Kawasaki · Modern air-cooled single (2000-)

W650 / W800 (modern)

Library entry covers 1999-2026

29 factory 29 guideline

Published source

Kawasaki W800 Owner's Manual 2015 (Kawasaki Heavy Industries), Periodic Maintenance Chart pp.68-77

Factory owner's handbook. Covers 2015 W800 owner's manual (fuel-injected); the carbureted W650 shares the engine layout, and its throttle-body sync item corresponds to carburetor sync.

Open the source

58 items for a 1999 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1999 Kawasaki W650 / W800 (modern)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 400 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain lubrication condition: inspect. Factory: Periodic maintenance chart pp.68-77: every 600 km (400 mile)

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain slack: inspect. Factory: Periodic maintenance chart pp.68-77: every 1,000 km (600 mile)

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 3,000 mi or 12 months

6 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline

Every 3,750 mi or 12 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Factory

Manual: Brake operation (effectiveness, play, drag) and brake light switch: inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; fluid level checked every 6 months; fluid leak and hose condition inspected at the same interval

Every 3,750 mi

2 items

Replace brake linings / skim drums (wear based)

Brakes

Factory

Manual: Brake pad and lining wear: inspect. Factory: Periodic maintenance chart pp.68-77: more often in severe conditions
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Spoke tightness and rim runout: inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; dealer item

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Synchronize carburetors

Fuel and air

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,500 mi or 12 months

9 items

Change engine oil

Engine

Factory

Manual: Engine oil: change. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; more often in severe conditions
Replace oil filter

Engine

Factory

Manual: Oil filter: replace. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle control system (play, smooth return, no drag): inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Factory

Manual: Lights, switches, headlight aim, side stand and engine stop switch: inspect. Factory: Periodic maintenance chart pp.68-77
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play: inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; dealer item
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Front forks and rear shock absorbers operation and oil leak: inspect. Factory: Periodic maintenance chart pp.68-77
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings damage: inspect. Factory: Periodic maintenance chart pp.68-77: dealer item
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire air pressure, wheels/tires damage, tread wear: inspect. Factory: Periodic maintenance chart pp.68-77
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Chassis parts: lubricate. Factory: Periodic maintenance chart pp.68-77: dealer item

Every 7,500 mi

8 items

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Bolts and nuts tightness: inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; dealer item
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: inspect. Factory: Periodic maintenance chart pp.68-77: dealer item
Check engine breather and oil return

Engine

Factory

Manual: Air suction system damage: inspect. Factory: Periodic maintenance chart pp.68-77: dealer item
Replace spark plugs

Engine

Factory

Manual: Spark plug: replace. Factory: Periodic maintenance chart pp.68-77: dealer item
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element: clean. Factory: Periodic maintenance chart pp.68-77: service more often in dusty conditions
Synchronize throttle bodies

Fuel and air

Factory

Manual: Engine vacuum synchronization: inspect. Factory: Periodic maintenance chart pp.68-77: dealer item
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch operation (play, engagement, disengagement): inspect. Factory: Periodic maintenance chart pp.68-77: first at 1,000 km; dealer item
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear and chain guide wear: inspect. Factory: Periodic maintenance chart pp.68-77

Every 8,000 mi or 2 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi or 2 years

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearings: lubricate. Factory: Periodic maintenance chart pp.68-77: dealer item
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (front): change. Factory: Periodic maintenance chart pp.68-77: dealer item

Every 15,000 mi

1 item

Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm pivot: lubricate. Factory: Periodic maintenance chart pp.68-77: dealer item

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 4 years

1 item

Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Rubber parts of master cylinder and caliper: replace. Factory: Periodic maintenance chart pp.68-77: dealer item

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

2 items

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element: replace. Factory: Periodic maintenance chart pp.68-77: dealer item; more often in severe conditions
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses: replace. Factory: Periodic maintenance chart pp.68-77: dealer item; brake hose damage and installation inspected yearly and every 6,000 km (3,750 mi)

Every 5 years

1 item

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hoses: replace. Factory: Periodic maintenance chart pp.68-77: dealer item; fuel leak, hose damage and installation inspected yearly and every 12,000 km (7,500 mi)

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.