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2015-2016 Kawasaki KLR650 Maintenance Schedule and Service Intervals

2015-2016 Kawasaki KLR650 Stock Image

This is the maintenance schedule and associated service intervals for the 2015-2016 Kawasaki KLR650.

This maintenance schedule applies to the following models:

  • 2015 Kawasaki KLR650
  • 2016 Kawasaki KLR650
  • 2016 Kawasaki KLR650 Camo

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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2015-2016 Kawasaki KLR650 Maintenance Schedule

Below is the maintenance schedule for the 2015-2016 Kawasaki KLR650.

The maintenance for the 2015-2016 Kawasaki KLR650 is broken into three sections: Engine Related Items, Chassis Related Items, and Change/Replacement items.

The maintenance for the 2015-2016 Kawasaki KLR650 shall be carried out whichever comes first.

Periodic Maintenance Chart

1. Periodic inspection (Engine Related Items)

Operation (Engine Item)
Every1000 km (600 mi)6000 km (3750 mi)12000 km (7500 mi)18000 km (11250 mi)24000 km (15000 mi)30000 km (18750 mi)36000 km (22500 mi)
Air cleaner element – clean(e)
Valve clearance – inspect (e)
Throttle control system (play, smooth return, no drag) – inspect (e)year
Choke operation – inspect (e)year
Idle speed – inspect (e)
Fuel leak (fuel hose and pipe) – inspectyear
Fuel hoses damage – inspectyear
Fuel hoses installation condition – inspectyear
Coolant level – inspect
Coolant leak – inspectyear
Radiator hose damage – inspectyear
Radiator hoses installation condition – inspectyear
Evaporative emission control system – function (California model only) (e)
Air suction system damage – inspect (e)
Balancer chain tension – adjust
Spark arrester – clean
2. Periodic Inspection (Chassis Related Items)

Operation (Chassis Items)

Clutch and drive train:
Clutch operation (play, engagement, disengagement) – inspect
Drive chain lubrication condition – inspect #every 600 km (400 mile)
Drive chain slack – inspect #every 1000 km (600 mile)
Drive chain wear – inspect #
KDrive chain guide wear – inspect
Wheels and Tires
Tire air pressure – inspectyear
Wheels/tires damage – inspect
Tire tread wear, abnormal wear – inspect
KWheel bearings damage – inspectyear
KSpoke tightness and rim runout -inspect
Brake system
Brake fluid leak – inspectyear
Brake hoses damage – inspectyear
Brake pad wear – inspect #
Brake hose installation condition – inspectyear
Brake fluid level – inspect6 month
Brake operation (effectiveness, play, drag) – inspectyear
Brake light switch operation – inspect
KFront forks/rear shock absorber operation (damping and smooth stroke) – inspect
KFront forks/rear shock absorber oil leak – inspectyear
KUni-trak rocker arm bearings – lubricate
KUni-trak rocker arm operation – inspect
KUni-trak tie rods operation – inspect
KUni-trak tie rods bearings – lubricate
KSwing arm pivot – lubricate
Steering system
KSteering play – inspectyear
KSteering stem bearings – lubricate2 years
Electrical system
Light and switches operation – inspectyear
Headlight aiming – inspectyear
Side stand switch operation – inspectyear
Engine stop switch operation -inspectyear
Battery electrolyte level – inspect6 months
Chassis parts – lubricateyear
Bolts and nuts tightness – inspect
3 Periodic Replacement

Change/Replacement items
Every1000 km (600 mi)12000 km (7500 mi)24000 km (15000 mi)36000 km (22500 mi)48000 km (30000 mi)
Air cleaner element – replace # (e)2 year
Engine oil # – changeyear
Oil filter – replaceyear
KFuel hoses – replace5 years
KCoolant – change3 years
KRadiator hoses and O-rings – replace3 years
KBrake hoses – replace4 years
KBrake fluid (front and rear) -change2 years
KRubber parts of master cylinder and caliper – replace4 years
Spark plug (e) – replace


K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
(e) Emission Related Item

Tyre size and tyre pressure for the 2015-2016 Kawasaki KLR650

The 2015-2016 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 2015-2016 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 2015-2016 Kawasaki KLR650

The KLR650 motorcycle uses a rock-solid 651cc four-stroke single-cylinder engine with a double engine balancer, provides ample horsepower, and smooth delivery to ensure this world-traveling explorer in reaching their destination. The five-speed transmission contributes to the robust bottom-end pull.

This versatile package gives the rider the confidence and ability to trek across the environment from deserts to metropolitan traffic – all handled with the same high level of proficiency. The suspension of the KLR650 provides an ample 7.9” of front wheel travel and 7.3” of rear suspension travel. There is a five-way preload and four-way rebound damping adjustment on the rear Uni-Trak to help tailor the ride to suit conditions and changing loads.

The 41mm front fork features firm spring and rebounds damping rates to create confidence-inspiring handling. Braking duties are handled by a dual-piston front caliper gripping a 280mm petal-style rotor, while a 240mm petal-style rotor is squeezed by a single-piston caliper in the rear.

Manual for the 2015-2016 Kawasaki KLR650

2015-2016 Kawasaki KLR650 Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2015-2016 Kawasaki KLR650.

You can download it from here.

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