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Kawasaki VERSYS ABS - User Manual

Kawasaki VERSYS ABS
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VERSYS
VERSYS ABS
Motorcycle
Service Manual

Table of Contents

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Summary

General Information

Model Identification

Visual identification of different motorcycle models.

General Specifications

Detailed technical specifications for motorcycle models.

Unit Conversion Table

Provides conversion factors for various measurement units.

Periodic Maintenance

Periodic Maintenance Chart

Chart detailing scheduled maintenance intervals based on odometer readings.

Torque and Locking Agent

Lists tightening torques and locking agents for major fasteners.

Periodic Maintenance Procedures

Step-by-step procedures for performing various periodic maintenance tasks.

Fuel System (DFI)

Fuel System Specifications

Detailed specifications for the Digital Fuel Injection system components.

DFI Servicing Precautions

Important precautions to follow when servicing the DFI system.

DFI System Troubleshooting

Guide for diagnosing and resolving issues within the DFI system.

Cooling System

Cooling System Specifications

Standard and service limit specifications for cooling system components.

Coolant Procedures

Procedures for inspecting, draining, filling, and testing coolant.

Water Pump Service

Covers removal, installation, and inspection of the water pump.

Radiator Service

Procedures for radiator and fan removal, installation, and inspection.

Engine Top End

Engine Top End Specifications

Standard and service limit specifications for engine top-end components.

Valve Service

Procedures for valve clearance inspection, adjustment, removal, and installation.

Cylinder and Piston Service

Covers cylinder removal/installation, piston removal/installation, and wear checks.

Clutch System

Clutch Specifications

Standard and service limit specifications for clutch components.

Clutch Lever and Cable Service

Procedures for clutch lever and cable inspection, adjustment, and lubrication.

Clutch Component Service

Detailed procedures for clutch removal and installation.

Clutch Plate Inspection

Inspection of clutch plates for wear, damage, and warp.

Engine Lubrication System

Lubrication System Specifications

Specifications for engine oil type, viscosity, capacity, and oil pressure.

Engine Oil and Filter Service

Procedures for inspecting oil level and changing engine oil/filter.

Oil Pressure Measurement

Procedure for measuring engine oil pressure.

Engine Removal and Installation

Engine Removal Procedure

Step-by-step instructions for removing the engine from the motorcycle.

Engine Installation Procedure

Procedures for installing the engine back into the motorcycle frame.

Crankshaft and Transmission

Crankshaft;Transmission Specifications

Technical specifications for crankshaft, connecting rods, and transmission components.

Crankshaft and Connecting Rod Service

Covers crankshaft and connecting rod removal, installation, and inspection.

Transmission Service

Procedures for transmission assembly, disassembly, and shaft/gear inspection.

Wheels and Tires

Wheels and Tires Specifications

Specifications for wheel runout, balance, rim size, tire pressure, and tread depth.

Front Wheel Service

Covers front wheel removal, installation, and inspection procedures.

Rear Wheel Service

Covers rear wheel removal, installation, and inspection procedures.

Tire Service

Procedures for tire inspection, removal, installation, and repair.

Hub Bearing Service

Covers hub bearing removal, installation, inspection, and lubrication.

Final Drive

Final Drive Specifications

Specifications for drive chain slack, wear, and sprocket warp.

Drive Chain Service

Covers drive chain inspection, adjustment, lubrication, removal, and installation.

Sprocket and Coupling Service

Procedures for engine and rear sprocket removal/installation, and coupling components.

Brakes

Brake System Specifications

Specifications for brake lever, pedal, pads, discs, and fluid.

Calipers Service

Covers caliper removal, installation, disassembly, assembly, and damage inspection.

Brake Pads Service

Procedures for brake pad removal, installation, and wear inspection.

Master Cylinder Service

Covers master cylinder removal, installation, disassembly, assembly, and inspection.

Brake Disc Service

Procedures for brake disc removal, installation, wear, and warp inspection.

Brake Fluid Service

Details on brake fluid level, change, and bleeding procedures.

Anti-Lock Brake System (ABS)

Comprehensive guide to ABS system troubleshooting and service.

Suspension System

Suspension Specifications

Specifications for front fork and rear shock absorber settings and dimensions.

Front Fork Service

Detailed procedures for adjusting, removing, installing, and servicing front forks.

Rear Shock Absorber Service

Covers adjustment, removal, installation, and inspection of the rear shock absorber.

Swingarm Service

Procedures for swingarm removal, installation, and bearing inspection.

Steering System

Steering Special Tools

Lists specialized tools for steering system service.

Steering Inspection and Adjustment

Procedure for inspecting steering play and alignment.

Steering Stem Service

Covers stem, bearing removal, installation, lubrication, and warp inspection.

Handlebar Service

Procedures for handlebar removal, installation, and related component checks.

Frame Components

Fairing Service

Covers removal and installation of lower, middle, and upper fairings.

Fender Service

Covers front fender and rear fender removal/installation.

Frame Inspection

Procedure for inspecting the frame for damage like cracks or bends.

Windshield Service

Details on windshield height adjustment, removal, and installation.

Sidestand Service

Procedures for sidestand removal, installation, and switch inspection.

Electrical System

Electrical System Specifications

Specifications for battery, charging, ignition, starter, and sensor systems.

Wiring Inspection Procedures

General inspection procedures for wiring, connectors, and continuity.

Battery Service

Covers battery removal, installation, activation, and charging.

Charging System Service

Detailed procedures for alternator cover, stator coil, rotor, and regulator/rectifier service.

Ignition System Service

Covers crankshaft sensor, timing rotor, stick coil, and spark plug service.

Starter Motor Clutch Service

Procedures for starter motor clutch removal, installation, and inspection.

Meter, Gauge, and Indicator Unit Service

Procedures for meter unit removal, inspection, and function checks.

Switches and Sensors Service

Inspection and testing procedures for various switches and sensors.

Appendix

Cable, Wire, and Hose Routing

Illustrations and instructions for correct routing of cables, wires, and hoses.

Troubleshooting Guide

A comprehensive guide for diagnosing and resolving common motorcycle problems.

Summary

General Information

Model Identification

Visual identification of different motorcycle models.

General Specifications

Detailed technical specifications for motorcycle models.

Unit Conversion Table

Provides conversion factors for various measurement units.

Periodic Maintenance

Periodic Maintenance Chart

Chart detailing scheduled maintenance intervals based on odometer readings.

Torque and Locking Agent

Lists tightening torques and locking agents for major fasteners.

Periodic Maintenance Procedures

Step-by-step procedures for performing various periodic maintenance tasks.

Fuel System (DFI)

Fuel System Specifications

Detailed specifications for the Digital Fuel Injection system components.

DFI Servicing Precautions

Important precautions to follow when servicing the DFI system.

DFI System Troubleshooting

Guide for diagnosing and resolving issues within the DFI system.

Cooling System

Cooling System Specifications

Standard and service limit specifications for cooling system components.

Coolant Procedures

Procedures for inspecting, draining, filling, and testing coolant.

Water Pump Service

Covers removal, installation, and inspection of the water pump.

Radiator Service

Procedures for radiator and fan removal, installation, and inspection.

Engine Top End

Engine Top End Specifications

Standard and service limit specifications for engine top-end components.

Valve Service

Procedures for valve clearance inspection, adjustment, removal, and installation.

Cylinder and Piston Service

Covers cylinder removal/installation, piston removal/installation, and wear checks.

Clutch System

Clutch Specifications

Standard and service limit specifications for clutch components.

Clutch Lever and Cable Service

Procedures for clutch lever and cable inspection, adjustment, and lubrication.

Clutch Component Service

Detailed procedures for clutch removal and installation.

Clutch Plate Inspection

Inspection of clutch plates for wear, damage, and warp.

Engine Lubrication System

Lubrication System Specifications

Specifications for engine oil type, viscosity, capacity, and oil pressure.

Engine Oil and Filter Service

Procedures for inspecting oil level and changing engine oil/filter.

Oil Pressure Measurement

Procedure for measuring engine oil pressure.

Engine Removal and Installation

Engine Removal Procedure

Step-by-step instructions for removing the engine from the motorcycle.

Engine Installation Procedure

Procedures for installing the engine back into the motorcycle frame.

Crankshaft and Transmission

Crankshaft;Transmission Specifications

Technical specifications for crankshaft, connecting rods, and transmission components.

Crankshaft and Connecting Rod Service

Covers crankshaft and connecting rod removal, installation, and inspection.

Transmission Service

Procedures for transmission assembly, disassembly, and shaft/gear inspection.

Wheels and Tires

Wheels and Tires Specifications

Specifications for wheel runout, balance, rim size, tire pressure, and tread depth.

Front Wheel Service

Covers front wheel removal, installation, and inspection procedures.

Rear Wheel Service

Covers rear wheel removal, installation, and inspection procedures.

Tire Service

Procedures for tire inspection, removal, installation, and repair.

Hub Bearing Service

Covers hub bearing removal, installation, inspection, and lubrication.

Final Drive

Final Drive Specifications

Specifications for drive chain slack, wear, and sprocket warp.

Drive Chain Service

Covers drive chain inspection, adjustment, lubrication, removal, and installation.

Sprocket and Coupling Service

Procedures for engine and rear sprocket removal/installation, and coupling components.

Brakes

Brake System Specifications

Specifications for brake lever, pedal, pads, discs, and fluid.

Calipers Service

Covers caliper removal, installation, disassembly, assembly, and damage inspection.

Brake Pads Service

Procedures for brake pad removal, installation, and wear inspection.

Master Cylinder Service

Covers master cylinder removal, installation, disassembly, assembly, and inspection.

Brake Disc Service

Procedures for brake disc removal, installation, wear, and warp inspection.

Brake Fluid Service

Details on brake fluid level, change, and bleeding procedures.

Anti-Lock Brake System (ABS)

Comprehensive guide to ABS system troubleshooting and service.

Suspension System

Suspension Specifications

Specifications for front fork and rear shock absorber settings and dimensions.

Front Fork Service

Detailed procedures for adjusting, removing, installing, and servicing front forks.

Rear Shock Absorber Service

Covers adjustment, removal, installation, and inspection of the rear shock absorber.

Swingarm Service

Procedures for swingarm removal, installation, and bearing inspection.

Steering System

Steering Special Tools

Lists specialized tools for steering system service.

Steering Inspection and Adjustment

Procedure for inspecting steering play and alignment.

Steering Stem Service

Covers stem, bearing removal, installation, lubrication, and warp inspection.

Handlebar Service

Procedures for handlebar removal, installation, and related component checks.

Frame Components

Fairing Service

Covers removal and installation of lower, middle, and upper fairings.

Fender Service

Covers front fender and rear fender removal/installation.

Frame Inspection

Procedure for inspecting the frame for damage like cracks or bends.

Windshield Service

Details on windshield height adjustment, removal, and installation.

Sidestand Service

Procedures for sidestand removal, installation, and switch inspection.

Electrical System

Electrical System Specifications

Specifications for battery, charging, ignition, starter, and sensor systems.

Wiring Inspection Procedures

General inspection procedures for wiring, connectors, and continuity.

Battery Service

Covers battery removal, installation, activation, and charging.

Charging System Service

Detailed procedures for alternator cover, stator coil, rotor, and regulator/rectifier service.

Ignition System Service

Covers crankshaft sensor, timing rotor, stick coil, and spark plug service.

Starter Motor Clutch Service

Procedures for starter motor clutch removal, installation, and inspection.

Meter, Gauge, and Indicator Unit Service

Procedures for meter unit removal, inspection, and function checks.

Switches and Sensors Service

Inspection and testing procedures for various switches and sensors.

Appendix

Cable, Wire, and Hose Routing

Illustrations and instructions for correct routing of cables, wires, and hoses.

Troubleshooting Guide

A comprehensive guide for diagnosing and resolving common motorcycle problems.

Kawasaki VERSYS ABS Specifications

General IconGeneral
Transmission6-speed, return
ABSYes
IgnitionDigital
Starting SystemElectric
LubricationForced lubrication, wet sump
Front Tire120/70ZR17M/C (58W)
Rear Tire160/60ZR17M/C (69W)
Displacement649 cc
Cooling SystemLiquid-cooled
Fuel SystemFuel injection: ø38 mm x 2
Front BrakeDual 300 mm petal discs
Seat Height840 mm
Fuel Capacity21 L
Maximum Torque61 Nm (6.2 kgf·m) / 7, 000 rpm
Final DriveChain
Frame TypeDiamond
Overall Length2, 165 mm
Overall Width840 mm
Wheelbase1, 415 mm
Ground Clearance170 mm
Curb Mass216 kg

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