Kawasaki KLR650 Repair Manual 1987-2007

The 1987-2007 Kawasaki KLR650 repair manual by Clymer covers off-road motorcycles models indicated. The comprehensive text gives complete information on maintenance, tune-up, repair and overhaul, and hundreds of photos and drawings guide you through every step. From start to finish. This book includes all you will need to know to keep your Kawasaki KLR650 running right.
Book Excerpt: 1987-2007 Kawasaki KLR650 Repair Manual THROTTLE CABLE REPLACEMENT

The throttle uses two cables. One cable pulls the throttle open during acceleration, while the other pulls the throttle closed during deceleration. In operation, the cables always move in opposite directions to one another. Use the following procedure to replace the throttle cables.

1. Remove the fuel tank.
2. At the carburetor, loosen the locknuts and remove the cables from the holders and throttle valve (Figure 60). The left cable is the accelerator cable. Identify the cables so the new cables can be matched and installed in the correct position.
3. Note how the cables are routed, then pull the cables from the frame.
4. At the handlebar, remove the screws from the housing and separate the parts (Figure 61). Remove the complete throttle assembly from the handlebar.
5. Remove the cable ends from the throttle drum, then remove the cable guide from the upper housing (Figure 62).

ENGINE

The following removal and installation procedure outlines the basic steps necessary to remove the engine from the frame. Depending on the planned level of disassembly, consider removing top end components, and those located in the crankcase covers, while the engine remains in the frame. Since the frame keeps the engine stabilized, tight nuts and bolts are easier to remove if the engine is held steady. Also, if the actual engine problem is unknown, it may be discovered in another assembly, other than the crankcase. During engine removal, make note of mounting bolt directions and how cables and wire harnesses are routed. Refer to the appropriate chapters for removal, inspection and installation procedures for the components in the engine top end and crankcase covers.

ENGINE LOWER END

This chapter provides procedures for servicing or removing the following lower end components:

1. Cam chain and lower guide.
2. Left crankcase cover.
3. Engine balancer.
4. Crankcase, bearings and seals.
5. Crankshaft and connecting rod.

To access and service some of these components, the engine must be removed from the frame, then dismantled of all assemblies attached to the crankshaft. Read the chapter before repairing the engine lower end. Become familiar with the procedures, photos and illustrations to understand the skill and equipment required. Refer to Chapter One for tool usage and techniques.

Subject: 1987,1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Kawasaki KLR650 service, maintenance, repair. ISBN-10: 1599692252 | ISBN-13: 9781599692258 | Clymer M474-3