1. 2004 Klr650 Service Manual

Official info for the 2018 KLR™650 - specs, photos, videos, brochure & reviews. Find dealer inventory, schedule a test ride & get a quote. Owner's & Service Manuals Parts. KAWASAKI CARES: Read Owner's Manual and all on-product warnings. Always wear a helmet, eye protection and proper apparel.

2004 Klr650 Service Manual

• 2

  Quick Reference Guide
• 5

  Safety Instructions
• 6

  Foreword
• 8

  General Information
• 8

  Table of Contents
• 9

  Torque and Locking Agent
• 11

  General Fasteners
• 12

  Cable, Wire and Hose Routing
• 12

  Control Cables
• 13

  Electrical Wires
• 15

  Fuel System
• 16

  Exploded View
• 18

  Specifications
• 21

  Engine Top End
• 23

  Service Data
• 25

  Camshaft Chain Tensioner
• 25

  Installation
• 26

  Cylinder, Piston
• 26

  Installation Points of Piston Rings
• 26

  Muffler
• 26

  Spark Arrester Cleaning (U.S. Model}
• 27

  Engine Right Side/Left Side
• 31

  Play Inspection
• 31

  Clutch Release Removal
• 31

  Engine Lubrication System
• 31

  Engine Sprosket
• 32

  Balancer Mechanism
• 32

  Removal Point
• 32

  Assembly Points
• 33

  Engine Removal/Installation
• 34

  Engine Unit
• 34

  Removal
• 36

  Engine Bottom End/Transmission
• 40

  Wheels/Tires
• 43

  Adjustment After Tire Installation
• 43

  Rear Wheel Removal
• 43

  Rear Wheel Installation Points
• 43

  Front Wheel Balance
• 45

  Final Drive
• 47

  Drive Chain
• 47

  Chain Slack Inspection
• 47

  Chain Slack Adjustment
• 47

  Drive Chain Removal
• 48

  Brakes
• 52

  Front Brake Adjustment/Inspection
• 52

  Front Brake Disassembly/Assembly
• 52

  Pad Removal Points
• 52

  Caliper Assembly Points
• 53

  Master Cylinder Disassembly Points
• 53

  Rear Brake Adjustment/Inspection
• 53

  Pedal Position Adjustment
• 54

  Brake Fluid Level Inspection
• 54

  Rear Brake Disassembly/Assembly
• 54

  Inspection and Adjustment After Installation
• 54

  Pad Removal
• 55

  Caliper Removal
• 55

  Master Cylinder Installation Points
• 55

  Brake Maintenance
• 55

  Brake Disc Runout Inspection
• 56

  Suspension/Steering
• 61

  Front Fork
• 61

  Fork Disassembly
• 61

  Guide Bush Replacement
• 61

  Spring Preload Adjustment
• 62

  Setting Table for Spring Preload and Damper Adjusters
• 62

  Rear Shock Removal
• 62

  Rear Shock Installation Point
• 63

  Controls/Instruments
• 67

  Throttle Grip
• 67

  Inspection
• 67

  Adjustment
• 68

  Meter Unit
• 69

  Frame
• 72

  Disassembly Flow Chart-Chassis
• 73

  Electrical System
• 77

  Precautions
• 77

  Charging System Wiring Diagram
• 77

  Measuring Stator Coil Resistance
• 77

  Regulator/Rectifier Inspection
• 78

  Regulator/Rectifier Terminal
• 78

  Rectifier Circuit Inspection
• 78

  Regulator Circuit Test
• 79

  Ignition System
• 79

  Spark Plug Cleaning and Gapping
• 79

  Magneto Removal or Installation
• 79

  Ignition Coil Installation
• 80

  Ignition System Wiring Diagram
• 80

  Switch Inspection
• 80

  Starter Lockout Switch Connections
• 80

  Engine Stop Switch and Starter Button Connections
• 81

  Ignition Coil Inspection
• 82

  CDI Unit Inspection
• 82

  CDI Unit Internal Resistance
• 82

  Exciter or Pickup Coil Inspection
• 83

  Starter Motor Removal
• 83

  Installation Points
• 83

  Starter Motol Disassembly
• 83

  Starter Motor Assembly Points
• 84

  Starter Clutch Removal
• 84

  Starter Motor Brush Length
• 84

  Brush Spring Inspection
• 84

  Commutator Cleaning and Inspection
• 85

  Armature Inspection
• 85

  Brush Plate Inspection
• 85

  Positive Brush Assembly Inspection
• 85

  Starter Relay Inspection
• 86

  Starter Circuit Relay Inspection
• 86

  Starter Button Inspection
• 86

  Starter Clutch Inspection
• 87

  Electric Starter System Wiring Diagram
• 87

  Lighting System
• 87

  Headlight Vertical Adjustment
• 88

  Headlight, Dimmer, or Passing Switch Inspection
• 88

  Headlight, Dimmer, or Passing Switch Connections
• 88

  Tachometer and Water Temperature Gauge
• 89

  Tachometer Inspection
• 89

  Radiator Fan
• 89

  Initial Check
• 89

  Fan Motor/Relay Inspection
• 90

  Wiring Diagram
• 92

  Appendix
• 93

  Troubleshooting Guide
• 93

  General Lubrication
• 93

  Nut, Bolt, and Fastener Tightness
• 95

  Supplement-2000-2001 Models
• 96

  How to Use This Manual
• 97

  Model Identification
• 97

  KL650-A14 Left Side View
• 97

  KL650-A14 Right Side View
• 98

  General Specifications
• 100

  Torgue and Locking Agent
• 100

  Fuel System Specification
• 108

  KL650-A14/A15 Wiring Diagram
• 108

  Left Handlebar Switch Connections
• 109

  Ignition Switch Connections
• 109

  Color Code
• 110

  Supplement-2002 Model
• 116

  Model Application