1986 KLR 600 Manual

The 1986 Kawasaki KLR 600 is a dual-sport motorcycle featuring a 564cc liquid-cooled single-cylinder engine, 5-speed transmission, dual-purpose tires, front disc brake, rear drum brake, adjustable suspension, and electric start. This manual covers maintenance, operation, specifications, and troubleshooting for optimal performance and longevity.

1. Features at a Glance 2. Installation & Assembly 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Maintenance Procedures 7. Operating Instructions 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: 564cc single-cylinder engine, 5-speed transmission, front disc brake, rear drum brake, adjustable suspension, dual-purpose tires.

Feature	Description
Engine	564cc liquid-cooled single-cylinder
Transmission	5-speed constant mesh
Brakes	Front disc, rear drum
Suspension	Telescopic fork front, swingarm rear
Tires	Dual-purpose 90/90-21 front, 120/80-17 rear
Fuel Capacity	2.9 gallons
Starting System	Electric start with kickstart backup
Weight	324 lbs (dry)
Seat Height	34.6 inches
Ground Clearance	9.1 inches

Installation & Assembly

Unpack and inspect contents. Assemble on stable surface.

Install handlebars: Align with top clamp, tighten bolts to specification.
Mount front wheel: Insert axle, align brake caliper, torque to 65 ft-lbs.
Install battery: Connect positive terminal first, then negative.
Add fluids: Engine oil (1.9 quarts), coolant (1.4 quarts).

WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are torqued to specification.

First-Time Setup

Complete pre-ride inspection before initial operation.

Check tire pressure: 21 psi front, 25 psi rear.
Adjust suspension: Set preload for rider weight.
Verify fluid levels: Engine oil, coolant, brake fluid.
Test controls: Throttle, brakes, clutch operation.
Break-in procedure: Vary RPM for first 500 miles.

CAUTION! Always wear proper protective gear. Never operate without checking all systems.

Specifications

Engine Type: 564cc liquid-cooled single-cylinder
Bore x Stroke: 90.0 x 88.4mm
Compression Ratio: 9.5:1
Fuel System: Keihin CVK34 carburetor
Ignition: CDI electronic
Transmission: 5-speed constant mesh
Final Drive: Chain
Suspension Travel: 8.3" front, 7.3" rear
Brakes: Single disc front, drum rear
Fuel Capacity: 2.9 gallons
Curb Weight: 347 lbs

Controls and Settings

Standard motorcycle controls: Left handlebar - clutch, high/low beam, turn signals, horn. Right handlebar - front brake, throttle, engine stop switch.

Instrument Cluster: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.

Adjustments: Handlebar position, clutch and brake levers, suspension preload, idle speed. Maintenance intervals: Oil change every 3,000 miles, valve adjustment every 6,000 miles.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Engine oil change: Every 3,000 miles with 10W-40 motorcycle oil.
Air filter cleaning: Every 6,000 miles or in dusty conditions.
Chain adjustment: Maintain 1.2-1.6 inches of free play.
Valve clearance: Check every 6,000 miles (0.10-0.15mm intake, 0.15-0.20mm exhaust).
Brake service: Check pads and fluid level monthly.

Tip: Always use genuine Kawasaki parts for optimal performance.

Operating Instructions

Proper operation techniques for various conditions.

Starting: Turn key on, pull choke, press start button.
Shifting: Use clutch for all gear changes.
Braking: Use both brakes together for maximum stopping power.
Off-road operation: Stand on pegs, weight back for rough terrain.
Highway riding: Maintain proper lane position, use mirrors frequently.
Fueling: Use unleaded gasoline with minimum 87 octane.
Storage: Add fuel stabilizer for periods over 30 days.

WARNING! Always wear helmet and protective gear. Never operate under influence of drugs or alcohol.

Safety Features

Standard safety equipment: Front disc brake for reliable stopping, rear drum brake, neutral safety switch, engine stop switch, reflectors, horn.

Care & Cleaning

Clean after riding in wet or dirty conditions. Use mild soap and water; avoid high-pressure sprays near seals and bearings.

CAUTION! Do not use harsh chemicals on plastic components. Keep chain lubricated but avoid over-application.

Regulatory Information

Manufactured to meet 1986 EPA and DOT standards. California models include additional emissions equipment. Copyright © 1986 Kawasaki Motors Corp., U.S.A. For support, contact Kawasaki customer service or authorized dealers.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel, spark, compression	Check fuel flow, spark plug, compression; use choke when cold.
Poor idle	Carburetor adjustment	Adjust idle speed screw; clean carburetor if necessary.
Chain noise	Loose chain	Adjust chain to proper tension; lubricate regularly.
Brake fade	Worn pads/contaminated fluid	Replace brake pads; flush brake fluid.
Electrical issues	Battery/connections	Check battery voltage; clean and tighten connections.

Reset: Disconnect battery for 30 seconds to reset electrical system.

Service: Contact authorized Kawasaki dealer for major repairs.