1984-2007 Kawasaki KLR600 KLR650 Cyclepedia Printed Service Manual


SKU: CPP-103 Category: Tag:


The Cyclepedia Kawasaki KLR650 printed service manual features detailed black and white photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Kawasaki dealer trained technician.

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The KLR650 Manual covers the following KLR motorcycles:

2007 Kawasaki KLR650-A21
2006 Kawasaki KLR650-A20
2005 Kawasaki KLR650-A19
2004 Kawasaki KLR650-A18
2003 Kawasaki KLR650-A17
2002 Kawasaki KLR650-A16
2001 Kawasaki KLR650-A15
2000 Kawasaki KLR650-A14
1999 Kawasaki KLR650-A13
1998 Kawasaki KLR650-A12
1997 Kawasaki KLR650-A11
1996 Kawasaki KLR650-A10
1995 Kawasaki KLR650-A9
1994 Kawasaki KLR650-A8
1994 Kawasaki KLR250-D11
1993 Kawasaki KLR650-A7
1992 Kawasaki KLR650-A6
1991 Kawasaki KLR650-A5
1990 Kawasaki KLR650-A4
1990 Kawasaki KL650B2 Tengai
1989 Kawasaki KLR650-A3
1988 Kawasaki KLR650-A2
1987 Kawasaki KLR650-A1
1986 Kawasaki KL600B2 KLR
1985 Kawasaki KL600B1 KLR
1984 Kawasaki KLR600A1

Table of Contents


Quick Reference – Bolt and Nut Torque and Size Specification, Bolt Tightening Torque, Specifications KLR600 1984-1986, Specifications KL650 1987-1999, Specifications KL650 2000-2001, Specifications KL650 2002-2006, Periodic Maintenance, Torque Conversions, VIN Number Location


External Components – Fuel Tank, Headlight Removal, Seat, Side Covers


Periodic Maintenance – Air Filter Servicing, Brake Fluid (Front), Brake Fluid (Rear), Compression Check, Crankcase Oil Replacement, Drive Chain, Engine Coolant & Hoses, Engine Idle Speed, Exhaust System, Periodic Maintenance Chart, Sparkplug Inspection, Throttle Free Play, Tire Inspection


Engine – Cylinder Head Removal, Cylinder, Piston, Compression Check, Oil Change, Valve Adjustment, Valve Shim Charts, Valve Shim Replacement, Valve Train Reassembly, Valve Train Removal, Clutch, Starter Clutch, Engine Troubleshooting, Top End Specifications, Water Pump


Final Drive – Chain, Front Sprocket, Rear Sprocket


Front Wheel – Front Wheel Bearing, Front Wheel Inspection, Front Wheel Installation, Front Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing


Rear Wheel – Rear Wheel Bearing Replacement, Rear Wheel Inspection, Rear Wheel Installation, Rear Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing


Steering – Steering Installation and Adjustment, Steering Removal and Inspection, Steering/Suspension Troubleshooting


Front Suspension – Fork Disassembly, Fork Inspection, Fork Oil Replacement, Fork Seal Replacement, Fork Reassembly


Rear Suspension – Rear Suspension Settings, Removal & Installation


Fuel System – Air Filter, Carburetor Disassembly, Carburetor Removal, Pilot Screw Removal


Front Brakes – Front Brake Disc Inspection, Front Brake Fluid Inspection, Front Brake Removal & Inspection, Front Brake and Caliper Installation, Brake Troubleshooting


Rear Brakes – Rear Brake Disc Inspection, Rear Brake Fluid Inspection, Rear Brake Pad & Caliper Installation, Rear Brake Pedal Adjustment, Rear Brake Removal & Inspection, Brake Troubleshooting


Cooling Systems – Coolant Removal, Coolant System Inspection


Exhaust System – Exhaust Removal


Electrical System – Electrical Component Location, Electric Starter Motor, Starter Relay Inspection, Ignition Coil, Headlight Bulb Replacement, Taillight Bulb Replacement, Testing Electrical Components, Turn Signal Bulb Replacement, Spark Plug, Battery, Wiring Diagrams, Service Data, Electrical Troubleshooting

Additional information

Weight 2.75 lbs
Dimensions 11 × 8.5 × 2 in

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