Kawasaki Klr650

by Bogart, Jay

• ISBN13: 9780892878529
• ISBN10: 0892878525
• Format: Paperback
• Copyright: 2003-09-01
• Publisher: Clymer Pubns

Table of Contents

QUICK REFERENCE DATA	IX
CHAPTER ONE GENERAL INFORMATION	1	(30)
Manual organization
Fasteners
Warnings, cautions and notes
Shop supplies
Safety
Basic tools
Warning labels
Precision measuring tools
Serial numbers
Storage
CHAPTER TWO TROUBLESHOOTING	31	(12)
Operating requirements
Motorcycle noise
Starting the engine
Engine leakdown test
Four-stroke operating principles
Leak-down tester
Engine spark test
Clutch
Engine performance
Gear shift linkage and transmission
Electrical testing
Brakes
Starting system
Steering and handling
Engine noise
CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP	43	(36)
Pre-ride inspection
Periodic lubrication
Engine break-in
Maintenance and inspection
Tune-up and service intervals
Engine tune-up
Battery
Spark plugs
Fuel and lubricants
CHAPTER FOUR ENGINE TOP END	79	(35)
Shop cleanliness
Cylinder head
Exhaust system
Valves
Cylinder head cover
Cylinder
Camshafts and cam chain tensioner
Piston and piston rings
CHAPTER FIVE ENGINE LOWER END	114	(23)
Shop cleanliness
Crankcase
Engine
Seal replacement
Cam chain and lower guide
Crankcase bearing replacement
Left crankcase cover
Crankshaft Engine balancer
CHAPTER SIX CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM	137	(19)
Right crankcase cover
Primary drive gear
Clutch
Clutch cable replacement
External gearshift linkage
Kickstarter Oil pump
CHAPTER SEVEN TRANSMISSION AND INTERNAL SHIFT MECHANISM	156	(15)
Transmission operation
Output shaft
Service notes
Transmission inspection
Input shaft
Shift drum and forks
CHAPTER EIGHT FUEL SYSTEM	171	(18)
Carburetor
Evaporative emissions control system
Carburetor cleaning and inspection
(California models only)
Float adjustment
Throttle cable replacement
Carburetor systems
Air filter housing Fuel valve
CHAPTER NINE ELECTRICAL SYSTEM	189	(34)
Resistance testing guidelines
Ignition system
Continuity testing guidelines
Charging system
Ignition and charging system operation
Fan system
Alternator cover
Water temperature gauge and sending unit
Stator and pickup coil
Rotor and starter clutch
Turn signal relay
Starter
Headlight
Starting system
Left handlebar switches
CHAPTER TEN COOLING SYSTEM	223	(7)
Safety precautions
Water temperature sending unit
Radiator and fan
Water pump Thermostat
CHAPTER ELEVEN WHEELS, TIRES AND DRIVE CHAIN	230	(19)
Front wheel and speedometer drive unit
Rim and spoke service
Drive chain
Rear wheel
Sprockets
Front and rear hubs
Tire changing
CHAPTER TWELVE FRONT SUSPENSION AND STEERING	249	(18)
Handlebar
Fork removal and installation
Steering stem and head
Fork service
CHAPTER THIRTEEN REAR SUSPENSION	267	(17)
Link-type suspension system
Swing arm
Shock absorber
Swing arm service
Shock absorber linkage
Shock absorber adjustment
CHAPTER FOURTEEN BRAKES	284	(31)
Disc brake fundamentals
Rear master cylinder
Front brake pads
Rear brake pedal
Front brake caliper
Brake system draining
Front master cylinder
Brake system bleeding
Rear brake pads
Brake disc
Rear brake caliper
CHAPTER FIFTEEN BODY	315	(4)
Side covers
Skid plate
Seat
Front fender
Fuel tank
Fairing
Radiator covers
Subframe
INDEX	319	(6)
WIRING DIAGRAMS	325