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Kawasaki KLR650 1987-2007 Service & Repair Manual (ECM474-3)

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Written from hands-on experience gained from the complete strip-down and rebuild of a Kawasaki KLR650, Haynes can help you understand, care for and repair your Kawasaki KLR650. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Kawasaki KLR650 can help maintain its resale value, save you money, and make it safer to ride.

Models:

KLR650 (1987-2007)

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Warning labels / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Four-stroke operating principles / Engine spark test / Engine performance / Electrical testing / Starting system / Engine noise / Motorcycle noise / Engine leakdown test / Leak-down tester / Clutch / Gear shift linkage and transmission / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Break in / Engine oil and filter change / Fork oil change / Air filter / Cable lubrication / Drive chain cleaning and lubrication / Air filter housing draining / Muffler and spark arrestor cleaning / Balancer chain tensioner adjustment / Carburetor float chamber draining / Cooling system inspection / Drive chain adjustment / Throttle and clutch cable adjustment / Brake pedal adjustment / Idle speed and mixture adjustment / Engine timing check / Compression check / Spark plug plugs / Specifications

CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts cam shafts camshaft shaft / Cam chain tensioner / Cylinder head / Valves / Cylinder / Piston / Piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine removal installation / Cam chain lower guide / Left crankcase crank case cover / Engine balancer / Crankcase crank case / Seal replacement / Crankshaft crank shaft / Specifications

CHAPTER SIX / CLUTCH / GEARSHIFT GEAR SHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase cover / Clutch / External gear shift linkage / Oil pump / Primary drive gear / Clutch cable replacement / Kick starter kickstarter / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Input shaft / Output shaft / Transmission inspection / Specifications

CHAPTER EIGHT / FUEL SYSTEM
Carburetor carb / Cleaning inspection adjustment / Float / Fuel valve / Evaporative emissions control system / Air filter housing / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Resistance testing / Continuity testing / Alternator / Stator and pickup pick up coil / Rotor and starter clutch / Starter / Ignition system / Lighting system / Fan / Water temperature gauge and sending unit / Turn signal relay / Start button / Kill switch / Specifications

CHAPTER TEN / COOLING SYSTEM
Safety precautions / Radiator / Fan / Thermostat / Water pump / Specifications

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Speedometer drive unit / Front and rear wheel wheels / Hub hubs / Rim and spoke service / Drive chain / Sprocket / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering head and stem / Front forks / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Link-type suspension system / Shock absorber / Linkage / Swingarm / Specifications

CHAPTER FOURTEEN / BRAKES
Brake pad removal installation / Front and rear caliper / Master cylinder / Brake pedal / Brake fluid bleeding / Specifications

CHAPTER FIFTEEN / BODY
Side covers / Seat / Fuel tank / Radiator covers / Skid plate / Front fender / Fairing / Sub frame / Specifications

COLOR WIRING DIAGRAMS

More details
Part number: ECM4743
Language: English

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Key features:

  • All colour step-by-step guides for over 200 jobs with 700+ photos
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  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
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  • Dictionary of automotive terms
  • Quick links to popular DIY tasks and other jobs linked to your task
  • Conversion calculator – imperial and metric units
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