Kawasaki Versys 2010-2013 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: Versys Model Years Covered: 2010, 2011, 2012, 2013 Platform Code: LE250-A 👋 Introduction Market Position Product Segment: Sport-touring motorcycle, known for its versatility, upright riding position, and parallel-twin engine. Competes in a segment that often includes models like the Yamaha MT-07/Tracer, Suzuki V-Strom, and Honda NC700X. Competitive Analysis Key Competitors Segment: Mid-weight adventure-sport and sport-touring motorcycles. Key Features Versatility: Designed for a wide range of riding conditions, from commuting to touring, offering a balance of sportiness and comfort. Engine Configuration: Parallel-twin engine, derived from Kawasaki's Ninja sportbike lineage, providing a torquey and engaging power delivery. Ergonomics: Upright riding position, wide handlebars, and comfortable seating designed for rider comfort over longer distances. 📋 Manual Details Coverage Areas Coverage Type: Full Service Repair Repair Focus: Maintenance, Diagnostics, Repair, Rebuild, Refurbishment, Restoration Page Count Estimated Page Count: Comprehensive (exact number not specified, but implied to be extensive) Manual Type Manual Type: Service Manual / Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Printability: Full Printable Software Requirements: Adobe PDF Reader, WinRAR Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine: Internal combustion engine (ICE) systems, including disassembly, inspection, assembly, lubrication, cooling, ignition, fuel injection, and exhaust. Transmission: Clutch operation, gearbox (6-speed sequential), shift drum, shift forks, lubrication, and maintenance procedures. Chassis: Frame structure, suspension (front telescopic fork, rear UNI-TRAK system), steering system, and wheel/tire service. Brakes: Front dual petal discs with dual piston calipers, rear single petal disc with single piston caliper, hydraulic system, brake fluid specifications, bleeding procedures, and component replacement. Electrical System: Battery, charging system (alternator, regulator/rectifier), ignition system, lighting (headlight, taillight, turn signals, brake lights), instrumentation, starter motor, and wiring diagrams. Fuel System: Fuel tank, fuel pump, fuel injectors, throttle body, ECU control, and emissions systems. Cooling System: Radiator, cooling fan, thermostat, water pump, hoses, and coolant specifications. Exhaust System: Exhaust manifold, catalytic converter (if applicable for specific market variants), mufflers, and mounting hardware. Bodywork And Trim: Fairing panels, fuel tank cover, seat assembly, fenders, and associated fasteners. Procedures Included Maintenance Procedures: Routine checks, lubrication, oil and filter changes, air filter cleaning/replacement, spark plug replacement, coolant flushes, brake fluid replacement, chain adjustment and lubrication. Diagnostic Procedures: Troubleshooting guides for common problems, fault code interpretation (if applicable to this generation), and diagnostic steps for electrical and mechanical issues. Repair Procedures: Detailed, step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Rebuild Procedures: Comprehensive instructions for complete engine teardowns and rebuilds, including piston, ring, cylinder, crankshaft, and valve train service. Electrical Service: Troubleshooting specific electrical faults, wiring harness inspection, connector service, and detailed wiring diagrams. Suspension Service: Fork oil replacement, seal replacement, shock absorber service, and linkage lubrication. Wheel And Tire Service: Tire mounting/dismounting, wheel balancing, bearing service, and spoke tensioning (if applicable). Technical Depth Depth Of Information: Professional-grade technical data, suitable for both experienced technicians and dedicated DIY enthusiasts. Covers granular details for intricate repairs. Diagnostic Tools: While specific diagnostic tool requirements aren't detailed, the manual likely covers procedures that would necessitate standard motorcycle mechanic tools and potentially basic electrical testing equipment. 📊 Manual Specifications File Format File Type: PDF File Portability: Savable to hard drive, burnable to CD-ROM Print Quality Print Capability: High-quality printing of all pages Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Searchability Text Searchability: Assumed searchable due to PDF format, aiding quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 mm x 60.0 mm Compression Ratio: 10.5:1 Fuel Delivery: Digital Fuel Injection with dual 38mm throttle bodies Ignition System: TCBI with electronic advance Lubrication System: Forced lubrication, wet sump Performance Horsepower Approx: Approx. 70-72 hp @ 8,000 rpm (model specific variations may apply) Torque Approx: Approx. 45-47 lb-ft @ 6,000 rpm (model specific variations may apply) Fuel System Fuel Type: Unleaded gasoline, 87 octane or higher recommended. 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, sequential return Clutch Type: Wet, multi-disc Final Drive: Sealed chain, 520 O-ring type Features Gear Ratios: Detailed gear ratios are provided within the manual for each gear. Transmission Fluid Type: API GL-4, SAE 80W-90 hypoid gear oil (specific Kawasaki recommendation likely detailed in manual). 📐 Dimensions Exterior Length: Approx. 2,150 mm (84.6 in) Width: Approx. 830 mm (32.7 in) Height: Approx. 1,360 mm (53.5 in) Wheelbase: Approx. 1,415 mm (55.7 in) Ground Clearance: Approx. 155 mm (6.1 in) Seat Height: Approx. 840 mm (33.1 in) Weights Curb Weight: Approx. 204 kg (450 lbs) Fuel Tank Capacity: 19 Liters (5.0 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles typically do not undergo standardized crash testing like automobiles; safety relies on rider skill and active...
Sport-touring motorcycle, known for its versatility, upright riding position, and parallel-twin engine. Competes in a segment that often includes models like the Yamaha MT-07/Tracer, Suzuki V-Strom, and Honda NC700X.
Competitive Analysis
Key Competitors Segment:
Mid-weight adventure-sport and sport-touring motorcycles.
Key Features
Versatility:
Designed for a wide range of riding conditions, from commuting to touring, offering a balance of sportiness and comfort.
Engine Configuration:
Parallel-twin engine, derived from Kawasaki's Ninja sportbike lineage, providing a torquey and engaging power delivery.
Ergonomics:
Upright riding position, wide handlebars, and comfortable seating designed for rider comfort over longer distances.
Front dual petal discs with dual piston calipers, rear single petal disc with single piston caliper, hydraulic system, brake fluid specifications, bleeding procedures, and component replacement.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), ignition system, lighting (headlight, taillight, turn signals, brake lights), instrumentation, starter motor, and wiring diagrams.
Radiator, cooling fan, thermostat, water pump, hoses, and coolant specifications.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable for specific market variants), mufflers, and mounting hardware.
Bodywork And Trim:
Fairing panels, fuel tank cover, seat assembly, fenders, and associated fasteners.
Procedures Included
Maintenance Procedures:
Routine checks, lubrication, oil and filter changes, air filter cleaning/replacement, spark plug replacement, coolant flushes, brake fluid replacement, chain adjustment and lubrication.
Diagnostic Procedures:
Troubleshooting guides for common problems, fault code interpretation (if applicable to this generation), and diagnostic steps for electrical and mechanical issues.
Repair Procedures:
Detailed, step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Rebuild Procedures:
Comprehensive instructions for complete engine teardowns and rebuilds, including piston, ring, cylinder, crankshaft, and valve train service.
Electrical Service:
Troubleshooting specific electrical faults, wiring harness inspection, connector service, and detailed wiring diagrams.
Suspension Service:
Fork oil replacement, seal replacement, shock absorber service, and linkage lubrication.
Professional-grade technical data, suitable for both experienced technicians and dedicated DIY enthusiasts. Covers granular details for intricate repairs.
Diagnostic Tools:
While specific diagnostic tool requirements aren't detailed, the manual likely covers procedures that would necessitate standard motorcycle mechanic tools and potentially basic electrical testing equipment.
📊 Manual Specifications
File Format
File Type:
PDF
File Portability:
Savable to hard drive, burnable to CD-ROM
Print Quality
Print Capability:
High-quality printing of all pages
Binding Type
Binding Type:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
Searchability
Text Searchability:
Assumed searchable due to PDF format, aiding quick information retrieval.
Digital Fuel Injection with dual 38mm throttle bodies
Ignition System:
TCBI with electronic advance
Lubrication System:
Forced lubrication, wet sump
Performance
Horsepower Approx:
Approx. 70-72 hp @ 8,000 rpm (model specific variations may apply)
Torque Approx:
Approx. 45-47 lb-ft @ 6,000 rpm (model specific variations may apply)
Fuel System
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, sequential return
Clutch Type:
Wet, multi-disc
Final Drive:
Sealed chain, 520 O-ring type
Features
Gear Ratios:
Detailed gear ratios are provided within the manual for each gear.
Transmission Fluid Type:
API GL-4, SAE 80W-90 hypoid gear oil (specific Kawasaki recommendation likely detailed in manual).
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm (84.6 in)
Width:
Approx. 830 mm (32.7 in)
Height:
Approx. 1,360 mm (53.5 in)
Wheelbase:
Approx. 1,415 mm (55.7 in)
Ground Clearance:
Approx. 155 mm (6.1 in)
Seat Height:
Approx. 840 mm (33.1 in)
Weights
Curb Weight:
Approx. 204 kg (450 lbs)
Fuel Tank Capacity:
19 Liters (5.0 US gal)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles typically do not undergo standardized crash testing like automobiles; safety relies on rider skill and active safety features.)
Active Features
Braking System:
Dual front disc brakes and a single rear disc brake. Optional ABS (Anti-lock Braking System) may be available on some market variants, details would be in the manual.
Lighting:
Halogen headlight, LED taillight, and standard turn signals for visibility.
Passive Features
Chassis Design:
Sturdy frame and suspension geometry contribute to stable handling.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD instrument panel providing speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and indicator lights.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on select models and markets during these years. The manual will detail its operation and service if equipped.
Connectivity
Connectivity Features:
No advanced connectivity features like Bluetooth or smartphone integration were standard on this generation.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Recommended every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Inspection:
Inspect every 3,700 miles (6,000 km), clean or replace as needed.
Spark Plug Replacement:
Recommended at 7,500 miles (12,000 km) or 12 months.
Coolant Change:
Recommended every 2 years or 15,000 miles (24,000 km).
Brake Fluid Change:
Recommended every 2 years or 18,000 miles (30,000 km).
Chain Lubrication And Adjustment:
Lubricate every 300-500 miles (500-800 km) or after riding in the rain. Adjust chain slack as per manual specifications (typically 1-1.5 inches of play).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH, Jaso MA certified motorcycle oil. (Specific grade may vary slightly based on ambient temperature, consult manual).
Engine Oil Capacity:
Approx. 2.4 liters (2.5 US qt) with filter change; 2.2 liters (2.3 US qt) without filter change.
Coolant Type:
High-quality ethylene glycol-based antifreeze/coolant mixed 50/50 with distilled water. Kawasaki recommends their own coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type And Level:
SAE 10W suspension fluid. Level typically around 120-130mm from the top of the fork stanchion when fully compressed with spring removed.
Known Issues
Fuel Pump Reliability:
Early models sometimes experienced fuel pump issues, though improvements were made. Early detection of weak fuel delivery is key.
Idle Control Issues:
Occasional reports of erratic idle speed, often related to throttle body synchronization or sensor readings.
Suspension Softness:
While generally competent, some riders find the stock suspension slightly soft for aggressive riding or heavy loads, prompting aftermarket upgrades. The manual will detail proper adjustment and maintenance.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries has a long-standing reputation for performance motorcycles, particularly in sportbikes and off-road models. The Versys line leverages this engineering expertise.
Model Evolution
Versys Lineage:
The Versys (a portmanteau of 'versatile' and 'system') was introduced as Kawasaki's answer to the growing sport-touring and adventure-touring market. The 650cc parallel-twin platform has been a consistent success.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Model Generation:
These model years represent the first generation of the Versys 650, launched in 2007 (for the 2008 model year) with updates through the period covered by this manual.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Versys 650 platform has consistently been praised for its value, versatility, and enjoyable parallel-twin engine by motorcycle publications worldwide.
Ratings
Rider Reviews:
Generally receives positive reviews for its blend of sportbike DNA with touring comfort, making it a popular choice for commuting and light touring.
Certifications
Emissions Compliance:
Complies with prevailing emissions standards for the respective model years and market regions. Manual likely includes emission-related specifications.
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