The Kawasaki KLR650 is a versatile dual-sport motorcycle renowned for its reliability, durability, and capability in both on-road and off-road conditions. Produced for the 2008 through 2012 model years, this adventure touring machine offers a robust 652cc single-cylinder engine, a 5-speed transmission, and a substantial 6.1-gallon fuel tank, providing extended range for commuting, touring, and light trail riding. Its design emphasizes practicality and enduring performance, supported by a strong aftermarket and a legacy of dependable service, making it a popular choice for riders seeking adventure without compromising on practicality or affordability. This comprehensive workshop service manual provides in-depth technical information and detailed procedures for the Kawasaki KLR650. It covers all essential aspects of maintenance, repair, and troubleshooting, including engine mechanicals, fuel and cooling systems, transmission, chassis, suspension, and braking systems. Additionally, the manual details electrical system components, bodywork, and wheel/tire services, along with scheduled maintenance, adjustments, and torque specifications. Its purpose is to serve as a complete guide for owners and technicians, ensuring the KLR650 remains in optimal condition through clear, professional instructions and diagnostic guidance. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Code: A1/A2 (depending on region, typically refers to generation) Years Covered: 2008, 2009, 2010, 2011, 2012 Vehicle Type: Dual-sport Motorcycle 👋 Introduction Market Position Vehicle Segment: Adventure Touring / Dual-Sport Key Selling Points: Reliability, versatility for both on-road and off-road use, affordability, strong aftermarket support. Competitive Analysis Primary Competitors: BMW F650GS (pre-2008), Suzuki V-Strom 650, Honda Transalp (earlier models). Key Features Versatility: Designed for commuting, touring, and light off-road excursions. Durability: Known for its robust construction and longevity. Fuel Capacity: Large fuel tank providing extended range. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual (WSM) Language: English Format: PDF Download Manual Completeness: Full Professional Quality, In-Depth 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, and repair of all internal components (pistons, rings, cylinders, crankshaft, connecting rods, camshaft, valves, valve train). Engine Fuel System: Carburetor (CVK40) tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank maintenance. Engine Cooling System: Radiator, cooling fan, coolant flow, thermostat, and related components. Engine Ignition System: CDI unit, ignition coil, spark plug specifications, timing, and troubleshooting. Engine Exhaust System: Exhaust pipes, muffler, catalytic converter (if applicable), and emissions control. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, shifting mechanism, final drive (chain and sprockets). Chassis Frame: Frame inspection, steering head bearing service, and general chassis integrity. Suspension Front: Front fork disassembly, seal replacement, oil levels and type, spring rates, and damping adjustments. Suspension Rear: Rear shock absorber servicing, linkage inspection, and swingarm maintenance. Braking System Front: Front brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul, disc inspection. Braking System Rear: Rear brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul, disc inspection. Electrical System Lighting: Headlight, taillight, turn signals, brake lights, and accessory lighting. Electrical System Instruments: Speedometer, tachometer, odometer, indicator lights, and dashboard assembly. Electrical System Charging: Alternator, stator, rectifier/regulator, battery specifications, and charging system testing. Electrical System Starting: Starter motor, starter solenoid, and battery testing. Electrical System Wiring Harness: Wiring diagrams, component identification, troubleshooting electrical faults. Bodywork Fairings: Fairing removal and installation, plastic component repair, body panel alignment. Wheels Tires: Wheel bearing service, tire pressure specifications, wheel balancing, spoke tensioning (if applicable). Procedures Included Scheduled Maintenance: Detailed procedures for routine checks and servicing at specified intervals (oil changes, filter replacements, chain lubrication, brake checks). Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon mechanical and electrical issues. Disassembly Reassembly: Step-by-step instructions for removing, overhauling, and reinstalling major components and systems. Adjustments: Procedures for adjusting clutch, throttle cables, idle speed, valve clearances, and chain slack. Specifications Torque: Comprehensive list of torque specifications for all critical fasteners and bolts. Component Testing: Instructions for testing the functionality of electrical components like the stator, rectifier, and starter. Technical Depth Diagnostic Capabilities: Advanced diagnostic routines, including electrical system testing and carburetor tuning. Repair Depth: Covers everything from basic fluid changes to full engine and transmission rebuilds. Special Tools: Identifies any specialized tools required for specific procedures. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (typically, dependent on scan quality) Printable: Yes Print Quality Image Resolution: High Resolution (professional quality) Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, four-valve Displacement: 652 cc Bore X Stroke: 100.0 x 83.0 mm Compression Ratio: 8.8:1 Performance Horsepower: Approx. 47 hp @ 6,000 rpm (specifications may vary slightly by region) Torque: Approx. 41.7 lb-ft @ 4,500 rpm (specifications may vary slightly by region) Fuel System Fuel Delivery: Carburetor: Keihin CVK40 Fuel Type: Unleaded gasoline Lubrication Oil Type: SAE 10W-40 API SG or SH, SE, SF classification Oil Capacity With Filter Change: 3.4 US qt (3.2 L) Cooling...