This manual covers the KLX 650 R, a versatile dual-sport motorcycle produced from 1987 to 2007. Renowned for its robust engineering and reliability, the KLX 650 R is designed for both on-road commuting and off-road adventures. Its durable liquid-cooled, 4-stroke, single-cylinder engine, coupled with a 5-speed transmission and chain drive, provides dependable performance across a variety of terrains. The model's extended production run signifies its enduring popularity and capability, reflecting a legacy in producing capable off-road and dual-sport machines. This comprehensive Workshop Service Manual provides detailed instructions for the maintenance, repair, and overhaul of the KLX 650 R. It covers all major systems, including the engine, transmission, fuel system, ignition, brakes, and suspension. The manual includes routine maintenance procedures, diagnostic guides for common issues, and step-by-step repair instructions for component disassembly and reassembly. Essential technical specifications, troubleshooting advice, and safety precautions, including the proper use of tools and equipment, are also detailed. This resource is intended for mechanical technicians and knowledgeable owners seeking to perform professional-quality service. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX 650 R Vehicle Type: Dual-sport Motorcycle Generation Production Years Covered By Manual: 1987-2007 Codes Chassis Code Range: Not specified in provided information, but typically includes variations like KL650A, KL650B for different configurations. 👋 Introduction Market Position Target Audience: Mechanical technicians and knowledgeable motorcycle owners undertaking maintenance and repair. Competitive Analysis Manual Advantage: Provides detailed, OEM-level information enabling professional-quality service and cost savings for DIY repairs. Key Features Information Reliability: Cited as the most reliable information, mirroring authorized dealer service department procedures. Safety Emphasis: Highlights the importance of safety equipment and precautions, including the use of a torque wrench. Document Structure: Emphasizes important information through WARNING, CAUTION, and NOTE notations. 📋 Manual Details Coverage Areas Engine Systems: Engine overhaul, tune-ups, lubrication system, fuel system, ignition system, exhaust system. Transmission Systems: Transmission disassembly and assembly, clutch operation. Chassis Systems: Frame, suspension (front and rear), wheels, tires, brakes (front and rear), steering. Electrical Systems: Electrical system diagnostics, wiring diagrams, lighting, charging system, ignition. Bodywork And Accessories: Body panel removal and installation, fairings, seat, fuel tank, fenders. Page Count Estimated Page Count: Not explicitly stated, but comprehensive workshop manuals typically range from 300-800+ pages depending on the depth of coverage. Manual Type Manual Type: Workshop Service Manual Language Language: English Format Delivery Method: PDF Download (Electronic Delivery via Email) 📖 Manual Coverage Systems Covered Engine: Complete engine repair and overhaul, including top-end and bottom-end procedures. Covers all internal components, timing, and sealing. Transmission: Detailed procedures for gearbox removal, disassembly, inspection, repair, and reassembly. Includes gear shift mechanism. Fuel System: Carburetor (likely Keihin CVK type for the era) inspection, cleaning, adjustment, and overhaul. Fuel tank and petcock service. Ignition System: Ignition timing, spark plug specifications, CDI unit, coil testing, and troubleshooting. Suspension: Front fork (telescopic) service, seal replacement, oil level and type, rear shock absorber adjustments and service. Brakes: Front and rear brake system servicing, including hydraulic brake fluid replacement, caliper disassembly, pad replacement, and disc inspection. Electrical: Comprehensive electrical troubleshooting, wiring diagrams, lighting system (headlight, taillight, indicators), battery maintenance, charging system (stator, regulator/rectifier). Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks, air filter cleaning/replacement, brake fluid checks, tire pressure checks. Diagnostics: Troubleshooting guides for common problems across all major systems, including engine performance issues, electrical faults, and brake problems. Repair And Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for virtually every part of the motorcycle. Tune Ups: Specific procedures for optimizing engine performance, including carburetor adjustments, ignition timing verification, and valve clearance checks. Special Tools: Identification and usage instructions for specialized tools required for specific maintenance and repair tasks. Technical Depth Depth Of Information: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis component overhauls. 📊 Manual Specifications File Format File Format: PDF Print Quality Printable: Yes Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, single-cylinder (typically a 651cc or similar displacement, though exact spec not provided here). Bore X Stroke: Specifics not provided, but typical for this era and displacement. Compression Ratio: Specifics not provided, but typically around 9.5:1 to 10.5:1. Performance Horsepower: Estimated 47-50 HP at peak RPM, specific figures not provided. Torque: Estimated 37-40 lb-ft at peak RPM, specific figures not provided. Fuel System Carburetor Type: Likely a single Keihin CVK (Constant Velocity Carburetor), with specifications for jetting and settings detailed in the manual. Fuel Capacity: Typically around 3.7 gallons (14 liters), but specific to model variations. Lubrication System Oil Type Capacity: Manual will specify recommended oil grade (e.g., SAE 10W-40 motorcycle oil) and capacity. Likely around 2.5-3.0 quarts (2.4-2.8 liters) with filter change. 🔧 Transmission Standard Transmission Type: 5-speed...