This manual covers the motorcycle, a versatile motorcycle designed for adventure-touring and sport-touring. First introduced globally for the 2007 model year, this first-generation model, including variants like the KLE650CAF, KLE650DAF, KLE650CBF, and KLE650DBF, offers a unique blend of sportbike handling and adventure bike ergonomics. It is powered by a 649 cc liquid-cooled, parallel-twin engine and features a trellis frame, petal disc brakes, and a 6-speed transmission. The motorcycle is engineered for riders seeking adaptability for commuting, long-distance touring, and light off-road excursions, combining performance with a comfortable, upright riding position.
This comprehensive workshop service and repair manual provides detailed information for the maintenance, diagnosis, and repair of the motorcycle. It covers all major systems, including the engine, fuel system, drivetrain, chassis, and electrical components. The manual includes step-by-step repair procedures, diagnostic guides, troubleshooting information, and detailed technical specifications, supported by hundreds of diagrams and illustrations. This factory service manual is an essential resource for owners, mechanics, and technicians to ensure the proper upkeep and longevity of their motorcycle.
Model Codes Covered:
KLE650CAF, KLE650DAF, KLE650CBF, KLE650DBF
Model Variant Covered:
ABS Model
Generation Identifier:
First Generation
Kawasaki Model Code Explanation:
CAF/DAF (2010), CBF/DBF (2011) denote regional variants and minor updates within the model year for the North American market, with 'D' often indicating ABS.
Motorcycle Segment:
Lightweight Adventure-Touring / Sport-Touring motorcycle.
Target Audience:
Riders seeking versatility for commuting, touring, and light off-road use.
Key Competitors 2010-2011:
Suzuki V-Strom 650, Honda Transalp (if applicable market), BMW F650GS/F700GS.
Versys Philosophy:
Combines sportbike handling with the upright riding position and long-travel suspension of an adventure bike.
Usbility:
Adaptable for various riding conditions and rider preferences.
Manual Scope:
Comprehensive workshop service and repair manual for Kawasaki KLE650 Versys models.
Manual Classification:
Original Factory Service Repair Workshop Manual
Language Of Manual:
English
File Format:
PDF Download
Software Requirements:
Adobe PDF Reader
Operating System Compatibility:
All Versions of Windows & Mac
Engine Systems:
Fuel System (DFI - Digital Fuel Injection), Cooling System, Engine Top End (Cylinder Head, Valves), Engine Lubrication System, Crankshaft, Transmission.
Drivetrain Systems:
Clutch System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive (Chain Drive).
Chassis Systems:
Brakes (Front and Rear), Suspension (Front and Rear), Steering System, Frame.
Electrical Systems:
Complete Electrical System, Wiring Diagrams (implied by 'Original Service Manuals, Wiring Diagrams and Bulletins').
General Coverage:
General Information, Periodic Maintenance, Appendix.
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, inspections.
Diagnostic Procedures:
Comprehensive diagnostic information for all major systems.
Repair Procedures:
Detailed step-by-step repair instructions for components and systems.
Troubleshooting:
Systematic troubleshooting guides for identifying and resolving issues.
Assembly Disassembly:
Detailed procedures for component disassembly and reassembly, including engine and transmission.
Depth Of Information:
High - Designed for professional technicians, covering detailed diagnostics, repair, and maintenance.
Diagrams Illustrations:
Hundreds of pages of diagrams and detailed information.
PDF Quality:
High-resolution, likely searchable text for ease of use.
Printability:
Printable pages for workshop use.
Binding Style:
N/A (Digital PDF Download)
Paper Quality Recommendation:
N/A (Digital PDF Download) - Recommend durable paper if printing.
Engine Type:
Liquid-cooled, Four-stroke, DOHC, Parallel-twin.
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
10.6:1
Horsepower Estimate:
Approx. 63.7 hp @ 8,000 rpm (claimed)
Torque Estimate:
Approx. 44.3 lb-ft @ 7,000 rpm (claimed)
Fuel Injection:
DFI with 38mm Keihin throttle bodies, downdraft induction.
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Fuel Tank Capacity:
Approx. 4.7 US gallons (17.7 Liters)
Transmission Type:
6-speed, constant mesh, return shift.
Optional Transmission:
N/A
Clutch Type:
Wet, multiple-disc, manual activation.
Final Drive:
Sealed O-ring chain.
Length:
Approx. 84.0 in (2135 mm)
Width:
Approx. 33.1 in (840 mm)
Height:
Approx. 51.2 in (1300 mm)
Wheelbase:
Approx. 55.7 in (1415 mm)
Ground Clearance:
Approx. 6.7 in (170 mm)
Curb Weight:
Approx. 443.1 lb (201 kg) for ABS model.
Dry Weight:
Approx. 423.3 lb (192 kg)
Crash Test Ratings:
N/A (Motorcycle specific ratings vary by region and are not typically standardized like automotive.)
Braking System:
Dual 300mm petal discs with dual-piston calipers (front); Single 220mm petal disc with dual-piston caliper (rear).
ABS Availability:
Available as an option (indicated by model codes like DAF/DBF).
Lighting:
Halogen headlights, LED taillight.
Frame Type:
Trellis frame, high-tensile steel.
Instrument Panel:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
ABS:
Anti-lock Braking System available on specific models, enhancing safety during braking.
Charging Ports:
N/A (No factory-integrated USB or 12V ports, though aftermarket options exist).
Oil Change Interval:
Refer to manual, typically every 3,750 miles (6,000 km) or 6 months.
Chain Maintenance Interval:
Clean and lubricate every 300-500 miles (500-800 km).
Major Service Interval:
Refer to manual, typically valve clearance checks around 15,000 miles (24,000 km).
Engine Oil Type:
API SG, SH, SJ, SL or SAE 10W-40 SE or SF or SG with JASO MA certified.
Engine Oil Capacity:
Approx. 2.7 US qt (2.5 L) without filter change; 2.9 US qt (2.7 L) with filter change.
Coolant Type:
Permanent antifreeze solution (Ethylene Glycol based), typically a 50/50 mix with distilled water.
Clutch Fluid Type:
DOT 4 (Hydraulic Clutch).
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (with high mileage).
Electrical Concerns:
While generally reliable, checking battery terminals and connections for corrosion is recommended.
Fuel System Considerations:
Ensuring clean fuel and regular use of fuel stabilizer can prevent injector clogging.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long history of motorcycle manufacturing known for performance and innovation.
Versys Lineage:
The Versys nameplate (Variable System) was introduced to offer a unique blend of sportbike agility and adventure bike ergonomics.
First Generation Launch:
The first generation KLE650 Versys was launched globally for the 2007 model year.
Production Location General:
Typically manufactured in Japan.
Key Updates 2010-2011:
Minor styling updates, potential ECU remapping for emissions or performance, introduction/refinement of ABS option.
Industry Acclaim:
Consistently praised for its value proposition, handling, and versatility in motorcycle publications.
Rider Reviews:
Generally high ratings for its balance of performance, comfort, and price.
Manual Certification:
Original factory documentation, indicating high accuracy and completeness.
