🏷️ Basic Information

Make:

Kawasaki

Model:

Versys

Model Years:

2006, 2007, 2008

Product Name:

2006-2008 Kawasaki Versys Service Repair Manual

Product Description:

2006-2008 Kawasaki Versys Service Manual

Chassis Code Designation:

EX650A

👋 Introduction

Motorcycle Segment:

Sport-touring motorcycle with a focus on versatility and affordability.

Target Audience:

Riders seeking a capable, adaptable motorcycle for commuting, sport riding, and light touring.

Competitors Similar Era:

Suzuki V-Strom 650, Yamaha FZ6, Honda CBF600S.

Versatility:

Combines sportbike ergonomics with touring comfort and practicality.

Engine Layout:

Parallel-twin engine, known for its tractable power delivery and good fuel economy.

Suspension Design:

Long-travel suspension with adjustable components for varying road conditions and loads.

📋 Manual Details

Systems Covered:

General Information, Periodic Maintenance, Fuel System (DFI), Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System

Estimated Page Count:

Approximately 400-500 pages (typical for this era and model type)

Manual Type:

Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Complete coverage including DFI, cooling, lubrication, top end, crankshaft, and transmission systems.

Chassis:

Detailed information on wheels, tires, final drive, brakes, suspension, steering, and frame.

Electrical:

Comprehensive diagnostics and repair procedures for the electrical system.

Maintenance:

Scheduled maintenance, fluid changes, inspections, and adjustments.

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues.

Repair:

Detailed instructions for component removal, disassembly, repair, reassembly, and installation.

Engine Rebuild:

Full engine rebuild procedures, including specifications for wear limits and tolerances.

Depth:

Comprehensive, covering everything from basic checks to complete engine and chassis overhauls, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Text-searchable for quick information retrieval.

Printable:

Yes, designed for printing specific sections or the entire manual.

Image Resolution:

High-resolution images, diagrams, and schematics.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Horsepower Approx:

78 hp @ 8,000 rpm (approx.)

Torque Approx:

67 Nm @ 7,000 rpm (approx.)

Fuel Delivery:

Digital Fuel Injection (DFI) with dual 38mm Keihin throttle bodies

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

19 Liters (5.0 US gal)

Cooling Type:

Liquid-cooled

Coolant Type:

Kawasaki Long Life Coolant (or equivalent ethylene glycol-based antifreeze)

🔧 Transmission

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Sealed chain

Final Drive Ratio:

16/43 (2.688)

📐 Dimensions

Length:

2,125 mm (83.7 in)

Width:

800 mm (31.5 in)

Height:

1,275 mm (50.2 in)

Wheelbase:

1,415 mm (55.7 in)

Ground Clearance:

155 mm (6.1 in)

Seat Height:

840 mm (33.1 in)

Dry Weight:

198 kg (436.5 lbs)

Curb Weight:

214 kg (471.8 lbs) (approx., with fluids)

🛡️ Safety Features

Crash Safety Ratings:

Motorcycle safety is primarily assessed through rider skill and adherence to road regulations; specific crash test ratings like automotive standards are not typically applied.

Braking System:

Dual 300mm petal disc front brakes with 2-piston calipers, Single 220mm petal disc rear brake with 1-piston caliper. Optional ABS available on some models.

Lighting:

Halogen headlights, LED taillight.

Frame Construction:

High-tensile steel backbone frame designed for rigidity and rider feedback.

💡 Technology Features

Instrument Cluster:

Digital LCD display with analog tachometer, speedometer, odometer, trip meters, clock, fuel gauge, and indicator lights.

ABS Availability:

Optional Anti-lock Braking System (ABS) was available on some models/markets.

Charging Port:

Not standard; aftermarket options for USB or 12V outlets are common.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Spark Plug Replacement Interval:

Every 12,000 km (7,500 miles)

Valve Clearance Check Interval:

Every 12,000 km (7,500 miles)

Engine Oil Type:

SAE 10W-40 API SG or SH, ACEA A2 or A3, conforming to Kawasaki standard.

Engine Oil Capacity With Filter:

3.4 Liters (3.6 US qt)

Brake Fluid Type:

DOT 4

Coolant Type:

Kawasaki Long Life Coolant or a mixture of 50% distilled water and 50% ethylene glycol-based antifreeze.

Clutch Fluid Type:

Non-synthetic brake fluid (DOT 3 or DOT 4)

Common Wear Item:

Clutch plates can wear over time with aggressive riding.

Potential Recall Or Service Bulletin:

Check for specific recalls related to the fuel pump or ignition coils for certain VIN ranges.

Maintenance Point:

Regular cleaning and lubrication of the chain and sprockets are critical for longevity.

📚 Vehicle History

Manufacturer Origin:

Kawasaki Heavy Industries, Ltd. Motorcycle & Engine division, Japan.

Introduction Year:

2006

Generation Designation:

First Generation (2006-2014)

Design Philosophy:

Developed to offer a versatile, affordable, and sporty alternative in the middleweight sport-touring and naked bike categories.

Manufacturing Locations:

Primarily assembled in Japan, with components sourced globally.

🏆 Awards & Recognition

Industry Acclaim:

Praised for its value proposition, versatility, and capable parallel-twin engine, often considered a strong performer in its class for budget-conscious riders.