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- 2Quick Reference Guide
- 5Safety Instructions
- 6Foreword
- 8General Information
- 8Table of Contents
- 9Torque and Locking Agent
- 11General Fasteners
- 12Cable, Wire and Hose Routing
- 12Control Cables
- 13Electrical Wires
- 15Fuel System
- 16Exploded View
- 18Specifications
- 21Engine Top End
- 23Service Data
- 25Camshaft Chain Tensioner
- 25Installation
- 26Cylinder, Piston
- 26Installation Points of Piston Rings
- 26Muffler
- 26Spark Arrester Cleaning (U.S. Model}
- 27Engine Right Side/Left Side
- 31Play Inspection
- 31Clutch Release Removal
- 31Engine Lubrication System
- 31Engine Sprosket
- 32Balancer Mechanism
- 32Removal Point
- 32Assembly Points
- 33Engine Removal/Installation
- 34Engine Unit
- 34Removal
- 36Engine Bottom End/Transmission
- 40Wheels/Tires
- 43Adjustment After Tire Installation
- 43Rear Wheel Removal
- 43Rear Wheel Installation Points
- 43Front Wheel Balance
- 45Final Drive
- 47Drive Chain
- 47Chain Slack Inspection
- 47Chain Slack Adjustment
- 47Drive Chain Removal
- 48Brakes
- 52Front Brake Adjustment/Inspection
- 52Front Brake Disassembly/Assembly
- 52Pad Removal Points
- 52Caliper Assembly Points
- 53Master Cylinder Disassembly Points
- 53Rear Brake Adjustment/Inspection
- 53Pedal Position Adjustment
- 54Brake Fluid Level Inspection
- 54Rear Brake Disassembly/Assembly
- 54Inspection and Adjustment After Installation
- 54Pad Removal
- 55Caliper Removal
- 55Master Cylinder Installation Points
- 55Brake Maintenance
- 55Brake Disc Runout Inspection
- 56Suspension/Steering
- 61Front Fork
- 61Fork Disassembly
- 61Guide Bush Replacement
- 61Spring Preload Adjustment
- 62Setting Table for Spring Preload and Damper Adjusters
- 62Rear Shock Removal
- 62Rear Shock Installation Point
- 63Controls/Instruments
- 67Throttle Grip
- 67Inspection
- 67Adjustment
- 68Meter Unit
- 69Frame
- 72Disassembly Flow Chart-Chassis
- 73Electrical System
- 77Precautions
- 77Charging System Wiring Diagram
- 77Measuring Stator Coil Resistance
- 77Regulator/Rectifier Inspection
- 78Regulator/Rectifier Terminal
- 78Rectifier Circuit Inspection
- 78Regulator Circuit Test
- 79Ignition System
- 79Spark Plug Cleaning and Gapping
- 79Magneto Removal or Installation
- 79Ignition Coil Installation
- 80Ignition System Wiring Diagram
- 80Switch Inspection
- 80Starter Lockout Switch Connections
- 80Engine Stop Switch and Starter Button Connections
- 81Ignition Coil Inspection
- 82CDI Unit Inspection
- 82CDI Unit Internal Resistance
- 82Exciter or Pickup Coil Inspection
- 83Starter Motor Removal
- 83Installation Points
- 83Starter Motol Disassembly
- 83Starter Motor Assembly Points
- 84Starter Clutch Removal
- 84Starter Motor Brush Length
- 84Brush Spring Inspection
- 84Commutator Cleaning and Inspection
- 85Armature Inspection
- 85Brush Plate Inspection
- 85Positive Brush Assembly Inspection
- 85Starter Relay Inspection
- 86Starter Circuit Relay Inspection
- 86Starter Button Inspection
- 86Starter Clutch Inspection
- 87Electric Starter System Wiring Diagram
- 87Lighting System
- 87Headlight Vertical Adjustment
- 88Headlight, Dimmer, or Passing Switch Inspection
- 88Headlight, Dimmer, or Passing Switch Connections
- 88Tachometer and Water Temperature Gauge
- 89Tachometer Inspection
- 89Radiator Fan
- 89Initial Check
- 89Fan Motor/Relay Inspection
- 90Wiring Diagram
- 92Appendix
- 93Troubleshooting Guide
- 93General Lubrication
- 93Nut, Bolt, and Fastener Tightness
- 95Supplement-2000-2001 Models
- 96How to Use This Manual
- 97Model Identification
- 97KL650-A14 Left Side View
- 97KL650-A14 Right Side View
- 98General Specifications
- 100Torgue and Locking Agent
- 100Fuel System Specification
- 108KL650-A14/A15 Wiring Diagram
- 108Left Handlebar Switch Connections
- 109Ignition Switch Connections
- 109Color Code
- 110Supplement-2002 Model
- 116Model Application
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