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Table of Contents
VERSYS
VERSYS ABS
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki VERSYS ABS

   Summary of Contents for Kawasaki VERSYS ABS

  • Page 1 VERSYS VERSYS ABS Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 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 Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6: Country And Area Codes

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
  • Page 8: How To Use This Manual

    Be alert for problems and non-scheduled maintenance. • NOTICE Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and NOTICE is used to address practices not testers that are necessary when servicing related to personal injury.
  • Page 9 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • Page 12: Before Servicing

    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.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 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.
  • Page 15 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.
  • Page 16 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.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLE650CAF Left Side View KLE650CAF Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification KLE650DAF Left Side View KLE650DAF Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications KLE650CAF ∼ CBF, KLE650DAF ∼ DBF Items Dimensions Overall Length 2 125 mm (83.7 in.) Overall Width 840 mm (33.1 in.) Overall Height 1 330 mm (52.4 in.) Wheelbase 1 415 mm (55.7 in.) Road Clearance 180 mm (7.1 in.) Seat Height 845 mm (33.3 in.)
  • Page 20 1-10 GENERAL INFORMATION General Specifications KLE650CAF ∼ CBF, KLE650DAF ∼ DBF Items Valve Timing: Intake: Open 26° (BTDC) Close 54° (ABDC) Duration 260° Exhaust: Open 47° (BBDC) Close 25° (ATDC) Duration 252° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications KLE650CAF ∼ CBF, KLE650DAF ∼ DBF Items 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...
  • Page 22: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............
  • Page 24 2-2 PERIODIC MAINTENANCE Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection................. 2-43 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Replacement Parts ......................
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 26: Periodic Maintenance

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) INSPECTION Every Drive chain slack - inspect # Every 1 000 km (600 mile) 2-30 •...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (22.5) (30) ITEM Every Air cleaner element # - replace 2 years 2-46 •...
  • Page 28: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Throttle Body Assy Holder Bolts 106 in·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Nut (M10) MO, S Cylinder Bolts (M6) 106 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolt (Front) Muffler Body Mounting Bolt (Rear) Clutch...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolt (M8, L = 110 mm) 27.5 Crankcase Bolt (M6, L = 32 mm) 19.6 Crankcase Bolts (M6, L = 38 mm) 19.6 Crankcase Bolts (M6, L = 45 mm) 19.6 Crankcase Bolts (M8, L = 50 mm) 27.5...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb 0.15 13 in·lb Front Brake Reservoir Cap Screws Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts 97 in·lb Bleed Valve 0.80...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 87 in·lb Engine Ground Cable Terminal Bolt Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws...
  • Page 33: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference) –...
  • Page 34 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: KLE650CAF/DAF...
  • Page 35: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Throttle Sensor Setting Adapter: 57001-143 57001-1538 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Oil Filter Wrench: Pilot Screw Adjuster, E: 57001-1249 57001-1603 Vacuum Gauge: 57001-1369...
  • Page 36: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, pos- sibly causing accident.
  • Page 37: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame any- where near the working areas. Do not use gasoline or low-flash point solvents to clean the element.
  • Page 38: Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the locknut [A] at the middle of the decelerator cable. • Turn the adjuster [B] until there is no play when the throttle grip is completely closed. • Tighten the locknut. • Turn the accelerator cable adjuster until the proper amount of throttle grip free play is obtained.
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If the vacuum is not within the specification, turn the by- pass screw until the vacuum becomes within the specifi- cation. Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603 • Open and close the throttle after each measurement, and adjust the idle speed as necessary.
  • Page 40: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 41: Idle Speed Adjustment

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 42 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Remove the canister [A], and disconnect the hoses from the canister. ○ Visually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NOTE ○...
  • Page 43: Cooling System

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (do not use the sidestand). If the coolant level is lower than the “L”...
  • Page 44: Air Suction System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Fuel Hose (see Fuel Hose Replacement) • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C]...
  • Page 45: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedu