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Kawasaki KLX650 1987-2007 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX650 Codes Engine Code Range: KLE650A 👋 Introduction Market Position Segment: Dual-sport / Enduro motorcycle segment. Competitive Analysis Competitors: Competed against models like...
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Taper: Motorcycle
Distributeur:
Kawasaki
UGS: 390527
Mots clés: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Kawasaki KLX Series KLX650 Motorcycle Motorcycles
Kawasaki KLX650 1987-2007 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX650
Codes
Engine Code Range:
KLE650A
👋 Introduction
Market Position
Segment:
Dual-sport / Enduro motorcycle segment.
Competitive Analysis
Competitors:
Competed against models like Honda XR series, Yamaha TT series, Suzuki DR series during its production run.
Key Features
Durability:
Known for its robust construction and reliability, making it suitable for both on-road and off-road use.
Versatility:
Adaptable for commuting, trail riding, and light off-road exploration.
User Base:
Popular with DIY mechanics and owners seeking to maintain and repair their motorcycles independently.
📋 Manual Details
Coverage Areas
Applicable Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Page Count
Total Pages:
357
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine assembly, disassembly, inspection, repair, tuning, and troubleshooting.
Fuel System:
Carburetor (model specific) tuning, cleaning, rebuilding, fuel pump, fuel lines, and tank servicing.
Ignition System:
CDI unit, spark plugs, ignition coils, timing adjustments, and troubleshooting.
Transmission:
Clutch operation, gear shifting mechanisms, transmission disassembly and assembly, lubrication.
Cooling System:
Radiator, coolant flow, fan operation (if applicable), thermostat, and hose servicing.
Exhaust System:
Muffler, header pipes, exhaust gaskets, and emissions control components.
Suspension:
Front forks (telescopic), rear shock absorber, spring rates, damping adjustments, seals, and bushings.
Brakes:
Front and rear brake calipers, master cylinders, brake pads, brake discs, hydraulic lines, bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, lighting systems, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid).
Wheels And Tires:
Spoke wheel maintenance, tire replacement, balancing, wheel bearing service.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, and fairing components.
Procedures Included
Maintenance:
Regular maintenance tasks, lubrication points, fluid changes, filter replacements, chain adjustment.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding charts.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Comprehensive guides for taking apart and reassembling all major and minor components.
Adjustments:
Carburetor idle speed, mixture, throttle cable, clutch cable, brake lever adjustments.
Special Tools:
Identification and usage instructions for specific Kawasaki service tools required for various procedures.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance and routine service to complete engine rebuilds and complex electrical diagnostics.
Detail Level:
Detailed step-by-step procedures, accompanied by clear illustrations, exploded diagrams, and photographs.
Data Precision:
Includes critical specifications such as torque values, measurement tolerances, wear limits, and fluid capacities.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Fully printable, high-resolution pages.
Binding Type
Binding:
Digital (PDF) - No physical binding.
Paper Type
Paper Quality:
N/A (Digital format)
Software Requirement
Reader:
Adobe Reader required for viewing.
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux operating systems.
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, liquid-cooled, DOHC, single-cylinder.
Displacement:
651 cc (approximately, varies slightly by sub-model and region)
Bore X Stroke:
94.0 x 93.0 mm (typical for later models, confirm specific year)
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower:
Approx. 47-50 hp (at crankshaft, varies by year and tuning)
Torque:
Approx. 42-45 Nm (at crankshaft, varies by year and tuning)
Fuel System
Carburetor:
Keihin CVK34 (typical, may vary by year)
Fuel Type:
Unleaded gasoline
Oil Capacity
With Filter Change:
Approx. 2.3 L (refer to manual for exact specification)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Optional
Availability:
N/A (no automatic transmission offered)
Features
Clutch Type:
Wet, multi-disc, manual operation
Lubricant Spec
Transmission Oil:
Kawasaki genuine motorcycle oil or equivalent API SG, SF, SE SAE 10W-40 (refer to manual for specific grade)
📐 Dimensions
Exterior
Length:
Approx. 2,235 mm (refer to manual for specific year variations)
Width:
Approx. 890 mm (refer to manual for specific year variations)
Height:
Approx. 1,230 mm (refer to manual for specific year variations)
Weights
Dry Weight:
Approx. 156 kg (refer to manual for specific year variations)
Curb Weight:
Approx. 170 kg (fully fueled, refer to manual)
Fuel Capacity
Tank Size:
Approx. 12 Liters (refer to manual for specific year variations)
🛡️ Safety Features
Ratings
NHTSA Rating:
N/A (Motorcycle safety ratings are not directly comparable to automobiles).
Active Features
Braking System:
Disc brakes front and rear for reliable stopping power.
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
Passive Features
Frame Construction:
Sturdy steel frame designed for stability and rider control.
Warnings
Manual Emphasis:
Manual highlights DANGER, CAUTION, and NOTE warnings for safe operation and to prevent damage.
💡 Technology Features
Infotainment
Features:
Basic analogue instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems.
Driver Assistance
Features:
N/A (No electronic rider aids like ABS or traction control are featured on these models).
Connectivity
Features:
N/A (No Bluetooth or smartphone connectivity).
🔧 Maintenance
Service Intervals
Oil Change:
Recommended every 3,000-5,000 km or annually (refer to manual's periodic maintenance chart).
Air Filter:
Inspect every 1,000-2,000 km, clean or replace as needed (refer to manual).
Spark Plug:
Replace every 8,000-12,000 km, inspect and gap at intermediate intervals (refer to manual).
Chain Maintenance:
Lubricate and adjust chain tension every 500-1,000 km.
Fluid Specifications
Engine Oil Type:
JASO MA certified motorcycle engine oil, SAE 10W-40 recommended.
Coolant Type:
Kawasaki-specified coolant (ethylene glycol base) or equivalent anti-freeze/coolant.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Carburetor Gumming:
Can occur if the motorcycle sits for extended periods without fuel stabilizer, requiring cleaning.
Cam Chain Tensioner:
Some models may develop a noisy cam chain tensioner over time, which is a replaceable part.
Fork Seals:
Wear and tear on fork seals can lead to oil leaks, especially with hard off-road use.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long and storied history in motorcycle racing and performance engineering.
Model Evolution
Klx Lineage:
The KLX series has evolved from early dual-sport designs, with the KLX650 representing a significant iteration for off-road capability and trail use.
Production
Production Period:
1987-2007, indicating a long and successful production run with minor updates over the years.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the KLX650 are not widely documented, it was well-regarded in its segment for performance and durability.
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