Kawasaki Klr 650 Maintenance Manual
Instant download 1987-2002 KAWASAKI KLR650 SERVICE REPAIR MANUAL, Fix it! Keep Your Motorcycle Running Smoothly. 1987-2002 KAWASAKI KLR650 SERVICE REPAIR MANUAL. This is the COMPLETE factory service workshop repair manua1 printed for the KAWASAKI KLR650. KLR650.NET - #1 Ranked Kawasaki KLR650 Forums! Tech support, KLR650 parts, maintenance forum, reviews, used KLR650 for sale, modifications and MORE!
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Instant download 1987-2002 KAWASAKI KLR650 SERVICE REPAIR MANUAL, Fix it!
Keep Your Motorcycle Running Smoothly.
Nlite. 1987-2002 KAWASAKI KLR650 SERVICE REPAIR MANUAL
This is the COMPLETE factory service workshop repair manua1 printed for the KAWASAKI KLR650.
Production model years 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002.
All styles covered.
These manua1s are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manua1 is an inexpensive way to keep your KAWASAKI KLR650 working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Simply print out the pages you need or print the entire manua1 as a whole!!! Hundreds of pages allow you to print it out in its entirety or just the pages you need!!
1987-2002 KAWASAKI KLR650 SERVICE REPAIR MANUAL includes:
* Detailed substeps expand on repair procedure information
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Numbered instructions guide you through every repair procedure step by step.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
* Numbered table of contents easy to use so that you can find the information you need fast.
* This manual also makes it easy to diagnose and repair problems with your machines electrical system.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
TABLE OF CONTENTS:
General Information
Fuel System
Cooling System
Engine Top End
Engine Lubrication System
Engine Removal/Installation
Crankshaft/Transmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix
Kawasaki Klr 650 Reviews
Models Covers:
1987 Kawasaki KL650-A1
1987 Kawasaki KL500-A1
1988 Kawasaki KL650-A2
1988 Kawasaki KL500-A2
1989 Kawasaki KL650-A3
1990 Kawasaki KL650-A4
1991 Kawasaki KL650-A5
1992 Kawasaki KL650-A6
1993 Kawasaki KL650-A7
1994 Kawasaki KL650-A8
1995 Kawasaki KL650-A9
2000 Kawasaki KL650-A14
2001 Kawasaki KL650-A15
2002 Kawasaki KL650-A16
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Kawasaki Klr 650 Maintenance Manual Download
- 2Quick Reference Guide
- 5Safety Instructions
- 6Foreword
- 8General Information
- 8Table of Contents
- 9Torque and Locking Agent
- 11General Fasteners
- 12Cable, Wire and Hose Routing
- 12Control Cables
- 13Electrical Wires
- 15Fuel System
- 16Exploded View
- 18Specifications
- 21Engine Top End
- 23Service Data
- 25Camshaft Chain Tensioner
- 25Installation
- 26Cylinder, Piston
- 26Installation Points of Piston Rings
- 26Muffler
- 26Spark Arrester Cleaning (U.S. Model}
- 27Engine Right Side/Left Side
- 31Play Inspection
- 31Clutch Release Removal
- 31Engine Lubrication System
- 31Engine Sprosket
- 32Balancer Mechanism
- 32Removal Point
- 32Assembly Points
- 33Engine Removal/Installation
- 34Engine Unit
- 34Removal
- 36Engine Bottom End/Transmission
- 40Wheels/Tires
- 43Adjustment After Tire Installation
- 43Rear Wheel Removal
- 43Rear Wheel Installation Points
- 43Front Wheel Balance
- 45Final Drive
- 47Drive Chain
- 47Chain Slack Inspection
- 47Chain Slack Adjustment
- 47Drive Chain Removal
- 48Brakes
- 52Front Brake Adjustment/Inspection
- 52Front Brake Disassembly/Assembly
- 52Pad Removal Points
- 52Caliper Assembly Points
- 53Master Cylinder Disassembly Points
- 53Rear Brake Adjustment/Inspection
- 53Pedal Position Adjustment
- 54Brake Fluid Level Inspection
- 54Rear Brake Disassembly/Assembly
- 54Inspection and Adjustment After Installation
- 54Pad Removal
- 55Caliper Removal
- 55Master Cylinder Installation Points
- 55Brake Maintenance
- 55Brake Disc Runout Inspection
- 56Suspension/Steering
- 61Front Fork
- 61Fork Disassembly
- 61Guide Bush Replacement
- 61Spring Preload Adjustment
- 62Setting Table for Spring Preload and Damper Adjusters
- 62Rear Shock Removal
- 62Rear Shock Installation Point
- 63Controls/Instruments
- 67Throttle Grip
- 67Inspection
- 67Adjustment
- 68Meter Unit
- 69Frame
- 72Disassembly Flow Chart-Chassis
- 73Electrical System
- 77Precautions
- 77Charging System Wiring Diagram
- 77Measuring Stator Coil Resistance
- 77Regulator/Rectifier Inspection
- 78Regulator/Rectifier Terminal
- 78Rectifier Circuit Inspection
- 78Regulator Circuit Test
- 79Ignition System
- 79Spark Plug Cleaning and Gapping
- 79Magneto Removal or Installation
- 79Ignition Coil Installation
- 80Ignition System Wiring Diagram
- 80Switch Inspection
- 80Starter Lockout Switch Connections
- 80Engine Stop Switch and Starter Button Connections
- 81Ignition Coil Inspection
- 82CDI Unit Inspection
- 82CDI Unit Internal Resistance
- 82Exciter or Pickup Coil Inspection
- 83Starter Motor Removal
- 83Installation Points
- 83Starter Motol Disassembly
- 83Starter Motor Assembly Points
- 84Starter Clutch Removal
- 84Starter Motor Brush Length
- 84Brush Spring Inspection
- 84Commutator Cleaning and Inspection
- 85Armature Inspection
- 85Brush Plate Inspection
- 85Positive Brush Assembly Inspection
- 85Starter Relay Inspection
- 86Starter Circuit Relay Inspection
- 86Starter Button Inspection
- 86Starter Clutch Inspection
- 87Electric Starter System Wiring Diagram
- 87Lighting System
- 87Headlight Vertical Adjustment
- 88Headlight, Dimmer, or Passing Switch Inspection
- 88Headlight, Dimmer, or Passing Switch Connections
- 88Tachometer and Water Temperature Gauge
- 89Tachometer Inspection
- 89Radiator Fan
- 89Initial Check
- 89Fan Motor/Relay Inspection
- 90Wiring Diagram
- 92Appendix
- 93Troubleshooting Guide
- 93General Lubrication
- 93Nut, Bolt, and Fastener Tightness
- 95Supplement-2000-2001 Models
- 96How to Use This Manual
- 97Model Identification
- 97KL650-A14 Left Side View
- 97KL650-A14 Right Side View
- 98General Specifications
- 100Torgue and Locking Agent
- 100Fuel System Specification
- 108KL650-A14/A15 Wiring Diagram
- 108Left Handlebar Switch Connections
- 109Ignition Switch Connections
- 109Color Code
- 110Supplement-2002 Model
- 116Model Application