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Kawasaki KLR650

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. 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)

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 ftlbf (46 Nm) @ 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; 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

520106 links O-Ring Chain

Sponsored organizations

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 ftlbf (45.3 Nm) 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.

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

Wikimedia Commons has media related to: Kawasaki KLR 650

MotorcycleUSA 2008 KLR650 Review

KLR650 on Kawasaki's website

First review of the 2008 model KLR650E

2008 KLR650 Review

KLR650 vs. DR650 Comparison

RIDER Magazine 2008 KLR650 Review

Motorcycle Daily reviews the 2008 KLR650

2002 KLR650 Review in Minnesota Motorcycle Monthly

v  d  e

Kawasaki motorcycle timeline, 1990sresent

Type

1990s

2000s

2010s

0

1

2

3

4

5

6

7

8

9

0

1

2

3

4

5

6

7

8

9

0

Standard

W650

Versys

ER-5

ER-6n/ER-6f/Ninja 650R

Zephyr

ZR-7

Z750

Z1000

ZRX1100

ZRX1200R

Dual-sport

Super Sherpa KL250

KLR650

Sport

Ninja 250R

Ninja ZX-2R/Ninja ZXR250

ZXR400 (L Model)

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

Ninja ZX-12R

ZZR1400/Ninja ZX-14

Touring

GTR1000/Connie/Concours

1400GTR/Concours 14

Cruiser

454 LTD

EL250

EL125/Eliminator

Vulcan 900 Classic/VN900B

MotoGP

Ninja ZX-RR

Categories: Kawasaki motorcycles | Dual-sport motorcyclesHidden categories: Articles needing additional references from August 2009 | All articles needing additional references
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What are the main bearing bolt torque specifications for a 1990 Mitsubishi Galant GS?

The engine is DOHC (non turbo) 4 cylinder and might be a 2.0L or 1.6. I also need a diagram or chart of how the rings around a piston goes. I owe the Service Manual for Mitsubishi but it it nowhere in there.

http://mysite.verizon.net/t2bedlam/gap.jpg
theres the ring layout

the main cap bearing bolts are 37 to 39 foot pounds for the torque setting.

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