Target User:
Enthusiasts and professional mechanics performing maintenance, diagnostics, and repairs on the Kawasaki KLX 650.
Utility:
Essential resource for maintaining optimal performance, reliability, and longevity of the KLX 650 motorcycle.
Competitor Manuals:
Comparable to official Kawasaki factory service manuals in terms of depth and detail.
Content Focus:
Emphasis on practical repair procedures, clear diagnostics, and accurate specifications for the KLX 650 model.
Engine Systems:
Complete engine overhaul, top-end, bottom-end, cooling system, lubrication system, fuel system (carburetor tuning and rebuild), ignition system, exhaust system.
Transmission Systems:
Clutch operation and adjustment, gearbox inspection and repair, shift mechanism, transmission fluid specifications and change intervals.
Chassis Systems:
Frame inspection, suspension fork service (oil change, seal replacement), rear shock absorber maintenance, steering head bearing service, swingarm and linkage maintenance.
Braking Systems:
Front and rear brake caliper service, master cylinder rebuild, brake fluid type and bleeding procedures, brake pad replacement, rotor inspection.
Electrical Systems:
Wiring diagrams, charging system (stator, rectifier/regulator), starting system (starter motor, battery), lighting system (headlight, taillight, indicators), ignition coil troubleshooting, sensor diagnostics.
Fuel System Details:
Carburetor model (e.g., Keihin CVK), jetting specifications, float height adjustment, idle mixture screw settings, fuel filter replacement.
Maintenance Procedures:
Routine checks, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, valve clearance adjustment.
Repair Procedures:
Engine disassembly and reassembly, transmission rebuild, carburetor overhaul, suspension fork rebuild, brake system repairs, electrical component replacement.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common issues such as starting problems, poor performance, electrical faults, and braking irregularities.
Diagnostic Capabilities:
Detailed troubleshooting charts, expected readings for electrical components (resistance, voltage), torque specifications for critical fasteners, timing procedures.
Rebuild Information:
Comprehensive instructions for complete engine and transmission rebuilds, including piston ring gap specifications, bearing clearances, and component tolerances.
Engine Type:
4-stroke, Single Cylinder, DOHC, 4 valves
Displacement:
652 cc (651.9 cc)
Bore X Stroke:
100.0 mm x 83.0 mm
Cooling System:
Liquid-cooled
Horsepower:
Approx. 47 HP (varies by market and tuning)
Torque:
Approx. 38 lb-ft (varies by market and tuning)
Fuel Delivery:
Carburetor (e.g., Keihin CVK36 or similar)
Fuel Type:
Unleaded gasoline, 87 octane minimum recommended
Ignition Type:
Digital CDI
Overall Length:
Approx. 2,200 mm (Varies by specific model year)
Overall Width:
Approx. 800 mm (Varies by specific model year)
Overall Height:
Approx. 1,235 mm (Varies by specific model year)
Wheelbase:
Approx. 1,470 mm (Varies by specific model year)
Ground Clearance:
Approx. 255 mm
Dry Weight:
Approx. 169 kg
Wet Weight:
Approx. 182 kg (Includes fluids)
Fuel Capacity:
Approx. 14 Liters (3.7 US gal)
Oil Capacity:
Approx. 2.4 Liters (with filter change)
Crash Test Data:
N/A for motorcycles; manual focuses on mechanical safety.
Braking System Type:
Dual hydraulic disc front, single hydraulic disc rear
Front Brake Spec:
260 mm disc, dual piston caliper
Rear Brake Spec:
240 mm disc, single piston caliper
Lighting:
Halogen headlight, LED taillight and brake light, incandescent turn signals.
Tire Sizes:
Front: 90/90-21, Rear: 130/90-17 (typical, verify with specific model year)
Infotainment System:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light.
Driver Assistance Features:
N/A for this model.
Connectivity Features:
N/A for this model.
Engine Oil Change:
Every 6,000 km or 6 months, whichever comes first (typical, refer to manual for exact specification).
Oil Filter Replacement:
With every oil change.
Air Filter Cleaning:
Every 6,000 km or 6 months; replacement as needed.
Spark Plug Replacement:
Every 12,000 km or 12 months.
Valve Clearance Check:
Every 12,000 km or 12 months.
Chain Lubrication Adjustment:
Every 1,000 km or as needed, adjust for proper slack.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 10W-50 motorcycle oil.
Coolant Type:
Permanent type anti-freeze coolant (ethylene glycol based), mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets, carburetor gaskets.
Potential Engine Problems:
Valve seat wear (less common), carburetor jet clogging due to fuel varnish, stator failure (rare).
Electrical Quirks:
Rectifier/regulator failure can lead to battery charging issues; wiring harness connections can corrode over time.
Kawasaki Motorsports:
Kawasaki has a long and storied history in motorsports, including success in Superbike, motocross, and off-road racing, contributing to the development of models like the KLX.
Klx Lineage:
The KLX series is Kawasaki's line of dual-sport and off-road motorcycles, known for their versatility and off-road capability. The KLX 650 was positioned as a larger displacement, more powerful option within this line.
Production Years:
Typically produced from 1993 to 1996 (may vary slightly by region).
Manufacturing Location:
Japan
