Segment:
Dual-sport motorcycle, adventure touring
Target Audience:
Riders seeking a reliable, versatile, and affordable motorcycle capable of both on-road commuting and off-road exploration.
Key Competitors Era:
Honda XR650L, Suzuki DR650, Yamaha XT600/XT660 (depending on specific market availability and year).
Distinctive Attributes:
Legendary durability, simplicity of design, excellent fuel economy, capable off-road suspension, large fuel tank for extended range, robust luggage-carrying capabilities.
Manual Value Proposition:
Essential guide for owners and technicians to maintain, diagnose, and repair the KLR650, ensuring longevity and optimal performance, thus maximizing rider satisfaction and resale value.
Engine Mechanical:
Complete engine overhaul, top-end (cylinder head, valves), bottom-end (crankshaft, connecting rod, pistons), timing system, lubrication system.
Fuel System:
Carburetor assembly and tuning (CVK), fuel tank, fuel lines, fuel filter replacement.
Cooling System:
Radiator, cooling fan, hoses, thermostat, coolant specifications and replacement.
Exhaust System:
Muffler, exhaust pipe, exhaust gasket replacement.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, final drive chain and sprockets maintenance and replacement.
Suspension Steering:
Front fork (telescopic) overhaul, fork oil replacement, rear shock absorber adjustment and replacement, swingarm maintenance, steering head bearing service.
Braking System:
Front and rear disc brake system, caliper overhaul, brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder service.
Electrical System:
Ignition system, charging system (stator, rectifier/regulator), starting system (starter motor, battery), lighting system (headlight, taillight, turn signals), wiring diagrams, fuse and relay specifications.
Bodywork Chassis:
Frame inspection, body panel removal and installation, seat maintenance, fuel tank mounting, fairing components.
Preventative Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, lubrication points, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts for common performance issues, electrical faults, starting problems, and fuel system malfunctions.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major systems.
Adjustments:
Carburetor idle and mixture adjustments, clutch lever free play, throttle cable slack, chain tension.
Specifications Torques:
Comprehensive listing of all critical torque values for engine, chassis, and component fasteners.
Depth Level:
Comprehensive, covering everything from basic servicing to complete engine and transmission rebuilds. Suitable for both novice mechanics and experienced technicians.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
651 cc (39.7 cu in)
Bore X Stroke:
100.0 x 83.0 mm (3.94 x 3.27 in)
Cooling Method:
Liquid-cooled
Horsepower Estimate:
Approximately 32-36 HP @ 6000 RPM (at the crankshaft, depending on region and tuning)
Torque Estimate:
Approximately 35-38 lb-ft @ 4500 RPM (at the crankshaft, depending on region and tuning)
Carburetor Type:
Keihin CVK-40 (Constant Velocity Carburetor), dual-stage, with accelerator pump
Fuel Capacity:
18 Liters (4.7 US gal)
Fuel Type:
Unleaded gasoline, 87 octane (or higher)
Safety Certifications:
Meets applicable EPA and CARB emissions standards; conforms to road legality standards for its intended markets.
Braking System Type:
Hydraulic disc brakes, front and rear.
Front Brake Spec:
Single 230 mm disc, twin-piston caliper.
Rear Brake Spec:
Single 203 mm disc, single-piston caliper.
Lighting:
Halogen headlight, LED taillight, incandescent turn signals.
Frame Construction:
Semi-double cradle, steel tubing.
Infotainment System:
N/A (Basic motorcycle instrumentation)
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, neutral indicator, oil pressure warning light, turn signal indicators, high beam indicator.
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first. Refer to manual for specific conditions.
Air Filter Cleaning Interval:
Every 8,000 km (5,000 miles), or more frequently in dusty conditions.
Valve Clearance Check Interval:
Every 12,000 km (7,500 miles).
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) or as needed based on inspection.
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
3.2 L (3.4 US qt) with filter change; 2.9 L (3.1 US qt) without filter change.
Fork Oil Type:
KHL15-10 (or equivalent SAE 10W fork oil)
Fork Oil Quantity:
572 ml (19.3 US fl oz) per fork leg.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, valve stem seals (can lead to oil consumption), steering head bearings, rear shock absorber linkage bearings.
Carburetor Quirks:
Can be sensitive to altitude and temperature changes; proper synchronization and jetting are critical for optimal performance. CDI box failures have been reported on some units.
Charging System Notes:
Stator output can degrade over time. Rectifier/regulator is a common failure point.
Kawasaki Legacy:
Kawasaki Heavy Industries, Ltd. is a Japanese conglomerate with a long history in motorcycle manufacturing, known for innovation and robust engineering across various product lines including aerospace, heavy industry, and rolling stock.
Klr650 Lineage:
The KLR650 platform, introduced in 1987, is renowned for its longevity and minimal changes, a testament to its successful and enduring design. The 2007 model is part of the 'A' series generation, which saw incremental updates but retained its core character.
Manufacturing Location:
Primarily manufactured in Japan (Hyogo Prefectural Plant).
Production Years Era:
The 'A' model series was produced roughly from 1987 to 2007/2008, with minor variations. The 2007 model represents the culmination of this generation before the introduction of the redesigned 'E' model in 2008.
Industry Acclaim:
The KLR650 has consistently been praised for its ruggedness, reliability, and value proposition in the dual-sport segment, earning a reputation as a 'workhorse' motorcycle suitable for adventure touring and everyday use.
Consumer Reputation:
Highly regarded by owners for its low running costs, ease of maintenance, and go-anywhere capability. Often cited in 'best budget adventure bike' discussions.
Emissions Compliance:
Meets EPA and relevant regional emissions standards for its model year.
