The Kawasaki KLE 650 Versys, produced between 2010 and 2011, is a versatile sport touring motorcycle powered by a 649.3 cc parallel-twin engine known for its smooth power delivery and reliability. Designed as a capable platform for commuting, long-distance touring, and even light off-road excursions, this model bridges the gap between sportbikes and adventure motorcycles. Its engineering emphasizes practicality and rider enjoyment, making it a popular choice for a wide range of riding styles and conditions. The KLE 650 Versys features a multi-reflector headlamp, LED tail light, and an optional ABS system for enhanced safety. This comprehensive workshop service manual provides detailed guidance for the maintenance and repair of the 2010-2011 Kawasaki KLE 650 Versys. It covers all essential systems, including the engine, transmission, chassis, and electrical components, offering in-depth information on overhaul, repair procedures, and scheduled maintenance. The manual includes troubleshooting guides, technical specifications, torque values, and fluid recommendations, making it an indispensable resource for professional technicians and experienced owners alike. Its purpose is to ensure the longevity, performance, and safe operation of your motorcycle through accurate and detailed technical information. 🏷️ Basic Information Identification Make: Kawasaki Model: KLE 650 Versys Year: 2010-2011 Engine Type: Parallel-Twin, Liquid-Cooled, DOHC, 8-Valve Engine Displacement: 649.3 cc Vin Code: KLE650B (2010), KLE650C (2011) 👋 Introduction Market Position Market Segment: Sport Touring / Adventure Touring Lightweight Motorcycle Competitive Analysis Key Competitors: Suzuki V-Strom 650, Honda CB500X (later models), Yamaha Tracer 700 (later models). Key Features Versatility: Designed as a versatile platform capable of commuting, touring, and light off-road use. Engine Basis: Utilizes a detuned version of the ER-6f/ER-6n engine, known for its reliability and smooth power delivery. Manual Purpose Primary Audience: Mechanical technicians and experienced motorcycle owners for maintenance and repair. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Workshop Service Manual Page Count Page Count: 631 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, top end, bottom end, lubrication system, cooling system, fuel system, intake and exhaust systems, ignition system, starting system, charging system. Transmission: Clutch, gearbox, drive chain, shift mechanism. Chassis: Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires, braking system (front and rear discs, calipers, master cylinders, lines). Electrical: Wiring diagrams, lighting system, instrument panel, battery, starter motor, alternator, sensors, ECUs, diagnostic codes. Bodywork: Fairings, body panels, seat, fuel tank, fasteners, accessories. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacement, spark plug replacement, chain adjustment, brake fluid replacement, coolant replacement, valve clearance checks and adjustments. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding charts, symptom-based troubleshooting. Repair: Detailed step-by-step repair instructions for all major components, including engine rebuilds, suspension overhauls, brake system repairs, electrical component replacement. Specifications: Torque specifications for all fasteners, clearances, fluid capacities, electrical values, performance data. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers from basic maintenance to full engine and chassis teardowns and rebuilds. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear and legible text and diagrams. Printable pages. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Searchability Searchable Text: Yes (typically, depending on PDF creation) ⚙️ Engine Specifications Primary Engine Engine Layout: 649cc Liquid-cooled, 4-stroke, DOHC, parallel-twin Performance Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Horsepower Rating: Approximately 64 hp @ 8,000 rpm (claimed) Torque Rating: Approximately 44 lb-ft @ 7,000 rpm (claimed) Fuel System Fuel Delivery: Fuel Injection (DFI) with dual 38mm throttle bodies Ignition Ignition System: Digital CDI with Electronic Advance Cooling System Cooling Type: Liquid-cooled Lubrication Lubrication System: Forced lubrication, wet sump 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Features Clutch Type: Wet, multiple-disc Final Drive: Sealed chain Fluid Type Transmission Oil: SAE 10W-40 API SG, SH, SJ or SL (refer to manual for specific recommendations) 📐 Dimensions Exterior Length: 2,195 mm (86.4 in) Width: 800 mm (31.5 in) Height: 1,350 mm (53.1 in) / 1,365 mm (53.7 in) (California) Wheelbase: 1,415 mm (55.7 in) Ground Clearance: 175 mm (6.9 in) Seat Height: 835 mm (32.9 in) Weights Curb Weight: Approximately 210 kg (463 lbs) Fuel Tank Capacity: 19 Liters (5.0 US gal) Wheels Tires Front Tire Size: 120/70ZR17M/C (58W) Rear Tire Size: 180/55ZR17M/C (73W) Wheel Type: Cast aluminum 🛡️ Safety Features Ratings ABS Availability: Optional ABS (Anti-lock Braking System) Active Features Braking System: Dual 300mm petal discs with dual piston calipers (front), Single 220mm petal disc with dual piston caliper (rear) Passive Features Lighting: Multi-reflector headlamp, LED tail light 💡 Technology Features Infotainment Instrument Cluster: Digital LCD instrument cluster with analog tachometer. Includes speedometer, odometer, trip meters, fuel gauge, clock, engine temperature, gear position indicator, and neutral indicator. Driver Assistance ABS: Optional ABS system, described in detail for service and maintenance...