Kawasaki KLR650 Repair Manual 1987-2007

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Item # M474-3  ISBN: 9781599692258




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This repair and service manual covers Kawasaki KLR650 off-road motorcycles, 1987 to 2007.

Table of Contents:

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Warning label | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Storage

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 | Steering and handling

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Pre-ride inspection | Engine break-in | Tune-up and service intervals | Battery | Fuel and lubricants | Periodic lubrication | Maintenance and inspection | Engine tune-up | Spark plugs

CHAPTER FOUR: ENGINE TOP-END
Shop cleanliness | Exhaust system | Cylinder head cover | Camshafts and cam chain tensioner | Cylinder head | Valves | Cylinder | Piston and piston rings

CHAPTER FIVE: ENGINE LOWER-END
Shop cleanliness | Engine | Cam chain and lower guide | Left crankcase cover | Engine balancer | Crankcase | Seal replacement | Crankcase bearing replacement | Crankshaft

CHAPTER SIX: CLUTCH, GEARSHIFT LINKAGE and LUBRICATION SYSTEM
Right crankcase cover | Clutch | External gearshift linkage | Oil pump | Primary drive gear | Clutch cable replacement | Kickstarter

CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission operation | Service notes | Input shaft | Output shaft | Transmission inspection | Shift drum and forks

CHAPTER EIGHT: FUEL SYSTEM
Carburetor | Carburetor cleaning and inspection | Float adjustment | Carburetor systems | Fuel valve | Evaporative emissions control system (California models only) | Throttle cable replacement | Air filter housing

CHAPTER NINE: ELECTRICAL SYSTEM
Resistance testing guidelines | Continuity testing guidelines | Ignition and charging system operation | Alternator cover | Stator and pickup coil | Rotor and starter clutch | Starter | Starting system | Ignition system | Charging system | Fan system | Water temperature gauge and sending unit | Turn signal relay | Headlight | Left handlebar switches

CHAPTER TEN: COOLING SYSTEM
Safety precautions | Radiator and fan | Thermostat | Water temperature sending unit | Water pump

CHAPTER ELEVEN: WHEELS, TIRES and DRIVE CHAIN
Front wheel and speedometer drive unit | Rear wheel | Front and rear hubs | Rim and spoke service | Drive chain | Sprockets | Tire changing

CHAPTER TWELVE: FRONT SUSPENSION and STEERING
Handlebar | Steering stem and head | Fork removal and installation | Fork service

CHAPTER THIRTEEN: REAR SUSPENSION
Link-type suspension system | Shock absorber | Shock absorber linkage | Swing arm | Swing arm service | Shock absorber adjustment

CHAPTER FOURTEEN: BRAKES
Disc brake fundamentals | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Rear brake pedal | Brake system draining | Brake system bleeding | Brake disc

CHAPTER FIFTEEN: BODY
Side covers | Seat | Fuel tank | Radiator covers | Skid plate | Front fender | Fairing | Subframe

COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Kawasaki KLR650 Repair Manual 1987-2007