1999–2006 Kawasaki W650/EJ650 Service Manual (P/N 99924-1245-08)
433 Pages • 7.69 MB • Printable PDFs (ZIP Download)
Kawasaki Models Covered & Key Technical Specifications
Models: 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
Model Years: 1999–2006 (1996, 1997, 1998, 1998, 2000, 2001, 2002, 2003, 2004, 2005, 2006)
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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
This 433-page PDF contains Kawasaki's W650 Motorcycle Service Manual, Part No. 99924-1245-08, in 8th Edition (1), dated October 18, 2005. It covers the 1999-2006 EJ650-A and EJ650-C model sequence through the C6F production run. Kawasaki states that the manual was designed primarily for trained mechanics in a properly equipped shop; owners with basic mechanical knowledge and the correct tools can also use it for basic maintenance and repair.
- Exact model coverage: Identifies EJ650-A1, A2, A3, A4, A5 and EJ650-C3, C4, C5, C6P, C7, and C6F, with a model-application chart listing the beginning frame number for each year and model.
- Hypoid-bevel camshaft drive repair: Details gear-noise and backlash adjustment, camshaft- and crankshaft-side case service, drive/driven gear replacement, shim selection, tooth-contact checks with machinist's dye, and the Bevel Gear Adjustment Flowchart.
- Engine and transmission work: Includes engine removal and installation; camshaft, rocker-arm, cylinder-head, valve-seat, cylinder, and piston repair; clutch service; crankcase splitting; crankshaft, connecting-rod, balancer, five-speed transmission, shift-drum, and kick-starter inspection and assembly.
- Fuel and emissions systems: Explains Keihin CVK34 carburetor synchronization, service fuel-level testing, carburetor removal, separation, disassembly, joining, and inspection, plus clean-air-system testing, California/Taiwan evaporative-emissions components, and carburetor-heater diagnosis for applicable markets.
- Chassis and brake procedures: Provides wheel and hub-bearing service, spoke and rim inspection, tire replacement and balancing, drive-chain and sprocket work, front-disc and rear-drum brake repair, hydraulic bleeding, fork overhaul, swingarm-bearing service, and steering-stem bearing replacement and adjustment.
- Electrical diagnosis and reference data: Supplies market-specific wiring diagrams, charging and ignition tests, starter-motor repair, meter and sensor checks, junction-box circuit tests, symptom-based troubleshooting, torque and locking-agent tables, fluid capacities, wear limits, clearance data, and electrical test specifications.
Model and Frame-Number Application
| Year | Model | Beginning frame number |
|---|---|---|
| 1999 | EJ650-A1 | JKAEJ650AAA000001 or JKAEJEA1□XA000001 |
| 2000 | EJ650-A2 | JKAEJEA1□YA015001 |
| 2001 | EJ650-A3 | JKAEJEA1□1A030001 or JKAEJ650AAA030001 |
| 2001 | EJ650-C3 | JKAEJ650ACA030001 |
| 2002 | EJ650-A4 | JKAEJEA1□2A037001 or JKAEJ650AAA037001 |
| 2002 | EJ650-C4 | JKAEJ650ACA037001 |
| 2003 | EJ650-A5 | JKAEJEA1□3A041001 or JKAEJ650AAA041001 |
| 2003 | EJ650-C5 | KAEJ650ACA041001 |
| 2004 | EJ650-C6P | JKAEJ650ACA046001 |
| 2005 | EJ650-C7 | JKAEJ650ACA049001 |
| 2006 | EJ650C6F | JKAEJ650ACA053001 |
The square symbol identifies a VIN digit that changes from one motorcycle to another. Market-specific material includes separate U.S./Canada and other-market maintenance charts, with further distinctions for California, Australia, Europe/Norway/Spain, Taiwan, and France applications. It also identifies later-production differences such as revised front-fork data beginning with EJ650-A3/C3, the battery change beginning with A5/C5, and a dedicat
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