Kawasaki W800 Service Manual (2011–2016)

Kawasaki W800 Service Manual (2011–2016)
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Factory workshop manual for the Kawasaki W800 EJ800A series. This revision covers 2011 EJ800AB, 2012 EJ800AC, 2013 EJ800AD, 2014 EJ800AE, 2015 EJ800AF and 2016 EJ800AG, with specifications, scheduled maintenance, DFI self-diagnosis, engine and transmission service, wheels and chain drive, brakes, suspension, frame, electrical testing and wiring diagrams.

About the Manual

Manual type
Factory Service Manual
Years covered*
2011–2016
Pages
541
Language
English
Format
PDF
Main sections
16
Searchable PDF
Yes
Printable PDF
Yes
File size
9.1 MB
Delivery
Digital download

* Indicative only. Please do your own research and confirm compatibility with your exact motorcycle and model year before purchasing.

Kawasaki W800 EJ800AB–AG, P/N 99924-1441-06 Motorcycle Details

Manufacturer
Kawasaki
Models Covered
W800
Generation / variant
EJ800AB–AG, P/N 99924-1441-06
Engine
4-stroke, SOHC, 2-cylinder
Displacement
773 cm³ (47.2 cu in)
Bore × Stroke
77.0 × 83.0 mm (3.03 × 3.27 in)
Compression Ratio
8.4:1
Cooling System
Air-cooled
Fuel System
Fuel injection, 2 × Keihin TTK34 throttle bodies
Clutch
Wet multi-disc
Transmission
5-speed constant mesh, return shift
Final Drive
Chain drive, 2.467 (37/15) reduction ratio
Curb mass
217 kg (478 lb)
Seat height
790 mm (31.1 in)
Front tire
100/90-19 M/C 57H
Rear tire
130/80-18 M/C 66H
Front suspension
Telescopic fork, 130 mm travel
Rear suspension
Swingarm with twin shock absorbers, 106 mm travel
Brakes
Single front disc; rear drum
Battery
12 V, 10 Ah
Maximum horsepower
35 kW (48 PS) @ 6,500 rpm
Maximum torque
60 N·m (44 ft·lb) @ 2,500 rpm
Valve clearance
Intake 0.08–0.13 mm; exhaust 0.14–0.19 mm

What’s Included in the Kawasaki W800 EJ800AB–AG, P/N 99924-1441-06 Service Manual?

  1. General Information
  2. Periodic Maintenance
  3. Fuel System (DFI)
  4. Engine Top End
  5. Clutch
  6. Engine Lubrication System
  7. Engine Removal/Installation
  8. Crankshaft/Transmission
  9. Wheels/Tires
  10. Final Drive
  11. Brakes
  12. Suspension
  13. Steering
  14. Frame
  15. Electrical System
  16. Appendix

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About the Kawasaki W800

The Kawasaki W800 was introduced for 2011 as the latest evolution of Kawasaki's long-running W-series heritage. Kawasaki's launch announcement traced that line back to the W1, first shown in the mid-1960s, and positioned the W800 as a modern motorcycle intended to reproduce the appearance and riding character of a classic machine. The W800 also followed the later W650, continuing the vertical-twin theme with traditional proportions, large-diameter wheels, extensive polished metalwork and a simple roadster layout.

At its center is a 773 cc air-cooled fuel-injected parallel twin with a long-stroke 77.0 × 83.0 mm bore and stroke, SOHC valve gear and 8.4:1 compression ratio. The service manual specifies Keihin TTK34 dual throttle bodies and electronic fuel injection, with 35 kW (48 PS) at 6,500 rpm and 60 N·m at 2,500 rpm on the main specification. That low-speed torque peak reflects the model's emphasis on relaxed road use rather than high-rpm performance. Engine lubrication is wet-sump, with a total oil capacity of 3.2 L.

Power passes through a wet multi-disc clutch and five-speed constant-mesh return-shift gearbox to a chain final drive with a 2.467 reduction ratio. The chassis uses a tubular double-cradle frame with 27-degree rake, 108 mm trail and a 1,465 mm wheelbase. The W800 rides on a 100/90-19 front tire and 130/80-18 rear tire, with a conventional telescopic fork offering 130 mm travel and twin-shock swingarm rear suspension with 106 mm travel. Braking combines a single front disc with a rear drum. Factory dimensions include a 790 mm seat height, 14 L fuel tank and 217 kg curb mass.

Kawasaki's official W800 launch announcement documents the model's W-series lineage, 773 cm³ air-cooled twin and vintage-oriented design, while Kawasaki's 2011 W800 Owner Center page confirms the EJ800AB model family. The uploaded PDF is the sixth edition dated July 17, 2015; its Model Application page lists EJ800AB through EJ800AG for 2011–2016 under part number 99924-1441-06. Because 2017 is not listed, the previous 2017 tag is removed. For related documentation, browse the Kawasaki W800 manual category.

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