2011 Kawasaki KLR650 Owners Manual
2011 Kawasaki KLR650 Manual
2011 Kawasaki KLR650 manual content summary:
- 2011 Kawasaki KLR650 | Owners Manual - Page 1
KLR650 Motorcycle - 2011 Kawasaki KLR650 | Owners Manual - Page 2
- 2011 Kawasaki KLR650 | Owners Manual - Page 3
Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION HOW TO RIDE THE MOTORCYCLE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j A Table of Contents is included after the Foreword. - 2011 Kawasaki KLR650 | Owners Manual - Page 4
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER - 2011 Kawasaki KLR650 | Owners Manual - Page 5
. This manual offers many safe riding tips, but its purpose is not to provide instruction in all trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual - 2011 Kawasaki KLR650 | Owners Manual - Page 6
available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Motorcycle & Engine Company © 2010 Kawasaki Heavy - 2011 Kawasaki KLR650 | Owners Manual - Page 7
TABLE OF CONTENTS SPECIFICATIONS...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS...LOADING INFORMATION ...GENERAL INFORMATION ...Meter Instruments ...Speedometer and Tachometer: ...Coolant Temperature Gauge: ...Warning/Indicator Lights: ...Key ...Ignition Switch/Steering Lock - 2011 Kawasaki KLR650 | Owners Manual - Page 8
Beam...Rear Turn Signal Light ...Fuses ...General Lubrication...Cleaning Your Motorcycle ...Bolt and Nut Tightening...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...Reporting Safety Defects ...ENVIRONMENTAL PROTECTION ...LABEL INFORMATION ...MAINTENANCE RECORD ... 120 124 126 - 2011 Kawasaki KLR650 | Owners Manual - Page 9
SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetion System Ignition System DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled 651 cm³ (39.7 cu - 2011 Kawasaki KLR650 | Owners Manual - Page 10
8 SPECIFICATIONS Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio 5-speed, return shift Wet, multi - 2011 Kawasaki KLR650 | Owners Manual - Page 11
SPECIFICATIONS 9 Gear Ratio: 1st 2nd 3rd 4th 5th 2.267 (34/15) 1.444 (26/18) 1.136 (25/22) 0.955 (21/22) 0.792 (19/24) 28° 112 mm (4.4 in.) FRAME Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 55 W × 2/55 W (Hi/Lo) 12 - 2011 Kawasaki KLR650 | Owners Manual - Page 12
10 SPECIFICATIONS Specifications subject to change without notice. - 2011 Kawasaki KLR650 | Owners Manual - Page 13
SERIAL NUMBER LOCATIONS 11 SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In - 2011 Kawasaki KLR650 | Owners Manual - Page 14
12 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. Clutch Lever Left Handlebar Switches Meter Instruments Brake Fluid Reservoir (Front) 5. 6. 7. 8. Right Handlebar Switches Front Brake Lever Throttle Grip Ignition Switch/Steering Lock - 2011 Kawasaki KLR650 | Owners Manual - Page 15
LOCATION OF PARTS 13 9. 10. 11. 12. 13. 14. Turn Signal Light Headlight Spark Plugs Main Fuse Battery Seat 15. Tool Kit/Storage Compartments 16. Helmet Hook 17. Tying Hooks 18. Front Fork 19. Brake Disc 20. 21. 22. 23. 24. Brake Caliper Shift Pedal Side Stand Rear Shock Absorber Drive Chain - 2011 Kawasaki KLR650 | Owners Manual - Page 16
14 LOCATION OF PARTS 25. Tail/Brake Light 26. Rear Carrier 27. Brake Fluid Reservoir (Rear) 28. Air Cleaner 29. 30. 31. 32. Fuel Tank Fuel Tank Cap Muffler Rear Brake Light Switch 33. 34. 35. 36. Rear Brake Pedal Oil Level Gauge Idle Adjusting Screw Coolant Reserve Tank - 2011 Kawasaki KLR650 | Owners Manual - Page 17
LOCATION OF LABELS 15 LOCATION OF LABELS 1. 2. 3. 4. Brake Fluid (Front) Brake Fluid (Rear) Tire and Load Data Important Drive Chain Information - 2011 Kawasaki KLR650 | Owners Manual - Page 18
16 LOCATION OF LABELS 5. Daily Safety Checks 6. Vehicle Emission Control Information 7. Noise Emission Control Information *8. Vacuum Hose Routing Diagram 9. Battery Vent Hose 10. Weight and Manufacture *: only on California model - 2011 Kawasaki KLR650 | Owners Manual - Page 19
LOCATION OF LABELS 17 11. Carrier Caution 12. Battery Poison/Danger *13. Fuel Level *: only on California model - 2011 Kawasaki KLR650 | Owners Manual - Page 20
in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some - 2011 Kawasaki KLR650 | Owners Manual - Page 21
still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle. 2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator or grab rail. Do not carry a passenger - 2011 Kawasaki KLR650 | Owners Manual - Page 22
20 LOADING INFORMATION affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle's operation. 7. Weight attached to the handlebar or front fork will increase the mass of the - 2011 Kawasaki KLR650 | Owners Manual - Page 23
GENERAL INFORMATION 21 GENERAL INFORMATION Meter Instruments A. Tachometer B. Red Zone C. Speedometer D. Odometer E. Coolant Temperature Gauge F. Neutral Indicator Light G. Trip RESET Button H. Trip Meter I. High Beam Indicator Light J. Turn Signal Indicator Light - 2011 Kawasaki KLR650 | Owners Manual - Page 24
22 GENERAL INFORMATION Speedometer and Tachometer: The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to - 2011 Kawasaki KLR650 | Owners Manual - Page 25
GENERAL INFORMATION 23 NOTICE Do not let the engine continue running when the gauge needle reaches the "H" line. Prolonged engine operation will result in severe damage from overheating. Warning/Indicator Lights: : When the headlight is on high beam, the high beam indicator light is lit. N: When - 2011 Kawasaki KLR650 | Owners Manual - Page 26
24 GENERAL INFORMATION A. Ignition Key B. Tag C. Key Number Write your key number here. In the event you lose your keys, you will need the key number to have a duplicate made. If you cannot locate your key number, contact the dealer where you purchased your Kawasaki motorcycle. It's possible the - 2011 Kawasaki KLR650 | Owners Manual - Page 27
GENERAL INFORMATION 25 Ignition Switch/Steering Lock This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF or LOCK position. OFF ON LOCK Engine off. All electrical circuits off. Engine on. All electrical equipment can be used. Steering locked. - 2011 Kawasaki KLR650 | Owners Manual - Page 28
26 GENERAL INFORMATION Right Handlebar Switches Engine Stop Switch: In addition to the ignition switch, the engine stop switch must be in position for the motorcycle to the operate. The engine stop switch is for emergency use. If required, move the switch position. to the NOTE żAlthough the - 2011 Kawasaki KLR650 | Owners Manual - Page 29
starter when the transmission is in neutral. Refer to the Starting the Engine section of the "How to Ride the Motorcycle" chapter for starting instructions. Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the ), the headlight is on high beam - 2011 Kawasaki KLR650 | Owners Manual - Page 30
28 GENERAL INFORMATION NOTE żWhen the headlight is on high beam, both head lights are lit. When the headlight is on low beam, only one headlight is lit. Turn Signal Switch: When the turn signal switch is turned ) or right ( ), the to the left ( corresponding turn signal flashes on and off. To - 2011 Kawasaki KLR650 | Owners Manual - Page 31
GENERAL INFORMATION 29 Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position. NOTE żDo not - 2011 Kawasaki KLR650 | Owners Manual - Page 32
30 GENERAL INFORMATION Fuel Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition key to "OFF". Do not smoke. Make sure the area is - 2011 Kawasaki KLR650 | Owners Manual - Page 33
hesitation. Fuel Requirement: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps. The octane rating of a gasoline is a measure of its resistance to detonation or "knocking". The Antiknock Index is an average - 2011 Kawasaki KLR650 | Owners Manual - Page 34
. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty. Fuels Containing Oxygenates - 2011 Kawasaki KLR650 | Owners Manual - Page 35
unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up - 2011 Kawasaki KLR650 | Owners Manual - Page 36
"gasohol" in the fuel system. Before storage it is recommended that you drain all fuel from the fuel system. See the Storage section in this manual. Fuel Tap The fuel tap has three positions: ON, RES (reserve), and OFF. For normal operation, turn the tap lever to the ON position. If - 2011 Kawasaki KLR650 | Owners Manual - Page 37
GENERAL INFORMATION 35 Turn the fuel tap lever to the OFF position when the fuel tank is removed for maintenance and adjustments or the motorcycle is stored for long time. WARNING Practice operating the fuel tap with the motorcycle stopped. To prevent an accident you should be able to operate the - 2011 Kawasaki KLR650 | Owners Manual - Page 38
36 GENERAL INFORMATION Stand The motorcycle is equipped with a side stand. Whenever the side stand is used, make it a practice to kick the stand fully up before sitting on the motorcycle. NOTE żThe motorcycle is equipped with a side stand switch. This switch is designed so that the engine does - 2011 Kawasaki KLR650 | Owners Manual - Page 39
GENERAL INFORMATION 37 Helmet Hook Helmet can be secured to the motorcycle using the helmet hook. The helmet hook can be unlocked by inserting the ignition switch key into the lock, and turning the key to the right. WARNING Riding with a helmet attached to the hook could cause an accident by - 2011 Kawasaki KLR650 | Owners Manual - Page 40
38 GENERAL INFORMATION Rear Carrier The motorcycle is equipped with a carrier on the rear. Vehicle Total Payload (must not exceed). Rear Carrier Maximum Load Capacity 182 kg (401 lb) 10 kg (22 lb) WARNING Overloading the motorcycle and failure to adjust speed for additional cargo could result in - 2011 Kawasaki KLR650 | Owners Manual - Page 41
the motorcycle. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Tying Hooks When tying up light loads to the rear carrier, use the tying hooks located under the rear carrier. A. B. C. D. Rear Carrier - 2011 Kawasaki KLR650 | Owners Manual - Page 42
40 BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a "broken in" motorcycle after a few thousand kilometers. The - 2011 Kawasaki KLR650 | Owners Manual - Page 43
acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by a competent mechanic following the procedures in the Service Manual. - 2011 Kawasaki KLR650 | Owners Manual - Page 44
42 HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine the fuel tap lever to the ON po• Turn sition. • Check that the engine stop switch is position. in the Turn the ignition key to "ON". • Make sure the transmission is in neu• tral. A. Engine Stop Switch B. Starter Button C. - 2011 Kawasaki KLR650 | Owners Manual - Page 45
HOW TO RIDE THE MOTORCYCLE 43 NOTE żWhen the engine is already warm or the throttle completely • Leaving closed, push the starter button with the clutch lever pulled in until the engine starts. on hot days (35°C, 95°F or more), open the throttle part way instead of using the choke, and then - 2011 Kawasaki KLR650 | Owners Manual - Page 46
44 HOW TO RIDE THE MOTORCYCLE NOTE żIf the engine is flooded, crank the en- return the choke lever to• Gradually ward the off position a little at a time as necessary to keep the engine speed below 2 000 r/min (rpm) during warm-up. When the engine is warmed up enough to idle without using the - 2011 Kawasaki KLR650 | Owners Manual - Page 47
HOW TO RIDE THE MOTORCYCLE 45 Ambient temperature choke off after running for Jump Starting If your motorcycle battery is "run down", it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. 20°C (68°F) ∼ 35°C 15 - 2011 Kawasaki KLR650 | Owners Manual - Page 48
46 HOW TO RIDE THE MOTORCYCLE DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection when - 2011 Kawasaki KLR650 | Owners Manual - Page 49
HOW TO RIDE THE MOTORCYCLE 47 the bolt on both side and • Unscrew remove the seat. a jumper cable from the • Connect positive (+) terminal of the booster battery to the positive (+) terminal of the motorcycle battery. A. Seat B. Bolt sure the ignition key is turned • Make to OFF. A. Motorcycle - 2011 Kawasaki KLR650 | Owners Manual - Page 50
48 HOW TO RIDE THE MOTORCYCLE booster battery to your motorcycle footpeg or other unpainted metal surface. Do not use the negative (-) terminal of the battery. WARNING Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last - 2011 Kawasaki KLR650 | Owners Manual - Page 51
HOW TO RIDE THE MOTORCYCLE 49 NOTICE Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. the engine has started, - 2011 Kawasaki KLR650 | Owners Manual - Page 52
50 HOW TO RIDE THE MOTORCYCLE Moving Off the clutch starts to engage, open • As the throttle a little more, giving the enCheck that the side stand is up. Pull in the clutch lever. Shift into 1st gear. Open the throttle a little, and start to let out the clutch lever very slowly. gine just enough - 2011 Kawasaki KLR650 | Owners Manual - Page 53
HOW TO RIDE THE MOTORCYCLE 51 Shifting Gears WARNING Downshifting to a lower gear at high speed causes engine rpm to increase excessively, potentially damaging the engine and it may also cause the rear wheel to skid and cause an accident. Downshifting should be done below 5,000 rpm for each - 2011 Kawasaki KLR650 | Owners Manual - Page 54
52 HOW TO RIDE THE MOTORCYCLE Braking • • • • Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. When stopping, - 2011 Kawasaki KLR650 | Owners Manual - Page 55
HOW TO RIDE THE MOTORCYCLE 53 Stopping the Engine the throttle completely. • Close Shift the into neutral. • Turn the transmission ignition key to "OFF". • Support the motorcycle a firm, • level surface with the sideon stand. • Lock the steering. A. Rear Brake Pedal - 2011 Kawasaki KLR650 | Owners Manual - Page 56
Improper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. 2. During removal of the air cleaner - 2011 Kawasaki KLR650 | Owners Manual - Page 57
such as grasses or dry leaves may contact with muffler or exhaust pipe. Shift the transmission into neutral and turn the ignition key to "OFF". Support the motorcycle on a firm, level surface with the side stand. NOTICE Do not park on a soft or steeply inclined surface, or the motorcycle may fall - 2011 Kawasaki KLR650 | Owners Manual - Page 58
56 HOW TO RIDE THE MOTORCYCLE WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch "OFF". Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this - 2011 Kawasaki KLR650 | Owners Manual - Page 59
HOW TO RIDE THE MOTORCYCLE 57 WARNING The muffler and exhaust pipe are very hot while the engine is running and just after the engine stop. This can ignite a fire, resulting in property damage or severe personal injury. Do not idle or park your vehicle in an area where flammable materials such as - 2011 Kawasaki KLR650 | Owners Manual - Page 60
58 SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. Gloves and suitable footwear should - 2011 Kawasaki KLR650 | Owners Manual - Page 61
SAFE OPERATION 59 In general your actions should be smooth as sudden acceleration, braking or turning may cause loss of control, especially when riding in wet conditions or on loose roadway surfaces, when the ability to maneuver will be reduced. When going up steep slopes, shift to a lower gear so - 2011 Kawasaki KLR650 | Owners Manual - Page 62
60 SAFE OPERATION When quick acceleration is necessary as in passing, shift to a lower gear to obtain the necessary power. Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving. Avoiding unnecessary weaving is important to the safety of both the rider and other - 2011 Kawasaki KLR650 | Owners Manual - Page 63
SAFE OPERATION 61 Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment - 2011 Kawasaki KLR650 | Owners Manual - Page 64
62 SAFE OPERATION Tires ...Air pressure (when cold): Front 150 kPa (1.5 kg/cm², 21 psi) Up to 97.5 kg (215 lbs) 150 kPa (1.5 kg/cm², 21 Load psi) 97.5 ∼ 182 kg (215 ∼ 401 lbs) Load 200 kPa (2.0 kg/cm², 28 psi) Rear Install the air valve cap. Drive chain ...Slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) - 2011 Kawasaki KLR650 | Owners Manual - Page 65
SAFE OPERATION 63 Electrical equipment ...All lights (Headlight, Tail/Brake Lights, Turn Signal Lights, Warning/Indicator Lights) and horn work. Engine stop switch ...Stops engine. Side stand ...Returns to its fully up position by spring tension. Returns spring not weak or not damaged. Refer to the - 2011 Kawasaki KLR650 | Owners Manual - Page 66
64 SAFE OPERATION Additional Considerations for OFF Road Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of - 2011 Kawasaki KLR650 | Owners Manual - Page 67
SAFE OPERATION 65 WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills. - 2011 Kawasaki KLR650 | Owners Manual - Page 68
66 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and - 2011 Kawasaki KLR650 | Owners Manual - Page 69
MAINTENANCE AND ADJUSTMENT 67 EMISSION CONTROL INFORMATION 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 - 2011 Kawasaki KLR650 | Owners Manual - Page 70
only are not considered to be emissions system "tampering" and vehicle performance is generally unchanged as a result. Installation Instructions: High altitude adjustment requires replacement of certain carburetor components. Installation of these optional parts may be performed by an authorized - 2011 Kawasaki KLR650 | Owners Manual - Page 71
Service Manual. MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels. This Owner's Manual recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited - 2011 Kawasaki KLR650 | Owners Manual - Page 72
the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. * Periodic Maintenance Chart K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here - 2011 Kawasaki KLR650 | Owners Manual - Page 73
MAINTENANCE AND ADJUSTMENT 71 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Engine Item) Air cleaner element - clean (e) Valve clearance inspect (e) Throttle control system (play, smooth return, no - 2011 Kawasaki KLR650 | Owners Manual - Page 74
72 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Engine Item) Fuel leak (fuel hose and pipe) inspect Fuel hoses damage - inspect Fuel hoses installation condition - inspect Coolant level inspect Coolant leak inspect - 2011 Kawasaki KLR650 | Owners Manual - Page 75
MAINTENANCE AND ADJUSTMENT 73 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Engine Item) Radiator hoses installation condition - inspect Evaporative emission control system - function (California model only) (e) Air suction system damage - inspect - 2011 Kawasaki KLR650 | Owners Manual - Page 76
74 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Clutch and drive train: Clutch operation (play, engagement, disengagement) inspect Drive chain lubrication - 2011 Kawasaki KLR650 | Owners Manual - Page 77
AND ADJUSTMENT 75 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) K Drive chain guide wear - inspect Tire air pressure inspect Wheels/tires damage - inspect Tire tread wear, abnormal wear inspect K Wheel bearings damage - inspect - 2011 Kawasaki KLR650 | Owners Manual - Page 78
76 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Spoke tightness K and rim runout inspect Brake system: Brake fluid leak inspect Brake hoses damage - inspect Brake pad wear inspect # Brake hose installation - 2011 Kawasaki KLR650 | Owners Manual - Page 79
MAINTENANCE AND ADJUSTMENT 77 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Brake fluid level inspect Brake operation (effectiveness, play, drag) inspect Brake light switch operation - inspect Suspensions: Front forks/rear shock - 2011 Kawasaki KLR650 | Owners Manual - Page 80
78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Front forks/rear K shock absorber oil leak - inspect Uni-trak rocker K arm bearings lubricate Uni-trak rocker K arm operation inspect K Uni-trak tie rods - 2011 Kawasaki KLR650 | Owners Manual - Page 81
MAINTENANCE AND ADJUSTMENT 79 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) K Swing arm pivot lubricate Steering play inspect Every 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • year 2 years - Steering - 2011 Kawasaki KLR650 | Owners Manual - Page 82
80 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Side stand switch operation - inspect Engine stop switch operation inspect Every year year 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) - 2011 Kawasaki KLR650 | Owners Manual - Page 83
MAINTENANCE AND ADJUSTMENT 81 3. Periodic Replacement Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) 1 12 24 36 48 (0.6) (7.5) (15) (22.5) (30) See Page Change/Replacement Items Air cleaner element # (e) replace Engine oil # - change Oil filter - replace K Fuel hoses - 2011 Kawasaki KLR650 | Owners Manual - Page 84
82 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) 1 12 24 36 48 (0.6) (7.5) (15) (22.5) (30) See Page Change/Replacement Items K Rubber parts of master cylinder and caliper - replace Spark plug (e) - replace Every 4 years • • • • • - 95 - 2011 Kawasaki KLR650 | Owners Manual - Page 85
transmission seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner's Manual. - 2011 Kawasaki KLR650 | Owners Manual - Page 86
84 MAINTENANCE AND ADJUSTMENT the engine oil level through • Check the oil level gauge. With the motorcycle held level, the oil level should come up between the upper and lower level lines next to the gauge. the oil level is too high, remove the • If excess oil through the oil filler open- • ing - 2011 Kawasaki KLR650 | Owners Manual - Page 87
MAINTENANCE AND ADJUSTMENT 85 • Remove the engine oil drain plug. the oil completely drain with • Let the motorcycle perpendicular to the ground. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible - 2011 Kawasaki KLR650 | Owners Manual - Page 88
86 MAINTENANCE AND ADJUSTMENT the oil filter is to be changed, re• If move the oil filter cover bolts and take off the cover with O-ring. • push the mounting pin into the element. Be careful that the grommets do not slip out of place. Install them with the smaller end of the pin inside. A. Bolts - 2011 Kawasaki KLR650 | Owners Manual - Page 89
, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 NOTE żIf a torque wrench is not available, this item should be serviced by a Kawasaki dealer. NOTE żReplace the any gasket with a new one. the engine up to the upper level • Fill line with a good quality motor oil - 2011 Kawasaki KLR650 | Owners Manual - Page 90
your riding area. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. - 2011 Kawasaki KLR650 | Owners Manual - Page 91
MAINTENANCE AND ADJUSTMENT 89 Cooling System Radiator and Cooling Fan Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water. NOTICE Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair - 2011 Kawasaki KLR650 | Owners Manual - Page 92
engines and radiators include harmful chemicals for human body. Drinking coolant can result in serious injury or death. Use coolant in accordance with the instructions of the manufacturer. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. - 2011 Kawasaki KLR650 | Owners Manual - Page 93
-rust properties. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer. NOTE żA permanent type of antifreeze is in- stalled in the cooling system when shipped. It is colored green and - 2011 Kawasaki KLR650 | Owners Manual - Page 94
92 MAINTENANCE AND ADJUSTMENT the coolant level if it is be• Check tween the F (Full) and L (Low) level lines. NOTE Coolant Filling If the amount of coolant is insufficient, remove the right shroud by unscrewing the bolts and add coolant into the reserve tank. • żCheck the level when the engine - 2011 Kawasaki KLR650 | Owners Manual - Page 95
MAINTENANCE AND ADJUSTMENT 93 removing the shroud, push the top of shroud to the front. the reserve tank cover by • Remove removing the screws. the cap from the reserve • Remove tank and add coolant through the filler opening to the F (Full) level line. A. Cap B. Reserve Tank A. Reserve Tank - 2011 Kawasaki KLR650 | Owners Manual - Page 96
94 MAINTENANCE AND ADJUSTMENT NOTE żIn an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. Coolant Change Have the coolant changed by an authorized Kawasaki - 2011 Kawasaki KLR650 | Owners Manual - Page 97
should be replaced in accordance with the Periodic Maintenance Chart. Spark plug removal should be done only by a competent mechanic following the instructions in the service manual. Spark Plug Standard Plug Plug Gap Tightening Torque NGK DPR8EA-9 or ND X24EPR-U9 0.8 ∼ 0.9 mm (0.032 ∼ 0.036 in.) 14 - 2011 Kawasaki KLR650 | Owners Manual - Page 98
96 MAINTENANCE AND ADJUSTMENT Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection - 2011 Kawasaki KLR650 | Owners Manual - Page 99
power is greatly reduced, or there are abnormal engine noises. Air suction valve removal and inspection should be done only by a competent mechanic following the instructions in the Service Manual. - 2011 Kawasaki KLR650 | Owners Manual - Page 100
98 MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. following the instructions in the Service Manual. NOTICE If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly open, which lowers - 2011 Kawasaki KLR650 | Owners Manual - Page 101
MAINTENANCE AND ADJUSTMENT 99 Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cleaned in accordance with the Periodic Maintenance Chart. In dusty areas, the - 2011 Kawasaki KLR650 | Owners Manual - Page 102
100 MAINTENANCE AND ADJUSTMENT the wing bolt, and take out • Remove the element. • Remove the element from the frame. A. Element B. Wing Bolt A. Element B. Frame a clean, lint-free towel over the • Put air cleaner housing to keep dirt or • other foreign material from entering. Inspect the - 2011 Kawasaki KLR650 | Owners Manual - Page 103
MAINTENANCE AND ADJUSTMENT 101 WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may stick or become inoperable resulting in a hazardous operating condition. the element with compressed air • Dry or by shaking it. cleaning, saturate the element • After with SG, - 2011 Kawasaki KLR650 | Owners Manual - Page 104
102 MAINTENANCE AND ADJUSTMENT Oil Draining Inspect the transparent reservoir below the swingarm pivot section on the right side of the motorcycle to see if any oil has run down from the air cleaner housing. • there is any oil in the reservoir, re• If move the plug from the lower end of the drain - 2011 Kawasaki KLR650 | Owners Manual - Page 105
MAINTENANCE AND ADJUSTMENT 103 Throttle Control System Check the throttle grip play in accordance with the Periodic Maintenance Chart, and adjust it if necessary. Throttle Grip The throttle grip controls the throttle valves. If the throttle grip has excessive play due to either cable stretch or - 2011 Kawasaki KLR650 | Owners Manual - Page 106
104 MAINTENANCE AND ADJUSTMENT Adjustment Turn out the decelerator cable adjusting nut until there is no play when the throttle grip is completely closed. Tighten the locknut. • the accelerator cable adjusting • Turn nut until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of throttle grip play is obtained. Tighten - 2011 Kawasaki KLR650 | Owners Manual - Page 107
MAINTENANCE AND ADJUSTMENT 105 WARNING Too much cables play can prevent throttle operation and cause an accident resulting in serious injury or death. When adjusting the throttle or replacing the cables, be sure the upper ends of the outer cables are fully seated in their adjusting nuts, or they - 2011 Kawasaki KLR650 | Owners Manual - Page 108
a rich starting mixture that is necessary to enable easy starting when the engine is cold. If starting difficulty or rich fuel mixture trouble occurs, inspect the choke lever, and adjust it if necessary. WARNING Operation with an improperly adjusted, incorrectly routed, or damaged cables could - 2011 Kawasaki KLR650 | Owners Manual - Page 109
MAINTENANCE AND ADJUSTMENT 107 Inspection Check that the choke lever returns properly and that the inner cable slides smoothly. If there is any irregularity, in accordance with the Periodic Maintenance Chart have the choke cable checked by an authorized Kawasaki dealer. • Idle Speed The idle - 2011 Kawasaki KLR650 | Owners Manual - Page 110
108 MAINTENANCE AND ADJUSTMENT Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked each day before riding the motorcycle, and in accordance with the Periodic Maintenance Chart. WARNING A. Idle Adjusting Screw WARNING - 2011 Kawasaki KLR650 | Owners Manual - Page 111
MAINTENANCE AND ADJUSTMENT 109 the clutch lever play as shown • Check in the figure. Clutch Lever Play 8 ∼ 12 mm (0.31 ∼ 0.47 in.) Adjustment Loosen the locknut, and turn the adjuster so that the clutch lever will have the proper play. • WARNING Too much cable play can prevent clutch - 2011 Kawasaki KLR650 | Owners Manual - Page 112
110 MAINTENANCE AND ADJUSTMENT the locknut. • Tighten If it cannot done, use the mounting • nuts at thebe lower end of the cable so that clutch lever has 8 ∼ 12 mm (0.31 ∼ 0.47 in.) of play. NOTE żAfter the adjustment is made, start the engine and check that the clutch does not slip and that it - 2011 Kawasaki KLR650 | Owners Manual - Page 113
MAINTENANCE AND ADJUSTMENT 111 Spark Arrester This motorcycle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Spark Arrester - 2011 Kawasaki KLR650 | Owners Manual - Page 114
112 MAINTENANCE AND ADJUSTMENT the drain plugs on the muf• Remove fler. and lower engine speed while • Raise tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling - 2011 Kawasaki KLR650 | Owners Manual - Page 115
MAINTENANCE AND ADJUSTMENT 113 Drive Chain The drive chain slack and lubrication must be checked each day before riding the motorcycle, and in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the chain becomes badly worn or maladjusted - either too loose - 2011 Kawasaki KLR650 | Owners Manual - Page 116
114 MAINTENANCE AND ADJUSTMENT the drive chain is too tight or too • If loose, adjust it so that the chain slack will be within the standard value. Drive Chain Slack Standard 35 ∼ 45 mm (1.4 ∼ 1.8 in.) the cotter pin, and loosen • Remove the axle nut. Chain Slack Adjustment Loosen the left and - 2011 Kawasaki KLR650 | Owners Manual - Page 117
MAINTENANCE AND ADJUSTMENT 115 out both chain adjusters evenly • Turn until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left wheel alignment indicator should align with the same swingarm mark that the right indicator notch aligns - 2011 Kawasaki KLR650 | Owners Manual - Page 118
AND ADJUSTMENT Tightening Torque Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb) NOTE żIf a torque wrench is not available, this item should be serviced by a Kawasaki dealer. the wheel, measure the chain • Rotate slack again at the tightest position, a new cotter pin through the • Install rear axle - 2011 Kawasaki KLR650 | Owners Manual - Page 119
injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. the rear brake (see the Brakes • Check section). A. Chain Guide B. Bolts the chain taut either by using • Stretch the chain adjusters, or by hanging a the length of 20 links on • Measure the straight part of - 2011 Kawasaki KLR650 | Owners Manual - Page 120
the • Rotate drive chain for damaged rollers, and • If the length exceeds the service limit, the chain should be replaced. • A. Measure B. Weight loose pins and is exaggerated for il- lustration. See Service Manual for wear limits. Drive Chain 20-Link Length Service Limit 323 mm (12.7 in.) - 2011 Kawasaki KLR650 | Owners Manual - Page 121
MAINTENANCE AND ADJUSTMENT 119 any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Apply - 2011 Kawasaki KLR650 | Owners Manual - Page 122
120 MAINTENANCE AND ADJUSTMENT the chain is especially dirty, clean it • If using diesel oil or kerosine and then apply oil as mentioned above. Brakes Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0. - 2011 Kawasaki KLR650 | Owners Manual - Page 123
MAINTENANCE AND ADJUSTMENT 121 Disc Brake Fluid In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in both the front and rear brake fluid reservoirs and change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Fluid - 2011 Kawasaki KLR650 | Owners Manual - Page 124
122 MAINTENANCE AND ADJUSTMENT the fluid level in either reservoir is • If lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reservoir is a stepped line showing the upper level line. A. Rear Brake - 2011 Kawasaki KLR650 | Owners Manual - Page 125
MAINTENANCE AND ADJUSTMENT 123 WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled - 2011 Kawasaki KLR650 | Owners Manual - Page 126
124 MAINTENANCE AND ADJUSTMENT Brake Light Switches When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Inspection Turn the - 2011 Kawasaki KLR650 | Owners Manual - Page 127
MAINTENANCE AND ADJUSTMENT 125 Adjustment To adjust the rear brake light switch, move the switch up or down. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. • A. B. C. D. Rear Brake Light Switch Adjusting Nut - 2011 Kawasaki KLR650 | Owners Manual - Page 128
126 MAINTENANCE AND ADJUSTMENT Front Fork The front fork operation and oil leakage should be checked in accordance with the Periodic Maintenance Chart by an authorized Kawasaki dealer. Rear Shock Absorbers The rear shock absorber can be adjusted by changing the spring preload and rebound damping - 2011 Kawasaki KLR650 | Owners Manual - Page 129
MAINTENANCE AND ADJUSTMENT 127 the bracket bolts and take • Remove out the separator (California model). changing the adjuster position • When from 1st to 5th in numerical order • (1stĺ2ndĺ3rdĺ4thĺ5th), turn the adjusting bolt clockwise. When changing the adjuster position from 5th to 1st in - 2011 Kawasaki KLR650 | Owners Manual - Page 130
128 MAINTENANCE AND ADJUSTMENT Rebound Damping Force Adjustment The rebound damping force adjuster is located at the lower end of the rear shock absorber. A. Adjusting Bolt B. 1st Position C. 5th Position D. Turn Clockwise E. Turn Counterclockwise F. Rear Shock Absorber A. Rebound Damping Force - 2011 Kawasaki KLR650 | Owners Manual - Page 131
MAINTENANCE AND ADJUSTMENT 129 The standard setting positions of the spring preload adjuster and rebound damping force adjuster for an average -build rider of 68 kg (150 lb) with no passenger and no accessories are as follows: Spring Preload Adjuster Rebound Damping Force Adjuster 1st position 1 - 2011 Kawasaki KLR650 | Owners Manual - Page 132
130 MAINTENANCE AND ADJUSTMENT NOTE żMeasure the tire pressure when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). żTire pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked - 2011 Kawasaki KLR650 | Owners Manual - Page 133
MAINTENANCE AND ADJUSTMENT 131 Tire Wear, Damage As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90 % worn). So it is false economy and unsafe to use the tires - 2011 Kawasaki KLR650 | Owners Manual - Page 134
132 MAINTENANCE AND ADJUSTMENT WARNING Tires that have been punctured and repaired do not have the same capabilities as undamaged tires and can suddenly fail, causing an accident resulting in serious injury or death. Replace damaged tires as soon as possible. To ensure safe handling and stability, - 2011 Kawasaki KLR650 | Owners Manual - Page 135
MAINTENANCE AND ADJUSTMENT 133 WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. Battery Battery - 2011 Kawasaki KLR650 | Owners Manual - Page 136
134 MAINTENANCE AND ADJUSTMENT NOTICE Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery. Battery Charging Remove the battery from the motorcycle (see Battery Removal). • A. Lower Level Line B. Upper Level - 2011 Kawasaki KLR650 | Owners Manual - Page 137
MAINTENANCE AND ADJUSTMENT 135 charging, check the elec• Before trolyte level in each cell. If the electrolyte level is low in any cell, fill to above the lower level line but not up to the upper level line since the level rises during charging. Remove the caps from all the cells, and connect the - 2011 Kawasaki KLR650 | Owners Manual - Page 138
136 MAINTENANCE AND ADJUSTMENT the battery at a rate that is • Charge 1/10th of the battery capacity. For example, the charging rate for a 10 Ah battery would be 1.0 ampere. A. B. C. D. Battery Charger Filler Caps (+) terminal (-) terminal - 2011 Kawasaki KLR650 | Owners Manual - Page 139
MAINTENANCE AND ADJUSTMENT 137 NOTICE Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level required for motorcycle batteries. Charging the battery at a rate higher than specified may ruin - 2011 Kawasaki KLR650 | Owners Manual - Page 140
138 MAINTENANCE AND ADJUSTMENT Battery Removal Remove the side covers. Remove the seat. Disconnect the leads from the battery, first from the (-) terminal and then the (+) terminal. Take off the battery holder. the battery out. • Take Clean battery using a solution of • bakingthe soda and - 2011 Kawasaki KLR650 | Owners Manual - Page 141
MAINTENANCE AND ADJUSTMENT 139 NOTICE Make sure the battery vent hose is kept away from the drive system and exhaust system. Battery electrolyte can corrode and dangerously weaken the drive system. Do not let the vent hose become folded, pinched, or melted by the exhaust system. An unvented battery - 2011 Kawasaki KLR650 | Owners Manual - Page 142
140 MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. Vertical Adjustment The headlight beam is adjustable vertically. If adjusted too low, - 2011 Kawasaki KLR650 | Owners Manual - Page 143
MAINTENANCE AND ADJUSTMENT 141 Rear Turn Signal Light To replace the bulb of the rear turn signal light, remove the screw and lightly twist the lens counterclockwise. Fuses Fuses are located under the seat. The main fuse is mounted on the starter relay behind the cover. If a fuse fails during - 2011 Kawasaki KLR650 | Owners Manual - Page 144
142 MAINTENANCE AND ADJUSTMENT the cover by unscrewing the • Remove screw. WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse box - 2011 Kawasaki KLR650 | Owners Manual - Page 145
MAINTENANCE AND ADJUSTMENT 143 General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty - 2011 Kawasaki KLR650 | Owners Manual - Page 146
Apply grease to the following points: ż(K)Clutch Inner Cable Upper End ż(K)Throttle Inner Cable Upper Ends * żSpeedometer Inner Cable (K): Should be serviced by an authorized Kawasaki dealer. *: Grease the lower part of the inner cable sparigly. A. Grease NOTE żAfter connecting the cables, adjust - 2011 Kawasaki KLR650 | Owners Manual - Page 147
MAINTENANCE AND ADJUSTMENT 145 Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help - 2011 Kawasaki KLR650 | Owners Manual - Page 148
146 MAINTENANCE AND ADJUSTMENT Washing Your Motorcycle Rinse your bike with cold water from a garden hose to remove any loose dirt. Mix a mild neutral detergent (designed for motorcycles or automobiles) and water in bucket. Use a soft cloth or sponge to wash your motorcycle. If needed, use a mild - 2011 Kawasaki KLR650 | Owners Manual - Page 149
or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. Windshield and Other Plastic Parts After washing use a soft cloth to gently dry plastic parts. When dry, treat the windshield - 2011 Kawasaki KLR650 | Owners Manual - Page 150
148 MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with - 2011 Kawasaki KLR650 | Owners Manual - Page 151
MAINTENANCE AND ADJUSTMENT 149 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki - 2011 Kawasaki KLR650 | Owners Manual - Page 152
150 MAINTENANCE AND ADJUSTMENT 16. Front Axle Nut 17. Spoke Nipples 18. Brake Pedal Mounting Bolt 19. Rear Axle Nut 20. UNI TRACK Lever Rod Nuts 21. Front Axle Clamp Bolts 22. Rear Shock Absorber Mounting Nut 23. Exhaust Pipe Holder Nuts 24. Muffler Body Mounting Nut - 2011 Kawasaki KLR650 | Owners Manual - Page 153
STORAGE 151 STORAGE the entire vehicle thoroughly. • Clean Run the engine for about five minutes to warm the oil, shut it off, and drain the • engine oil. Preparation for Storage: WARNING Motorcycle oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved - 2011 Kawasaki KLR650 | Owners Manual - Page 154
152 STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition key to "OFF". Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance - 2011 Kawasaki KLR650 | Owners Manual - Page 155
STORAGE 153 plastic bags over the mufflers to prevent moisture from entering. • Tie Put • a cover over the motorcycle to keep dust and dirt from collecting on it. Preparation after Storage: the plastic bags from the mufflers. • Remove the battery in the motorcycle and charge the battery if - 2011 Kawasaki KLR650 | Owners Manual - Page 156
154 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Engine Does Not Start: Starter Motor Won't Turn Engine stop switch off Transmission not in neutral Fuse blown Battery leads do not make good electrical - 2011 Kawasaki KLR650 | Owners Manual - Page 157
YOUR WARRANTY/OWNER SATISFACTION 155 YOUR WARRANTY/OWNER SATISFACTION Welcome to the Kawasaki family! Congratulations on buying your Kawasaki vehicle. You've chosen a great, highquality product with state-of-the-art features and built to Kawasaki's high standards. Your satisfaction is important to - 2011 Kawasaki KLR650 | Owners Manual - Page 158
schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner the first scheduled service. You can have the required servicing done by your Kawasaki dealer (recommended) or an equally-qualified service facility. You - 2011 Kawasaki KLR650 | Owners Manual - Page 159
. Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform the maintenance so that in the event of a failure you can document - 2011 Kawasaki KLR650 | Owners Manual - Page 160
whether they are covered by the limited warranty or not. How Do I Get Warranty Service? If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and - 2011 Kawasaki KLR650 | Owners Manual - Page 161
a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren't satisfied with your dealership's repair work or operations, a review of the issue. If you are unable to resolve a problem after consulting with the dealership management and need further assistance, contact Kawasaki - 2011 Kawasaki KLR650 | Owners Manual - Page 162
? This owner's manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. Please send your correspondence to: Consumer Services Kawasaki Motors Corp - 2011 Kawasaki KLR650 | Owners Manual - Page 163
that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at - 2011 Kawasaki KLR650 | Owners Manual - Page 164
162 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their - 2011 Kawasaki KLR650 | Owners Manual - Page 165
LABEL INFORMATION 163 LABEL INFORMATION (1) - 2011 Kawasaki KLR650 | Owners Manual - Page 166
164 LABEL INFORMATION (2) - 2011 Kawasaki KLR650 | Owners Manual - Page 167
LABEL INFORMATION 165 (3) (4) - 2011 Kawasaki KLR650 | Owners Manual - Page 168
166 LABEL INFORMATION (5) - 2011 Kawasaki KLR650 | Owners Manual - Page 169
LABEL INFORMATION 167 (6) - 2011 Kawasaki KLR650 | Owners Manual - Page 170
168 LABEL INFORMATION (6) only on California model - 2011 Kawasaki KLR650 | Owners Manual - Page 171
LABEL INFORMATION 169 (7) (8) only on California model - 2011 Kawasaki KLR650 | Owners Manual - Page 172
170 LABEL INFORMATION (9) (10) - 2011 Kawasaki KLR650 | Owners Manual - Page 173
LABEL INFORMATION 171 (11) - 2011 Kawasaki KLR650 | Owners Manual - Page 174
172 LABEL INFORMATION (12) - 2011 Kawasaki KLR650 | Owners Manual - Page 175
LABEL INFORMATION 173 (13) only on California model - 2011 Kawasaki KLR650 | Owners Manual - Page 176
174 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Key Number ...Selling Dealer Name ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Odometer Reading Maintenance - 2011 Kawasaki KLR650 | Owners Manual - Page 177
MAINTENANCE RECORD 175 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2011 Kawasaki KLR650 | Owners Manual - Page 178
176 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2011 Kawasaki KLR650 | Owners Manual - Page 179
MAINTENANCE RECORD 177 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2011 Kawasaki KLR650 | Owners Manual - Page 180
178 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2011 Kawasaki KLR650 | Owners Manual - Page 181
KL650EB Printed in Thailand Part No. 99987-1649 GB
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KLR650
Motorcycle