Kawasaki KLR650 Supplementary 1987

Kawasaki KLR500/KLR650-A (1st generation) Supplementary Repair Manual (1987-2007)

Complete PDF version of the Supplementary Service Manual for the Kawasaki KLR500/650-A. A MUST for every KLR650-A owner.

Download: Immediately after payment!

Important: This Supplementary manual is to be used in conjunction with the standard Service Manual for the KLR600 that can also be found on this website.

OEM Original factory workshop manual.

Models covered by this manual: 1987 to 2007

Number of pages: 130 pages

Table of contents:

Kawasaki KLR650

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

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Kawasaki KLR650

The Kawasaki KLR650 is a 651 cc (39.7 cu in) dual-sport motorbike designed for both on- and off-road use. It was a long-running model in Kawasaki‘s portfolio, having debuted in 1987 to replace the 564 cc (34.4 cu in) 1984–1986 Kawasaki KLR600 and lasting almost unaltered until the 2007 edition. The 2008 model was the KLR650’s first substantial change since its beginnings. The engine was a 651 cc four-stroke, DOHC, dual-counterbalanced, single-cylinder, water-cooled four-stroke. The KLR had a second big redesign in 2022, which included additional features like as fuel injection and ABS.

The KLR is popular as a low-cost adventure/tour bike. The inclusion of baggage and customized adaptations (GPS, heated handgrips, wider windscreens) make it more practical for extended journeys. Bikes have been used for long-distance and transcontinental journeys, as well as entire globe circumnavigation rides, such as those undertaken by Dr. Gregory Frazier in 2001 and 2002.

Generation 1 (1987-2007)

  • KLR650-A: Based on the KLR600, the “A” variant was released in 1987. (1984 to 1986). The “A” model stayed essentially unmodified until the 2008 model was introduced in the United States, Canada, Australia, and South Africa. Due to pollution rules, it is not available in Europe.
  • Tengai vs. KLR650-B: The Tengai has Adventure/Dakar style, a complete fairing that blends into the tank, different sidepanels, and an unsprung front mudguard. It was offered in the United States beginning in 1990 and in other countries for two years after that – this may be considered a different model in its own right because the others are more trail bike oriented. The name “Tengai” is a traditional Japanese phrase that signifies “The End of the Sky.”
  • KLR650-C: The “C” variant has a completely redesigned body and is a dirt-oriented motorbike with stronger 41 mm (1.6 in) front forks, upgraded brakes, a tubular engine guard, a smaller 14 l (3.1 imp gal; 3.7 US gal) petrol tank, and steel wheel rims. It lacks a temperature gauge but does include an over-heat bulb.
  • Hayes Diversified Technologies has adapted KLR650s for the US military to burn military-spec fuels such as diesel. (M1030M1) To replace the 4-stroke gasoline engines, all-new engines were developed. The original unit-construction main cases and transmission are used in the new engines, but new pistons, cylinders, and other components are used. The gasoline KLR650 engines’ balancing mechanism (used to decrease engine vibration) was removed from the military diesel KLR engines. Some components of the military diesel version, like as the nonspillable absorbed glass mat battery, can be used in “civilian” KLR650 variants, offering various advantages over standard unsealed KLR batteries.

Source: Wikipedia

Kawasaki KZ400 (1st generation) Models 1974 to 1975 Service Manual PDF download

Kawasaki KZ400 1st generation Service Manual (1974-75)

Complete PDF version of the Service Manual for the Kawasaki KZ400. A MUST for every KZ400 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 1974 and 1975

Number of pages: 189 pages

Table of contents:

Kawasaki KZ400Kawasaki KZ400

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

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Kawasaki KZ400

The Kawasaki KZ400/Z400 is a street motorcycle manufactured by Kawasaki from 1974 to 1984. The dual cylinder engine’s displacement was raised to 443cc for the KZ440/Z440. A 399cc two-cylinder engine powered the subsequent KZ400-J.

From 1974 until 1984, the Kawasaki KZ400 was a 398 cc two engine motorbike. To decrease vibration, the engine included two balancer shafts, one in front of the crankshaft and one behind it, both moving in the opposite direction of the rotating crankshaft. An emission control system reused “by-product” gases. It was marketed as a “most practical all-around machine” by the producers.

Later variants displaced 443 cubic centimeters. The KZ400 was manufactured in Akashi, Japan, and Lincoln, Nebraska. With the construction of the Lincoln facility in 1974, Kawasaki became the first foreign motorcycle manufacturer to have a plant in the United States. Throughout the 1970s, the KZ400 outsold Honda in the 400 cc twins market. These bikes were touted as fuel-efficient vehicles; a 1975 magazine commercial for Kawasaki displayed the KZ400 next to a Volkswagen Beetle with the tag line “Think even smaller.”

Early versions had oil leaks and erratic idling. Beginning in 1977, both the carburetors and the architecture of the oil passageways were modified. Some variants were available as basic transportation, with no electric start and front drum brakes. Most, on the other hand, featured a single disc in front and a drum in the back, as well as electric and kick starters. A fairing and saddle bags were also included on the deluxe versions.

Source: Wikipedia

Kawasaki Versys 1000 Mk1 Service Manual (2012-14)

Complete PDF version of the Service Manual for the Kawasaki Versys 1000 Mk1. A MUST for every Versys 1000 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2012 to 2014

Number of pages: 689 pages

Table of contents:

Kawasaki Versys 1000

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

Paypal Secure checkout

Kawasaki Versys 1000

The Kawasaki Versys 1000 is a dual-sport motorcycle made by Kawasaki since 2012. It is equipped with a four-cylinder engine with a capacity of 1043cm3 derived from the Kawasaki Z1000. This is the biggest model in the Versys line, which derives its name from the phrases versatile system and system.

Source: Wikipedia

Kawasaki Vulcan VN900 Custom Repair Manual (2007-22)

Complete PDF version of the Service Manual for the Kawasaki Vulcan VN900 Custom. A MUST for every VN900 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2007 to 2022

Number of pages: 617 pages

Table of contents:

Kawasaki Vulcan VN900 Custom service manual

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

Paypal Secure checkout

Kawasaki Vulcan VN900

Since 1984, Kawasaki has used the Vulcan moniker for its custom or cruiser bikes, model code VN, with predominantly V-twin engines ranging from 125 to 2,053 cc (7.6 to 125.3 cu in).

2006-present: Vulcan 900 series

  • Vulcan 900 Classic
    • 903 cc (55.1 cu in) Liquid Cooled Fuel injected V-twin SOHC engine
    • 50 HP @ 5,700 RPM
    • 45.4 ft-lb TQ @ 3,500 RPM
    • Belt drive
    • Four-valve Cylinder Head
    • Tank-Mounted Speedometer with Turn Signal Indicators and Caution Lamps
  • Vulcan 900 Classic LT
    • Same as the Classic, with the addition of:
      • Passenger backrest, saddlebags, windshield, and studded accents standard
  • Vulcan 900 Custom
    • Same as the Classic, except for:
      • 180 mm rear tire, and a thin 21-inch cast front wheel
      • Smaller, lower-profile seat with smaller pillion
      • Drag-Style handlebars

Source: Wikipedia

Kawasaki Versys 650 ABS

Kawasaki Versys 650 ABS Mk2 Service Manual (2010-14)

Complete PDF version of the Service Manual for the Kawasaki Versys 650 ABS Mk2. A MUST for every Versys 650 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2010 to 2014

Number of pages: 631 pages

Table of contents:

Kawasaki Versys ABS Service Manual 2010

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

Paypal Secure checkout

Kawasaki Versys 650

The Kawasaki Versys 650 (KLE650) is a mid-size motorbike. It borrows design features from dual-sport bikes, ordinary bikes, adventure tourers, and sport bikes, sharing qualities from all of them but not cleanly fitting into any of them. Versys is a combination of the terms versatile and system. Kawasaki debuted it as a 2007 model in the European and Canadian markets, and as a 2008 model in the US market. In 2009, a California emissions-compliant variant was introduced. In 2010, the headlights and farings received new design, as well as various functional upgrades such as bigger mirrors and enhanced rubber engine mounts. In 2015, a new model was released with a new fairing type that replaced the earlier, stacked headlamps with the more traditional twin headlight layout found on sportbikes.

The Versys rides on the same chassis as Kawasaki’s two 650cc twins, the Ninja 650R and the ER-6n. Its siblings share the same electronics, motor, wheels, brakes, and main frame. The riding posture, rear subframe, suspension components, and engine tune are where it varies.

The Versys’ 650 cc liquid-cooled, four-stroke parallel-twin engine has been retuned for improved low- and mid-range torque. This is accomplished through the use of variable camshafts and fuel injection settings. These modifications cause peak torque to occur at a lower engine speed and improve throttle responsiveness between 3,000 and 6,000 rpm. A balancing tube has also been installed between the exhaust headers to level out power delivery. Power is 68 hp (51 kW) at 8,500 rpm, compared with the Ninja’s 67 hp (50 kW) at 8,000 rpm. Torque is 47.2 lbft (64.0 Nm) versus the Ninja’s 48.45 lbft (65.69 Nm). However, improving the engine’s low and mid-range responsiveness comes at the price of a little decrease in peak output.

Honda recently used a same strategy with its CBF1000 model. The engine has a crankshaft that rotates 180 degrees. This necessitates an irregular firing interval (180 degrees, 540 degrees), which results in a characteristic “throbbing” sound at idle.

The suspension offers more vertical travel and adjustability than the Versys 650 brothers’ suspensions. Externally adjustable preload and rebound damping are available on the front thicker/stiffer 41 mm inverted telescopic forks. The right fork leg houses a damping cartridge, while both legs are spring-loaded. The rebound damping of the rear shock absorber is adjustable. The rear suspension preload is adjustable via a screw collar on the shock. Models from 2015 and above feature an external adjustment. Instead of the more basic steel swing arm used on the Ninja and ER-6, the rear shock/spring is directly attached, without linkages, to a non-symmetrical, gull wing, aluminium swing arm.

Source: Wikipedia

Kawasaki Versys 650 Mk1 Service Manual (2007-09)

Complete PDF version of the Service Manual for the Kawasaki Versys 650 Mk1. A MUST for every Versys 650 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2007 to 2009

Number of pages: 627 pages

Table of contents:

Kawasaki Versys Service Manual 2006

This PDF repair manual can be downloaded right after the payment process in complete, on the device of your choice.

We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
  4. you receive your manual immediately after payment
  5. it is searchable

Paypal Secure checkout

Kawasaki Versys 650

The Kawasaki Versys 650 (KLE650) is a mid-size motorbike. It borrows design features from dual-sport bikes, ordinary bikes, adventure tourers, and sport bikes, sharing qualities from all of them but not cleanly fitting into any of them. Versys is a combination of the terms versatile and system. Kawasaki debuted it as a 2007 model in the European and Canadian markets, and as a 2008 model in the US market. In 2009, a California emissions-compliant variant was introduced. In 2010, the headlights and farings received new design, as well as various functional upgrades such as bigger mirrors and enhanced rubber engine mounts. In 2015, a new model was released with a new fairing type that replaced the earlier, stacked headlamps with the more traditional twin headlight layout found on sportbikes.

The Versys rides on the same chassis as Kawasaki’s two 650cc twins, the Ninja 650R and the ER-6n. Its siblings share the same electronics, motor, wheels, brakes, and main frame. The riding posture, rear subframe, suspension components, and engine tune are where it varies.

The Versys’ 650 cc liquid-cooled, four-stroke parallel-twin engine has been retuned for improved low- and mid-range torque. This is accomplished through the use of variable camshafts and fuel injection settings. These modifications cause peak torque to occur at a lower engine speed and improve throttle responsiveness between 3,000 and 6,000 rpm. A balancing tube has also been installed between the exhaust headers to level out power delivery. Power is 68 hp (51 kW) at 8,500 rpm, compared with the Ninja’s 67 hp (50 kW) at 8,000 rpm. Torque is 47.2 lbft (64.0 Nm) versus the Ninja’s 48.45 lbft (65.69 Nm). However, improving the engine’s low and mid-range responsiveness comes at the price of a little decrease in peak output.

Honda recently used a same strategy with its CBF1000 model. The engine has a crankshaft that rotates 180 degrees. This necessitates an irregular firing interval (180 degrees, 540 degrees), which results in a characteristic “throbbing” sound at idle.

The suspension offers more vertical travel and adjustability than the Versys 650 brothers’ suspensions. Externally adjustable preload and rebound damping are available on the front thicker/stiffer 41 mm inverted telescopic forks. The right fork leg houses a damping cartridge, while both legs are spring-loaded. The rebound damping of the rear shock absorber is adjustable. The rear suspension preload is adjustable via a screw collar on the shock. Models from 2015 and above feature an external adjustment. Instead of the more basic steel swing arm used on the Ninja and ER-6, the rear shock/spring is directly attached, without linkages, to a non-symmetrical, gull wing, aluminum swing arm.

Source: Wikipedia