Kawasaki VERSYS ABS User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

VERSYS
VERSYS ABS
Motorcycle
Service Manual
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Referto the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1
j
Periodic Maintenance 2
j
Fuel System (DFI) 3
j
Cooling System 4
j
Engine Top End 5
j
Clutch 6
j
Engine Lubrication System 7
j
Engine Removal/Installation 8
j
Crankshaft/Transmission 9
j
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 17
j
VERSYS
VERSYS ABS
Motorcycle
Service Manual
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 D
ivision/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as poss
ible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after t
his publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2009 Kawasaki Heavy Industries, Ltd. Second Edition (0) : Aug. 17, 2010
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) ohm(s)
L liter(s)
COUNTRY AND AREA CODES
AT Austria GB United Kingdom
AU Australia MY Malaysia
AU LAMS
Australia Leaner Approved Motorcycle
Scheme model
SEA Southeast Asia
BR Brazil TH Thailand
CA Canada US United States
CAL California WVTA Whole Vehicle Type Approval
CH Switzerland
WVTA
(FULL H)
WVTA Model with Honetcomb Catalytic
Converter (Full Power)
DE Germany
GB WVTA
(FULL H)
WVTA Model with Honetcomb Catalytic
Converter (LeftSide Traffic, Full Power)
EUR Europe
EMISSION CONTROL INFORMATION
Toprotecttheenvironment inwhich weall live, Kawasakihas incorporatedcrankcaseemission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board.
1. Crankcase Emission Control System
Thissystemeliminatesthereleaseof crankcasevaporsinto theatmosphere. Instead,thevapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
NOTE
The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Additionof componentsoraccessoriesthatresultinthevehicleexceedingthe stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperativeby any person other than for purposes of maintenance, repair, orreplacement, ofany
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trainedmechanics in a properlyequipped shop.
However, itcontainsenough detailandbasicin-
formationto makeit usefulto theowner who de-
siresto performhisown basic maintenanceand
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
beforestartingwork, andthendo the work ca
re-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem
ents
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in
accordance with
thisservicemanual. Anyownermaintenanceor
repair procedure not performed in accordance
with this manual may void
the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and
genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki moto
rcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the p
rocedures in this manual care-
fully. Don’t take shortcuts.
Remembertokeepcompleterecordsofmain-
tenance a
nd repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section.
Whenever you see symbols, heed their in-
structions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situa-
tion which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situa-
tion which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situa-
tion which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more s
ymbols
which will help you distinguish different types
of information.
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.
Indicates a conditional step or what action to
takebasedon the resultsofthe testor inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructionsindicating which partsrequirespec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Contents
Before Servicing..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-12
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. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any serviceon the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point so
lvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
otherforeignmaterialsenteringintosealed areasduringve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassemblyparts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visuallyinspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for servicelimits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
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.
Assembly Order
In most cases assembly order is the reverse ofdisassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
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. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.
Force
Use common sense during disas
sembly and assembly,
excessiveforce can cause expensiveor hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent
applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
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. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Donotremovepressedoilorgreasesealsunlessremoval
is necessary. Replace with new ones whenever removed.
Pressnew oilseals with manufactureand sizemarks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replacecirclipsorcotterpinsthatwereremovedwithnew
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
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. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identifie
d first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
KLE650CAF Left Side View
KLE650CAF Right Side View
1-8 GENERAL INFORMATION
Model Identification
KLE650DAF Left Side View
KLE650DAF Right Side View
Frame Number Engine Number
GENERAL INFORMATION 1-9
General Specifications
Items KLE650CAF CBF, KLE650DAF DBF
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.)
Curb Mass:
KLE650CAF CBF 206 kg (454 lb)
KLE650DAF DBF
209 kg (461 lb)
Front:
KLE650CAF CBF 103 kg (227 lb)
KLE650DAF DBF
105 kg (232 lb)
Rear:
KLE650CAF CBF 103 kg (227 lb)
KLE650DAF DBF
104 kg (229 lb)
Fuel Tank Capacity 19 L (5.0 US gal)
Performance
Minimum Turning Radius 2.7 m (8.8 ft)
Engine
Type 4-stroke, DOHC, 2-cylinder
Cooling System Liquid-cooled
Bore and Stroke 83 × 60 mm (3.3 × 2.4 in.)
Displacement 649 cm³ (39.6 cu in.)
Compression Ratio 10.6 : 1
Maximum Horsepower 47 kW (64 PS) @8 000 r/min (rpm)
(KLE650DAF, AU LAMS) 25 kW (34 PS) @6 500 r/min (rpm)
(KLE650DBF, AU LAMS) 34 kW (46 PS) @7 000 r/min (rpm)
(CA, US)
Maximum Torque 61 N·m (6.2 kgf·m, 45 ft·lb) @6 800 r/min (rpm)
(KLE650DAF, AU LAMS) 50 N·m (5.1 kgf·m, 37 ft·lb) @3 000
r/min (rpm)
(KLE650DBF, AU LAMS) 54 N·m (5.5 kgf·m, 40 ft·lb) @4 700
r/min (rpm)
(CA, US)
Carburetion System FI (Fuel injection), KEIHIN TTK38 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU)
Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 33° BTDC @5 000 r/min
(rpm)
Spark Plug NGK CR9EIA-9
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
1-10 GENERAL INFORMATION
General Specifications
Items KLE650CAF CBF, KLE650DAF DBF
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 SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2.095 (88/42)
Clutch Type Wet multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.438 (39/16)
2nd
1.714 (36/21)
3rd
1.333 (32/24)
4th 1.111 (30/27)
5th 0.966 (28/29)
6th 0.852 (23/27)
Final Drive System:
Type Chain drive
Reduction Ratio 3.067 (46/15)
Overall Drive Ratio 5.473 @Top gear
Frame
Type Tubular,diamond
Caster (Rake Angle) 25°
Trail 108 mm (4.3 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 MC (58W)
Rear Tire:
Type Tubeless
Size 160/60 ZR17 MC (69W)
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Kawasaki VERSYS ABS User manual

Category
Motorcycles
Type
User manual
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