Model Variant:
Standard Dual-Sport
Model Code:
KLR650-A (typically)
Generation Name:
First Generation (Newer iteration)
Generation Years:
2008-2018 (This manual covers a specific subset)
Engine Code:
EX650A (Engine Family designation, actual engine internal codes vary)
Chassis Code:
KL650A (Chassis designation)
Market Position:
The Kawasaki KLR650 is a renowned dual-sport motorcycle, celebrated for its versatility, reliability, and affordability. It appeals to a broad range of riders, from commuters to adventure touring enthusiasts, due to its ability to handle both on-road and off-road conditions.
Competitive Analysis:
In its segment, the KLR650 competes with motorcycles like the Suzuki DR650, Honda XR650L, and Yamaha XT660 (in markets where available). Its strong torque, comfortable riding position, and robust build make it a favored choice for long-distance travel and rugged use.
Key Features:
Simple, proven technology, large fuel tank for extended range, comfortable ergonomics, rugged chassis, and a reputation for durability.
Manual Purpose:
This workshop service manual provides detailed technical information for the maintenance, repair, and overhaul of the Kawasaki KLR650 (2008-2012 models), enabling owners and technicians to perform a wide range of tasks.
Engine System:
Complete overhaul, diagnosis, tuning, lubrication system, cooling system, fuel system, ignition system, emission control systems.
Transmission System:
Clutch operation, gearbox disassembly and assembly, lubrication, troubleshooting.
Chassis System:
Frame, suspension (front forks and rear shock absorber), steering system, wheels, tires, spokes, brakes (front and rear), drive chain.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting system, instrumentation, starting system, horn, fuses, relays.
Fuel System:
Carburetor (Mikuni BSR36), fuel tank, petcock, fuel lines, fuel filter.
Body And Controls:
Fairing, body panels, seat, handlebars, controls, luggage rack, kickstand, center stand (if applicable).
Maintenance Procedures:
Oil changes, filter replacement, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment, brake fluid flush, coolant flush, tire pressure checks, battery maintenance.
Diagnostic Procedures:
Troubleshooting guides for common issues, electrical system diagnosis, engine performance issues, starting problems, braking system faults.
Repair Procedures:
Engine rebuilds, transmission repairs, suspension fork seal replacement, brake caliper overhaul, carburetor rebuild, electrical component replacement.
Assembly Disassembly:
Detailed step-by-step instructions for disassembling and reassembling all major components and systems.
Technical Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers routine maintenance to complete engine and transmission overhauls.
Engine Type:
Four-stroke, Single-cylinder, DOHC, 4 valves
Displacement:
651 cc (39.7 cu. in.)
Bore X Stroke:
100.0 mm x 83.0 mm (3.94 in. x 3.27 in.)
Cooling System:
Liquid-cooled
Lubrication:
Forced lubrication, wet sump
Horsepower:
Approx. 42 hp @ 6,000 rpm (Varies slightly by region and exact tune)
Torque:
Approx. 39 lb-ft @ 4,500 rpm (Varies slightly by region and exact tune)
Fuel Delivery:
Carburetor: Mikuni BSR36
Fuel Type:
Unleaded gasoline, 87 octane (AKI) minimum
Ignition System:
Digital CDI with electronic advance
Spark Plug:
NGK CR9E or equivalent (Refer to manual for specific gap and torque)
Crash Test Ratings:
N/A (Motorcycles are not typically crash-tested by agencies like NHTSA or Euro NCAP in the same manner as cars).
Braking System:
Front: Single 230 mm petal disc with dual-piston caliper. Rear: Single 200 mm petal disc with single-piston caliper. (ABS was not standard or typically available on this generation).
Lighting:
Halogen headlight, LED taillight, standard turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame, designed for durability and off-road resilience.
Ergonomics:
Upright riding position for rider comfort and control, contributing to safety during long rides and varied terrain.
Infotainment Features:
Basic analogue/digital instrumentation including speedometer, odometer, trip meter, tachometer, and indicator lights. No integrated infotainment system.
Driver Assistance Features:
ABS was not standard. Focus is on mechanical reliability and rider control rather than electronic rider aids.
Connectivity Features:
None. Basic electrical system for lighting, ignition, and instrumentation.
Oil Change Interval:
Every 3,700 miles or 6 months (Refer to manual for specific recommendations based on riding conditions).
Oil Filter Replacement:
At every oil change (Recommended: Kawasaki 16099-003 or equivalent).
Valve Clearance Check:
Every 7,500 miles or 12 months (Crucial for engine health).
Air Filter Cleaning:
Every 3,700 miles or 6 months (More frequently in dusty conditions).
Chain Maintenance:
Clean and lubricate every 600 miles or more often in wet/dusty conditions. Adjust slack as needed.
Engine Oil Type:
API SG or SH, SAE 10W-40 (Check manual for specific viscosity based on temperature range).
Engine Oil Capacity:
2.1 L (2.2 US qt) without filter change; 2.4 L (2.5 US qt) with filter change. (Refer to manual for precise capacity).
Coolant Type:
Permanent type antifreeze coolant (Ethylene glycol based), pre-mixed 50/50 with distilled water.
Coolant Capacity:
Approx. 1.5 L (1.6 US qt). (Check manual for exact capacity).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Fork Oil Type:
SAE 10W fork oil (Refer to manual for specific type and level).
Known Issues:
Common KLR650 issues, often addressed in this manual, include: Cam chain tensioner wear (leading to rattling noise), DooHickey upgrade (balancer lever on clutch slave cylinder), Carburetor jetting for altitude/modifications, Valve seat wear (less common but possible), Subframe cracking (usually under heavy loads or with modifications).
Brand Heritage:
Kawasaki Heavy Industries, Ltd. has a long and storied history in motorcycle manufacturing, dating back to the early 1960s. Known for engineering prowess and performance-oriented machines.
Model Evolution:
The KLR650 was first introduced in 1987 and has undergone relatively few major redesigns, testament to its enduring and functional design. This 2008-2012 iteration represents a significant update to the previous generation, featuring improved bodywork, a larger fuel tank, and revised suspension.
Production Years:
1987-Present (with significant updates in 2008 and 2022)
Manufacturing Location:
Japan (Historically; production locations can vary over time for specific models).
