Model Variant:
KZ650-B1, KZ650-C1, KZ650-D1, KZ650-E1, KZ650-F1
Years Covered:
1978, 1979, 1980
Vin Range:
KZ650-B1 (1978): 60001-65350; KZ650-C1 (1978): 10001-11100; KZ650-D1 (1978): 20001-21100; KZ650-E1 (1978): 30001-30300; KZ650-F1 (1978): 40001-40400; KZ650-B2 (1979): 65351-71500; KZ650-C2 (1979): 11101-12200; KZ650-D2 (1979): 21101-22200; KZ650-E2 (1979): 30301-30700; KZ650-B3 (1980): 71501-80000; KZ650-C3 (1980): 12201-13300; KZ650-D3 (1980): 22201-23300; KZ650-F2 (1980): 40401-40700
Positioning:
The Kawasaki KZ650 was a significant model in the mid-size motorcycle market of the late 1970s and early 1980s, offering a balance of performance, reliability, and styling. It served as a popular all-around motorcycle, suitable for commuting, touring, and sport riding.
Competitors:
Competed with models like the Honda CB650, Yamaha XS650, and Suzuki GS650. The KZ650 was often praised for its smoother inline-four engine compared to the parallel-twin rivals.
Engine Configuration:
Inline-four cylinder, air-cooled.
Shaft Drive Option:
The KZ650-E model offered shaft drive, a premium feature at the time, while other models featured chain drive.
Handling:
Known for its good handling characteristics and comfortable riding position.
Design Evolution:
Represented Kawasaki's evolution towards more refined multi-cylinder engines.
Engine:
Complete overhaul, tuning, carburetor service, ignition system, cooling system, lubrication system.
Transmission:
Gearbox disassembly and reassembly, clutch service, shift mechanism, lubrication.
Drivetrain:
Chain and sprocket maintenance, final drive inspection.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber adjustment and replacement, swingarm maintenance.
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad replacement.
Electrical:
Wiring diagrams, charging system (alternator, rectifier/regulator), ignition system components (CDI, coils, spark plugs), lighting, starting system, battery maintenance, troubleshooting electrical faults.
Fuel System:
Carburetor identification, disassembly, cleaning, synchronization, jetting, fuel tank maintenance, petcock service.
Exhaust System:
Muffler and pipe inspection, gasket replacement.
Bodywork And Frame:
Frame inspection, body panel removal and installation, seat, tank, side covers, fenders.
Maintenance:
Regular service, oil changes, filter replacements, chain adjustment, brake adjustments, valve clearance checks.
Troubleshooting:
Step-by-step diagnostic procedures for common issues, symptom-based troubleshooting guides.
Repair:
Detailed instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine, carburetor, and brake system overhaul procedures.
Adjustments:
Carburetor synchronization, ignition timing, clutch and throttle cable adjustments, suspension adjustments.
Depth:
Comprehensive. Covers everything from basic rider maintenance to full engine and transmission rebuilds, including detailed troubleshooting and electrical diagnostics.
Type:
Four-stroke, DOHC, air-cooled, inline-four cylinder
Displacement:
652 cc (40.0 cu in)
Bore X Stroke:
62.0 mm x 54.0 mm (2.44 in x 2.13 in)
Horsepower:
Approximately 64 hp @ 9000 rpm (claimed)
Torque:
Approximately 37.7 lb-ft @ 7500 rpm (claimed)
Carburetors:
Four Mikuni VM26SC, constant velocity
Fuel Tank Capacity:
17.0 L (4.5 US gal)
Ignition System:
Electronic Ignition (CDI)
Lubrication System:
Wet sump
Starter System:
Electric starter
Overall Length:
Approx. 2,180 mm (85.8 in)
Overall Width:
Approx. 770 mm (30.3 in)
Overall Height:
Approx. 1,150 mm (45.3 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Dry Weight:
Approx. 200 kg (441 lbs) for chain drive models
Wet Weight:
Approx. 215 kg (474 lbs) for chain drive models
Front Wheel:
18-inch spoke
Rear Wheel:
18-inch spoke
Bolt Pattern:
N/A (Spoked wheels)
Safety Features:
Standard motorcycle safety equipment for the era. Emphasis on reliable braking and stable handling.
Braking System:
Dual front disc brakes, single rear disc brake (standard on most models, some earlier models may have had drum rear).
Lighting:
Halogen headlight, taillight, turn signals.
Infotainment System:
N/A (Classic motorcycle, no integrated infotainment)
Driver Assistance Systems:
N/A (Classic motorcycle, no driver assistance features)
Connectivity Options:
N/A (Classic motorcycle, no connectivity features)
Oil Change:
Every 3,000 km (1,860 miles) or 6 months.
Oil Filter Replacement:
Every 6,000 km (3,720 miles) or 12 months.
Air Filter Cleaning:
Every 3,000 km (1,860 miles), replace every 6,000 km (3,720 miles).
Spark Plug Replacement:
Every 6,000 km (3,720 miles).
Valve Clearance Check:
Every 6,000 km (3,720 miles) or 12 months.
Chain Adjustment:
Every 1,000 km (620 miles) or as needed.
Engine Oil Type:
SAE 10W-40 API SE or SF
Brake Fluid Type:
DOT 3 or DOT 4
Engine Oil Capacity W Filter:
2.7 L (2.9 US qt)
Engine Oil Capacity Wo Filter:
2.5 L (2.6 US qt)
Carburetor Issues:
Diaphragm degradation, jet clogging, synchronization drift. Requires regular cleaning and tuning.
Electrical Issues:
Rectifier/regulator failure, aging wiring harnesses, starter motor issues.
Engine Wear:
Cam chain tensioner noise, potential piston ring wear on high-mileage examples.
Suspension Wear:
Fork seal leaks, worn rear shock absorbers.
Oil Filter Part Number Example:
Hiflofiltro HF101, K&N KN-101 (check compatibility)
Spark Plug Part Number Example:
NGK CR9E (check specific model for exact spec)
Heritage:
Kawasaki has a long history of producing performance-oriented motorcycles, known for their innovative engineering and powerful engines. The KZ series continued this legacy.
Kz Lineage:
The KZ650 was introduced as a more refined and powerful alternative to the popular KZ400 and KZ500 models, and as a four-cylinder successor to the parallel-twin KZ650 models from the 1970s. It set the stage for larger KZ models like the KZ750 and KZ1000.
Production Period:
1978-1980 (for this specific manual coverage).
Manufacturing Location:
Japan
