Kawasaki KLR650 2008 – 2012 Service Repair Manual M240-2

This Kawasaki KLR650 Manual is 312 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine spark test / Engine performance / Electrical testing / Starting system / Engine noise / Motorcycle noise / Engine lubrication / Engine leakdown test / Clutch / Gear shift linkage and transmission / Brakes / Steering and handling / Disc brake troubleshooting / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Tune-up, service and maintenance intervals / Fuel and lubricants / Oil and filter change / Fork oil change / Control cable lubrication / Drive chain cleaning, lube and adjustment / Air filter cleaning and replacement / Air filter housing draining / Muffler cleaning / Balancer chain tensioner adjustment / Coolant level check / Coolant draining refill / Throttle play adjustment and inspection / Valve clearance / Engine tune-up / Spark plugs / Specifications

CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts and cam chain tensioner / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine / Cam chain and lower guide / Left crankcase cover / Engine / Balancer / Crankcase / Seal replacement / Crankcase bearing replacement / Crankshaft / Engine break-in / Specifications

CHAPTER SIX / CLUTCH, GEARSHIFT MECHANISM AND LUBRICATION SYSTEM
Right crankcase cover / External gearshift linkage / Oil pump / Primary drive gear / Clutch cable / Specifications

CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM
Input shaft / Output shaft / Inspection / Shift drum and forks / Specifications

CHAPTER EIGHT / FUEL SYSTEM
Carburetor cleaning and inspection / Float adjustment / Fuel valve / Evaporative emissions control system / Throttle and choke cable / Air filter housing / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Continuity testing / Battery / Charging system / Alternator cover / Stator / Rotor and starter clutch / Regulator rectifier / Starting system / Starter / Starter relay / Starter circuit relay / Ignition system / Fan / Coolant temperature gauge and sender / Meter unit / Lighting system / Switches / Fuses / Specifications

CHAPTER TEN / COOLING STSTEM
Safety precautions / Radiator and fan / Thermostat / Water temperature sending unit / Water pump / Coolant reserve tank / Specifications

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front and rear wheel / Speedometer drive unit / Front and rear hubs / Rim and spoke / Drive chain / Sprockets / Tire changing / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Left hand grip replacement / Balancer weights / Front fork / Fork service Steering stem and head / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Linkage / Swing arm / Shock adjustment / Specifications

CHAPTER FOURTEEN / BRAKES
Fluid / Front and rear brake pads Front and rear brake caliper / Front and rear master cylinder / Rear brake pedal / Brake system draining and bleeding / Brake disc / Specifications

CHAPTER FIFTEEN / BODY
Side covers / Seat / Fuel tank / Lower and lower fairing / Fender / Carrier / Subframe / Skid plate / Specifications

INDEX

COLOR WIRING DIAGRAMS

Models covered:
2008 2009 2010 2011 2012 Kawasaki KLR650 KLR 650

Dual Sport Dualsport 2402b2402p