KLR mania

The Kawasaki KLR250 was a motorcycle produced from 1984 to 2007, with only minor changes during the model run. This lightweight dualsport motorcycle was used for several years by the US military for a variety of tasks, including messenger duty and reconnaissance. It was produced by Kawasaki Heavy Industries in Japan and exported to many parts of the world, including the U.S. and Canada, Europe and Australia.

Somewhat similar in appearance to the larger KLR650 (sold in the same colors), the 250 is often described as being a better trail bike (due to lighter weight and reduced bulk) but less enjoyable on long stretches of highway. The user-friendly power delivery and light weight make it a popular bike for novice riders. Like the 650, the KLR250 has continued to sell well into the 21st century despite being questionably "state of the art" even at its introduction, and having no styling changes, except paint and the color of the plastic. You can tell approximately what year a KLR is (either size) by the color of the bodywork:

• 1985 White/Dark Blue
• 1985/'86 Lime Green/Dark Blue, * OR Red/Dark Blue (non-US)
• ? Black/Red
• 1987 White/Red with Blue/Red Tank Decal (patriotic year)
• 1988/'89 Half Blue/Half White with Green Stripes
• 1990-'93 White/Light Blue
• 1994-'96 Teal/Purple, * (often referred to as "Barbie Years")
• 1995 Seafoam/Black (Spain only?)
• ? Black/Black with Purple Tank Decal
• 1991 (UK) Black/Dark Blue
• 1997-'99 Dark Blue "Forest Bluish Green"
• 2000 Olive/Black Tank Decal
• 2001/'02 "Galaxy Silver"/Olive
• 2003 Black/Olive
• 2004/'05 Black/"Aztec Red"

Unlike the 650, the 250 shares many engine parts with an ATV sold by Kawasaki, the KSF250 "Mojave". This has resulted in the availability of engine performance parts, though many owners prefer to use their bike relatively unmodified.

Owners report highway fuel economy figures ranging from 55-70 mpg U.S. (3.4 to 4.3 L/100 km), and city fuel economy of 45-50 mpg U.S> (4.7 to 5.2 L/100 km). The combination of excellent fuel economy, high reliability, light weight and easy handling have made it a favorite among dualsport riders as well as urban commuters and it remains popular even though production has ceased.

Kawasaki discontinued the KLR250 at the end of the 2005 model run. It is replaced by the KLX250R as of 2006.

The base specifications have remained virtually unchanged through out the production period.

Engine:

• Type: Four-stroke, DOHC, four-valve, single cylinder,
• Displacement: 249 cc
• Bore and Stroke: 74.0 x 58.0 mm
• Carburetor: Keihin CVK34
• Compression ratio: 11.0:1
• Output: 28 horsepower 1986–1989, 22 horsepower 1990–2005
• Starting Method: Kick

Drivetrain:

• Transmission: 6-speed
• Final Drive: O-ring chain

Brakes:

• Front: Hydraulic disc
• Rear: Drum

Suspension:

• Front: Air-adjustable hydraulic telescopic fork
• Rear: UNI-TRAK single-shock system

Wheels and tires:

• Front: 3.00 x 21 tire
• Rear: 4.60 x 17 tire

Dimensions:

• Length: 84.3 in
• Seat height: 33.7 in
• Rake and Trail: 28.5 degrees / 4.6 in
• Wheelbase: 55.7 in
• Weight: 258 lb dry
• Fuel Capacity: 2.9 US gal
• Engine oil capacity: 2 liters

The Kawasaki KLR650 is a dual-purpose motorcycle intended for use on both paved and unpaved roads. It has been a long-standing model in Kawasaki's lineup, having been introduced in 1987 and remaining almost unchanged through the 2007 model. Kawasaki, in releasing the much-anticipated 2008 model, introduced the first significant redesign of the KLR650 since its inception.

The KLR650 is heavier than specialized off-road dirt bikes, but it can handle most conditions when ridden carefully by a skilled rider. Its 4-stroke DOHC dual-counter balanced, single-cylinder, water-cooled engine develops a claimed 44hp at the crank; typical measurements at the rear wheel are 35 horsepower. Typical fuel economy is 45 to 60 miles per U.S. gallon (3.9 to 4.7 L/100 km). It has a claimed 6.1 gallon (23 litre) fuel tank and a top speed of approximately 105 mph (160 km/h). The KLR is widely used as an inexpensive adventure/touring bike. The addition of luggage and personalized modifications (GPS, heated handgrips, larger windscreens) make it more functional on long trips.

KLRs have been ridden to the Arctic, across North and South America, and throughout Europe, Africa, and Asia, as well as on full global circumnavigation rides (e.g., Dr. Gregory Frazier in 2001-2002^[1]). Nicknames include "Swamp Thing" "The Mule" and "The Tractor."

Note: While advertised capacity is 6.1 gallons, usable gas tank capacity is approximately 5.6 gallons including reserve, because approximately one half gallon of fuel sits below the top of the petcock intake tube within the tank, or on the other side of the main frame member, which divides the lowest portion of the tank into two lobes (the petcock draws only from one of these two lobes). In an emergency, this extra fuel can be utilized by tipping the bike on its side (nearly horizontal) allowing the fuel to slosh from one side of the tank to the other. This yields a maximum range of approximately 250-300 miles between fill-ups, depending on riding conditions.

2008 redesign

In 2008 the klr 650 was radically redesigned with improved aesthetics, modern dual headlights and a more powerful engine. But, the new piston rings on the early 2008 models often caused oil consumption problems. The new 651cc single cylinder engine puts out 37 bhp at 6200 rpm and 33.4 lb ft of torque at 4950 rpm. Other improvements include: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38mm to 41mm, new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36watts capacity. Kawasaki finally addressed the "doohickey" issue on the 2008. The doohickey is the balancer chain tensioning mechanism. Kawasaki finally made the doohickey stronger but it didn't do anything about the spring tensioner that pulls on the doohickey. The KLR650 has always been considered extremely reliable except for the doohickey on all years and the oil consumption issue on the 2008. Robust aftermarket doohickey systems are available. There are even doohickey parties at tech days! At tech days regional KLRistas meet and share expertise, parts and tools.

Models

• KLR650-A: The "A" model was introduced in 1987, based on its KLR600 predecessor (1984-1986). The "A" model remained nearly unchanged until the introduction of the 2008 model in USA, Canada and Europe
• KLR650-B or Tengai: was sold in the USA starting 1990 and in other countries for several years afterward
• KLR650-C: The "C" model is a more dirt-oriented motorcycle fitted with stiffer 41mm front forks, improved brakes, tubular engine guard, smaller 14 liter fuel tank, and steel wheel rims. Lacking a temperature gauge, it has an over-heat lamp.
• KLR650-E: 2008 was the first major redesign of the KLR650. The primary changes include upgraded 41mm forks, a new D-section swingarm, dual beam headlight, dual-piston rear brake caliper, upgraded cooling system, 4mm spokes, cowling and fairing redesign as well as various redesigned parts. (error corrected specifications)
• The U.S. Military has KLR650s modified by Hayes Diversified Technologies to burn military-spec fuels including diesel. (M1030M1 [1]) All-new engines were designed to replace the 4-stroke gasoline engines. See HDT KLR650s

KLR history

Specifications (1987-2007 KLR650-A)

1998 KLR650 in its environment (the luggage is not standard)

1995 KLR650

Sponsored organizations

Although rare, Kawasaki has chosen to offer KLR650 motorcycles to a few select organizations that would put their bike to the test. These individuals have taken the bikes to some of the most remote locations in the world and have documented the journey on their websites. They include the following:

• Moon Riders: 1997 trip to Latin America. Team Green provided support, parts, and service throughout Central and South America.

• Bikers Without Borders: 2003 trip through 13 Latin America countries volunteering at hospitals, orphanages, Christian Missions and dental clinics. Kawasaki provided 2 brand new KLR 650's for this organization.

Changes over the years

Aside from the paint job, not much changed between the 1987 introduction and the 2008 revisions. The key differences are:

• 1987: Crankshaft is unique to this year.
• 1988: Beefed up the engine cases with extra bolts between the crank and countershaft; crank has a different part number, and may be lighter.
• 1990: Countershaft improved with longer splines for increased engagement with sprocket.
• 1992: Changes to front brake master cylinder.
• Mid-1996: Changed valve cover, added bracket to hold cam chain bumper; changed crank to heavier unit; improved clutch basket with more clutch plates; changed countershaft sprocket retainer from slotted plate to large nut; changed 2nd and 3rd gear ratios. Kickstarter no longer fits with new clutch basket. New left balancer weight/sprocket begins with engine #KLE650AE032206.
• (?) Service manual indicates higher charging system output; only part number change is the rotor. The new power rating is 17A/14V (238 W) @ 7000 rpm; the earlier one was 14A/14V (196 W) @ 8000 rpm (yes, above redline).
• 2001(?) Final assembly shifts from Japan to Thailand. All major parts still made in Japan.
• 2007: New shift lever
• 2008: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38mm to 41mm, new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36watts capacity.

References

http://en.wikipedia.org