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