Kawasaki KLR650

Kawasaki KLR650

Manufacturer	Kawasaki
Production	since 1987
Engine	651 cc single-cylinder, water-cooled, 4-stroke, DOHC, 4-valves
Compression ratio	9.5 : 1
Power	37 bhp (28 kW)
Suspension	Telescoping fork, Uni-Trak swingarm
Dimensions	L 2,165 mm (85.2 in)
Weight	176 kg (390 lb) (dry) 182 kg (400 lb) (wet)
Fuel capacity	6.1 US gal (23 l; 5.1 imp gal)
Oil capacity	2.6 U.S. quarts (2.5 L)

The Kawasaki KLR650 is a dual-sport motorcycle intended for use on both paved and unpaved roads. It has been a long-standing model in Kawasaki's lineup, having been introduced in 1987 and remaining almost unchanged through the 2007 model. The 2008 model was the first significant redesign of the KLR650 since its inception. It has a 650 cc four-stroke, DOHC, dual-counter balanced, single-cylinder, water-cooled engine.

The KLR is widely used as an inexpensive adventure/touring bike. The addition of luggage and personalized modifications (GPS, heated handgrips, larger windscreens) make it more functional on long trips. Bikes have been used for long distance and intercontinental trips, as well as full global circumnavigation rides e.g., by Dr. Gregory Frazier in 2001-2002.^[1]).

1 Models
2 Specifications (1987-2007 KLR650-A)
3 2008 redesign
4 Changes over the years
5 References
6 External links

Models

KLR650-A: The "A" model was introduced in 1987, based on its KLR600 predecessor (1984 to 1986). The "A" model remained nearly unchanged until the introduction of the 2008 model in USA, Canada and Europe
KLR650-B or Tengai: The Tengai got Adventure/Dakar styling, a full fairing blending into the tank, different sidepanels, and an unsprung front mudguard. It was sold in the USA starting 1990 and in other countries for several years afterward - this could be classified as a separate model in its own right as the others are more trail bike orientated. It's name "Tengai" is used in old traditional Japanese sayings to imply, "Throughout the World".
KLR650-C: The "C" model gets completely new bodywork and is a more dirt-oriented motorcycle fitted with stiffer 41 mm (1.6 in) front forks, improved brakes, tubular engine guard, smaller 14 l (3.1 imp gal; 3.7 US gal) fuel tank, and steel wheel rims. Lacking a temperature gauge, it has an over-heat lamp.
KLR650-E: 2008 was the second major redesign of the KLR650. The primary changes include upgraded 41 mm (1.6 in) forks, a new D-section swingarm, dual beam headlight, dual-piston rear brake caliper, upgraded cooling system, 4 mm spokes, cowling and fairing redesign as well as various redesigned parts.
The U.S. Military has KLR650s modified by Hayes Diversified Technologies to burn military-spec fuels including diesel. (M1030M1) All-new engines were designed to replace the 4-stroke gasoline engines.^[2] The new engines employ the original unit-construction main cases and transmission, but with new piston, cylinder, and other components. The balancing system that is used in the gasoline KLR650 engines (to reduce engine vibration) was removed from the military diesel KLR engines. Some components of the military diesel version can be applied to "civilian" KLR650 models, such as the nonspillable absorbed glass mat battery which offers several advantages over the conventional unsealed KLR batteries.

Specifications (1987-2007 KLR650-A)

Specifications for 1987-2007 U.S. Model
Engine Type	Single-cylinder, water-cooled, four-stroke, DOHC, 4 valves
Carburetion	Keihin CVK-40 constant velocity carburetor
Displacement	651 cc
Bore × Stroke	100 × 83 mm (3.9 × 3.3 in)
Compression Ratio	9.5 : 1
Fuel Capacity	6.1 US gallons (23 l; 5.1 imp gal) / 5.6 US gallons (21 l; 4.7 imp gal) usable
Oil Capacity	2.64 US quarts (2,500 ml; 88 imp fl oz)
Charging System Output	238 W @ 14 V
Seat Height	35.0 in (889 mm)
Dry Weight	337 lb (153 kg) claimed, 402 lb (182 kg) wet weight actual
GVWR	738 lb (335 kg)
Tires	Front: 90/90-21 Rear: 130/90-17
Brakes	Front: 1 disc, dual piston caliper; Rear: 1 disc, single piston caliper.
Final drive	520×106 links O-Ring Chain

2008 redesign

In 2008 the KLR650 was radically redesigned with new aesthetics, modern dual headlights and a more powerful engine. The new 651 cc single-cylinder engine puts out 37 bhp (28 kW) at 6200 rpm and 33.4 ft·lbf (45.3 N·m) of torque at 4950 rpm. other improvements include: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38 to 41 mm (1.5 to 1.6 in), new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36 watt capacity.

Criticism of the new design include its wide use of "sportbike plastics" for the new body panels which are prone to cracking and damage in the event of a tip-over, especially true for this genre of dual-sport motorcycles. First and second year models have been recalled due to the wiring harness rubbing on sharp frame edges which have caused electrical shorts and documented fires.

Changes over the years

Aside from the colors, not much changed between the 1987 introduction and the 2008 revisions. The key differences are:

1987: Crankshaft is unique to this year.
1988: Beefed up the engine cases with extra bolts between the crank and countershaft; crank has a different part number, and may be lighter.
1990: Countershaft improved with longer splines for increased engagement with sprocket.
1992: Changes to front brake master cylinder.
Mid-1996: Changed valve cover, added bracket to hold cam chain bumper; changed crank to heavier unit; improved clutch basket with more clutch plates; changed countershaft sprocket retainer from slotted plate to large nut; changed second and third gear ratios. Kickstarter no longer fits with new clutch basket. At least some early 1996 models had the matte black engine cases and covers rather than the later hammer-finished dark gray coloration found in the 1997 and later models. New left balancer weight/sprocket begins with engine #KLE650AE032206.
(?) Service manual indicates higher charging system output; only part number change is the rotor. The new power rating is 17 A, 14 V (238 W) @ 7000 rpm; the earlier one was 14 A, 14 V (196 W) @ 8000 rpm (above redline).
2001 around this time final assembly moved from Japan to Thailand. All major parts still made in Japan.
2007: New shift lever
2008: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38 to 41 mm (1.5 to 1.6 in), new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes increased from 3.5 mm to 4 mm. Stator "alternator" upgraded to 17 A output, providing an additional 36 watt capacity.
2009: New piston rings are thinner and have more tension, resulting in a significant reduction in oil consumption.

References

^ August 30, 2002: USA – American Roadkill, Shipping Bikes and BIG DOGS, http://www.horizonsunlimited.com/gregfrazier/news/2002-08-30.shtml, retrieved 2008-01-27
^ HDT KLR650s

External links


Type	1990s										2000s										2010s
Type	0	1	2	3	4	5	6	7	8	9	0	1	2	3	4	5	6	7	8	9	0	1
Standard										W650												W800
																		Versys
								ER-5									ER-6n/ER-6f/Ninja 650R
		Zephyr								ZR-7					Z750
														Z1000
								ZRX1100					ZRX1200R
Dual-sport								Super Sherpa KL250
	KLR250																KLX250S
	KLR650
Sport	Ninja 250R
	Ninja 400
	Ninja ZX-2R/Ninja ZXR250
	ZXR400
	EX500/GPZ500/Ninja 500
	ZX600C-E/Ninja ZX-6						ZX600J/Ninja ZX-6R
														ZZR600
	ZXR750						Ninja ZX-7R
	GPZ900R
					ZX900/Ninja ZX-9R										Ninja ZX-10R
												ZX12R/Ninja ZX-12R
Sport-Touring	ZZR1100C/Ninja ZX-11C					ZZR1100D/Ninja ZX-11D					ZZR1200/ZX-12C					ZZR1400/Ninja ZX-14
Touring	GTR1000/Connie/Concours																	1400GTR/Concours 14
Cruiser	EL250															EL125/Eliminator
	454 LTD
	Vulcan EN500A
							Vulcan VN500C
	Vulcan VN750
							Vulcan VN800A/Vulcan Classic VN800B
																	Vulcan VN900 Classic/VN900B
MotoGP													Ninja ZX-RR