Kawasaki KLX 650 1987-2007 Workshop Service Repair Manual for Repai

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX 650 Vehicle Type: Dual-Sport Motorcycle Generation Production Years: 1987-2007 Codes Engine Code General: Likely a variant of Kawasaki's 650cc single-cylinder engine, specific...

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Type: Motorcycle

Vendor:

Sku: 450973

Tags: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Kawasaki KLX 650 KLX Series Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX 650

Vehicle Type:

Dual-Sport Motorcycle

Generation

Production Years:

1987-2007

Codes

Engine Code General:

Likely a variant of Kawasaki's 650cc single-cylinder engine, specific code not provided in product info.

👋 Introduction

Market Position

Segment:

Mid-size Dual-Sport Motorcycle, known for versatility and off-road capability.

Competitive Analysis

Competitors:

Likely competed with other Japanese manufacturers' dual-sport offerings in the 600-650cc class during its production run (e.g., Honda XR series, Suzuki DR series, Yamaha XT series).

Key Features

Versatility:

Designed for both on-road commuting and off-road trail riding, offering a balance of performance and durability.

Engine Type:

Robust single-cylinder engine, generally known for good torque and reliability.

Longevity:

The extended model year coverage (1987-2007) indicates a well-received and enduring platform with consistent updates or minimal changes over a significant period.

📋 Manual Details

Coverage Areas

Covered Model 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:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Digital Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including disassembly, assembly, inspection, repair, and adjustment of all internal components (pistons, rings, valves, camshaft, crankshaft, etc.).

Fuel System:

Carburetor service, adjustment, cleaning, and troubleshooting; fuel tank, fuel lines, and petcock inspection and repair.

Ignition System:

Spark plug inspection and replacement, ignition timing checks, CDI unit, and associated wiring.

Transmission:

Clutch operation, disassembly, inspection, and adjustment; gear shifting mechanisms, internal transmission components, and lubrication.

Suspension:

Front fork service (oil changes, seal replacement, spring inspection), rear shock absorber inspection and potential service, linkage adjustments.

Brakes:

Front and rear brake system maintenance, including hydraulic fluid replacement, caliper service, pad inspection and replacement, and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, lighting systems, starter motor, charging system (stator, rectifier/regulator), and fuses.

Cooling System:

If applicable (air-cooled engine likely, but may cover oil cooling if present), radiator, coolant levels, hoses.

Exhaust System:

Inspection, gasket replacement, and minor repairs.

Frame And Bodywork:

Frame inspection, fairing/plastics removal and installation, seat service.

Wheels And Tires:

Tire inspection, pressure checks, wheel bearing maintenance, spoke tensioning (if applicable).

Procedures Included

Maintenance:

Scheduled maintenance, routine checks, fluid changes, lubrication, filter replacements.

Troubleshooting:

Systematic diagnosis of common problems, including electrical, engine performance, and mechanical issues.

Repair:

Detailed, step-by-step instructions for removing, disassembling, inspecting, repairing, and reassembling all vehicle components.

Installation:

Correct procedures for installing new or rebuilt parts and components.

Disassembly Assembly:

Comprehensive guidance on taking apart and putting back together all major systems and components.

Adjustments:

Precise instructions for adjusting carburetor settings, clutch, brakes, suspension, and other critical parameters.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed specifications, diagrams, and troubleshooting guidance.

Pictorial Content:

Detailed illustrations, exploded diagrams, drawings, and photos for clear procedural guidance.

Special Tools:

References to specific service tool numbers and illustrations showing their usage where applicable.

Specifications:

Includes service data, factory specifications, allowable limits, and tightening torques for all components.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely searchable text within the PDF for quick information retrieval.

Print Quality

Printable:

Resolution:

Assumed to be high enough for clear printing of text and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Compatibility

Operating Systems:

Windows, Mac, Linux OS

Software Requirement:

Adobe Reader

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, 4-stroke, SOHC (Single Overhead Camshaft). Likely air-cooled, typical for this era of dual-sport.

Displacement:

651cc (This is a common displacement for models labeled '650' in this class, exact figure would be in the manual).

Performance

Horsepower:

Estimated around 45-50 HP, specific figures depend on the exact year and tuning, detailed in the manual.

Torque:

Strong low-to-mid range torque, characteristic of a larger displacement single-cylinder engine, detailed in the manual.

Fuel System

Carburetion:

Typically a single, larger-bore carburetor (e.g., Keihin CVK or similar) for fuel delivery. Specific model and size would be listed in the manual.

Fuel Type:

Unleaded gasoline, specified octane rating in manual.

🔧 Transmission

Standard

Type:

5-speed manual transmission.

Optional

Optional Transmissions:

None typically offered for this model.

Features

Clutch Type:

Wet multi-plate clutch, operated by cable.

Final Drive:

Chain drive.

📐 Dimensions

Exterior

Wheelbase:

Varies slightly by year, but generally around 57 inches (approx. 1450 mm). Specific measurement in manual.

Seat Height:

Tall, typical for dual-sport, likely around 35 inches (approx. 890 mm). Exact figure in manual.

Weights

Dry Weight:

Around 330-350 lbs (approx. 150-159 kg). Specific weight for various years in manual.

Fuel Capacity:

Typically around 4.0-4.5 gallons (approx. 15-17 liters). Exact capacity in manual.

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable in the same way as cars; relies on robust engineering and adherence to safety procedures outlined in the manual.

Active Features

Active Safety:

Effective braking systems (disc brakes front and rear), responsive handling.

Passive Features

Passive Safety:

Sturdy frame, protective bodywork (minimal on dual-sports), rider positioning.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable; this is a utilitarian motorcycle with minimal electronic amenities.

Driver Assistance

Rider Aids:

None (e.g., no ABS, no traction control). Focus is on mechanical reliability and rider skill.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 6 months, refer to manual for exact intervals and oil type.

Air Filter Cleaning:

Frequent checks and cleaning/replacement recommended, especially if used off-road. Specified interval in manual.

Chain Lubrication Adjustment:

Regularly, every 500-1000 miles, or after riding in wet conditions. Adjustments as needed per manual.

Fluid Specifications

Engine Oil:

Kawasaki recommends specific grades like SAE 10W-40 or 10W-50 motorcycle-specific oil. Exact API service classification and JASO MA/MA2 rating required, detailed in the manual.

Brake Fluid:

DOT 4 or DOT 5.1 (check manual for specific compatibility and replacement intervals).

Fork Oil:

Specific weight (e.g., 10W or 15W) and volume per fork leg, as per manual.

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, chain and sprockets, and potentially the cam chain tensioner can be common wear items over time.

Carburetor Issues:

Older carburetors can experience issues with fuel leakage, clogged jets, or worn diaphragms, requiring cleaning and rebuilding.

Electrical Gremlins:

Older wiring harnesses can develop corrosion or breaks, leading to intermittent electrical problems.

📚 Vehicle History

Brand Heritage

Kawasaki Heritage:

Kawasaki has a long and distinguished history in motorcycle manufacturing, particularly in sportbikes and off-road models, known for performance and innovation.

Model Evolution

Klx Lineage:

The KLX line represents Kawasaki's commitment to off-road and dual-sport motorcycles. The KLX 650 was a significant model in this range for its displacement and versatility.

Production

Production Span:

The extended production run from 1987 to 2007 indicates a successful and well-regarded platform that underwent refinements but maintained its core identity.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards not highlighted in product information, but the extended production run suggests strong market acceptance and reliability.