CLYMER PUBLICATIONS PRIMEDIA Business Magazines & Media Chief Executive OfficerMartin Maleska Senior Vice President, Sales Operation John French Vice President, PRIMEDIA Business Directories & Books Bob Moraczewski EDITORIAL MARKETINGtSALES AND ADMIM[STRATION Managing Editor Publisher James Grooms Shawn Etheridge Marketing Manager Associate Editor Elda Starke Jason Beaver Advertising & Promotions Coordinators Melissa Abbott Technical Writers Wendy Stringfellow Ron Wright Ed Scott Art Directors George Parise Chris Paxton Mark Rolling Tony Barmann Michael Morlan Jay Bogart Sales Managers Ted Metzger, Manuals Dutch sailer, Marine Editorial Production Manager Matt Tusken, Motorcycles Dylan Goodwin Sales Coordinator Senior Production Editors Marcia Jungles Greg Araujo Operations Manager Shirley Renicker Patricia Kowalczewski Production Editors Customer Service Manager Holly Messinger Terri Cannon Shara Pierceall Customer Service Supervisor Darin Watson Ed McCarty Associate Production Editor Customer Service Representatives Susan Hartington Susan Kohlmeyer April LeBlond Courtney Hollars Technical Illustrators Jennifer Lassiter Steve Amos Ernesto Suarez Errol McCarthy Shawna Davis Mitzi McCarthy Bob Meyer Warehouse & Inventory Manager Mike Rose Leah Hicks The following books and guides are published by PRIMEDIA Business Directories & Books. PR#NI€DlA me - ~~e~tr~nicss~~~eBW~ "')PRICE EQUIPMENTI CLYM E DlGESTS WWW L( WArcH.eq,,l,,...L,,c~l~Ell ,,,, PR~SERI-E-S Your Valuat~on8, Spec f~caton Author~h/ More information available atprimediabooks.com Chapter One General Information Chapter Two Troubleshooting Chapter Three Lubrication, Maintenance and Tune-up Chapter Four Engine Top End Chapter Five Engine Lower End Chapter Six Clutch, Gearshift Linkage and Lubrication System Chapter Seven Transmission and Internal Shift Mechanism Chapter Eight Fuel System Chapter Nine Electrical System Chapter Ten Cooling System Chapter Eleven Wheels, Tires and Drive Chain Chapter Twelve Front Suspension and Steering Chapter Thirteen Rear Suspension Chapter Fourteen Brakes Chapter Fifteen Body Index Wiring Diagrams CONTENTS QUICK REFERENCE DATA ............................... IX CHAPTER ONE GENERAL INFORMATION ............................... 1 Manual organitzation Fasteners Warnings, cautions and notes Shop supplies Safety Basic tools Warning labels Precision measuring tools Serial numbers Storage CHAPTER TWO TROUBLESHOOTING. ............... ..................31 Operating requirements Motorcycle noise Starting the engine Engine leakdown test Four-stroke operating principles Leak-down tester Engine spark test Clutch Engine performance Gear shift linkage and transmission Electrical testing Brakes Starting system Steering and handling Engine noise CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP .................... 43 Pre-ride inspection Periodic lubrication Engine break-in Maintenance and inspection Tune-up and service intervals Engine tune-up Battery Spark plugs Fuel and lubricants CHAPTER FOUR ENGINE TOP END. ...................................79 Shop cleanliness Cylinder head Exhaust system Valves Cylinder head cover Cylinder Camshafts and cam chain tensioner Piston and piston rings CHAPTER FIVE ENGINE LOWER END. ................................. 114 Shop cleanliness Crankcase Engine Seal replacement Cam chain and lower guide Crankcase bearing replacement Left crankcase cover Crankshaft Engine balancer CHAPTER SIX CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM. ...........137 Right crankcase cover Primary drive gear Clutch Clutch cable replacement External gearshift linkage Kickstarter Oil pump CHAPTERSEVEN TRANSMISSION AND INTERNAL SHIFT MECHANISM ................156 Transmission operation Output shaft Service notes Transmission inspection Input shaft Shift drum and forks CHAPTER EIGHT FUEL SYSTEM. .....................................171 Carburetor Evaporative emissions control system Carburetor cleaning and inspection (California models only) Float adjustment Throttle cable replacement Carburetor systems Air filter housing Fuel valve CHAPTER NINE ELECTRICAL SYSTEM ................................. 189 Resistance testing guidelines Ignition system Continuity testing guidelines Charging system Ignition and charging system operation Fan system Alternator cover Water temperature gauge and Stator and pickup coil sending unit Rotor and starter clutch Turn signal relay Starter Headlight Starting system Left handlebar switches CHAPTER TEN COOLING SYSTEM ...................................223 Safety precautions Water temperature sending unit Radiator and fan Water pump Thermostat CHAPTER ELEVEN WHEELS, TIRES AND DRIVE CHAIN ..........................230 Front wheel and speedometer Rim and spoke service drive unit Drive chain Rear wheel Sprockets Front and rear hubs Tire changing CHAPTER TWELVE FRONT SUSPENSION AND STEERING. ........................249 Handlebar Fork removal and installation Steering stem and head Fork service CHAPTER THIRTEEN REAR SUSPENSION ..................................267 Link-type suspension system Swing arm Shock absorber Swing arm service Shock absorber linkage Shock absorber adjustment CHAPTER FOURTEEN BRAKES. ........................................ 284 Disc brake fundamentals Rear master cylinder Front brake pads Rear brake pedal Front brake caliper Brake system draining Front master cylinder Brake system bleeding Rear brake pads Brake disc Rear brake caliper CHAPTER FIFTEEN BODY ...........................................315 Side covers Skid plate Seat Front fender Fuel tank Fairing Radiator covers Subframe INDEX ..........................................319 WIRING DIAGRAMS. ..................................325 CARBURETOR Cooling system c Brake pedal height Choke lever free play Clutch lever free play Drive chain play Drive chain length w Fork air pressure Loads up to 97.5 kg (215 Ib 200 kPa (29 psi) CHAPTER ONE GENERAL INFORMATION This detailed and comprehensive manual covers For example, the sub-heading Handling Gasoline the 1987-2003 Kawasaki KLR650. Safely is located within the main heading SAFETY; 1 The text provides complete information on main- This chapter provides general information on tenance, tune-up, repair and overhaul. Hundreds of shop safety, tools and their usage, service funda- photos and drawings guide the reader through every mentals and shop supplies. Tables 1-7, at the end of job. the chapter, list the following: All procedures are in step-by-step form and Table 1 lists the year and model code numbers for designed for the reader who may be working on the the models covered in this manual. motorcycle for the first time. Table 2 lists general dimensions and weight. Table 3 lists technical abbreviations. MANUAL ORGANITZATION Table 4 lists general torque specifications. Table 5 lists conversion formulas. A shop manual is a tool and as in all Clymer man- Table 6 lists metric tap and drill sizes. uals, the chapters are thumb tabbed for easy refer- Table 7 lists decimal and metric equivalents. ence. Main headings are listed in the table of contents and the index. Frequently used specifica- Chapter Two provides methods for quick and ac- tions and capacities from the tables at the end of curate diagnosis of problems. Troubleshooting pro- each individual chapter are listed in the Quick Ref- cedures present typical symptoms and logical erence Data section at the front of the manual. methods to pinpoint and repair the problem. Specifications and capacities are provided in U.S. Chapter Three explains all routine maintenance standard and metric units of measure. and recommended tune-up procedures necessary to During some of the procedures there will be ref- keep the motorcycle running well. erences to headings in other chapters or sections of Subsequent chapters describe specific systems the manual. When a specific heading is called out it such as engine, transmission, clutch, drive system, in a step it will be italicized as it appears in the man- fuel and exhaust systems, suspension and brakes. ual. If a sub-heading is indicated as being "in this Each disassembly, repair and assembly procedure is section" it is located within the same main heading. discussed in step-by-step form. 2 CHAPTER ONE WARNINGS, CAUTIONS AND NOTES 10. Wear eye protection anytime eye injury is pos- sible. This includes procedures involving drilling, The terms WARNING, CAUTION and NOTE grinding, hammering, compressed air and chemi- have specific meanings in this manual. cals. A WARNING emphasizes areas where injury or 11. Wear the correct clothing for the job. Tie up or even death could result from negligence. Mechani- cover long hair so it cannot get caught in moving cal damage may also occur. WARNINGS are to be equipment. taken seriously. 12. Do not carry sharp tools in clothing pockets. A CAUTION emphasizes areas where equipment 13. Always have an approved fire extinguisher damage could result. Disregarding a CAUTION available. Check that it is rated for gasoline (Class could cause permanent mechanical damage, though B) and electrical (Class C) fires. injury is unlikely. 14. Do not use compressed air to clean clothes, the ANOTE provides additional information to make motorcycle or the work area. Debris may be blown a step or procedure easier or clearer. Disregarding a into the eyes or skin. Never direct compressed air at NOTE could cause inconvenience, but would not yourself or others. Do not allow children to use or cause equipment damage or injury. play with any compressed air equipment. 15. When using compressed air to dry rotating