The KLR650 Online Manual covers the following KLR motorcycles:

1984-1986 Kawasaki KLR600
1987-2007 Kawasaki KLR650A

Note: This guide was authored using a 2005 Kawasaki KLR650. This guide does not cover the 2008 KLR650.

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Quick Reference – Bolt and Nut Torque and Size Specification, Bolt Tightening Torque, Specifications KLR600 1984-1986, Specifications KL650 1987-1999, Specifications KL650 2000-2001, Specifications KL650 2002-2006, Periodic Maintenance, Torque Conversions, VIN Number Location

External Components – Fuel Tank, Headlight Removal, Seat, Side Covers

Periodic Maintenance – Air Filter Servicing, Brake Fluid (Front), Brake Fluid (Rear), Compression Check, Crankcase Oil Replacement, Drive Chain, Engine Coolant & Hoses, Engine Idle Speed, Exhaust System, Periodic Maintenance Chart, Sparkplug Inspection, Throttle Free Play, Tire Inspection

Engine – Cylinder Head Removal, Cylinder, Piston, Compression Check, Oil Change, Valve Adjustment, Valve Shim Charts, Valve Shim Replacement, Valve Train Reassembly, Valve Train Removal, Clutch, Starter Clutch, Engine Troubleshooting, Top End Specifications, Water Pump

Final Drive – Chain, Front Sprocket, Rear Sprocket

Front Wheel – Front Wheel Bearing, Front Wheel Inspection, Front Wheel Installation, Front Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing

Rear Wheel – Rear Wheel Bearing Replacement, Rear Wheel Inspection, Rear Wheel Installation, Rear Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing

Steering – Steering Installation and Adjustment, Steering Removal and Inspection, Steering/Suspension Troubleshooting

Front Suspension – Fork Disassembly, Fork Inspection, Fork Oil Replacement, Fork Seal Replacement, Fork Reassembly

Rear Suspension – Rear Suspension Settings, Removal & Installation

Fuel System – Air Filter, Carburetor Disassembly, Carburetor Removal, Pilot Screw Removal

Front Brakes – Front Brake Disc Inspection, Front Brake Fluid Inspection, Front Brake Removal & Inspection, Front Brake and Caliper Installation, Brake Troubleshooting

Rear Brakes – Rear Brake Disc Inspection, Rear Brake Fluid Inspection, Rear Brake Pad & Caliper Installation, Rear Brake Pedal Adjustment, Rear Brake Removal & Inspection, Brake Troubleshooting

Cooling Systems – Coolant Removal, Coolant System Inspection

Exhaust System – Exhaust Removal

Electrical System – Electrical Component Location, Electric Starter Motor, Starter Relay Inspection, Ignition Coil, Headlight Bulb Replacement, Taillight Bulb Replacement, Testing Electrical Components, Turn Signal Bulb Replacement, Spark Plug, Battery, Wiring Diagrams, Service Data, Electrical Troubleshooting

Troubleshooting