Kawasaki KLR650 Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro- cedure . Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page . *Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required . Quick Reference Guide General Information u Periodic Maintenance u Fuel System u Cooling System 4 j Engine Top End F5 1 Clutch 6 Engine Lubrication System 7 Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering 8 Frame Appendix Electrical System 171 Kawasaki KLR650 Motorcycle Service Manual All rights reserved . No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd ., Japan . No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible . The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously . See your Motorcycle dealer for the latest information on product improvements incorporated after this publication . All information contained in this publication is based on the latest product information available at the time of publication . Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts . © 2007 Kawasaki Heavy Industries, Ltd . First Edition (1) : Apr. 12, 2007 (M) LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h L hour(s) liter(s) 0 ohm(s) COUNTRY AND AREA CODES AU Australia CAL California CA Canada US United States EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board . Addi- tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only . 1 . Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere . Instead, the vapors are routed through an oil separator to the inlet side of the engine . While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system . 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle . The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels . The exhaust system of this model motorcycle manufactured primarily for sale in California in- cludes a catalytic converter system . 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere . In- stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped . Liquid fuel is caught by a vapor separator and returned to the fuel tank . The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's "tampering provisions" . "Sec . 203(a) The following acts and the causing thereof are prohibited . (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser . (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know- ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow- ing its sale and delivery to the ultimate purchaser . . ." NOTE oThe phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows . 1 . Tampering does not include the temporary removal or rendering inoperative of de- vices or elements of design in order to perform maintenance . 2. Tampering could include . a.Maladjustment of vehicle components such that the emission standards are ex- ceeded . b. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle . c.Addition of components or accessories that result in the vehicle exceeding the stan- dards . d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems . WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION . TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof . (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person . Among those acts presumed to constitute tampering are the acts listed below . • Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations . • Removal of the muffler(s) or any internal portion of the muffler(s) . • Removal of the air box or air box cover. • Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels . This manual is designed primarily for use by trained mechanics in a properly equipped shop . However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work . A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily . When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics . In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area . Whenever special tools or equipment are specified, do not use makeshift tools or equipment . Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation . For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual . Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle . • Follow the Periodic Maintenance Chart in the Service Manual . • Be alert for problems and non-scheduled maintenance . • Use proper tools and genuine Kawasaki Mo- torcycle parts . Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual . Genuine parts provided as spare parts are listed in the Parts Catalog . • Follow the procedures in this manual care- fully. Don't take shortcuts . • Remember to keep complete records of main- tenance and repair with dates and any new parts installed . How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters . The Quick Reference Foreword Guide shows you all of the product's system and assists in locating their chapters . Each chapter in turn has its own comprehensive Ta- ble of Contents . For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter . Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section . Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices . A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life . CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment . This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion . NOTE oThis note symbol indicates points of par- ticular interest for more efficient and con- venient operation . *Indicates a procedural step or work to be done . Olndicates a procedural sub-step or how to do the work of the procedural step it follows . It also precedes the text of a NOTE . *Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows . In most chapters an exploded view illustration of the system components follows the Table of Contents . In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly . General Information Table of Contents Before Servicing 1-2 Model Identification 1-7 General Specifications 1-8 Unit Conversion Table 1-11 GENERAL INFORMATION 1-1 A 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below . To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary . This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts . Especially note the following . Battery Ground Before completing any service on the motorcycle, discon- nect the battery cables from the battery to prevent the en- gine from accidentally turning over. Disconnect the ground cable (-) first and then the positive (+) . When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (-) ca- ble to the negative terminal . Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts . Solvent Use a high-flush point solvent when cleaning parts . High -flush point solvent should be used according to directions of the solvent manufacturer . Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly . Dirt or other foreign materials entering into sealed areas during ve- hicle disassembly can cause excessive wear and decrease performance of the vehicle . Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse . Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly . Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area . Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly . Inspection Reuse of worn or damaged parts may lead to serious ac- cident . Visually inspect removed parts for corrosion, discol- oration, or other damage . Refer to the appropriate sections of this manual for service limits on individual parts . Replace the parts if any damage has been found or if the part is be- yond its service limit . Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI . Gaskets, 0-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled . Assembly Order In most cases assembly order is the reverse of disassem- bly, however, if assembly order is provided in this Service Manual, follow the procedures given . GENERAL INFORMATION 1-3 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction . Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar- ter turn and then remove them . If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage . Tighten fasteners to the specified torque using a good quality torque wrench . Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam- age . When necessary, remove screws that have a non -permanent locking agent applied using an impact driver . Use a plastic-faced mallet whenever tapping is necessary . Gasket, 0-ring Hardening, shrinkage, or damage of both gaskets and 0-rings after disassembly can reduce sealing performance . Remove old gaskets and clean the sealing surfaces thor- oughly so that no gasket material or other material remains . Install the new gaskets and replace the used 0-rings when re-assembling . Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them exces- sively. Excessive application can clog oil passages and cause serious damage . Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area . Be sure to maintain proper alignment and use smooth movements when installing . Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary . Replace with new ones whenever removed . Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown . Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage . Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed . Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing . Apply specified grease to the lip of seal before installing the seal . Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones . Take care not to open the clip excessively when installing to prevent deformation . GENERAL INFORMATION 1-5 GB0204BBS1 C GB02026B S