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2005-2007 Kawasaki KLR650 Maintenance Schedule and Service Intervals

2005-2007 Kawasaki KLR650 Stock Image

This is the maintenance schedule and associated service intervals for the 2005-2007 Kawasaki KLR650.

This maintenance schedule applies to the following models:

  • 2005 Kawasaki KLR650
  • 2006 Kawasaki KLR650
  • 2007 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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2005-2007 Kawasaki KLR650 Maintenance Schedule

Below is the maintenance schedule for the 2005-2007 Kawasaki KLR650.

The maintenance for the 2005-2007 Kawasaki KLR650 is broken into two sections: Emission related and Non-emissions.

The maintenance for the 2005-2007 Kawasaki KLR650 shall be carried out whichever comes first.

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 2005-2007 Kawasaki KLR650

The 2005-2007 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 2005-2007 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 2005-2007 Kawasaki KLR650

The KLR650 is one of those rare motorcycles with the ability to play just about any role its rider chooses. The KLR’s roomy ergonomics, bump swallowing suspension, large fuel capacity and efficient engine provide riders with amazing range and the versatility to travel far beyond city streets or highways. Equipped with optional Kawasaki accessories, the KLR650 might just be the ultimate world traveler.

Power for the KLR650 comes from a strong, dual overhead cam, four-valve, liquid-cooled, single-cylinder, 651cc four-stroke engine. The engine 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.

The frame for the KLR650 is made of round-section high-tensile steel, and a detachable rear subframe simplifies maintenance by providing easier access to the airbox, carburetor, and rear shock. The adjustable, long-travel suspension provides a plush ride on both pavement and off-road.

Manual for the 2005-2007 Kawasaki KLR650

2005-2007 Kawasaki KLR650 Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2005-2007 Kawasaki KLR650.

You can download it from here.

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