Model Variant:
Standard, R (Competition)
Covered Years:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Owners and independent mechanics seeking detailed repair and maintenance information for their Kawasaki KLX650 motorcycles.
Competitors:
Honda XR650L, Suzuki DR650SE, Yamaha XT600/XT660
Value Proposition:
Provides essential technical data and step-by-step procedures to maintain, diagnose, and repair the Kawasaki KLX650 across a significant production run, enabling owners to perform their own servicing and repairs.
Engine:
Full overhaul, top end, bottom end, cooling system, lubrication system, ignition system, carburetor/fuel injection (depending on specific model year variations)
Transmission:
Clutch, gearbox, shift mechanism, lubrication
Chassis:
Frame, suspension (front forks, rear shock absorber), swingarm, steering system, wheels, tires, brakes (front and rear disc brakes), drive chain and sprockets
Electrical:
Wiring diagrams, lighting, charging system (stator, regulator/rectifier), starting system (starter motor, battery), ignition system, instrumentation, sensors
Bodywork:
Fuel tank, seat, fenders, plastics, handlebars, controls, exhaust system
Maintenance:
Routine checks, oil changes, filter replacements, chain lubrication and adjustment, spark plug service, brake fluid flush, coolant checks
Troubleshooting:
Diagnostic procedures for common problems related to starting, running, electrical issues, and component failures
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation of major and minor parts
Adjustment:
Carburetor tuning, chain tension, suspension settings, brake lever adjustment, clutch free play
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and transmission rebuilds. Includes torque specifications, clearances, and detailed diagrams.
Digital Quality:
High-resolution, searchable PDF with clear diagrams and text. Typically printable.
Physical Attributes:
Likely a professionally bound manual, comparable to OEM service manuals. Paper quality and print clarity are crucial for durability in a workshop environment.
Physical Attributes:
Typically saddle-stitched or perfect bound for durability and ease of use.
Physical Attributes:
Durable, often coated paper to resist grease and moisture in a workshop setting.
Type:
Four-stroke, single-cylinder, DOHC, liquid-cooled
Displacement:
651 cc (652 cc in later models)
Bore X Stroke:
100.0 mm x 82.0 mm (approximate)
Compression Ratio:
9.5:1 (varies slightly by year)
Horsepower:
Approximately 45-50 HP at 6,500 RPM (varies by year and configuration)
Torque:
Approximately 39-42 lb-ft at 5,500 RPM (varies by year and configuration)
Carburetion:
Mikuni BST40 (CV carburetor) on most models. Some earlier or special editions might have different configurations.
Fuel Type:
Unleaded gasoline, octane rating 87 or higher
Fuel Tank Capacity:
Approximately 2.6 US gallons (9.8 Liters)
Type:
5-speed constant mesh manual transmission
Availability:
Not applicable, all KLX650 models featured a 5-speed manual transmission.
Clutch:
Wet multi-disc, cable-operated
Final Drive:
O-ring sealed chain, 520 pitch
Transmission Fluid Type:
API SG or SH SAE 10W-40 motorcycle oil
Overall Length:
Approx. 2,215 mm (87.2 in)
Overall Width:
Approx. 845 mm (33.3 in)
Overall Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,465 mm (57.7 in)
Ground Clearance:
Approx. 280 mm (11.0 in)
Seat Height:
Approx. 890 mm (35.0 in)
Dry Weight:
Approx. 143 kg (315 lbs)
Wet Weight:
Approx. 155 kg (342 lbs) (fully fueled)
Gross Vehicle Weight Rating Gvwr:
Not officially specified, but generally considered around 330 kg (727 lbs).
Crash Test Results:
Motorcycle safety is not typically rated by organizations like NHTSA or IIHS. Safety relies on rider skill and adherence to road laws.
Braking System:
Dual front disc brakes, single rear disc brake. Highly effective for its class.
Lighting:
Halogen headlight, taillight, brake lights, turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame for rigidity and impact absorption.
Handlebar Design:
Vibration-damping handlebars (rubber-mounted on some models) to reduce rider fatigue.
Features:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators. No advanced infotainment systems.
Features:
No electronic rider aids or driver assistance systems typically found on modern vehicles. Safety relies on mechanical systems and rider skill.
Features:
No onboard connectivity or Bluetooth features. Designed for rugged utility and performance.
Oil Change:
Every 3,000-4,000 miles (4,800-6,400 km) or 6 months. Check manual for exact interval.
Air Filter Cleaning:
Every 1,000-2,000 miles (1,600-3,200 km), or more frequently in dusty conditions.
Chain Cleaning And Lubrication:
Every 500-800 miles (800-1,300 km) and after riding in wet conditions.
Spark Plug Replacement:
Every 6,000-8,000 miles (9,600-12,800 km) or as per manual recommendations.
Brake Fluid Flush:
Every 2 years or as recommended by manual.
Engine Oil:
API SG or SH, JASO MA certified SAE 10W-40 motorcycle oil. Capacity approx. 2.0 liters.
Coolant:
Permanent type antifreeze coolant (ethylene glycol based) mixed with distilled water in a 50/50 ratio. Capacity approx. 1.5 liters.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Kawasaki KHL15-10 (10W) or equivalent fork oil. Capacity typically 360-370 ml per fork leg.
Common Problems:
Carburetor adjustment and cleaning (especially the CV carb), clutch wear over time, occasional stator failures, and potential for kickstand switch issues. The R model may require more frequent maintenance due to its performance focus.
Preventative Maintenance:
Regularly cleaning the air filter, ensuring proper chain tension, and checking for oil leaks are crucial for longevity.
Kawasaki Legacy:
Kawasaki has a long history of producing robust and capable motorcycles, including performance dirt bikes and dual-sport models.
Klx Lineage:
The KLX650 built upon Kawasaki's off-road expertise, bridging the gap between pure motocross bikes and street-legal dual-sport machines. It offered a potent single-cylinder engine suitable for both on-road commuting and off-road adventure.
Klx650 Specifics:
Introduced in 1993, the KLX650 was renowned for its torquey engine and capable chassis. The 'R' model offered higher performance with features like more suspension travel and a different carburetor setup for off-road competition.
Production Period:
1993-2007
Manufacturing Location:
Primarily Japan
