Introduction
This manual, Clymer M474-3, provides comprehensive service, repair, and maintenance information for Kawasaki KLR650 dual-sport/adventure motorcycles manufactured between 1987 and 2007. It includes step-by-step instructions, detailed specifications, and hundreds of photos and illustrations to assist with various procedures.
The manual contains 329 pages of technical content, including color wiring diagrams, to guide users through complex repairs and routine maintenance tasks.
Image: Cover of the Clymer M474-3 Repair Manual for Kawasaki KLR650 motorcycles, showing a green KLR650 in a desert landscape.
Applicable Models:
- 1987 Kawasaki KLR650-A1
- 1988 Kawasaki KLR650-A2
- 1989 Kawasaki KLR650-A3
- 1990 Kawasaki KLR650-A4
- 1991 Kawasaki KLR650-A5
- 1992 Kawasaki KLR650-A6
- 1993 Kawasaki KLR650-A7
- 1994 Kawasaki KLR650-A8
- 1995 Kawasaki KLR650-A9
- 1996 Kawasaki KLR650-A10
- 1997 Kawasaki KLR650-A11
- 1998 Kawasaki KLR650-A12
- 1999 Kawasaki KLR650-A13
- 2000 Kawasaki KLR650-A14
- 2001 Kawasaki KLR650-A15
- 2002 Kawasaki KLR650-A16
- 2003 Kawasaki KLR650-A17
- 2004 Kawasaki KLR650-A18
- 2005 Kawasaki KLR650-A19
- 2006 Kawasaki KLR650-A20
- 2007 Kawasaki KLR650-A21
General Information and Safety
This section covers fundamental information essential before beginning any work on your motorcycle. It emphasizes safety procedures and proper handling of tools and materials.
- Manual Organization: Understanding the structure of this manual, including warnings, cautions, and notes.
- Safety Precautions: General safety guidelines, including the importance of reading warning labels.
- Serial Numbers: Locating and understanding your motorcycle's serial numbers.
- Fasteners: Information on different types of fasteners and their proper use.
- Shop Supplies: Recommended supplies for maintenance and repair tasks.
- Basic and Precision Tools: Guidance on selecting and using appropriate tools, including precision measuring instruments.
- Storage: Recommendations for proper motorcycle storage.
Lubrication, Maintenance, and Tune-up
Regular maintenance is crucial for the longevity and performance of your Kawasaki KLR650. This section details all necessary lubrication, inspection, and tune-up procedures.
- Pre-ride Inspection: Essential checks before each ride.
- Engine Break-in: Procedures for new or rebuilt engines.
- Tune-up and Service Intervals: Recommended schedule for routine maintenance.
- Battery Maintenance: Inspection and care of the motorcycle battery.
- Fuel and Lubricants: Specifications and recommendations for fuel and various lubricants.
- Periodic Lubrication, Maintenance, and Inspection: Step-by-step guides for scheduled tasks.
- Engine Tune-up: Procedures for optimizing engine performance.
- Spark Plugs: Inspection, cleaning, and replacement of spark plugs.
Engine Top End Service
This section provides detailed instructions for servicing the upper components of the engine, ensuring proper function and sealing.
- Shop Cleanliness: Importance of maintaining a clean work environment.
- Exhaust System: Removal, inspection, and installation of exhaust components.
- Cylinder Head Cover: Procedures for removal and installation.
- Camshafts and Cam Chain Tensioner: Inspection, adjustment, and replacement.
- Cylinder Head: Removal, inspection, and reinstallation.
- Valves: Inspection, adjustment, and servicing of valves.
- Cylinder: Inspection and maintenance of the cylinder bore.
- Piston and Piston Rings: Removal, inspection, and installation of pistons and rings.
Troubleshooting
This section assists in diagnosing and resolving common issues that may arise with your Kawasaki KLR650. It covers various systems and provides systematic approaches to problem-solving.
- Operating Requirements: Basic conditions for proper motorcycle operation.
- Starting the Engine: Diagnosis for starting difficulties.
- Four-stroke Operating Principles: Understanding engine cycles for better diagnosis.
- Engine Spark Test: How to check for proper ignition spark.
- Engine Performance: Identifying and addressing performance issues.
- Electrical Testing: Basic electrical system diagnostics.
- Starting System: Troubleshooting the electric starting system.
- Engine Noise and Motorcycle Noise: Identifying sources of unusual sounds.
- Engine Leakdown Test: Procedure for checking engine internal condition.
- Clutch: Diagnosis and adjustment of clutch issues.
- Gear Shift Linkage and Transmission: Troubleshooting shifting problems.
- Brakes: Diagnosis and repair of braking system issues.
- Steering and Handling: Addressing problems related to steering and motorcycle stability.
Specifications
This section provides key specifications for the Clymer M474-3 repair manual.
| ASIN | B00O3GQAUG |
| Publisher | by Publisher |
| Publication Date | January 1, 2004 |
| Language | English |
| Item Weight | 1.35 pounds |
| Number of Pages | 329 |
| Features | Color Wiring Diagrams, Hundreds of Photos and Illustrations |
