1999-2006 Kawasaki W650/EJ650 Service Manual (P/N 99963-1315-01)

7.69 MB • Printable PDFs (ZIP Download)

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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:

  • Engine: 4-stroke, 2-cylinder, SOHC, 4-valve, air-cooled

  • Displacement: 675 cm³ (41.2 cu in.)

  • Compression Ratio: 8.6:1

  • Maximum Power: 37.0 kW (50 PS) @ 7,000 r/min (standard variants)

  • Maximum Torque: 56 N·m (41 ft·lb) @ 5,500 r/min

  • Carburetion: Keihin CVK 34 x 2

  • Transmission: 5-speed constant mesh, return shift

  • Drive System: Chain drive

  • Engine Oil Capacity: 3.0 L (3.2 US qt) (when engine is completely dry)

Technical Specifications
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Document Number / Seller:
26290 / Donald Rogers
File Size:
7.69 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Jun 5, 2026

Kawasaki Manual Features & Content Preview

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.

  • 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)
Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

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