Segment:
Dual-sport / Adventure motorcycle, known for its ruggedness and versatility.
Comparisons:
Competed against other single-cylinder dual-sport bikes of its era, offering a balance of on-road civility and off-road capability.
Durability:
Renowned for its robust construction and reliability, a hallmark of the KLR line.
Versatility:
Suitable for commuting, touring, and light off-road exploration.
Engine:
Full disassembly, assembly, tuning, troubleshooting of the 651cc single-cylinder engine.
Fuel System:
Carburetor (Mikuni VM26SS), fuel tank, fuel lines, fuel pump operation, and maintenance.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing, troubleshooting.
Transmission:
Clutch operation, gear shifting mechanisms, transmission disassembly and assembly, lubrication.
Drivetrain:
Drive chain adjustment and maintenance, sprocket inspection and replacement.
Cooling System:
Liquid cooling system, radiator, fan operation, coolant specifications and replacement.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Suspension:
Front telescopic forks (including oil level and type, seal replacement), rear monoshock suspension (adjustment, rebuild).
Brakes:
Front disc brake (caliper service, pad replacement, fluid flush), rear drum brake (adjustment, shoe replacement).
Wheels And Tires:
Wheel bearing inspection and replacement, spoke tension adjustment, tire pressure recommendations, rim specifications.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, horn.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank, fenders.
Controls:
Handlebar, levers, cables (throttle, clutch, brake), footpegs, and shifter linkage.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain lubrication, brake adjustments.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Overhaul:
Detailed procedures for complete engine, transmission, and suspension overhauls.
Specifications:
Torque values, clearances, fluid capacities, electrical values.
Diagnostics:
Testing procedures for electrical components, mechanical checks.
Depth:
Comprehensive, covering routine maintenance to complete engine and component rebuilds.
Diagrams:
Includes detailed exploded view diagrams, wiring schematics, and system layouts.
Engine Type:
4-stroke, DOHC, 4-valve, single-cylinder, liquid-cooled
Bore X Stroke:
100.0 x 83.0 mm
Horsepower Est:
Approx. 46 hp @ 6,500 rpm (flywheel)
Torque Est:
Approx. 53 Nm (39 lb-ft) @ 5,000 rpm (flywheel)
Carburetor:
Mikuni VM26SS
Fuel Capacity:
18 Liters (4.7 US gal)
Oil Type:
API SE, SF or SG classification, SAE 10W-40 or 20W-50 (refer to manual for specific recommendations based on temperature)
Oil Capacity W Filter:
3.2 L (3.4 US qt)
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first (typical, consult manual for exact interval).
Air Filter Cleaning:
Every 3,000 km (1,800 miles) or 3 months (more frequently in dusty conditions).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (typical, check manual).
Valve Clearance Check:
Every 12,000 km (7,500 miles) (critical for engine health).
Engine Oil Recommendation:
SAE 10W-40 or 20W-50 API SE/SF/SG, or equivalent JASO MA motorcycle oil.
Coolant Type:
Permanent type ethylene glycol based coolant, mixed with distilled water (typically 50/50).
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid (refer to manual for specific DOT rating).
Doohickey:
The timing chain tensioner lever (often called 'doohickey') is known to be a weak point and can break. Replacement with an aftermarket upgraded part is a common preventative measure.
Cam Chain Rattle:
Some models can develop a cam chain rattle if the tensioner wears or fails.
Carburetor Cleaning:
Regular cleaning and adjustment of the Mikuni carburetor can be necessary for optimal performance, especially with older fuel or storage.
Kawasaki Legacy:
Kawasaki has a long history of producing reliable motorcycles across various segments, including off-road and dual-sport.
Klr650 Lineage:
The KLR650 debuted in 1987 and became an enduring model, evolving through several generations (A, B, C, E, F, G, H) with significant updates over its long production run.
Original Production Start:
1987
