The Kawasaki KLR650 is a versatile dual-sport motorcycle renowned for its durability and capability across a wide range of conditions, from urban commuting to adventure touring and light off-road excursions. Produced for the 2008 through 2012 model years, this third-generation model (KL650E) builds on Kawasaki's legacy of producing reliable and practical machines. Its robust 651cc liquid-cooled single-cylinder engine, coupled with a 5-speed transmission and long-travel suspension, provides a comfortable and capable riding experience. The KLR650 is celebrated for its strong value proposition, offering a blend of performance, ruggedness, and affordability that makes it a popular choice for riders seeking a dependable all-around motorcycle. This comprehensive workshop service repair manual provides detailed guidance for the maintenance and repair of your Kawasaki KLR650 motorcycle. Covering all essential systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, frame, suspension, brakes, and electrical systems, this manual offers step-by-step instructions for everything from routine maintenance, such as oil changes and valve adjustments, to more complex repairs and overhauls. It includes troubleshooting procedures, technical specifications with precise torque values, and detailed diagrams to assist owners, mechanics, and technicians in keeping their KLR650 in optimal condition and ensuring its longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Type: Motorcycle Generation Generation Code: KL650E (Third Generation) Codes Vin Code: 3K2 👋 Introduction Market Position Category: Dual-sport motorcycle, adventure touring Target Audience: Commuters, adventure riders, touring enthusiasts, budget-conscious motorcyclists. Competitive Analysis Key Competitors: BMW G 650GS, Suzuki DR650, Honda XR650L. Key Features Durability: Renowned for its ruggedness and reliability, often referred to as the 'workhorse' of Kawasaki's lineup. Versatility: Capable of handling paved roads, dirt trails, and long-distance touring. Value Proposition: Offers a strong balance of performance, durability, and affordability. 📋 Manual Details Coverage Areas Applicable Years: 2008, 2009, 2010, 2011, 2012 Region Of Operation: Global (specific market variations may exist) Page Count Estimated Pages: 400-500 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (e.g., PDF) 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, inspection, and repair of the 651cc single-cylinder engine. Fuel System: Carburetor (Mikuni BSR32) system, fuel tank, fuel pump, and fuel lines. Ignition System: CDI ignition system, spark plug, ignition coil, and timing. Cooling System: Liquid cooling system, radiator, fan, thermostat, and coolant flow. Transmission: 5-speed constant mesh transmission, clutch assembly, shift mechanism, and lubrication. Drivetrain: Final drive chain and sprockets, inspection, adjustment, and replacement. Frame And Suspension: Frame inspection, front forks (telescopic, cartridge type), rear shock absorber (Uni-Trak system), adjustments, and servicing. Brakes: Front disc brake (single piston caliper), rear disc brake (single piston caliper), hydraulic system, brake fluid, pad replacement, and bleeding procedures. Electrical System: Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, and wiring diagrams. Wheels And Tires: Spoke wheels, tire inspection, pressure, and replacement. Bodywork And Trim: Fairing, fenders, seat, fuel tank cover, and related components. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain lubrication, valve clearance checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common running issues, starting problems, electrical faults, and performance anomalies. Repair: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Adjustments: Carburetor adjustment, idle speed, clutch lever play, brake lever play, chain slack, suspension settings. Specifications: Detailed technical specifications for all components, including torque values, clearances, fluid capacities, and electrical tolerances. Technical Depth Depth: Comprehensive coverage from basic rider maintenance to complete engine and transmission rebuilds. Diagnostic Tools: Guidance on using basic tools and understanding diagnostic flowcharts. Special Tools: Identification and usage of any specialized tools required for specific procedures. 📊 Manual Specifications File Format Type: Portable Document Format (PDF) Searchability: Likely text-searchable, enabling quick access to specific information. Print Quality Resolution: High-resolution, suitable for on-screen viewing and printing. Illustrations: Detailed diagrams, exploded views, and photographs for visual guidance. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, DOHC, 4-valve Displacement: 651 cc (39.7 cu. in.) Bore X Stroke: 100.0 x 83.0 mm Cooling System: Liquid-cooled Compression Ratio: 8.3:1 Performance Horsepower: Approx. 42 hp @ 6,000 rpm (specifications may vary slightly by year/market) Torque: Approx. 39 lb-ft @ 5,000 rpm (specifications may vary slightly by year/market) Fuel System Carburetor: Mikuni BSR32 (constant velocity type) Fuel Tank Capacity: 18 Liters (4.8 US gal) 🔧 Transmission Standard Type: 5-speed, constant mesh Clutch: Wet, multi-disc, cable-actuated Optional Optional Transmission: N/A Features Gear Ratios: Specific ratios are detailed within the manual. Transmission Fluid: Refer to manual for specific type and capacity (typically SAE 10W-30 or 10W-40 motorcycle specific engine oil). 📐 Dimensions Exterior Length: 2,255 mm (88.8 in.) Width: 910 mm (35.8 in.) Height: 1,410 mm (55.5 in.) Wheelbase: 1,465 mm (57.7 in.) Ground Clearance: 210 mm (8.3 in.) Seat Height: 860 mm (33.9 in.) Weights Curb Weight: Approx. 194 kg (427.7 lbs)...