2007 Kawasaki Kle650 Versys Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Versys Year: 2007 Chassis Code: KLE650A7F, KLE650B7F Codes Internal Product Code Potential: KLE650-2007-SM-EN 👋 Introduction Market Position Category: Sport-touring motorcycle Target Audience: Riders...

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类型: Motorcycle

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标签: 2007 Kawasaki Kle650 Versys Motorcycle Motorcycles Versys

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Versys

Year:

Chassis Code:

KLE650A7F, KLE650B7F

Codes

Internal Product Code Potential:

KLE650-2007-SM-EN

👋 Introduction

Market Position

Category:

Sport-touring motorcycle

Target Audience:

Riders seeking versatility for commuting, touring, and light sport riding.

Competitive Analysis

Key Competitors 2007:

Suzuki V-Strom 650, Honda Transalp, Yamaha FZ6 (depending on specific variant and market).

Key Features

Engine Platform:

Shared with the popular Ninja 650R, providing a proven and reliable parallel-twin engine.

Suspension Setup:

Long-travel suspension for comfortable ride over varied surfaces and adjustable front forks.

Ergonomics:

Upright riding position with adjustable handlebars for rider comfort on longer journeys.

Design Philosophy:

Designed as a versatile, affordable, and practical motorcycle for everyday use and touring.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Engine Coverage:

Top End, Lubrication System, Fuel System (DFI), Cooling System

Drivetrain Coverage:

Clutch, Crankshaft, Transmission, Final Drive

Chassis Coverage:

Wheels, Tires, Brakes, Suspension, Steering, Frame

Electrical Coverage:

Complete Electrical System, Wiring Diagrams

Maintenance Coverage:

Periodic Maintenance, Troubleshooting

Page Count

Estimated Page Count:

Approximately 350-450 pages (typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Digital Format:

Platform

Supported Platforms:

Windows, Mac

Delivery

Download Type:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed coverage of the Digital Fuel Injection (DFI) system, including sensor diagnostics, injector service, and throttle body cleaning.

Cooling System:

Procedures for coolant checks, radiator service, thermostat replacement, and fan operation diagnostics.

Lubrication System:

Complete details on oil changes, oil filter replacement (e.g., Kawasaki part number 16099-004), oil pump service, and lubrication system checks.

Engine Internals:

In-depth coverage of engine top-end components including cylinder head removal/installation, valve clearance adjustment, piston and ring inspection, and camshaft timing.

Clutch Operation:

Procedures for clutch lever adjustment, clutch cover removal, friction plate replacement, and clutch spring checks.

Transmission And Gearbox:

Detailed instructions for transmission inspection, gear assembly, shift drum and fork service, and gearbox lubrication requirements.

Final Drive System:

Guidance on rear shock linkage lubrication, swingarm bearing service, and final drive sprocket and chain maintenance (including adjustment and lubrication specs).

Braking System:

Comprehensive brake service including front and rear brake pad replacement, caliper service, master cylinder overhauls, brake fluid bleeding procedures (DOT 4 recommended), and disc inspection.

Suspension System:

Front fork servicing (oil change, seal replacement, spring preload adjustment), rear shock absorber inspection, and linkage bearing maintenance.

Steering And Handlebars:

Steering head bearing inspection and adjustment, handlebar replacement, and control lever adjustments.

Frame And Bodywork:

Frame inspection, subframe mounting checks, and body panel removal/installation procedures.

Electrical System:

Full electrical system diagnostics, including battery service, charging system checks (stator and regulator/rectifier testing), starter motor operation, lighting systems, and detailed wiring diagrams with color coding.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, chain lubrication and adjustment, brake adjustments, tire pressure checks.

Diagnostic Procedures:

Troubleshooting common problems, fault code interpretation for DFI system, component testing procedures.

Repair Procedures:

Engine removal and installation, major component disassembly and reassembly, suspension overhaul, brake system repairs, electrical component replacement.

Performance Tuning:

While not explicitly a tuning manual, it provides baseline specifications and procedures for ensuring optimal performance.

Safety Checks:

Procedures for inspecting safety-critical components like brakes, tires, and steering.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and component rebuilds.

Diagnostic Capability:

Advanced diagnostics for DFI system, electrical faults, and mechanical issues, with specific troubleshooting trees.

Torque Specifications:

Detailed torque values for all critical fasteners throughout the motorcycle.

Clearances And Tolerances:

Precise specifications for valve clearances, piston-to-cylinder wall clearances, bearing tolerances, etc.

Special Tools:

Identification of specific Kawasaki special tools required for certain procedures, often with part numbers.

📊 Manual Specifications

File Format

Format:

Searchability:

Typically text-searchable PDF for easy information retrieval.

Print Quality

Quality:

High resolution for clear diagrams, illustrations, and text, suitable for printing.

Binding Type

Binding If Printed:

N/A (Digital Format)

Paper Type

Paper Quality If Printed:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, DOHC, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Performance

Horsepower Estimated:

Approx. 72 hp @ 8,000 rpm (crank)

Torque Estimated:

Approx. 64 Nm @ 6,500 rpm (crank)

Fuel System

Fuel Delivery:

Digital Fuel Injection (DFI)

Throttle Body:

Dual 38mm throttle bodies

Fuel Type:

Unleaded gasoline, 91 octane or higher recommended

Fuel Tank Capacity:

19 Liters (5.0 US gal)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multiple-disc, cable-actuated

Final Drive Type:

Sealed O-ring chain

📐 Dimensions

Exterior

Overall Length:

2,185 mm (86.0 in)

Overall Width:

840 mm (33.1 in)

Overall Height:

1,230 mm (48.4 in)

Wheelbase:

1,415 mm (55.7 in)

Ground Clearance:

170 mm (6.7 in)

Seat Height:

835 mm (32.9 in)

Weights

Curb Weight:

Approx. 206 kg (454 lbs)

Dry Weight Estimated:

Approx. 191 kg (421 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle specific safety ratings vary by region and are not standardized like automotive).

Active Features

Braking System Type:

Dual hydraulic disc front, single hydraulic disc rear.

ABS Availability:

Not typically available on the base 2007 model; ABS may have been an option on later or specific market versions.

Passive Features

Lighting:

Halogen headlamp, LED taillight.

Tire Construction:

Bias-ply or radial tires, depending on OEM fitment.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle of this era did not feature integrated infotainment systems).

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver aids beyond basic ABS on optional models).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,750 miles) or 12 months, whichever comes first.

Oil Filter Change Interval:

Every 12,000 km (7,500 miles) or 24 months.

Valve Clearance Check:

Every 24,000 km (15,000 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in rain/washing.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH, or JASO MA certified.

Engine Oil Capacity:

3.0 L (3.2 US qt) with filter change; 2.7 L (2.9 US qt) without filter change.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based), mixed with distilled water at a 50:50 ratio.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, brake pads, tires, chain and sprockets, steering head bearings, fork seals.

Potential Electrical Concerns:

Voltage regulator/rectifier failure is a common issue on many Kawasaki models of this era; inspect wiring and connections.

Fueling Issues:

While DFI is generally reliable, occasional issues can arise from dirty injectors or faulty sensors, requiring diagnostic tools.

📚 Vehicle History

Brand Heritage

Kawasaki Heritage:

Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.

Model Evolution

Versys Introduction:

The Versys (Variable System) line was introduced to offer a more practical and versatile motorcycle alternative in Kawasaki's lineup, blending sportbike characteristics with adventure-touring capabilities.

First Generation:

The 2007 model represents the first generation of the Versys 650.

Production

Manufacturing Location:

Typically manufactured in Japan or Thailand.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2007 model are not widely publicized, the Versys line has generally received positive reviews for its value, versatility, and performance within the sport-touring segment.

Ratings

Expert Reviews:

Often praised for its comfortable ergonomics, capable engine, and value proposition.

Certifications

Emissions Certification:

Meets emissions standards for its respective model year and market.