How to Change the Oil in a 2016 Kawasaki KLR650: A Complete MotoSport.com Guide

Shop parts for a 2016 Kawasaki KLR650 Dirt Bike.

The 2016 Kawasaki KLR650 is a rugged, adventure-ready dual sport motorcycle, but like any high-performance machine, it requires regular maintenance. The most frequent task you’ll face is the oil change. Proper oil changes preserve engine longevity, optimize bike performance, and reveal early signs of engine wear. Below, find a detailed, proprietary guide tailored for the 2016 Kawasaki KLR650, covering every essential tool, step, and model-specific tip to make your oil change hassle-free.

Tools and Supplies Needed

  • 3/8-inch ratchet
  • 17mm socket
  • 8mm or 10mm socket (Check your side cover bolt size before starting)
  • Torque wrench (for proper bolt tightening)
  • Drain pan (large enough to handle at least 3 quarts)
  • New Kawasaki KLR650 oil filter (OEM recommended)
  • New crush washer (recommended for every change)
  • 2.6 quarts of 10W-40 motorcycle oil (Kawasaki approved)
  • Clean rags or paper towels
  • Funnel
  • Flathead screwdriver (to help remove the filter cover, optional)
  • Gloves (to protect your hands)

Step-By-Step Oil Change Process

  1. Warm up the engine: Start the bike and let it idle for 2-3 minutes. Warm oil will drain more completely and take more contaminants with it.
    Specific KLR650 note: Don’t over-rev or let the bike sit for too long—just enough to get the oil warm and fluid.
  2. Remove the oil filler cap: Twist off the cap on the right side of the engine crankcase. This allows air in and helps oil flow out quickly.
    Tip: Set the cap aside in a clean area so no dirt gets on it.
  3. Locate the drain bolt: Find the drain bolt underneath the engine—near the skid plate. Use a 17mm socket to loosen it.
    KLR650 tip: Older bikes use a 17 ft-lb torque spec, Gen 2 (your 2016) requires 21 ft-lb on reinstallation.
  4. Drain the oil:
    • Place the drain pan underneath.
    • Remove the drain bolt carefully—be prepared for a hot stream of oil.
    • Allow oil to drain out completely. Rock the bike side to side gently to get as much old oil out as possible
      • .
    • Don’t lose the crush washer—replace it with a new one to avoid leaks
      • .
  5. Remove the oil filter cover:
    • On the right side, use your 8mm or 10mm socket to remove the oil filter cover bolts.
    • Careful: A small tab on the cover is fragile—pry gently with a flathead screwdriver if needed.
    • Your KLR650 filter cover has an O-ring—ensure it is not pinched, dried out, or damaged. Replace if needed.
  6. Swap out the oil filter:
    • Remove the old oil filter and the inner spring/valve if equipped.
    • Install the new filter in the correct orientation—the metal bezel side faces the engine on most models
      • .
    • Lubricate the O-ring and new filter with a little fresh oil for better sealing.
  7. Reinstall the filter cover and drain bolt:
    • Double-check and clean both sealing surfaces (engine and filter cover).
    • Reinstall the drain bolt with a new crush washer. Torque to 21 ft-lb for your 2016 KLR650
      • .
    • Install the filter cover, making sure the arrow faces up and the tab is at the lower right. Tighten bolts finger-tight first, then snug with the socket. Do not over-torque—these are small bolts and can strip easily
      • .
  8. Fill with fresh oil:
    • Place a funnel in the filler neck.
    • Pour in 2.6 quarts (2.5 liters) of quality 10W-40 motorcycle oil
      • .
    • Replace the filler cap and check that its O-ring is clean and undamaged.
    • Clean up any drips.
  9. Start and check:
    • Start the engine and let it run for 1-2 minutes. Watch for oil pressure and leaks around the filter cover and drain bolt.
    • Shut down the bike. Allow oil to settle, then check the sight glass. Add oil as needed to bring it up to the “Full” mark.
    • Dispose of old oil and filter in accordance with local environmental regulations.

Model-Specific Call-Outs for the 2016 Kawasaki KLR650

  • 2016 is a Gen 2 KLR650—21 ft-lb torque spec on the drain plug, not 17 ft-lb as for Gen 1 bikes
    • .
  • The oil filter cover O-ring is prone to pinching—ensure it is seated flat before reinstalling.
  • The oil capacity is 2.6 quarts; overfilling can cause leaks and foaming.
  • Never use automotive oil; always use motorcycle-specific oil for proper clutch and gearbox protection.
  • If the oil is unusually black, gritty, or smells burnt, investigate further as this may signal internal wear.

Final Inspection and Tips

  • Keep a maintenance log of your oil changes—note mileage and any observations.
  • Inspect for any leaks after your next ride, especially around the drain bolt and oil filter cover.
  • Replace your crush washer every oil change for best sealing performance.
  • Clean your work area and wash your hands thoroughly—old oil can be harmful if left on skin.

Changing the oil on your 2016 Kawasaki KLR650 is a straightforward job, but following these careful, model-specific steps helps ensure years of trouble-free riding. MotoSport.com recommends using only OEM or high-quality equivalent parts and lubricants to keep your KLR running strong—on the highway or the trail.

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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.