Market Position:
The Kawasaki Z650 (KZ650) was a highly successful and popular middleweight motorcycle in the late 1970s, known for its smooth inline-four engine and accessible performance.
Competitive Analysis:
Competed with models like the Honda CB650, Yamaha XS650, and Suzuki GS650, offering a refined riding experience and a good balance of power and handling.
Key Features:
Smooth DOHC inline-four engine, accessible performance, comfortable riding posture, reliable mechanicals.
Engine:
Complete engine overhaul, internal components, lubrication system, cooling system (air-cooled), ignition system, fuel system (carburetors)
Transmission:
Gearbox disassembly, assembly, clutch operation, maintenance
Chassis:
Frame, suspension (front fork, rear shock absorbers), steering system
Electrical:
Wiring diagrams, lighting, charging system (alternator, battery), ignition system, starter motor
Brakes:
Front disc brake system, rear drum brake system, hydraulic components
Fuel System:
Carburetor identification (e.g., Mikuni VM series), tuning, maintenance, fuel tank, petcock
Exhaust System:
Removal, installation, and general inspection
Wheels And Tires:
Tire pressure, wheel bearing maintenance, spoke tensioning (if applicable)
Bodywork:
Fenders, side covers, seat, handlebars
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment
Troubleshooting:
Diagnostic guides for common issues, identification of problems and solutions
Repair:
Detailed step-by-step instructions for component repair and replacement
Disassembly Assembly:
Comprehensive guidance for taking apart and putting together all major components
Adjustments:
Carburetor synchronization, ignition timing, valve clearance, brake adjustments, suspension setup
Installation:
Procedures for installing new or replacement parts
Technical Depth:
Comprehensive, from basic maintenance to full engine rebuilds and advanced diagnostics.
Illustrations:
Detailed pictorial diagrams, exploded views, drawings, and photos
Special Tools:
Identification and usage of special service tools required for specific procedures
Specifications:
Service data, critical measurements, factory specifications, allowable limits, torque values
Engine Displacement:
652cc
Bore X Stroke:
62.0 mm x 54.0 mm
Compression Ratio:
8.7:1 (typical)
Valve Train:
DOHC, 2 valves per cylinder
Horsepower:
Approx. 64 hp @ 8,500 rpm (varies slightly by year/model)
Torque:
Approx. 37 lb-ft @ 7,000 rpm (varies slightly by year/model)
Carburetors:
4 x Mikuni VM24SS or VM26SS (depending on year/market)
Fuel Tank Capacity:
Approximately 3.7 US gallons (14 liters)
Oil Type:
API SE, SAE 10W-40 or 20W-40 motorcycle oil
Oil Capacity:
Approx. 2.9 US quarts (2.7 liters) with filter change
Oil Change Interval:
Every 3,000-4,000 miles (4,800-6,400 km) or 6 months.
Air Filter Cleaning:
Every 3,000 miles (4,800 km) or as needed based on conditions.
Spark Plug Replacement:
Every 6,000-8,000 miles (9,600-12,800 km) or as specified by manual.
Valve Clearance Check:
Every 6,000-8,000 miles (9,600-12,800 km).
Engine Oil Grade:
SAE 10W-40 or 20W-40 (API SE)
Brake Fluid:
DOT 3 or DOT 4 brake fluid (ensure compatibility with original seals).
Fork Oil Type:
Approx. SAE 10W motorcycle fork oil.
Known Issues:
Carburetor synchronization issues, cam chain wear, electrical connector corrosion, fork seal leaks.
Common Wear Items:
Clutch plates, brake pads/shoes, fork seals, battery, tires.
Brand Heritage:
Kawasaki Heavy Industries has a long history of producing high-performance motorcycles, particularly known for its powerful 'Z' series of bikes.
Model Evolution:
The Z650 was introduced as a more refined and smoother alternative to the larger Z1/Z900, offering a potent inline-four experience in a more manageable package. It served as a foundational model for future Kawasaki inline-fours.
Production Period:
1976-1983 (though this manual specifically covers the early '76-'80 models).
Manufacturing Locations:
Japan
