The Versys, chassis code EX650, is a middleweight adventure-sport motorcycle manufactured for the 2010, 2011, 2012, and 2013 model years. This versatile machine is engineered for riders seeking a capable option for commuting, touring, and light off-road excursions. It features a torquey and reliable 649cc parallel-twin engine, shared with the Ninja 650R, providing approximately 72 horsepower. Notable characteristics include longer travel suspension for improved comfort over varied terrain, distinctive styling with an upright riding position, and a strong reputation for value and overall performance within its class. This comprehensive workshop service manual offers in-depth guidance for the maintenance, repair, and overhaul of the Versys. Covering a wide array of systems, including the engine, fuel, ignition, cooling, lubrication, transmission, drivetrain, chassis, suspension, brakes, and electrical systems, this manual is an essential resource. It provides detailed procedures for routine maintenance, component disassembly and reassembly, troubleshooting common issues, and understanding complex systems. With over 600 pages of professional-quality information, this English-language manual is designed to empower owners and technicians in effectively servicing and maintaining their vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: Versys Applicable Model Years: 2010, 2011, 2012, 2013 Codes Chassis Code General: EX650 👋 Introduction Market Position Category: Middleweight Adventure-Sport Motorcycle Target Audience: Riders seeking versatility for commuting, touring, and light off-road use Competitive Analysis Key Competitors: Yamaha TDM series, Suzuki V-Strom 650, Honda CB500X (later models), BMW F 650 GS Key Features Versatility: Combines sporty handling with comfortable ergonomics and luggage carrying capability Engine Platform: Shared with Ninja 650R, known for its torquey and reliable parallel-twin configuration Suspension Travel: Longer travel suspension compared to sportbikes, offering better compliance over rough roads Styling: Distinctive 'beak' or fender extension, upright riding position 📋 Manual Details Coverage Areas General Coverage: Comprehensive Service and Repair Specific Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Bodywork, Troubleshooting Page Count Estimated Pages: 600+ Manual Type Type: Workshop Service Manual (WSM) / Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair of cylinder head, valves, piston, connecting rods, crankshaft, oil pump, timing components Fuel System: Fuel injection system, throttle body, fuel pump, fuel filter, injectors, sensors, ECU diagnostics Ignition System: Spark plugs, ignition coils, ignition control unit (ICU), timing adjustments Cooling System: Radiator, cooling fan, thermostat, water pump, coolant specifications and procedures Lubrication System: Oil pump, oil filter, oil passages, oil specifications and change intervals Transmission Drivetrain: Clutch assembly, gearbox, gear inspection, lubrication, chain and sprocket maintenance Chassis Suspension: Frame inspection, front fork (telescopic), rear suspension (monoshock), bearings, lubrication Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications, pad replacement, bleeding procedures Electrical System: Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting, horn, wiring diagrams, component testing Bodywork Fittings: Fairings, seat, fuel tank, fenders, mirrors, levers, control cables, disassembly and reassembly procedures Procedures Included Maintenance: Routine maintenance, lubrication, fluid changes, filter replacements, chain adjustment, brake pad inspection Troubleshooting: Diagnostic procedures for common issues, fault code interpretation, systematic problem-solving Repair Overhaul: Detailed step-by-step instructions for engine, transmission, suspension, brake, and electrical component repairs and overhauls Wiring Diagrams: Complete and detailed electrical wiring diagrams for all vehicle systems Technical Depth Depth: Full professional quality, in-depth service and repair 📊 Manual Specifications File Format Quality: Full Printable Quality Searchability: Likely text-searchable PDF (standard for professional manuals) Print Quality Printability: All pages printable Binding Type Delivery Format: Digital Download (PDF) Paper Type Physical Format: Not Applicable (Digital) Requirements Software Requirement: Adobe PDF Reader Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 8-valve, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 10.8:1 Performance Horsepower Est: 72 hp @ 8,500 rpm (approximate, may vary slightly by year/market) Torque Est: 47 lb-ft @ 7,000 rpm (approximate, may vary slightly by year/market) Fuel System Induction: Digital Fuel Injection (DFI) with Keihin throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane Lubrication Oil Type: SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil Oil Capacity: 3.4 US qt (3.2 L) with filter change 🔧 Transmission Standard Type: 6-speed, constant mesh Features Clutch Type: Wet, multiple disc Final Drive: Sealed chain, 525 Gear Ratios: Specific ratios covered in manual (e.g., 1st: 2.750, 2nd: 2.056, 3rd: 1.611, 4th: 1.333, 5th: 1.150, 6th: 1.000) Transmission Oil: Refer to manual for specific type (typically engine oil in this design) 📐 Dimensions Exterior Overall Length: 2,195 mm (86.4 in) Overall Width: 840 mm (33.1 in) Overall Height: 1,370 mm (53.9 in) Wheelbase: 1,445 mm (56.9 in) Ground Clearance: 160 mm (6.3 in) Seat Height: 840 mm (33.1 in) Weights Dry Weight Est: 181 kg (399 lbs) Wet Weight Est: 200 kg (441 lbs) Fuel...