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Kawasaki KLR650 Gen 1 (Pre-2007) Maintenance Schedule and Service Intervals

2005-2007 Kawasaki KLR650 Stock Image

This is the maintenance schedule and associated service intervals for the Gen 1 Kawasaki KLR650, which is every model from 1987 up to 2007.

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, fed by a carburettor.

To be clear, this KLR650 maintenance schedule applies to the KLR650 models including (get ready): 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, and 2007. In all those years, only superficial things changed.

2000-2001 Kawasaki KLR650 Stock Image
2001 Gen 1 KLR650

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What you need to service the Gen 1 Kawasaki KLR650

If you’re servicing the Kawasaki KLR650 (of any generation!), you at least need motorcycle maintenance tools — things like an oil catch pan, a paddock stand, and so on.

For the Kawasaki KLR650 engine, the manual recommends the following specific consumables.

Only the brake pads change between the generations.

OilKawasaki recommends SAE 10W-40 “API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2” like Kawasaki 10W-40 engine oil. You need 2.1 L (about half a US gallon). Don’t over-torque the bolt (spec is 29 Nm/21 lb-ft for the oil drain bolt per the manual) — use a torque wrench if you don’t have experience with how much torque is enough.
Oil filterNeeds to be changed every time you change the oil. Either get a stock one (part 16099-004, used for other Kawasaki bikes) or K&N KN-123.
Engine coolantKawasaki recommends permanent “green” antifreeze that’s a 50/50 ethylene glycol pre-mix. You can either use pre-mix or concentrate (for which you’d need demineralised water).
Spark PlugsThe spark plug to use is NGK DPR8EA-9 per the manual. Make sure it’s gapped correctly to 0.8-0.9mm (get a gapping tool) and torqued to 14 Nm / 10 lb-ft.
Air filterKawasaki’s part number for the OEM air filter is 11013-1152. You can also get the K&N equivalent, KA-6589.
Brake padsOEM brake pads are X for the front and X for the rear. You can also use EBC brake pads, which tend to grip harder and last longer.
KLR650 Gen 1 (up to 2007)
Front: OEM 43082-1078 or EBC FA229HH
Rear: OEM 43082-1096 or EBC FA067R (or equivalent)
KLR650 Gen 2 (2008-2020)
Front: OEM 43082-0060 or EBC FA228HH
Rear: OEM 43082-0080 or EBC FA197HH
Oil, filters, coolant, plugs, and brake pads for the Kawasaki KLR650

And the following general consumables are useful as well.

motorcycle maintenance tools - paddock standPaddock Stand — Makes maintaining your chain or doing other maintenance much easier.
motorcycle maintenance tools - motul chain pasteMotul chain paste — one of the most highly-regarded chain lubes. Easy to apply, doesn’t fling off. If you need more stuff, get the Motul chain care kit as an affordable package.
Valvoline full synthetic lithium soap-based greaseAlways good to have on hand lithium soap-based grease for lubing external pivot points (like the swingarm) and bearings.
motorcycle maintenance - cable lubricantUse Protect all cable life to lubricate your cables and controls.
General motorcycle maintenance consumables

Gen 1 Kawasaki KLR650 Maintenance Schedule

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

The maintenance for the gen 1 Kawasaki KLR650 is broken into two sections: Emission related and Non-emissions.

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

Emissions related maintenance

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)
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 †
1st Gen KLR650 Emissions-related maintenance

Non-emissions (Chassis)-related maintenance

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)
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)
Kawasaki KLR650 – Non-emissions related maintenance

Tyre size and tyre pressure for the Gen 1 Kawasaki KLR650

The Gen 1 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 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 Gen 1 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.

People often ask “should I get a gen 1 or a gen 2 KLR650?” And the simple answer is: both are great, and it will depend on which one you find in good condition. As time wears on, the Gen 1 KLR650 is getting harder to find, and so a Gen 2 is more likely to be a candidate.

Manual for the Gen 1 Kawasaki KLR650

Gen 1 Kawasaki KLR650 Maintenance Schedule Screenshot From Manual
Gen 1 KLR650 manual

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

You can download it from here.

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