🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Model Variant:

A14

Year:

2000

Chassis Code:

KL650A

Engine Code Prefix:

KL650AE

👋 Introduction

Positioning:

The Kawasaki KLR650 (A14 model) is a venerable dual-sport motorcycle, celebrated for its ruggedness, versatility, and long-distance touring capability. Positioned as an affordable and reliable adventure touring platform, it appeals to riders seeking both on-road comfort and off-road exploration.

Competitors:

Competed with models like the Honda XR650L, Suzuki DR650, and Yamaha XT600/XT660 in the dual-sport segment.

Dual Sport Design:

Combines on-road practicality with off-road prowess, featuring a robust chassis, long-travel suspension, and durable engine.

Reliability:

Known for its bulletproof engine and robust construction, making it a favored choice for adventure touring and commuting.

Ergonomics:

Comfortable riding position for long distances, with a supportive seat and upright handlebars.

Wind Protection:

Standard large windshield offering considerable wind protection for the rider.

Fuel Capacity:

Generous fuel tank capacity providing extended range.

📋 Manual Details

Primary Coverage:

Workshop Service Repair Manual

Estimated Pages:

Approximately 350-450 pages (typical for this era of workshop manual)

Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (likely PDF), printable

📖 Manual Coverage

Engine System:

Full disassembly, assembly, inspection, and repair of the 651cc liquid-cooled 4-stroke single-cylinder engine, including valve timing, carburetor tuning, and cooling system.

Transmission System:

Inspection, adjustment, and repair of the 5-speed constant mesh transmission and clutch assembly.

Fuel System:

Detailed procedures for the Mikuni VM26SS carburetor, fuel pump, fuel tank, and fuel lines.

Electrical System:

Wiring diagrams, ignition system (CDI), lighting, charging system (alternator, battery), starter motor, and instrument panel.

Suspension System:

Front fork (telescopic, cartridge type) disassembly, service, and adjustment; rear shock absorber (monoshock, adjustable) inspection and replacement.

Braking System:

Front disc brake system maintenance, caliper service, pad replacement, and fluid bleeding; rear drum brake maintenance and adjustment.

Cooling System:

Radiator, fan, coolant lines, and thermostat service and troubleshooting.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, handlebars, and footpegs.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug service, air filter cleaning/replacement, and general lubrication.

Troubleshooting Guides:

Diagnostic flowcharts and common problem solutions for various systems.

Engine Rebuilding:

Complete engine disassembly, component inspection (piston, rings, cylinder, crankshaft, connecting rod), and reassembly procedures.

Carburetor Overhaul:

Detailed steps for cleaning, rebuilding, and adjusting the Mikuni VM26SS carburetor, including jetting information.

Suspension Servicing:

Fork seal replacement, oil level and type specification, and rear shock absorber service.

Electrical Diagnostics:

Component testing procedures for ignition, charging, and starting systems, with reference to wiring diagrams.

Brake System Service:

Bleeding procedures, pad replacement, caliper and master cylinder inspection.

Wheel And Tire Service:

Spoke tightening, tire mounting/demounting, and balancing.

Depth:

Comprehensive, covering routine maintenance, diagnostics, component replacement, and full unit overhauls.

📊 Manual Specifications

Digital Format:

PDF

Quality:

High-resolution, enabling clear reproduction of diagrams and text.

Binding:

N/A (Digital)

Paper:

N/A (Digital)

Text Search:

Likely text-searchable PDF for efficient information retrieval.

Coverage Level:

This is a complete workshop service repair manual, intended for professional technicians and experienced DIY mechanics. It provides in-depth information for all aspects of the vehicle's maintenance and repair.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve, single-cylinder

Displacement:

651 cc (39.7 cubic inches)

Bore X Stroke:

100.0 mm x 83.0 mm

Compression Ratio:

8.3:1

Valve Actuation:

DOHC, 4 valves per cylinder

Cooling Method:

Liquid Cooling

Horsepower Est:

Approximately 47-50 hp at 6,500 rpm (rear wheel)

Torque Est:

Approximately 39-41 ft-lbs at 5,000 rpm (rear wheel)

Carburetor:

Mikuni VM26SS, single 26mm slide-valve carburetor with accelerator pump

Fuel Delivery:

Mechanical fuel pump

Oil Capacity W Filter:

2.7 L (2.9 US qt)

Ignition Type:

Digital CDI (Capacitor Discharge Ignition)

🔧 Transmission

Transmission Type:

5-speed, constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain drive

Gear Ratios 1St:

2.643 (37/14)

Gear Ratios 2Nd:

1.833 (22/12)

Gear Ratios 3Rd:

1.400 (21/15)

Gear Ratios 4Th:

1.130 (26/23)

Gear Ratios 5Th:

0.964 (27/28)

Transmission Oil Type:

Kawasaki motorcycle gear oil SAE 80W-90 (or equivalent API GL-4 rated)

📐 Dimensions

Length:

2,245 mm (88.4 in)

Width:

880 mm (34.6 in)

Height:

1,275 mm (50.2 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

255 mm (10.0 in)

Seat Height:

890 mm (35.0 in)

Dry Weight Est:

176 kg (388 lbs)

Curb Weight Est:

193 kg (425 lbs)

Gross Vehicle Weight Rating Est:

380 kg (838 lbs)

Fuel Tank Capacity:

18 L (4.8 US gal)

Front Suspension Travel:

205 mm (8.1 in)

Rear Suspension Travel:

176 mm (6.9 in)

🛡️ Safety Features

Safety Ratings:

Not applicable in the same way as automobiles; inherent safety relies on rider skill and maintenance.

Braking System:

Front: Single 280mm disc with dual-piston caliper. Rear: 230mm disc with single-piston caliper. (ABS was not standard or widely available on this generation).

Lighting:

Halogen headlight, taillight, and turn signals for visibility.

Frame Construction:

High-tensile steel semi-double cradle frame for rigidity and durability.

Ergonomic Design:

Promotes rider control and awareness.

💡 Technology Features

Instrument Panel:

Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, and indicator lights for neutral, turn signals, and high beam.

ABS:

Anti-lock Braking System (ABS) was not standard on this model year.

Connectivity Features:

N/A (No electronic connectivity features like Bluetooth or USB ports on this generation).

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km (2,000-3,000 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 3,000-6,000 km (2,000-4,000 miles), depending on riding conditions.

Spark Plug Replacement:

Every 10,000-12,000 km (6,000-7,500 miles).

Valve Clearance Check:

Every 6,000-10,000 km (4,000-6,000 miles).

Chain Lubrication Adjustment:

Regularly, every 500-1,000 km (300-600 miles), and adjust as needed.

Engine Oil Type:

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

Coolant Type:

Mixture of Kawasaki All Season Performance Coolant (or equivalent ethylene glycol-based coolant) and distilled water (50/50 ratio).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Doohickey Failure:

The torsion spring balancer lever (commonly called 'doohickey') can fatigue and break, leading to noise and potential damage. Early replacement with an upgraded aftermarket part is a common preventative measure.

Carburetor Lean Condition:

Some models can run lean, especially at higher altitudes, requiring jetting adjustments or modifications for optimal performance and cooler running.

Countershaft Seal Leak:

The countershaft seal can develop leaks over time, requiring replacement.

Cam Chain Tensioner:

The automatic cam chain tensioner can sometimes fail or become noisy, though manual replacements are often preferred for reliability.

Subframe Cracking:

Under heavy loads or rough off-road use, the subframe can develop cracks near the rear fender mounting points. Reinforcement is a common modification.

📚 Vehicle History

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long and distinguished history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments, from sportbikes to cruisers and off-road machines.

Klr650 Lineage:

The KLR650 platform was introduced in 1987 and has seen remarkable longevity, undergoing only minor updates for much of its production run due to its inherent design suitability for adventure touring. The A-series represents the early, highly regarded iterations.

Manufacturing Location:

Primarily manufactured in Japan for the initial years, with some later production potentially shifting.

Production Years For A Series:

The 'A' designation generally covers models from 1987 up to the early 2000s, with the A14 specifically being the 2000 model year.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for the 2000 KLR650 A14 are not extensively documented, the KLR650 model line has consistently been recognized by motorcycle publications and riders for its outstanding value, durability, and go-anywhere capability.

Rider Satisfaction:

Consistently high rider satisfaction ratings due to its reliability and low cost of ownership, making it a popular choice for long-term ownership and modifications.