1987-2007 KAWASAKI KLR650
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Torque specifications / Special tips / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic's tips / Ball bearing replacement / Seals / Riding safety / Storage
CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Spark test / Electrical testing / Engine leakdown test
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Break in / Engine oil and filter change / Fork oil change / Air filter / Cable lubrication / Drive chain cleaning and lubrication / Air filter housing draining / Muffler and spark arrestor cleaning / Balancer chain tensioner adjustment / Carburetor float chamber draining / Cooling system inspection / Drive chain adjustment / Throttle and clutch cable adjustment / Brake pedal adjustment / Idle speed and mixture adjustment / Engine timing check / Compression check / Spark plug plugs
CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts cam shafts camshaft shaft / Cam chain tensioner / Cylinder head / Valves / Cylinder / Piston / Piston rings
CHAPTER FIVE / ENGINE LOWER END
Engine removal installation / Cam chain lower guide / Left crankcase crank case cover / Engine balancer / Crankcase crank case / Seal replacement / Crankshaft crank shaft
CHAPTER SIX / CLUTCH / GEARSHIFT GEAR SHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase cover / Clutch / External gear shift linkage / Oil pump / Primary drive gear / Clutch cable replacement / Kick starter kickstarter
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Input shaft / Output shaft / Transmission inspection
CHAPTER EIGHT / FUEL SYSTEM
Carburetor carb / Cleaning inspection adjustment / Float / Fuel valve / Evaporative emissions control system / Air filter housing
CHAPTER NINE / ELECTRICAL SYSTEM
Resistance testing / Continuity testing / Alternator / Stator and pickup pick up coil / Rotor and starter clutch / Starter / Ignition system / Lighting system / Fan / Water temperature gauge and sending unit / Turn signal relay / Start button / Kill switch
CHAPTER TEN / COOLING SYSTEM
Safety precautions / Radiator / Fan / Thermostat / Water pump
CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Speedometer drive unit / Front and rear wheel wheels / Hub hubs / Rim and spoke service / Drive chain / Sprocket
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering head and stem / Front forks
CHAPTER THIRTEEN / REAR SUSPENSION
Link-type suspension system / Shock absorber / Linkage / Swingarm
CHAPTER FOURTEEN / BRAKES
Brake pad removal installation / Front and rear caliper / Master cylinder / Brake pedal / Brake fluid bleeding
CHAPTER FIFTEEN / BODY
Side covers / Seat / Fuel tank / Radiator covers / Skid plate / Front fender / Fairing / Sub frame
COLOR WIRING DIAGRAMS
