Kawasaki Versys 2010-2013 Full Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 80260

Mots clés: 2010 2011 2012 2013 Kawasaki Motorcycle Motorcycles Versys

Variantes de produits

Description

Welcome to the comprehensive service manual for the Versys, covering model years 2010 through 2013. This versatile sport-touring motorcycle is renowned for its adaptable nature, comfortable upright riding position, and spirited parallel-twin engine, drawing on a legacy of performance engineering. Designed for a wide spectrum of riding, from daily commutes to extended journeys, the Versys (platform code LE250-A) offers a compelling blend of agility and comfort, making it a popular choice in its segment. Its robust construction and reliable parallel-twin powerplant are hallmarks of a commitment to quality and rider satisfaction. This manual provides full service repair coverage, encompassing detailed maintenance procedures, diagnostic strategies, and step-by-step repair instructions for all major systems. You will find in-depth guidance on engine, transmission, chassis, brakes, and electrical systems, along with specific procedures for component disassembly, inspection, and reassembly. Whether you are performing routine maintenance, troubleshooting a complex issue, or undertaking a full restoration, this English-language resource is designed to assist owners, mechanics, and technicians in keeping their Versys in optimal condition. Its extensive coverage ensures that all aspects of the motorcycle's operation and upkeep are thoroughly addressed.

🏷️ 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:

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:

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 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.