Used 1993-1996 1999 2001 Kawasaki KLX650 Dual Sport Motorcycle Service Manual

Description

This Used 1993-2001 Kawasaki KLX650 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for KLX650 A, B, D & C 1993-1996, 1999, 2001 motorcycles. This is the same manual used by Kawasaki Dealers.

General Information
Before Servicing
Model Identification
General Specifications
Periodic Maintenance Chart – KLX650A
Periodic Maintenance Chart – KLX650C
Technical Information 1 – Two – Stage Cam Drive System
Technical Information 2 – Interlock Circuit (KLX650C)
Technical Information 3 – Electrofusion Cylinder (KLX650A)
Torque and Locking Agent
Special Tools and Sealant
Cable, Wire and Hose Routing
Exploded View
Specifications
Throttle Grip and Cables
Grip Free Play Inspection
Grip Free Play Adjustment
Throttle Cable Removal
Throttle Cable Installation
Throttle Cable Lubrication and Inspection
Choke Cable
Choke Cable Installation
Choke Cable Lubrication and Inspection
Carburetor
Idle Speed Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Coolant Filter Cleaning
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining (KLX650C)
Air Cleaner Housing Removal (KLX650A)
Air Cleaner Housing Removal (KLX650C)
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tap Removal (KLX650A)
Fuel Tap Installation (KLX650A)
Fuel Tap Removal (KLX650C)
Fuel Tap Installation (KLX650C)
Fuel Tank and Tap Cleaning
Fuel Tap Inspection
Evaporative Emission Control System (KLX650C, US California Vehicle)
Parts Removal/Installation
Hose Inspection (Periodic Inspection)
Separator Inspection (Periodic Inspection)
Separator Operation Test
Canister Inspection (Periodic Inspection)
Cooling System
Exploded View|1M-
Coolant Flow Chart
Specifications;v4!*
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Refilling
Pressure Testing
Cooling System Flushing
Coolant Filter Cleaning
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Mechanical Seal Replacement
Mechanical Seal Inspection
Radiator
Radiator Removal
Radiator Installation
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Hose Inspection
Thermostat (KLX650C)
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Thermostatic Fan Switch (other than KLX650-A1)
Thermostatic Fan Switch Removal
Thermostatic Fan Switch Installation
Thermostatic Fan Switch Inspection
Coolant Temperature Switch (KLX650C)
Coolant Temperature Switch Removal
Coolant Temperature Switch Installation
Coolant Temperature Switch Inspection
Engine Top End
Exploded View
Specifications
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Cylinder Head Cover Assembly
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Chain Tension Spring Removal
Chain Tension Spring Installation
Camshaft, Camshaft Chain
Camshaft Removal
Camshaft Installation
Camshaft Disassembly
Camshaft Assembly
KACR Inspection
Camshaft Bearing Wear
Camshaft Chain Removal
Camshaft Chain Installation
Camshaft Chain Wear
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Cleaning
Cylinder Head Warp-
Valves
Valve Clearance Measurement
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement
Valve Seat Inspection—
Valve Seat Repair (Valve Lapping)
Cylinder, Piston
Cylinder, Piston Removal
Cylinder, Piston Installation
Cylinder/Piston WearJ
Piston/Cylinder Clearance
Cylinder Boring and Honing (KLX650C)
Piston Ring and Ring Groove Wear
Piston Ring End Gap Measurement
Exhaust System
Spark Arrester Cleaning (US models)
Muffler Removal
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust Pipe Assembly
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
Clutch Release Installation
Clutch
Clutch Removal
Clutch Installation
Friction and Steel Plate Damage, Wear Inspection
Friction and Steel Plate Warp Inspection
Clutch Spring Free Length Measurement
Clutch Housing Finger Damage
Clutch Hub Spline Damage
Primary Gear
Primary Gear Removal
Primary Gear Installation
Kickstarter (KLX650A)
Kick Pedal Installation
Kickstarter Removal
Kickstarter Installationg
Kickstarter Assembly
Engine Lubrication System
Engine Oil Flow Chart
Exploded View
Specifications
Engine Oil and Oil Filter
Oil Level Inspection
Oil Change
Oil Filter Change
Oil Pressure
Oil Pressure Measurement
Oil Screens
Oil Screen Removal
Oil Screen Installation
Oil Pump and Relief Valve
Crankcase Oil Pump Removal
Crankcase Oil Pump Installation
Clutch Cover Oil Pump Removal
Clutch Cover Oil Pump Installation
Oil Pump Inspection
Relief Valve Inspection
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
Engine Removal I Installation
Exploded View
Specifications
Engine Removal/Installation
Engine Removal
Engine Installation
Crankshaft / Transmission
Exploded View
Specifications
Crankcase
Crankcase Disassembly
Crankcase Assembly
Crankshaft and Connecting Rod
Crankshaft Removal
Crankshaft Installation
Crankshaft Disassembly
Crankshaft Assembly
Connecting Rod Big End Seizure
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Alignment
Transmission
Shift Pedal Installation
External Shift Mechanism Removal
External Shift Mechanism Installation
External Shift Mechanism Inspection
Transmission Removal
Transmission Installation
Transmission Shaft Disassembly
Transmission Shaft Assembly
Shift Fork Bending
Shift Fork Ear/Gear Shift Fork Groove Wear
Shift Fork Guide Pin/Shift Drum Groove Wear
Gear Dog/Dog Recess Damage
Balancer
Balancer Shaft Removal
Balancer Shaft Installation
Balancer Shaft Disassembly
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
Ball and Needle Bearing Wear
Oil Seal Inspection
Wheels I Tires
Exploded View
Specifications
WheelsHI
Front Wheel Removal
Front Wheel Installation
Rear Wheel Removal (KLX650A)
Rear Wheel Installation (KLX650A)
Rear Wheel Removal (KLX650C)
Rear Wheel Installation
VVheel Inspection
Spoke Inspection
Rim Inspection-
Axle Inspection
Wheel Balance (KLX650C)
Balance Inspection (KLX650C)
Balance Adjustment (KLX650C)
Tires
Air Pressure Inspection/Adjustment
Tire Inspection
Tire Removal
Tire Installation
Hub Bearings (Wheel Bearings)
Bearing Removal
Bearing Installation
Bearing Inspection
Speedometer or Odometer Gear Housing
Gear Housing Disassembly
Gear Housing Assembly
Gear Housing Lubrication
Final Drive
Exploded View
Specifications
Drive Chain
Chain Slack Inspection (KLX650A)
Chain Slack Adjustment (KLX650A)
Chain Slack Inspection (KLX650C)
Chain Slack Adjustment (KLX650C)
Chain Wear Inspection
Chain Lubrication (KLX650A)
Chain Lubrication (KLX650C)
Chain Removal (KLX650A)
Chain Installation (KLX650A)
Chain Removal (KLX650C)
Chain Installation (KLX650C)
Sprocket, Coupling
Engine Sprocket Removal (KLX650A)
Engine Sprocket Installation (KLX650A)
Engine Sprocket Removal (KLX650C)
Engine Sprocket Installation (KLX650C)
Rear Sprocket Removal (KLX650A)
Rear Sprocket Installation (KLX650A)
Rear Sprocket, Coupling Removal (KLX650C)
Rear Sprocket, Coupling Installation (KLX650C)
Sprocket Wear
Rear Sprocket Warp
Coupling Bearing Removal (KLX650C)
Coupling Bearing Inspection, Lubrication (KLX650C)
Damper Inspection (KLX650C)
Brakes
Exploded View
Specifications
Brake Lever, Brake Pedal
Brake Lever Play Adjustment
Brake Pedal Position Adjustment
Brake Pedal Removal
Brake Pedal Installation
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Changing
Brake Line Air Bleeding
Calipers
Front Caliper Removal
Rear Caliper Removal
Caliper Installation
Front Caliper Disassembly
Rear Caliper Disassembly
Caliper Assembly
Caliper Fluid Seal Damage
Caliper Dust Seal and Friction Boot Damage
Caliper Piston and Cylinder Damage
Caliper Holder Shaft Wear
Brake Pads
Front Brake Pad Removal
Rear Brake Pad Removal
Brake Pad Installation
Brake Pad Wear Inspection
Master Cylinder
Front Master Cylinder Removal
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Visual Inspection
Brake Discs
Disc Installation
Disc Wear
Disc Cleaning
Disc Warp Inspection
Brake Hoses
Brake Hose Removal
Brake Hose Installation
Brake Hose Inspection
Suspension
Exploded View
Specifications
Front Fork
Air Pressure Adjustment
Compression Damping Adjustment (KLX650A)
Fork Oil Change
Front Fork Removal
Front Fork Installation
Front Fork Disassembly
Front Fork Assembly
Inner Tube Inspection
Dust Seal Inspection
Fork Spring Tension
Rear Shock Absorber
Rebound Damping Adjustment (KLX650A)
Compression Damping Adjustment (KLX650A)
Spring Adjustment (KLX650A)
Spring Adjustment (KLX650C)
Rear Shock Absorber Removal (KLX650A)
Rear Shock Absorber Installation (KLX650A)
Rear Shock Absorber Removal (KLX650C)
Rear Shock Absorber Installation (KLX650C)
Oil Draining (KLX650A)
Oil Filling (KLX650A)
Spring Tension (KLX650A)
Scrapping
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Bearing Removal
Swingarm Bearing Installation
Swingarm Pivot Check (KLX650A)
Swingarm Bearing, Sleeve Inspection
Tie- Rod, Rocker Arm
Tie- Rod Removal
Tie-Rod Installation
Rocker Arm Removal
Rocker Arm Installation
Rocker Arm/Tie-Rod Bearing Removal
Rocker Arm/Tie-Rod Bearing Installation
Uni-Trak Link Pivot Check (KLX650A)
Rocker Arm/Tie-Rod Bearing Inspection
Rocker Arm/Tie-Rod Sleeve Inspection
Steering
Exploded View
Specifications
Steering
Steering Inspection
Steering Adjustment
Handlebar
Handlebar Removal
Handlebar Installation
Steering Stem
Steering Stem Removal
Steering Stem Installation
Steering Stem Warp
Steering Stem Bearing
Stem Bearing Removal
Stem Bearing Installation
Stem Bearing Lubrication
Frame
Exploded View
Seat
Seat Removal
Seat Installation
Side Covers
Side Cover Removal
Rear Fender (KLX650A)
Rear Fender Front Section Removal
Rear Fender Rear Section Removal
Rear Fender (KLX650C)
Rear Fender Front Section Removal
Rear Fender Rear Section Removal
Electrical System
Exploded View
Parts Location (KLX650A)
Parts Location (KLX650C)
KLX650-A1 Wiring Diagram
KLX650-C1 ,C2 Wiring Diagram
(US, Australia)
KLX650-C1,C2 Wiring Diagram
(Other than US, Australia)
Specifications
Precautions
Electrical Wiring
Wiring Inspection
Battery (KLX650C)
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
Interchangeability with Ordinary Battery
Charging Condition Inspection
Refreshing Charge
Flywheel Magneto
Magneto Cover Removal (KLX650A)
Magneto Cover Installation (KLX650A)
Magneto Cover Removal (KLX650C)
Magneto Cover Installation (KLX650C)
Magneto Flywheel Removal (KLX650A)
Magneto Flywheel Installation (KLX650A)
Magneto Flywheel Removal (KLX650C)
Magneto Flywheel Installation (KLX650C)
Magneto Stator Removal
Magneto Stator Installation
Magneto Inspection
Magneto Case (KLX650C)
Magneto Case Removal
Magneto Case Installation
Charging System (KLX650C)
Regulator/Rectifier Removal
Regulator/Rectifier Output
Voltage Inspection
Alternator (Magneto) Inspection
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal/Installation
Spark Plug Cleaning/Inspection
Spark Plug Gap-
Ignition Coil Removal
Ignition Coil Installation
[anition Coil Inspection
Pickup Coil Removal
Pickup Coil Inspection
Exciter Coil Inspection
Magneto Flywheel Inspection
Iqnition Timing Test
CDI Unit Removal (KLX650A)
CDI Unit Removal (KLX650C)
CDI Unit Inspection
CDI Unit Troubleshooting:
Interlock Diode Unit Inspection (KLX650C)
Electric Starter System (KLX650C)
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commutator Cleaning/Inspection
Armature Inspection
Starter Motor Brush Length
Brush Plate Assembly Inspection
Positive Brush Assembly Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Starter Clutch (KLX650C)
Starter Clutch Removal
Starter Clutch Installation
Starter Clutch Inspection
Starter Torque Limiter Removal
Starter Torque Limiter Installation
Starter Torque Limiter Inspection
Lighting System
Headlight Beam Vertical
Adjustment (KLX650A)
Headlight Beam Horizontal
Adjustment (KLX650C)
Headlight Beam Vertical
Adjustment (KLX650C)
Headlight Bulb Replacement (KLX650A)
Headlight Bulb Replacement (KLX650C)
Headlight Unit Installation
Taillight Bulb Replacement (KLX650A)
Taillight Bulb Replacement (KLX650C)
License Light Bulb Replacement (KLX650C)
AC Lighting Voltage Measurement (KLX650A)
Alternator (Magneto) Inspection (KLX650A)
Regulator Removal (KLX650A)
Regulator Inspection (KLX650A)
Headlight Capacitor Inspection (KLX650A)
Headlight Relay Inspection (KLX650C-US, AS)
Headlight Diode Inspection (KLX650C-US, AS)
Turn Signal Relay Inspection (KLX650C)
Meters (KLX650C)
Meter Removal
Meter Disassembly
Indicator Bulb Replacement
Meter Assembly
Tachometer Inspection
Radiator Fan (other than KLX650-A1)
Radiator Fan Removal
Fan System Circuit Inspection
Fan Motor Inspection
Fan Relay Inspection
Coolant Temperature Warning
System (KLX650C)
Warning System Inspection
Warning Light Operation Inspection
Switches
Brake Light Timing Inspection (KLX650C)
Brake Light Timing Adjustment (KLX650C)
Switch Inspection (KLX650C)
Thermostatic Fan Switch
Inspection (other than KLX650-A1)
Coolant temperature Switch
Inspection (KLX650C)
Fuses (KLX650C)
20 A Main Fuse Removal
10 A Fan and Light Fuse Removal
Fuse Installation
Fuse Inspection
KLX650-A2 Wiring Diagram
Appendix
Additional Considerations for Racing (KLX650C)
Carburetor:
Spark Plug:
Spark Plug Inspection
Troubleshooting Guide
Nut, Bolt, and Fastener Tightness
Tightness Inspection
General Lubrication
Lubrication
Unit Conversion Table