Kawasaki KLR650 2013 Owner's manual

Quick Reference Guide

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GENERAL INFORMATION	j
HOW TO RIDE THE MOTORCYCLE	j
SAFE OPERATION	j
MAINTENANCE AND ADJUSTMENT	j
STORAGE	j
TROUBLESHOOTING GUIDE	j

A Table of Contents is included after the Foreword.

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

NOTE

○NOTE indicates information that may help or guide you in the operation or service of the vehicle.

WARNING

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

NOTICE

THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, capabilities, and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without our prior written permission.

This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2013 Kawasaki Heavy Industries, Ltd.

Sep. 13, 2013. (1)

TABLE OF CONTENTS

SPECIFICATIONS...............................	8
SERIAL NUMBER LOCATIONS.........	12
LOCATION OF PARTS .......................	13
LOCATION OF LABELS.....................	16
LOADING INFORMATION..................	20
GENERAL INFORMATION.................	23
Meter Instruments ............................	23
Speedometer and Tachometer: ....	24
Coolant Temperature Gauge: .......	24
Indicator Lights: ............................	25
Key...................................................	25
Ignition Switch/Steering Lock...........	27
To lock the steering:......................	27
Right Handlebar Switches................	28
Engine Stop Switch: .....................	28
Starter Button: ..............................	29
Left Handlebar Switches ..................	29
Dimmer Switch: ............................	29
Turn Signal Switch:.......................	30
Horn Button: .................................	30

Fuel Tank Cap..................................	31
Fuel Tank .........................................	32
Fuel Tap ...........................................	36
Stand................................................	38
Helmet Hook ....................................	39
Rear Carrier .....................................	40
Tool Kit Container/Tool Kit................	41
Tying Hooks .....................................	41
BREAK-IN...........................................	42
HOW TO RIDE THE MOTORCYCLE . 44
Starting the Engine ..........................	44
Jump Starting...................................	47
Moving Off........................................	52
Shifting Gears ..................................	53
Braking.............................................	54
Stopping the Engine.........................	55
Stopping the Motorcycle in an
Emergency ...................................	56
Parking.............................................	57
Catalytic Converter...........................	58

SAFE OPERATION.............................	61
Safe Riding Technique .....................	61
Daily Checks ....................................	64
Additional Considerations for OFF
Road Operation ............................	67
MAINTENANCE AND ADJUSTMENT	69
Periodic Maintenance Chart.............	73
Engine Oil ........................................	86
Cooling System ................................	92
Spark Plugs......................................	98
Evaporative Emission Control
System (California model only).....	99
Kawasaki Clean Air System .............	100
Valve Clearance ...............................	101
Air Cleaner .......................................	102
Throttle Control System ...................	106
Choke Lever.....................................	110
Idle Speed........................................	111
Clutch...............................................	112
Spark Arrester..................................	114
Drive Chain ......................................	116

Brakes..............................................	123
Brake Light Switches........................	127
Front Fork.........................................	129
Rear Shock Absorbers.....................	129
Wheels .............................................	132
Tires -............................................	132
Battery..............................................	136
Headlight Beam................................	143
Rear Turn Signal Light .....................	144
Fuses ...............................................	145
General Lubrication..........................	146
Cleaning Your Motorcycle ................	149
Bolt and Nut Tightening....................	154
STORAGE...........................................	156
TROUBLESHOOTING GUIDE............	159
YOUR WARRANTY/OWNER
SATISFACTION ...........................	160
Reporting Safety Defects..................	166
ENVIRONMENTAL PROTECTION.....	167
LABEL INFORMATION ......................	168
MAINTENANCE RECORD .................	174

8 SPECIFICATIONS

	SPECIFICATIONS
PERFORMANCE
Minimum Turning Radius	2.4 m (94 in.)
DIMENSIONS
Overall Length	2 295 mm (90.4 in.)
Overall Width	960 mm (37.8 in.)
Overall Height	1 350 mm (53.1 in.)
Wheelbase	1 480 mm (58.3 in.)
Road Clearance	210 mm (8.3 in.)
Curb Mass	196 kg (432 lb)
ENGINE
Type	DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled
Displacement	651 cm³ (39.7 cu in.)
Bore × Stroke	100.0 × 83.0 mm (3.94 × 3.27 in.)
Compression Ratio	9.8 : 1
Starting System	Electric starter

		SPECIFICATIONS 9
Carburetion System		KEIHIN CVK 40 × 1
Ignition System		Battery and coil (transistorized ignition)
Ignition Timing		10° BTDC @1 300 r/min (rpm)
(Electronically advanced)		30° BTDC @4 000 r/min (rpm)
Spark Plugs		NGK DPR8EA-9, ND X24EPR-U9
Lubrication System		Forced lubrication (wet sump)
Engine Oil:	Type	API SG, SH, SJ, SL or SM with JASO MA, MA1
		or MA2
	Viscosity	SAE 10W-40
	Capacity	2.1 L (2.2 US qt)
Coolant Capacity		1.5 L (1.6 US qt)
TRANSMISSION
Transmission Type		5-speed, constant mesh, return shift
Clutch Type		Wet, multi disc
Driving System		Chain drive
Primary Reduction Ratio		2.273 (75/33)
Final Reduction Ratio		2.867 (43/15)

10 SPECIFICATIONS
Overall Drive Ratio		5.158	(Top gear)
Gear Ratio:	1st	2.267	(34/15)
	2nd	1.444	(26/18)
	3rd	1.136	(25/22)
	4th	0.955	(21/22)
	5th	0.792	(19/24)
FRAME
Castor		28°
Trail		112 mm (4.4 in.)
Tire Size:	Front	90/90-21 M/C 54S
	Rear	130/80-17 M/C 65S
Rim Size:	Front	21 × 1.60
	Rear	17M/C × MT2.50
Fuel Tank Capacity		22 L (5.8 US gal)
ELECTRICAL EQUIPMENT
Battery		12 V 14 Ah

SPECIFICATIONS 11

Headlight	12 V 55 W × 2/55 W (Hi/Lo)
Tail/Brake Light	12 V 5/21 W

Specifications are subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it.

Frame No.		Engine No.

A. Frame Number

A. Engine Number

LOCATION OF PARTS 13

LOCATION OF PARTS

1.	Clutch Lever	5.	Right Handlebar Switches
2.	Left Handlebar Switches	6.	Front Brake Lever
3.	Meter Instruments	7.	Throttle Grip
4.	Brake Fluid Reservoir (Front)	8.	Ignition Switch/Steering Lock

14 LOCATION OF PARTS

9.	Turn Signal Light	15.	Tool Kit/Storage	20.	Brake Caliper
10.	Headlight	16.	Compartments	21.	Shift Pedal
11.	Spark Plugs		Helmet Hook	22.	Side Stand
12.	Main Fuse	17.	Tying Hooks	23.	Rear Shock Absorber
13.	Battery	18.	Front Fork	24.	Drive Chain
14.	Seat	19.	Brake Disc

LOCATION OF PARTS 15

25.	Tail/Brake Light	29.	Fuel Tank	33.	Rear Brake Pedal
26.	Rear Carrier	30.	Fuel Tank Cap	34.	Oil Level Inspection
27.	Brake Fluid Reservoir	31.	Muffler	35.	Window
28.	(Rear)	32.	Rear Brake Light		Idle Adjusting Screw
	Air Cleaner		Switch	36.	Coolant Reserve Tank

16 LOCATION OF LABELS

LOCATION OF LABELS

All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your vehicle. Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.

NOTE

○The sample warning labels in this section have part numbers to help you and your dealer obtain the correct replacement.

○Refer to the actual vehicle label for model specific data grayed out in the illustration.

1. Brake Fluid (Front)

LOCATION OF LABELS 17

2.Brake Fluid (Rear)

3.Tire and Load Data

4.Important Drive Chain Information

18 LOCATION OF LABELS

5. Vehicle Emission Control

Information

6. Noise Emission Control Information

*7. Vacuum Hose Routing Diagram

8. Battery Vent Hose

9. Radiator Cap Danger

10. Weight and Manufacture

*: only on California model

LOCATION OF LABELS 19

11.Carrier Caution

12.Battery Poison/Danger *13. Fuel Level

*: only on California model

20 LOADING INFORMATION

LOADING INFORMATION

WARNING

Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure that the motorcycle is not overloaded and that you have followed these instructions.

With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or motorcycle modification, will void the motorcycle

warranty. In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other persons involved.

NOTE

○Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components.

Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories.

The following general guidelines have been prepared to assist you in making your determinations.

1.Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper positioning during cornering and sudden movements. It is important that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle.

2.You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator or grab rail. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided.

3.All baggage should be carried as low as possible to reduce the effect

LOADING INFORMATION 21

on the motorcycle center of gravity. Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle.

4.Baggage should be securely attached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary.

5.Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces.

6.Do not install accessories or carry baggage that impairs the performance of the motorcycle. Make sure that you have not adversely

22 LOADING INFORMATION

affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle’s operation.

7.Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition.

8.Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an unsafe riding condition.

9.This motorcycle was not intended to be equipped with a sidecar or to

be used to tow any trailer or other vehicle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the effects of such accessories on handling or stability, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage, and accessories must not exceed 182 kg (401 lb).

GENERAL INFORMATION 23

GENERAL INFORMATION

Meter Instruments

A.Tachometer

B.Red Zone

C.Speedometer

D.Odometer

E.Coolant Temperature Gauge

F.Neutral Indicator Light

G.Trip RESET Button

H.Trip Meter

I.High Beam Indicator Light

J.Turn Signal Indicator Light

24 GENERAL INFORMATION

Speedometer and Tachometer:

The speedometer shows the speed of the vehicle. In the speedometer face are the odometer and trip meter. The odometer shows the total distance that the vehicle has been ridden. The trip meter shows the distance traveled since it was last reset to zero. The trip meter can be reset to zero by pushing the trip reset button.

The tachometer shows the engine speed in the revolutions per minute (r/min, rpm). On the right side of the tachometer face is a portion called the “red zone”. Engine r/min (rpm) in the red zone is above maximum recommended engine speed and is also above the range for good performance.

NOTICE

Engine r/min (rpm) should not be allowed to enter the red zone; operation in the red zone will overstress the engine and may cause serious engine damage.

Coolant Temperature Gauge:

This gauge shows the temperature of coolant. Ordinarily, the needle should stay within the white zone. If the needle reaches the “H” line, stop the engine and check the coolant level in the reserve tank after the engine cools down.

NOTICE

Do not let the engine continue running when the gauge needle reaches the “H” line. Prolonged engine operation will result in severe damage from overheating.

Indicator Lights:

: When the headlight is on high beam, the high beam indicator light is lit.

N: When the transmission is in neutral, the neutral indicator light is lit.

: When the turn signal switch is turned to left or right, the turn signal indicator light flashes on and off.

GENERAL INFORMATION 25

Key

This motorcycle has a combination key, which is used for the ignition switch/steering lock, seat lock, helmet hook and fuel tank cap.

Included with the key is a key number, which may be stamped on a separate plate. Record the key number in the space provided and store the number in a safe place. If your keys came with a plate, store it in a safe place as well.

26 GENERAL INFORMATION

A.Ignition Key

B.Tag

C.Key Number

Write your key number here.

In the event you lose your keys, you will need the key number to have a duplicate made. If you cannot locate your key number, contact the dealer where you purchased your Kawasaki motorcycle. It’s possible the dealer may have the number in its records. If the key number is lost completely, you will need to replace the ignition switch and all other locks operated by that key.

Contact your Kawasaki dealer to purchase additional spare keys either using your original key as a master or using the key code on the tag or your key. Store one key at home and keep another spare in your wallet or riding gear, in case the original is lost.

Ignition Switch/Steering Lock

This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF or LOCK position.

A.Ignition Switch/Steering Lock

B.ON position

C.OFF position

D.LOCK position

GENERAL INFORMATION 27

	OFF	Engine off.	All electrical
		circuits off.
	ON	Engine on.	All electrical
		equipment can be used.
	LOCK	Steering locked. Engine off.
		All electrical circuits off.

NOTE

○The head, and tail lights are on whenever the ignition key is in the ON position. One headlight goes on when the ignition key is in the ON position. To avoid battery discharge, always start the engine immediately after turning the ignition key to “ON”.

To lock the steering:

1.Turn the handlebar fully to the left.

2.With the ignition key in the OFF position, push down and release the key.

3.Turn the key to LOCK position.

4.Pull the key out.

28 GENERAL INFORMATION

Right Handlebar Switches

Engine Stop Switch:

In addition to the ignition switch, the engine stop switch must be in

theposition for the motorcycle to operate.

The engine stop switch is for emergency use. If required, move the switch

to theposition.

NOTE

○Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine.

A.Engine Stop Switch

B.Starter Button

Starter Button:

The starter button operates the electric starter when the transmission is in neutral.

Refer to the Starting the Engine section of the "How to Ride the Motorcycle" chapter for starting instructions.

GENERAL INFORMATION 29

Left Handlebar Switches

Dimmer Switch:

High or low beam can be selected with the dimmer switch. When the headlight is on high beam (), the high beam indicator light is lit.

High beam	.......(			)
Low beam.......	(		)