1993-1996 Kawasaki KLX650R, KLX650 Motorcycle Service Manual
Troubleshooting, parts diagrams, and service data for Kawasaki KLX650R and KLX650 models. This manual details engine, chassis, and electrical system repairs. PN 99969-1040-03.
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Models Covered & Key Technical Specifications
Unified Operations Hydraulic Manual: Kawasaki KLX650R, KLX650 1993-1996 Motorcycle Service Manual Calibration-Manual Technical Manual Archive | Suite.
- Designated Spacing Data: 88 N-m is set to prevent overtightening of the axle nuts. Sequences.
- Verified Dimensional Tolerance: For optimal operation, 2.00-2.10 mm is standardized to ensure proper fitment of components. Baseline.
- Nominal Generation Capacity: 1.5 kg -- signifies the active weight capacity of the rear shock absorber. Requirements.
- Design Velocity Specs: The front fork travel corresponds to 285 mm for standard operation. Threshold.
- Engineered Output Quality: Suspension damping reaches 69.5-72.5 C for optimal performance. Mapping.
- Essential Gap Specs: The primary drive gear requires 2.272 for maximum throughput. Configuration.
Professional Workshop Service Manual & Technical Specifications
Kawasaki KLX650R, KLX650 Motorcycle Service Manual 1993-1996 Service Manual: Kawasaki KLX650R, KLX650 (Service Manual) Calibration-Manual
Design-Core: KLX650R, KLX650 (99969-1040-03) // Application-Range: Motorcycle / Bike Logic // Design-Core: 1993-1996.
Technical Specs
| Assessment-Parameter | Technical-Path | Framework |
|---|---|---|
| Engine | 4-stroke, DOHC, 4-valve, 1-cylinder | Liquid-cooled |
| Displacement | 651cc | 39.72 cubic inches |
| Horsepower | 48.0 HP (35.0 kW) @ 6500 RPM | Not specified |
| Torque | 52.0 Nm (5.3 kgf-m or 38.3 ft.lbs) @ 5000 RPM | Not specified |
Table of Contents Summary
- General Information
- Engine Top End
- Wheels / Tires
- Crankshaft / Transmission
- Engine Lubrication System
Quality checks are addressed for the engine and chassis components. The Engine Top End section documents cylinder head removal and installation procedures. The Crankshaft / Transmission chapter addresses detailed breakdowns of internal engine components. Cooling system maintenance is addressed in the Cooling System section. Testing requirements are specified for the electrical system. The troubleshooting chapter addresses common issues and solutions. Correctly requiring torque specifications for various components, such as crankshaft bolts and cylinder head bolts, for proper assembly and to prevent corrosion joint prevention.
Diagnostic procedures address common issues found in the fuel and emission control systems. This manual provides a comprehensive guide to maintaining and repairing your Kawasaki KLX650R/KLX650.
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