Kawasaki MLR650 2013 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
HOW TO RIDE THE MOTORCYCLE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
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 in-
jury.
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, 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
© 2013 Kawasaki Heavy Industries, Ltd. Mar. 15, 2013. (1)
TABLE OF CO NTE NTS
SPECIFICATIONS............................... 8
SERIAL NUMBER L OCATIONS......... 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.............................................. 124
Brake Light Switches........................ 128
Front Fork......................................... 130
Rear Shock Absorbers ..................... 130
Wheels ............................................. 133
Tires -............................................ 133
Battery.............................................. 137
Headlight Beam................................ 144
Rear Turn Signal Light ..................... 145
Fuses ............................................... 146
General Lubrication.......................... 147
Cleaning Your Motorcycle ................ 150
Bolt and Nut Tightening.................... 155
STORAGE........................................... 157
TROUBLESHOOTING GUIDE............ 160
YOUR WARRANTY/OWNER
SATISFACTION ........................... 161
Reporting Safety Defects.................. 1 67
ENVIRONMENTAL PROTECTION ..... 168
LABEL INFORMATION ...................... 169
MAINTENANCE RECORD ................. 175
8 SPECIFICATIONS
SPECIFICATIONS
PERFORMAN
Minimum Turning Radius
DIMENSIO
Overall L
Overall W
Overall H
Wheelbase
Road Cle
Curb Mas
ENGINE
Type
Displacement
Bore × S
Compre
ing System Electric starter
Start
CE
NS
ength
idth
eight
arance
s
troke
ssion Ratio 9.8 : 1
2.4m(94in
2295mm(9
960 mm (37
1350mm(5
1480mm(
210 mm (8
196 kg (4
DOHC, 4-valve, 1-cylinder, 4-stroke, liquid-cooled
651 cm³
100.0 ×
.)
0.4 in.)
.8 in.)
3.1 in.)
58.3 in.)
.3 in.)
32 lb)
(39.7 cu in.)
83.0 mm (3.94 × 3.27 in.)
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
Clutch Type
5-speed, constant mesh, return shift
Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio
Final Red uction Ratio
2.273 (75/33)
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
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.
SPECIFICATIONS 11
12 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS
The engine and frame serial numbe rs are u se d t o re g ister the motorcycle. T he y
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 m odel type and any peculiar features of your machine that can help
them id entify it.
Frame No.
A. Frame Number
Engine No.
A. Engine Number
LOCATION OF PARTS
LOCATION OF PARTS 13
1. Clutch Lever
2. Left Handlebar Switches
3. Meter Instruments
4. Brake Fluid Reservoir (Front)
5. Right Handlebar Switches
6. Front Brake Lever
7. T hrot tle Grip
8. Ig nition Switch/Steering Lock
14 LOCATION OF PARTS
9. Turn Signal Light
10. Headlight
11. Spa rk Pl ugs
12. Main Fuse
13. B attery
14. S eat
15. Tool Kit/Storage
Compartments
16. Helmet Hook
17. Tying Hooks
18. Front Fork
19. Brake Disc
20. B rake Caliper
21. Shift Pedal
22. Side Stand
23. R ear Sho ck Absorber
24. D rive Chain
LOCATION OF PARTS 15
25. Tail/Brake Light
26. Rear Carrier
27. Brake Fluid Reservoir
(Rear)
28. Air Cleaner
29. F ue l Tank
30. Fuel Tank Cap
31. M uffler
32. R ear B rake Light
Switch
33. Rear Brake Pedal
34. Oil Level Inspection
Window
35. Idle Adjusting Screw
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 a nd understand them
thoroughly. They contain information
which is important for your safety a nd
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. I f
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. Ba ttery 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 o ver 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
andaccessoriesyouaddtoyour
motorcycle be genuine Kawasaki
components.
Because a motorcycle is sensitive to
changes in weight and aerodynamic
forces, y ou must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.
LOADING INFORMATION 21
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 moto rcycle. 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
thesteeringassemblyandcanresult 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 motorcy cle 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).
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 23
GENERAL INFORMATION
24 GENERAL INFOR M ATION
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“redzone”. Enginer/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.
GENERAL INFORMATION 25
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.
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 INFOR M ATION
A. Ignition Key
B. Tag
C. Key Number
Write your key number here.
Intheeventyouloseyourkeys,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 i n 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 usingthekeycodeonthetagoryourkey.
Store one key at home and keep another spare in your wallet or riding gear,
in case the original is lost.
GENERAL INFORMATION 27
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.
28 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 29
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
Loading...