- Camchain Issues
The KLX650 engine is largely "bullet-proof" due to the robust design of the bottom-end, primary drive, clutch and gearbox, and the modest "race-state" of the camshaft. Unfortunately, Kawasaki opted for a double camchain arrangement, ostensibly to reduce the diameter of the camshaft sprockets and produce a smaller, neater top-end. Although many would argue this concept is needlessly complex, it functions quite well.
Camchain/Timing failure, which does happen on occasion, is not due to the complex design as such, but to the automatic camchain tensioner. The upper camchain tensioner is a spring-loaded, ratchet design, similar to that found in many other motorcycle engines, and identical (or almost so) to that found in many Kawasaki engines. It produces pressure on the rear upper camchain guide arm, to maintain camchain tautness. Occasionally, the ratchet teeth become slightly worn, and backing the engine off suddenly from high revs can result in the upper camchain becoming loose enough to alter the camshaft timing, usually with catastophic results (valves engaging directly with the piston etc.).
It should be stressed that this is not a common fault (or there wouldn't be so many motorcycle manufacturers continuing the design), but fortunately there are many excellent manual camchain tensioners available commercially, so it is strongly suggested that one of
these is fitted while the engine is still going OK.
- Valve Clearance Issues
Over a period of time, wear takes place on the overhead valve components, inevitably leading to a change in the valve clearances. Wear on the cam lobes and shims is usually minimum, but some wear will usually take place on either end of the valves (top end of valve stem and valve to seat face) and the valve seats. This is caused by the constant percussive nature of the valvetrain, combined with the rotation of the valves (the latter occurs in a most uneven and unpredictable fashion).
Wear on the top end of the valve stem leads to an increase in valve clearance, while wear on the valve to seat face and the seat face itself, leads to a decrease in valve clearance. This is why it is essential to regularly check the valve clearances.
Valve clearances that are greater than recommended will result in a noisy (tapping) engine, and will lead to greater than normal additional wear on the upper end of the valves. Valve clearances that are less than recommended will eventually lead to loss of compression when the engine reaches operating temperature. This is due to the valve(s) being held slightly open on the compression stroke. Unfortunately this loss of compression can easily be incorrectly diagnosed as bore/piston/piston ring issues, so rectifying incorrect valve clearances can often solve what at first may appear to be a major engine problem.
The KLX650 uses a 29mm diameter shim inserted into a recess in the valve spring cap. Shims are available in 0.05mm increments, from 2.00mm to 3.20mm. They are usually available through Kawasaki dealers, but can also be purchased either individually or in sets, from maufacturers such as Vintco.
The correct valve clearances are:-
Inlet: 0.10 - 0.19mm
Exhaust: 0.15 - 0.24mm
Consult the service manual for the correct procedure to release the camchain and remove the camshafts, prior to replacing the shims. See the engine top end parts breakdown on the Diagrams page.
- Understanding The VIN (Vehicle Identification Number)
The VIN is found in two places: - firstly stamped on the frame, usually on the headstem;
secondly stamped on the Compliance Plate (if the bike has one), which is also mounted on the headstem.
- Example VIN:
JKALXEB141A007077
First 3 characters = WMI (World Manufacturer Identifier), in this case JKA = Japan, Kawasaki
4th and 5th characters = model series, in this case LX = KLX series
6th character = model size, in this case E = 650
7th and 8th characters = model designation, in this case B1 = B1 series
9th character = check digit (set arbitrarily by manufacturer)
10th character = year of manufacture, in this case 1 = 2001
Final 7 characters = actual frame number
- Year Characters
1993 = P 1994 = R 1995 = S 1996 = T 1997 = V 1998 = W
1999 = X 2000 = Y
2001 = 1 2002 = 2 2003 = 3
- Paint Codes
The following is a list of known (official) paint codes for the various colour schemes between 1993 and 2003. The paint code(s) are not located on the compliance plate, like most cars, but are supposedly on a sticker somewhere attached to the frame. Usually the sticker is also not present, so paint code(s) need to be sought via a Kawasaki dealer, or direct from Kawasaki themselves in the corresponding country where the bike was sold.
Some automotive paint suppliers have a Spectrophotometer available to accurately measure the exact colour of a sample. This is ideal for things like plastic fenders etc. but impractical for things like a motorcycle frame.
Color Rite paint suppliers have a useful search function for various automotive paints, on their website, however they only list a few years of the KLX650.
1993 - 1996
KLX650C1-C4 (Electric Start)
Colour Scheme 1: Purple Frame - Green Tank/Guards/Fenders
- Frame Colour Code: Kawasaki Frame Violet 692 (some claim that it is Kawasaki Jet Ski Violet 694, but this is less likely)
- Tank/Guards/Fenders Colour Code: Kawasaki Lime Green 617 (this Lime Green was active on Kawasaki bikes up until 2004)
- Seat Colour Code: Kawasaki Frame Violet 692
Colour Scheme 2: Purple Frame - Red Tank/Guards/Fenders/Side Covers
- Frame Colour Code: Kawasaki Frame Violet 692
- Tank/Guards/Fenders/Side Covers Colour Code: Kawasaki Sunbeam Red 639
- Seat Colour Code: Kawasaki Frame Violet 692
Colour Scheme 3: Teal Green Frame - Black Tank/Guards/Fenders/Side Covers
- Frame Colour Code: Unknown (at present, but enquiries are being made)
- Tank/Guards/Fenders/Side Covers Colour Code: Kawasaki Ebony Black 602
- Seat Colour Code: Unknown (same as frame)
1993 - 1995
KLX650A1-A3 (KLX650R)
Colour Scheme 1: Purple Frame - Green Tank/Guards/Fenders
- Frame Colour Code: Kawasaki Frame Violet 692
- Tank/Guards/Fenders Colour Code: Kawasaki Lime Green 617
- Seat Colour Code: Kawasaki Frame Violet 692
1996 - 1998
KLX650B1 (KLX650R Australia)
KLX650D1-D3 (KLX650R Europe/USA)
Colour Scheme 1: Purple Frame - Green Tank/Guards/Fenders
- Frame Colour Code: Kawasaki Frame Violet 692
- Tank/Guards/Fenders Colour Code: Kawasaki Lime Green 617
- Seat Colour Code: Kawasaki Frame Violet 692
1999 - 2000
KLX650B2 (KLX650R Australia)
KLX650D4-D5 (KLX650R Europe/USA)
Colour Scheme 1: Black Frame - Green Tank/Guards/Fenders
- Frame Colour Code: Unknown (at present, but enquiries are being made)
- Tank/Guards/Fenders Colour Code: Kawasaki Lime Green 617
- Seat Colour Code: Unknown "Grey" (at present, but enquiries are being made)
2001 - 2003
KLX650B3 (KLX650R Australia)
KLX650D6 (KLX650R Europe/USA)
Colour Scheme 1: Green Frame - Green Tank/Guards/Fenders
- Frame Colour Code: Kawasaki Lime Green 617
- Tank/Guards/Fenders Colour Code: Kawasaki Lime Green 617
- Seat Colour Code: Unknown "Grey" (at present, but enquiries are being made)
* Note: Kawasaki Lime Green 617 was superceded in 2005 by Kawasaki Lime Green 777.
Most after-market plastics available to fit KLX650's are in the latter colour (777), which is a deeper lime green.
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