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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类型: Motorcycle

斯库: 450973

标签: 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

产品多属性

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.