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Kawasaki KLR 600 - User Manual

Kawasaki KLR 600
171 pages
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Table of Contents

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Summary

Safety Awareness

Warning Symbols Explained

Meaning of warning and caution symbols for safety.

List of Abbreviations

Glossary of common abbreviations used in the manual.

Emission Control Information

Emission Control Systems Overview

Details on crankcase and exhaust emission control systems.

Foreword

Manual Usage and Warranty Advice

Guidance on using the manual and maintaining warranty.

General Information

Pre-Service Procedures and Model ID

Essential checks before service and model identification.

Specifications and Torque Values

Key technical specs and standard torque for fasteners.

Lubrication and Maintenance Schedule

General lubrication guidelines and periodic maintenance chart.

Fuel System

Fuel System Service Data and Components

Technical data and diagrams for fuel system parts.

Carburetor Service and Adjustment

Procedures for carburetor inspection, adjustment, and disassembly.

Air Cleaner and Emission Control

Maintenance of air cleaner and overview of emission control system.

Engine Top End

Top End Service Data and Special Tools

Specifications, limits, and necessary tools for top end service.

Cam Chain Tensioner and Cylinder Head

Service procedures for cam chain tensioner and cylinder head cover.

Camshafts, Valves, and Piston Service

Installation, timing, clearance adjustment, and piston/cylinder service.

Engine Side Components

Engine Lubrication and Clutch Service

Details on lubrication system and clutch maintenance.

Oil and Filter Change, Pressure Checks

Procedures for engine oil changes and pressure measurements.

Sprocket, Magneto, and Balancer Service

Maintenance for engine sprocket, magneto, and balancer.

Cooling System

Cooling System Data and Coolant Service

Specifications for coolant and procedures for checks and changes.

Leak Inspection and Flushing

Methods for inspecting leaks and flushing the cooling system.

Radiator Fan, Sender, and Thermostat

Service for radiator fan, temperature sender, and thermostat.

Water Pump and Mechanical Seal

Disassembly, inspection, and assembly of the water pump.

Engine Removal and Installation

Engine Removal Procedure

Step-by-step guide to safely removing the engine.

Engine Installation Procedure

Steps for correctly installing the engine.

Engine Disassembly Precautions

Safety and procedural notes before engine disassembly.

Engine Bottom End and Transmission

Bottom End and Transmission Diagrams

Exploded views of bottom end and transmission components.

Crankcase and Crankshaft Service

Procedures for splitting, assembling crankcase, and installing crankshaft.

Transmission Service Data and Maintenance

Specifications and maintenance for transmission parts.

Connecting Rod and Crankshaft Checks

Measuring clearances and checking crankshaft runout.

Wheel and Tires

Wheel and Tire Data and Tools

Specifications, special tools, and diagrams for wheel and tire service.

Tire Removal and Installation

Step-by-step procedures for tire service.

Wheel Bearing and Rim Service

Procedures for wheel bearing and rim inspection and maintenance.

Final Drive

Final Drive Data and Components

Specifications and diagrams for the final drive system.

Drive Chain Inspection and Adjustment

Procedures for checking and adjusting drive chain slack.

Wheel Alignment and Chain Lubrication

Adjusting wheel alignment and lubricating the drive chain.

Brake System

Front Brake Service and Fluid Management

Adjusting, inspecting, and servicing front brake fluid.

Front Brake Caliper Service

Disassembly, assembly, and inspection of the front brake caliper.

Rear Brake Service and Pedal Adjustments

Procedures for rear brake adjustment and lining inspection.

Brake Light Switch Service

Inspecting and adjusting the rear brake light switch.

Suspension System

Suspension Data and Special Tools

Specifications and specialized tools for suspension service.

Steering and Stem Bearing Service

Procedures for steering and stem bearing maintenance.

Front Fork and Oil Service

Information on front fork service, including oil replacement.

Rear Shock Absorber Service

Adjusting preload and servicing the rear shock absorber.

Controls and Instruments

Control Specifications and Clutch Service

Specs for controls and procedures for clutch adjustment.

Throttle Grip and Meter Unit Service

Adjusting throttle grip and servicing meter units.

Speedometer Service

Procedures for speedometer disassembly and lubrication.

Frame

Frame Exploded Views and Disassembly Chart

Diagrams of the frame and a chassis disassembly flowchart.

Suggested Cable or Hose Routing

Guidance on routing cables and hoses on the frame.

Electrical System

Wiring Diagram and Service Data

Motorcycle wiring diagram and electrical system specifications.

Charging System and Regulator;Rectifier

Service procedures for charging system and regulator/rectifier.

Ignition System and Spark Plugs

Service for ignition system components, including spark plugs.

Lighting System and Turn Signals

Adjusting and inspecting headlights and turn signals.

Appendix

Racing Considerations and Carburetor Notes

Special advice for racing and carburetor tuning.

Spark Plug Condition and Troubleshooting

Interpreting spark plug condition and a troubleshooting guide.

Summary

Safety Awareness

Warning Symbols Explained

Meaning of warning and caution symbols for safety.

List of Abbreviations

Glossary of common abbreviations used in the manual.

Emission Control Information

Emission Control Systems Overview

Details on crankcase and exhaust emission control systems.

Foreword

Manual Usage and Warranty Advice

Guidance on using the manual and maintaining warranty.

General Information

Pre-Service Procedures and Model ID

Essential checks before service and model identification.

Specifications and Torque Values

Key technical specs and standard torque for fasteners.

Lubrication and Maintenance Schedule

General lubrication guidelines and periodic maintenance chart.

Fuel System

Fuel System Service Data and Components

Technical data and diagrams for fuel system parts.

Carburetor Service and Adjustment

Procedures for carburetor inspection, adjustment, and disassembly.

Air Cleaner and Emission Control

Maintenance of air cleaner and overview of emission control system.

Engine Top End

Top End Service Data and Special Tools

Specifications, limits, and necessary tools for top end service.

Cam Chain Tensioner and Cylinder Head

Service procedures for cam chain tensioner and cylinder head cover.

Camshafts, Valves, and Piston Service

Installation, timing, clearance adjustment, and piston/cylinder service.

Engine Side Components

Engine Lubrication and Clutch Service

Details on lubrication system and clutch maintenance.

Oil and Filter Change, Pressure Checks

Procedures for engine oil changes and pressure measurements.

Sprocket, Magneto, and Balancer Service

Maintenance for engine sprocket, magneto, and balancer.

Cooling System

Cooling System Data and Coolant Service

Specifications for coolant and procedures for checks and changes.

Leak Inspection and Flushing

Methods for inspecting leaks and flushing the cooling system.

Radiator Fan, Sender, and Thermostat

Service for radiator fan, temperature sender, and thermostat.

Water Pump and Mechanical Seal

Disassembly, inspection, and assembly of the water pump.

Engine Removal and Installation

Engine Removal Procedure

Step-by-step guide to safely removing the engine.

Engine Installation Procedure

Steps for correctly installing the engine.

Engine Disassembly Precautions

Safety and procedural notes before engine disassembly.

Engine Bottom End and Transmission

Bottom End and Transmission Diagrams

Exploded views of bottom end and transmission components.

Crankcase and Crankshaft Service

Procedures for splitting, assembling crankcase, and installing crankshaft.

Transmission Service Data and Maintenance

Specifications and maintenance for transmission parts.

Connecting Rod and Crankshaft Checks

Measuring clearances and checking crankshaft runout.

Wheel and Tires

Wheel and Tire Data and Tools

Specifications, special tools, and diagrams for wheel and tire service.

Tire Removal and Installation

Step-by-step procedures for tire service.

Wheel Bearing and Rim Service

Procedures for wheel bearing and rim inspection and maintenance.

Final Drive

Final Drive Data and Components

Specifications and diagrams for the final drive system.

Drive Chain Inspection and Adjustment

Procedures for checking and adjusting drive chain slack.

Wheel Alignment and Chain Lubrication

Adjusting wheel alignment and lubricating the drive chain.

Brake System

Front Brake Service and Fluid Management

Adjusting, inspecting, and servicing front brake fluid.

Front Brake Caliper Service

Disassembly, assembly, and inspection of the front brake caliper.

Rear Brake Service and Pedal Adjustments

Procedures for rear brake adjustment and lining inspection.

Brake Light Switch Service

Inspecting and adjusting the rear brake light switch.

Suspension System

Suspension Data and Special Tools

Specifications and specialized tools for suspension service.

Steering and Stem Bearing Service

Procedures for steering and stem bearing maintenance.

Front Fork and Oil Service

Information on front fork service, including oil replacement.

Rear Shock Absorber Service

Adjusting preload and servicing the rear shock absorber.

Controls and Instruments

Control Specifications and Clutch Service

Specs for controls and procedures for clutch adjustment.

Throttle Grip and Meter Unit Service

Adjusting throttle grip and servicing meter units.

Speedometer Service

Procedures for speedometer disassembly and lubrication.

Frame

Frame Exploded Views and Disassembly Chart

Diagrams of the frame and a chassis disassembly flowchart.

Suggested Cable or Hose Routing

Guidance on routing cables and hoses on the frame.

Electrical System

Wiring Diagram and Service Data

Motorcycle wiring diagram and electrical system specifications.

Charging System and Regulator;Rectifier

Service procedures for charging system and regulator/rectifier.

Ignition System and Spark Plugs

Service for ignition system components, including spark plugs.

Lighting System and Turn Signals

Adjusting and inspecting headlights and turn signals.

Appendix

Racing Considerations and Carburetor Notes

Special advice for racing and carburetor tuning.

Spark Plug Condition and Troubleshooting

Interpreting spark plug condition and a troubleshooting guide.

Kawasaki KLR 600 Specifications

General IconGeneral
Displacement564 cc
Compression Ratio9.5:1
IgnitionCDI
Transmission5-speed
Front SuspensionTelescopic fork
Front BrakeSingle disc
Rear BrakeDrum
Front Tire3.00-21
Rear Tire4.60-17
Fuel SystemCarburetor
Wheelbase1, 465 mm
Seat Height890 mm
Cooling SystemAir
Rear SuspensionMono-shock, Uni-Trak
Weight153 kg (dry)

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