2010-2011 Kawasaki VERSYS/VERSYS ABS Service Repair Manual
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This manual covers the VERSYS and VERSYS ABS motorcycles, specifically for the 2010 and 2011 model years. Known for its versatility as an adventure touring and sport touring motorcycle, the VERSYS is powered by a 649 cc liquid-cooled, four-stroke parallel-twin engine, delivering approximately 64 horsepower and 46 lb-ft of torque. Its design philosophy emphasizes a lightweight, affordable, and adaptable platform, making it suitable for a wide range of riding, from daily commuting to light touring. Key features include a 6-speed transmission, digital fuel injection, and available Anti-lock Braking System (ABS) on select models, enhancing rider control and safety. This comprehensive Service Repair Manual in English provides detailed factory-level information essential for the maintenance, repair, and troubleshooting of your VERSYS. It covers all major systems, including the engine, drivetrain, chassis, and electrical components. Specific procedures detailed within include periodic maintenance, routine service, assembly and disassembly, component repair, and in-depth diagnostics for the fuel injection and electrical systems. This manual is an indispensable resource for owners and professional technicians alike, ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: VERSYS / VERSYS ABS Model Codes: KLE650CAF (2010), KLE650DAF (2010), KLE650CBF (2011), KLE650DBF (2011) Applicable Years: 2010, 2011 👋 Introduction Market Position Vehicle Segment: Adventure Touring / Sport Touring Motorcycle Competitive Analysis Competitors: Suzuki V-Strom 650, Yamaha TDM900 (in some markets), Honda NC700X (later model) Key Features Design Philosophy: Versatile, lightweight, and affordable sport-touring motorcycle with a parallel-twin engine and adjustable ergonomics. Target Audience: Riders seeking a comfortable and capable motorcycle for commuting, sport riding, and light touring. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: PDF Download Page Count: Not Specified (typically 500+ pages for this type of manual) Completeness: Complete factory service information, covering all aspects of maintenance, repair, and troubleshooting. 📖 Manual Coverage Systems Covered Engine: Includes General Information, Fuel System (DFI), Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission Drivetrain: Includes Clutch, Crankshaft/Transmission, Final Drive Chassis: Includes Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical: Includes Electrical System, Wiring Diagrams Procedures Included Maintenance: Periodic Maintenance, Routine Service Procedures Repair: Assembly, Disassembly, Component Repair, Troubleshooting Diagnostics: Fuel System (DFI) Diagnostics, Electrical System Diagnostics Technical Depth Depth: Comprehensive factory-level service and repair information, suitable for professional technicians and experienced DIY mechanics. Specific Procedures: Detailed procedures for engine rebuilding, transmission overhaul, suspension adjustments and rebuilds, brake system bleeding and component replacement, electrical troubleshooting using wiring diagrams, DFI system diagnostics and adjustments. 📊 Manual Specifications File Specifications File Format: PDF Print Quality: High Quality, All pages printable Searchability: Assumed searchable due to PDF format, though not explicitly stated. Delivery Delivery Method: Instant Download Shipping Cost: None Delivery Timeframe: Immediate Compatibility Operating Systems: All Versions of Windows & Mac Required Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, Four-stroke Parallel-Twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.1:1 Valve Train: DOHC, 8 valves Performance Horsepower: Approx. 64 HP @ 8000 RPM (manufacturer's claim, may vary) Torque: Approx. 46 lb-ft @ 7000 RPM (manufacturer's claim, may vary) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 38mm throttle bodies Fuel Type: Unleaded Gasoline (91 Octane or higher recommended) Lubrication Oil Type: SAE 10W-40 API SG or SH with JASO MA Oil Capacity: Approx. 2.0 L (with filter change) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Optional ABS: Available on ABS models (KLE650DAF, KLE650DBF) Features Clutch Type: Wet, multiple-disc 📐 Dimensions Exterior Length: 2,195 mm (86.4 in) Width: 840 mm (33.1 in) Height: 1,410 mm (55.5 in) / 1,420 mm (55.9 in) (ABS) Wheelbase: 1,415 mm (55.7 in) Ground Clearance: 170 mm (6.7 in) Weights Curb Weight: Approx. 208 kg (459 lbs) / 211 kg (465 lbs) (ABS) Fuel Capacity: 19 L (5.0 US gal) Wheels Tires Front Tire Size: 120/70ZR17M/C (58W) Rear Tire Size: 180/55ZR17M/C (73W) Front Brake Type: Dual semi-floating 300 mm petal discs with hydraulic calipers Rear Brake Type: Single 250 mm petal disc with hydraulic caliper ABS System: Bosch Anti-lock Brake System (on ABS models) 🛡️ Safety Features Ratings Safety Certification: N/A (Motorcycle safety is typically regulated by national standards rather than standardized ratings like cars). Active Features ABS: Available as an option, preventing wheel lock-up during braking. Passive Features Lighting: Dual headlights, LED taillight Ergonomics: Adjustable windscreen, upright riding position for rider comfort and visibility. 💡 Technology Features Infotainment Dash Display: Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights. Driver Assistance ABS: Optional Anti-lock Braking System for enhanced safety. Connectivity Charging Ports: None from factory (aftermarket options available, manual may cover installation of accessory power outlets). 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km (3,700 miles) or 6 months, whichever comes first. Spark Plugs: Inspection at 12,000 km (7,500 miles), replacement as...
This manual covers the VERSYS and VERSYS ABS motorcycles, specifically for the 2010 and 2011 model years. Known for its versatility as an adventure touring and sport touring motorcycle, the VERSYS is powered by a 649 cc liquid-cooled, four-stroke parallel-twin engine, delivering approximately 64 horsepower and 46 lb-ft of torque. Its design philosophy emphasizes a lightweight, affordable, and adaptable platform, making it suitable for a wide range of riding, from daily commuting to light touring. Key features include a 6-speed transmission, digital fuel injection, and available Anti-lock Braking System (ABS) on select models, enhancing rider control and safety.
This comprehensive Service Repair Manual in English provides detailed factory-level information essential for the maintenance, repair, and troubleshooting of your VERSYS. It covers all major systems, including the engine, drivetrain, chassis, and electrical components. Specific procedures detailed within include periodic maintenance, routine service, assembly and disassembly, component repair, and in-depth diagnostics for the fuel injection and electrical systems. This manual is an indispensable resource for owners and professional technicians alike, ensuring the longevity and optimal performance of the motorcycle.
Suzuki V-Strom 650, Yamaha TDM900 (in some markets), Honda NC700X (later model)
Key Features
Design Philosophy:
Versatile, lightweight, and affordable sport-touring motorcycle with a parallel-twin engine and adjustable ergonomics.
Target Audience:
Riders seeking a comfortable and capable motorcycle for commuting, sport riding, and light touring.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
PDF Download
Page Count:
Not Specified (typically 500+ pages for this type of manual)
Completeness:
Complete factory service information, covering all aspects of maintenance, repair, and troubleshooting.
📖 Manual Coverage
Systems Covered
Engine:
Includes General Information, Fuel System (DFI), Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission
Drivetrain:
Includes Clutch, Crankshaft/Transmission, Final Drive
Chassis:
Includes Wheels/Tires, Brakes, Suspension, Steering, Frame
Fuel System (DFI) Diagnostics, Electrical System Diagnostics
Technical Depth
Depth:
Comprehensive factory-level service and repair information, suitable for professional technicians and experienced DIY mechanics.
Specific Procedures:
Detailed procedures for engine rebuilding, transmission overhaul, suspension adjustments and rebuilds, brake system bleeding and component replacement, electrical troubleshooting using wiring diagrams, DFI system diagnostics and adjustments.
📊 Manual Specifications
File Specifications
File Format:
PDF
Print Quality:
High Quality, All pages printable
Searchability:
Assumed searchable due to PDF format, though not explicitly stated.
Delivery
Delivery Method:
Instant Download
Shipping Cost:
None
Delivery Timeframe:
Immediate
Compatibility
Operating Systems:
All Versions of Windows & Mac
Required Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, Four-stroke Parallel-Twin
Displacement:
649 cc
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.1:1
Valve Train:
DOHC, 8 valves
Performance
Horsepower:
Approx. 64 HP @ 8000 RPM (manufacturer's claim, may vary)
Torque:
Approx. 46 lb-ft @ 7000 RPM (manufacturer's claim, may vary)
Fuel System
Fuel Delivery:
Digital Fuel Injection (DFI) with dual 38mm throttle bodies
Fuel Type:
Unleaded Gasoline (91 Octane or higher recommended)
Lubrication
Oil Type:
SAE 10W-40 API SG or SH with JASO MA
Oil Capacity:
Approx. 2.0 L (with filter change)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
ABS:
Available on ABS models (KLE650DAF, KLE650DBF)
Features
Clutch Type:
Wet, multiple-disc
📐 Dimensions
Exterior
Length:
2,195 mm (86.4 in)
Width:
840 mm (33.1 in)
Height:
1,410 mm (55.5 in) / 1,420 mm (55.9 in) (ABS)
Wheelbase:
1,415 mm (55.7 in)
Ground Clearance:
170 mm (6.7 in)
Weights
Curb Weight:
Approx. 208 kg (459 lbs) / 211 kg (465 lbs) (ABS)
Fuel Capacity:
19 L (5.0 US gal)
Wheels Tires
Front Tire Size:
120/70ZR17M/C (58W)
Rear Tire Size:
180/55ZR17M/C (73W)
Front Brake Type:
Dual semi-floating 300 mm petal discs with hydraulic calipers
Rear Brake Type:
Single 250 mm petal disc with hydraulic caliper
ABS System:
Bosch Anti-lock Brake System (on ABS models)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Motorcycle safety is typically regulated by national standards rather than standardized ratings like cars).
Active Features
ABS:
Available as an option, preventing wheel lock-up during braking.
Passive Features
Lighting:
Dual headlights, LED taillight
Ergonomics:
Adjustable windscreen, upright riding position for rider comfort and visibility.
💡 Technology Features
Infotainment
Dash Display:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System for enhanced safety.
Connectivity
Charging Ports:
None from factory (aftermarket options available, manual may cover installation of accessory power outlets).
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Spark Plugs:
Inspection at 12,000 km (7,500 miles), replacement as needed.
Air Filter:
Inspection at 6,000 km (3,700 miles), cleaning/replacement as needed. Detailed cleaning procedure in manual.
Chain Lubrication:
Every 1,000 km (600 miles) or after washing/riding in rain. Manual details chain slack adjustment.
Fluid Specifications
Coolant Type:
Kawasaki All Weather Coolant or equivalent (50/50 mix with distilled water).
Brake Fluid:
DOT 4 recommended
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (high mileage).
Potential Concerns:
Some owners report minor electrical connector issues or vibration at certain RPMs. Fuel pump reliability is generally good but should be checked as per manual. The manual provides detailed troubleshooting for these.
Technical Specifications
Idle Speed:
1,200 ± 100 rpm
Valve Clearance Intake:
0.11 - 0.20 mm (0.004 - 0.008 in)
Valve Clearance Exhaust:
0.21 - 0.30 mm (0.008 - 0.012 in)
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company, Japan
Model Evolution
Previous Generation:
Based on the Ninja 650R platform, adapted for a more upright and versatile riding posture.
Updates 2010 2011:
Minor styling updates and the introduction of ABS as an option.
Production
Production Years:
Introduced in 2006, current generation covers 2006-2016.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards for the 2010-2011 model year are not widely documented, the VERSYS platform is generally praised for its value, versatility, and performance for its price point.