To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board 7- on vehicles sold in California only. 1. Crankcase Emission...

Table of Contents

Exploded View 4-2 Flow Chart - Right Side Parts Removal 4-4 Flow Chart - Left Side Parts Removal 4-5 Engine Lubrication System Service Data 4-6 Special Tools Clutch 4-7 Play Inspection 4-7 Clutch Release Removal 4-7 Clutch Release Installation 4-7 Clutch Housing Finger Inspection Clutch Hub Spline Inspection Kick Starter (Optional) Engine Lubrication System 4-7 Engine Oil and Filter 4-7 Installation Points of Oil Filter Relief Valve Opening Pressure Engine Sprocket 4-7 Balancer Mechanism 4-8...

Exploded View

M Molybdenum Disulfide Grease S Follow the specific tightening sequence. T1 25 N-m (2.5 kg-m, 18.0 ft-lb) T2 44 N-m (4.5 kg-m, 33 ft-lb) T3 98 N-m (10.0 kg-m, 72 ft-lb) For later installation convenience, note and record how and where cables, wires, and hoses are routed. They should not be bent sharply, kinked, or twisted. Drain the engine oil (chapter 4) and coolant (chapter 5). Remove the parts and free the cables and wiring shown in the chart. Place a stand or block under the engine and...

Supplement 2002 Model

This Supplement - 2002 Model designed to be used in conjunction with the front part of this manual (up to 16-15) and or Base Manual KLR600 Service Manual - Part No. 99924-1050-01. The specifications and maintenance procedures described in this chapter are only those that are unique to the KL650-A16 model. Complete and proper servicing of the KL650-A16 model therefore requires mechanics to read both this chapter and the front of this manual. 55 N m (5.6 kgf-m. 40.5 ft-lb) 5500 r min (rpm)

Front Wheel Balance

To improve stability and decrease vibration at high speed, the front wheel must be kept balanced. Check and balance the front wheel when required, or when a tire and or rim is replaced with a new one. Raise the front wheel so that it can be spun freely. Check that all the spokes are tightened evenly and the rim runout is within the service limit. Spin the wheel lightly, and mark the wheel at the top when the wheel stops. Repeat this procedure several times. lf the wheel stops of its own accord...

Engine Bottom End Transmission

Disassembly Flow Special Crankcase Crankcase Disassembly Point Crankcase Assembly Rear Balancer Transmission Disassembly Point Transmission Assembly Points Crankshaft Installation Points Transmission Shift Drum, Shift Fork, Shift Rod, Gear Groove Inspection Crankshaft Disassembly Assembly Crankshaft Connecting Rod Big End Radial Clearance Big End Connecting Rod Side Crankshaft Crankshaft Roller Bearing Wear, Damage Connecting rod big end radial clearance Cold-fitting tolerance between crankpin...

Fuel Tank and Cap Inspection

Visually inspect the gasket on the tank cap for any damage. Replace the gasket if it is damaged. Remove the hose s from the fuel tank, and open the tank cap. Check to see if the breather and water drain pipes also the fuel return pipe for the US California vehicle in the tank are not clogged. Check the tank cap breather too. lf the tank pipes are clogged, remove the tank and drain it and then blow the pipes free with compressed air. lf the tank cap breather is clogged, replace it.

Service Data

Mixed ratio provided coolant when shipping Freezing point provided coolant when shipping Total amount Thermostat Valve opening temperature Valve full opening lift Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Soft water 50 , coolant 50 35 C 31 F 1.3 L 69.5 - 72.5 C 157 - 162 F Not less than 3 mm 85 C 185 F 8. Through Thermostat Air Bl eder Hole

Clutch Release Installation

Refer to the Base Manual, noting the following. Before installing the lever and shaft assembly, check the oil seai and replace it if necessary. Refer to the Base Manual, noting the following. The engine drain plug is installed at the bottom of the crankcase. A. Clutch Lever Play at lever end 10 15 mm Refer to the Base Manual, noting the following. Before pulling out the clutch release lever and shaft assembly, take out the shaft positioning bolt. A. Clutch Lever Play at lever end 10 15 mm Refer...

Fuel System

Exploded Service Special Fuel Removal Idle Idle High Altitude Performance Adjustment U.S model 2-5 Service Fuel Level Service Fuel Level Carburetor Disassembly Assembly Carburetor Adjustment After I Air Element Inspection and Element Installation Body Body Installation Cleaning Fuel Tank and Cap Evaporative Emission Control System Californian Model Periodic Canister Liquid Vapor Separator Inspection Separator Fuel Tank lt West German Model U.S. Model w Swiss Model

Rear Wheel Removal

Klr 650 Rear Axle

Remove the rear caliper from the caliper holder with the brake hose connected. A. Caliper Mounting Bolts B. Caliper Holder A. Caliper Mounting Bolts B. Caliper Holder Remove the cotter pin and take off the rear axle nut. Place a stand or block under the motorcycle so that the rear wheel is raised off the ground. Pull the rear axle off the wheel and free the drive chain from the rear sprocket.