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Kawasaki 1993 KLX650R Service Manual

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KLX650R
Kawasaki
KLX650
Motorcycle
Service Manual
Kawasaki Heavy Industries. Ltd. 1993
First Edition (1) : Jan. 20, 1993 (C)

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  Summary of Contents for Kawasaki 1993 KLX650R

  • Page 1 KLX650R Kawasaki KLX650 Motorcycle Service Manual Kawasaki Heavy Industries. Ltd. 1993 First Edition (1) : Jan. 20, 1993 (C)
  • Page 2 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 3 , could result in personal nance. injury, or loss of life. • Use proper tools and genuine Kawasaki Motorcy- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcy-...
  • Page 4 This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of partic- ular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done. O Indicates a procedural sub-step or how to do the work of the procedural step it follows.
  • Page 5 E M I S S I O N C O N T R O L I N F O R M A T I O N To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
  • Page 6 NOTE The phrase "remove or render inoperative any device or element of design" has been generally interpreted follows: 1. Tampering does not include temporary or rendering inoperative of devices elements of design in order to perform maintenance. 2. Tampering could include: a.
  • Page 7 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal / Installation Crankshaft / Transmission Wheels / Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference guide will assist you in locating a desired topic or procedure.
  • Page 8: Table Of Contents

    GENERAL INFORMATION 1 General Information Table of Contents Before Servicing 1 -2 Model Identification 1 -4 General Specifications Periodic Maintenance Chart - KLX650A 1-12 Periodic Maintenance Chart - KLX650C 1-14 Technical Information 1 - Two - Stage Cam Drive System 1 -16 Technical Information 2 - Interlock Circuit (KLX650C) 1 -17...
  • Page 9: Before Servicing

    GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 10: General Information

    GENERAL INFORMATION Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevent races and balls or needles from being dented.
  • Page 11: Model Identification

    GENERAL INFORMATION Model Identification KLX650-A1 (US Model)
  • Page 12 GENERAL INFORMATION KLX650-A1 (Europe Model)
  • Page 13 GENERAL I N F O R M A T I O N KLX650-C1 (US Model)
  • Page 14 GENERAL INFORMATION KLX650-C1 (Europe Model)
  • Page 15: General Specifications

    GENERAL INFORMATION General Specifications Items KLX650-A1 Dimensions: Overall length 2215 mm Overall width 925 mm Overall height 1230 mm Wheelbase 1490 mm Road clearance 330 mm Seat height 950 mm Dry weight 127 kg Curb weight: Front 63 kg Rear 74 kg Fuel tank capacity Performance:...
  • Page 16 GENERAL INFORMATION KLX650-A1 Items Drive Train: Primary reduction system: Type Gear Reduction ratio 2.272 (75/33) Wet multi disc Clutch type Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.266 (34/15) 1.529 (26/17) 1.181 (26/22) 0.954 (21/22) 0.791 (19/24) Final drive system: Chain drive Type 3.500 (49/14)
  • Page 17 1-10 GENERAL INFORMATION KLX650-C1 Items Dimensions: 2250 mm, (FG)(GR)(NR)(SD)(ST) 2265 mm Overall length (IT) 2285 mm Overall width 900 mm 1190 mm Overall height 1510 mm Wheelbase 265 mm Road clearance Seat height 885 mm 153 kg, (CA) 154 kg Dry weight Curb weight: Front...
  • Page 18 GENERAL INFORMATION 1-11 Items KLX650-C1 Drive Train: Primary reduction system: Gear Type Reduction ratio 2.272 (75/33) Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.266 (34/15) 1.529 (26/17) 1.181 (26/22) 0.954(21/22) 0.791 (19/24) Final drive system: Chain drive Type 2.866 (43/15)
  • Page 19: Periodic Maintenance Chart - Klx650A

    1-12 G E N E R A L I N F O R M A T I O N Periodic Maintenance Chart - KLX650A The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
  • Page 20 GENERAL INFORMATION 1-13 (*) : Replace, add, adjust, clean, or torque if necessary. : Replace • : Service more frequently when operated in a race. (US) : U.S. model...
  • Page 21: Periodic Maintenance Chart - Klx650C

    1-14 G E N E R A L I N F O R M A T I O N Periodic Maintenance Chart - KLX650C The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
  • Page 22 GENERAL INFORMATION 1-15 ( t ) : For higher odometer readings, repeat at the frequency interval established here. (*): Replace, add, adjust, clean, or torque if necessary. (CA) : California Model (US) : U.S. Model...
  • Page 23: Technical Information 1 - Two - Stage Cam Drive System

    1-16 GENERAL INFORMATION Technical Information 1 - T w o - Stage Cam Drive System By unsing a two-stage camshaft chain drive on this double overhead-cam engine, the camshaft sprockets can be made smaller. Accordingly, the space between the camshafts can be narrowed for a better looking design, allowing the KLX650 to have such a compact engine that does not seem to have double overhead cams.
  • Page 24: Technical Information 2 - Interlock Circuit (Klx650C)

    GENERAL INFORMATION 1-17 Technical Information 2 - Interlock Circuit (KLX650C) The interlock circuit is designed so the motorcycle will not run when the side stand is d o w n . The side stand switch is operated by the side stand, and kills the engine by preventing ignition. W h e n Side Stand is Down: When the side stand is d o w n , the side stand switch is turned ON and micro current flows into the CDI unit and stops ignition sparks.
  • Page 25 1-18 GENERAL INFORMATION When Side Stand is Up: When the side stand is up, the side stand switch is turned OFF and the ignition system can work. Summary: The interlock circuit controls the ignition system and the starter system as follows. After all, the new system (closed stop type) has the same operation as the conventional system (open stop type).
  • Page 26: Technical Information 3 - Electrofusion Cylinder (Klx650A)

    GENERAL INFORMATION 1-19 Technical Information 3 - Electrofusion Cylinder (KLX650A) Electrofusion is a steel-molybdenum manufacturing treatment of the cylinder bore. The process involves using high voltage to alternately explode thin high-carbon steel wires [A] and thin molybdenum wires directly inside the aluminum cylinder bore. Multiple explosions apply alternating layers of molybdenum and high-carbon steel.
  • Page 27: Torque And Locking Agent

    1-20 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the The table below, relating tightening torque to thread major fasteners requiring use of a non-permanent locking diameter, lists the basic torque for the bolts and nuts. Use agent or liquid gasket.
  • Page 28 GENERAL INFORMATION 1-21 Fastener Torque Remarks Remarks l\l-m kg-m ft-lb 10 mm Engine Mounting Bolts and Nuts 8 mm Engine Mounting Bolts and Nuts 0.90 Oil Pipe Bolt 78 in-lb Oil Pipe Banjo Bolts 14.5 Cylinder Head Bolts S, M (washer, threads) Cylinder Head Allen Bolts Cylinder Head Nuts...
  • Page 29 1-22 GENERAL INFORMATION Fastener Fastener Torque Remarks Remarks kg-m f t - l b Crankshaft/Transmission: Engine Drain Plug Engine Drain Allen Bolt 18.0 Crankcase Bolts 08 mm 18.0 ct>6 mm Allen 104 in-lb cp6 mm 87 in-lb Kickstarter Stopper Bolts (650A) 0.90 78 in-lb Main Bearing Retainer Screws...
  • Page 30 GENERAL INFORMATION 1-23 Fastener Torque Remarks Remarks kg-m N - m ft-lb Rear Disc Bolts 16.5 Rear Master Cylinder Bracket Locknut 13.0 Suspension: Front Fork Air Screws 0.12 10 in-lb Front Fork Upper Clamp Bolts 14.5 Front Fork Lower Clamp Bolts 18.0 Front Fork Top Plugs Push Rod Nut...
  • Page 31: Special Tools And Sealant

    1-24 GENERAL INFORMATION Special Tools and Sealant...
  • Page 32 GENERAL INFORMATION 1-25...
  • Page 33 1-26 GENERAL INFORMATION...
  • Page 34 GENERAL INFORMATION 1-27...
  • Page 35 1-28 GENERAL INFORMATION...
  • Page 36 GENERAL INFORMATION 1-29...
  • Page 37: Cable, Wire And Hose Routing

    1-30 GENERAL IWFORMATION Cable, Wire and Hose Routing 1. Choke Cable 7. Engine Breather Hose 2. Throttle Cables 8. CDI Unit (KLX650C) 3. Reserve Tank Hose 9. Reserve Tank Vent Hose, 4. Clutch Cable 10. CDI Unit (KLX650A) or 5. Rear Brake Light Switch Battery (KLX650C) (KLX650C) 11.
  • Page 38 GENERAL INFORMATION 1-31 K L X 6 5 0 A Headlight 2. Lighting Switch 3. Brake Hose 4. Throttle Cables 5. Odometer Cable 6. Choke Cable 7. Clutch Cable 8. Ignition Coil 9. Taillight 10. Regulator 1 1 . Headlight Capacitor 12.
  • Page 39 1-32 GENERAL INFORMATION KLX650C 1. Clutch Cable 2. Throttle Cables 3. Head Pipe 4. Main Harness 5. Left Handlebar Switch Leads 6. Right Handlebar Switch Leads 7. Turn Signal Relay 8. Headlight Diode (US, AS) 9. Headlight Relay (US, AS) 10.
  • Page 40 GENERAL INFORMATION 1-33 KLX650C 1. Throttle Cables 2. Choke Knob 3. Brake Hose 4. Right Handlebar Switch Leads 5. Clutch Cable 6. Left Handlebar Switch Leads 7. Main Harness 8. Speedometer Cable 9. Choke Cable 10. Horn 11. Horn (Italy) 12.
  • Page 41 1-34 GENERAL INFORMATION...
  • Page 43 1-36 GENERAL INFORMATION...
  • Page 44 FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View Air Cleaner Element Removal 2-18 Specifications Air Cleaner Element Installation 2-18 Throttle Grip and Cables Air Cleaner Element Cleaning and Inspection ...2-19 Grip Free Play Inspection Air Cleaner Draining (KLX650C) 2-20 Grip Free Play Adjustment Air Cleaner Housing Removal (KLX650A)
  • Page 45: Exploded View

    2-2 FUEL SYSTEM Exploded View 1. Throttle Cables 2. Choke Cable 3. Pilot Screw 4. Pilot Jet 5. Needle Jet 6. Needle Jet Holder 7. Main Jet 8. Jet Needle 9. Canister 10. Separator 1 1 . Canister Guard 12. Coasting Enricher The device prevents back firing during engine braking by supplying a rich fuel mixture to the engine.
  • Page 46 FUEL S Y S T E M 2 - 3 KLX650A KLX650C (CA): California OR: Apply high-quality-foam-air-filter oil. T1: 0.8 N-m (0.08 kg-m, 7 in-lb) T2: 5.9 N-m (0.60 kg-m, 52 in-lb)
  • Page 47: Specifications

    2-4 FUEL SYSTEM Specifications KLX650A S t a n d a r d Item T h r o t t l e Grip Free Play 2 ~ 3 mm Carburetor Make, type KE1HIN, CVK40 Idle speed Slowest smooth idle speed Pilot screw (turns out) 1 7/8 ±...
  • Page 48 FUEL SYSTEM 2-5 KLX650C Main Air Jet [F] Pilot Screw [A] Pilot Jet [B] Valve Seat [G] Jet Needle [C] Float Valve [ H ] Needle Jet [D] Jet Needle Holder [I] Pilot Air Jet [E] Main Jet [J] Special Tools - Pressure Cable Luber: K56019-021 Pilot Screw A ljuster, A: 57001 -1239 Fuel Level Gauge: 57001-1017...
  • Page 49: Throttle Grip And Cables

    FUEL SYSTEM Throttle Grip and Cables If the throttle grip has excessive free play due to cable stretch or maladjustment, there will be a delay in throttle response. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic.
  • Page 50: Throttle Cable Removal

    FUEL SYSTEM Throttle Cable Removal • Remove: Fuel Tank (see this chapter) • Take off the adjusting nuts [ A ] at the carburetor. • Slip the inner cable tips [B] out of the lever. • Remove the right hand guard of the brake lever (KLX650A). •...
  • Page 51: Throttle Cable Lubrication And Inspection

    FUEL SYSTEM AWARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition. Throttle Cable Lubrication and Inspection •Whenever the cables are removed, and in accordance with the Periodic Maintenance Chart, lubricate the throttle cables (see General Lubrication in the Appendix chapter).
  • Page 52: Carburetor

    FUEL SYSTEM 2-9 Carburetor Since the carburetor regulates and mixes the fuel and air going into the engine, there are two general types of carburetor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.
  • Page 53: Service Fuel Level Inspection

    2-10 FUEL SYSTEM Service Fuel Level Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 54: Fuel System Cleanliness Inspection

    FUEL SYSTEM 2-11 • Bend the tang [A] on the float arm very slightly to change the float height. O Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 17.5 ±...
  • Page 55: Carburetor Removal

    2-12 FUEL SYSTEM Carburetor Removal AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 56: Carburetor Installation

    CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. Carburetor Installation • Adjust the pilot screw. • * i f the carburetor has been disassembled, or if there is some other reason that the fuel level may be incorrect, inspect the fuel level (see Service Fuel Level Inspection).
  • Page 57: Carburetor Assembly

    2-14 FUEL SYSTEM • T a k e the jet needle [A] out of the vacuum piston [ B ] . It comes out w i t h a spring seat [ C ] . • Remove the carburetor bottom end as follows. OTurn in the pilot screw [A] and count the number of turns until it seats fully but not tightly, and then remove the screw.
  • Page 58 • Carefully screw in the needle jet holder. It will seat against the needle jet, pushing the end of the jet into the carburetor bore. CAUTION Do not force or overtighten the jets. The jets or the carburetor body could be damaged requiring replacement. •...
  • Page 59: Carburetor Cleaning

    2-16 FUEL SYSTEM Carburetor Cleaning A WARNING Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetor.
  • Page 60 FUEL SYSTEM 2-17 • Check the plastic tip of the float valve needle. It should be smooth, without any grooves, scratches, or tears. • If the plastic tip [A] is damaged [B], replace the needle [C]. • Push the rod [D] in the valve needle, then release it. * l f the rod does not spring out, replace the needle.
  • Page 61: Air Cleaner

    2-18 FUEL S Y S T E M A i r Cleaner Air Cleaner Element Removal • Remove: Seat (see Frame chapter) Air Cleaner Housing Cap [A] Air Cleaner Housing Cap Screw [B] • Remove: Wing Bolt [ A ] Element [B] •...
  • Page 62: Air Cleaner Element Cleaning And Inspection

    • Be sure the foam gasket [A] is in place in the groove in the element cap. Air Cleaner Element Cleaning and Inspection NOTE 0//7 dusty areas, the element should be cleaned more frequently than recommended interval. OAfter riding through rain or on muddy roads, the element should be cleaned immediately.
  • Page 63: Air Cleaner Draining (Klx650C)

    2-20 FUEL SYSTEM Air Cleaner Draining (KLX650C) A catch tank [A] is provided beneath the air cleaner housing, and catches the water or oil from the bottom of the housing. Usually water or oil does not collect at the bottom of the housing. In the event that rain water is drawn in through the air cleaner, or if engine oil is blown back, drain the housing.
  • Page 64: Air Cleaner Housing Removal (Klx650C)

    • Unscrew the air cleaner housing bolts [ A ] . • Remove the muffler bolts [A] and the muffler Allen bolt [B] to facili- tate air cleaner housing removal. • Loosen the clamp, and remove the air cleaner housing from the end of the air cleaner duct.
  • Page 65 2-22 FUEL SYSTEM • Remove Battery [A] (see Electrical System chapter) Element Cap [B] Tool Box Bracket [C] Breather Hose [D] Canister Purge Hose (California) [E] • Unscrew the air cleaner housing bolts [ A ] . • Pull off the regulator/rectifier connector. •...
  • Page 66: Fuel Tank

    FUEL SYSTEM 2-23 Fuel Tank Fuel Tank Removal AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 67: Fuel Tap Removal (Klx650A)

    2-24 FUEL SYSTEM • For California vehicles, install the blue breather hose [A] and the red fuel return hose [B] as shown. Red Mark[C] Blue Mark [ D ] • T i g h t e n the fuel tap bolts [ A ] . Torque - 5.9 N-m (0.60 kg-m, 52 in-lb) AWARNING Be sure to use the standard fuel tap bolts : 06 x L8 mm.
  • Page 68: Fuel Tap Installation (Klx650A)

    FUEL S Y S T E M 2-25 Fuel Tap Installation (KLX650A) • Be sure the O-rings [A] are in good condition to prevent leakage. • Clamp the fuel hose to the tap to prevent leakage. Fuel Tap Removal (KLX650C) •...
  • Page 69: Fuel Tank And Tap Cleaning

    2-26 FUEL SYSTEM Fuel Tank and Tap Cleaning • Remove the fuel tank and drain it (see Fuel Tank Removal). • Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. AWARNING Clean the tank in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area;...
  • Page 70: Evaporative Emission Control System (Klx650C, Us California Vehicle)

    FUEL S Y S T E M 2-27 Evaporative Emission C o n t r o l System (KLX650C, US California Vehicle) The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped.
  • Page 71: Separator Operation Test

    2-28 FUEL SYSTEM Separator Operation Test AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 72 COOLING SYSTEM 3 Cooling System Table of Contents Exploded View Coolant Flow Chart Specifications Coolant Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Cooling System Flushing Water Pump Water Pump Installation Water Pump Inspection Mechanical Seal Replacement 3-10 Mechanical Seal Inspection 3-11...
  • Page 73: Exploded View

    3-2 COOLING SYSTEM Exploded View Fan Relay (KLX650C) Thermostatic Fan Switch (KLX650C) Coolant Temperature Switch (KLX650C) Thermostat (KLX650C) T1: 2.0 N-m (0.20 kg-m, 17 in-lb) T2: 8.8 N-m (0.90 kg-m, 78 in-lb) Replacement Part...
  • Page 74: Coolant Flow Chart

    COOLING SYSTEM Coolant Flow Chart 8. To reserve tank 1. Water Pump When the engine is very hot, the pressure valve in 2. Cylinder Jacket the radiator cap allows air and vapor to escape into 3. Cylinder Head Jacket the reserve tank. When the engine cools d o w n , the 4.
  • Page 75: Specifications

    3-4 COOLING SYSTEM Specifications Standard Item Recommended Coolant Type Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point - 3 5 °...
  • Page 76: Coolant

    C O O L I N G S Y S T E M Coolant Coolant Deterioration Inspection • Visually inspect the coolant [A] in the reserve tank. * l f whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 77: Coolant Filling

    3-6 COOLING SYSTEM • Remove the radiator cap [A] in two steps. First turn the cap counter- clockwise to the first stop. Then push and turn it further in the same direction and remove the cap. • The coolant will drain from the radiator and engine. •...
  • Page 78: Pressure Testing

    • Bleed the air from the cooling system as follows. OStart the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. OTap the radiator hoses to force any air bubbles caught inside. OStop the engine and add coolant up to the radiator filler neck.
  • Page 79 3-8 COOLING SYSTEM CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product. • Warm up the engine, and run it at normal operating temperature for about ten minutes.
  • Page 80: Water Pump

    COOLING SYSTEM Water Pump • Drain the coolant (see Coolant Draining). • Remove: Radiator Hoses [A] Water Pump Cover [B] • T u r n the water pump impeller nut [A] counterclockwise and remove OThe impeller has an O-ring. Turn the impeller counterclockwise during removal, and clockwise during installation.
  • Page 81: Mechanical Seal Replacement

    3-10 COOLING SYSTEM Mechanical Seal Replacement • Remove: Water Pump Impeller (see Water Pump Removal) Clutch Cover [A] (see Clutch chapter) Circlip [B] Water Pump Gear [C] Special Tool - Outside Circlip Pliers: 57001-144 • Pull out the water pump shaft [D] from the inside of the clutch cover. •...
  • Page 82: Mechanical Seal Inspection

    COOLING SYSTEM 3-11 O Be sure to replace the mechanical seal, oil seal and ball bearing. • Apply plenty of high temperature grease to the oil seal lips. • Press the oil seal [A] into the hole from the inside of the clutch cover with the bearing driver set (special tool) [B] so that the spring side of the seal lips are toward the inside of the cover.
  • Page 83: Radiator

    3-12 COOLING SYSTEM Radiator Radiator Removal AWARNING NEVER TOUCH THE RADIATOR FAN UNTIL THE IGNITION SWITCH IS TURNED OFF. TOUCHING THE FAN BEFORE THE IGNITION SWITCH IS TURNED OFF COULD CAUSE INJURY FROM THE FAN BLADES. • Drain the coolant (see Coolant Draining). •...
  • Page 84: Radiator Inspection

    Radiator Inspection • Check the radiator core. * If there are obstructions to air flow, remove them. * l f the corrugated fins [A] are deformed, carefully straighten them. •*-If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
  • Page 85: Hose Inspection

    3-14 COOLING SYSTEM Hose Inspection • In accordance with the Periodic Maintenance Chart, visually inspect the radiator hoses [A] for signs of deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen. •...
  • Page 86: Thermostat (Klx650C)

    C O O L I N G S Y S T E M 3-15 T h e r m o s t a t (KLX650C) Thermostat Removal • Drain the coolant (see Coolant Draining). • Unscrew the housing bolts [A] and remove the thermostat [ B ] . Thermostat Installation •...
  • Page 87: Thermostatic Fan Switch (Klx650C)

    3 - 1 6 C O O L I N G S Y S T E M Thermostatic Fan Switch (KLX650C) Thermostatic Fan Switch Removal CAUTION The fan switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. •...
  • Page 88 ENGINE TOP END 4 Engine Top End Table of Contents Exploded View Cylinder Head Warp 4-23 Specifications 4 - 4 Valves 4-24 Cylinder Head Cover Valve Clearance Measurement 4-24 Cylinder Head Cover Removal Valve Clearance Adjustment 4-24 Cylinder Head Cover Installation Valve Removal 4-28 Cylinder Head Cover Assembly...
  • Page 89: M: Apply Molybdenum Disulfide Grease

    4-2 ENGINE TOP END Exploded View Arrow points to the front. " N " mark faces up. "2N" mark faces up. EO: Apply engine oil. Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. Replacement Parts Follow the specific tightening sequence.
  • Page 90 ENGINE TOP END 4-3 4. Closed coil end faces d o w n . 5. White paint faces up. 6. KACR Unit Kawasaki Automatic Compression Release (KACR) momentarily opens one of the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting.
  • Page 91: Klx650A

    4-4 ENGINE TOP END Specifications Item Standard Service Limit Camshaft: Cam height: Exhaust 36.24 ~ 36.36 mm 36.14 mm Inlet 36.74 ~ 36.86 mm 36.64 mm Camshaft, camshaft cap clearance 0.020 ~ 0.062 mm 0.15 mm Camshaft journal diameter 22.959 ~ 22.980 mm 22.93 mm Camshaft bearing inside diameter 23.000 ~ 23.021 mm...
  • Page 92 ENGINE TOP END 4-5 Item Standard Service Limit Valve seat surface: Width: Exhaust 0.8 ~ 1.2 mm Inlet 0.8 ~ 1.2 mm Outside diameter: Exhaust 31.9 ~ 32.1 mm Inlet 36.9 ~ 37.1 mm Valve spring free length: Outer 37.0 mm 35.1 mm Inner 35.2 mm...
  • Page 93 Valve Seat Cutter, 60° - 041: 57001-1124 Valve Seat Cutter Holder, 07: 57001-1126 Valve Seat Cutter Holder Bar: 57001-1128 Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 095 ~ 0108: 57001-1358 Sealant- Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 94: Spark Plug

    >Be sure to install the gasket [ A ] , • Apply silicone sealant [A] to the cylinder head as shown. S e a l a n t - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Cylinder Head Cover Bolts: 9.8 N-m (1.0 kg-m, 87 in-lb)
  • Page 95: Cylinder Head Cover Assembly

    4-8 ENGINE TOP END Cylinder Head Cover Assembly • Fit the damper into the oil separator [A] so that the larger flange [B] of the damper faces outward. •Tighten the oil separator bolts [A]. Torque - Oil Separator Bolts: 59 N-m (0.60 kg-m, 52 in-lb)
  • Page 96: Camshaft Chain Tensioner

    E N G I N E T O P E N D 4 - 9 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal • Remove the idle adjusting screw. • Remove the cap bolt [A] and spring. • Remove the mounting bolts [B] and take off the camshaft chain tensioner [ C ] .
  • Page 97: Chain Tension Spring Bolt

    4-10 ENGINE TOP END Chain Tension Spring Installation • Replace the O-ring [A] with a new one, if it is damage. • Insert the tension spring [B] on the chain guide protrusion [C] and install the chain tension spring bolt. Torque - Chain Tension Spring Bolt: 15 N-m (1.5 kg-m, 11.0 ft-lb)
  • Page 98: Camshaft Cap Bolts

    E N G I N E T O P E N D 4-11 Camshaft, Camshaft Chain Camshaft Removal • Remove the t w o caps on the magneto cover. • Position the crankshaft at TDC. OTurn the crankshaft counterclockwise with a wrench on the magneto flywheel bolt and watch the intake valve.
  • Page 99 4-12 ENGINE TOP END NOTE O The exhaust camshaft [A] has the compression re/ease mechanism [B]. Be careful not to mix up these shafts when installing. OThe inlet camshaft for the KLX650A has a groove [A] for identification. • Blow the oil passage [A] of the cap clean with compressed air. •Apply engine oil to the camshaft bearing in the cylinder head.
  • Page 100: Camshaft Disassembly

    ENGINE TOP END 4-13 • Be sure to install the O-rings [ A ] . • Check that the t w o dowel pins [B] are in place. • Install the camshaft cap bolts as shown. Four B o l t s - 4 6 L [A] Eight B o l t s - 3 8 L [B] Front [C] •...
  • Page 101: Camshaft Assembly

    4-14 ENGINE TOP END Camshaft Assembly OThe inlet and exhaust sprockets are identical. • Install the sprocket on the inlet camshaft [ A ] , using " I N " bolt holes [ B ] . • Install the sprocket on the exhaust camshaft [ A ] , using "EX" bolt holes [ B ] .
  • Page 102: Camshaft Bearing Wear

    ENGINE TOP END 4-15 Camshaft Bearing Wear The journal wear is measured using plastigauge (press gauge), which is inserted into the clearance to be measured. The plastigauge indicates the clearance by the amount it is compressed and widened when the parts are assembled.
  • Page 103: Camshaft Chain Installation

    4-16 ENGINE TOP END • Remove the rear lower chain guide [ A ] . • Remove the front upper chain guide bolt [A] and guide [ B ] . • Remove the intermediate sprocket plug. • Remove the intermediate sprocket shaft [ A ] , using the cylinder head bolt [ B ] .
  • Page 104 ENGINE TOP END 4-17 • Set the piston at TDC by turning the primary gear nut on the right side. OThe key groove [A] should point upward and the crankshaft sprocket mark [B] should align with the crankcase mark [C] at TDC. •...
  • Page 105: Camshaft Chain Wear

    4-18 ENGINE TOP END Non-permanent Locking Agent - Rear Lower Chain Guide Bolts Torque - Camshaft Chain Holder Bolts: 8.8 N-m (0.90 kg-m, 78 in-lb) Front Lower Chain Guide Bolt: 8.8 N-m (0.90 kg-m, 78 in-lb) Rear Lower Chain Guide Bolts: 8.8 N-m (0.90 kg-m, 78 in-lb) Front Upper Chain Guide Bolt: 29 N-m (3.0 kg-m, 22 ft-lb) •...
  • Page 106: Cylinder Head

    ENGINE TOP END 4-19 Cylinder Head Cylinder Compression Measurement NOTE O Use the battery which is fully charged (KLX650C). • Warm up the engine thoroughly. • Remove the fuel tank (see Fuel System chapter). • Remove the spark plug (see Electrical System chapter). •...
  • Page 107: Cylinder Head Removal

    4-20 ENGINE TOP END Cylinder Head Removal • Remove: Fuel Tank (see Fuel System chapter) Carburetor (see Fuel System chapter) Radiators (see Cooling System chapter) Exhaust Pipe (see this chapter) Water Hose on the Cylinder Head Camshafts (see Camshaft Removal) Ignition Coil •...
  • Page 108: Cylinder Head Installation

    ENGINE TOP END 4-21 H a p lightly up the cylinder head with a plastic mallet [A] to separate from the cylinder. • Lift off the cylinder head [A] toward the left side. • Remove the cylinder head gasket. Cylinder Head Installation •...
  • Page 109 4-22 ENGINE TOP END O Insert the lever [A] of the rear upper chain guide behind the top of the lower chain guide [B] as shown. Torque - Rear Upper Chain Guide Bolt [C]: 29 N-m (3.0 kg-m, 22 ft-lb) •...
  • Page 110: Timing Inspection Plug

    ENGINE TOP END 4-23 • Engage the upper camshaft chain with the camshaft sprockets as shown (see Camshaft Installation). • Install: Cam Chain Tensioner (see this chapter) Cam Chain Tension Spring (see this chapter) Torque - Oil Pipe Banjo Bolt: 20 N-m (2.0 kg-m, 14.5 ft-lb) Oil Pipe Bolt: 8.8 N-m (0.90 kg-m, 78 in-lb) •...
  • Page 111: Valve Clearance Measurement

    4-24 ENGINE TOP END Valves Valve Clearance Measurement NOTE O Check the valve clearance when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) T w o Plugs on Magneto Cover • T u r n the crankshaft counterclockwise with a wrench on the magneto flywheel bolt and watch the intake valve.
  • Page 112 • Install the camshafts. Be sure to time the camshafts properly. • Remeasure any valve clearance that was adjusted. Readjust if necessary. CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim.
  • Page 113 4-26 ENGINE TOP END VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE MOTE Olf the valve clearance is smaller (larger) than the standard, select a thinner (thicker) shim and then measure the clearance again. 1. Measure the clearance (with engine cold). 2. Check present shim size. 3.
  • Page 114 ENGINE TOP END 4-27 VALVE CLEARANCE ADJUSTMENT CHART I N L E T V A L V E N O T E Olf the valve clearance is smaller (larger) than the standard, select a thinner (thicker) shim and then measure the clearance again. 1.
  • Page 115: Valve Removal

    4-28 ENGINE TOP END Valve Removal • Remove the cylinder head (see Cylinder Head Removal). O Mark and record the valve location so it can be installed in the original position. • Using the valve spring compressor assembly, remove the valve. Special Tools - Valve Spring Compressor Assembly: 57001-241 [A] Valve Spring Compressor Adapter, 029.5: 57001-1078...
  • Page 116: Valve-To-Guide Clearance Measurement

    Valve-to-Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide f B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 117 4-30 ENGINE TOP END * l f the manufacturer's instructions are not available, use the following procedure. Seat Cutter Operating Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purpose than seat repair.
  • Page 118 Operating Procedures: • Clean the seat area carefully. • Coat the seat with machinist's dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press d o w n lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 119 4-32 ENGINE TOP END • Lap the valve [A] to the seat [ B ] , using a lapper [C] once the seat w i d t h and O.D. are within the ranges specified above. OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head.
  • Page 120 ENGINE TOP END 4-33...
  • Page 121: Cylinder, Piston 4 - 3

    4-34 ENGINE TOP END Cylinder, Piston Cylinder, Piston Removal • Remove: Cylinder Head (see Cylinder Head Removal) Water Hose Fitting Front Upper Chain Guide [A] • Remove the intermediate sprocket shaft plug [ B ] . • Remove the intermediate sprocket shaft [ A ] , using the cylinder head b o l t [ B ] .
  • Page 122: Cylinder, Piston Installation

    ENGINE TOP END 4-35 • Remove the snap ring from one side of each piston pin hole. CAUTION Do not reuse snap rings as removal weakens and deforms them. They could (all out and score the cylinder wall. • Push out the piston pin and remove the piston. O l f necessary, use the piston pin puller assembly [A] along with a 22 mm washer [ B ] .
  • Page 123 4-36 ENGINE TOP END • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. OWhen installing the piston pin snap ring, compress it only enough to install it and no more.
  • Page 124: Cylinder/Piston Wear

    ENGINE TOP END 4-37 • Slip the upper camshaft chain (wider one) [A] over the smaller intermediate sprocket [ B ] . • Be sure to pull the camshaft chains and intermediate sprockets up through the chain tunnel during cylinder installation. •...
  • Page 125: Piston/Cylinder Clearance

    4-38 ENGINE TOP END • Measure the piston diameter at the point shown with a micrometer. Piston Diameter KLX650A: Standard: 99.967 ~ 99.982 mm Service Limit: 99.82 mm KLX650C: Standard: 99.922 ~ 99.937 mm Service Limit: 99.77 mm * l f the piston diameter is less than the service limit, replace it. * l f the cylinder has been bored oversize, use the oversize piston diameter (KLX650C).
  • Page 126: Piston Ring And Ring Groove Wear

    ENGINE TOP END 4-39 Piston Ring and Ring Groove Wear • Check for uneven groove wear by inspecting the ring seating. * T h e rings should fit perfectly parallel to groove surfaces. If not, the piston must be replaced. •...
  • Page 127: Muffler Removal 4 - 4

    4 - 4 0 E N G I N E T O P END • Remove the drain plug(s) [A] on the muffler. KLX650A • In an open area away from combustible materials, start the engine w i t h the transmission in neutral.
  • Page 128 CLUTCH 5-1 Clutch Table of Contents Exploded View Specifications Clutch Lever and Cable Lever Free Play Inspection Lever Free Play Adjustment Clutch Cable Removal Clutch Cable Installation Clutch Cable Lubrication and Inspection Clutch Cover Clutch Cover Removal Clutch Cover Installation Clutch Cover Disassembly Clutch Cover Assembly Clutch Release Removal...
  • Page 129: Exploded View

    CLUTCH Exploded View Apply engine oil. Apply grease. Apply a non-permanent locking agent. Apply molybdenum disulfide grease. Apply oil. Replacement Parts Stake the fasteners. 155 N-m (16.0 kg-m, 1 1 5 f t - l b ) 8.8 N-m (0.90 kg-m, 78 in-lb) 5.9 N-m (0.60 kg-m, 52 in-lb) 25 N-m (2.5 kg-m, 18.0 ft-lb) 4.9 N-m (0.50 kg-m, 43 in-lb)
  • Page 130: Specifications

    CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 - 3 mm Clutch Lever Free Play (at lever end) 10 ~ 20 mm Clutch Friction plate thickness 2.9 ~ 3.1 mm 2.75 mm 0.2 mm or less Friction and steel plate warp 0.3 mm Clutch spring free length KLX650A...
  • Page 131: Lever Free Play Adjustment

    5-4 CLUTCH Lever Free Play Adjustment AWARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Slide the dust cover at the clutch cable lower end out of place. • Loosen both adjusting nuts [A] at the clutch cover as far as they will •...
  • Page 132: Clutch Cable Installation

    CLUTCH CAUTION Do not pull out the clutch release shaft unless It is absolutely necessary. Clutch release shaft removal damages the oil seal in the clutch cover, necessitating oil seal replacement. • Pull the clutch cable out of the frame. Clutch Cable Installation •...
  • Page 133: Clutch Cover

    C L U T C H Clutch Cover Clutch Cover Removal • Drain: Engine Oil (see Engine Lubrication System chapter) Coolant (see Cooling System chapter) • Remove: Brake Pedal (see Brakes chapter) [A] Kick Pedal (KLX650A) [B] Oil Filter (see Engine Lubrication System) [C] Water Pump Hoses [ D ] •...
  • Page 134 CLUTCH 5-7 • Using compressed air, blow out [A] any particles which may obstruct the oil passage on the clutch cover. • Apply molybdenum disulfide grease to the crankshaft oil seal lips [ A ] . • Locate the oil pump shafts as shown so that the clutch cover oil pump shaft projection [A] fits the crankcase oil pump shaft slot [B] as shown.
  • Page 135: Clutch Cover Disassembly

    CLUTCH • Fit the O-ring [A] for the oil filter in, being careful not to twist the O-ring. • Install the clutch cover with the clutch release lever turned toward the rear. • Engage the clutch release shaft with the clutch spring plate pusher by turning the clutch release lever toward the front [ A ] .
  • Page 136: Clutch Cover Assembly

    CLUTCH Clutch Cover Assembly • Using a press and the bearing driver set, push each needle bearing until the face of the bearing is even with the end of the hole as shown. • Install the lower bearing [ A ] . Either side of the bearing may face upward.
  • Page 137: Clutch Removal

    5-10 CLUTCH Clutch Clutch Removal NOTE Olf the primary gear [A] is to be removed, remove the primary gear nut before clutch removal (see Primary Gear Removal). (Remove: Clutch Spring Bolts [ A ] , Washer, and Springs Clutch Spring Plate [ B ] , Thrust Bearing, and Pusher [C] Friction Plates and Steel Plates •...
  • Page 138 CLUTCH 5-11 i Install: Washer [A] Clutch Hub [B] Spring Washer [C] O Install the spring washer [A] and the primary gear nut [B] as shown. • Replace the clutch hub nut [A] with a new one. Special Tool - Clutch Holder: 57001-1243 [B] Torque - Clutch Hub Nut: 130 N-m (13.5 kg-m, 98 ft-lb) •...
  • Page 139: Friction And Steel Plate Damage, Wear Inspection

    5-12 CLUTCH • Apply engine oil to the thrust bearing. • A p p l y molybdenum disulfide grease to the rubbing portion [A] of clutch spring plate pusher. • Install the clutch spring plate with the thrust bearing and pusher assembled.
  • Page 140: Clutch Hub Spline Damage

    CLUTCH 5-13 Clutch Hub Spline Damage • Visually inspect where the teeth on the steel plates wear against the clutch hub splines. * l f there are notches worn into the clutch hub splines [A], replace the clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 141: Primary Gear

    5-14 C L U T C H Primary Gear Primary Gear Removal • Remove the clutch cover (see Clutch Cover Removal). • Remove the oil pipe banjo bolt [ A ] . • Install the gear holder using suitable bolts and nut as shown. Bolt, 06 x 25L [A] Bolt, 08 x 60L [ D ] Gear Holder [ B ]...
  • Page 142 • T i g h t e n the primary gear nut [A] using the gear holder. Torque - Primary Gear Nut: 155 N-m (16.0 kg-m, 115 ft-lb) Special Tool - Gear Holder: 57001-1357 • Bend the lockwasher tab [B] over the primary gear nut. •...
  • Page 143: Kickstarter (Klx650A)

    5-16 C L U T C H Kickstarter (KLX650A) Kick Pedal Installation • Install the kick pedal [A] so that the pedal end is even with the kick shaft end [ B ] . •Temporarily install the kick pedal bolt [ C ] . * l f the kick pedal contacts the brake pedal, install the kick pedal as follows.
  • Page 144 E N G I N E L U B R I C A T I O N S Y S T E M Engine Lubrication System Table of Contents Engine Oil Flow Chart Exploded View Specifications Engine Oil and Oil Filter Oil Level Inspection Oil Change Oil Filter Change...
  • Page 145: 6-2 Engine Lubrication System

    6-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 146 ENGINE LUBRICATION SYSTEM 6-3 1. Right Oil Screen 6. Crankshaft 1 1 . Breather Hose 2. Crankcase Oil Pump 7. Crankshaft Oil Seal 12. Drive Shaft 3. Relief Valve 8. Oil Pipe Banjo Bolts 13. Output Shaft 4. Clutch Cover Oil Passage 9.
  • Page 147: Exploded View

    6-4 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 148: Specifications

    ENGINE LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil: Grade SE or SF class Viscosity SAE 10W-40, 10W-50, 20W-40, or 20W-50 KLX650A Capacity 1.7 L (when filter is not removed) 1.7 L (when filter is removed) 1.9 L (when engine is completely dry) KLX650C 1.9 L (when filter is not removed) 1.9 L (when filter is removed)
  • Page 149: Engine Oil And Oil Filter

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter AWARNING Motorcycle operation with Insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. * l f the oil has just been changed, start the engine and run it for several minutes at idle speed.
  • Page 150: Oil Filter Change

    ENGINE LUBRICATION SYSTEM • If the oil filter is to be changed, replace it with a new one. • Check the gaskets at the drain plug and Allen bolt for damage. • Replace the gasket with a new one if it is damaged. •...
  • Page 151: Oil Pressure Measurement

    6-8 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Relief Valve Opening Pressure Measurement NOTE O Measure the oil pressure before the engine is warmed up if you want to test relief valve opening pressure. • Remove the oil passage plug in the clutch cover and screw in the oil pressure gauge adapter [A] until the O-ring is adequately compressed.
  • Page 152: Oil Screens

    ENGINE LUBRICATION SYSTEM 6-9 • Stop the engine. • Remove the oil pressure gauge and adapter. • Install the oil passage plug. Torque - Oil Passage Plug : 25 N-m (2.5 kg-m, 18.0 ft-lb) Oil Screens Oil Screen Removal • Remove the clutch cover (see Clutch chapter). •...
  • Page 153: Oil Pump And Relief Valve

    6-10 E N G I N E L U B R I C A T I O N S Y S T E M Oil Pump and Relief Valve Crankcase Oil Pump Removal • Remove the clutch cover (see Clutch chapter). •...
  • Page 154: Clutch Cover Oil Pump Removal

    E N G I N E L U B R I C A T I O N S Y S T E M 6-11 Clutch Cover Oil Pump Removal • Remove the clutch cover [A] (see Clutch chapter). • Remove the oil pump bolts [ B ] . •...
  • Page 155: Oil Pipe

    6-12 ENGINE LUBRICATION SYSTEM * l f any rough spots are found during above inspection, wash the valve clean w i t h a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air. AWARNING Clean the parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area.
  • Page 156 ENGINE REMOVAL / INSTALLATION 7- Engine Removal / Installation Table of Contents Exploded View Specifications Engine Removal/Installation Engine Removal Engine Installation...
  • Page 157: Exploded View

    ENGINE REMOVAL / INSTALLATION Exploded View...
  • Page 158: Specifications

    ENGINE REMOVAL / INSTALLATION 7-3 Specifications Special Tool - Jack: 57001-1238 Engine Removal/Installation Engine Removal • Drain the coolant (see Cooling System chapter) • Drain the engine oil (see Engine Lubrication System chapter). • Remove: Fuel Tank (see Fuel System chapter) Carburetor (see Fuel System chapter) Exhaust Pipe (see Engine Top End chapter) Right Footpeg...
  • Page 159 ENGINE REMOVAL / INSTALLATION Pickup Coil Lead Connector [A] (KLX650A) Exciter Coil Lead Connector [B] (KLX650A) Battery Negative Lead [A] (KLX650C) Neutral Switch Lead Connector [B] (KLX650C) Alternator Lead Connector [C] (KLX650C) Exciter Coil Lead Connector [ D ] (KLX650C) Pickup Coil Lead Connector [E] (KLX650C) Starter Motor Cable [A] (KLX650C) »Place the jack [A] under the frame to lift the rear wheel off the ground.
  • Page 160: Engine Installation

    ENGINE REMOVAL / INSTALLATION A WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. OThe following parts may be removed with the engine in the frame if the crankcase is to be split.
  • Page 161 ENGINE REMOVAL / INSTALLATION •Temporarily install: Front Lower Engine Mounting Bolts [A] Front Lower Engine Mounting Bolt and Nut [B] Other Engine Mounting Bolts and Nuts • Tighten the following fasteners in the order listed. Torque - Swingarm Pivot Nut: 88 N-m (9.0 kg-m, 65 ft-lb) Rocker Arm Nut: 98 N-m (10.0 kg-m, 72 ft-lb) 10 mm Engine Mounting Bolts and Nuts: 44 N-m (4.5 kg-m, 33 ft-lb)
  • Page 162 CRANKSHAFT / T R A N S M I S S I O N Crankshaft / Transmission Table of Contents Exploded View Specifications Crankcase Crankcase Disassembly Crankcase Assembly Crankshaft and Connecting Rod Crankshaft Removal ..8-9 Crankshaft Installation Crankshaft Disassembly Crankshaft Assembly Connecting Rod Big End Seizure 8-10 Connecting Rod Big End Radial Clearance...
  • Page 163: Crankshaft / T R A N S M I S S I O N

    C R A N K S H A F T / T R A N S M I S S I O N Exploded View...
  • Page 164 C R A N K S H A F T / T R A N S M I S S I O N...
  • Page 165: Specifications

    Shift fork guide pin diameter 5.9 ~ 6.0 mm 5.8 mm Shift drum groove width 6.05 ~ 6.20 mm 6.3 mm Special Tool - Outside Circlip Pliers: 57001-144 Bearing Driver Set: 57001-1129 Sealant- Kawasaki Bond (Liquid Gasket - Silver): 92104-002...
  • Page 166: Crankcase

    C R A N K S H A F T / T R A N S M I S S I O N Crankcase Crankcase Disassembly • Remove the engine sprocket [A] (see Final Drive chapter). • Remove the engine (see Engine Removal/Installation chapter). •...
  • Page 167: Crankcase Assembly

    CRANKSHAFT / TRANSMISSION iRemove the balancer shaft assembly [ A ] . • Remove the crankshaft [ A ] from the crankcase half by hand. CAUTION Do not remove the ball bearings and the oil seals unless it is necessary. Removal may damage them. Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the...
  • Page 168 C R A N K S H A F T / T R A N S M I S S I O N • T i g h t e n the main bearing retainer screws [ A ] . Non-permanent Locking Agent: Main Bearing Retainer Screws Torque - Main Bearing Retainer Screws : 4.9 N-m (0.50 kg-m, 43 in-lb) [A]...
  • Page 169 • A p p l y liquid gasket to the mating surface of the left crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104-002 • Replace the output shaft O-ring [B] and grease the new O-ring.
  • Page 170: Crankshaft And Connecting Rod

    C R A N K S H A F T / T R A N S M I S S I O N Crankshaft and Connecting Rod Crankshaft Removal See Crankcase Disassembly. Crankshaft Installation See Crankcase Assembly. Crankshaft Disassembly CAUTION Since assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and...
  • Page 171: Connecting Rod Big End Seizure

    8-10 CRANKSHAFT / T R A N S M I S S I O N Connecting Rod Big End Seizure ~k\n the case of serious seizure with damaged flywheels, the crankshaft must be replaced. * l n the case of less serious damage, disassemble the crankshaft and replace the crankpin, needle bearing, side washers, and connecting rod.
  • Page 172 C R A N K S H A F T / T R A N S M I S S I O N 8-11 * l f runout at either location exceeds the service limit, align the crankshaft so that runout is within the service limits. •...
  • Page 173: Transmission

    8-12 CRANKSHAFT / TRANSMISSION Transmission Shift Pedal Installation • A d j u s t the shift pedal position from the footpeg top to suit you. OThe standard shift pedal position [A] is about 40 mm below the footpeg top. External Shift Mechanism Removal •...
  • Page 174: External Shift Mechanism Installation

    CRANKSHAFT / TRANSMISSION 8-13 • For the KLX650A, remove the shift drum cam [A] by taking off the bolt. • For the KLX650C, remove the neutral switch plate [A] and the shift r"~ drum cam [B] by taking off the bolt. External Shift Mechanism Installation •...
  • Page 175: External Shift Mechanism Inspection

    8-14 CRANKSHAFT / T R A N S M I S S I O N • Install: Dowel Pins [ A ] New Gasket [ B ] • Install the cover and tighten the bolts to the specified torque. Torque - External Shift Mechanism Cover Bolts : 8.8 N-m (0.90 kg-m, 88 in-lb) •...
  • Page 176: Transmission Shaft Disassembly

    CRANKSHAFT / TRANSMISSION 8-15 NOTE O The shift rods are identical. O The output shaft forks [A] are identical. QBe careful not to confuse the shift forks. • Install the shift forks as shown. OThe machined surfaces [B] of the output shaft forks face to the engine right side.
  • Page 177: Shift Fork Bending

    8-16 CRANKSHAFT / T R A N S M I S S I O N Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
  • Page 178: Shift Fork Guide Pin/Shift Drum Groove Wear

    CRANKSHAFT / T R A N S M I S S I O N 8-17 • Measure the width [A] of the gear shift fork grooves. * l f a gear fork groove is worn over the service limit, the gear must be replaced.
  • Page 179: Balancer

    8-18 C R A N K S H A F T / T R A N S M I S S I O N Balancer Balancer Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Lift the balancer shaft [A] out of the right-hand crankcase half. Balancer Shaft Installation See Crankcase Assembly.
  • Page 180 CRANKSHAFT / T R A N S M I S S I O N 8-19 • Install the balancer gear assembly [A] on the balancer shaft, aligning the gear line mark [B] with the shaft punch mark [C].
  • Page 181: Ball Bearing, Needle Bearing, And Oil Seal

    8-20 CRANKSHAFT / T R A N S M I S S I O N Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.
  • Page 182 W H E E L S / T I R E S 9 - 1 Wheels / Tires Table of Contents Exploded View Specifications Wheels Front Wheel Removal Front Wheel Installation Rear Wheel Removal (KLX650A) Rear Wheel Installation (KLX650A) Rear Wheel Removal (KLX650C) Rear Wheel Installation Wheel Inspection Spoke Inspection...
  • Page 183: 9-2 Wheels / Tires

    9-2 WHEELS / TIRES Exploded View...
  • Page 184 WHEELS / TIRES 9-3 KLX650C Apply grease. Follow the specific tightening sequence. Apply soap and water solution or rubber lubricant. 88 N-m (9.0kg-m, 65 ft-lb) 9.3 N-m (0.95 kg-m, 82 in-lb) 98 N-m (10.0 kg-m, 72 ft-lb) 1.5 N-m (0.15 kg-m, 13 in-lb) 1.5 ~ 2.1 N-m (0.15 ~ 0.21 kg-m, 13 ~ 18 in-lb)
  • Page 185: Specifications

    9-4 WHEELS / TIRES Specifications Item Standard Service Limit Rim runout: Axial 0.5mm or less 2 mm 0.8 mm or less Radial 2 mm Axle runout/100 mm 0.10 mm or less 0.2 mm Wheel balance 10 g or less 10 g, 20 g, 30 g Balance weights Tire tread depth KLX650A...
  • Page 186: Wheels

    Wheels Front Wheel Removal • Remove: Speedometer (or Odometer) Cable Screw [A] • Pull out the cable lower end. (Loosen: Right Side Axle Clamp Nuts [A] Axle [B] • Using the jack [ A ] , raise the front wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 187: Rear Wheel Removal (Klx650A)

    9-6 WHEELS / TIRES • Fit the gear housing stop [A] into the fork leg stops [ B ] , •Tighten the axle [ A ] . Torque - Axle : 88 N-m (9.0 kg-m, 65 ft-lb) OThe arrow mark [ B ] on the axle clamps must point upward. •...
  • Page 188: Rear Wheel Installation (Klx650A)

    WHEELS / TIRES 9-7 • Remove the clip [A] from the master link using pliers and free the drive chain from the rear sprocket [B]. • Pull out the axle. • Move the rear wheel [A] back and remove the wheel from the rear caliper [B].
  • Page 189: Rear Wheel Removal (Klx650C)

    9-8 WHEELS / TIRES • A d j u s t the drive chain (see Final Drive chapter). Torque - Rear Axle Nut: 98 N-m (10.0 kg-m, 72 It-lb) • Install a new cotter pin. • Check the rear brake effectiveness. AWARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the...
  • Page 190: Rear Wheel Installation

    Rear Wheel Installation • Install the caliper bracket [A] onto the swingarm stop [ B ] . • Apply high-temperature grease to the grease seals. • Engage the drive chain with the rear sprocket and install the rear wheel. • Install the collars [A] on the left and right sides of the hub. •...
  • Page 191: Rim Inspection

    9-10 WHEELS / T I R E S Rim Inspection • Place the jack under the frame so that the front or rear wheel is off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warping. * l f there is any damage to the rim, it must be replaced.
  • Page 192: Balance Inspection (Klx650C)

    41075-1007 41075-1008 41075-1009 NOTE O Balance weights are available from Kawasaki Dealers in 10, 20, and 30 gram sizes. An imbalance of less than 10 grams will not usually affect running stability. O Do not use four or more balance weight (more than 90 gram).
  • Page 193: Tires

    9-12 WHEELS / TIRES Tires Air Pressure Inspection I Adjustment • Using a tire air pressure gauge [ A ] , measure the tire pressure when the tires are cold. * Adjust the tire air pressure according to the following specifications, if necessary.
  • Page 194: Tire Removal

    WHEELS / T I R E S 9-13 Standard Tire KLX650A: DUNLOP Front Make D752F (Tube) Type: 80/100-21 51M Size: DUNLOP Rear Make D752 (Tube) Type: 110/100-18 64M Size: KLX650C: Front Make : DUNLOP TRAILMAX (Tube) Type: (AS) TRAILMAX J (Tube) (US) K850A (Tube) 90/90-21 54S Size:...
  • Page 195: Tire Installation

    9-14 WHEELS / TIRES • Protecting the rim with rim protectors [ A ] , pry the tire off. Special Tool - Rim Protector: 57001-1063 Tire Irons of the Bead Breaker Assembly: 57001-1072 [B] Tire Installation • Check the tire rotation mark on the front or rear tire and install it on the rim accordingly (KLX650C).
  • Page 196: Hub Bearings (Wheel Bearings)

    WHEELS / T I R E S 9-15 Hub Bearings (Wheel Bearings) Bearing Removal • Remove the wheel, and take out the following: Collar(s) Coupling (rear hub, KLX650C) Grease Seals Circlip Special Tool - Inside Circlip Pliers: 57001-143 [A] Speedometer (Odometer) Gear Drive (front hub) •...
  • Page 197: Bearing Inspection

    9-16 W H E E L S / TIRES • Replace the grease seals with new ones. O Apply high temperature grease to the grease seal lips. • Press in the grease seal so that the seal surface is flush with the end of the hole.
  • Page 198 FINAL D R I V E 10-1 Final Drive Table of Contents Exploded View 10-2 Specifications 10-4 Drive Chain 10-5 Chain Slack Inspection (KLX650A) 10-5 Chain Slack Adjustment (KLX650A) 10-5 Chain Slack Inspection (KLX650C) 10-6 Chain Slack Adjustment (KLX650C) 10-6 Chain Wear Inspection 10-7 Chain Lubrication (KLX650A)
  • Page 199: 10-2 Final Drive

    10-2 FINAL DRIVE Exploded View Apply heavy oil. Apply a non-permanent locking agent. Replacement Part 98 N-m (10.0kg-m, 72 ft-lb) 29 N-m (3.0 kg-m, 22 ft-lb)
  • Page 200 FINAL DRIVE 10-3 K L X 6 5 0 C Apply grease. Apply heavy oil. Apply a non-permanent locking agent. Replacement Part 98 N-m (10.0 kg-m, 72 ft-lb) 32 N-m (3.3 kg-m, 24 ft-lb)
  • Page 201: Specifications

    10-4 FINAL DRIVE Specifications Iterr Standard Service Limit Drive Chain: Standard Chain KLX650A: Make DAI DO Type D.I.D. 520K, Joint Endless Link 110 links KLX650C: Make ENUMA Type EK520SR-02, Endless Link 112 links Too tight: less than 55 mm Chain slack 55 ~ 65 mm Too loose: more than 70 mm 323 mm...
  • Page 202: Drive Chain

    FINAL DRIVE 10-5 Drive Chain Chain Slack Inspection (KLX650A) • Set the motorcycle up on its side stand. • Check to see that the notches [A] on the chain adjusters [B] on both sides are in the same relative position. * l f they are not, adjust the chain slack and align them.
  • Page 203: Chain Slack Inspection (Klx650C)

    10-6 FINAL DRIVE • T u r n the wheel, measure the chain slack again at the tightest position, and readjust if necessary. • Insert a new cotter pin and spread its ends. • Check the rear brake effectiveness. AWARNING Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
  • Page 204: Chain Wear Inspection

    FINAL DRIVE 10-7 AWARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. • T i g h t e n both chain adjuster locknuts securely. • T i g h t e n the rear axle nut. Torque - Rear Axle Nut: 98 N-m (10.0 kg-m, 72 ft-lb) AWARNING If the axle nut is not securely tightened, an unsafe riding condition...
  • Page 205: Chain Lubrication (Klx650A)

    10-8 FINAL DRIVE Chain Lubrication (KLX650A) ~k\i the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in a heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller. •...
  • Page 206: Chain Removal (Klx650A)

    FINAL DRIVE 10-9 Chain Removal (KLX650A) • Remove the engine sprocket cover. • Remove the clip [A] from the master link using pliers, and free the drive chain from the sprockets. • Remove the drive chain from the chassis, being careful that the chain does not get dirty from contact with the ground.
  • Page 207: Sprocket, Coupling

    10-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal (KLX650A) • Remove: Engine Sprocket Cover [A] Drive Chain (see Chain Removal) • Bend the lockwasher tab up. • Using the engine sprocket holder [ A ] , loosen the engine sprocket nut [ B ] .
  • Page 208: Engine Sprocket Removal (Klx650C)

    Engine Sprocket Removal (KLX650C) • Remove the engine sprocket cover. • Bend the lockwasher tab [A] up and loosen the engine sprocket nut [ B ] . NOTE O When loosening the engine sprocket nut, hold the rear brake on. •...
  • Page 209: Rear Sprocket Removal (Klx650A)

    10-12 FINAL DRIVE • Install the chain guide [A] as shown. • A p p l y a non-permanent locking agent to the bolt [B] shown. • Adjust the drive chain (see this chapter). Rear Sprocket Removal (KLX650A) • Remove the rear wheel (see Wheels/Tires chapter) CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 210: Rear Sprocket, Coupling Installation (Klx650C)

    FINAL DRIVE 10-13 Rear Sprocket, Coupling Installation (KLX650C) • Grease the following and install the coupling. Ball Bearing [A] Coupling Grease Seal [B] Coupling Internal Surface [C] • Install the sprocket [A] facing the tooth number marking [B] outward. Torque - Rear Sprocket Nuts : 32 N-m (3.3 kg-m, 24 fl-lb) (Install the rear wheel (see Wheels/Tires chapter).
  • Page 211: Coupling Bearing Removal (Klx650C)

    10-14 FINAL DRIVE Rear Sprocket Warp Standard: 0.4 mm or less Service Limit: 0.5 mm Coupling Bearing Removal (KLX650C) • Pull out the coupling collar from the coupling. • Remove the circlip. • Using the bearing driver set [A] or some other suitable tool, remove the bearing [ B ] by tapping from the wheel side.
  • Page 212 BRAKES 11-1 Brakes Table of Contents Exploded View 11-2 Brake Pads 11-15 Specifications 11-4 Front Brake Pad Removal 11-15 Brake Lever, Brake Pedal 11 -5 Rear Brake Pad Removal 11-15 Brake Lever Play Adjustment 11 -5 Brake Pad Installation 11-16 Brake Pedai Position Adjustment 11 -5 Brake Pad Wear Inspection...
  • Page 213: Exploded View

    11-2 BRAKES Exploded View Apply brake fluid. Apply grease. Replacement Parts Apply silicone grease. 7.8 N-m (0.80 kg-m, 69 in-lb) 25 N-m (2.5 kg-m, 18.0 ft-lb) 9.8 N-m (1.0 kg-m, 87 in-lb) 5.9 N-m (0.60 kg-m, 52 in-lb) 1.1 N-m (0.11 kg-m, 10 in-lb) 8.8 N-m (0.90 kg-m, 78 in-lb) 1.5 N-m (0.15 kg-m, 13 in-lb) 18 N-m (1.8 kg-m, 13.0 ft-lb)
  • Page 214 BRAKES 11-3...
  • Page 215: Specifications

    11-4 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever free play Adjustable (to suit rider) Pedal free play Non-adjustable Pedal position Adjustable (to suit rider) Brake Fluid: Grade D.0.T.3 Brand (recommended) Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castrol Girling - Universal...
  • Page 216: Brake Lever, Brake Pedal

    B R A K E S 1 1 - 5 Brake Lever, Brake Pedal Brake Lever Play Adjustment • Adjust the front brake lever play [A] to suit you. • Loosen the adjuster locknut [B] and turn the adjuster [C] to either side.
  • Page 217: Brake Pedal Removal

    11-6 BRAKES Brake Pedal Removal • Remove: Brake Pedal Return Spring [A] Cotter Pin and Joint Pin [B] Brake Light Switch Spring Lower End (KLX650C) [C] Brake Shaft Cotter Pin [D] • Pull out the brake pedal. Brake Pedal Installation •...
  • Page 218: Brake Fluid

    BRAKES 11-7 Brake Fluid A WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 219: Brake Fluid Level Inspection

    11-8 BRAKES Brake Fluid Level Inspection In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front and rear brake fluid reservoirs. • Check the brake fluid level in the reservoir. NOTE O Hold the reservoir horizontal when checking brake fluid level. OFor the KLX650A, the front reservoir must be kept more than half full [ A ] with brake fluid.
  • Page 220: Brake Fluid Changing

    BRAKES 11-9 Brake Fluid Changing NOTE O The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. • Remove the reservoir cap and the rubber cap on the bleed valve. •...
  • Page 221: Brake Line Air Bleeding

    1 1 - 1 0 BRAKES Brake Line Air Bleeding NOTE O The procedure to bleed the front brake line Is as follows. Bleeding the rear brake line is the same as for the front brake. • Bleed the air whenever brake parts are replaced or reassembled. •...
  • Page 222: Calipers

    BRAKES 11-11 Calipers Front Caliper Removal • Drain the front brake fluid (see Brake Fluid Change). • Remove the fork protector [A] • Remove: Banjo Bolt [B] Brake Hose Joint Bolt [C] • Remove the caliper bolts [D] and take off the caliper [E]. * l f the caliper is to be disassembled after removal and if compressed air is not available, remove the pistons using the following steps before disconnecting the brake hose from the caliper.
  • Page 223: Caliper Installation

    11-12 BRAKES Caliper Installation • Tighten the caliper bolts. Torque - Caliper Bolts : 25 N-m (2.5 kg-m, 18.0 ft-lb) • Connect the brake hose to the caliper putting a new flat washer on each side of the brake hose fitting. •...
  • Page 224: Caliper Assembly

    BRAKES 11-13 AWARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers. • Remove the dust seal and fluid seal. •...
  • Page 225: Caliper Fluid Seal Damage

    11-14 BRAKES Caliper Fluid Seal Damage The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temper- ature.
  • Page 226: Brake Pads

    B R A K E S 1 1 - 1 5 Brake Pads Front Brake Pad Removal • Remove the front master cylinder clamp bolts [A] to slack the brake hose. • Loosen the pad bolts [ A ] . •...
  • Page 227: Brake Pad Installation

    11-16 BRAKES • Remove the caliper from the disc with the hose left installed. • Push the caliper holder [A] toward the piston side and then remove the pads [ B ] . Brake Pad Installation • Before installation, clean the pads with a high-flash point solvent. •...
  • Page 228: Master Cylinder

    BRAKES 11-17 Master Cylinder Front Master Cylinder Removal • Drain the front brake fluid (see Brake Fluid Change) • Remove: Handguard [A] Nuts [B] Bolts [C] • Remove: Brake Hose Banjo Bolt [A] Master Cylinder Clamp Bolts [B] • Remove the front master cylinder [ C ] . CAUTION Brake fluid quickly ruins painted surface;...
  • Page 229: Rear Master Cylinder Installation

    11-18 BRAKES Rear Master Cylinder Installation • Use a new flat washer on each side of the brake hose fitting. Torque - Banjo Bolt: 25 N-m (2.5 kg-m, 18.0 ft-lb) • Fill the brake line with the brake fluid (see Brake Fluid Changing). •...
  • Page 230: Rear Master Cylinder Disassembly

    BRAKES 11-19 Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal position adjustment. • Remove: Rear Master Cylinder (see Rear Master Cylinder Removal) Dust Cover [A] on Push Rod Retainer [B] (use the inside circlip pliers : 57001 -143) Push Rod [C] with Clevis installed Piston [D] with Secondary Cup and Primary Cup...
  • Page 231 11-20 BRAKES • Check the dust covers [E] for damage. * l f they are damaged, replace them. • Check that the relief [F] and supply [G] ports are not plugged. + If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.
  • Page 232: Brake Discs

    BRAKES 11-21 Brake Discs Disc Installation •Tighten the disc bolts. Torque - Front Disc Bolts (650A) 9.8 N-m (1.0 kg-m, 87 in-lb) [A] Front Disc Bolts (650C) 23 N-m (2.3 kg-m, 16.5 ft-lb)[A] Rear Disc Bolts 23 N-m (2.3 kg-m, 16.5 ft-lb)[B] °...
  • Page 233: Brake Hoses

    1 1 - 2 2 B R A K E S Brake Hoses Brake Hose Removal • Drain the brake fluid (see Brake Fluid Change). • Remove the banjo bolts [A] at both ends of the brake hose [B] and pull the hose off the motorcycle.
  • Page 234 SUSPENSION 12 Suspension Table of Contents Exploded View 12-2 Rear Shock Absorber Installation (KLX650C) 1 2 - 1 9 Specifications 12-4 Front Fork 12-5 Oil Draining (KLX650A) 12-19 Oil Filling (KLX650A) 12-21 Air Pressure Adjustment 12-5 Spring Tension (KLX650A) 12-24 Compression Damping Adjustment Scrapping 1 2 - 2 4...
  • Page 235: Exploded View

    12-2 SUSPENSION Exploded View Needle Bearings: Face the manufacturer's marks out. 25 N-m (2.5 kg-m, 18.0 ft-lb) : Apply fork oil. 29 N-m (3.0 kg-m, 22 ft-lb) : Apply grease. 15 N-m (1.5 kg-m, 11.0 ft-lb) : Apply a non-permanent locking agent. 54 N-m (5.5 kg-m, 40 ft-lb) : Apply molybdenum disulfide grease.
  • Page 236 SUSPENSION 12-3...
  • Page 237: Specifications

    12-4 SUSPENSION Specifications Item S t a n d a r d Front Fork (per one unit): Fork inner tube diameter 43 mm Air pressure Atomospheric pressure (Non-adjustable) Compression damper setting KLX650A 14th click from the first click of the fully clockwise position Fork oil viscosity KAYABA 01 or SAE5W 547 ±...
  • Page 238: Front Fork

    S U S P E N S I O N 1 2 - 5 Front Fork Air Pressure Adjustment The standard air pressure in the fork legs is atmospheric pressure. The air pressure in the fork legs increases as the fork heats up, so the fork action will get stiffer as the vehicle operation progresses.
  • Page 239 12-6 SUSPENSION • Push d o w n the fork spring [A] and insert the fork spring holder [B] under the push rod nut [C] as shown. Special Tool - Fork Spring Holder: 57001-1286 O A person should push d o w n the fork spring and another person should insert the fork spring holder.
  • Page 240 SUSPENSION 12-7 • Purge the air from the fork cylinder by gently moving the piston rod puller [A] up and d o w n five times. Special Tool - Fork Piston Rod Puller, M10 x 1.0: 57001-1298 • Purge the air from between the inner and outer tubes by pumping the outer tube [A] up and d o w n .
  • Page 241 12-8 SUSPENSION • After purging the air from the fork, let it sit for about five minutes so that any suspended air bubbles can surface. • Measure the oil level, using the fork oil level gauge [ A ] , Special Tool - Fork Oil Level Gauge: 57001-1290 OSet the gauge stopper [B] so that its lower side shows the oil level distance specified [ C ] .
  • Page 242: Front Fork Removal

    SUSPENSION 12-9 • Remove the fork piston rod puller (special tool). • Check the O-ring on the top plug and replace it with a new one if damaged. • Screw the top plug onto the push rod. • Holding the top plug [A] with a wrench, tighten the push rod nut [B] against the top plug.
  • Page 243: Front Fork Installation

    12-10 SUSPENSION • Remove: Headlight Rubber Bands Headlight Unit • Loosen the upper and lower fork clamp bolts [ A ] . • W i t h a twisting motion, work the fork leg [A] d o w n and out. Front Fork Installation •...
  • Page 244 SUSPENSION 12-11 • Remove: Push Rod Nut [A] Collar [B] Spring Guide fC] • Hold the front fork horizontally in a vise. • Stop the cylinder unit [A] from turning by using the fork cylinder holder [ B ] . •...
  • Page 245 12-12 SUSPENSION • Pull the push rod assembly [A] out the bottom of the inner cylinder [B]. • Separate the inner tube [A] from the outer tube [B] as follows: O Slide up the spring band [C]. O Remove the dust seal [D] from the outer tube. O Do not remove the dust seal from the inner tube unless it is absolutely necessary.
  • Page 246: Front Fork Assembly

    SUSPENSION 12-13 Front Fork Assembly • Replace the following parts removed with new one. Outer Tube Guide Bush [A] Oil Seal [B] Retaining Ring [C] Dust Seal (If removed from the inner tube) [D] Inner Tube Guide Bush [E] Cylinder Valve Assembly Bottom Gasket [F] •...
  • Page 247: Inner Tube Inspection

    12-14 SUSPENSION • Install the spring guide [A] so that the large chamfered side [B] is d o w n w a r d . • Install the collar [ C ] , • Pull the piston rod up above the outer tube top. •...
  • Page 248: Dust Seal Inspection

    SUSPENSION 12-15 CAUTION If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube. Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. * Replace it if necessary.
  • Page 249: Rear Shock Absorber

    1 2 - 1 6 S U S P E N S I O N Rear Shock Absorber Rebound Damping Adjustment (KLX650A) • T u r n the rebound damping adjuster [ A ] the desired number of clicks. OThe standard adjuster setting for an average-build rider 68 kg (1 50 lb) is the 9th click back from the 1st click of the fully clockwise position.
  • Page 250: Spring Adjustment (Klx650C)

    SUSPENSION 12-17 • T u r n i n g the adjusting nut [A] downward makes the spring action harder and upward softer. • Measure the adjusting nut position shown and adjust the spring as follows. Spring Preload Setting Standard adjusting nut position [B] : 117.5 mm (4.65 in) Nut adjusting range : 106 ~ 126 mm (4.16 ~ 4.95 in) Standard spring preload : 1052 N (107.3 kg, 236 lb) Preload change per turn of the nut: 109 N (11.1 kg, 24.5 lb)
  • Page 251: Rear Shock Absorber Removal (Klx650A)

    12-18 SUSPENSION Rear Shock Absorber Removal (KLX650A) • Using the jack (special tool), raise the rear wheel off the ground (see Wheels/Tires chapter). • Remove: Lower Tie-rod Bolt [ A ] Lower Shock Absorber Bolt [B] Upper Shock Absorber Bolt [C] Front [ D ] •...
  • Page 252: Rear Shock Absorber Installation

    SUSPENSION 12-19 • Remove: Lower Tie-rod Bolt [A] Lower Shock Absorber Bolt [B] Upper Shock Absorber Bolt [C] Front [ D ] • Support the rocker arm to slide out the bolts. • Remove the shock absorber [A] from the motorcycle left side. Rear Shock Absorber Installation (KLX650C) •...
  • Page 253 12-20 SUSPENSION • Point the reservoir valve away from you. Slowly release the nitrogen gas pressure from the gas reservoir [A] by pushing d o w n the valve core [ B ] with a screwdriver. AWARNING Do not point the valve toward your face or body when releasing the nitrogen gas pressure.
  • Page 254: Oil Filling (Klx650A)

    • Install a steel tire valve cap [A] on the gas reservoir valve and pull the gas reservoir cap out of the gas reservoir using pliers. OThe bladder [B] comes out with the gas reservoir cap. Oil Filling (KLX650A) • Pour KYB K2-C (SAE5W or Bel-Ray SE2 #40) oil into the gas reservoir [A] half full.
  • Page 255 12-22 SUSPENSION • Fit the circlip [A] in the groove in the gas reservoir [ B ] . • Pull up the gas reservoir cap [A] against the circlip. The end [B] of the gas reservoir cap must be 0.7 mm upper than the end [C] of the gas reservoir.
  • Page 256 SUSPENSION 12-23 • Push the seal assembly into the rear shock body until it just clears the circlip groove. • Check the circlip. If it is deformed or damaged, replace it with a new one. • Fit the circlip [A] into the groove in the rear shock body [ B ] . AWARNING If the circlip is not a certain fit in the groove in the rear shock body, the push rod assembly may come out of the shock absorber when...
  • Page 257: Spring Tension (Klx650A)

    12-24 SUSPENSION • Install the spring and spring guide. O Both damping adjusters must be on the same side. Compression Damping Adjuster [A] Rebound Damping Adjuster [ B ] • Adjust the following (see this chapter). Spring Preload Compression Damping Adjuster Rebound Damping Adjuster •...
  • Page 258: Swingarm

    S U S P E M S I O N 1 2 - 2 5 Swingarm Swingarm Removal • Squeeze the brake lever slowly and hold it with a band [ A ] , CAUTION Be sure to hold the front brake when removing the swingarm or the motorcycle may fall over.
  • Page 259: Swingarm Bearing Removal

    12-26 SUSPENSION • T i g h t e n : Torque - Rocker Arm Nut: 98 N-m (10.0 kg-m, 72 ft-lb) Swlngarm Pivot Nut: 88 N-m (9.0 kg-m, 65 ft-lb) Shock Absorber Bolt: 39 N-m (4.0 kg-m, 29 ft-lb) Tie-rod Nut: 81 N-m (8.3 kg-m, 60 ft-lb) •...
  • Page 260: Swingarm Pivot Check (Klx650A)

    SUSPENSION 12-27 Swingarm Pivot Check (KLX650A) • Check the pivot of the swingarm and uni-trak link (tie-rod and rocker arm) for wear periodically, or whenever excessive play is suspected. • Raise the rear wheel off the ground (see Wheels/Tires chapter). •...
  • Page 261: Tie-Rod, Rocker Arm

    12-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Raise the rear wheel off the ground (see Wheels/Tires chapter). • Squeeze the brake lever slowly and hold it with a band. • Remove the following. Front and Rear Tie-rod Bolts [A] CAUTION When pulling out the tie-rod bolts, lift the swingarm or the rocker arm slightly.
  • Page 262: Rocker Arm Installation

    SUSPENSION 12-29 Rocker Arm Installation • Apply plenty of molybdenum disulfide grease to the inside of needle bearings and sleeves. Rocker Arm Needle Bearings Tie-rod Needle Bearings Torque - Rocker Arm Nut: 98 N-m (10.0 kg-m, 72 ft-lb) Swingarm Pivot Nut: 88 N-m (9.0 kg-m, 65 ft-lb) Rear Shock Absorber Bolt: 39 N-m (4.0 kg-m, 29 ft-lb) Tie-rod Nuts : 81 N-m (8.3 kg-m, 60 ft-lb) Rocker Arm/Tie-Rod Bearing Removal...
  • Page 263 12-30 SUSPENSION Rocker Arm/Tie-Rod Sleeve Inspection * l f there is visible damage, replace the sleeves and all the needle bearings as a set.
  • Page 264 STEERING 13-1 Steering Table of Contents Exploded View 13-2 Specifications 13-3 Steering 13-3 Steering Inspection 13-3 Steering Adjustment 13-3 Handlebar 13-4 Handlebar Removal 13-4 Handlebar Installation 13-4 Steering Stem 13-5 Steering Stem Removal 13-5 Steering Stem Installation 13-5 Steering Stem Warp 13-6 Steering Stem Bearing 13-7...
  • Page 265: 13-2 Steering

    13-2 STEERING Exploded View...
  • Page 266: Specifications

    STEERING 13-3 Specifications Special Tools - Jack: 57001-1238 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Remover: 57001-1107 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver: 57001-1106 Head Pipe Outer Race Driver: 57001-1077 Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter: 57001-1074 S t e e r i n g Steering Inspection...
  • Page 267: Handlebar

    13-4 STEERING Handlebar Handlebar Removal • Remove: Handguards Lighting Switch (KLX650A) [A] Engine Stop Switch (KLX650A) [B] Right Handlebar Switch (KLX650C) [C] Left Handlebar Switch (KLX650C) [D] Throttle Cable Upper Ends and Throttle Grip Front Brake Master Cylinder [E] Clutch Lever Assembly [F] •...
  • Page 268: Steering Stem

    S T E E R I N G 1 3 - 5 Steering Stem Steering Stem Removal • Remove: Handlebar (see this chapter) Headlight Cover Bands [A] Headlight Cover [B] • Raise the front wheel off the ground (see Wheels/Tires chapter) Special Tool - Jack: 57001-1238 •...
  • Page 269: Steering Stem Warp

    13-6 STEERING • Install: Front Fork (see Suspension chapter) Front wheel (see Wheels/Tires chapter) Handlebar (see this chapter) • Check and adjust the following items after installation. Steering (see this chapter) Throttle Cables (see Fuel System chapter) Clutch Cable (see Clutch chapter) Headlight Aim Front Brake AWARNING...
  • Page 270: Steering Stem Bearing

    STEERING 13-7 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see this chapter). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover: 57001-1107 [A] NOTE Olf either steering stem bearing is damaged, it is recommended that both upper and lower bearings (including outer races)
  • Page 271: Stem Bearing Lubrication

    13-8 STEERING O Check that there is no play and the steering stem turns smoothly w i t h o u t rattles. If not, the steering stem bearings may be damaged. O Again back out the stem nut a fraction of a turn until it turns lightly. OTurn the stem nut lightly clockwise until it just becomes hard to turn.
  • Page 272 F R A M E 1 4 - 1 Frame Table of Contents Exploded View 14-2 Seat 14-4 Seat Removal 14-4 Seat Installation 14-4 Side Covers 14-4 Side Cover Removal 14-4 Rear Fender (KLX650A) 14-5 Rear Fender Front Section Removal 14-5 Rear Fender Rear Section Removal 14-5...
  • Page 273: Exploded View

    14-2 FRAME Exploded View...
  • Page 274 FRAME 14-3...
  • Page 275: Seat

    14-4 FRAME Seat Seat Removal • Remove the seat bolts [A] on both sides. • Pull the seat rearward [B] and remove it. Seat Installation • Slip the seat hooks [A] under the washer [B] and the frame brace [C]. Side Covers Side Cover Removal •...
  • Page 276: Rear Fender (Klx650A)

    Rear Fender (KLX650A) Rear Fender Front Section Removal • Remove: Seat (see Seat Removal) Side Covers (see Side Cover Removal) • Unscrew the rear fender front section bolts [A] and take off the rear fender front section [B] downward [ C ] . Rear Fender Rear Section Removal •...
  • Page 277: Rear Fender Rear Section Removal

    14-6 FRAME • Unscrew the rear fender front section bolts [ A ] , • T a k e off the rear fender front section [A] downward [ B ] . Rear Fender Rear Section Removal • Remove: Seat (see Seat Removal) Side Covers (see Side Cover Removal) •...
  • Page 278 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Exploded View .15-2 Brush Plate Assembly Inspection 15-43 Parts Location (KLX650A) .15-6 Positive Brush Assembly Inspection 15-43 Parts Location KLX650C .15-7 Starter Relay Inspection 1 5-43 KLX650-A1 Wiring Diagram .15-8 Starter Circuit Relay Inspection 1 5-43 KLX650-C1 Wiring Diagram (US, Australia).
  • Page 279: Exploded View

    15-2 ELECTRICAL SYSTEM Exploded View...
  • Page 280 ELECTRICAL SYSTEM 15-3 Regulator/Rectifier Starter Torque Limiter Starter Relay Starter Clutch Idle Gear EO: Apply engine oil. Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. T 1 : 8.8 N-m (0.90 kg-m, 78 in-lb) T2: 2.5 N-m (0.25 kg-m, 22 in-lb) T3: 12 N-m (1.2 kg-m, 104 in-lb) T4: 21 6 N-m (22.0 kg-m, 1 59 ft-lb) T5: 11 N-m (1.1 kg-m, 95 in-lb)
  • Page 281 15-4 ELECTRICAL SYSTEM Left-handlebar Switch Right-handlebar Switch Ignition Switch Headlight Relay 5. Turn Signal Relay Interlock Diode Unit Fuse Case Coolant Temperature Switch Thermostatic Fan Switch 10. Radiator Fan 11. Starter Circuit Relay 12. Fan Relay 13. Neutral Switch TV. 8.8 N-m (0.90 kg-m, 78 in-lb) T2: 15 N-m (1.5 kg-m, 11.0 ft-lb)
  • Page 282 ELECTRICAL SYSTEM 15-5 1. Headlight Unit 2. Tail/Brake Light 3. License Light...
  • Page 283: Parts Location (Klx650A)

    15-6 ELECTRICAL SYSTEM Parts Location (KLX650A) 1. Ignition Coil 4. Pickup Coil 7. Lighting Switch 2. Headlight Capacitor 5. Magneto Flywheel 3. CDI Unit 6. Regulator...
  • Page 284: Parts Location Klx650C

    ELECTRICAL SYSTEM 15-7 Parts Location (KLX650C) 1. Starter Lockout Switch 8. Coolant Temperature Switch 15. Battery 9. Pickup Coil 16. Starter Circuit Relay 2. Ignition Coil 3. Interlock Diode Unit 10. Magneto Flywheel 17. Turn Signal Relay 4. 10A Fuse 1 1 .
  • Page 286: Klx650-C1 Wiring Diagram (Us, Australia)

    KLX650-C1 Wiring Diagram (US, Australia)
  • Page 287 ELECTRICAL SYSTEM 15-9...
  • Page 288: Klx650-C1 Wiring Diagram (Other Than Us, Australia)

    15-10 ELECTRICAL SYSTEM KLX650-C1 Wiring Diagram (Other than US, Australia)
  • Page 290: Specifications

    ELECTRICAL SYSTEM 15-11 Specifications Item Standard Service Limit Battery(KLX650C): Type MF (Maintenance Free) Battery 12 V 8 Ah Capacity 12.6 V or more Voltage Charging System(KLX650C): Alternator type Three-phase AC Charging voltage 14 ~ 1 5 V (regulator/rectifier output voltage) Alternator output voltage more than 34 V @4000 r/min (rpm) Charging coil resistance...
  • Page 291 Flywheel Holder: 57001-1313 Rotor Puller, M16/M18/M20/M22 x 1.5: 57001-1216 Flywheel Puller, M30 x 1.5: 57001-1191 Rotor Holder: 57001-1184 Spark Plug Wrench, Hex 18: 57001-1024 Timing Light: 57001-1241 S e a l a n t - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 292: Precautions

    ELECTRICAL SYSTEM 15-13 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. O D o not reverse the battery lead connections. This will burn out the diodes in the electrical parts (KLX650C). OAlways check battery condition before condemning other parts of an electrical system.
  • Page 293: Electrical Wiring

    15-14 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • V i s u a l l y inspect the wiring for signs of burning, fraying, etc. * l f any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 294: Battery (Klx650C)

    ELECTRICAL S Y S T E M 1 5 - 1 5 Battery (KLX650C) Battery Removal • Remove: Seat (see Frame chapter) Left Side Cover (see Frame chapter) Battery Cover Band [A] Battery Holder [B] • Disconnect the battery negative ( - ) cable [C] first, and then the positive ( + ) cable [ D ] .
  • Page 295 15-16 ELECTRICAL SYSTEM • T a k e the electrolyte container out of the vinyl bag. • Detach the strip of caps [A] from the container. NOTE ODo not discard the strip of caps because it is used as the battery plugs later.
  • Page 296: Initial Charge

    ELECTRICAL SYSTEM 15-17 Initial Charge While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of higher than 12.5 V after 10 minutes of filling (Note 1), no initial charge is necessary.
  • Page 297: Charging Condition Inspection

    15-18 ELECTRICAL SYSTEM Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage. • Remove: Seat (see Frame chapter) Left Side Cover (see Frame chapter) • Disconnect the battery terminal leads. CAUTION Be sure to disconnect the negative terminal lead first. •...
  • Page 298 ELECTRICAL SYSTEM 15-19 OTerminal Voltage: less than 11.5 V Charging Method: 0.9 A x 20 h NOTE O Raise the voltage (25 V as maximum), and charge for about 5 minutes as a yardstick. (If ammeter shows no change in current after 5 minutes, you need a new battery.) The current, if it can flow into the battery, tends to become excessive.
  • Page 299: Flywheel Magneto

    15-20 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal (KLX650A) • Drain the oil (see Engine Lubrication System chapter). • Remove: Side Covers (see Frame chapter) Seat (see Frame chapter) • Pull off the magneto lead connector [ A ] . •...
  • Page 300: Magneto Cover Removal

    ELECTRICAL SYSTEM 15-21 Magneto Cover Removal (KLX650C) • Drain the oil (see Engine Lubrication System chapter). • Remove: Left Side Cover (see Frame chapter) Battery Cover Engine Sprocket Cover [A] CAUTION To avoid damage to the neutral switch lead, be sure to remove the engine sprocket cover.
  • Page 301: Magneto Flywheel Removal (Klx650A)

    15-22 ELECTRICAL SYSTEM • Run the neutral switch lead [A] as shown to avoid its being pinched by the engine sprocket cover [ B ] , • Route the magneto leads in accordance with the Cable, Wire, and Hose Routing section of the General Information chapter. Torque - Magneto Cover Bolts : 8.8 N-m (0.90 kg-m, 78 in-lb) •...
  • Page 302: Magneto Flywheel Removal

    ELECTRICAL SYSTEM 15-23 Special Tool - Flywheel Holder: 57001-1313 • Install a new gasket and the magneto cover (see this chapter). Magneto Flywheel Removal (KLX650C) • Remove: Shift Pedal Magneto Cover (see Magneto Cover Removal) Magneto Lead Clamp Starter Clutch Idle Gear [A] Starter Torque Limiter [B] •...
  • Page 303: Magneto Stator Removal

    15-24 ELECTRICAL SYSTEM • Install the starter clutch gear [A] and the washer [B] on the crankshaft. • Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone. AWARNING These cleaning fluids are usually highly flammable and harmful If breathed for prolonged periods.
  • Page 304: Magneto Stator Installation

    ELECTRICAL S Y S T E M 1 5 - 2 5 Magneto Stator Installation • Fit the stator coil lead grommet first, and the pickup coil lead grommet into the notch of the cover securely. Torque - Magneto Stator Bolts : KLX650A : 8.8 N-m (0.90 kg-m, 78 in-lb) KLX650C : 12 N-m (1.2 kg-m, 104 in-lb) Magneto Inspection...
  • Page 305: Charging System (Klx650C)

    1 5 - 2 6 ELECTRICAL S Y S T E M Charging System (KLX650C) Regulator I Rectifier Removal • Remove: Left Side Cover (see Frame chapter) Battery Cover • Pull off the regulator/rectifier connector [ A ] . • Remove the regulator/rectifier [B] from the bottom of the battery case. Regulator/Rectifier Output Voltage Inspection •...
  • Page 306: Regulator/Rectifier Inspection

    [ B ] . CAUTION Use only Hand Tester 57001-983 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the regulator/rectifier will be damaged.
  • Page 307 15-28 ELECTRICAL SYSTEM...
  • Page 308: Ignition System

    ELECTRICAL SYSTEM 15-29 Ignition System A WARNING The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the CDI connectors while the engine is running.
  • Page 309: Ignition Coil Installation

    15-30 ELECTRICAL SYSTEM Ignition Coil Installation • Connect the primary winding leads to the ignition coil terminals as shown. BK/Y Lead [ A ] -»• ( - ) Mark BL (KLX650C, BK/W) Lead [B] -* ( + ) Mark Ignition Coil Inspection •...
  • Page 310: Pickup Coil Removal

    ELECTRICAL SYSTEM 15-31 Pickup Coil Removal • Remove the magneto cover (see Magneto Cover Removal). • Remove the holding plates [ A ] . • Pull the pickup coil lead grommet [B] out of the notch of the cover. • Remove the screws and take off the pickup coil [ C ] . Pickup Coil Inspection •...
  • Page 311: Magneto Flywheel Inspection

    15-32 ELECTRICAL SYSTEM Magneto Flywheel Inspection • Check the timing projection [A] for damage such as chipping or grooving. * l f the timing projection on the flywheel is visibly damaged, replace the magneto flywheel. Ignition Timing Test • Remove the ignition timing inspection plug. •...
  • Page 312: Cdi Unit Removal (Klx650C)

    * l f the tester readings are not as specified, replace the CDI unit. CAUTION Use only Hand Tester 57001-983 for this test. A multi-meter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the CDI unit will be damaged.
  • Page 313 15-34 ELECTRICAL SYSTEM CDI Unit Resistance (KLX650C) unit: kQ Range Range Tester Positive ( + ) Lead Connections x 1 kQ x 1 kQ W/Y BK/R BK/W BK/R " BK/W Tester Negative (-) Lead Connections...
  • Page 314: Cdi Unit Troubleshooting

    ELECTRICAL SYSTEM 15-35 CDI Unit Troubleshooting:...
  • Page 315: Interlock Diode Unit Inspection (Klx650C)

    15-36 ELECTRICAL SYSTEM Interlock Diode Unit Inspection (KLX650C) • Remove the seat (see Frame chapter). • Remove the interlock diode unit [A] from the motorcycle. • Zero the hand tester and connect it to the diode unit terminals. Special Tool - Hand Tester: 57001-983 •...
  • Page 316 ELECTRICAL SYSTEM 15-37 Ignition Circuit (KLX650A)
  • Page 317 15-38 ELECTRICAL SYSTEM Ignition Circuits (KLX650C) 13. Battery 1. Ignition Switch 7. Interlock Diode Unit 14. CDI Unit 2. Engine Stop Switch 8. Starter Circuit Relay 15. Pickup Coil 9. Starter Lockout Switch 3. Starter Button 16. Neutral Switch 10. Side Stand Switch 4.
  • Page 318: Electric Starter System (Klx650C)

    ELECTRICAL SYSTEM 15-39 Electric Starter System (KLX650C) Starter Motor Removal • Remove: Exhaust Pipe and Muffler (see Engine Top End chapter) Magneto Cover (see Magneto Cover Removal) Magneto Flywheel (see Magneto Flywheel Removal) Magneto Case Removal (see Magneto Case Removal) •...
  • Page 319 15-40 ELECTRICAL SYSTEM • Pull the armature [A] out of the yoke [B]. •Take off the brush plate assembly [A]. • Unscrew the terminal locknut [B], and take off the washers and positive brush assembly [C]. • Remove the springs [A] from the brush plate assembly [B]. Starter Motor Assembly •...
  • Page 320 ELECTRICAL SYSTEM 15-41 • Fit the brushes into the holders and install the armature. NOTE O Turning the spring end clockwise, insert the suitable plate between the spring end and the brush holder [B] to prevent the brush [C] from pushing in by spring force. •...
  • Page 321: Armature Inspection

    1 5 - 4 2 ELECTRICAL S Y S T E M Commutator Cleaning I Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [ B ] , and clean out the grooves. • Measure the diameter [A] of the commutator. * Replace the starter motor with a new one if the commutator diameter is less than the service limit.
  • Page 322: Brush Plate Assembly Inspection

    ELECTRICAL S Y S T E M 1 5 - 4 3 Brush Plate Assembly Inspection • Using the x 1 D hand tester range, measure the resistance [ A ] between the negative brushes [B] and the metal plate [C], ~k\i there is not close to zero ohms, the brush plate assembly must be replaced.
  • Page 323 15-44 ELECTRICAL SYSTEM • Connect the hand tester [A] and 12 V battery [B] to the starter cirucit relay [C] as shown. * l f the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: x 1 Q Criteria: When battery is connected - + 0 Q...
  • Page 324: Starter Clutch (Klx650C)

    ELECTRICAL S Y S T E M 1 5 - 4 5 Starter Clutch (KLX650C) Starter Clutch Removal • Remove the magneto flywheel (see Magneto Flywheel Removal). • Remove the starter gear [A] from the magneto flywheel [ B ] . •...
  • Page 325: Starter Torque Limiter Removal

    1 5 - 4 6 ELECTRICAL S Y S T E M Starter Torque Limiter Removal • Remove: Magneto Cover (see this chapter) Starter Clutch Idle Gear • Remove the starter torque limiter [A]. Starter Torque Limiter Installation • Apply molybdenum disulfide grease to the torque limiter shaft [B]. Starter Torque Limiter Inspection •...
  • Page 326: Lighting System

    ELECTRICAL SYSTEM 15-47 Lighting System The KLX650C's US and Australia models have a headlight relay. these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 327: Headlight Bulb Replacement Klx650A)

    15-48 ELECTRICAL SYSTEM • Loosen the lower headlight bolt [A] and adjust the headlight vertically. •Tighten the lower headlight bolt. • Install the headlight cover and tighten the screws securely. NOTE OOn high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 328 ELECTRICAL SYSTEM 15-49 • Remove: Lower Headlight Bolts [A] Upper Headlight Bolts [B] • Pull out the bulb socket [A] from the headlight unit. • Slide back the dust cover f B] • Push the holder [A] in, turn it counterclockwise, and remove it. •...
  • Page 329: Headlight Unit Installation

    15-50 ELECTRICAL SYSTEM • Install the dust cover [A] so that the "TOP" mark points up and the cover fits onto the bulb firmly as shown. • Check the headlight aim after installation. Headlight Unit Installation • Install the headlight unit [A] so that the "TOP" mark [B] on the lens points up.
  • Page 330: Taillight Bulb Replacement (Klx650C)

    ELECTRICAL SYSTEM 15-51 Taillight Bulb Replacement (KLX650C) • Replace the taillight bulb [A] in the same manner as the KLX650A's taillight bulb. License Light Bulb Replacement (KLX650C) • Replace the license light bulb in the same manner as the KLX650A's taillight bulb.
  • Page 331: Alternator (Magneto) Inspection (Klx650A)

    15-52 ELECTRICAL SYSTEM Alternator (Magneto) Inspection (KLX650A) There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor, or flywheel magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.
  • Page 332: Regulator Inspection (Klx650A)

    * l f the tester readings are not as specified, replace the regulator [ B ] , CAUTION Use only Hand Tester 57001-983 for this test. An ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the regulator will be damaged.
  • Page 333 15-54 ELECTRICAL SYSTEM • Measure the resistance of the capacitor, using the hand tester. This is a simple, but not a complete check. O Use the highest resistance range of the hand tester. Special Tool - Hand Tester: 57001-983 * l f the tester indicates some deflection of the hand and returns, the capacitor may be good.
  • Page 334: Headlight Relay Inspection (Klx650C-Us, As)

    ELECTRICAL SYSTEM 15-55 Headlight Relay Inspection (KLX650C-US, AS) • Remove the headlight cover (see Headlight Bulb Replacement). • Remove the headlight relay [A] from the headlight bracket [ B ] . • Connect the hand tester [ A ] and 12 V battery [ B ] to the headlight relay [C] as shown.
  • Page 335 15-56 ELECTRICAL SYSTEM Headlight Circuit (KLX650C US, Australia) 6. Headlight Relay 11. Alternator (Magneto) 1. Ignition Switch 12. Starter Relay 2. High Beam Indicator Light 7. Headlight Diodes 8.10A Headlight Fuse 13. 20A Main Fuse 3. Headlight 14. Battery 9. Dimmer Switch 4.
  • Page 336 ELECTRICAL SYSTEM 15-57 Headlight Circuit (KLX650C, Other than US, Australia) 1. Ignition Switch 4. Headlight Switch 7. Starter Relay 2. High Beam Indicator Light 5. 10A Headlight Fuse 8. 20A Main Fuse 3. Headlight 6. Dimmer Switch 9. Battery...
  • Page 337: Turn Signal Relay Inspection

    15-58 ELECTRICAL SYSTEM Turn Signal Relay Inspection (KLX650C) Since the turn signal relay is designed to operate correctly only when t w o turn signals (one front and one rear) and the turn signal indicator light are properly connected in the circuit, trouble may result from a burned out bulb, a bulb of incorrect wattage, loose wiring, as well as from a defect in the relay itself.
  • Page 338 ELECTRICAL SYSTEM 15-59 Turn Signal Light Circuit 1. Ignition Switch 5. Front Left Turn Signal Light 9. Battery 2. Turn Signal Relay 6. Turn Signal Switch 10. Rear Right Turn Signal Light 3. Turn Signal Indicator Light 7. Starter Relay 1 1 .
  • Page 339: Meters (Klx650C)

    15-60 ELECTRICAL SYSTEM Meters (KLX650C) Meter Removal • Remove: Headlight Unit (see Headlight Bulb Replacement) Turn Signal Relay • Disconnect the meter lead connector [ A ] . • Disconnect the speedometer cable upper end [ B ] . • Unscrew the mounting bolts [A] and remove the meter unit [B] CAUTION Place the meter so that the face is up.
  • Page 340: Indicator Bulb Replacement

    ELECTRICAL S Y S T E M 15-61 Indicator Bulb Replacement CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. All the indicator bulbs are of a wedge-base type. Do not use bulb rated for greater wattage than the specified value. •...
  • Page 341: Radiator Fan (Klx650C)

    15-62 ELECTRICAL SYSTEM Tachometer Circuit 1. Ignition Switch 4. Ignition Coil 7. CDI Unit 2. Tachometer 5. 20A Main Fuse 8. Battery 3. Spark Plug 6. Starter Relay Radiator Fan (KLX650C) Radiator Fan Removal AWARNING NEVER TOUCH THE RADIATOR FAN UNTIL THE IGNITION SWITCH IS TURNED OFF.
  • Page 342: Fan Motor Inspection

    ELECTRICAL SYSTEM 15-63 Fan Motor Inspection • Disconnect the 2-pin connector [A] in the fan leads. • Using two auxiliary wires, supply battery power [B] to the fan motor. * l f the fan does not rotate at this time, the fan motor is defective and must be replaced.
  • Page 343: Coolant Temperature Warning System (Klx650C)

    15-64 ELECTRICAL SYSTEM Radiator Fan Circuit 7. Starter Relay 1. Radiator Fan Motor 4. Fan Relay 8. 20 A Main Fuse 5 . 1 0 A Fan Fuse 2. Fan Switch 6. Battery 3. Radiator Coolant Temperature Warning System (KLX650C) When the ignition switch is turned on with the transmission in neutral, the warning light flashes regardless of coolant temperature.
  • Page 344: Warning Light Operation Inspection

    ELECTRICAL SYSTEM 15-65 (3) Coolant temperature is not high but the warning light stays on continuously. • Check the warning circuit wiring. • If it is good, check the coolant temperature switch [ A ] (see this chapter). (4) Warning light goes on and off irregularly. •...
  • Page 345: Switches (Klx650C)

    15-66 ELECTRICAL SYSTEM Switches (KLX650C) Brake Light Timing Inspection • T u r n on the ignition switch. • Check the operation of the rear brake light switch by depressing the brake pedal. * l f it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 10 mm of pedal travel [A]...
  • Page 346: Thermostatic Fan Switch Inspection

    ELECTRICAL S Y S T E M 1 5 - 6 7 Thermostatic Fan Switch Inspection • Remove the fan switch from the radiator (see Thermostatic Fan Switch Removal in the Cooling System chapter). • Suspend the switch in a container of water so that the temperature-sensing projection and threaded portion are submerged.
  • Page 347: Fuses (Klx650C)

    1 5 - 6 8 ELECTRICAL S Y S T E M Fuses (KLX650C) 20 A Main Fuse Removal • Remove the fuse [A] from the starter relay [B], 10 A Fan and Light Fuse Removal • Remove the seat (see Frame chapter). •...
  • Page 348 APPENDIX 16-1 Appendix Table of Contents Additional Considerations for Racing (KLX650C) 16-2 Carburetor: 16-2 SparkPlug: 16-2 Spark Plug Inspection 16-3 Troubleshooting Guide 16-4 Nut, Bolt, and Fastener Tightness 16-8 Tightness Inspection 16-8 General Lubrication 16-9 Lubrication 16-9 Unit Conversion Table 16-10...
  • Page 349 • You are entirely responsible for the use of your motorcycle under abnormal conditions such as racing, and Kawasaki shall not be liable for any damages w h i c h might arise from such use.
  • Page 350 APPENDIX 16-3 When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800°C (750 ~ 1450°F) and can be judged by noting the condition and color of the ceramic insulator around the center electrode.
  • Page 351: Troubleshooting Guide

    16-4 APPENDIX Troubleshooting Guide NOTE Flywheel magneto damaged Ignition or engine stop switch shorted O This is not an exhaustive list, giving every possible Neutral, or starter locknut switch trouble (KLX650C) cause for each problem listed. It is meant simply as a Interlock diode unit trouble (KLX650C) rough guide to assist the troubleshooting for some of Wiring shorted or open...
  • Page 352: Poor Running Or No Power At High Speed

    APPENDIX 16-5 Compression release cam (K.A.C.R.) sticks open Brakes dragging (Engine stalls when moving off) Clutch slipping Other: Overheating Engine oil level too high CDI unit trouble Engine oil viscosity too high Carburetor vacuum piston doesn't slide smoothly Balancer mechanism malfunctioning Engine oil viscosity too high Drive train trouble Drive train trouble...
  • Page 353 1 6 - 6 A P P E N D I X Friction plate worn or warped Piston ring worn, broken, or stuck Steel plate worn or warped Piston seizure, damage Clutch spring broken or weak Cylinder head gasket leaking Clutch release mechanism trouble Exhaust pipe leaking at cylinder head connection Clutch hub or housing unevenly worn...
  • Page 354 APPENDIX 16-7 Black smoke: Contaminated pad Brake fluid deteriorated Air cleaner clogged Primary or secondary cup damaged master Main jet too large or fallen off cylinder Starter plunger stuck open Master cylinder scratched inside Fuel level in carburetor float bowl too high Brown smoke: Main jet too small Battery Discharged (KLX650C):...
  • Page 355 1 6 - 8 A P P E N D I X Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.
  • Page 356: General Lubrication

    APPENDIX 16-9 General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant in accord- ance with the Periodic Maintenance Chart. NOTE O Whenever the vehicle has been operated under wet or rainy condi- tions, or especially after using a high-pressure spray water, perform...
  • Page 357 1 6 - 1 0 A P P E N D I X Unit Conversion Table Units of Volume:...

This manual is also suitable for:

1993 klx650