Kawasaki KLE 650 Versys 2010 2011 Workshop Service Manual

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The Kawasaki KLE 650 Versys, produced between 2010 and 2011, is a versatile sport touring motorcycle powered by a 649.3 cc parallel-twin engine known for its smooth power delivery and...

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UGS: 85102

Mots clés: 2010 2011 Kawasaki KLE 650 Versys Misc Motorcycle Motorcycles

Variantes de produits

Description

The Kawasaki KLE 650 Versys, produced between 2010 and 2011, is a versatile sport touring motorcycle powered by a 649.3 cc parallel-twin engine known for its smooth power delivery and reliability. Designed as a capable platform for commuting, long-distance touring, and even light off-road excursions, this model bridges the gap between sportbikes and adventure motorcycles. Its engineering emphasizes practicality and rider enjoyment, making it a popular choice for a wide range of riding styles and conditions. The KLE 650 Versys features a multi-reflector headlamp, LED tail light, and an optional ABS system for enhanced safety. This comprehensive workshop service manual provides detailed guidance for the maintenance and repair of the 2010-2011 Kawasaki KLE 650 Versys. It covers all essential systems, including the engine, transmission, chassis, and electrical components, offering in-depth information on overhaul, repair procedures, and scheduled maintenance. The manual includes troubleshooting guides, technical specifications, torque values, and fluid recommendations, making it an indispensable resource for professional technicians and experienced owners alike. Its purpose is to ensure the longevity, performance, and safe operation of your motorcycle through accurate and detailed technical information.

🏷️ 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:

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:

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

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.