Klr 650 Service Manual

  1. 2008 Klr 650 Service Manual Pdf
  2. 2008 Kawasaki Klr 650 Service Manual
  • 2
    Quick Reference Guide
  • 5
    Safety Instructions
  • 6
    Foreword
  • 8
    General Information
  • 8
    Table of Contents
  • 9
    Torque and Locking Agent
  • 11
    General Fasteners
  • 12
    Cable, Wire and Hose Routing
  • 12
    Control Cables
  • 13
    Electrical Wires
  • 15
    Fuel System
  • 16
    Exploded View
  • 18
    Specifications
  • 21
    Engine Top End
  • 23
    Service Data
  • 25
    Camshaft Chain Tensioner
  • 25
    Installation
  • 26
    Cylinder, Piston
  • 26
    Installation Points of Piston Rings
  • 26
    Muffler
  • 26
    Spark Arrester Cleaning (U.S. Model}
  • 27
    Engine Right Side/Left Side
  • 31
    Play Inspection
  • 31
    Clutch Release Removal
  • 31
    Engine Lubrication System
  • 31
    Engine Sprosket
  • 32
    Balancer Mechanism
  • 32
    Removal Point
  • 32
    Assembly Points
  • 33
    Engine Removal/Installation
  • 34
    Engine Unit
  • 34
    Removal
  • 36
    Engine Bottom End/Transmission
  • 40
    Wheels/Tires
  • 43
    Adjustment After Tire Installation
  • 43
    Rear Wheel Removal
  • 43
    Rear Wheel Installation Points
  • 43
    Front Wheel Balance
  • 45
    Final Drive
  • 47
    Drive Chain
  • 47
    Chain Slack Inspection
  • 47
    Chain Slack Adjustment
  • 47
    Drive Chain Removal
  • 48
    Brakes
  • 52
    Front Brake Adjustment/Inspection
  • 52
    Front Brake Disassembly/Assembly
  • 52
    Pad Removal Points
  • 52
    Caliper Assembly Points
  • 53
    Master Cylinder Disassembly Points
  • 53
    Rear Brake Adjustment/Inspection
  • 53
    Pedal Position Adjustment
  • 54
    Brake Fluid Level Inspection
  • 54
    Rear Brake Disassembly/Assembly
  • 54
    Inspection and Adjustment After Installation
  • 54
    Pad Removal
  • 55
    Caliper Removal
  • 55
    Master Cylinder Installation Points
  • 55
    Brake Maintenance
  • 55
    Brake Disc Runout Inspection
  • 56
    Suspension/Steering
  • 61
    Front Fork
  • 61
    Fork Disassembly
  • 61
    Guide Bush Replacement
  • 61
    Spring Preload Adjustment
  • 62
    Setting Table for Spring Preload and Damper Adjusters
  • 62
    Rear Shock Removal
  • 62
    Rear Shock Installation Point
  • 63
    Controls/Instruments
  • 67
    Throttle Grip
  • 67
    Inspection
  • 67
    Adjustment
  • 68
    Meter Unit
  • 69
    Frame
  • 72
    Disassembly Flow Chart-Chassis
  • 73
    Electrical System
  • 77
    Precautions
  • 77
    Charging System Wiring Diagram
  • 77
    Measuring Stator Coil Resistance
  • 77
    Regulator/Rectifier Inspection
  • 78
    Regulator/Rectifier Terminal
  • 78
    Rectifier Circuit Inspection
  • 78
    Regulator Circuit Test
  • 79
    Ignition System
  • 79
    Spark Plug Cleaning and Gapping
  • 79
    Magneto Removal or Installation
  • 79
    Ignition Coil Installation
  • 80
    Ignition System Wiring Diagram
  • 80
    Switch Inspection
  • 80
    Starter Lockout Switch Connections
  • 80
    Engine Stop Switch and Starter Button Connections
  • 81
    Ignition Coil Inspection
  • 82
    CDI Unit Inspection
  • 82
    CDI Unit Internal Resistance
  • 82
    Exciter or Pickup Coil Inspection
  • 83
    Starter Motor Removal
  • 83
    Installation Points
  • 83
    Starter Motol Disassembly
  • 83
    Starter Motor Assembly Points
  • 84
    Starter Clutch Removal
  • 84
    Starter Motor Brush Length
  • 84
    Brush Spring Inspection
  • 84
    Commutator Cleaning and Inspection
  • 85
    Armature Inspection
  • 85
    Brush Plate Inspection
  • 85
    Positive Brush Assembly Inspection
  • 85
    Starter Relay Inspection
  • 86
    Starter Circuit Relay Inspection
  • 86
    Starter Button Inspection
  • 86
    Starter Clutch Inspection
  • 87
    Electric Starter System Wiring Diagram
  • 87
    Lighting System
  • 87
    Headlight Vertical Adjustment
  • 88
    Headlight, Dimmer, or Passing Switch Inspection
  • 88
    Headlight, Dimmer, or Passing Switch Connections
  • 88
    Tachometer and Water Temperature Gauge
  • 89
    Tachometer Inspection
  • 89
    Radiator Fan
  • 89
    Initial Check
  • 89
    Fan Motor/Relay Inspection
  • 90
    Wiring Diagram
  • 92
    Appendix
  • 93
    Troubleshooting Guide
  • 93
    General Lubrication
  • 93
    Nut, Bolt, and Fastener Tightness
  • 95
    Supplement-2000-2001 Models
  • 96
    How to Use This Manual
  • 97
    Model Identification
  • 97
    KL650-A14 Left Side View
  • 97
    KL650-A14 Right Side View
  • 98
    General Specifications
  • 100
    Torgue and Locking Agent
  • 100
    Fuel System Specification
  • 108
    KL650-A14/A15 Wiring Diagram
  • 108
    Left Handlebar Switch Connections
  • 109
    Ignition Switch Connections
  • 109
    Color Code
  • 110
    Supplement-2002 Model
  • 116
    Model Application

The Kawasaki KLR 650 manual by Clymer is the best reference book for repair and service information for your KLR650 motorcycle. Every Clymer motorcycle service manual is written for the do-it-yourself-er as well as the experienced mechanic, Clymer motorcycle repair manuals are the cheapest way to keep your motorcycle running properly.

2008 Klr 650 Service Manual Pdf

650Klr 650 Service Manual

2008 Kawasaki Klr 650 Service Manual

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