The Cyclepedia.com Kawasaki KLR650 online service manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Kawasaki dealer trained technician.
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If you need to replace or adjust your balancer chain tension adjuster, otherwise known as the doohickey or doohicky, this service manual will provide all the instructions you will need. The doohickey provides tension for the balancer chain. If the doohickey is far out adjustment or fails you have a major problem that will cause damage to your Kawasaki KLR650 dual sport motorcycle.
This is what the doohickey spring looks like when the owner doesn’t adjust the balancer chain tension and the spring gets sucked through the balancer chain.
In the example above the failed doohickey spring caused the engine to jump time. This KLR650 engine ate both exhaust valves, damaged the cylinder head, cylinder, and piston all because the doohickey was not adjusted correctly. Get instant access to this online service manual, adjust the doohickey and maintain your KLR650 dual sport motorcycle to keep it running in top form for your next adventure.
The KLR650 Online Manual covers the following KLR dual sport motorcycles:
2007 Kawasaki KLR650-A21
2006 Kawasaki KLR650-A20
2005 Kawasaki KLR650-A19
2004 Kawasaki KLR650-A18
2003 Kawasaki KLR650-A17
2002 Kawasaki KLR650-A16
2001 Kawasaki KLR650-A15
2000 Kawasaki KLR650-A14
1999 Kawasaki KLR650-A13
1998 Kawasaki KLR650-A12
1997 Kawasaki KLR650-A11
1996 Kawasaki KLR650-A10
1995 Kawasaki KLR650-A9
1994 Kawasaki KLR650-A8
1993 Kawasaki KLR650-A7
1992 Kawasaki KLR650-A6
1991 Kawasaki KLR650-A5
1990 Kawasaki KLR650-A4
1990 Kawasaki KL650B2 Tengai
1989 Kawasaki KLR650-A3
1988 Kawasaki KLR650-A2
1987 Kawasaki KLR650-A1
1986 Kawasaki KL600B2 KLR
1985 Kawasaki KL600B1 KLR
1984 Kawasaki KLR600A1
Also Available – 2008+ Kawasaki KLR650 Online Service Manual
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Kawasaki KLR650 Quick Reference
General Torque 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
Kawasaki KLR650 External Components
Fuel Tank, Headlight Removal, Seat, Side Covers
Kawasaki KLR650 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
Kawasaki KLR650 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
Kawasaki KLR650 Final Drive
Chain, Front Sprocket, Rear Sprocket
Kawasaki KLR650 Front Wheel
Front Wheel Bearing, Front Wheel Inspection, Front Wheel Installation, Front Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing
Kawasaki KLR650 Rear Wheel
Rear Wheel Bearing Replacement, Rear Wheel Inspection, Rear Wheel Installation, Rear Wheel Removal, Tires Removal/Installation, Tire Inspection, Wheel Truing, Wheel Balancing
Kawasaki KLR650 Steering
Steering Installation and Adjustment, Steering Removal and Inspection, Steering/Suspension Troubleshooting
Kawasaki KLR650 Front Suspension
Fork Disassembly, Fork Inspection, Fork Oil Replacement, Fork Seal Replacement, Fork Reassembly
Kawasaki KLR650 Rear Suspension
Rear Suspension Settings, Removal & Installation
Kawasaki KLR650 Fuel System
Air Filter, Carburetor Disassembly, Carburetor Removal, Pilot Screw Removal
Kawasaki KLR650 Front Brakes
Front Brake Disc Inspection, Front Brake Fluid Inspection, Front Brake Removal & Inspection, Front Brake and Caliper Installation, Brake Troubleshooting
Kawasaki KLR650 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
Kawasaki KLR650 Cooling Systems
Coolant Removal, Coolant System Inspection
Kawasaki KLR650 Exhaust System
Exhaust System
Kawasaki KLR650 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
Tech Support with an Experienced Kawasaki Technician
My Service Records – Online Service Log With Reminders New!
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The Cyclepedia Kawasaki KLR650 manual is 100% of what I needed to repair my motorcycle! – Jason L.
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I purchased the Cyclepedia.com Kawasaki KLR 650 online manual to solve a carb problem and take care of some routine maintenance. I like the program. – J. Negrych
gription says
I just purchased a lifetime membership for the Kawasaki KLR650 manual and so far I think it is great. I am a first-time motorcycle owner and know very very little about mechanics and routine maintenance. So I’m learning. I performed my first oil and filter change on my bike yesterday and was pleased with this accomplishment. Your online manual is a great product and I look forward to using it more in the future. – A. Bentley
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Hey Cyclepedia! I really appreciate the follow up email I received today. I was trying to do some maintenance and was stumped about something. In my opinion, outstanding customer service is, relatively speaking, kinda rare. So, thanks! I’m so glad I subscribed to your online manual for my 2007 Kawasaki KLR650 – it’s definitely been worth the money I paid & already I’m getting to know my bike better. Thanks again! Peace. Tim
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Canada’s Online Motorcycle Magazine CMG Reviews the KLR manual…
“The content is much the same as a shop manual, only the well-shot pictures are bigger and in full color (and so are the PDF format wiring diagrams, which are very useful). The instructions appear to be quite comprehensive… Price is not a lot for a good manual and you get access to a fully qualified mechanic for the duration of your subscription should you have any questions.”