Kawasaki KLR 650 (1987–2007): The Swiss Army Knife of Dual-Sport Motorcycles

Introduction

The Kawasaki KLR 650 is the motorcycle equivalent of a trusty leatherman: not the flashiest tool in the shed, but capable of handling almost anything you throw at it. Produced from 1987 to 2007 with minimal changes, this single-cylinder stalwart earned a cult following for its rugged simplicity, go-anywhere versatility, and unshakeable reliability. Whether you’re commuting through city traffic, touring backcountry highways, or picking your way through rocky trails, the KLR 650 molds itself to the task with a shrug and a throaty exhaust note. This review dives into what makes the KLR 650 a legend—and why it remains a compelling choice for riders who value substance over spectacle.

Design and Engineering: Built to Endure

At the heart of the KLR 650 lies a 651cc liquid-cooled, single-cylinder engine with a DOHC valvetrain and a Keihin CVK40 carburetor. Outputting 42–48 HP (30.7–35 kW) and 46–47 Nm (34–35 lb-ft) of torque, this mill prioritizes low-end grunt over peak power, making it a tractor-like companion for technical terrain or highway cruising. The 5-speed transmission is bulletproof, though some riders lament the occasional “bonus neutral” between gears—a quirk that becomes part of the bike’s charm over time.

The semi-double cradle steel frame strikes a balance between rigidity and flexibility, while the 21-inch front and 17-inch rear spoked wheels (shod with 90/90-21 and 130/80-17 tires, respectively) offer a confident stance on mixed surfaces. Suspension travel is generous: 230 mm (9.1 inches) at both ends, though the soft damping can lead to brake dive or wallowing under heavy loads.

Key specs: - Dry weight: 153 kg (337 lbs)
- Seat height: 889 mm (35 inches)
- Fuel capacity: 23 liters (6.1 gallons)
- Range: 350–450 km (217–280 miles)

On-Road Performance: The Unlikely Tourer

The KLR 650 defies expectations on pavement. The upright riding position, wide handlebars, and plush seat (initially comfortable, though it softens over time) make it a surprisingly capable commuter and tourer. The fairing and windshield—basic but effective—divert windblast at highway speeds, while the rubber-mounted pegs and handlebars mitigate vibrations from the thumping single.

Highway notes:
- The engine hums contentedly at 100 km/h (62 mph), though sustained speeds above 120 km/h (75 mph) feel strained.
- Fuel efficiency averages 18.1 km/L (42.5 mpg), stretching to 25 km/L (59 mpg) with gentle throttle input.
- The single 230mm front disc brake lacks bite; upgrading to braided steel lines or a larger rotor is a popular fix.

Off-Road Capability: More Than a Poseur

The KLR 650 isn’t a dirt bike in disguise, but it’s competent enough for fire roads, gravel trails, and mild single-track. The 239 mm (9.4 inches) of ground clearance shrugs off rocks and ruts, while the long-travel suspension soaks up bumps—though heavier riders might crave stiffer springs.

Trail quirks:
- The 337-lb (153 kg) dry weight demands respect on technical terrain; drop it, and you’ll wrestle to upright it.
- The stock Dunlop K750 tires are a compromise: adequate on dirt but slippery in mud. Swapping to aggressive knobbies (like Pirelli MT21s) unlocks better grip.
- The exposed exhaust can melt luggage; aftermarket heat shields or luggage racks are wise investments.

Comfort and Ergonomics: All-Day Companion

The KLR’s ergonomics cater to a wide range of riders. The 35-inch seat height is intimidating for shorter inseams, but the narrow tank and soft suspension sag help tip-toers reach the ground. For touring, the rear rack supports soft luggage, and the tank’s sculpted sides let you grip with your knees during long slogs.

Upgrade tips:
- Seat: The stock foam collapses over time. Corbin or Seat Concepts replacements add support.
- Windshield: A taller aftermarket screen (like from Puig) reduces buffeting.
- Handguards: Barkbusters protect levers and fingers in drops.

Competition: How the KLR Stacks Up

The KLR 650’s rivals are few but fierce. Here’s how it compares:

| Model | Pros | Cons | |--------------------|-------------------------------------------|-------------------------------------------| | Suzuki DR650S | Lighter (149 kg / 328 lbs), more agile off-road | No stock fairing, shorter fuel range | | Yamaha XT600E | Punchier mid-range, air-cooled simplicity | Smaller tank, less comfortable for touring| | BMW F650GS | Fuel-injected, premium build quality | Higher cost, complex maintenance |

The KLR’s trump card is its balance: it’s more road-biased than the DR650, more durable than the XT600, and far cheaper to own than the BMW. It’s the Goldilocks of dual-sports—just right for riders who want one bike to rule them all.

Maintenance: Keep It Simple, Keep It Running

The KLR 650 thrives on neglect but rewards attention. Key maintenance points:

1. Sidestand Safety Switch: Prone to failure. Bypass it with a $5 eBay dongle.
2. Countershaft Sprocket: Check for seal leaks. Upgrade to a Loctite-fixed sprocket to prevent spline wear.
3. Valve Adjustments: Shim-over-bucket design requires checks every 10,000 km (6,200 miles).
4. Suspension: The rear shock fades on rough terrain. A rebuilt unit from Cogent Dynamics transforms handling.

MOTOPARTS.store Recommendations:
- Braided brake lines for sharper stopping.
- Skid plates and crash bars for off-road protection.
- LED headlights to replace the dim stock bulb.

Conclusion: The Everyman’s Adventure Bike

The Kawasaki KLR 650 isn’t perfect. It’s heavy, underpowered, and about as stylish as a pair of Crocs. But like those rubber clogs, it’s functional, comfortable, and damn near indestructible. For riders who value practicality over panache, the KLR remains a benchmark—a machine that invites you to explore the world without mortgaging your future. Twenty years on, it’s still the bike you ride further, longer, and with more stories to tell.

Specifications sheet