The 2008-2017 Kawasaki KLR650 repair manual by Clymer covers the dual-purpose motorcycle models indicated.

The text provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos guide the reader through every job with step-by-step procedures intended for the reader who may be working on the motorcycle for the first time. The manual contains more than 300 pages, and the illustrations should truly facilitate the DIY service projects riders are trying to tackle.

Learn how to remove, disassemble, inspect, repair and assemble a carburetor. Get instructions on fuel valve servicing, replacing throttle and choke cables, removing air filter housing and lubricating and adjusting cables. Learn how the carburetor operates with clear illustrations to show you the way. There are also tips on the exhaust, electrical system, front and rear suspension, and a section on troubleshooting.

Book Excerpt: 2008-2017 Kawasaki KLR 650 Repair Manual FUEL SYSTEM

This chapter provides service procedures for removing, disassembling, inspecting, repairing and assembling the carburetor. Also included is carburetor operation. Table 1 at the end of this chapter provides standard carburetor specifications. Refer to this chapter for fuel valve servicing, throttle and choke cable replacement and air filter housing removal. Also included is a schematic of the evaporative emission control system (California models only). Refer to Chapter Three for air filter service, cable adjustments and cable lubrication. Refer to Safety and Service Methods in Chapter One.

CARBURETOR: OPERATION

The Keihin CVK 40 is a vacuum-controlled, constant velocity carburetor. It uses both a throttle valve and diaphram-operated slide to regulate fuel to the engine. The throttle valve (Figue 1) is located on the outlet end of the carburetor and is connected to the throttle cables. The slide and diaphragm assembly, located at the center of the carburetor, regulates fuel by a jet needle at the bottom of the slide (Figure 2). The diaphragm is located at the top of the slide in the diaphragm chamber (Figure 3). The diaphragm divides and seals the large chamber into a lower and upper chamber.

COOLANT RESERVE TANK: REMOVAL/INSTALLATION

1. Remove the skid plate as described in Chapter Fifteen.
2. Support the motorcycle so it is vertical and level.
3. Remove the right, lower fairing as described in Chapter Fifteen.
4. Remove the reserve tank cover.
5. Detach the reserve tank overflow hose (A, Figure 20) from the tank.
6. Remove the bolts from the corners of the reserve tank (B, Figure 20), then invert the tank and pour out the contents.
7. Detach the radiator overflow hose from the tank, then remove the tank.

Subject: 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017 Kawasaki KLR650 service, maintenance, repair. ISBN-10: 1620922746 | ISBN-13: 9781620922743 | Clymer M240-2