Kawasaki KLR650 EFI (2022+, including Adventure) Maintenance Schedule and Service Intervals
This is the maintenance schedule and service intervals for the Kawasaki KLR650 EFI, the long-awaited (and somewhat surprising) update to the carburettor-fed KLR650 that went fundamentally unchanged for decades.
The 2022 Kawasaki KLR650 is still the same basic concept — a bare-minimum adventure tourer. It’s powered by a 652 cc single-cylinder four-stroke engine that makes modest enough power for it to be learner-approved in Europe and Australia/NZ.
But the 2022 KLR650 got some significant upgrades. Firstly, it’s now fuel-injected. This means it’s more reliable, though less easy to home-tune. And secondly, the KLR650 now has ABS standard. There are a few more changes, too.
To differentiate it from the carburettor-fed earlier gen, people are already referring to it as the KLR650 EFI.
Here are all the generations of KLR650:
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Kawasaki KLR650 EFI Service Intervals
Generally, the Kawasaki KLR650 EFI has 7600 mile or 12000 km minor service intervals.
At every minor service, change the oil, oil filter, and spark plug, and give the whole bike a once-over, looking for leaks, cracks, notchy bearings, parts in need of lubrication, and so on.
Every two services (ever 15200 miles or 24000 km), check the valve clearances. Even once you get there, the valve clearance check is a quick job on a KLR.
Since the KLR650 has a liquid-cooled engine, you need to regularly change the coolant. Also, keep the brake fluid fresh.
What you need to service the Kawasaki KLR650 EFI
|Part||Kawasaki KLR650 EFI spec|
|Oil||The manual recommends SAE 10W-40 Kawasaki motor oil (standard, semi-synthetic, or fully synthetic), meeting standards JASO MA or API SG or above. This is many motorcycle oils. Motul 5100 10W-40 is a good and middle-range option.|
|Oil filter||The standard oil filter part is a TK03441B G.|
|Coolant||The KLR650 has a “permanent” type of antifreeze (an OAT coolant) based on ethylene glycol with corrosion inhibitors suitable for aluminium engines. If you need to top it up, Pro Honda HP coolant is a good option.|
|Air cleaner||You can clean the air filter, but need to replace it when it’s damaged.|
|Cable lubricant||Use Protect all cable life to lubricate control cables.|
|Chain lube||Use a Motul chain care kit to take care of the chain. Many KLR owners pick up a Scottoiler for long distance hauls.|
|Battery||The battery for the KLR650 EFI is a Siam Furukawa FTX9-BS.|
Maintenance schedule for the Kawasaki KLR650 EFI
Below is the maintenance for the Kawasaki KLR650 EFI from the manual.
|km x 1000||1||12||24||36||48|
|mi x 1000||0.6||7.6||15.2||22.8||30.4||Every|
|Engine oil||R||R||R||R||R||Year, R. Service more often if riding in dirty / aggressive conditions|
|Air cleaner element||I||I||I||I||2 years, R. Inspect more often if riding in dusty / wet conditions|
|Cooling system||I||I||I||I||I||Year, I|
|Coolant, water hoses, and O-rings||R||3 years, R|
|Throttle control system (play, smooth return, no drag)||I||I||I||I||I||Year, I|
|Fuel system||I||I||I||I||I||Year, I|
|Fuel hose||5 years, R|
|Evaporative emission control system||I||I|
|Air suction system||I||I||I||I|
|Air suction valve||I||I||I||I|
|Spark arrester (if fitted)||Every 6K km (3.8K mi), I|
|Clutch operation (play, engagement, disengagement)||I||I||I||I||I||Year, I|
|Balancer chain tension||I||I||I||I||Year, I|
|Wheel bearing damage||I||I||I||I||Year, I|
|Spoke tightness and rim runout||I||Every 6K km (3.8K mi), I|
|Drive chain wear||I||I||I||I||Inspect more often if riding in dusty / wet conditions|
|Drive chain guide wear||I||I||I||I|
|Brake system||I||I||I||I||I||Year, I|
|Brake operation (effectiveness, play, no drag)||I||I||I||I||I||Year, I|
|Brake fluid (front and rear)||R||R||2 years, R|
|Brake hose||4 years, R|
|Rubber parts of brake master cylinder and caliper||R||4 years, R|
|Suspension system||I||I||I||I||Year, I|
|Lubrication of rear suspension||L||L|
|Steering play||I||I||I||I||I||Year, I|
|Steering stem bearing||L||L||2 years, L|
|Electrical system||I||I||I||I||Year, I|
|Chassis parts||L||L||L||L||Year, L|
|Condition of bolts, nuts, and fasteners||I||I||I||I||I||–|
Daily checks for the KLR650 EFI
The Kawasaki KLR650 EFI’s manual specifies a number of daily checks to do. They are listed here below.
|Fuel||* Adequate supply in tank, no leaks|
|Engine oil||* Oil level between level lines|
|Tyres||* Air pressure (when cold), install the air valve cap|
* Tyre wear
|Drive chain||* Daily or periodically (see below)|
|Bolts, nuts, and fasteners||* Check for loose and/or missing bolts, nuts, and fasteners|
|Steering||* Action smooth but not loose from lock to lock|
* No binding of control cables
|Brakes||* Brake pad wear|
* Brake fluid level
* No brake fluid leakage
|Throttle||* Throttle grip free play|
|Clutch||* Clutch lever free play|
* Clutch lever operates smoothly
|Coolant||* No coolant leakage|
* Coolant level between level lines (when engine is cold)
|Electrical equipment||* All lights (head, city, brake/tail, turn signal, license plate, warning/indicator) and horn work|
|Engine stop switch||* Stops engine|
|Side stand||* Return to its fully up position by spring tension|
* Return spring not weak or not damaged
|Rear view mirrors||* Rear view sight|
Chain Maintenance — Kawasaki KLR650
The chain of a KLR650, being on an adventure bike, is likely to have a hard life. So it’s important to keep it lubricated and cleaned, more than on most chain-driven motorcycles.
Use a good-quality chain lubricant like Motul chain paste, or a Motul chain care kit which comes with a couple of handy tools to maintain the chain.
Kawasaki recommends you follow the following chain maintenance schedule:
|Chain maintenance item||Every|
|Check drive chain lubrication condition, lubricating if necessary (Motul chain paste)||400 mi / 600 km|
|Check drive chain slack, adjusting if necessary||600 mi / 1000 km|
- Do these items (checking/adjusting slack, and checking/applying lubrication) more often if you ride your KLR650 in dusty or rainy conditions.
- Always lubricate the chain after washing the motorcycle.
Wheel and tyre sizes for the KLR650 EFI
The KLR650 EFI ships with Dunlop K750 dual sport tyres.
|Wheel||Tyre (Tire) size||Tyre (Tire) pressure when cold|
|Front||90/90-21 M/C 54S||150 kPa / 1.5 bar / 21 psi|
|Rear||130/80-17 M/C 65S||150 kPa / 1.5 bar / 21 psi (solo, up to 97.5 kg / 215 lb)|
250 kPa / 2.5 bar / 36 psi (above 97.5kg / 215 lb
Adjust the pressures in the table to suit your ride style and the load on the bike.
About the 2022 Kawasaki KLR650 EFI
The Kawasaki KLR650 EFI is a “sticking to the basics” move for Team Green.
The KLR650 needs almost no introduction. But for those who don’t know: it’s an iconic dual sport or adventure touring motorcycle, so iconic in fact that it has barely changed in decades. It has always been a somewhat heavy big “thumper” bike with plastic fairings and a windshield — just enough comfort for highway runs.
The KLR650 stands in contrast to other thumpers like the Honda XR650L or the Suzuki DR650, for example, which are big dirt bikes but which have engines large enough to take you on the highway. The KLR650 is much more highway oriented.
But it’s a simple bike. The old KLR650 had a carburettor! And just one piston. So it was favoured for adventure travellers because it’s so easy to fix — you can even carry a lot of spare parts with you.
As times changed, it became clear the old KLR’s days were numbered. European regulations mean that new bikes have to conform to emissions regulations and have ABS fitted to them as standard these days. Some people expected Kawasaki to adapt the parallel twin from the Versys 650, but that’s not what they did.
So the new KLR650 is very much like the old one, but with just a few more modern touches. Here are the improvements
- Fuel injection, first and foremost, replacing the carburettor.
- ABS as standard, with a bigger (300mm) front brake disc, and thicker rear brake disc. The ABS system is “dual-purpose” — less invasive, and allowing some wheel slippage for off-road use
- Digital LCD gauge cluster (but with no tachometer)
- Comfort tweaks (slightly wider handlebars, slightly forward pegs, rubber mounts for reduced vibration)
- Taller windscreen
- Options including top case, USB port, and power outlet
The new KLR650 still doesn’t have a sixth gear, though.
Manual for the Kawasaki KLR650 EFI
The maintenance schedule for the KLR650 EFI came from the manual, which was released some time before the bike actually became available.
You can view it online at Kawasaki’s site here.
An archive copy of the KLR650 EFI’s owner manual is below.