Product Name:
Kawasaki KLR650 1987-2002 Service Repair Manual
Covered Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Segment:
Dual-sport motorcycle
Target Audience:
Adventure riders, commuters, off-road enthusiasts.
Competitors Of Era:
Honda Transalp, Suzuki DR650, Yamaha Tenere models.
Versatility:
Renowned for its ability to handle both paved roads and light off-road trails.
Durability:
Known for its robust construction and long-term reliability.
Simplicity:
Relatively simple mechanical design, making it accessible for DIY maintenance.
Diy Support:
Empowers owners to perform a wide range of maintenance and repair tasks, saving on labor costs.
Diagnostic Aid:
Provides essential troubleshooting information for quick problem identification.
Restoration Guide:
Crucial for owners undertaking vintage restorations or major overhauls.
Primary Coverage:
Complete Service and Repair
Vehicle Generations Covered:
First Generation KLR650 (KL650-A, KL650-B, KL650-C)
Estimated Page Count:
Approximately 400-500 pages (typical for comprehensive service manuals of this era)
Type:
Service Repair Manual
Engine:
Complete engine overhaul, carburetor tuning, valve clearance adjustment, timing chain, lubrication system, cooling system (liquid-cooled).
Transmission:
Clutch operation, gearbox inspection and repair, shift mechanism.
Fuel System:
Carburetor (Mikuni BS40) disassembly, cleaning, adjustment, fuel pump operation.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, fuses.
Suspension:
Front fork (including oil change and seal replacement), rear shock absorber (Uni-Trak system), linkage maintenance.
Brakes:
Front and rear brake system inspection, fluid replacement, caliper and master cylinder overhaul, brake pad replacement.
Chassis And Frame:
Frame inspection, swingarm, steering head bearings.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic charts, common problems and their solutions.
Repair And Rebuild:
Complete disassembly and reassembly procedures for major components.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications.
Depth:
Comprehensive, covering everything from basic tune-ups to complete engine and chassis rebuilds.
Engine Type:
Four-stroke, DOHC, single-cylinder
Displacement:
651 cc (cc)
Bore X Stroke:
100.0 x 83.0 mm (mm)
Cooling System:
Liquid-cooled
Compression Ratio:
9.5:1 (typical for this generation)
Horsepower:
Approximately 46-48 hp @ 6500 rpm (peak, depending on specific sub-model and market tuning)
Torque:
Approximately 52-54 Nm @ 5000 rpm (peak, depending on specific sub-model and market tuning)
Carburetor Type:
Mikuni BS40 (constant velocity, 40mm) with DFI on later models
Fuel Type:
Unleaded gasoline, minimum octane rating 87 (R+M)/2
Oil Capacity:
2.4 Liters (with filter change) (L)
Recommended Oil Viscosity:
10W-40 API SG or higher
Ignition System:
Digital CDI
NHTSA Rating:
N/A (Motorcycle safety ratings differ from automotive)
Brakes Front:
Single Disc (230mm disc, 2-piston caliper - standard, later models may have optional dual disc)
Brakes Rear:
Drum Brake (or Disc on later models, depending on sub-variant)
Lighting:
Halogen headlamp, LED taillight (on some later models)
Frame Construction:
High-tensile steel semi-double cradle frame.
Oil Change Interval:
Every 6,000 km or 6 months, whichever comes first (check manual for specific model year variations)
Air Filter Cleaning:
Every 6,000 km or 6 months, replacement as needed.
Spark Plug Inspection:
Every 12,000 km or 12 months.
Valve Clearance Check:
Every 24,000 km or 24 months.
Chain Adjustment:
As needed, typically every 1,000-2,000 km.
Engine Oil:
SAE 10W-40, API SG or higher (e.g., Motul 5100 10W-40, Castrol Power 1 10W-40)
Coolant:
50/50 mixture of permanent antifreeze and distilled water (e.g., Kawasaki Genuine Coolant, Prestone All-Season)
Brake Fluid:
DOT 4 (e.g., Castrol DOT 4, Valvoline DOT 4)
Fork Oil:
KHL15-10 (Kawasaki Fork Oil 10W) or equivalent
Doohickey Failure:
The balancer shaft lever (often called 'doohickey') can break, causing timing chain issues. Highly recommended to upgrade to an aftermarket unit.
Carburetor Icing:
Can occur in cold, humid conditions, affecting engine performance. Manual covers carburetor cleaning and adjustment.
Oil Consumption:
Some models may exhibit increased oil consumption with high mileage, requiring monitoring and potential engine work. Manual details engine inspection.
Charging System Issues:
Stator and regulator/rectifier can fail over time. Manual provides testing procedures for these components.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Introduction Year:
1984 (globally, initial models) and 1987 (US market launch of the first generation KLR650)
Key Generations Within Covered Period:
First Generation (KL650-A, KL650-B Tengai, KL650-C ADV) - 1987-2007 (with minor updates within this range).
Design Philosophy:
Developed to be a rugged, versatile, and affordable dual-purpose motorcycle.
Manufacturing Location:
Japan
