Kawasaki KLR650 2015 Owner's manual

Quick Reference Guide

This Quick Reference Guide will
assist you in finding the information
you’re looking for.

A Table of Contents is included after
the Foreword.

GENERAL INFORMATION j

BREAK-IN j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

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

NOTICE

NOTICE is used to address prac­ticesnotrelatedtopersonalin­jury.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNING indicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

NOTE

NOTE indicates information that may

○

help or guide you in the operation or
service of the vehicle.

NOTICE

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

(Australian model only)

TAMPERING WITH NOISE CONTROL SYSTEM

PROHIBITED

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes

of maintenance, repair or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; and

(b) The use of the vehicle after such device or element of design has been

removed or rendered inoperative by any person.

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, c apabilities, and limita tio ns. 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 p ro gram 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 th e motorcycle whe n 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

© 2014 Kawasaki Heavy Industrie s, Ltd. Jun. 16, 2014. (2)

TABLE OF CO NTE NTS

SPECIFICATIONS............................... 10

LOCATION OF PARTS....................... 14

LOADING INFORMATION.................. 17

GENERAL INFORMATION................. 20

Meter Instruments ............................ 20

Speedometer and Tachometer: .... 21

Coolant Temperature Gauge: ....... 21

Indicator Lights: ............................ 22

Key................................................... 22

Ignition Switch/Steering Lock ........... 23

To lock the steering:...................... 23

Right Handlebar Switches ................ 24

Engine Stop Switch: ..................... 24

Starter Button: .............................. 25

Left Handlebar Switches .................. 25

Dimmer Switch: ............................ 25

Turn Signal Switch:....................... 26

Horn Button: ................................. 26

Fuel Tank ......................................... 27

Fuel Tap ........................................... 31

Stand................................................ 33

Helmet Hook .................................... 34

Rear Carrier ..................................... 35

Tool Kit Container/Tool Kit ................ 36

Tying Hooks ..................................... 36

BREAK-IN ........................................... 37

HOW TO RIDE THE MOTORCYCLE .39

Starting the Engine .......................... 39

Jump Starting ................................... 42

Moving Off........................................ 47

Shifting Gears .................................. 48

Braking............................................. 49

Stopping the Engine ......................... 50

Stopping the Motorcycle in an

Emergency ................................... 51

Parking............................................. 52

Catalytic Converter........................... 54

SAFE OPERATION............................. 56

Safe Riding Technique ..................... 56

Daily Checks .................................... 59

Additional Considerations for OFF

Road Operation ............................ 62

MAINTENANCE AND ADJUSTMENT 64

Periodic Maintenance Chart ............. 64

Engine Oil ........................................ 76

Cooling System ................................ 82

Spark Plugs...................................... 88

Valve Clearance ............................... 89

Air Cleaner ....................................... 89

Throttle Control System ................... 94

Choke Lever..................................... 97

Idle Speed ........................................ 98

Clutch............................................... 99

Drive Chain ...................................... 101

Brakes.............................................. 109

Brake Light Switches........................ 113

Front Fork......................................... 115

Rear Shock Absorbers ..................... 115

Wheels ............................................. 118

Tires -............................................ 118

Battery.............................................. 122

Headlight Beam................................ 128

Rear Turn Signal Light ..................... 130

Fuses ............................................... 130

General Lubrication.......................... 132

Cleaning Your Motorcycle ................ 134

STORAGE........................................... 139

OWNER SATISFACTION................. 142

ENVIRONMENTAL PROTECTION ..... 144

LOCATION OF LABELS ..................... 145

10 SPECIFICATIONS

SPECIFICATIONS

PERFORMAN

Maximum Hosepow er

Maximum Torque

Minimum Turning Radius

DIMENSI

Overall

Overall

Overall

Wheelbase

Road Cl

Curb Ma

CE

ONS

Length

Width

Height

earance

ss

15.0 kW (20

(VE) 32.0

40 N·m (4.

(VE) 50 N·

2.4m(94i

2295mm(

960 mm (3

1350mm(

1480mm

210 mm (

194 kg (

(VE) 19

kW (44 PS) @6 500 r/min (rpm)

8.3 in.)

428 lb)

6kg(432lb)

PS) @4 500 r/min (rpm)

1kgf·m,30ft·lb)@3000r/min(rpm)

m (5.1 kgf·m, 37 ft·lb) @5 500 r/min (rpm)

n.)

90.4 in.)

7.8 in.)

53.1 in.)

(58.3 in.)

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

Carburetion System KEIHIN CVK 40 × 1

Ignition System Battery and coil (transistorized ignition)

Ignition Timing 10° BTDC @1 300 r/min (rpm) ∼

(Electronically ad vanced) 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

SAE 10W-40

Capacity 2.1 L (2.2 US qt)

Coolant Capacity 1.5 L (1.6 US qt)

SPECIFICATIONS 11

12 SPECIFICATIONS

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)

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

Caster 28°

Trail 112 mm (4.4 in.)

Tire Size: Front 90/90–21 M/C 54S

Rear 130/80–17 M/C 65S

SPECIFICATIONS 13

Rim Size: Front 21 × 1.60

Rear 17M/C × MT2.50

Fuel Tank Capacity 22 L (5.8 US gal)

ELECTRICAL EQUIPMENT

Battery 12V14Ah(10HR)

Headlight 12 V 55 W × 2/55 W (Hi/Lo)

Brake/Tail Light 12 V 2 1/5 W

(VE) Venezuela Model

Specifications are subject to change without notice, and may not apply to every
countries.

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Left Handlebar S witches

3. Meter Instruments

4. Brake Fluid Reservoir (Front)

5. R ight Handlebar Switches

6. Fr on t Brake Lever

7. T hro ttle Grip

8. Ig nit ion Switch/Steering Lock

LOCATION OF PARTS 15

9. Turn Signal Light

10. Headlight

11. Spark Plug s

12. Main Fuse

13. Battery

14. Seat

15. Tool Kit/Storage Com part men ts

16. Helmet Hook

17. Tying Hooks

18. Front Fork

19. Brake Disc

20. Brake Caliper

21. Shift Pedal

22. Side Stand

23. Rear Shock Absorber

24. Drive Chain

16 LOCATION OF PARTS

25. Tail/Brake L igh t

26. Rear Carrier

27. Brake Fluid Reservoir (R ear)

28. Air Cleaner

29. Fuel Tank

30. Fuel Tank Cap

31. Muffler

32. R ear Brake Light Swi tch

33. R ear Brake Pedal

34. Oil Level Inspection Window

35. Id le Adjusting Screw

36. C oo lant Reserve Tank

LOADING INFORMATION

LOADING INFORMATION 17

WARNING

Incorrect loading, improper in­stallation or use of accessories,
or modification of your motorcy­cle may result in an unsafe rid­ing condition. Before you ride
themotorcycle,makesurethat
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 s en sitive to
changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.

18 LOADING INFORMATION

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

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

LOADING INFORMATION 19

affected any lighting components,
road clearance, banking cap a bility
(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 r e­sult 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
thattheeffectscanbeadverseand
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).

20 GENERAL INFOR M ATION

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

GENERAL INFORMATION

GENERAL INFORMATION 21

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
thetripresetbutton.

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.

22 GENERAL INFOR M ATION

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.

Key

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

Blank keys are available at your
Kawasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as a
master.

GENERAL INFORMATION 23

Ignition Switch/Steering Lock

This is a three-position, key-operated
switch. The key can be removed from
theswitchwhenitisintheOFFor
LOCK position.

A. Ignition Switch/Steering Lock
B. ON position
C. OFF position
D. LOCK position

OFF

ON

LOCK

Engine off. All electrical circuits
off.

Engine on. All electrical
equipment can be used.

Steering locked. Engine off. All
electrical circuits off.

NOTE

The head, and tail lights are on when-

○

ever 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.

24 GENERAL INFOR M ATION

Right Handlebar Switches

Engine Stop Switch:

In addition to the ignition switch,

theenginestopswitchmustbein
the

operate.

gency use. If required, move the switch
to the

position for the motorcycle to

Theenginestopswitchisforemer-

position.

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

GENERAL INFORMATION 25

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.

Left Handlebar Switches

Dimmer Switch:

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

High beam.......(

Low beam.......(

)

)

), the

26 GENERAL INFOR M ATION

NOTE

When the headlight is on high beam,

○

both head lights are lit. W hen the
headlight is on low beam, only one
headlight is lit.

A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button

Turn Signal Switch:

When the turn signal switch is turned

to the left (

)orright( ), the
corresponding turn signal flashes on
and off.

To stop flashing, push the switch in.

Horn Button:

When the horn button is pushed, the

horn sounds.

GENERAL INFORMATION 27

Fuel Tank

Fuel Requirements:

Your Kawasaki engine is designed
to use only unleaded gasoline with a
minimum octane rating shown below.
Neverusegasolinewithanoctanerat­ing lower than the minimum specified
by Kawasaki to prevent severe engine
damage.

The octane rating of a gasoline is a
measure of its resistance to detona­tion or “knocking”. The term commonly
used to describe a gasoline’s octane
rating is the Research Octane Number
(RON).

NOTICE

If engine “knocking" or “ping­ing" occurs, use a different
brand of gasoline of a higher
octane rating. If this condition is
allowed to continue, it can lead
to severe engine damage. Gaso­line quality is important. Fuels
of low quality or not meeting
standard industry specifications
may result in unsatisfactory per­formance. Operating problems
that result from the use of poor
quality or no recommended fuel
may not be covered under your
warranty.

Fuel Type and Octane Rating:
(Except for Australia Specification)

Use clean, fresh unleaded gasoline
with an octane rating equal to or higher
than that shown in the table.

28 GENERAL INFOR M ATION

Fuel Type Unleaded Gasoline

Minimum
Octane Rating

Research Octane
Number (RON) 91

NOTICE

Do not use any fuel with an
ethanol in this vehicle. It has
not been tested and certified for
use with such fuels. Damage
to the engine and fuel system,
or engine starting and/or per­formance problems may result
from the use of improper fuel.

(For Australia Specificatio n )

Use clean, fresh unleaded gasoline
with an octane rating equal to or higher
than that shown in the table.

Fuel Type Unleaded Gasoline

Ethanol Content E10 or less

Minimum Octane
Rating

Research Octane
Number (RON)
91

NOTICE

Do not use any fuel that con­tains more ethanol or other oxy­genates than specified for E10
fuel* in this vehicle. Damage
to the engine and fuel system,
or engine starting and/or per­formance problems may result
from the use of improper fuel.

*E10 means fuel containing up to

10% ethanol.

GENERAL INFORMATION 29

Filling the Tank:

Avoid filling th e tank in th e rain or
where heavy dust is blowing so that the
fuel does not get contaminated.

(Fuel Tank Cap)

Insert the ignition key into the fuel

•

tank cap.
Turn the key clockwise while pushing

•

down the fuel tank cap.

A. Ignition Key
B. Fuel Tank Cap

Open the fuel tank cap.

•

Fill the fuel.

•

Push the fuel tank cap down into

•

place with the key inserted.
The key can be removed by turning

•

counterclockwise to the original po­sition.

NOTE

The fuel tank cap cannot be closed

○

without the key inserted, and the key
cannot be removed unless the cap is
locked properly.
Do not push on the key to close the

○

cap, or the cap cannot be locked.