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Kawasaki KLR600 - User Manual

Kawasaki KLR600
173 pages
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Summary

General Information

Before Servicing

Essential procedures to follow before beginning motorcycle maintenance.

Specifications

Technical data and measurements for the motorcycle.

Bolt and Nut Tightening

Correct torque values for various bolts and nuts used on the motorcycle.

Periodic Maintenance Chart

Schedule for routine maintenance tasks based on mileage or time.

Fuel System

Exploded Views

Diagrams showing disassembled fuel system components.

Service Data

Key specifications and service limits for fuel system components.

Carburetor

Detailed information and procedures for the motorcycle's carburetor.

Air Cleaner

Instructions for removing, inspecting, cleaning, and installing the air filter element.

Engine Top End

Exploded Views

Illustrated breakdown of engine top end parts.

Service Data

Specifications and service limits for engine top end components.

Cam Chain Tensioner

Instructions for the removal and installation of the cam chain tensioner.

Camshafts

Procedures for camshaft removal, installation, and timing.

Engine Right Side; Left Side

Exploded Views

Diagrams showing disassembled engine components for the right and left sides.

Engine Lubrication System

Diagram and explanation of the engine's oil circulation and lubrication.

Service Data

Specifications and service limits for engine components on both sides.

Clutch

Procedures for clutch inspection, adjustment, removal, and installation.

Cooling System

Exploded Views

Illustrated breakdown of the cooling system components.

Service Data

Specifications and service limits for cooling system components.

Coolant

Procedures for checking coolant level, condition, and coolant changes.

Radiator, Radiator Fan

Information on radiator and fan removal, inspection, and cleaning.

Engine Removal, Installation

Engine Unit Removal

Step-by-step guide for safely removing the engine from the motorcycle.

Engine Unit Installation

Procedures for correctly installing the engine back into the motorcycle.

Engine Disassembly Flow Chart

A flowchart outlining the engine disassembly process.

Engine Bottom End; Transmission

Disassembly Flow Chart

A visual guide to the sequence of parts removal for the engine bottom end.

Crankcase Splitting

Detailed steps for safely separating the engine crankcase halves.

Transmission Assembly Points

Important considerations during the assembly of the motorcycle's transmission.

Crankshaft Maintenance

Procedures for inspecting, aligning, and maintaining the crankshaft.

Wheel and Tires

Exploded Views

Illustrated breakdown of wheel and tire components.

Service Data

Specifications and service limits for tires and rims.

Tires

Procedures for tire removal, installation, and wear inspection.

Wheel Bearing

Procedures for removing, inspecting, and lubricating wheel bearings.

Final Drive

Exploded Views

Illustrated breakdown of the final drive components.

Service Data

Specifications and limits for the drive chain.

Drive Chain

Instructions for drive chain inspection, adjustment, and lubrication.

Wear Inspection

Methods for checking drive chain and sprocket wear.

Brakes

Exploded Views

Illustrated breakdown of brake system components.

Service Data

Specifications and service limits for brake components.

Front Brake Adjustment;Inspection

Procedures for front brake adjustment and inspection.

Brake Fluid Change

Steps for safely draining and refilling the brake fluid.

Suspension

Exploded Views

Illustrated breakdown of suspension components.

Service Data

Specifications and limits for suspension components.

Steering

Procedures for steering inspection and adjustment.

Front Fork

Maintenance and adjustment of the front fork, including air pressure and oil.

Controls and Instruments

Exploded Views

Diagrams showing disassembled control and instrument components.

Throttle Grip Adjustment

How to adjust the play in the throttle grip for proper operation.

Clutch Adjustment

Procedures for adjusting the clutch cable for optimal engagement.

Choke Lever Adjustment

Adjusting the choke lever for correct starting and warm-up.

Frame

Exploded Views

Diagrams showing disassembled frame components.

Disassembly Flow Chart - Chassis

A flowchart guiding the disassembly of the motorcycle's chassis.

Suggested Cable or Hose Routing

Recommended routing for cables and hoses on the motorcycle frame.

Electrical System

Wiring Diagram

Detailed electrical wiring schematic for the entire motorcycle.

Precautions

Important safety warnings and general precautions for electrical system work.

Battery Troubleshooting

Guide to diagnosing and resolving common battery issues.

Ignition System

Information on spark plugs, ignition timing, and related components.

Appendix

Additional Considerations for Racing

Specific advice and modifications for using the motorcycle in racing.

Spark Plug Information

Guidance on spark plug selection, installation, and condition analysis.

Troubleshooting Guide

Common problems, their causes, and recommended solutions for the motorcycle.

Unit Conversion Table

Reference table for converting various units of measurement.

Summary

General Information

Before Servicing

Essential procedures to follow before beginning motorcycle maintenance.

Specifications

Technical data and measurements for the motorcycle.

Bolt and Nut Tightening

Correct torque values for various bolts and nuts used on the motorcycle.

Periodic Maintenance Chart

Schedule for routine maintenance tasks based on mileage or time.

Fuel System

Exploded Views

Diagrams showing disassembled fuel system components.

Service Data

Key specifications and service limits for fuel system components.

Carburetor

Detailed information and procedures for the motorcycle's carburetor.

Air Cleaner

Instructions for removing, inspecting, cleaning, and installing the air filter element.

Engine Top End

Exploded Views

Illustrated breakdown of engine top end parts.

Service Data

Specifications and service limits for engine top end components.

Cam Chain Tensioner

Instructions for the removal and installation of the cam chain tensioner.

Camshafts

Procedures for camshaft removal, installation, and timing.

Engine Right Side; Left Side

Exploded Views

Diagrams showing disassembled engine components for the right and left sides.

Engine Lubrication System

Diagram and explanation of the engine's oil circulation and lubrication.

Service Data

Specifications and service limits for engine components on both sides.

Clutch

Procedures for clutch inspection, adjustment, removal, and installation.

Cooling System

Exploded Views

Illustrated breakdown of the cooling system components.

Service Data

Specifications and service limits for cooling system components.

Coolant

Procedures for checking coolant level, condition, and coolant changes.

Radiator, Radiator Fan

Information on radiator and fan removal, inspection, and cleaning.

Engine Removal, Installation

Engine Unit Removal

Step-by-step guide for safely removing the engine from the motorcycle.

Engine Unit Installation

Procedures for correctly installing the engine back into the motorcycle.

Engine Disassembly Flow Chart

A flowchart outlining the engine disassembly process.

Engine Bottom End; Transmission

Disassembly Flow Chart

A visual guide to the sequence of parts removal for the engine bottom end.

Crankcase Splitting

Detailed steps for safely separating the engine crankcase halves.

Transmission Assembly Points

Important considerations during the assembly of the motorcycle's transmission.

Crankshaft Maintenance

Procedures for inspecting, aligning, and maintaining the crankshaft.

Wheel and Tires

Exploded Views

Illustrated breakdown of wheel and tire components.

Service Data

Specifications and service limits for tires and rims.

Tires

Procedures for tire removal, installation, and wear inspection.

Wheel Bearing

Procedures for removing, inspecting, and lubricating wheel bearings.

Final Drive

Exploded Views

Illustrated breakdown of the final drive components.

Service Data

Specifications and limits for the drive chain.

Drive Chain

Instructions for drive chain inspection, adjustment, and lubrication.

Wear Inspection

Methods for checking drive chain and sprocket wear.

Brakes

Exploded Views

Illustrated breakdown of brake system components.

Service Data

Specifications and service limits for brake components.

Front Brake Adjustment;Inspection

Procedures for front brake adjustment and inspection.

Brake Fluid Change

Steps for safely draining and refilling the brake fluid.

Suspension

Exploded Views

Illustrated breakdown of suspension components.

Service Data

Specifications and limits for suspension components.

Steering

Procedures for steering inspection and adjustment.

Front Fork

Maintenance and adjustment of the front fork, including air pressure and oil.

Controls and Instruments

Exploded Views

Diagrams showing disassembled control and instrument components.

Throttle Grip Adjustment

How to adjust the play in the throttle grip for proper operation.

Clutch Adjustment

Procedures for adjusting the clutch cable for optimal engagement.

Choke Lever Adjustment

Adjusting the choke lever for correct starting and warm-up.

Frame

Exploded Views

Diagrams showing disassembled frame components.

Disassembly Flow Chart - Chassis

A flowchart guiding the disassembly of the motorcycle's chassis.

Suggested Cable or Hose Routing

Recommended routing for cables and hoses on the motorcycle frame.

Electrical System

Wiring Diagram

Detailed electrical wiring schematic for the entire motorcycle.

Precautions

Important safety warnings and general precautions for electrical system work.

Battery Troubleshooting

Guide to diagnosing and resolving common battery issues.

Ignition System

Information on spark plugs, ignition timing, and related components.

Appendix

Additional Considerations for Racing

Specific advice and modifications for using the motorcycle in racing.

Spark Plug Information

Guidance on spark plug selection, installation, and condition analysis.

Troubleshooting Guide

Common problems, their causes, and recommended solutions for the motorcycle.

Unit Conversion Table

Reference table for converting various units of measurement.

Kawasaki KLR600 Specifications

General IconGeneral
Displacement564 cc
Compression Ratio9.5:1
IgnitionCDI
Transmission5-speed
Front SuspensionTelescopic fork
Front BrakeSingle disc
Rear BrakeDisc
Fuel Capacity14 L (3.7 US gal)
Wheelbase1, 460 mm
Seat Height890 mm
Engine Type4-stroke, single cylinder
Fuel SystemCarburetor

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