Kawasaki KLR650

Kawasaki KLR650

Manufacturer	Kawasaki
Production	1987-current
Engine	Single Cylinder, Water Cooled, Four-Stroke, DOHC, 4 valves
Compression ratio	9.5 : 1
Top speed	approx. 108mph, 175km/h (indicated)
Power	44 bhp (33 kW)
Suspension	Telescoping fork, Uni-Trak swingarm
Dimensions	L: 2165mm W: ? H: ?
Fuel capacity	6.1 U.S. gallons (23 L)

The Kawasaki KLR650 is a dual-purpose motorcycle intended for use on both paved and unpaved roads. It has been a long-standing model in Kawasaki's lineup, having been introduced in 1987 and remaining almost unchanged through the 2007 model. Kawasaki, in releasing the much-anticipated 2008 model, introduced the first significant redesign of the KLR650 since its inception.

The KLR650 is heavier than specialized off-road dirt bikes, but it can handle most conditions when ridden carefully by a skilled rider. Its 4-stroke DOHC dual-counter balanced, single-cylinder, water-cooled engine develops a claimed 44 hp (33 kW) at the crank; typical measurements at the rear wheel are 35 horsepower (26 kW). Typical fuel economy is 45 to 60 miles per U.S. gallon (3.9 to 4.7 L/100 km). It has a claimed 6.1 gallon (23 litre) fuel tank and a top speed of approximately 105 mph (160 km/h). The KLR is widely used as an inexpensive adventure/touring bike. The addition of luggage and personalized modifications (GPS, heated handgrips, larger windscreens) make it more functional on long trips.

KLRs have been ridden to the Arctic, across North and South America, and throughout Europe, Africa, and Asia, as well as on full global circumnavigation rides (e.g., Dr. Gregory Frazier in 2001-2002).

Note: While advertised capacity is 6.1 gallons, usable gas tank capacity is approximately 5.6 gallons including reserve, because approximately one half gallon of fuel sits below the top of the petcock intake tube within the tank, or on the other side of the main frame member, which divides the lowest portion of the tank into two lobes (the petcock draws only from one of these two lobes). In an emergency, this extra fuel can be utilized by tipping the bike on its side (nearly horizontal) allowing the fuel to slosh from one side of the tank to the other. This yields a maximum range of approximately 250-300 miles between fill-ups, depending on riding conditions.

2008 redesign

in 2008 the KLR650 was radically redesigned with improved aesthetics, modern dual headlights and a more powerful engine. the new 651 cc single cylinder engine puts out 37 bhp (28 kW) at 6200 rpm and 33.4 ft⋅lbf (45.3 N⋅m) of torque at 4950 rpm. other improvements include: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38 mm to 41 mm, new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36watts capacity. There are 5 issues with the redesign. 1)The early 08s had oil consumption issues. 2) The muffler bolts were not torqued properly at the factory and may rattle out (recall issued) 3).The turn signals fall off due to rubber rot (recall issued). 4)The "Doohickey" or balancer shaft chain tensioning mechanism is more robust but its spring is still weak. 5)There is some rubbing issues on the main electrical bundle under the tank that can lead to a shortage and cause the bike to not start (recall issued).

Models

• KLR650-A: The "A" model was introduced in 1987, based on its KLR600 predecessor (1984-1986). The "A" model remained nearly unchanged until the introduction of the 2008 model in USA, Canada and Europe
• KLR650-B or Tengai: was sold in the USA starting 1990 and in other countries for several years afterward
• KLR650-C: The "C" model is a more dirt-oriented motorcycle fitted with stiffer 41 mm front forks, improved brakes, tubular engine guard, smaller 14 liter fuel tank, and steel wheel rims. Lacking a temperature gauge, it has an over-heat lamp.
• KLR650-E: 2008 was the first major redesign of the KLR650. The primary changes include upgraded 41 mm forks, a new D-section swingarm, dual beam headlight, dual-piston rear brake caliper, upgraded cooling system, 4 mm spokes, cowling and fairing redesign as well as various redesigned parts. shooooooooooooooooooooooooooooo(error corrected specifications)
• The U.S. Military has KLR650s modified by Hayes Diversified Technologies to burn military-spec fuels including diesel. (M1030M1 [1]) All-new engines were designed to replace the 4-stroke gasoline engines. See HDT KLR650s

KLR History Timeline

Specifications (1987-2007 KLR650-A)

1998 KLR650 in its environment (the luggage is not standard)

1995 KLR650

Specifications for 1987-2007 U.S. Model

Engine Type	Single Cylinder, Water Cooled, Four-Stroke, DOHC, 4 valves
Carburetion	Keihin CVK-40 constant velocity carburetor
Displacement	651 cc
Bore × Stroke	100 mm × 83 mm
Peak Power	44 bhp (33 kW) @ 6,000 rpm
Peak Torque	34 lbf·ft (46 N·m) @ 5,000 rpm
Compression Ratio	9.5 : 1
Fuel Capacity	6.1 U.S. gallons (23 L) (5.6 gal usable)
Oil Capacity	2.64 U.S. quarts (2.5 L)
Charging System Output	238 W @ 14 V
Seat Height	35.0 in. (88.9 cm)
Dry Weight	337 lb (176 kg) claimed, 402 lb (182 kg) wet weight actual
GVWR	738 lb (330 kg)
Tires	Front: 90/90-21 in. Rear: 130/90-17 in.
Brakes	Front: 1 disc, dual piston caliper; Rear: 1 disc, single piston caliper.
Final drive	520×106 links O-Ring Chain

Sponsored organizations

Although rare, Kawasaki has chosen to offer KLR650 motorcycles to a few select organizations that would put their bike to the test. These individuals have taken the bikes to some of the most remote locations in the world and have documented the journey on their websites. They include the following:

• Moon Riders: 1997 trip to Latin America. Team Green provided support, parts, and service throughout Central and South America.

• Bikers Without Borders: 2003 trip through 13 Latin America countries volunteering at hospitals, orphanages, Christian Missions and dental clinics. Kawasaki provided 2 brand new KLR 650s for this organization.

Changes over the years

Aside from the paint job, not much changed between the 1987 introduction and the 2008 revisions. The key differences are:

• 1987: Crankshaft is unique to this year.
• 1988: Beefed up the engine cases with extra bolts between the crank and countershaft; crank has a different part number, and may be lighter.
• 1990: Countershaft improved with longer splines for increased engagement with sprocket.
• 1992: Changes to front brake master cylinder.
• Mid-1996: Changed valve cover, added bracket to hold cam chain bumper; changed crank to heavier unit; improved clutch basket with more clutch plates; changed countershaft sprocket retainer from slotted plate to large nut; changed 2nd and 3rd gear ratios. Kickstarter no longer fits with new clutch basket. New left balancer weight/sprocket begins with engine #KLE650AE032206.
• (?) Service manual indicates higher charging system output; only part number change is the rotor. The new power rating is 17A/14V (238 W) @ 7000 rpm; the earlier one was 14A/14V (196 W) @ 8000 rpm (above redline).
• 2001(?) Final assembly shifts from Japan to Thailand. All major parts still made in Japan.
• 2007: New shift lever
• 2008: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38 mm to 41 mm, new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36watts capacity.

External links

• MotorcycleUSA 2008 KLR650 Review
• KLR650 on Kawasaki's website
• First review of the 2008 model KLR650E
• 2008 KLR650 Review
• KLR650 vs. DR650 Comparison
• RIDER Magazine 2008 KLR650 Review
• Motorcycle Daily reviews the 2008 KLR650
• 2002 KLR650 Review in Minnesota Motorcycle Monthly
• KLR650 FAQ