potential for carbon buildup in the combustion chamber over time, requiring decarbonization.
Electrical:
Voltage regulator/rectifier can be a failure point on older models.
Part Replacement:
Emphasizes using genuine Kawasaki parts or equivalent specified parts
Tool Usage:
Strictly advises against makeshift tools and stresses the use of correct special service tools
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Heritage Focus:
Known for robust and reliable motorcycles, including a strong presence in dual-sport and off-road segments
Predecessor:
KLR600 (established the KLR lineage)
Successor:
KLR650 (evolution and larger displacement model)
Key Changes During Production:
Likely minor updates in styling, suspension tuning, and possibly emissions controls across the years. The core mechanical platform remained consistent.
Manufacturing Country:
Japan (typical for Kawasaki motorcycles of this era)