Target Audience:
Mechanics and DIY enthusiasts seeking to perform maintenance, repairs, and adjustments on the Kawasaki W650.
Comprehensiveness:
The most detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams available for the W650.
Readability:
Prepared with simple explanations for easy understanding by personnel of varying experience levels.
Benefits:
Enables owners to perform satisfactory after-services, disassembly, and maintenance, ensuring vehicle reliability and customer satisfaction.
Market Segment:
Retro motorcycle segment, competing with models from Triumph (Bonneville), Royal Enfield, and other manufacturers offering classic styling.
Covered Models:
Kawasaki W650 EJ650 (1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006)
Manual Type:
Workshop Service Repair Manual
Delivery:
Instant Download
Payment Methods:
Accepts all major credit/debit cards and PayPal.
Engine:
Detailed coverage including disassembly, assembly, inspection, and adjustment procedures for engine components, valve timing, ignition system, and lubrication system.
Fuel System:
Carburetor removal, installation, adjustment, and troubleshooting. Fuel tank and petcock servicing.
Transmission:
Clutch operation, removal, installation, and adjustment. Gearbox inspection, disassembly, and assembly procedures.
Chassis:
Frame inspection, fork assembly, shock absorber servicing, steering head bearing maintenance.
Electrical System:
Wiring diagrams, troubleshooting electrical faults, component testing (ignition, lighting, starter, charging system).
Brakes:
Front and rear brake system inspection, maintenance, and repair. Master cylinder and caliper servicing.
Wheels And Tires:
Wheel bearing maintenance, spoke tension adjustment, tire inspection and replacement.
Bodywork And Trim:
Fender, seat, fuel tank, and other body panel removal and installation.
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, and lubrication points.
Troubleshooting:
Diagnostic procedures for common issues related to starting, running, and electrical systems.
Repair:
Comprehensive step-by-step repair instructions for all major components and systems.
Disassembly Assembly:
Detailed procedures for taking apart and putting back together various vehicle components.
Adjustments:
Specific instructions for adjusting clutch, throttle, brakes, idle speed, and suspension.
Safety Precautions:
Includes safety measures for potentially dangerous procedures, indicated by DANGER, CAUTION, or NOTE remarks.
Depth Of Coverage:
From basic rider maintenance to complete engine and transmission overhauls, including detailed specifications and tolerances.
Troubleshooting Methodology:
Provides troubleshooting information including servicing specification lists, tightening torques, checking and adjusting procedures.
Specifications Data:
Contains service data, precautions, factory specifications, and allowable limits for components.
Pictorial Diagrams:
Detailed illustrations, exploded diagrams, drawings, and photos guide through every service repair procedure.
Tool References:
Includes reference to special service tool numbers and visual depiction of tool usage where necessary.
PDF Quality:
High-quality PDF, viewable on any computer, zoomable.
Printability:
All pages are printable for easy reference during work.
Operating Systems:
Compatible with Windows, Mac, and Linux OS.
Reader Software:
Requires Adobe Reader or compatible PDF viewer.
Integrity:
100% complete and intact, no missing/corrupt pages/sections guaranteed.
Engine Type:
Air-cooled, 4-stroke, SOHC, 2-valve, parallel-twin (as inferred from model history and typical W650 specifications, though not explicitly stated in provided text)
Displacement:
675 cc (as inferred from model history)
Carburetor Type:
Dual carburetors (likely Keihin, as per typical specifications)
Power Output:
Approximately 50 hp (as inferred from model history)
Torque Output:
Approximately 40 lb-ft (as inferred from model history)
Valve Adjustment:
Detailed procedures for valve clearance checking and adjustment are covered.
Ignition Timing:
Specifications and procedures for checking and adjusting ignition timing are included.
Oil Type:
Specific lubricant specifications are provided in the manual.
Oil Change Interval:
Specific interval for oil changes will be detailed in the maintenance schedule section.
Periodic Maintenance:
Accurate following of the periodic maintenance chart is essential for maximizing motorcycle life.
Engine Oil Type Spec:
The manual will specify the correct SAE viscosity grade and API service classification for engine oil.
Brake Fluid Type Spec:
Likely DOT 4 brake fluid will be specified.
Cooling System Fluid:
Not applicable, as the engine is air-cooled.
Common Wear Items:
The manual will provide information on wear limits for critical components like brake pads, clutch plates, and chain/sprockets.
Fastener Usage:
Emphasizes using correct OEM fasteners and highlights the importance of correct torque values during assembly.
