Kawasaki KLR650 2008 – 2017 Online Manual (Clymer ECM240-2)

Complete coverage for your vehicle

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.

KLR650 (2008-2017)

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine spark test / Engine performance / Electrical testing / Starting system / Engine noise / Motorcycle noise / Engine lubrication / Engine leakdown test / Clutch / Gear shift linkage and transmission / Brakes / Steering and handling / Disc brake troubleshooting / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Tune-up, service and maintenance intervals / Fuel and lubricants / Oil and filter change / Fork oil change / Control cable lubrication / Drive chain cleaning, lube and adjustment / Air filter cleaning and replacement / Air filter housing draining / Muffler cleaning / Balancer chain tensioner adjustment / Coolant level check / Coolant draining refill / Throttle play adjustment and inspection / Valve clearance / Engine tune-up / Spark plugs / Specifications

CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts and cam chain tensioner / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine / Cam chain and lower guide / Left crankcase cover / Engine / Balancer / Crankcase / Seal replacement / Crankcase bearing replacement / Crankshaft / Engine break-in / Specifications

CHAPTER SIX / CLUTCH, GEARSHIFT MECHANISM AND LUBRICATION SYSTEM
Right crankcase cover / External gearshift linkage / Oil pump / Primary drive gear / Clutch cable / Specifications

CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM
Input shaft / Output shaft / Inspection / Shift drum and forks / Specifications

CHAPTER EIGHT / FUEL SYSTEM
Carburetor cleaning and inspection / Float adjustment / Fuel valve / Evaporative emissions control system / Throttle and choke cable / Air filter housing / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Continuity testing / Battery / Charging system / Alternator cover / Stator / Rotor and starter clutch / Regulator rectifier / Starting system / Starter / Starter relay / Starter circuit relay / Ignition system / Fan / Coolant temperature gauge and sender / Meter unit / Lighting system / Switches / Fuses / Specifications

CHAPTER TEN / COOLING STSTEM
Safety precautions / Radiator and fan / Thermostat / Water temperature sending unit / Water pump / Coolant reserve tank / Specifications

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front and rear wheel / Speedometer drive unit / Front and rear hubs / Rim and spoke / Drive chain / Sprockets / Tire changing / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Left hand grip replacement / Balancer weights / Front fork / Fork service Steering stem and head / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Linkage / Swing arm / Shock adjustment / Specifications

CHAPTER FOURTEEN / BRAKES
Fluid / Front and rear brake pads Front and rear brake caliper / Front and rear master cylinder / Rear brake pedal / Brake system draining and bleeding / Brake disc / Specifications

CHAPTER FIFTEEN / BODY
Side covers / Seat / Fuel tank / Lower and lower fairing / Fender / Carrier / Subframe / Skid plate / Specifications

INDEX

COLOR WIRING DIAGRAMS