The Kawasaki KLR650 is a versatile dual-sport motorcycle, produced for the model years 2008 through 2012. Renowned for its durability, simplicity, and affordability, it is engineered as a capable machine for both on-road commuting and light off-road adventures. Its robust construction and reliable single-cylinder engine have earned it a reputation as a dependable companion for riders seeking a no-nonsense, go-anywhere motorcycle. The KLR650 platform is appreciated for its straightforward mechanical design, making it accessible for riders who prefer to perform their own maintenance. This comprehensive workshop service manual provides detailed guidance for the repair and maintenance of the Kawasaki KLR650 from 2008 to 2012. Covering all essential systems, including the engine, fuel system, transmission, brakes, suspension, and electrical components, this manual offers step-by-step procedures for disassembly, assembly, inspection, and adjustment. It also includes routine maintenance schedules, troubleshooting guides for common issues, and technical specifications. This resource is designed to assist owners, mechanics, and technicians in keeping their KLR650 in optimal condition, ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Years Covered: 2008, 2009, 2010, 2011, 2012 Vehicle Type: Dual-Sport Motorcycle Codes Manual Product Name: Kawasaki KLR650 2008 2009 2010 2011 2012 Service Manual W PDF Download 👋 Introduction Market Position Segment: Mid-weight adventure touring motorcycle Target Audience: Riders seeking a versatile, reliable, and affordable motorcycle for commuting, touring, and light off-road use Competitive Analysis Competitors: Honda XR650L, Suzuki DR650SE, Yamaha XT660R (comparable era) Key Features Durability: Known for its robust construction and long-term reliability Versatility: Capable on pavement and gravel roads, suitable for commuting and touring Simplicity: Relatively simple mechanical design, making it easier to maintain and repair Affordability: Often positioned as a budget-friendly option in the dual-sport segment 📋 Manual Details Coverage Areas Primary Coverage: Repair and maintenance of Kawasaki KLR650 models from 2008-2012 Page Count Total Pages: 477 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair Fuel System: Carburetor adjustment and overhaul, fuel pump, fuel tank, fuel lines Cooling System: Radiator, fan, thermostat, coolant flow Ignition System: Spark plugs, ignition coils, CDI unit, timing Transmission: Clutch operation, gearbox disassembly and assembly, shift drum and forks Drivetrain: Chain adjustment and replacement, countershaft and rear sprocket Suspension: Front fork (telescopic, cartridge type) overhaul and adjustment, rear shock absorber (mono-shock) service Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, rotor inspection and replacement Electrical System: Wiring diagrams, battery, charging system, lighting, starting system, fuses, relays Frame And Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, controls Wheels And Tires: Wheel bearing service, tire replacement, balancing Exhaust System: Muffler and header pipe inspection and service Procedures Included Maintenance: Routine maintenance, lubrication, filter changes, fluid checks and replacements Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides Removal Installation: Step-by-step instructions for removing and reinstalling all major components Disassembly Assembly: Detailed breakdown and reassembly of engine, transmission, suspension, and other systems Adjustments: Carburetor, valve clearance, chain tension, brake lever, clutch lever adjustments Inspection: Wear limits, tolerances, and condition checks for various parts Technical Depth Depth: Comprehensive, from basic rider maintenance to full engine rebuilds and advanced diagnostics Detail Level: Detailed explanations, pictorial diagrams, exploded views, and step-by-step procedures Special Tools: References to required special service tools with illustrations of their usage 📊 Manual Specifications File Format Quality: High-quality PDF, printable pages, searchable content (implied) Print Quality Printability: Yes, all pages are printable Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Compatibility Operating Systems: Windows, Mac, Linux OS Requirements Software Requirement: Adobe Reader ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves Displacement: 651 cc (cubic centimeters) Bore X Stroke: 100.0 mm x 83.0 mm (approximate) Cooling Method: Liquid-cooled Performance Horsepower Peak: Approx. 48 HP @ 6500 RPM (may vary slightly by year and specific market) Torque Peak: Approx. 42 lb-ft @ 5500 RPM (may vary slightly by year and specific market) Fuel System Carburetor: Keihin CVK40 (Constant Velocity Carburetor) Fuel Capacity: 6.1 gal (23 L) Lubrication System Oil Capacity: Approx. 2.1 L (with filter change) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-disc Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: 2,275 mm (89.6 in) Width: 905 mm (35.6 in) Height: 1,320 mm (52.0 in) Weights Curb Weight: Approx. 195 kg (430 lbs) Seat Height: Approx. 860 mm (33.9 in) Ground Clearance: Approx. 210 mm (8.3 in) Wheelbase: 1,470 mm (57.9 in) 🛡️ Safety Features Ratings Safety Features Overview: Emphasis on user-applied safety through correct maintenance and operation as detailed in the manual Active Features Braking System: Dual piston front caliper, single piston rear caliper; disc brakes front and rear Passive Features Frame Construction:...