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Kawasaki KLE 650 Versys 2010 2011 Workshop Service Manual

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🏷️ 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...
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Taper: Motorcycle
Distributeur:
UGS: 85102
Kawasaki KLE 650 Versys 2010 2011 Workshop Service Manual
🏷️ 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 within the manual.
Connectivity
Diagnostic Ports:
Diagnostic connectors and procedures for reading error codes are detailed.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (refer to manual for exact intervals and oil type).
Valve Clearance Interval:
Every 24,000 km (15,000 miles) or 24 months.
Chain Maintenance:
Lubricate and adjust every 1,000 km (600 miles) or after riding in wet conditions.
Fluid Specifications
Engine Oil Capacity:
3.0 L (3.2 US qt) without filter change; 3.2 L (3.4 US qt) with filter change.
Coolant Type:
Kawasaki Coolant 50/50 (or equivalent ethylene glycol-based coolant with demineralized water).
Brake Fluid Type:
DOT 4
Known Issues
Stalling At Low Rpm:
Some owners reported occasional stalling or rough idling at very low RPM, often resolvable through ECU remapping or adjustments to idle speed. Covered in the manual's troubleshooting section.
Suspension Compliance:
While generally competent, the stock suspension can be a point of improvement for aggressive riding or heavier loads, with the manual detailing adjustment procedures.
Engine Vibration:
As a parallel-twin, some vibration is inherent. The manual provides torque specs for engine mounts to ensure proper damping.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.
Model Evolution
Versys Introduction:
The Versys line was introduced to provide a versatile, sporty, and practical motorcycle experience, bridging the gap between sportbikes and adventure bikes.
Production
Manufacturing Location:
Japan
Model Updates
2010-2011:
This generation (often referred to as the 'first generation' or 'B-model' Versys) received minor updates for these years, building on the initial 2007-2009 model.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2010-2011 model year are not widely documented, the Versys line has consistently been praised for its value, versatility, and fun-to-ride nature, often appearing on 'best of' lists for affordable sport-touring motorcycles.
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