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Kawasaki KLR650

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Kawasaki KLR650
ManufacturerKawasaki
Productionsince 1987
EngineSingle Cylinder, Water Cooled, Four-Stroke, DOHC, 4 valves
Compression ratio9.5 : 1
Top speedapprox. 108 mph (174 km/h)
Power44 bhp (33 kW)
SuspensionTelescoping fork, Uni-Trak swingarm
DimensionsL: 2,165 mm (85.2 in)
Weight176 kg (388 lb) (dry)
182 kg (401 lb) (wet)
Fuel capacity6.1 US gal (23 L; 5.1 imp gal)
Oil capacity2.6 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.

The KLR650 is heavier than specialized off-road dirt bikes, but it can handle most conditions when ridden carefully by a skilled rider. Its 4-stroke DOHC dual-counter balanced, single-cylinder, water-cooled engine develops a claimed 44 hp (33 kW) at the crank; typical measurements at the rear wheel are 35 horsepower (26 kW). Typical fuel economy is 45 to-[convert: unknown unit]. It has a claimed 23 L (5.1 imp gal; 6.1 US gal) fuel tank and a top speed of approximately 105 mph (169 km/h). 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.

KLRs have been ridden to the Arctic, across North and South America, and throughout Europe, Africa, and Asia, as well as on full global circumnavigation rides (e.g., Dr. Gregory Frazier in 2001-2002[1]).

Note: While advertised fuel capacity is 6.1 US gallons (23 L; 5.1 imp gal), usable capacity is approximately 5.6 US gallons (21 L; 4.7 imp gal) including reserve, because some fuel sits below the top of the petcock intake tube within the tank, or on the other side of the main frame member, which divides the lowest portion of the tank into two lobes (the petcock draws only from one of these two lobes).

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: was sold in the USA starting 1990 and in other countries for several years afterward
  • KLR650-C: The "C" model 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 first 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]

Specifications (1987-2007 KLR650-A)

1998 KLR650 in its environment (the luggage is not standard)
1995 KLR650
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 mm × 83 mm (3.9 in × 3.3 in)
Peak Power 44 bhp (33 kW) @ 6000 rpm
Peak Torque 34 ft⋅lbf (46 J) @ 5000 rpm
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)
Charging System Output 238 W @ 14 V
Seat Height Template:Auto in
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

Although rare, Kawasaki has chosen to offer KLR650 motorcycles to a few select organizations that would put their bike to the test. These individuals have taken the bikes to some of the most remote locations in the world and have documented the journey on their websites. They include the following:

  • Moon Riders: 1997 trip to Latin America. Team Green provided support, parts, and service throughout Central and South America.
  • Bikers Without Borders: 2003 trip through 13 Latin America countries volunteering at hospitals, orphanages, Christian Missions and dental clinics. Kawasaki provided two new KLR 650s for this organization.

2008 redesign

in 2008 the KLR650 was radically redesigned with improved 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.

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 2nd and 3rd gear ratios. Kickstarter no longer fits with new clutch basket. 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(?) Final assembly shifts 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. 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. Back to single-piston rear brake caliper.

References

  1. ^ August 30, 2002: USA – American Roadkill, Shipping Bikes and BIG DOGS, retrieved 2008-01-27
  2. ^ HDT KLR650s
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