Kawasaki KLR600 (KL600-A/B) Repair Manual & Supplement, covers 1984-1994

Kawasaki KLR 600 (1984-1994) Complete Service & Repair Manual Bundle

Master the maintenance and repair of your legendary dual-sport motorcycle with this comprehensive service resource. This bundle includes both the original Base Manual and the vital Electric Starter Supplement, providing the technical depth required to keep your Kawasaki KLR 600 running at peak performance.

Whether you own the early kick-start models or the later electric-start versions, this guide offers factory-level specifications and step-by-step procedures. The KLR 600 is renowned for its liquid-cooled, DOHC 4-valve engine and its pioneering role in the adventure-touring segment; this manual ensures you can preserve that legacy through precise mechanical care.

Extensive Model Coverage

This manual covers the full production run of the KLR 600 series, including specific details for the following model year variations:

• Kawasaki KLR 600 (1984-1994)
• KL600-A1 (1984: Kick-start only)
• KL600-B1 through B9 (1985-1994: Electric-start models)

Vehicle Identification & Serial Numbers

For precise parts ordering and technical accuracy, this manual references the following starting serial numbers:

• KL600-A1: Starting at JKAKL6A1 EA000001
• KL600-B1: Starting at JKAKL6B1 EA000001 (and subsequent B-series iterations through 1994)

Professional-Grade Technical Chapters

• General Information: Essential data, torque settings, and specialized tool requirements.
• Periodic Maintenance: Comprehensive service schedules to extend engine life and reliability.
• Fuel System: Detailed breakdown of the Keihin CVK40 carburetor, including tuning and cleaning procedures.
• Cooling System: Maintenance of the liquid-cooling circuit, radiator, and thermostat—critical for the KLR’s high-compression 564cc engine.
• Engine Top End & Valves: Instructions for camshaft timing, valve clearance adjustments, and cylinder head servicing.
• Engine Bottom End: Complete guide to the crankshaft, 5-speed transmission, and the complex balancer chain system.
• Electric Starter Supplement: Exclusive coverage for the B-series, including the starter motor, relay testing, and updated wiring diagrams.
• Electrical System: Full schematics for ignition, charging, and lighting circuits.
• Chassis & Suspension: Servicing the Uni-Trak rear suspension and front telescopic forks.
• Brakes: Maintenance for the front hydraulic disc and rear drum brake systems.

Why This Manual is Essential

The Kawasaki KLR 600 features a unique balancer system and a sophisticated DOHC head design that requires exact specifications to avoid common mechanical pitfalls. This manual provides those specific tolerances, clearance measurements, and wiring paths that generic guides often miss.

Designed for clarity and ease of use, the documentation follows a logical flow from simple troubleshooting to complete engine teardowns. It is an indispensable asset for DIY enthusiasts looking to save on shop labor costs and for professional mechanics who require an authoritative reference for vintage Kawasaki dual-sport hardware.