Category:
Versatile dual-sport motorcycle, capable of both on-road commuting and light off-road exploration
Competitors 1984-1986:
Honda XL series, Yamaha XT/TT series, Suzuki DR series
Engine Type:
Air-cooled, four-stroke, single-cylinder
Suspension Type:
Telescopic front forks, Uni-Trak rear suspension (starting 1985 for KLR600)
Transmission Type:
5-speed
Engine:
Engine disassembly, assembly, inspection, tuning, valve adjustment, lubrication system, cooling system
Fuel System:
Carburetor (likely Mikuni BS32) removal, cleaning, adjustment, fuel pump, fuel tank, fuel lines
Transmission:
Clutch, gearbox disassembly, assembly, inspection, lubrication
Electrical System:
Ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, wiring diagrams, troubleshooting
Chassis And Suspension:
Front fork (telescopic) disassembly, servicing, rear shock absorber, swingarm, suspension adjustments
Brakes:
Front disc brake system, rear drum brake system, caliper overhaul, brake fluid replacement, bleeding procedures
Wheels And Tires:
Wheel bearing service, tire removal/installation, spoke tension adjustment
Bodywork And Frame:
Fairing removal/installation, seat, fuel tank, fenders, frame inspection
Cooling System:
Radiator, cooling fan, coolant replacement (if applicable, though early KLR600 models are primarily air-cooled with some oil cooling)
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment, spark plug replacement
Troubleshooting:
Systematic fault finding, common problems, diagnostic flowcharts
Repair:
Detailed step-by-step instructions for component repair and replacement
Disassembly And Assembly:
Complete procedures for breaking down and reassembling all major vehicle components
Adjustments:
Carburetor synchronization, idle speed, valve clearances, clutch and throttle cable free play
Technical Specifications:
Torque values, fluid capacities, wear limits, electrical specifications
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds
Visual Aids:
Detailed illustrations, exploded diagrams, drawings, and photos
Special Tools:
Reference to specific Kawasaki special service tool numbers and their usage
Engine Type:
4-stroke, SOHC, single-cylinder, air-cooled
Displacement:
564 cc (approx.)
Bore X Stroke:
92.0 mm x 82.0 mm (approx.)
Horsepower:
Estimated 35-40 HP (varies by source and tuning)
Torque:
Not explicitly stated, but strong mid-range torque characteristic of this engine
Carburetor:
Mikuni VM34SS or BS32 (specific model may vary by region/year)
Fuel Delivery:
Gravity feed with possible vacuum-operated fuel pump
Oil Capacity:
Approx. 2.3 L (5.0 US qt) with filter change
Ignition Type:
CDI (Capacitor Discharge Ignition)
Length:
Approx. 2,200 mm (86.6 in)
Width:
Approx. 860 mm (33.9 in)
Height:
Approx. 1,225 mm (48.2 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Dry Weight:
Approx. 155 kg (341.7 lbs)
Curb Weight:
Approx. 170 kg (375 lbs) (with all fluids)
Fuel Capacity:
20 L (5.3 US gal)
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months
Air Filter Cleaning:
Every 3,000 km (1,800 miles)
Valve Clearance Check:
Every 6,000 km (3,600 miles)
Engine Oil Type:
API SE or SF, SAE 10W-40 or 20W-40 (refer to manual for exact specifications)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification)
Coolant Type:
Not applicable for primarily air-cooled engine; if any liquid cooling components are present, use standard ethylene glycol coolant.
Common Issues 1984-1986:
Carburetor jetting issues, weak ignition coils, potential rear shock absorber wear (especially pre-Uni-Trak models), cam chain tensioner noise.
Preventative Maintenance Tips:
Regular cleaning of the carburetor, ensuring proper valve clearance, and checking for oil leaks are crucial.
Kawasaki Legacy:
Kawasaki has a long history of producing robust and capable motorcycles, particularly in the dual-sport and off-road segments.
Klr600 Introduction:
The KLR600 was introduced in 1984 as a modern dual-purpose machine, succeeding models like the KLR250 and building on the 'dual-purpose' concept for a larger displacement.
Klr600 Updates:
Key updates during this period included the introduction of the Uni-Trak rear suspension in 1985, a significant improvement over previous linkage systems.
Production Years:
1984-2007 (with significant redesign in 2008 to KLR650)
Manufacturing Location:
Japan
