2015 Kawasaki KLR650 Owners Manual

2015 Kawasaki KLR650 Manual

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  • 2015 Kawasaki KLR650 | Owners Manual - Page 1
  • 2015 Kawasaki KLR650 | Owners Manual - Page 2
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 3
    you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. or serious injury. ○NOTE indicates information that may NOTE help or guide you in the operation or service of the vehicle. WARNING WARNING indicates a hazardous situation which, if
  • 2015 Kawasaki KLR650 | Owners Manual - Page 4
    WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A
  • 2015 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
  • 2015 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 © 2014 Kawasaki Heavy
  • 2015 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: ...Indicator Lights: ...Key ...Ignition Switch/Steering Lock ...To
  • 2015 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 ... 123 127 129
  • 2015 Kawasaki KLR650 | Owners Manual - Page 9
    8 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Minimum Turning Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled 651 cm³ (39.7 cu
  • 2015 Kawasaki KLR650 | Owners Manual - Page 10
    SPECIFICATIONS 9 Carburetion System Ignition System 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 KEIHIN CVK 40 ×
  • 2015 Kawasaki KLR650 | Owners Manual - Page 11
    10 SPECIFICATIONS Overall Drive Ratio Gear Ratio: 1st 2nd 3rd 4th 5th FRAME Caster Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery 12 V 14 Ah (10 HR) Front Rear Front Rear 28° 112 mm (4.4 in.) 90/90-21 M/C 54S 130/80-17 M/C 65S 21 × 1.60 17M/C × MT2.50 22 L (5.8 US gal) 5.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 12
    SPECIFICATIONS 11 Headlight Brake/Tail Light 12 V 55 W × 2/55 W (Hi/Lo) 12 V 21/5 W Specifications are subject to change without notice.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 13
    12 SERIAL NUMBER LOCATIONS 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 14
    LOCATION OF PARTS 13 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 15
    14 LOCATION OF PARTS 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 16
    LOCATION OF PARTS 15 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. Rear Brake Pedal 34. Oil Level Inspection Window 35. Idle Adjusting Screw 36. Coolant Reserve Tank
  • 2015 Kawasaki KLR650 | Owners Manual - Page 17
    16 LOCATION OF LABELS LOCATION OF LABELS All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your vehicle. Therefore, it
  • 2015 Kawasaki KLR650 | Owners Manual - Page 18
    LOCATION OF LABELS 17 2. Brake Fluid (Rear) 3. Tire and Load Data 4. Important Drive Chain Information
  • 2015 Kawasaki KLR650 | Owners Manual - Page 19
    18 LOCATION OF LABELS 5. Vehicle Emission Control Information 6. Noise Emission Control Information *7. Vacuum Hose Routing Diagram 8. Battery Vent Hose 9. Radiator Cap Danger 10. Weight and Manufacture *: only on California model
  • 2015 Kawasaki KLR650 | Owners Manual - Page 20
    LOCATION OF LABELS 19 11. Carrier Caution 12. Battery Poison/Danger *13. Fuel Level *: only on California model
  • 2015 Kawasaki KLR650 | Owners Manual - Page 21
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 22
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 23
    22 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 24
    GENERAL INFORMATION 23 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 25
    24 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 26
    GENERAL INFORMATION 25 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. Indicator Lights: : When the headlight is on high beam, the high beam indicator light is lit. N: When the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 27
    26 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 28
    GENERAL INFORMATION 27 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. Ignition Switch/Steering Lock OFF ON LOCK Engine off. All electrical circuits off. Engine on. All electrical equipment can be used. Steering locked
  • 2015 Kawasaki KLR650 | Owners Manual - Page 29
    28 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 to the position. ○Although NOTE the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 30
    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. Dimmer Switch: High or low beam can be selected with the dimmer switch. When the ), the headlight is on high beam ( high beam indicator
  • 2015 Kawasaki KLR650 | Owners Manual - Page 31
    30 GENERAL INFORMATION ○When the headlight is on high beam, both head lights are lit. When the headlight is on low beam, only one headlight is lit. NOTE Turn Signal Switch: When the turn signal switch is turned ) or right ( ), the to the left ( corresponding turn signal flashes on and off. To
  • 2015 Kawasaki KLR650 | Owners Manual - Page 32
    GENERAL INFORMATION 31 Fuel Tank Cap • • Insert the ignition key into the fuel tank cap. Turn the key clockwise while pushing down the fuel tank cap. the fuel tank cap down into • Push place with the key inserted. key can be removed by turning • The counterclockwise to the original position. ○
  • 2015 Kawasaki KLR650 | Owners Manual - Page 33
    32 GENERAL INFORMATION Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. Fuel Tank 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 34
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 35
    . 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 36
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 37
    "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. The fuel tap has three positions: ON, RES (reserve), and OFF. For normal operation, turn the tap lever to the ON position. If the fuel
  • 2015 Kawasaki KLR650 | Owners Manual - Page 38
    GENERAL INFORMATION 37 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 39
    38 GENERAL INFORMATION The motorcycle is equipped with a side stand. Stand Do not sit on the motorcycle while it is on its side stand. Always kick the stand fully up before sitting on the motorcycle. ○The NOTE motorcycle is equipped with a side stand switch. This switch is designed so that the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 40
    GENERAL INFORMATION 39 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. Helmet Hook WARNING Riding with a helmet attached to the hook could cause an accident by
  • 2015 Kawasaki KLR650 | Owners Manual - Page 41
    40 GENERAL INFORMATION 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) Rear Carrier WARNING Overloading the motorcycle and failure to adjust speed for additional cargo could result in
  • 2015 Kawasaki KLR650 | Owners Manual - Page 42
    with the motorcycle. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Tool Kit Container/Tool Kit When tying up light loads to the rear carrier, use the tying hooks located under the rear carrier. Tying
  • 2015 Kawasaki KLR650 | Owners Manual - Page 43
    42 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 44
    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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 45
    44 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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 46
    HOW TO RIDE THE MOTORCYCLE 45 ○When the engine is already warm or NOTE 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 47
    46 HOW TO RIDE THE MOTORCYCLE ○If the engine is flooded, crank the en- NOTE return the choke lever to• Gradually ward the off position a little at a time gine over with the throttle fully open until the engine starts. ○The motorcycle is equipped with a starter lockout switch. This switch
  • 2015 Kawasaki KLR650 | Owners Manual - Page 48
    HOW TO RIDE THE MOTORCYCLE 47 Ambient temperature choke off after running for 20°C (68°F) ∼ 35°C 15 seconds (95°F) Below 20°C (68°F) Below 5°C (40°F) 1.5 minutes 2 minutes If your motorcycle battery is "run down", it should be removed and charged. If this is not practical, a 12 volt booster
  • 2015 Kawasaki KLR650 | Owners Manual - Page 49
    48 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 50
    HOW TO RIDE THE MOTORCYCLE 49 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 51
    50 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. DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last
  • 2015 Kawasaki KLR650 | Owners Manual - Page 52
    HOW TO RIDE THE MOTORCYCLE 51 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,
  • 2015 Kawasaki KLR650 | Owners Manual - Page 53
    52 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 54
    HOW TO RIDE THE MOTORCYCLE 53 Shifting Gears the throttle while pulling in the • Close clutch lever. into the next higher or lower • Shift gear. smooth riding, each gear position • For should cover the proper rate of speed WARNING Downshifting to a lower gear at high speed causes engine rpm to
  • 2015 Kawasaki KLR650 | Owners Manual - Page 55
    54 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, always
  • 2015 Kawasaki KLR650 | Owners Manual - Page 56
    HOW TO RIDE THE MOTORCYCLE 55 Stopping the Engine the throttle completely. • Close Shift the into neutral. • Turn the transmission key to "OFF". • Support ignition the motorcycle on a firm, • level surface with the side stand. Lock the steering. • A. Rear Brake Pedal
  • 2015 Kawasaki KLR650 | Owners Manual - Page 57
    . 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. Stopping the Motorcycle in an
  • 2015 Kawasaki KLR650 | Owners Manual - Page 58
    operation or after stopping the engine. the transmission into neutral • Shift and turn the ignition key to "OFF". the motorcycle on a firm, • Support level surface with the side stand. Operating or parking the vehicle near flammable materials can cause a fire, and can result in property damage or
  • 2015 Kawasaki KLR650 | Owners Manual - Page 59
    58 HOW TO RIDE THE MOTORCYCLE and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light. WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch
  • 2015 Kawasaki KLR650 | Owners Manual - Page 60
    HOW TO RIDE THE MOTORCYCLE 59 WARNING Operating or parking the vehicle near flammable materials can cause a fire, and can result in property damage or severe personal injury. Do not idle or park your vehicle in an area where tall or dry vegetation, or other flammable materials could come into
  • 2015 Kawasaki KLR650 | Owners Manual - Page 61
    60 HOW TO RIDE THE MOTORCYCLE NOTICE In order to protect the emission control parts, do not turn off the ignition switch when the motorcycle is in motion.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 62
    SAFE OPERATION 61 SAFE OPERATION 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 also be used for added
  • 2015 Kawasaki KLR650 | Owners Manual - Page 63
    62 SAFE OPERATION 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 64
    SAFE OPERATION 63 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 65
    64 SAFE OPERATION 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 chapter or see your
  • 2015 Kawasaki KLR650 | Owners Manual - Page 66
    SAFE OPERATION 65 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.)
  • 2015 Kawasaki KLR650 | Owners Manual - Page 67
    66 SAFE OPERATION Electrical equipment ...All lights (Headlight, Tail/Brake Lights, Turn Signal Lights, 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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 68
    SAFE OPERATION 67 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 control. Check to see that the handlebar turns
  • 2015 Kawasaki KLR650 | Owners Manual - Page 69
    68 SAFE OPERATION 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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 70
    MAINTENANCE AND ADJUSTMENT 69 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 71
    70 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 72
    modifications 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 73
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 74
    by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. # : Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping. (e): Emission Related Item Periodic Maintenance
  • 2015 Kawasaki KLR650 | Owners Manual - Page 75
    74 MAINTENANCE AND ADJUSTMENT 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes first Operation (Engine Item) Air cleaner element - clean (e) Valve clearance inspect (e) Throttle control system (play, smooth return, no drag) - inspect (e) Choke operation inspect (e) Idle speed
  • 2015 Kawasaki KLR650 | Owners Manual - Page 76
    MAINTENANCE AND ADJUSTMENT 75 Frequency Whichever comes first 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 Radiator hose damage - inspect year year *Odometer Reading
  • 2015 Kawasaki KLR650 | Owners Manual - Page 77
    76 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Engine Item) Radiator hoses installation condition - inspect Evaporative emission control system - function (California model only) (e) Air suction system damage - inspect (e) Balancer chain tension- adjust Spark arresterclean
  • 2015 Kawasaki KLR650 | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first Operation (Chassis Items) Clutch and drive train: Clutch operation (play, engagement, disengagement) inspect Drive chain lubrication condition - inspect # Drive chain slack - inspect # Drive
  • 2015 Kawasaki KLR650 | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first 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 year *Odometer Reading km × 1 000 (
  • 2015 Kawasaki KLR650 | Owners Manual - Page 80
    MAINTENANCE AND ADJUSTMENT 79 Frequency Whichever comes first 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 condition - inspect year year year *Odometer Reading
  • 2015 Kawasaki KLR650 | Owners Manual - Page 81
    80 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Chassis Items) Brake fluid level inspect Brake operation (effectiveness, play, drag) inspect Brake light switch operation - inspect Suspensions: Front forks/rear shock absorber operation K (damping and smooth stroke) inspect *
  • 2015 Kawasaki KLR650 | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 Frequency Whichever comes first 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 operation - inspect *Odometer Reading km × 1 000 (mile ×
  • 2015 Kawasaki KLR650 | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Chassis Items) K Swing arm pivot lubricate Steering play inspect *Odometer Reading km × 1 000 (mile × 1 000) See Page 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 system
  • 2015 Kawasaki KLR650 | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever comes first Operation (Chassis Items) Side stand switch operation - inspect Engine stop switch operation inspect *Odometer Reading km × 1 000 (mile × 1 000) See Page Every year year 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22
  • 2015 Kawasaki KLR650 | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT 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 - replace # (e) Engine oil - change # Oil filter - replace K Fuel
  • 2015 Kawasaki KLR650 | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 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 - replace (e) Every 4 years • • • • • -
  • 2015 Kawasaki KLR650 | Owners Manual - Page 87
    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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 the engine oil level through • Check the oil level inspection window. With the motorcycle held level, the oil level should come up between the upper and lower level lines next to the oil level inspection window. the oil level is too high, remove the • If excess oil
  • 2015 Kawasaki KLR650 | Owners Manual - Page 89
    88 MAINTENANCE AND ADJUSTMENT • Remove the engine oil drain plug. the oil completely drain with • Let the motorcycle perpendicular to the ground. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible
  • 2015 Kawasaki KLR650 | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 91
    : SAE 10W-40 with its gasket. Proper torque for it is shown in the table. ○If a torque wrench is not available, this item should be serviced by a Kawasaki dealer. NOTE ○Replace the any gasket with a new one. the engine up to the upper level • Fill line with a good quality motor oil
  • 2015 Kawasaki KLR650 | Owners Manual - Page 92
    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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 94
    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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 95
    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. ○A permanent type of antifreeze is installed in the cooling system when shipped. It is colored green and contains ethylene
  • 2015 Kawasaki KLR650 | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 the coolant level if it is be• Check tween the F (Full) and L (Low) level lines. ○Check the level when the engine is cold (room or atmospheric temperature). NOTE Coolant Filling If the amount of coolant is insufficient, remove the right shroud by unscrewing the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 97
    96 MAINTENANCE AND ADJUSTMENT 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. Reserve Tank Cover B. Screws A. Cap B.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 ○In NOTE 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 99
    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 (0.031 ∼ 0.035 in.) 14
  • 2015 Kawasaki KLR650 | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 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 must be made at the intervals specified by the Periodic
  • 2015 Kawasaki KLR650 | Owners Manual - Page 101
    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.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 Valve and valve seat wear decreases valve clearance, upsetting valve timing. Valve Clearance 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT 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 element should
  • 2015 Kawasaki KLR650 | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT 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. NOTICE If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 106
    MAINTENANCE AND ADJUSTMENT 105 WARNING Gasoline and low flash-point solvents are extremely flammable and may explode, causing severe burns. Do not use gasoline or a low flash-point solvent to clean the element. Clean the element in a well-ventilated area. Be sure there are no sparks or flame in the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT WARNING Oil on tires will make them slippery and can cause an accident and injury. Be sure to install the plug in the drain hose after draining. Check the throttle grip play in accordance with the Periodic Maintenance Chart, and adjust it if necessary. Throttle Grip
  • 2015 Kawasaki KLR650 | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 Inspection Check that the throttle grip play is correct by lightly turning the throttle grip back and forth. • Adjustment Turn out the decelerator cable adjusting nut until there is no play when the throttle grip is completely closed. Tighten the locknut. • A.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT throttle grip play is obtained. Tighten the locknut. ○If the NOTE throttle cables cannot be adjusted by using the cable adjusting nuts at the upper end of the throttle cables, use the cable adjusters at the lower end of the throttle cables (at the carburetor). Do
  • 2015 Kawasaki KLR650 | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 111
    provides 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. Choke Lever Inspection Check that the choke lever returns properly and that the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 The idle speed should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment Start the engine, and warm it up thoroughly. Adjust the idle speed by turning the idle adjusting screw. Idle Speed • • Idle
  • 2015 Kawasaki KLR650 | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT 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. Clutch the clutch lever play as shown • Check in the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 Adjustment Loosen the locknut, and turn the adjuster so that the clutch lever will have the proper play. • it cannot be done, have the • If clutch cable adjusted by authorized Kawasaki dealer. WARNING Too much cable play can prevent clutch disengagement and cause
  • 2015 Kawasaki KLR650 | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT 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 Spark
  • 2015 Kawasaki KLR650 | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 the drain plugs on the muf• Remove fler. and lower engine speed while • Raise tapping on the muffler with a rub- ber mallet until carbon particles are purged from the muffler. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT 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 or too tight
  • 2015 Kawasaki KLR650 | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 119
    118 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 120
    AND ADJUSTMENT 119 Tightening Torque Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb) ○If 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 121
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 the length exceeds the service limit, • If the chain should be replaced. wear unevenly, take measurements at pins and links. A. Measure B. Weight ○Sprocket wear is exaggerated for illustration. See Service Manual for wear limits. NOTE Drive Chain 20-Link Length
  • 2015 Kawasaki KLR650 | Owners Manual - Page 123
    sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains following the instructions supplied by the chain cleaner manufacturer. Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings
  • 2015 Kawasaki KLR650 | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 off any lubricant that gets on the • Wipe tire surface. 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 (0.04 in.), replace both pads in the caliper as a set. Pad
  • 2015 Kawasaki KLR650 | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 128
    MAINTENANCE AND ADJUSTMENT 127 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 ignition key to "ON
  • 2015 Kawasaki KLR650 | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 The front fork operation and oil leakage should be checked in accordance with the Periodic Maintenance Chart by an authorized Kawasaki dealer. Front Fork The rear shock absorber can be adjusted by changing the spring preload and rebound damping force for various
  • 2015 Kawasaki KLR650 | Owners Manual - Page 131
    130 MAINTENANCE AND ADJUSTMENT the bracket bolts and take • Remove out the separator (California model). changing the adjuster position • When from 1st to 5th in numerical order • (1st→2nd→3rd→4th→5th), turn the adjusting bolt clockwise. When changing the adjuster position from 5th to 1st in
  • 2015 Kawasaki KLR650 | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 133
    132 MAINTENANCE AND ADJUSTMENT 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 3rd position 1
  • 2015 Kawasaki KLR650 | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 ○Measure the tire pressure when the NOTE tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). ○Tire pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked
  • 2015 Kawasaki KLR650 | Owners Manual - Page 135
    134 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 136
    MAINTENANCE AND ADJUSTMENT 135 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,
  • 2015 Kawasaki KLR650 | Owners Manual - Page 137
    136 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 138
    MAINTENANCE AND ADJUSTMENT 137 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 Line
  • 2015 Kawasaki KLR650 | Owners Manual - Page 139
    138 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 140
    MAINTENANCE AND ADJUSTMENT 139 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 141
    140 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 142
    MAINTENANCE AND ADJUSTMENT 141 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 143
    142 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 144
    MAINTENANCE AND ADJUSTMENT 143 the warranty. If you do not drive for four weeks or more, disconnect the battery from the vehicle. Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than
  • 2015 Kawasaki KLR650 | Owners Manual - Page 145
    144 MAINTENANCE AND ADJUSTMENT The proper angle is 0.4 degrees below horizontal. This is a 50 mm (2.0 in.) drop at 7.6 m (25 ft) measured from the center of the headlight, with the motorcycle on its wheels and the rider seated. ○Do not allow anything to cover the headlight lens when the headlight
  • 2015 Kawasaki KLR650 | Owners Manual - Page 146
    MAINTENANCE AND ADJUSTMENT 145 To replace the bulb of the rear turn signal light, remove the screw and lightly twist the lens counterclockwise. Rear Turn Signal Light Fuses are located under the seat. The main fuse is mounted on the starter relay behind the cover. If a fuse fails during operation
  • 2015 Kawasaki KLR650 | Owners Manual - Page 147
    146 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 148
    MAINTENANCE AND ADJUSTMENT 147 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 spots with rust
  • 2015 Kawasaki KLR650 | Owners Manual - Page 149
    grease to the following points: (K)Clutch Inner Cable Upper End (K)Throttle Inner Cable Upper Ends • • * •Speedometer Inner Cable (K): Should be serviced by an authorized Kawasaki dealer. *: Grease the lower part of the inner cable sparigly. A. Grease ○After connecting the cables, adjust them
  • 2015 Kawasaki KLR650 | Owners Manual - Page 150
    reaching its surfaces. WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 151
    150 MAINTENANCE AND ADJUSTMENT sure the engine and exhaust are • Be cool before washing. applying degreaser to seals, • Avoid brake pads, and tires. use non-abrasive wax and • Always cleaner/polisher. all harsh chemicals, solvents, • Avoid detergents, and household cleaning • components and
  • 2015 Kawasaki KLR650 | Owners Manual - Page 152
    MAINTENANCE AND ADJUSTMENT 151 detergent can damage parts of your motorcycle). Use a soft cloth to dry your motorcycle. As you dry, inspect your motorcycle for chips and scratches. Do not let the water air dry as this can damage the painted surfaces. Start the engine and let it idle for several
  • 2015 Kawasaki KLR650 | Owners Manual - Page 153
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 154
    MAINTENANCE AND ADJUSTMENT 153 should be washed with a mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special non-acid based wheel spray cleaners. Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special
  • 2015 Kawasaki KLR650 | Owners Manual - Page 155
    154 MAINTENANCE AND ADJUSTMENT 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 dealer for torque values.
  • 2015 Kawasaki KLR650 | Owners Manual - Page 156
    MAINTENANCE AND ADJUSTMENT 155 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 157
    156 STORAGE STORAGE • • Preparation for Storage: Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved
  • 2015 Kawasaki KLR650 | Owners Manual - Page 158
    STORAGE 157 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 159
    158 STORAGE the motorcycle on a box or stand so that both wheels are raised off the ground. • Set (If this cannot be done, put boards under the front and rear wheels to keep dampoil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on • Spray rubber parts or in the brakes. the
  • 2015 Kawasaki KLR650 | Owners Manual - Page 160
    TROUBLESHOOTING GUIDE 159 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 161
    160 YOUR WARRANTY/OWNER SATISFACTION 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 162
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 163
    . 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 164
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 165
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 166
    ? 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 167
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 168
    ENVIRONMENTAL PROTECTION 167 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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 169
    168 LABEL INFORMATION LABEL INFORMATION (1) (2) (3)
  • 2015 Kawasaki KLR650 | Owners Manual - Page 170
    LABEL INFORMATION 169 (4) (5) (5) only on California model
  • 2015 Kawasaki KLR650 | Owners Manual - Page 171
    170 LABEL INFORMATION (6) (7) only on California model
  • 2015 Kawasaki KLR650 | Owners Manual - Page 172
    LABEL INFORMATION 171 (8) (9) (10)
  • 2015 Kawasaki KLR650 | Owners Manual - Page 173
    172 LABEL INFORMATION (11) (12)
  • 2015 Kawasaki KLR650 | Owners Manual - Page 174
    LABEL INFORMATION 173 (13) only on California model
  • 2015 Kawasaki KLR650 | Owners Manual - Page 175
    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
  • 2015 Kawasaki KLR650 | Owners Manual - Page 176
    MAINTENANCE RECORD 175 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki KLR650 | Owners Manual - Page 177
    176 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki KLR650 | Owners Manual - Page 178
    MAINTENANCE RECORD 177 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki KLR650 | Owners Manual - Page 179
    178 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki KLR650 | Owners Manual - Page 180
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