1999-2006 Kawasaki W650/EJ650 Service Manual
Kawasaki W650/EJ650 motorcycle service documentation featuring engine, fuel system, clutch, and more
Kawasaki Models Covered & Key Technical Specifications
Models: Kawasaki W650, EJ650-A1, EJ650-A2, EJ650-A3, EJ650-A4, EJ650-A5, EJ650-C3, EJ650-C4, EJ650-C5, EJ650-C6P, EJ650-C7, EJ650-C6F
Sub-models / Variants: USA Model, California (CAL) Model, Australia (AU) Model, France (FR) Model
Trade Names: W650, EJ650
Model Years: 1999–2006
Technical Data:
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Engine: 4-stroke, 2-cylinder, SOHC, 4-valve, air-cooled
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Displacement: 675 cm³ (41.2 cu in.)
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Compression Ratio: 8.6:1
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Maximum Power: 37.0 kW (50 PS) @ 7,000 r/min (standard variants)
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Maximum Torque: 56 N·m (41 ft·lb) @ 5,500 r/min
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Carburetion: Keihin CVK 34 x 2
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Transmission: 5-speed constant mesh, return shift
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Drive System: Chain drive
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Engine Oil Capacity: 3.0 L (3.2 US qt) (when engine is completely dry)
Kawasaki Manual Features & Content Preview
Official Kawasaki W650 & EJ650 (1999–2006) Service Documentation
Working on the unique bevel gear drive of the W650 requires precise factory specifications, not guesswork. This 8th-edition official Kawasaki publication (99963-1315-01, dated October 2005) provides the unedited technical data needed for accurate tear-downs, routine maintenance, and system diagnostics.
- Instant download: Get immediate access directly from your device as soon as your order is placed.
- Fully searchable OCR: Stop flipping pages. Use keywords to jump instantly to the exact torque spec or wiring diagram you need.
- Shop-floor ready: Print specific sections to bring to the workbench, keeping your master digital copy completely grease-free.
- Permanent backup: The file is stored securely in your account, so you can easily retrieve it even after a hard-drive loss.
- Complete market coverage: Includes standard, USA, California, Australia, and France configurations, incorporating all technical updates up to the C6F production run.
Inside the Reference Material
Forget hunting through forums for unverified numbers. This 56-page reference delivers exact OEM data. Major sections break down the bevel gear drive system, carburetor synchronization procedures, and steering stem bearing maintenance. You also get comprehensive exploded-view diagrams that show correct part orientation, ensuring everything goes back together exactly as the factory intended. Always ensure your workspace adheres to standard safety protocols and utilize proper lifting equipment before initiating heavy engine work or chassis disassembly.
Key Factory Specifications
The manual clearly distinguishes between standard dimensions and strict service limits for critical components. Examples of the precise data included:
- Engine oil capacity: 3.0 liters (when completely dry)
- Clutch lever free play: 2–3 mm
- Idle speed: 900 ±50 RPM
- Inlet valve clearance: 0.08–0.13 mm
- Front fork oil level: 137 ±2 mm (Note: 112 ±2 mm for later EJ650-A3/C3 models)
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