Kawasaki Versys Service Manual

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Versys

Motorcycle
Service Manual

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 Quick Reference Guide

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

This quick reference guide will assist

Appendix 17 j
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
 Versys

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1) : Aug. 21, 2006 (K)
 LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)

COUNTRY AND AREA CODES

AT Austria GB United Kingdom
CA Canada MY Malaysia
CH Switzerland WVTA Whole Vehicle Type Approval
DE Germany
 Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want ignition coil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out Table of Contents on the first page of the chap-
maintenance and repair satisfactorily. When- ter to find the Ignition Coil section.
ever the owner has insufficient experience or Whenever you see these WARNING and
doubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!
ments, maintenance, and repair should be car- Always follow safe operating and maintenance
ried out only by qualified mechanics. practices.
In order to perform the work efficiently and
WARNING
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures This warning symbol identifies special
before starting work, and then do the work care- instructions or procedures which, if not
fully in a clean area. Whenever special tools or correctly followed, could result in per-
equipment are specified, do not use makeshift sonal injury, or loss of life.
tools or equipment. Precision measurements
can only be made if the proper instruments are CAUTION
used, and the use of substitute tools may ad-
This caution symbol identifies special
versely affect safe operation.
instructions or procedures which, if not
For the duration of the warranty period,
strictly observed, could result in dam-
we recommend that all repairs and scheduled
age to or destruction of equipment.
maintenance be performed in accordance with
this service manual. Any owner maintenance or This manual contains four more symbols (in
repair procedure not performed in accordance addition to WARNING and CAUTION) which will
with this manual may void the warranty. help you distinguish different types of informa-
To get the longest life out of your vehicle. tion.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Mo- venient operation.
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing • Indicates
done.
a procedural step or work to be
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
spare parts are listed in the Parts Catalog. also precedes the text of a NOTE.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main-
tenance and repair with dates and any new
tion in the procedural step or sub-step it fol-
lows.
parts installed. In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into instructions indicating which parts require spec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.
 GENERAL INFORMATION 1-1

General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Unit Conversion Table ............................................................................................................ 1-11
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
 GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.

Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
 GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing

the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
 GENERAL INFORMATION 1-7
Model Identification
KLE650B7F Left Side View

KLE650B7F Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION
General Specifications

Items KLE650A7F, KLE650B7F

Dimensions
Overall Length 2 125 mm (83.7 in.)
Overall Width 840 mm (33.1 in.)
Overall Height 1 315 mm (51.8 in.)
Wheelbase 1 415 mm (55.7 in.)
Road Clearance 180 mm (7.1 in.)
Seat Height 840 mm (33.1 in.)
Dry Mass:
KLE650A7F 181 kg (399 lb)
KLE650B7F 184 kg (405 lb)
Curb Mass:
Front:
KLE650A7F 103 kg (227 lb)
KLE650B7F 103 kg (227 lb)
Rear:
KLE650A7F 105 kg (232 lb)
KLE650B7F 104 kg (229 lb)
Fuel Tank Capacity 19 L (5.0 US gal)
Performance
Minimum Turning Radius 2.7 m (8.8 ft)
Engine
Type 4-stroke, DOHC, 2-cylinder
Cooling System Liquid-cooled
Bore and Stroke 83 × 60 mm (3.3 × 2.4 in.)
Displacement 649 cm³ (39.6 cu in.)
Compression Ratio 10.6 : 1
Maximum Horsepower 47.0 kW (64 PS) @8 000 r/min (rpm),
(MY) 44.0kW (60 PS) @7 000 r/min (rpm),
(CA) – – –
Maximum Torque 61 N·m (6.2 kgf·m, 114 ft·lb) @6 800 r/min (rpm),
(MY)61 N·m (6.2 kgf·m, 114 ft·lb) @6 000 r/min (rpm),
(CA) – – –
Carburetion System FI (Fuel injection), KEIHIN TTK38 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU)
Ignition Timing From 10° BTDC @1 300 r/min (rpm) to From 33° BTDC @5 000
r/min (rpm)
Spark Plug NGK CR9EIA-9
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
 GENERAL INFORMATION 1-9
General Specifications

Items KLE650A7F, KLE650B7F

Valve Timing:
Inlet:
Open 25° (BTDC)
Close 54° (ABDC)
Duration 260°
Exhaust:
Open 47° (BBDC)
Close 25° (ATDC)
Duration 252°
Lubrication System Forced lubrication (sem-dry sump)
Engine Oil:
Type API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2.095 (88/42)
Clutch Type Wet multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.438 (39/16)
2nd 1.714 (36/21)
3rd 1.333 (32/24)
4th 1.111 (30/27)
5th 0.966 (28/29)
6th 0.852 (23/27)
Final Drive System:
Type Chain drive
Reduction Ratio 3.067 (46/15)
Overall Drive Ratio 5.473 @Top gear
Frame
Type Tubular,diamond
Caster (Rake Angle) 25°
Trail 108 mm (4.2 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 MC (58W)
Rear Tire:
Type Tubeless
Size 160/60 ZR17 MC (69W)
1-10 GENERAL INFORMATION
General Specifications

Items KLE650A7F, KLE650B7F

Rim Size:
Front 17 × 3.50
Rear 17 × 4.50
Front Suspension:
Type Telescopic fork (upside-down)
Wheel Travel 150 mm (5.9 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 145 mm (5.7 in.)
Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12 V 10 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 55 W/55W (Hi/Lo)
Tail/Brake Light 12 V 0.5/3.7 W (LED)
Alternator:
Type Three-phase AC
Rated Output 8 A/14 V @4 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
 GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power
m × 3.281 = ft
mega M × 1 000 000
mm × 0.03937 = in
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
Units of Mass: kgf·m × 9.807 = N·m
kg × 2.205 = lb kgf·m × 7.233 = ft·lb
g × 0.03527 = oz kgf·m × 86.80 = in·lb

Units of Volume: Units of Pressure:

L × 0.2642 = gal (US) kPa × 0.01020 = kgf/cm²
L × 0.2200 = gal (imp) kPa × 0.1450 = psi
L × 1.057 = qt (US) kPa × 0.7501 = cmHg
L × 0.8799 = qt (imp) kgf/cm² × 98.07 = kPa
L × 2.113 = pint (US) kgf/cm² × 14.22 = psi
L × 1.816 = pint (imp) cmHg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp) Units of Speed:
mL × 0.06102 = cu in km/h × 0.6214 = mph

Units of Force: Units of Power:

N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP

Units of Temperature:
Kawasaki Versys Service Manual
Full download: http://manualplace.com/download/kawasaki-versys-service-manual/

This is the cut pages sample. Download all 627 page(s) at: ManualPlace.com