Z650
Z650 ABS

Recharge the Battery First!
This motorcycle comes with a pre-filled,
pre-charged sealed battery, eliminating the need
for dealers to prepare the battery by filling it with
electrolyte. However, the battery must be charged
upon initial receipt of each unit since it may have
been warehoused for a significant time period
before being delivered to your dealership.
After the initial charge at your dealership the battery should be recharged every six months. Because the battery will discharge more rapidly at
high ambient temperatures, more frequent charging intervals may be required for dealerships located in hot climate zones.
When the battery is not charged periodically during long term storage, its internal resistance increases and could prevent the battery from being
recharged. Refer to the "Battery Service" chapter
for details.
The battery is located within the crate at the lower
indicated with a dotted line. The battery can be
removed from the crate for charging by cutting off
a portion of the cardboard cover along the dotted
line.

A. Battery Location
B. Cardboard Cover

Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki Z650 and Z650 ABS.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.

© 2016 Kawasaki Heavy Industries, Ltd.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

NOTICE
NOTICE is used to address practices not
related to personal injury.

NOTE

○NOTE indicates information that may help or
guide you in the operation or service of the
vehicle.

Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.

Sep., 2016

Table of Contents
Uncrating ......................................................................................
Opening Crate for Pattern A........................................................
Opening Crate for pattern B ........................................................
Parts Check .................................................................................
Assembly ......................................................................................
Frame Cover ...............................................................................
Rear View Mirrors........................................................................
French Label (For Canada Model) ..............................................
Brake Disc Cleaning ....................................................................
Preparation ...................................................................................
Battery Service ............................................................................
Coolant ........................................................................................
Front Brake..................................................................................
Rear Brake ..................................................................................
Clutch Lever and Cable ...............................................................
Drive Chain..................................................................................
Rear Shock Absorber ..................................................................
Tire Air Pressures........................................................................
Fuel .............................................................................................
Engine Oil (4-stroke) ...................................................................
Throttle Grip and Cable ...............................................................
Rear Brake Light Switch ..............................................................
Idle Speed Adjustment ................................................................
Headlight Aim ..............................................................................
Digital Meter ................................................................................
License Plate Mounting Holes .....................................................
Fastener Check ...........................................................................
Standard Torque Table ................................................................
Test Ride the Motorcycle .............................................................
A & P Check List .........................................................................

3
3
4
6
7
7
7
7
8
8
8
12
12
14
16
16
18
18
18
19
20
21
21
22
23
23
26
28
28
28

UNCRATING 3

Uncrating
Opening Crate for Pattern A
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.

WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.

out all the bolts and screws and remove
• Take
the top and sides of the crate.
the front axle holding nut.
• Loosen
Remove
• discard it.the left front support bracket bolt and
the front axle holding nut, left front
• Remove
support bracket and rubber washer and discard them.

A.
B.
C.
D.

Front Axle Holding Nut
Left Front Support Bracket
Left Front Support Bracket Bolt
Rubber Washer

the right front support bracket bolt
• Remove
and discard it.
the front axle holding bolt, right front
• Remove
support bracket and rubber washer and discard them.

a space about 6 m (20 ft) square to give
• Clear
yourself plenty of space to work.
the crate upright on its base.
• Place
the cardboard cover.
• Remove
Remove
the parts boxes.
•

NOTICE

When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other components with the crate bracket.

A.
B.
C.
D.

Front Axle Holding Bolt
Right Front Support Bracket
Right Front Support Bracket Bolt
Rubber Washer

the lower support bracket bolt on the
• Remove
left and right sides and discard them.
the vehicle upward about 10 cm (4 in.).
• Lift
Remove
the lower support brackets and rub• ber washers
on the left and right sides.
Roll
the
vehicle
off the crate base.
•

4 UNCRATING

A. Lower Support Bracket Bolts
B. Lower Support Brackets
C. Rubber Washer

NOTICE
When rolling the vehicle off the crate
base, sharp edges on the crate can cut
or damage tires.
Cover sharp edges with waste cloth for
tire protection as necessary.

Opening Crate for pattern B
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.

WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.

a space about 6 m (20 ft) square to give
• Clear
yourself plenty of space to work.
the crate upright on its base.
• Place
Remove
cardboard cover.
• Remove the
the
parts boxes.
•

NOTICE

When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other components with the crate bracket.
out all the bolts and screws and remove
• Take
the top and sides of the crate.
the front axle holding nut.
• Loosen
Remove
• discard it.the left front support bracket bolt and
the front axle holding nut, left front
• Remove
support bracket and rubber washer and discard them.

A.
B.
C.
D.

Front Axle Holding Nut
Left Front Support Bracket
Left Front Support Bracket Bolt
Rubber Washer

the right front support bracket bolt
• Remove
and discard it.
the front axle holding bolt, right front
• Remove
support bracket and rubber washer and discard them.

UNCRATING 5

A.
B.
C.
D.

Front Axle Holding Bolt
Right Front Support Bracket
Right Front Support Bracket Bolt
Rubber Washer

the pivot holding nuts.
• Loosen
Remove
lower support bracket bolts on
• the left andtheright
sides and discard them.
the vehicle upward about 10 cm (4 in.).
• Lift
Remove
pivot holding nuts, pivot holding
• bolt, lowerthesupport
brackets and rubber wash-

•

ers.
Roll the vehicle off the crate base.

A.
B.
C.
D.
E.

Pivot Holding Nuts
Lower Support Bracket Bolts
Lower Support Brackets
Pivot Holding Bolt
Rubber Washers

NOTICE
When rolling the vehicle off the crate
base, sharp edges on the crate can cut
or damage tires.
Cover sharp edges with waste cloth for
tire protection as necessary.

6 UNCRATING

Parts Check

the parts box, and check the parts against the illustrations. There may be minor differences
• Open
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.

No.
1
2
3
4
5
6
7
8
9
10
11
12

Part Name
Left Rear View Mirror
Right Rear View Mirror
Left Frame Cover
Right Frame Cover
Socket Bolt
Washer
Battery YTZ10
Owner’s Manual
(French Label for Canada Model only)
French Table
Important Drive Chain Information
Tire and Load Data
Vehicle Emission Control Information

Qty
1
1
1
1
4
4
1
1
1
1
1
1

Remarks

D = 5, L = 16
D = 5.3
12 V 8.6 Ah

ASSEMBLY 7

Assembly
Frame Cover

the rubber boot.
• Reinstall
Adjust
the
rear view mirror by slightly moving
• only the mirror
portion of the assembly.

the left frame cover, and tighten its
• Install
bolts (D = 5, L = 16) together with the washers (D = 5.3).

A. Mirror
and adjustment of the right side
• Installation
mirror is common with the left side. Follow
A. Left Frame Cover
B. Bolts (D = 5, L = 16) and Washers (D
= 5.3)
the right frame cover in the same man• Install
ner as the left frame cover.

Rear View Mirrors

up the rubber boot.
• Slide
Screw
lower end of the left rear view mirror
• into thetheholder
all the way, and tighten the rear

•
•

the procedure specified for the left side.

French Label (For Canada Model)
When required, apply French label in the parts
bag over English label on the vehicle.
Wipe off any oil or grease from English label.
Refer to the following figure for the label location.
Peel the label in the parts bag off the backing
sheet and apply it over English label.

•
•

view mirror nut (lower).
Turn the stay to assure visibility to the rear
with the operator sitting on the motorcycle by
loosening the rear view mirror locknut (upper)
(left-hand thread) clockwise.
Hold the nut (lower) and tighten the locknut
(upper).

A. Vehicle Emission Control Information

A.
B.
C.
D.

Nut (Lower)
Locknut (Upper)
Rubber Boot
Stay

8 PREPARATION

time period before being delivered to your dealership.
After the initial charge at your dealership the
battery should be recharged every six months.
Because the battery will discharge more rapidly
at high ambient temperatures, more frequent
charging intervals may be required for dealerships located in hot climate zones.

NOTICE

B. Important Drive Chain Information
C. Tire and Load Data

This battery is a pre-filled, pre-charged
sealed battery. It is not necessary to fill
the battery with electrolyte. Do not try to
remove the strip of caps.

Battery Recharging

Brake Disc Cleaning

the front and rear brake discs using
• Clean
oilless solvent.

WARNING
An anticorrosive treatment applied to
the brake discs will increase braking
distance and can cause an accident
resulting in serious injury or death. Remove the anticorrosive treatment using
an oilless solvent.

DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can
cause serious injury and burns if ignited.
Keep the battery away from sparks and
open flames during charging. When
using a battery charger, connect the
battery to the charger before turning on
the charger. This procedure prevents
sparks at the battery terminals which
could ignite any battery gases.