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2002-2004 Kawasaki KLR650 Maintenance Schedule and Service Intervals

2002-2004 Kawasaki KLR650 Stock Image

This is the maintenance schedule and associated service intervals for the 2002-2004 Kawasaki KLR650.

This maintenance schedule applies to the following model:

  • 2002 Kawasaki KLR650
  • 2003 Kawasaki KLR650
  • 2004 Kawasaki KLR650

The Kawasaki KLR650 is a dual-sport motorcycle intended for both on-road and off-road riding.

It was 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 was built with a 651 cc four-stroke, DOHC, dual-counterbalanced, single-cylinder, water-cooled engine.

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2002-2004 Kawasaki KLR650 Maintenance Schedule

Below is the maintenance schedule for the 2002-2004 Kawasaki KLR650.

The maintenance for the 2002-2004 Kawasaki KLR650 is broken into two sections: Emission related and Non-emissions.

The highlighted elements are those that are new for the 2002-2004 years — the 2000-2001 KLR 650‘s maintenance chart didn’t have these.

Periodic Maintenance Chart

OperationEvery800 km (500 mi)5000 km (3000 mi)10000 km (6000 mi)15000 km (9000 mi)20000 km (12000 mi)25000 km (15000 mi)30000 km (18000 mi)
Emission Related
Idle speed–check †
Throttle grip play–check †
Spark plug–clean and gap †
Valve clearance–check †
Air cleaner element–clean
Air cleaner element–replace5 cleanings
Fuel system–check
Evaporative emission control system (c)–check †
Spark arrester–cleanEvery 5000 km (3000 mi)
Battery electrolyte level–check †month
Brake light switch–check †
Brake pad wear–check †
Brake fluid level–check †month
KBrake fluid–change2 years
KBrake hose, connection–check †
KFuel hose connection–check †
KSteering–check †
Balancer chain tension–adjust
Drive chain wear–check † #
KSpoke tightness and rim runout–check †
Nuts, bolts, and fasteners tightness-check †
Tire wear–check †
Engine oil–changeyear
Oil filter–replace
General Lubrication–perform
KFront fork oil–change
KSwingarm pivot, uni-trak linkage–lubricate
KCoolant–change2 years
Radiator hoses, connections–check †year
KSteering stem bearing–lubricate2 years
KMaster cylinder cup and dust seal–replace2 years
KCaliper piston seal and dust seal–replace2 years
KBrake hose–replace4 years
KFuel hose–replace4 years
Drive chain–lubricate #Every 600 km (400 mi)
Dive chain slack–check † #Every 1000 km (600 mi)

K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
(c): California model only
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping

Tyre size and tyre pressure for the 2002-2004 Kawasaki KLR650

The 2002-2004 Kawasaki KLR650 has the following tyres and tyre sizes standard:

  • Front: Dunlop 90/90-21 M/C 54S K750
  • Rear: Dunlop 130/80-17 M/C 65S K750

The manual for the 2004-2002 Kawasaki KLR650 recommends the following tyre pressures (when cold):

  • Front: 150 kPa/21 psi
  • Rear (up to 97.5 kg/215 lb load): 150 kPa/21 psi
  • Rear (over 97.5 kg/215 lb load): 200 kPa/28 psi

About the 2002-2004 Kawasaki KLR650

The KLR’s get-up-and-go comes courtesy of a strong, dual overhead cam, four-valve liquid-cooled 651cc engine. The motor provides a wide range of power equally suitable for negotiating low-speed trails and cruising at a more brisk highway pace. An engine crankshaft counterbalancer and electric starter provide additional rider comfort and convenience.

Designed with both street and dirt riding in mind, the large-displacement KLR more than meets adventure-touring requirements, thanks to an engine that cruises comfortably at highway speeds, an ample and comfortably padded seat for extended saddle time, a large 6.1-gallon fuel tank, handguards, and a mini fairing to help block the wind.

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 and 2002. It’s no wonder that so many riders have chosen the 2004 Kawasaki KLR650 dual-purpose bike for lengthy transcontinental rides.

Manual for the 2002-2004 Kawasaki KLR650

2002-2004 Kawasaki KLR650 Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2002-2004 Kawasaki KLR650.

You can download it from here.

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