1987 klr650A1 owners manual? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 6 Old 01-04-2019, 07:02 PM Thread Starter
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Question 1987 klr650A1 owners manual?

Hi my name is tom im 22 im new to this site, need some advice from those expericed with the gen1 Klr. Ive been riding for about a year now, im inexpericed as a mechanic, im learning and just recently gotten my klr for about 600 with no signs of life. Eventually got some of the lights on then got it to turn over, sadly no spark and the plug is dry.(i have an electrical issue near the stater and a fuel issue im assuming) I just ordered a service manual "supplement"(not sure why it says supplement) and most of everything beside torque values it says "refer to base manual, noting the following." If anyone has a link to where i can find one it would be very helpful as my searchs have come up empty. I apologize for my grammar lol thanks!

Last edited by Thomas Matthew McClain; 01-04-2019 at 07:04 PM.
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post #2 of 6 Old 01-04-2019, 09:19 PM
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Hi Tom,

Welcome to the forum!

The base manual is the KLR600 manual for 1984. It is part number 99924-1050-01. It turns up on e-bay quite frequently. They are usually available for less than $15.

Be careful not to get a KLR600 supplement by mistake. With the old manuals, the base manual has a motorcycle on the cover that is facing to the left. On the supplements, the motorcycle is facing to the right.

There are also Clymer manuals which are pretty good. I'm not sure if they are still in print; I do see them on e-bay now and again.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #3 of 6 Old 01-04-2019, 11:09 PM Thread Starter
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Thanks for the quick reply. I'll look into that. Is this compatible with the 87' Klr650? Also a colored wiring diagram that is compatible, would be very useful alongside the manuals. Please add any links that would be helpful.

Thanks,
Tom
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post #4 of 6 Old 01-05-2019, 06:31 AM
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Yes, it would be applicable and compatible. The way it worked was that the '84 KLR600 was the baseline. Every year after that a supplement was published that brought the baseline up to date. For example, the '84 was kick-start only. The supplement for the '85 KLR600 would have introduced the addition of electric start. The addition of electric start impacted the wiring loom, the ignition system, engine dis-assembly, re-assembly, handlebar controls, etc. All those things would have been documented in the '85 supplement and they would have been carried through in later supplements. All later supplements would have this information plus any information that was introduced specifically for the later model year.

What you need for your '87 is the base manual for the '84 KLR600 and the supplement for the '87 model year. You do not need to have the '85 and '86 supplements.

As a new owner, you will find Dave Pelletier's post very helpful: https://www.klrforum.com/1987-2007-w...kes-avoid.html

This spec sheet has a color wiring diagram, though it is a bit later than yours. It is still generally applicable: https://www.klrforum.com/1987-2007-w...t-gen-1-a.html

Here is a link to only the color wiring diagram: https://c1.staticflickr.com/3/2319/2...82c4ea30_b.jpg

A site that is stuck in time and not been updated since before Obama but good for Gen 1 service: MarkNet - KLR650

A couple of YouTube channels with good content:

Tim has moved on to a BMW but he was prolific with KLR650 content: https://www.youtube.com/channel/UCVa...SvtyZZ-rTBKrWQ
Some info on general KLR maintenance and info, especially doohickey and carburetor: https://www.youtube.com/souperdoo

Info on some of the more important KLR issues and fixes plus a lot of KLR tomfoolery: www.souperdoo.com

Understand that, in the broad sense, KLRs should be divided up into major groups that have the greatest similarity to one another:

1984 - 1987, the KLR600's. Smaller tank, different rear subframe and main frame, drum brake in the rear, had kickstarter.
1987 - 1995, the Gen 1 KLR with no kickstart, new frames, disk brake in the rear, revised rear suspension, kickstart eliminated, new dash, larger tank, revised bodywork, etc.
1996 - 2007, the Gen 1.5 KLR with improved cylinder, revised balancer, different clutch, strengthened case, etc.
2008 - 2014, the Gen 2 KLR with revised bodywork, revised suspension, new ignition system, stronger charging system, revised swingarm, larger brake disks with dual-piston, calipers, better lighting, etc.
2014 - 2018, the Gen 2.5 with the introduction of the 2014.5 KLR with improved suspension and a better seat.

We don't use the '.5' designator; we simply refer to KLR600, Gen 1 (1987 - 2007), Gen 2 (2008 - 2018) but it is important to remember the major change years of 1987, 1996, 2008, and 2014.5 because these years introduced major changes that affect parts interchangeability.

We jokingly refer to the changes in other years as nothing more than Bold New Graphics but it is important to note that there were subtle changes made almost every year, many were improvements. Usually, the new parts were interchangeable with the old parts. There is a lot of backward and forward compatibility such that "better stuff" can be carried both forward and backward to suit your needs. My bike is a 2009 but it has a Gen 1 ignition system, Gen 1 radiator, Gen 1 rear suspension linkage, Gen 1 valve cover, a kick start, KLR600 clutch and primary gears.

"Welcome to the jungle, we've got fun and games and an appetite for destruction," Tom sang out.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 01-05-2019 at 06:48 AM. Reason: Add link to color wiring diagram
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post #5 of 6 Old 01-05-2019, 07:09 AM
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There are a couple of weak points on the KLR that should be understood and perhaps addressed.

The balancer system has an adjustment mechanism that is sketchy. It is known as the 'doohickey' and should be fixed. Read up on it here.

They burn oil when running over 5000 rpm. Either do a simple mod to help with that or don't run it over 5K for extended periods. In any case, always watch the oil level and keep it topped off.

Do not, I repeat, do-****ing-not, torque the oil plug to more than 17-foot-pounds. It's a big bolt and looks like it should be torqued quite high, but you will strip the threads out of the case. Better still, use a neoprene washer and lock-wire.

Keep an eye on the airbox right above the junction of the mid-pipe and the muffler. They have been known to leak exhaust gasses there and cut a hole in the airbox. That let's dust into the intake which gets right into the motor. A bad thing. All this is easily remedied.

I will leave it to @pdwestman to tell you what things an '87 needs to have done to it.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #6 of 6 Old 01-06-2019, 12:58 AM Thread Starter
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Very informative! Thanks a bunch!

Tom.
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