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maintenance and adjustment

1. STEERING HEAD SE LIMIT CLOSING RPM RADB A RRRA RPM TE03521D S TE03523D S 6 8 ADANGER POISON FLUSH EYES Zeus D u og HME CAN CAUSE BLINDNESS FLANES BLINDNESS OR OR INJURY IMPORTANT DRIVE CHAIN INFORMATION To prevent an accident and or damage to the motorcycle the drive chain must be properly maintained 1t should be lubricated every 600km 400mi and adjusted as often as necessary to keep chain slack at about 25 35mm 1 0 1 4in measured midway between sprockets on the lower chain run with the motorcycle on the side stand The standard chain is an DAIDO DIDS20VP2 with estimated service life of 15000 45000km 9400 28000mi depending on the severity of use and the frequency of lubrication and adjustment For safety replace the chain with only the standard chain any time it wears to over 319mm 12 56in measured over a 20 link portion pulled straight with 98N 10kaf 201bf of tension See the Owner s Manual for chain information 96033 0366 IN U S A DIS BY KAWASAKI MOTORS CORP USA P O BOX 25252 SANTA ANA CA 92799 5252 TEO3522D S TE03294D S 9 Kawasaki Versys 650 Owner s Manual WFD BY KAWASAKI HEAVY INDUSTRIES LTD DATE EXXSOST THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE GVWR Bes TIRE ROCOCO Ox PSI COLD OOOO TIRE PSI COLD
2. A Adjuster A Adjuster B Mark B Mark C Brake Lever C Clutch Lever Kawasaki Versys 650 Owner s Manual GENERAL INFORMATION 37 Fuel Tank Cap To open the fuel tank cap pull up the key hole cover Insert the ignition key into the fuel tank cap and turn the key to the right To close the cap push it down into place with the key inserted The key can be removed by turning it to the left to the original position Close the key hole cover aoin NOTE A Key Hole Cover B Ignition Key O The fuel tank cap cannot be closed Fuel Tank Cap without the key inserted and the key cannot be removed unless the cap is locked properly O Do not push on the key to close the cap or the cap cannot be locked Kawasaki Versys 650 Owner s Manual 38 GENERAL INFORMATION Fuel Tank A WARNING The following octane rating gaso Gasoline is extremely flammable line is recommended for the fuel tank y and can be explosive under cer Avoid filling the tank in the rain or where Amn eendil one cedna heno heavy dust is blowing so that the fuel g p tential for serious burns Turn BOE PCE Ger Contained the ignition switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pi lot light Never fill the tank com pletely to the top If the tank is filled completely to the top heat may cause the fuel to expand and overflow through the ve
3. MOTOR CYCLE ROX MADE IN THAILAND TE03442DN9 C LOCATION OF LABELS 191 10 only on California model VACUUM HOSE ROUTING DIAGRAM AIR CLEANER THROTTLE INJECTOR CANISTER WHITE VACUUM 99464 0560 TE03986BN7 CG Kawasaki Versys 650 Owner s Manual 192 LOCATION OF LABELS 11 only on California model NOTICE Never fill tank so fuel level rises into filler neck If tank is overfilled heat may cause fuel to expand and flow into Evaporative Emission Control System resulting in hard starting and engine hesitation 56071 0158 TEO3524C S Kawasaki Versys 650 Owner s Manua KLE650CD cA ee E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Printed in Thailand Motorcycle amp Engine Company Part No 99987 1751
4. 24 GENERAL INFORMATION e Push the RESET button The hour display only blinks Push the MODE button to advance the hours eS A A TG02202B G e Push the RESET button The hour display stops blinking and the minute display starts blinking Push the MODE button to advance the min utes WI TG02203B G e Push the RESET button Both the hour and minute displays start blink ing again e Push the MODE button The dis plays stop blinking and the clock starts working NOTE O Pushing the MODE button momen tarily advances the hour or minute Step by step Pushing and hold ing the button advance the hour or minute continuously O The clock works normally from the back up power while the ignition switch is turned off OWhen the battery is disconnected the clock resets to 1 00 and starts working again when the battery is connected Kawasaki Versys 650 Owner s Manual Odometer The odometer shows the total dis tance the vehicle has been ridden This meter cannot be reset TGO2204B G NOTE O The data is maintained even if the battery is disconnected O When the figures come to 999999 they are stopped and locked GENERAL INFORMATION 25 Trip Meter The trip meters show the distance in kilometers traveled since they were last reset to zero TRIP A 0 0 999 9 TRIP B 0 0 9999 9 To reset the trip meter e Push the MODE button to display the trip meter A or B e Push the RESET button
5. B Bolts C Projections and Grommets A Right Side Cover B Screw C Projections and Grommets Kawasaki Versys 650 Owner s Manual 104 MAINTENANCE AND ADJUSTMENT e Remove the cap from the reserve tank and add coolant through the filler opening to the F Full level line TKO4052B G A Reserve Tank B Cap C F Full Level Line D L Low Level Line NOTE Oln an emergency you can add wa ter alone to the coolant reserve tank however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible NOTICE If coolant must be added of ten or the reserve tank com pletely runs dry there is proba bly leakage in the system Have the cooling system inspected by your authorized Kawasaki dealer Install the cap Kawasaki Versys 650 Owner s Manual Install the right middle fairing as fol lows e Fit the projections to the slots e Fit the projections to the grommets e Tighten the bolts TKO4127B G A Right Middle Fairing B Projections C Slots D Grommets MAINTENANCE AND ADJUSTMENT 105 Install the right side cover as follows e Fit the projections to the slots e Fit the projections to the grommets e Tighten the screw e Install the seat see Seat section in the GENERAL INFORMATION chapter A Right Side Cover B Projections C Slots D Grommets Kawasaki Versys 650 Owner s Manual 106 MAINTENANCE AN
6. Odometer Maintenance Performed Dealer Address Reading Kawasaki Versys 650 Owner s Manual MAINTENANCE RECORD 179 Kawasaki Versys 650 Owner s Manual 180 MAINTENANCE RECORD Kawasaki Versys 650 Owner s Manual MAINTENANCE RECORD 181 Kawasaki Versys 650 Owner s Manual 182 MAINTENANCE RECORD Kawasaki Versys 650 Owner s Manual LOCATION OF LABELS 183 LOCATION OF LABELS All warning labels which are on your vehicle are repeated here Read labels on your vehicle and understand them thoroughly They contain information which is important for your safety and the safety of anyone else who may op erate your vehicle Therefore it is very important that all warning labels be on your vehicle in the locations shown If any label is missing damaged or worn get a replacement from your Kawasaki dealer and install it in the correct posi tion NOTE OThe sample warning labels in this section have part numbers to help you and your dealer obtain the cor rect replacement O Refer to the actual vehicle label for model specific data grayed out in the illustration TEO2783B G 1 Vehicle Emission Control Infor mation Kawasaki Versys 650 Owner s Manual 184 LOCATION OF LABELS TE02278B G 2 Brake Fluid Front 3 Brake Fluid Rear 4 Daily Safety Checks TSS SSK ROSSER RI B55 252505 IEAA AA AAA AAA UESLI SISTIS RIRIS RISTIS ORSINI 282S ISSS LESELE ORERE ISSS 55252525 CxS TE
7. comes first Odometer Reading 4 gt km x 1000 mile x 1000 see Page 1 12 24 36 48 Change Replacement Items 0 6 7 5 15 22 5 30 Rubber parts of master K _ 4 years cylinder and caliper replace K spark pug reae e e e i K Should be serviced by an authorized Kawasaki dealer For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping e Emission Related Item Kawasaki Versys 650 Owner s Manual Engine Oil In order for the engine transmission and clutch to function properly main tain the engine oil at the proper level and change the oil and replace the oil filter in accordance with the Periodic Maintenance Chart Not only do dirt and metal particles collect in the oil but the oil itself loses its lubricative quality if used too long A WARNING Motorcycle operation with insuf ficient deteriorated or contam inated engine oil will cause ac celerated wear and may result in engine or transmission seizure accident and injury Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner s Manual MAINTENANCE AND ADJUSTMENT 93 Oil Level Inspection f the oil has just been changed start the engine and run it for several min utes at idle speed This fills the oil filter wit
8. AND ADJUSTMENT 77 Periodic Maintenance Chart 82 Engine Oil eriuwisnduiecncvsecesisunesneenscoresanges 93 Cooling System cccccseceesseeeeseees 99 Spark PIGS sssini eT eee eee eee 106 Evaporative Emission Control System California model only 107 Valve Clearance ccceececeeseeeeeees 108 Kawasaki Clean Air System 109 Air Cleaner eeen 110 Throttle Control System 00 111 Engine Vacuum Synchronization 114 Idle Speed cccccceeeccseeseeeeeseeees 114 NRG otic EA 116 Drive Chain ccccccceeccseceeseeeeaeeeeees 119 BAKOS wciaiccstcanstcestanecdsaascaecazewndoducd nen 127 Brake Light Switches 008 131 PTOI OM P 133 Rear Shock Absorber 0000 136 NVC CIS E EEA 139 BUCY save E E rctveien cee 144 Headlight Beam cccseceeeeeeeees 150 FSCS a N 152 General Lubrication ccccc0ee 155 Cleaning Your Motorcycle 156 Bolt and Nut Tightening 163 STORAGE een eee ee eee aero 166 TROUBLESHOOTING GUIDE 169 YOUR WARRANTY OWNER SATISFACTION o n 170 REPORTING SAFETY DEFECTS 176 ENVIRONMENTAL PROTECTION V77 MAINTENANCE RECORD 178 LOCATION OF LABELG 183 Kawasaki Versys 650 Owner s Manual 8 SPECIFICATIONS Displacement Bore x Stroke Compression Ratio Starting System SPECIFICATIONS PERFORMANCE Mini
9. K Air cleaner element 110 clean e K Valve clearance 108 inspect e Throttle control system play smooth return no Pe Be drag inspect e Engine vacuum K ras inspect e one nepen ECECEC Ee Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 see Page Operation 12 18 24 36 Engine Items o 6 3 pn 7 5 11 25 15 m A 22 5 K Fuel leak fuel hose year and pipe inspect m e ve fe e el ed inspect Fuel hoses K installation year condition inspect Coolant level 102 inspect inspect damage inspect Kawasaki Versys 650 Owner s Manual 84 MAINTENANCE AND ADJUSTMENT Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 see Operation Engine Items Radiator hoses installation condition inspect Evaporative emission control system function California model only e Air suction system damage inspect e Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 85 2 Periodic Inspection Chassis Related Items Frequency Whichever comes first gt Odometer Reading km x 1 000 mile x 1 000 See i Page hae 12 18 24 36 liers ic 0 6 3 n 7 5 11 25 15 rs 5 22 5 Clutch and drive train Clutch operation play engagement 116 disengagement inspect Drive chain lubrication condition inspect Drive chain
10. Manual 156 MAINTENANCE AND ADJUSTMENT Apply grease to the following points e K Clutch Inner Cable Upper End e K Throttle Inner Cable Upper Ends K Should be serviced by an authorized Kawasaki dealer NOTE OAfter connecting the cables adjust them Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance optimize overall per formance and extend its useful life Covering your motorcycle with a high quality breathable motorcycle cover will help protect its finish from harmful UV rays pollutants and reduce the amount of dust reaching its surfaces Kawasaki Versys 650 Owner s Manual A WARNING Build up of debris or flammable material in and around the vehi cle chassis engine and exhaust can cause mechanical problems and increase the risk of fire When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle inspect the engine electrical component and exhaust areas frequently If debris or flammable materials have collected park the vehi cle outside and stop the engine Allow the engine to cool then remove any collected debris Do not park or store the vehicle in an enclosed space prior to in specting for build up of debris or flammable materials MAINTENANCE AND ADJUSTMENT 157 e Be sure the engine and exhaust are cool before washing e Avoid applying degreaser
11. air valves must be used for replacement Do not install tube type tires on tubeless rims The beads may not seat properly on the rim causing tire deflation Do not install a tube inside a tubeless tire Excessive heat build up may damage the tube causing tire deflation Tires Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect han dling and performance of your motorcy cle and can result in loss of control The maximum recommended load in addi tion to vehicle weight is 180 kg 397 Ib including rider passenger baggage and accessories e Remove the air valve cap e Check the tire pressure often using an accurate gauge e Make sure to install the air valve cap securely NOTE O Measure the tire pressure when the tires are cold that is when the mo torcycle has not been ridden more than a mile during the past 3 hours Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 141 O Tire pressure is affected by changes Tire Air Pressure when cold in ambient temperature and altitude 225 kPa 2 25 kgf cm2 32 psi and so the tire pressure should be 7 checked and adjusted when your rid i a Ac ing involves wide variations in tem perature or altitude Tire Wear Damage E As the tire tread wears down the tire becomes more susceptible to puncture and failure An accepted estimate is that 90 of all tire failures occu
12. ask an authorized Kawasaki dealer to inspect the front brake light switch MAINTENANCE AND ADJUSTMENT 131 e Check the operation of the rear brake light switch by depressing the brake pedal The brake light should go on after the proper pedal travel A Brake Pedal B 10 mm 0 39 in e f it does not adjust the rear brake light switch Brake Pedal Travel 10 mm 0 39 in Kawasaki Versys 650 Owner s Manual 132 MAINTENANCE AND ADJUSTMENT Adjustment Jo adjust the rear brake light switch e Disconnect the connector move the switch up or down by turn ing the switch body 8041B G A Connector N TK18093B G A Rear Brake Light Switch B Adjusting Nut C Lights sooner D Lights later e Connect the connector Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 133 Front Fork e f there is any doubt about the front The front fork operation and oil leak fork it should be checked by an au age should be checked in accordance thorized Kawasaki dealer with the Periodic Maintenance Chart Front Fork Inspection e Holding the brake lever pump the front fork up and down by several times to inspect smooth stroke Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A Inner Tube Kawasaki Versys 650 Owner s Manual 134 MAINTENANCE AND ADJUSTMENT On the top of each front fork leg is a spring preload adjuster and on the
13. ator or interfering with normal vehicle operation Do not ride the motorcycle with helmets at tached to the hooks Tool Kit U Shaped Lock Compartment The tool kit is stored under the seat The kit contains tools that can be help ful in making roadside repairs adjust ments and some maintenance proce dures explained in this manual Also under the seat can hold a U shaped lock not supplied Install the U shaped part and lock separately and secure them each with the bands not supplied Kawasaki Versys 650 Owner s Manual gt TG19053B G A Tool Kit B Band Part No 92072 1203 not supplied C U Shaped Lock not supplied D Band Part No 92072 1085 not supplied GENERAL INFORMATION 47 Rear View Mirror Rear View Mirror Adjustment e Adjust the rear view mirror by slightly moving only the mirror portion of the assembly e f the rear visibility can not be as sured by moving the mirror loosen the upper locknut and turn the stay by hand TG34026B G A Stay B Rear View Mirror C Locknut Kawasaki Versys 650 Owner s Manual 48 GENERAL INFORMATION Windshield The windshield can be adjusted within 3 positions in height to suit the rider s preference Remove the bolts on the windshield A Windshield B Bolts e Remove the wellnuts and rivets and install them in the positions to suit the rider s preference After adjust ing make sure to tighten all four bolts securel
14. event of a failure you can document the service history What Are The Dealership s Responsibilities Your Kawasaki dealer offers a wide range of services parts accessories and in formation on your product and on Kawasaki Each dealer is independently owned and operated and is responsible for the deal ership s operations its repair warranty and service work and its personnel Kawasaki Versys 650 Owner s Manual YOUR WARRANTY OWNER SATISFACTION 173 Your dealer is responsible for completing the set up and pre delivery service of your new Kawasaki vehicle The dealership should also explain its operation mainte nance and warranty provisions so you understand them at the time of purchase or at any other time you have questions The dealership is responsible for inspecting your Kawasaki vehicle if there is a fail ure investigating the cause of the problem and getting any needed authorization from Kawasaki if the repair is one that will be covered by the limited warranty The dealership will also file all necessary paperwork The dealership is responsible for correctly completing any necessary repairs whether they are covered by the lim ited warranty or not How Do Get Warranty Service If there is a problem with your vehicle within the limited warranty period you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis You can go to an
15. every 1 000 km 600 mile 119 slack inspect Drive chain 124 wear inspect every 600 km 400 mile 126 Kawasaki Versys 650 Owner s Manual 86 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Odometer Reading 4 km x 1 000 mile x 1 000 Operation 12 30 36 page nassis o 0 6 3 5 7 5 18 75 22 5 Items Drive chain K guide wear inspect Wheels and tires inspect Wheels tires damage 141 inspect Tire tread wear abnormal wear 141 inspect Wheel bearings K damage inspect Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 87 Frequency Whichever comes first Odometer Reading 4 km x 1 000 mile x 1 000 See i Page iene ik 12 18 24 36 ay 0 0 6 3 75 7 5 11 25 15 ua 75 22 5 Brake system inspect Brake hoses damage year 127 inspect peee inspect Brake hose installation condition year inspect inspect Kawasaki Versys 650 Owner s Manual 88 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Odometer Reading 4 gt km x 1 000 mile x 1 000 i Page Chassis 1 6 12 30 36 items 0 6 3 75 7 5 18 75 22 5 Brake operation effectiveness play drag eae 130 inspect Brake light switch operation 131 inspect Suspensions Front forks rear shock absorber operation 133 damping and 136 smooth stroke inspect Kawasaki Versys 650 Owne
16. low quality or not meet ing standard industry specifi cations may result in unsatis factory performance Operating problems that result from the use of poor quality or nonrecom mended fuel may not be covered under your warranty Fuels Containing Oxygenates Gasoline frequently contains oxy genates alcohols and ethers espe cially in areas of the U S and Canada which are required to sell such refor mulated fuels as part of a strategy to reduce exhaust emissions The types and volume of fuel oxy genates approved for use in unleaded gasoline by the U S Environmental Protection Agency include a broad range of alcohols and ethers but only two components have seen any signif icant level of commercial use Gasoline Alcohol Blends Gasoline containing up to 10 ethanol alco hol produced from agricultural products such as corn also Known as gasohol is approved for use Kawasaki Versys 650 Owner s Manual NOTICE Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol contain ing more than 5 methanol Fuel system damage and perfor mance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 15 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 2 Fuel containing these oxy genates c
17. modification will void the motorcycle LOADING AND ACCESSORIES INFORMATION warranty can negatively affect per formance and can even be illegal In selecting and using accessories and in loading the motorcycle you are personally responsible for your own safety and the safety of other persons involved NOTE O Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components Because a motorcycle is sensitive to changes in weight and aerodynamic forces you must take extreme care Kawasaki Versys 650 Owner s Manual LOADING AND ACCESSORIES INFORMATION 17 in carrying cargo passengers and or in the fitting of additional accessories The following general guidelines have been prepared to assist you in making your determinations 1 Any passenger should be thor oughly familiar with motorcycle op eration The passenger can affect control of the motorcycle by im proper positioning during cornering and sudden movements It is im portant that the passenger sits still while the motorcycle is in motion and not interfere with the operation of the motorcycle Do not carry ani mals on your motorcycle 2 You should instruct any passenger before riding to keep his or her feet on the passenger footpegs and hold on to the operator or seat strap Do not carry a passenger unless he or
18. n ai N 25 108 mm 4 3 in 120 70 ZR17 M C 58W 160 60 ZR17 M C 69W Kawasaki Versys 650 Owner s Manual SPECIFICATIONS 11 Rim Size Front J17M C x MT3 50 Rear J17M C x MT4 50 Fuel Tank Capacity 19 L 5 0 US gal ELECTRICAL EQUIPMENT Battery 12 V 10 Ah Headlight High Beam 12 V 55 W Low Beam 12 V 55 W Tail Brake Light LED Even if one of LED Light Emitting Diode tail brake light is not lit consult with an authorized Kawasaki dealer Specifications are subject to change without notice Kawasaki Versys 650 Owner s Manual 12 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the motorcycle They are the only means of identifying your particular machine from others of the same model type These serial numbers may be needed by your dealer when ordering parts In the event of theft the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it TCOI104B G TC01105B G A Frame Number A Engine Number OuahWND Kawasaki Versys 650 Owner s Manual LOCATION OF PARTS 13 LOCATION OF PARTS 1D01233B G Clutch Lever 7 Spring Preload Adjuster Front Fork Left Handlebar Switches 8 Rebound Damping Force Adjuster Meter Instruments Front Fork Ignition Switch Steering Lock 9 Right Handlebar Switches Brake Fluid Reservoir Front 10 Throttle
19. oil level correct Tires in good condition wear within service limit air pressure correct LOCATION OF LABELS 189 Rear view mirror adjustment Brake lever play correct fluid up to upper level line no leakage Fuel in tank Throttle grip play correct Tail Brake light works Turn signals work Chain in good condition with proper slack oil if necessary Brake pedal play correct fluid up to upper level line no leakage No abnormal exhaust noise 96033 0312 TE03515029 CG Kawasaki Versys 650 Owner s Manual 190 LOCATION OF LABELS 5 7 T TIRE AND LOAD DATA The stability and handling characteristics of this motorcycle could become unsafe by the use of inoroper tire inflation pressures overvorn tires unsuitable replacement tires or overloading When tire tread wears down to the limit replace the i vith only the standard tire Waintain the inflation pressure specified All coe Size amp Make Type Tubeless Tire Winimam Tread Depth d E ta a ai a 10 BEET W189 ma SIME 1 mm 0 04in i 1 MOTORCYCLE NOISE FMISSION CONTROL INF S BRS MOTORCYCLE MEETS EPA ISE EMISSION REQUIREMENTS BY FEDERAL TEST PROCEDURE DIFICATIONS WHICH CAUSE THIS TORCYCLE TO EXCEED FEDERAL DUNLOP Up to 130 km N QOWPHY 2 nm 08i Up to 180k d E rear AE E Te TNE Fm SE STANDARDS ARE PROHIBITED DERAL LAW E OWNER S MANUAL RERA 96053 0496 SPECIFIC CODE REAARILA BER
20. push down the key in the OFF position and turn it to LOCK TG04097BZ2 C Left Handlebar Switches A Dimmer Switch B Turn Signal Switch C Horn Button D Passing Button E Hazard Switch Kawasaki Versys 650 Owner s Manual Dimmer Switch High or low beam can be selected with the dimmer switch When the headlight is on high beam gt the high beam indicator light goes on High Beam Low Beam NOTE O When the headlight is on high beam both headlights go on When the headlight is on low beam only one headlight goes on Turn Signal Switch When the turn signal switch is pushed to the left amp or right gt the corresponding turn sig nals blink on and off To stop blinking push the switch in GENERAL INFORMATION 33 Horn Button When the horn button is pushed the horn sounds Passing Button When the passing button is pushed the headlight high beam passing beam goes on to signal the driver of the vehicle ahead that you are about to pass The passing light is shut off as soon as the button is released Hazard Switch If an emergency requires you to park on the highway shoulder turn on the hazard lights to warn other drivers of your location Push in the hazard switch with the ignition switch in the ON or P Park position All the turn signals and turn signal indicator lights will blink on and off Kawasaki Versys 650 Owner s Manual 34 GENERAL INFORMATIO
21. she is tall enough to reach the foot pegs and footpegs are provided 3 All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity Baggage weight should also be dis tributed equally on both sides of the motorcycle Avoid carrying baggage that extends beyond the rear of the motorcycle Baggage should be securely at tached Make sure that the baggage will not move around while you are riding Recheck baggage security as often as possible not while the motorcycle is in motion and adjust as necessary Do not carry heavy or bulky items on a luggage rack They are designed for light items and overloading can affect handling due to changes in weight distribution and aerodynamic forces Kawasaki Versys 650 Owner s Manual 18 LOADING AND ACCESSORIES INFORMATION 6 Do not install accessories or carry designed or installed items can re baggage that impairs the perfor mance of the motorcycle Make sure that you have not adversely affected any lighting components road clearance banking capability i e lean angle control operation wheel travel front fork movement or any other aspects of the motor cycle s operation Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can re sult in an unsafe riding condition Fairings windshields backrests and other large items have the ca pability of adversely affectin
22. spring preload adjuster of the right front fork leg is a rebound damping force adjuster so that the spring force and damping force can be adjusted for different riding and loading condi tions Weaker spring force and damp ing force are for comfortable riding but they should be increased for high speed riding or riding on rough roads A Spring Preload Adjuster B Rebound Damping Force Adjuster Spring Preload Adjustment e Turn the spring preload adjuster into the nut to increase spring force and out to decrease spring force The adjusting range is as follows Adjusting Range 15 turns out Counterclockwise from the fully seated position Kawasaki Versys 650 Owner s Manual Rebound Damping Force Adjustment e Turn the rebound damping force adjuster all the way into the spring preload adjuster with a standard tip screwdriver This makes the damp ing force greatest e Turn out the adjuster to decrease damping force lt a ai TK19060B G A Standard Tip Screwdriver B Rebound Damping Force Adjuster MAINTENANCE AND ADJUSTMENT 135 The standard setting positions of the spring preload adjuster and rebound damping force adjuster for an average build rider of 68 kg 150 Ib with no pas senger and no accessories are as fol lows Spring Preload 5 Adjuster Rebound Damping Force 1 3 4 turns out Adjuster Counterclockwise from the fully seated position NOTICE Do not force to turn the rebo
23. the throt tle grip has not play the throttle will be hard to control and the idle speed will be erratic Kawasaki Versys 650 Owner s Manual 112 MAINTENANCE AND ADJUSTMENT Inspection e Check that the throttle grip play is correct by lightly turning the throttle grip back and forth TK11052B G A Throttle Grip B Throttle Grip Play Throttle Grip Play 2 3 mm 0 08 0 12 in e f there is improper play adjust it Adjustment e Loosen the locknut at the upper end of the throttle cable and turn the throttle cable adjuster in completely so as to give the throttle grip plenty of play TKI1053B G A Locknut B Adjuster C Throttle Cable Accelerator Cable Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 113 e f the throttle grip play cannot be ad e Turn out the accelerator cable ad justed with the accelerator cable ad juster until a play of 2 3 mm 0 08 juster at the throttle grip use the de 0 12 in is obtained at the throttle celerator cable adjuster located un grip der the fuel tank e Tighten the locknut e Turn out the decelerator cable adjust e With the engine idling turn the han E ing nut until there is no play when the dlebar to each side If handlebar throttle grip is completely closed movement changes the idle speed e Tighten the locknut the throttle cables may be improperly adjusted or incorrectly routed or they may be damages Be sure to correct any of thes
24. 02277B G Kawasaki Versys 650 Owner s Manual LOCATION OF LABELS 185 Z 5 d gt TE02784B G TE02762B G 5 Tire and Load Data 6 Important Drive Chain Informa tion 7 Noise Emission Control Informa tion 8 Battery Poison Danger 9 Weight and Manufacture TE02030BZ2 G 186 LOCATION OF LABELS Kawasaki Versys 650 Owner s Manual TE02781BZ2 C TE02785B G 10 Vacuum Hose Routing Diagram 11 Fuel Level only on California model Kawasaki Versys 650 Owner s Manual LOCATION OF LABELS 187 1 2 x VEHICLE EMISSION CONTROL INFORMATION ENG NETA LY CODE RRIZZIZZZZI PERMEATION FAMILY XHAUST EMISSION CONTROL SYSTEM x ISPLACENENT 222eneee eee RACE TUNE UP SPECIFICATIONS GHITTON TIMING TES ETTC TEZ karm MEEA tT O ants WARNING VALVE CTEARANCE TIMME F NGINE COLD EXHAUST K l GIE E EE RSE USE ONLY DOT4 BRAKE FLUID JEL GASOLINE WITH ANTIKNOGK INDEX RONSHONI 2 Bev FROM A SEALED CONTAINER ENGINE 0 SERVICE RATING API SG SH SJ SL OR SM veer tsb GLEAN FILLER GAP BEFORE REMOVING SEE THE OWNER S MANUAL FOR ENGINE OIL INFORMATION N UTILISER QUE DU FLUIDE THIS VEHICLE CONFORMS TO U S EPA REGULATIONS APPLICABLE TO RXZ MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO AN HC NOX nz DE FREIN DOT4 EMISSION STANDARD OF B25IG KW KAWASAKI MOTORS ENTERPRISE
25. D ADJUSTMENT Coolant Change Spark Plugs Have the coolant changed by an au The standard spark plug is shown in thorized Kawasaki dealer the table The spark plugs should be replaced in accordance with the Peri odic Maintenance Chart Spark plug removal should be done by an authorized Kawasaki dealer Spark Plug Standard Plug NGK CRY9EIA 9 0 8 0 9 mm Rug ep 0 031 0 035 in 15 Nem Tightening Torque 1 5 kgf m 11 ft lb Kawasaki Versys 650 Owner s Manual TK06006BZ2 C A 0 8 0 9 mm 0 031 0 035 in MAINTENANCE AND ADJUSTMENT 107 Evaporative Emission Control System California model only This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Although no ad justments are required a thorough vi sual inspection must be made at the in tervals specified by the Periodic Main tenance Chart Inspection e Check that the hoses are securely connected e Replace any kinked deteriorated or damaged hoses Kawasaki Versys 650 Owner s Manual 108 MAINTENANCE AND ADJUSTMENT VACUUM HOSE ROUTING DIAGRAM AIR CLEANER 99464 0560 TE03986BN7 CG Valve Clearance Valve and valve seat wear decreases valve clearance upsetting valve timing NOTICE If valve clearance is left un adjusted wear will eventually cause the valves to remain partly open which lowers per formance burns the valves and v
26. Grip Front Brake Lever Kawasaki Versys 650 Owner s Manual 14 LOCATION OF PARTS TD01261BZ8 C 1 Headlight City Light 7 Seat 12 Brake Caliper 2 Turn Signal Light 8 Helmet Hook 13 Front Fork 3 Spark Plugs 9 Tool Kit Storage 14 Shift Pedal 4 Air Cleaner Compartments 15 Side Stand 5 Main Fuse 10 Seat Lock 16 Drive Chain 6 Battery 11 Brake Disc ON License Plate Light Tail Brake Light Rebound Damping Force Adjuster Rear Shock Absorber Brake Fluid Reservoir Rear Kawasaki Versys 650 Owner s Manual oO 0 N Rear Shock Absorber Spring Preload Adjuster Rear Shock Absorber Fuel Tank Fuel Tank Cap Coolant Reserve Tank LOCATION OF PARTS 15 10 11 12 13 14 TD01235BZ8 CG Muffler Rear Brake Light Switch Rear Brake Pedal Oil Level Inspection Window Idle Adjusting Screw Kawasaki Versys 650 Owner s Manual 16 LOADING AND ACCESSORIES INFORMATION A WARNING Incorrect loading improper in stallation or use of accessories or modification of your motorcy cle may result in an unsafe rid ing condition Before you ride the motorcycle make sure that the motorcycle is not overloaded and that you have followed these instructions With the exception of genuine Kawasaki Parts and Accessories Kawasaki has no control over the design or application of accessories In some cases improper installation or use of accessories or motorcycle
27. Kawasaki Versys 650 Owner s Manua E Kawasaki Includes Important Safety Information Operating Instructions Maintenance and Storage VERSYS Motorcycle OWNER M Kawasaki Versys 650 Owner s Manua A WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm NOTICE THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY Kawasaki Versys 650 Owner s Manual Quick Reference Guide This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword GENERAL INFORMATION HOW TO RIDE THE MOTORCYCLE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE Kawasaki Versys 650 Owner s Manual Kawasaki Versys 650 Owner s Manual Whenever you see the symbols shown below heed their instructions Always follow safe operating and main tenance practices A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious in jury WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE NOTICE is used to address prac tices not related to personal in jury NOTE O This note symb
28. MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the en gine s air intake increasing fuel con sumption reducing engine power and causing spark plug fouling The air cleaner element must be cleaned in accordance with the Pe riodic Maintenance Chart In dusty rainy or muddy conditions the air cleaner element should be serviced more frequently than the recom mended interval by an authorized Kawasaki dealer Oil Draining e Inspect the drain hose located on the rear side of the engine to see if any oil or water has run down from the air cleaner housing 4 TK10170B G A Drain Hose B Plug e f there is any oil in the hose remove the plug from the lower end of the drain hose and drain the oil Kawasaki Versys 650 Owner s Manual A WARNING Oil on tires will make them slip pery and can cause an accident and injury Be sure to install the plug in the drain hose after drain ing MAINTENANCE AND ADJUSTMENT 111 Throttle Control System Check the throttle grip play in accor dance with the Periodic Maintenance Chart and adjust it if necessary Throttle Grip The throttle grip controls the butterfly valves in the throttle body If the throt tle grip has excessive play due to either cable stretch or maladjustment it will cause a delay in throttle response es pecially at low engine speed Also the throttle valve may not open fully at full throttle On the other hand if
29. N NOTICE If you leave the switch on for a long time the battery may be come totally discharged So be careful not to use the hazard lights for more than 30 minutes Right Handlebar Switches TGO7028B G A Engine Stop Switch B Starter Button Engine Stop Switch In addition to the ignition switch the engine stop switch must be in the Q position for the motorcycle to operate The engine stop switch is for emer gency use If required move the switch to the position Kawasaki Versys 650 Owner s Manual NOTE OAlthough the engine stop switch Stops the engine it does not turn off all the electrical circuits Ordinarily the ignition switch should be used to stop the engine Starter Button The starter button operates the elec tric starter when the transmission is in neutral Refer to the Starting the Engine sec tion of the How to Ride the Motorcycle chapter for starting instructions GENERAL INFORMATION 35 Brake Clutch Lever Adjusters There is an adjuster on both the brake and clutch levers Each adjuster has 5 positions so that the released lever position can be adjusted to suit the operator s hands Push the lever forward and turn the adjuster to align the number with the mark on the lever holder The distance from the grip to the re leased lever is minimum at Number 5 and maximum at Number 1 Kawasaki Versys 650 Owner s Manual 36 GENERAL INFORMATION TG10041B G TG10042B G
30. N Tachometer The tachometer shows the engine speed in revolutions per minute r min rpm On the right side of the tachome ter face is a portion called the red zone Engine r min rpm in the red zone is above maximum recom mended engine speed and is also above the range for good performance When the ignition key is turned to ON the tachometer needle momen tarily points to the last reading to check its operation If the tachometer nee dle does not operate correctly have it inspected by an authorized Kawasaki dealer NOTICE Engine r min rpm should not be allowed to enter the red zone operation in the red zone will overstress the engine and may cause serious engine damage LCD Speedometer Clock Odometer Trip Meter A B Fuel Gauge The LCD Liquid Crystal Display lo cated in the tachometer face is used to display the Speedometer Clock Odometer Trip Meter A B and Fuel Gauge Pushing the MODE button shifts the display through the follow ing four modes CLOCK ODO and TRIP A B When the ignition key is turned to ON all the LCD segments are displayed for three seconds then the clock or meters operate normally depending on the mode selected Kawasaki Versys 650 Owner s Manual TG02049BZ1 C A Clock B Odometer C Trip Meter A D Trip Meter B E Push MODE Button NOTE O For safe operation do not press the MODE button while riding GENERAL INFORMATION 21 Dig
31. ON BUTON snciterisiutsteuwetsaceiticeeneuns 33 Passing Button a ssciuisesciaeascedenensenst 33 Hazard Switch cccccceceeeeeeeees 33 Right Handlebar Switches 34 Engine Stop Switch 00 34 Starter Button cccceeeeeeeeees 35 Brake Clutch Lever Adjusters 35 Fuel Tank Cap cccccccseeeceeeeeeeeeees 37 FUGI TANK saxcitinasstosnerucsteevisesnatecnddeanite 38 Fuel Requirement 0c0008 39 S LALO PEE T E 42 Se EEE E E AT 43 Helmet OOK Sits inteecaesondceiereieeiocdns 45 Tool Kit U Shaped Lock Compartment ccccscceeeeeeeee es 46 Rear View Mirror cssceseeeeees 47 Windshield ccccseceeeeeeeeeeeeeeees 48 BREAKGIN cccccceeeeeseeeeeeeeeeees 51 HOW TO RIDE THE MOTORCYCLE 53 Starting the Engine ccccee 53 JUP STANO esinsin 59 MOVING OM esiseina veskaveas 58 Shifting Gears a seetvtscavyewevisiaeeesiveetinnns 59 Kawasaki Versys 650 Owner s Manual RAIN O siisii irna 62 Stopping the Engine 06 63 Stopping the Motorcycle in an Emergency cccessesssceesereeseenens 64 FPN E E 65 Catalytic Converter cccccceee 67 SAFE OPERATION 0088 69 Safe Riding Technique 06 69 Daily Safety Checks cccee 72 Additional Considerations for High Speed Operation cccceeee 75 MAINTENANCE
32. Owner s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information Kawasaki Versys 650 Owner s Manual This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the actual product and illustra tions and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company 2012 Kawasaki Heavy Industries Ltd Jun 2012 1 Kawasaki Versys 650 Owner s Manual TABLE OF CONTENTS SPECIFICATIONS 0000 ee 8 SERIAL NUMBER LOCATIONG 12 LOCATION OF PARTS 13 LOADING AND ACCESSORIES INFORMATION 0000000 16 GENERAL INFORMATION 19 Meter Instruments cceee ee 19 Tachometer 20 LCD Speedometer Clock Odometer Trip Meter A B Fuel GAUGE ecicprepnttecceapiatetsxciwensttenean 20 Warning Indicator Lights 27 PCC EEE E EEE 29 Ignition Switch Steering Lock 31 Left Handlebar Switches 32 Dimmer Switch ccccceeeeeee ees 33 Turn Signal Switch cccee 33 PI
33. Store one key at home and keep an other spare in your wallet or riding gear in case the original is lost Kawasaki Versys 650 Owner s Manual Ignition Switch Steering Lock This is a four position key operated switch The key can be removed from the switch when it is in the OFF LOCK or P Park position TGO4007BZ2 C A Ignition Switch Steering Lock B ON Position C OFF Position D LOCK Position E P Park Position GENERAL INFORMATION 31 Engine off All electrical circuits off Engine on All electrical equipment can be used Steering locked Engine ROGI off All electrical circuits off Steering locked Engine off License plate tail and city lights on and turn P Park signals can be used All other electrical circuits cut off NOTE O The city tail and license plate lights are on whenever the ignition key is in the ON position One headlight goes on when the starter button is released after starting the engine To avoid battery discharge always start the engine immediately after turning the ignition key to ON Kawasaki Versys 650 Owner s Manual 32 GENERAL INFORMATION Olf you leave the P Park position on for a long time one hour the battery may become totally discharged To operate the ignition switch oF lt ON P Park 1 Turn the handlebar fully to the left 2 a For parking push down the key in the ON position and turn it to P Park LOCK b For locking
34. THAILAND CO LTD Kawasaki TE03518D TEO3841BN9 C 1 only on California model VEHICLE EMISSION CONTROL INFORMATION ENGINE FAMILY CODE RRRRXXRRAPERMEATION FAMILY BERRA EVA FAMILY RT MODEL S EXHAUST EMISSION CONTROL SYSTEM CO DISPLACEMENT TUNE UP SPECIFICATIONS IGNITION TIMING IRS BTOC AT RSX RPM IDLE SPEED BROS TI RP IN NEUTRAL IOLE ATR FUEL NO ADJUSTMENT VALVE CLEARANCE INTAKE ENGINE COLD EXHAUST ove hS vs SPARK PLUG KARARI SPARK PLUG GAP REXX MN EAV IN FUEL GASOLINE WITH ANTIKNOCK INDEX RON HON 2 bed MIN ENGINE OIL SERVICE RATING API SG SH SJ SL OR SM WITH JASO MA VISCOSITY SAE 10W 40 SEE THE OWNER S MANUAL FOR ENGINE OIL INFORMATION THIS VEHICLE CONFORMS TO U S EPA AND CALIFORNIA REGULATIONS APPLICABLE 10 MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO B2IG KM HCHNOX ENGINE FAMILY EXHAUST IE EMISSION STANDARD IN CALIFORNIA Kawasaki KAWASAKI MOTORS ENTERPRISE THAILAND CO LTO TE03520D S Kawasaki Versys 650 Owner s Manual 188 LOCATION OF LABELS 3 TEQ3097B S Kawasaki Versys 650 Owner s Manual Clutch lever play correct releases properly no slippage Handlebar not loose Turn signals work Headlight works Steering turns freely but has no play No coolant leakage coolant level between level lines Horn works No abnormal engine noise Engine
35. aintain your motorcycle and become thoroughly familiar with its operation Improper maintenance can create a dangerous situation known as throt tle failure Two of the most common causes of throttle failure are 1 An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open 2 During removal of the air cleaner dirt is allowed to enter and jam the fuel injection system In an emergency situation such as throttle failure your vehicle may be stopped by applying the brakes and disengaging the clutch Once this stopping procedure is initiated the en gine stop switch may be used to stop the engine If the engine stop switch is used turn off the ignition switch after stopping the motorcycle Kawasaki Versys 650 Owner s Manual Parking A WARNING Operating or parking the vehi cle near flammable materials can cause a fire and can result in property damage or severe per sonal injury Do not idle or park your vehicle in an area where tall or dry veg etation or other flammable ma terials could come into contact with the muffler or exhaust pipe HOW TO RIDE THE MOTORCYCLE 65 A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch a hot engine ex haust pipe or muffler during op eration or after stopping the en gine e Shift the transmission into neutral and turn t
36. alve seats and may cause seri ous engine damage Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Mainte nance Chart Inspection and adjustment should be done by an authorized Kawasaki dealer Kawasaki Versys 650 Owner s Manual Kawasaki Clean Air System The Kawasaki Clean Air System KCA is a secondary air suction sys tem that helps the exhaust gases to burn more completely When the spent fuel charge is released into the ex haust system it is still hot enough to burn The KCA System allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as chang ing a significant portion of the carbon monoxide into carbon dioxide Air Suction Valve The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port Any air that has passed MAINTENANCE AND ADJUSTMENT 109 the air suction valve is prevented from returning Inspect the air suction valve in accordance with the Periodic Main tenance Chart Also inspect the air suction valve whenever stable idling cannot be obtained engine power is greatly reduced or there are abnormal engine noises Air suction valve removal and inspec tion should be done by an authorized Kawasaki dealer Kawasaki Versys 650 Owner s Manual 110
37. an also be used in your Kawasaki GENERAL INFORMATION 41 NOTICE Never use gasoline with an oc tane rating lower than the mini mum specified by Kawasaki Never use gasohol with more than 10 ethanol or more than 5 methanol Gasoline con taining methanol must also be blended with cosolvents and corrosion inhibitors Certain ingredients of gasoline may cause paint fading or dam age Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which mini mizes gummy deposits Kawasaki Versys 650 Owner s Manual 42 GENERAL INFORMATION NOTICE Never store this product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel system See the Storage section in this manual Stand The motorcycle is equipped with a side stand TG14018B G A Side Stand NOTE O When using the side stand turn the handlebar to the left Do not sit on the motorcycle while it is on its side stand Always kick the stand fully up before sitting on the motorcycle Kawasaki Versys 650 Owner s Manual NOTE O The motorcycle is equipped with a side stand switch This switch is de signed so that the engine does not Start if the transmission is in g
38. and hold it in e After two seconds the figure display turns to 0 0 and then starts counting when the vehicle is operated The meter counts until it is reset 26 GENERAL INFORMATION Kawasaki Versys 650 Owner s Manual NOTE O The data is maintained by the back up power if the ignition key is turned off O When the trip meter reaches 999 9 TRIP A or 9999 9 TRIP B while running the meters reset to 0 0 and continues counting O When the battery is disconnected the meter display resets to 0 0 TG02093BZ4 CG Kawasaki Versys 650 Owner s Manual Fuel Gauge The fuel in the fuel tank is shown by the number of segments displayed When the fuel tank is full all the seg ments are displayed As the fuel level in the tank goes down the segments disappear one by one from F full to E empty When only the most bottom segment is displayed approximately 5 0 L 1 3 US gal of usable fuel re main Furthermore when the lowest segment and FUEL blink in the digital meter approximately 3 6 L 0 9 US gal of usable fuel remain Refuel at the earliest opportunity if the most bottom segment of the fuel gauge blinks When vehicle stands with Side Stand Fuel Gauge cannot show the amount of fuel in the fuel tank exactly Stand upright the vehicle to check the fuel level GENERAL INFORMATION 27 TGO2205B G A Blink NOTE O When pushing the MODE button while FUEL is displayed the dis play ca
39. and lose control When going down long slopes control vehicle speed by closing the throttle Use the front and rear brakes for auxiliary braking In wet conditions rely more on the throttle to control vehicle speed and less on the front and rear brakes The throttle should also be used ju diciously to avoid skidding the rear wheel from too rapid acceleration or deceleration Riding at the proper rate of speed and avoiding unnecessarily fast ac celeration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation On rough roads exercise caution slow down and grip the fuel tank with the knees for better stability When quick acceleration is neces sary as in passing shift to a lower gear to obtain the necessary power Kawasaki Versys 650 Owner s Manual SAFE OPERATION 71 Do not downshift at too high an Avoiding unnecessary weaving is r min rpm to avoid damage to the important to the safety of both the engine from overrevving rider and other motorists Kawasaki Versys 650 Owner s Manual 72 SAFE OPERATION Daily Safety Checks Check the following items each day before you ride The time required is minimal and habitual performance of these checks will help ensure you a safe reliable ride a If any irregularities are found during these checks refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor cy
40. and related accessories contain lead and lead compounds Wash hands after handling TK22058B G A Red Cap Terminal B Terminal Kawasaki Versys 650 Owner s Manual Take the battery out e Clean the battery using a solution of baking soda and water Be sure that the cable connections are clean Battery Installation e Place the battery in the rear fender front e Connect the cable to the ter minal and then connect the cable to the terminal NOTICE Installing the cable to the terminal of the battery or the cable to the terminal of the battery can seriously damaged the electrical system MAINTENANCE AND ADJUSTMENT 149 e Put a light coat of grease on the ter minals to prevent corrosion e Cover the red cap Reinstall the removed parts Kawasaki Versys 650 Owner s Manual 150 MAINTENANCE AND ADJUSTMENT Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally If not properly adjusted horizontally the beam will point to one side rather than straight ahead e Turn the horizontal adjuster clock wise or counterclockwise until the beam points straight ahead TK23156B G A Horizontal Adjuster Vertical Adjustment The headlight beam is adjustable ver tically If adjusted too low neither low nor high beam will illuminate the road far enough ahead If adjusted too high the high beam will fail to illumin
41. ate the road close ahead and the low beam will blind oncoming drivers e Turn the vertical adjuster clockwise or counterclockwise to adjust its ver tical angle A Vertical Adjuster Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 151 NOTE OOn high beam the brightest point Should be slightly below horizontal The proper angle is 0 4 degrees be low horizontal This is a 50 mm 2 0 in drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated TK23159BZ2 C A 50 mm 2 0 in B Center of Brightest Spot C 7 6 m 25 ft D Height of Headlight Center Kawasaki Versys 650 Owner s Manual 152 MAINTENANCE AND ADJUSTMENT Fuses e Remove the bolt Fuses are arranged in the fuse box e Clear the projections from the grom located under the seat The main fuse mets and remove the left frame is mounted on the starter relay behind cover upward the left side cover If a fuse fails during operation inspect the electrical system to determine the cause and then re place it with a new fuse of proper am perage A Left Frame Cover B Bolt C Projections and Grommets TK25130B G A Fuse Box B Fuses C Spare Parts Kawasaki Versys 650 Owner s Manual e Remove the cover by removing the bolt MAINTENANCE AND ADJUSTMENT 153 e Disconnect the connector A Main Fuse B Spare Fuse C Connector Kawasaki Versys 650 Ow
42. ater temperature is too high Ifthe warning indicator light goes on stop the engine and check the coolant level in the reserve tank after the engine cools down Kawasaki Versys 650 Owner s Manual NOTICE Do not let the engine continue running when the warning indi cator light blinks Prolonged en gine operation will result in se vere damage from overheating GENERAL INFORMATION 29 Key This motorcycle has a combination key which is used for the ignition switch steering lock seat lock and fuel tank cap Included with the key is a key num ber which may be stamped on a sep arate plate Record the key number in the space provided and store the num ber in a safe place If your keys came with a plate store it in a safe place as well Kawasaki Versys 650 Owner s Manual 30 GENERAL INFORMATION Key Number Ignition Key TGO03002BZ4 C Write your key number here po In the event you lose your keys you will need the key number to have a du plicate made If you cannot locate your key number contact the dealer where you purchased your Kawasaki motor cycle It s possible the dealer may have the number in its records If the key number is lost completely you will need to replace the ignition switch and all other locks operated by that key Contact your Kawasaki dealer to pur chase additional spare keys either us ing your original key as a master or us ing the key code on the tag or your key
43. cle to a safe operating condition A WARNING Failure to perform these checks before operation may result in serious damage or an accident Always perform daily safety checks before oper ation A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas well ventilated area Operate only in a Fuel Engine Oil Adequate supply in tank no leaks Oil level between level lines Drive Chain Nuts Bolts Fasteners Steering ccececeeeee es Brakes ccceceececeeceees Throttle cccceeeee Clutch 2 0 cc cceecceececeeees Electrical Equipment Engine Stop Switch Kawasaki Versys 650 Owner s Manual SAFE OPERATION 73 Air pressure when cold 225 kPa 2 25 kgf cm 32 psi 250 kPa 2 50 kgf cm2 36 psi Install the air valve cap Slack 25 35 mm 1 0 1 4 in Lubricate the drive chain if dry Check that steering and suspension components axles and all controls are properly tightened or fastened Action smooth but not loose from lock to lock No binding of control cables Brake pad wear Lining thickness more than 1 mm 0 04 in left No brake fluid leakage Throttle grip play 2 3 mm 0 08 0 12 in Clutch lever play 2 3 mm 0 08 0 12 in Clutch lever operates smoothly No coolant leakage Coolant lev
44. ct sunlight moisture or freezing temperatures During storage it should be given a slow charge one ampere or less about once a month Keep the battery well charged especially during cold weather Tie plastic bags over the muffler to prevent moisture from entering Kawasaki Versys 650 Owner s Manual 168 STORAGE e Put a cover over the motorcycle to keep dust and dirt from accumulating on it Preparation after Storage e Remove the plastic bags from the muffler Install the battery in the motorcycle and charge the battery if necessary e Fill the fuel tank with fuel Check all the points listed in the Daily Safety Checks section Lubricate the pivots bolts and nuts Kawasaki Versys 650 Owner s Manual TROUBLESHOOTING GUIDE 169 TROUBLESHOOTING GUIDE Engine Does Not Start Starter Motor Won t Turn e Engine stop switch off e Transmission not in neutral e Fuse blown e Battery cables do not make good electrical contact with battery termi nals e Battery discharged Engine Cranks But Won t Start No fuel in tank e Fuel line clogged e Fuel broken down e Engine flooded Spark plugs not in good contact Spark plugs fouled or wet Incorrect spark plug gap Incorrect valve clearance e No first turning the ignition key to OFF when the motorcycle falls down Engine Stalls Just When Shifting Into 1st Gear e Side stand has been left down e Clutch does not properly disengage Whil
45. e Riding No fuel in tank e Fuel tank air vent is obstructed e Overheating e Battery discharged Kawasaki Versys 650 Owner s Manual 170 YOUR WARRANTY OWNER SATISFACTION YOUR WARRANTY OWNER SATISFACTION Welcome to the Kawasaki family Congratulations on buying your Kawasaki vehicle You ve chosen a great high quality product with state of the art features and built to Kawasaki s high stan dards Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp U S A Here is some important information regarding your vehicle s limited warranty Frequently Asked Questions What is a Limited Warranty The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty period You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale The warranty does not cover the cost of regularly scheduled maintenance The warranty also does not apply to the normal wear of items such as tires brake pads transmission drive belts chains sprockets etc Kawasaki Versys 650 Owner s Manual YOUR WARRANTY OWNER SATISFACTION 171 What is the Good Times Protection Plan Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki s Good Time Protection Plan GTPP See your Kawasaki dealer or go to Kawasaki com for
46. e conditions before idling A WARNING Operation with improperly ad justed incorrectly routed or damaged cable could result in an unsafe riding condition Be sure the control cable is ad justed and routed correctly and is free from damage TKI1131B G A Adjuster B Locknut C Throttle Cable Decelerator Cable Kawasaki Versys 650 Owner s Manual 114 MAINTENANCE AND ADJUSTMENT Engine Vacuum Synchronization Engine vacuum synchronization must be checked and adjusted period ically in accordance with the Periodic Maintenance Chart by an authorized Kawasaki dealer NOTE O Poor engine vacuum synchronization will cause unstable idling sluggish throttle response and reduce engine power and performance Idle Speed The idle speed check should be per formed in accordance with the Peri odic Maintenance Chart or whenever the idle speed is disturbed Kawasaki Versys 650 Owner s Manual Adjustment Start the engine and warm it up thor oughly e Adjust the idle speed by turning the idle adjusting screw Idle Speed 1 250 1 350 r min rpm TK13037B G A Idle Adjusting Screw MAINTENANCE AND ADJUSTMENT 115 e Open and close the throttle a few times to make sure that the idle speed does not change Readjust if necessary e With the engine idling turn the han dlebar to each side If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectl
47. ear and the side stand is down GENERAL INFORMATION 43 Seat Seat Removal Insert the ignition key into the seat lock located on the seat cover Turn the key clockwise while pulling on the rear end of the seat NOTE O If there is difficulty removing the seat be sure to insert the key all the way and to push down strongly on the rear end of the seat while turning the key clockwise Kawasaki Versys 650 Owner s Manual 44 GENERAL INFORMATION Seat Installation Install the seat in the reverse order of removal e Place the tabs into the matching slot and receptacles e Insert the hook at the rear of the seat into the lock on the frame TG16063B G A Seat B Seat Lock C Ignition Key D Pull up and rear TG17035B G B C Tabs D Receptacles E Hook F Lock Kawasaki Versys 650 Owner s Manual e Push down the rear part of the seat until the lock clicks e Pull up the rear end of the seat to make sure it is securely locked NOTE O If there is difficulty removing the ig nition key from the seat lock turn it lightly counterclockwise while pulling it out GENERAL INFORMATION 45 Helmet Hooks Helmets can be secured to the mo torcycle using the helmet hooks located under the seat TG21024B G A Helmet Hooks Kawasaki Versys 650 Owner s Manual 46 GENERAL INFORMATION By Awane Riding with helmets attached to the hooks could cause an ac cident by distracting the oper
48. el between level lines when engine is cold All lights Headlight City Light Tail Brake Lights Turn Sig nal Lights License Plate Light Warning Indicator Lights and horn work Stops engine Kawasaki Versys 650 Owner s Manual 74 SAFE OPERATION Side Stand Return to its fully up position by spring tension Return spring not weak or not damaged B Refer to the Daily Safety Checks caution label attached on the rear fender rear Kawasaki Versys 650 Owner s Manual SAFE OPERATION 75 Additional Considerations for High Speed Operation Brakes The importance of the brakes especially during high speed operation cannot be overemphasized Check to see that they are correctly adjusted and func tioning properly Steering Looseness in the steering can cause loss of control Check to see that the handlebar turns freely but has no play Tires High speed operation is hard on tires and good tires are crucial for riding safety Examine their overall condition inflate them to the proper pressure and check the wheel balance Fuel Have sufficient fuel for the high fuel consumption during high speed oper ation Engine Oil To avoid engine seizure and resulting loss of control make sure that the oil level is at the upper level line Coolant To avoid overheating check that the coolant level is at the upper level line Electrical Equipment Make sure that the headlight tail brake light turn signal lights
49. en the side stand is down However the gine engine can be Started if the clutch e Without holding the throttle grip push lever is pulled and the side stand is the starter button to start the engine fully up NOTICE Do not operate the starter con tinuously for more than 5 sec onds or the starter will overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and the bat tery power recover TIO2067B G A Clutch Lever B Starter Lockout Switch Kawasaki Versys 650 Owner s Manual NOTICE Do not let the engine idle longer than five minutes or engine overheating and damage may occur HOW TO RIDE THE MOTORCYCLE 55 Jump Starting lf your motorcycle battery is run down it should be removed and charged If this is not practical a 12 volt booster battery and jumper cables may be used to start the engine Kawasaki Versys 650 Owner s Manual 56 HOW TO RIDE THE MOTORCYCLE A DANGER Battery acid generates hydro gen gas which is flammable and explosive under certain con ditions It is present within a battery at all times even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of battery acid contact with skin eyes or clothing wash the affected ar eas immediately with water for at least 5 minutes Seek medical attention Co
50. eu tral detergent and then inspect for damage Avoid using abra sive pads or brushes to clean plastic parts as they will dam age the part s finish Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome alu minum polish Coated aluminum Kawasaki Versys 650 Owner s Manual 162 MAINTENANCE AND ADJUSTMENT should be washed with a mild neu tral detergent and finished with a spray polish Aluminum wheels both painted and unpainted can be cleaned with special non acid based wheel spray cleaners Leather Vinyl and Rubber lf your motorcycle has leather ac cessories special care must be taken Use a leather cleaner treatment to clean and care for leather accessories Washing leather parts with detergent and water will damage them shorten ing their life Vinyl parts should be washed with the rest of the motorcycle then treated with a vinyl treatment The sidewalls of tires and other rub ber components should be treated with a rubber protectant to help prolong their useful life A WARNING Rubber protectants can be slip pery and if used on the tread area cause loss of traction re sulting in accident causing in jury or death Do not apply rub ber protectant to any tread area Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 163 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart it is very important to check the tightness of t
51. f maintenance work orders bills etc as verification of this maintenance Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 81 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance re pair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels Kawasaki Versys 650 Owner s Manual 82 MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1 Periodic Inspection Engine Related Items Frequency Whichever Odometer Reading km x 1 000 mile x 1 000 see Page Operation 1 6 12 18 30 36 Engine Items 0 6 3 75 7 5 11 25 18 75 22 5
52. g stabil ity and handling of the motorcycle not only due to their weight but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation Poorly sult in an unsafe riding condition This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailers or other ve hicles Kawasaki does not manu facture sidecars or trailers for mo torcycles and cannot predict the ef fects of such accessories on han dling or stability but can only warn that the effects can be adverse and that Kawasaki cannot assume re sponsibility for the results of such unintended use of the motorcycle Furthermore any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty Maximum Load Weight of rider passenger baggage and accessories must not exceed 180 kg 397 lb Kawasaki Versys 650 Owner s Manual GENERAL INFORMATION 19 GENERAL INFORMATION Meter Instruments A Water Temperature Warning Indicator Light B Oil Pressure Warning Indicator Light RESET Button Neutral Indicator Light MODE Button High Beam Indicator Light G Left Turn Signal Indicator Light H Tachometer I Red Zone J Right Turn Signal Indicator Light K LCD Speedometer Clock Odometer Trip Meter A B Fuel Gauge L Fl Warning Indicator Light nmmogd TGO2206B G Kawasaki Versys 650 Owner s Manual 20 GENERAL INFORMATIO
53. h oil Stop the engine then wait several minutes until the oil set tles NOTICE Racing the engine before the oil reaches every part can cause en gine seizure Kawasaki Versys 650 Owner s Manual 94 MAINTENANCE AND ADJUSTMENT e f the motorcycle has just been used wait several minutes for all the oil to drain down e Check the engine oil level through the oil level inspection window With the motorcycle held level the oil level should come up between the upper and lower level lines next to the oil level inspection window TKO3089B G A Oil Level Inspection Window B Upper Level Line C Lower Level Line D Oil Filler Cap f the oil level is too high remove the excess oil through the oil filler open ing using a syringe or some other suitable device f the oil level is too low add the oil to reach the correct level Use the same type and brand of oil that is already in the engine NOTICE If the engine oil gets extremely low or if the oil pump does not function properly or oil pas sages are clogged the oil pres sure warning indicator light If it stays on when will go on the engine speed is above idle stop the engine immediately and have it serviced Failure to do so could cause serious engine damage Kawasaki Versys 650 Owner s Manual TKO3110B G A Oil Pressure Warning Indicator Light MAINTENANCE AND ADJUSTMENT 95 Oil and or Oil Filter Change e Warm up the engi
54. have the proper play e f it cannot be done loosen the lock nut and turn the adjusting nut at the lower end of the clutch cable e Tighten the locknut TKI5086B G A Clutch Cable B Locknut C Adjusting Nut Kawasaki Versys 650 Owner s Manual 118 MAINTENANCE AND ADJUSTMENT A WARNING The engine and exhaust system get extremely hot during normal A DANGER Exhaust gas contains carbon monoxide a colorless odor less poisonous gas __Inhaling operation and can cause serious burns Never touch a hot engine or an exhaust pipe during clutch adjustment carbon monoxide can cause serious brain injury or death DO NOT run the engine in en closed areas Operate only ina NOTE well ventilated area OAfter the adjustment is made start the engine and check that the clutch does not slip and releases properly OFor minor corrections use the ad juster at the clutch lever Kawasaki Versys 650 Owner s Manual Drive Chain The drive chain slack and lubrica tion must be checked each day be fore riding the motorcycle and in accor dance with the Periodic Maintenance Chart for safety and to prevent exces sive wear If the chain becomes badly worn or maladjusted either too loose or too tight the chain could jump off the sprockets or break A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it
55. hdl damage or severe per dioxide water nitrogen and oxygen re on i k hicl sulting in much cleaner exhaust gases hi not idle a a loan eo to be discharged into the atmosphere ih T ore ines a vi Bi veg For proper operation of the catalytic aa ae ea ani oA converter the following cautions must with the muffler or exhaust pipe be observed A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch a hot engine ex haust pipe or muffler during op eration or after stopping the en gine Kawasaki Versys 650 Owner s Manual 68 HOW TO RIDE THE MOTORCYCLE e Use only unleaded gasoline Never use leaded gasoline Leaded gaso line significantly reduces the capabil ity of the catalytic converter e Do not operate the vehicle with the engine or any one cylinder misfiring Under these conditions unburned air fuel mixture flowing out of engine excessively accelerates reaction in the converter allowing the converter to overheat and become damaged when the engine is hot or reduces converter performance when the en gine is cold Kawasaki Versys 650 Owner s Manual SAFE OPERATION 69 SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation For safety eye protection and a helmet are strongly recommended You should be aware of a
56. he bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition Please ask your authorized Kawasaki dealer for torque values 1 Clutch Lever Clamp Bolts 2 Handlebar Holder Bolts 3 Steering Stem Head Bolt 4 Steering Stem Nut 5 Front Master Cylinder Clamp Bolts TK28104B G Kawasaki Versys 650 Owner s Manual 164 MAINTENANCE AND ADJUSTMENT Front Fork Clamp Bolts Footpeg Stay Bolts Tandem Grip Mounting Bolts Front Fender Bolts Brake Disc Mounting Bolts Caliper Mounting Bolts Engine Mounting Bolts and Nuts 8 Side Stand Bolt 9 Swingarm Pivot Shaft Nut 10 Rear Axle Nut 11 Rear Sprocket Nuts ON NO of TK28105B2Z7 Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 165 lt LL S D 7 H Nes iG Mounting Bolts 3 Brake Pedal Bolt N 50 Z os Se O O I i Te Ke i 4 2 A p z 25 A X lo 1 Rear Shock Absorber Bolts 2 Rear Master Cylinder Far O m 5 O q amp 5 O O v m E pa 3 m c 3 S LL lt N ae a ieee TS oe Sate y DN f Veal I wN a Set p r ES eat i kz ee o y DOD OG TK28106BZ7 Kawasaki Versys 650 Owner s Manual 166 STORAGE STORAGE Preparation for Storage e Clean the entire vehicle thoroughly Run the engine for about five minute
57. he engine while the transmission is in neutral Kawasaki Versys 650 Owner s Manual 52 BREAK IN A WARNING New tires are slippery and may cause loss of control and injury A break in period of 160 km 100 miles is necessary to establish normal tire traction During break in avoid sudden and maximum braking and acceleration and hard cornering In addition to the above at 1 000 km 600 miles it is extremely important that the owner have the initial maintenance service performed by an authorized Kawasaki dealer HOW TO RIDE THE MOTORCYCLE 53 HOW TO RIDE THE MOTORCYCLE Starting the Engine e Without holding the throttle grip push a e Check that the engine stop switch is the starter button to start the engine inthe _ position TGO7028B G A Neutral Indicator Light A Engine Stop Switch a EA E B Starter Button l e Turn the ignition key to ON NOTE Make sure the transmission is in neu O The motorcycle is equipped with a tral vehicle down sensor which causes Kawasaki Versys 650 Owner s Manual 54 HOW TO RIDE THE MOTORCYCLE the engine to stop automatically and NOTE a the FI warning indicator light to blink The motorcycle is equipped with a when the motorcycle falls down Af starter lockout switch This switch is ter righting the motorcycle first turn designed so that the engine does not the ignition key to OFF and then start if the transmission is in gear and back to ON before starting the
58. he ignition key to OFF e Support the motorcycle on a firm level surface with the side stand NOTICE Do not park on a soft or steeply inclined surface or the motorcy cle may fall over e f parking inside a garage or other structure be sure it is well ventilated Kawasaki Versys 650 Owner s Manual 66 HOW TO RIDE THE MOTORCYCLE and the motorcycle is not close to any source of flame or sparks this includes any appliance with a pilot light A WARNING Gasoline is extremely flammable and can be explosive under cer tain conditions creating the po tential for serious burns Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pi lot light e Lock the steering to prevent theft NOTE O When stopping near traffic at night you can leave the taillight on for greater visibility by turning the igni tion key to the P Park position O Do not leave the ignition switch at P Park position too long or the bat tery will discharge Kawasaki Versys 650 Owner s Manual HOW TO RIDE THE MOTORCYCLE 67 Catalytic Converter A WARNING This motorcycle is equipped with a catalytic converter in the exhaust sys ee ee Rate pala tem The converter reacts with car aap ee eee oar cause a fire and can result in bon monoxide hydrocarbons and nitro gen oxides to convert them into carbon
59. he rear wheel skid and cause an accident resulting in severe injury or death as well as cause the engine to overrev and damage it When shifting down to a lower gear do not shift at such a high speed that engine rpm jumps excessively Downshift at the vehicle speeds shown in the table in this sec tion Kawasaki Versys 650 Owner s Manual HOW TO RIDE THE MOTORCYCLE 61 Vehicle speed when shifting Shifting up kwh mph Shifting down kmn mpm Past and so mos wa Cand ara s t sth ath so 3rd gt 4th 35 21 4th 3rd 20 12 4th 5th 45 27 3rd 2nd 45 9 5th 6th 55 34 2nd 1st 15 9 NOTE standing still The transmission will O The transmission is equipped with a shift only into neutral positive neutral finder When the mo torcycle is standing still the transmis sion cannot be shifted past neutral from 1st gear To use the positive neutral finder shift down to 1st gear then lift up on the shift pedal while Kawasaki Versys 650 Owner s Manual 62 HOW TO RIDE THE MOTORCYCLE Braking e Close the throttle completely leav ing the clutch engaged except when shifting gears so that the engine will help slow down the motorcycle Shift down one gear at a time so that you are in 1st gear when you come to a complete stop e When stopping always apply both brakes at the same time Normally the front brake should be applied a lit tle more than the rear Shift dow
60. her To remove the mois ture start the engine and turn on the headlight Gradually the condensa tion on the inside of the lens will clear off Semi gloss Finish To clean the semi gloss finish e When washing the motorcycle al ways use a mild neutral detergent and water e The semi gloss finish effect may be lost when the finish is excessively rubbed e If any doubt consult an authorized Kawasaki dealer Painted Surfaces After washing your motorcycle coat painted surfaces both metal and plas tic with a commercially available mo torcycle automotive wax Wax should be applied once every three months or as conditions require Avoid surfaces with satin or flat finishes Always Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 161 use non abrasive products and apply NOTICE them according to the instructions on the container Plastic parts may deteriorate and break if they come in con Windshield and Other Plastic Parts tact with chemical substances After washing use a soft cloth to gen or household cleaning products tly dry plastic parts When dry treat such as gasoline brake fluid the windshield headlight lens and window cleaners thread locking other non painted plastic parts with agents or other harsh chemi an approved plastic cleaner polisher cals If a plastic part comes in product contact with any harsh chemical substance wash it off immedi ately with water and a mild n
61. is located at the lower end of the rear shock absorber Kawasaki Versys 650 Owner s Manual 138 MAINTENANCE AND ADJUSTMENT TK20048B G A Rebound Damping Force Adjuster e Turn the rebound damping force ad juster towards the H mark to make the damping force greatest e Turn the adjuster towards the S mark to decrease damping force The standard setting position of the rebound damping force adjuster for an average build rider of 68 kg 150 Ib with no passenger and no accessories is as follows Rebound Damping ie Force Adjuster out from the fully seated position Kawasaki Versys 650 Owner s Manual Wheels Tubeless tires are installed on the wheels of this motorcycle The indica tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use gees TUBELESS A TUBELESS Mark MAINTENANCE AND ADJUSTMENT 139 TK21048B G A TUBELESS Mark The tire and rim form a leakproof unit by making airtight contacts at the tire chamfers and the rim flanges instead of using an inner tube Kawasaki Versys 650 Owner s Manual 140 MAINTENANCE AND ADJUSTMENT A WARNING Installing a tube inside a tube less type tire can create exces sive heat build up that can dam age the tube and cause rapid deflation The tires rims and air valves on this motorcycle are designed only for tubeless type wheels The recommended stan dard tires rims and
62. it is diluted excessively it loses its anti corrosion property Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer NOTE OA permanent type of antifreeze is in Stalled in the cooling system when shipped It is colored green and con tains ethylene glycol It is mixed at 50 and has the freezing point of 35 C 31 F Kawasaki Versys 650 Owner s Manual 102 MAINTENANCE AND ADJUSTMENT Coolant Level Inspection Situate the motorcycle so that it is perpendicular to the ground e Check the coolant level through the coolant level gauge on the reserve tank located to the right of the engine The coolant level should be between the F Full and L Low level lines TKO4124B G A F Full Level Line B L Low Level Line C Right Middle Fairing NOTE O Check the level when the engine is cold room or atmospheric tempera ture e f the amount of coolant is insuffi cient remove the right middle fair ing and add coolant into the reserve tank Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 103 Coolant Filling e Remove the bolts e Remove the seat see Seat section e Clear the projections from the grom in the GENERAL INFORMATION mets and remove the right middle chapter fairing forward e Remove the screw e Clear the projections from the grom mets and remove the right side cover backward TKO4126B G A Right Middle Fairing
63. ital Meter TG02199B G A Fuel Gauge B Speedometer C Clock Trip Meter A B Odometer NOTE O Do not shift the digital meter display while riding for safe operation Kawasaki Versys 650 Owner s Manual 22 GENERAL INFORMATION mph km h Display e Display the odometer in the digital mph km h Display can alternate be meter tween English and metric modes mph e The mph km h display shifts by push and km h in the digital meter Make ing the RESET button while the sure that mph or km h is correctly dis MODE button pushed in played according to local regulations before riding NOTE ODo not operate the vehicle with the digital meter displaying in the wrong unit mph or km h Shift the mph km h display in the digital meter as follows A mph km h Display Kawasaki Versys 650 Owner s Manual e The mph km h display shifts as fol lows E TG02102BZ1 C A mph Display B km h Display C Push RESET Button with MODE Button in NOTE O The data is maintained even if the battery is disconnected Speedometer The speedometer shows the speed of the vehicle in digital value GENERAL INFORMATION 23 Clock To adjust the hours and minutes e Turn the ignition key to ON e Push the MODE button to display the clock e Push the RESET button for more than two seconds Both the hour and minute displays start blinking ICK NY OPO TG02201B G Kawasaki Versys 650 Owner s Manual
64. license plate light horn etc all work properly Miscellaneous Make sure that all nuts and bolts are tight and that all safety related parts are in good condition Kawasaki Versys 650 Owner s Manual 76 SAFE OPERATION A WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds Do not attempt high speed operation unless you have received sufficient training and have the required skills MAINTENANCE AND ADJUSTMENT 77 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected With a basic knowledge of mechanics and the proper use of tools you should be able to carry out many of the maintenance items described in this chapter If you lack proper experience or doubt your ability all adjustments maintenance and repair work should be completed by a qualified technician Please note that Kawasaki cannot assume any responsibility for damage result ing from incorrect or improper adjustment done by the owner Kawasaki Versys 650 Owner s Manual 78 MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control syste
65. more information if you don t already have the GTPP What Am I Responsible For You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner s manual You are responsible for notifying your dealer immediately if there is a problem and you as the owner will need to authorize the dealer to inspect the unit You will be responsible for paying for routine maintenance including the first sched uled service You can have the required servicing done by your Kawasaki dealer recommended or an equally qualified service facility You can also do your own maintenance work if you have the proper tools service references and mechanical skills However if a failure is found to be caused by improper servicing it would not be covered by the limited warranty Kawasaki Versys 650 Owner s Manual 172 YOUR WARRANTY OWNER SATISFACTION You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki dealer You will be responsible for paying for repairs needed because of an accident to replace worn parts such as tires chains brakes and for repairs needed because of a lack of maintenance misuse or racing Whether you do it yourself or take your vehicle to a Kawasaki dealer be sure to record your service in the Maintenance Record section of this Owner s Manual Keep all receipts for the service and or items necessary to perform the maintenance so that in the
66. ms in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regu lations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into the combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model mo torcycle includes a catalytic converter system Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 79 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low per meation fuel hoses and fuel tank 3 Evaporative Emission Control System California Vapors caused by fuel evaporation in the fuel system are not vented into
67. mum Turning Radius 2 7 m 8 9 ft DIMENSIONS Overall Length 2 125 mm 83 7 in Overall Width 840 mm 33 1 in Overall Height 1 330 mm 52 4 in Wheelbase 1415 mm 55 7 in Road Clearance 180 mm 7 1 in Curb Mass 206 kg 454 Ib ENGINE Type 4 stroke DOHC 2 cylinder liquid cooled 649 cm 39 6 cu in 83 0 x 60 0 mm 3 3 x 2 4 in 10 6 1 Electric starter Cylinder Numbering Method Firing Order Fuel System Ignition System Ignition Timing Electronically advanced Spark Plug Lubrication System Engine Oil Type Viscosity Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Kawasaki Versys 650 Owner s Manual SPECIFICATIONS 9 Left to right 1 2 1 2 Fl Fuel Injection Battery and coil transistorized ignition 10 BTDC 1 300 r min rpm 33 BTDC 5 000 r min rpm NGK CRYEIA 9 Forced lubrication semi dry sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 2 4 L 2 5 US qt 1 2 L 1 3 US qt 6 speed return shift Wet multi disc 10 SPECIFICATIONS Driving System Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio 1st 2nd 3rd 4th oth 6th FRAME Caster Trail Tire Size Front Rear Kawasaki Versys 650 Owner s Manual Chain drive 2 095 88 42 3 067 46 15 5 473 Top gear 2 438 1 714 1 333 1 111 0 966 0 852 39 16 36 21 32 24 30 27 28 29 23 27 N m So So So
68. n be shifted to odometer trip meter or clock mode Warning Indicator Lights N When the transmission is in neu tral the neutral indicator light goes on Kawasaki Versys 650 Owner s Manual 28 GENERAL INFORMATION D When the headlight is on high beam the high beam indicator light goes on lt g gt When the turn signal switch is pushed to the left or right the cor responding turn signal indicator light blinks w7 The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition key is in the ON position with the engine not running and goes off when the engine oil pressure is high enough Refer to the Maintenance and Adjustment chap ter for more detailed engine oil informa tion FI The fuel injection Fl warning indicator light goes on when the igni tion switch is turned to ON and goes off soon after ensuring that its circuit functions properly The warning indi cator light also goes on whenever the troubles occur in digital fuel injection system DFI If the warning indicator light goes on have the DFI system checked by an authorized Kawasaki dealer When the warning indicator light blinks first turn the ignition key to OFF and then back to ON a The water temperature warning in dicator light goes on whenever the wa ter temperature rises to about 119 C 246 F when the motorcycle is in op eration This warns the operator that the w
69. n or fully disengage the clutch as neces sary to keep the engine from stalling e Never lock the brakes or it will cause the tires to skid When turning a cor ner itis better not to brake at all Re duce your speed before you get into the corner e For emergency braking disregard downshifting and concentrate on applying the brakes as hard as pos sible without skidding TI06094B G A Front Brake Lever A Rear Brake Pedal Kawasaki Versys 650 Owner s Manual TI06037B G HOW TO RIDE THE MOTORCYCLE 63 Stopping the Engine e Close the throttle completely Shift the transmission into neutral e Turn the ignition key to OFF e Support the motorcycle on a firm level surface with the side stand e Lock the steering NOTE O The motorcycle is equipped with a vehicle down sensor which causes the engine to stop automatically and the FI warning indicator light to blink when the motorcycle falls down Af ter righting the motorcycle first turn the ignition key to OFF and then back to ON before starting the en gine Kawasaki Versys 650 Owner s Manual 64 HOW TO RIDE THE MOTORCYCLE Stopping the Motorcycle in an Emergency Your Kawasaki Motorcycle has been designed and manufactured to pro vide you optimum safety and conve nience However in order to fully ben efit from Kawasaki s safety engineering and craftsmanship it is essential that you the owner and operator properly m
70. nd verify the applicable safety regulations in force prior to riding your motorcy cle Gloves and suitable footwear should also be used for added pro tection in case of a mishap A motorcycle does not provide the impact protection of an auto mobile so defensive riding in addi tion to wearing protective apparel is extremely important Do not let protective apparel give you a false sense of security When riding always keep both hands on the handlebars and both feet on the footpegs Removing your hands from the handlebars or feet from the footpegs while riding can be hazardous If you remove even one hand or foot you can reduce your ability to control the motorcycle Before changing lanes look over your shoulder to make sure the way is clear Do not rely solely on the rear view mirror you may misjudge a vehicle s distance and speed or you may not see it at all Kawasaki Versys 650 Owner s Manual 70 SAFE OPERATION In general your actions should be smooth as sudden acceleration braking or turning may cause loss of control especially when riding in wet conditions or on loose roadway surfaces when the ability to maneu ver will be reduced When going up steep slopes shift to a lower gear so that there is plenty of power to spare rather than over loading the engine When applying the brakes use both the front and rear brakes Ap plying only one brake for sudden braking may cause the motorcycle to skid
71. ndicator D Adjuster E Locknut NOTE OWheel alignment can also be checked using the straightedge or string method Kawasaki Versys 650 Owner s Manual 122 MAINTENANCE AND ADJUSTMENT A WARNING e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Install a new cotter pin through the rear axle nut and axle and spread its ends Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding con dition Align the rear wheel us ing the marks on the swingarm or measuring the distance be tween the center of the axle and swingarm pivot e Tighten both chain adjuster locknuts e Tighten the rear axle nut to the spec ified torque Tightening Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft lb TK16029BZ2 C A Cotter Pin NOTE Olf a torque wrench is not available this item should be serviced by a Kawasaki dealer Kawasaki Versys 650 Owner s Manual NOTE O When inserting the cotter pin if the Slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to the next alignment Olt should be within 30 degrees O Loosen once and tighten again when the slot goes past the nearest hole TK16030BZ2 C A Turning Clockwise MAINTENANCE AND ADJUSTMENT 123 A WARNING A loose axle nut can lead to an accident resulting in serious in jury or death Tighten the axle nut to the p
72. ne thoroughly and then stop it e Place an oil pan beneath the engine e Remove the engine oil drain bolt TKO3091B G A Drain Bolt Let the oil completely drain with the motorcycle perpendicular to the ground Kawasaki Versys 650 Owner s Manual 96 MAINTENANCE AND ADJUSTMENT A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recycling e Remove the oil filter and replace it with a new one TKO3092B G NOTE A Oil Filter Olf a torque wrench or required Kawasaki special tool is not avail able this item should be serviced by a Kawasaki dealer Kawasaki Versys 650 Owner s Manual e Apply a thin film of engine oil to the packing and tighten the oil filter to the specified torque Tightening Torque Oil Filter 17 5 N m 1 8 kgf m 13 ft lb TKO3021B G A Packing e Install the drain bolt with its new gas ket Tighten it to the specified torque MAINTENANCE AND ADJUSTMENT 97 O Replace the gasket with a new one NOTE Tightening Torque Engine Oil Drain Bolt 30 N m 3 1 kgf m 22 ft lb e Fill the engine up to the upper level line with a good quality engine oil specified in the table Recommended Engine Oil Viscosity Kawasaki Performance 4 Stroke Motorcycle Oil Kawasaki Performance 4 Stroke Semi Synthetic Oil Kawasaki Performance 4 Stroke Full Synthetic Oil or o
73. ner s Manual 154 MAINTENANCE AND ADJUSTMENT e Install the left frame cover as follows A WARNING e Fit the projection to the slot Subsite ses can cause e Fit the projections to the grommets a g i wiring to overheat catch fire e Tighten the bolt and or fail Do not use any sub stitute for the standard fuse Replace the blown fuse with a new one of the correct capacity as specified on the fuse box and main fuse _ za TK25124B G A Left Frame Cover B Projections C Slot D Grommets TK25007BZ2 C A Normal B Failed Kawasaki Versys 650 Owner s Manual General Lubrication Lubricate the points shown below with either motor oil or regular grease in accordance with the Periodic Main tenance Chart or whenever the vehicle has been operated under wet or rainy conditions Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime NOTE OA few drops of oil are effective to keep bolts and nuts from rusting and Sticking This makes removal easier Badly rusted nuts bolts etc should be replaced with new ones MAINTENANCE AND ADJUSTMENT 155 Apply motor oil to the following pivots e Side Stand e Clutch Lever e Front Brake Lever e Rear Brake Pedal Lubricate the following cables with a pressure cable lubber e K Clutch Inner Cable K Throttle Inner Cables TK26001BZ2 C Kawasaki Versys 650 Owner s
74. ngton D C area or write to NHTSA U S De partment of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline ENVIRONMENTAL PROTECTION 177 ENVIRONMENTAL PROTECTION To help preserve the environment properly discard used batteries tires oils and fluids or other vehicle components that you might dispose of in the future Con sult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure This also applies to disposal of the entire vehicle at the end of its life 178 MAINTENANCE RECORD MAINTENANCE RECORD Owner NAING visiscisiciicsiccintinvsieascnccesausscnawencenseatsatenncndsseneenestceneunusaenaswnaunns PC SS Saanen a ceca eee ean ete alee ease pene sce eat esa a Phone INN Oc eaececei nee sa esece gna case eee eancau eee vacacesceceudetiexecaeosseeak Engine NUMDeET 3 scarce este cane tata desea secs acasaasamsentsinsectanacndendtesncdvamennunsne Vehicle NUM DOM win civinccvecsniedvetndenntdaciiniesddowanetiedadentesccecsuebwctavsnsvtadwaneus TC OS E P E eee ante OEN T OEE A E Selling Dealer Name asnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn Phone NUM DON va sescececicegereactetccacesteesautsaancacarececenesetenustactetitedeaeeeibecuseet Warranty Start Date ce ceceee eee eeeeeeeeeeee eee eeseaseaaeeaeesaneeeaeesanes Note Keep this information and a spare key in a secure location Date
75. nnecting Jumper Cables e Remove the seat see Seat section in the GENERAL INFORMATION chapter e Make sure the ignition key is turned to OFF e Connect a jumper cable from the positive terminal of the booster battery to the positive terminal of the motorcycle battery e Connect another jumper cable from the negative terminal of the booster battery to your motorcy cle footpeg or other unpainted metal surface Do not use the negative terminal of the battery Kawasaki Versys 650 Owner s Manual HOW TO RIDE THE MOTORCYCLE 5 7 y DANGER Batteries contain sulfuric acid that can cause burns and pro duce hydrogen gas which is highly explosive Do not make this last connection at the fuel system or battery Take care not to touch the positive and nega tive cables together and do not lean over the battery when mak TIO3039B G A Motorcycle Battery Positive Terminal ae E ing this last connection Do not a ome Battery Positive Terminal connect to a frozen battery It D From Booster Battery Negative could explode Do not reverse Terminal polarity by connecting positive to negative or a battery explosion and serious damage to the electrical system may oc cur e Follow the standard engine starting procedure Kawasaki Versys 650 Owner s Manual 58 HOW TO RIDE THE MOTORCYCLE NOTICE Do not operate the starter con tinuously for more than 5 sec onds or the star
76. nts in the tank cap After refueling A Tank Cap make sure the tank cap is closed B Fuel Tank securely If gasoline is spilled on C Top Level the fuel tank wipe it off immedi D Filler Neck ately TG12016BZ2 C Kawasaki Versys 650 Owner s Manual NOTICE California model only Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and flow into the Evaporative Emission Control System resulting in hard start ing and engine hesitation and in compliance with the emission regulation Fuel Requirement Fuel Type Use clean fresh unleaded gasoline with a minimum Antiknock Index of 87 The Antiknock Index is posted on ser vice station pumps The octane rating GENERAL INFORMATION 39 of a gasoline is a measure of its resis tance to detonation or knocking The Antiknock Index is an average of the Research Octane Number RON and the Motor Octane Number MON as shown in the table Minimum Octane Rating Method Antiknock RON MON NOTICE Index 2 Use minimum of 87 octane gaso line only to prevent severe en gine damage Kawasaki Versys 650 Owner s Manual 40 GENERAL INFORMATION NOTICE If engine knocking or ping ing occurs use a different brand of gasoline of a higher octane rating If this condition is allowed to continue it can lead to severe engine damage Gasoline quality is important Fuels of
77. ol indicates points of particular interest for more efficient and convenient operation Kawasaki Versys 650 Owner s Manual FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle Your new mo torcycle is the product of Kawasaki s advanced engineering exhaustive testing and continuous striving for superior reliability safety and performance Please read this Owner s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle s controls its fea tures capabilities and limitations This manual offers many safe riding tips but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely Kawasaki strongly recommends that all operators of this vehi cle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation To ensure a long trouble free life for your motorcycle give it the proper care and maintenance described in this manual For those who would like more detailed in formation on their Kawasaki Motorcycle a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer The Service Manual contains de tailed disassembly and maintenance information Those who plan to do their own work should of course be competent mechanics and possess the special tools described in the Service Manual Keep this
78. onto any painted surface Do not use fluid from a container that has been left open or that has been unsealed for a long time Check for fluid leakage around the fittings Check brake hose for damage Kawasaki Versys 650 Owner s Manual 128 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection The brake fluid level in the front brake fluid reservoir must be kept above the line lower level line next to the gauge and that in the rear brake fluid reservoir located under the seat must be kept between the upper and lower level lines reservoirs held hor izontal ta TK17060B G A Rear Brake Fluid Reservoir B Upper Level Line C Lower Level Line TK17157 B G A Front Brake Fluid Reservoir B Lower Level Line Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 129 e If the fluid level in either reservoir is A WARNING lower than the lower level line check Mixing brands and types of for fluid leaks in the brake lines and i fill the reservoir to the upper level brake fluid oor reduce the brake system s effectiveness and line Inside the front brake fluid reser cause an accident resulting in voir is a Stepped line showing the up a per level line injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoi
79. operating on public roadways keep maximum speed under traffic law limits MAINTENANCE AND ADJUSTMENT 143 Standard Tire Tubeless Make Type DUNLOP SPORTMAX RADIAL D221FAG Size 120 70 ZR17 M C 58W Make Type DUNLOP SPORTMAX D221G Size 160 60 ZR17 M C 69W Replacement Tire Tubeless Make Type PIRELLI SCORPION SYNC FRONT Size 120 70 ZR17 M C 58W Make Type PIRELLI SCORPION SYNC RADIAL Size 160 60 ZR17 M C 69W Kawasaki Versys 650 Owner s Manual 144 MAINTENANCE AND ADJUSTMENT A WARNING Mixing tire brands and types can adversely affect handling and cause an accident resulting in injury or death Always use the same manufacturer s tires on both front and rear wheels A WARNING New tires are slippery and may cause loss of control and injury A break in period of 160 km 100 miles is necessary to estab lish normal tire traction During break in avoid sudden and max imum braking and acceleration and hard cornering Battery The battery installed in this motorcy cle is a sealed type so it is not nec essary to check the battery electrolyte level or add distilled water The sealing strip should not be pulled off once the specified electrolyte has been installed in the battery for initial service However in order to maximize bat tery life and ensure that it will provide the power needed to start the motor cycle you must properly maintain the battery s cha
80. or cycle for chips and scratches Do not let the water air dry as this can dam age the painted surfaces Kawasaki Versys 650 Owner s Manual e After cleaning your motorcycle check the rubber boot covering the shift pedal ball joint for correct instal lation Be sure the sealing lip of the rubber boot fits into the groove of the ball joint TK27012BZ2 C A Rubber Boot MAINTENANCE AND ADJUSTMENT 159 e f the boot is damaged replace it with a new one lf the boot is not posi tioned in the groove correctly place it in the correct position TK27001B G A Not correct position B Correct position e Start the engine and let it idle for sev eral minutes The heat from the en gine will help dry moist areas e Carefully ride your motorcycle at a slow speed and apply the brakes Kawasaki Versys 650 Owner s Manual 160 MAINTENANCE AND ADJUSTMENT several times This helps the brakes dry and restores its normal operating performance e Lubricate the drive chain to prevent rusting NOTE OAfter riding in an area where the roads are salted or near the ocean immediately wash your motorcycle with cold water Do not use warm water as it accelerates the chemical reaction of the salt After drying apply a corrosion protection spray on all metal and chrome surfaces to prevent corrosion Condensation may form on the inside of the headlight lens after riding in the rain washing the motorcycle or hu mid weat
81. ot obstruct or deflect air A WARNING flow through the radiator by installing unauthorized acces The cooling fan spins at high speed and can cause serious injuries Keep your hands and clothing away from the cooling fan blades at all times sories in front of the radiator or behind the cooling fan Inter ference with the radiator airflow can lead to overheating and con sequent engine damage Radiator Hoses Check the radiator hoses for leakage cracks or deterioration and connec tions for leakage or looseness each day before riding the motorcycle and in accordance with the Periodic Main tenance Chart Kawasaki Versys 650 Owner s Manual 100 MAINTENANCE AND ADJUSTMENT Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level be comes low the engine overheats and may suffer severe damage Check the coolant level each day before riding the motorcycle and in accordance with the periodic maintenance chart and replen ish coolant if the level is low Change the coolant in accordance with the Pe riodic Maintenance Chart Information for Coolant To protect the cooling system con sisting of the aluminum engine and radiator from rust and corrosion the use of corrosion and rust inhibitor chemicals in the coolant is essential If coolant containing corrosion and rust inhibitor chemicals is not used over a period of time the cooling s
82. r are unidentified A Front Brake Fluid Reservoir B Upper Level Line Kawasaki Versys 650 Owner s Manual 130 MAINTENANCE AND ADJUSTMENT NOTE Fluid Change O First tighten until slight resistance is Have the brake fluid changed by an felt indicating that the cap is seated authorized Kawasaki dealer on the reservoir body then tighten Front and Rear Brakes the cap an additional 1 6 turn while Disc and disc pad wear is automat holding the brake fluid reservoir _ ically compensated for and has no ef body fect on the brake lever or pedal action So there are no parts that require ad justment on the front and rear brakes A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever or pedal feels mushy when it is applied there might be air in the brake lines or the brake may be defective Have the brake C Clockwise checked immediately by an au D 1 6 turn thorized Kawasaki dealer TK17023B S A Reservoir B Cap Kawasaki Versys 650 Owner s Manual Brake Light Switches When either the front or rear brake is applied the brake light goes on The front brake light switch requires no ad justment but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart Inspection e Turn the ignition key to ON e The brake light should go on when the front brake is applied elf it does not
83. r during the last 10 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald TK21049B G A Tire Pressure Gauge Kawasaki Versys 650 Owner s Manual 142 MAINTENANCE AND ADJUSTMENT e ln accordance with the Periodic Maintenance Chart measure the depth of the tread with a depth gauge and replace any tire that has worn down to the minimum al lowable tread depth ON NE TK21050B G A Tire Depth Gauge Minimum Tread Depth 1mm 0 04 in Under 130 km h 2 mm 80 mph 0 08 in Over 130 km h 3 mm 80 mph 0 12 in e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indicate internal damage requiring tire replacement e Remove any imbedded stones or other foreign particles from the tread NOTE OHave the wheel balance inspected whenever a new tire is installed Kawasaki Versys 650 Owner s Manual A WARNING Tires that have been punctured and repaired do not have the same capabilities as undam aged tires and can suddenly fail causing an accident resulting in serious injury or death Re place damaged tires as soon as possible To ensure safe han dling and stability use only the recommended standard tires for replacement inflated to the stan dard pressure If it is necessary to ride on a repaired tire do not exceed 100 km h 60 mph until the tire is replaced NOTE O When
84. r four weeks or more dis connect the battery from the vehicle Kawasaki recommended__ chargers are Battery Mate 150 9 OptiMate 4 MAINTENANCE AND ADJUSTMENT 147 Yuasa MB 2040 2060 Christie C10122S If the above chargers are not avail able use equivalent one For more details ask a Kawasaki dealer Battery Charging e Remove the battery from the motor cycle see Battery Removal e Attach the leads from the charger and charge the battery at a rate am perage x hours that is indicated on the battery If it is not possible to read the rate charge the battery at an am perage that is about 1 1 0th of the bat tery capacity e The charger will keep the battery fully charged until you are ready to re install the battery in the motorcycle see Battery Installation Kawasaki Versys 650 Owner s Manual 148 MAINTENANCE AND ADJUSTMENT NOTICE Battery Removal e Remove the seat see Seat section in the GENERAL INFORMATION chapter Slide the red cap Never remove the sealing strip or the battery can be damaged Do not install a conventional battery in this motorcycle or the electrical system cannot work e Disconnect the cables from the bat properly tery first from the terminal and then the terminal NOTE Olf you charge the sealed battery never fail to observe the instructions shown in the label on the battery A WARNING Lead is a toxic substance Bat tery posts terminals
85. r s Manual MAINTENANCE AND ADJUSTMENT 89 Frequency Whichever comes first Odometer Reading km x 1 000 mile x 1 000 See f Page e 12 18 24 36 ne 3 a 7 5 11 25 15 i r 22 5 Items Front forks rear 133 shock absorber year i 136 oil leak inspect Steering system inspect Steering stem K bearings 2 years lubricate Electrical system Lights and switches year operation inspect Kawasaki Versys 650 Owner s Manual 90 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Odometer Reading 4 km x 1 000 mile x 1 000 Operation page Chassis ie E gt ca 3 5 7 5 18 75 22 5 Items e a l S e e aiming inspect Side stand switch operation year inspect Engine stop switch operation year inspect Chassis Chassis parts fnew over fet fet fe fs Bolts and nuts K tightness 163 inspect Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 91 3 Periodic Replacement Frequency Whichever comes first gt Odometer Reading 4 km x 1 000 mile x 1 000 hd Eve 24 36 48 ee Items ry ne Le 15 22 5 30 Kiger Semen nee aae ore LL re greont v fefefe e a OI fter replace COO E OOOO K Fuel hoses replace K coom crane Fie PP Pre years K replace K Brake hoses replace 4years years 4yers fo change Kawasaki Versys 650 Owner s Manual 92 MAINTENANCE AND ADJUSTMENT Frequency Whichever
86. rge When used regularly the charging system in the motorcycle helps keep the battery fully charged If your motorcycle is only used occasion ally or for short periods of time the bat tery is more likely to discharge Due to their internal composition batteries continually self discharge The discharge rate depends on the Kawasaki Versys 650 Owner s Manual type of battery and ambient temper ature As temperature rises so does the discharge rate Every 15 C 59 F doubles the rate Electrical accessories such as digi tal clocks and computer memory also draw current from the battery even when the key is switched off Due to a combination of such key off draws and hot temperature a battery can go from fully charged to completely dis charged in a matter of days MAINTENANCE AND ADJUSTMENT 145 Seldischarge Approx number of days from 100 charged to o Tempera 100 discharged ture Lead Lead Antimony Calcium Battery Battery 40 C 104 F 100 Days 300 Days 25 C 77 F 200 Days 600 Days 550 Days 950 Days Kawasaki Versys 650 Owner s Manual 146 MAINTENANCE AND ADJUSTMENT Current Drain Days from 100 charged to 100 discharged In extremely cold weather the fluid in an inadequately charged battery can easily freeze which can crack the case and buckle the plates A fully charged battery can withstand sub freezing temperature with no damage Days from 100 charged
87. roper torque and in stall a new cotter pin e Check the rear brake see Brakes section Kawasaki Versys 650 Owner s Manual 124 MAINTENANCE AND ADJUSTMENT Wear Inspection e Remove the bolts to take off the chain cover A Chain Cover B Bolts Stretch the chain taut either by using the chain adjusters or by hanging a 10 kg 22 Ib weight on the chain e Measure the length of 20 links on the straight part of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places e f the length exceeds the service limit the chain should be replaced TK16080B G A Measure B Weight Drive Chain 20 Link Length 319 mm 12 56 in Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 125 A WARNING NOTE For safety use only the standard O Sprocket wear is exaggerated for il chain It is an endless type and lustration See Service Manual for should not be cut for installa wear limits tion have it installed by an au thorized Kawasaki dealer Rotate the rear wheel to inspect the drive chain for damaged rollers and loose pins and links e Also inspect the sprockets for un evenly or excessively worn teeth and damaged teeth TK16025BZ2 C A Good Teeth B Worn Teeth C Damaged Teeth e f there is any irregularity have the drive chain and or the sprockets re placed by an authorized Ka
88. s to warm the oil shut it off and drain the engine oil A WARNING Motorcycle oil is a toxic substance Dispose of used oil properly Con tact your local authorities for approved disposal methods or possible re cycling e Put in fresh engine oil e Empty the fuel from the fuel tank by the pump or siphon Kawasaki Versys 650 Owner s Manual STORAGE 167 A WARNING Gasoline is extremely flammable and can be explosive under certain con ditions creating the potential for serious burns Turn the ignition key to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Gasoline is a toxic substance Dispose of gasoline properly Con tact your local authorities for approved disposal methods e Empty the fuel system by running the engine at idle speed until the engine stalls If left in for a long time the fuel will break down and could clog the fuel system e Reduce tire pressure by about 20 e Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep damp ness away from the tire rubber Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes Lubricate the drive chain and all the cables e Remove the battery and store it where it will not be exposed to dire
89. t of your correspondence Kawasaki Motors Corp U S A will contact the dealership and work with it in resolving your problem Kawasaki Versys 650 Owner s Manual YOUR WARRANTY OWNER SATISFACTION 175 Want to Contact Kawasaki This owner s manual should answer most of your questions about your Kawasaki Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you Please send your correspondence to Consumer Services Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 Kawasaki Versys 650 Owner s Manual 176 REPORTING SAFETY DEFECTS REPORTING SAFETY DEFECTS For Products Sold in the United States of America District of Columbia and U S Territories Only If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Kawasaki Motors Corpora tion U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems be tween you your dealer or Kawasaki Motors Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washi
90. ter will overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and the bat tery power recover e After the engine has started discon nect the jumper cables Disconnect the negative cable from the mo torcycle first Reinstall the removed parts Moving Off e Check that the side stand is up e Pull in the clutch lever Shift into 1st gear Open the throttle a little and start to let out the clutch lever very slowly e As the clutch starts to engage open the throttle a little more giving the en gine just enough fuel to keep it from stalling T104045B G A Shift Pedal Kawasaki Versys 650 Owner s Manual NOTE O The motorcycle is equipped with a side stand switch This switch is de signed so that the engine does not Start if the transmission is in gear and the side stand is down O When the headlight is on high beam two headlight beams go on and on low beam one headlight goes on HOW TO RIDE THE MOTORCYCLE 59 Shifting Gears Close the throttle while pulling in the clutch lever Shift into the next higher or lower gear Open the throttle halfway while re leasing the clutch lever e For smooth riding each gear position should cover the proper rate of speed shown in the table Kawasaki Versys 650 Owner s Manual 60 HOW TO RIDE THE MOTORCYCLE A WARNING Downshifting at high speed can make t
91. the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank High Altitude Performance Adjustment Information High Altitude adjustment is not required Kawasaki Versys 650 Owner s Manual 80 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND WARRANTY Proper maintenance is necessary to ensure that your motorcycle will continue to have low emission levels This Owner s Manual contains those maintenance rec ommendations for your motorcycle Those items identified by the Periodic Mainte nance Chart are necessary to ensure compliance with the applicable standards As the owner of this motorcycle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense The Kawasaki Limited Emission Control System Warranty requires that you re turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains You should keep a maintenance record for your motorcycle To assist you in keeping this record we have provided space on pages 178 through 182 of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies o
92. ther 4 stroke oils with API SG SH SJ SL SM and JASO MA MA1 MA2 rating SAE 10W 40 Kawasaki Versys 650 Owner s Manual 98 MAINTENANCE AND ADJUSTMENT Kawasaki Performance Oils and Lubricants have been specifically en gineered for your vehicle Consistent use of these products meets or ex ceeds warranty and service require ments and can help to extend the life of your Kawasaki NOTE ODo not add any chemical additive to the oil Oils fulfilling the above re guirements are fully formulated and provide adequate lubrication for both the engine and the clutch Engine Oil Capacity Capacity 1 7 L 1 8 US qt when filter is not removed 1 9 L 2 0 US qt when filter is removed 2 4 L 2 5 US qt when engine is completely dry Although 10W 40 engine oil is the recommended oil for most condi tions the oil viscosity may need to be changed to accommodate atmo spheric conditions in your riding area ay ee SAE 10W 30 20 30 40 C 86 104 TKO3023BZ2 C e Start the engine Check the oil level and oil leakage Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 99 Cooling System NOTICE Radiator and Cooling Fan Using high pressure water as Check the radiator fins for obstruc from a car wash facility could tion by insects or mud Clean off damage the radiator fins and im any obstructions with a stream of pair the radiator s effectiveness low pressure water Do n
93. to 50 discharged 60 Days 42 Days 28 Days 21 Days 14 Days Discharging Ampere Battery Sulfation A common cause of battery failure is sulfation Sulfation occurs when the battery is left in a discharged condition for an ex tended time Sulfate is a normal by product of the chemical reactions within a battery But when continuous dis charge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold a charge Battery failure due to sulfa tion is not warrantable Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded If you are riding your vehicle infre quently inspect the battery voltage weekly using a voltmeter If it drops below 12 8 volts the battery should be charged using an appropriate charger check with a Kawasaki dealer If Kawasaki Versys 650 Owner s Manual you will not be using the motorcy cle for longer than two weeks the battery should be charged using an appropriate charger Do not use an au tomotive type quick charger that may overcharge the battery and damage it NOTE OLeaving the battery connected causes the electrical components clock etc to make the battery dis charged resulting the over discharge of the battery In this case the repair or replacement of the battery is not included in the warranty If you do not drive fo
94. to go out of control Inspect the chain for damage and proper adjust ment before each ride MAINTENANCE AND ADJUSTMENT 119 Chain Slack Inspection e Set the motorcycle up on its side stand Rotate the rear wheel to find the po sition where the chain is tightest and measure the maximum chain slack by pulling up and pushing down the chain midway between the engine sprocket and rear wheel sprocket TK16043BZ2 C A Chain Slack Kawasaki Versys 650 Owner s Manual 120 MAINTENANCE AND ADJUSTMENT e f the drive chain is too tight or too Chain Slack Adjustment loose adjust it so that the chain slack e Remove the cotter pin and loosen will be within the standard value the rear axle nut Drive Chain Slack Loosen the left and right chain ad E Standard 25 35 mm 1 0 1 4 in juster locknuts TKIGO77B G A Rear Axle Nut B Cotter Pin C Adjuster D Locknut Kawasaki Versys 650 Owner s Manual MAINTENANCE AND ADJUSTMENT 121 f the chain is too loose turn out the left and right chain adjusters evenly f the chain is too tight turn in the left and right chain adjusters evenly e Turn out both chain adjusters evenly until the drive chain has the cor rect amount of slack To keep the chain and wheel properly aligned the notch on the left wheel alignment indicator should align with the same TK16078B G swingarm mark that the right indica A Marks tor notch aligns with B Notch C I
95. to seals brake pads and tires e Always use non abrasive wax and cleaner polisher Avoid all harsh chemicals solvents detergents and household cleaning products such as ammonia based window cleaners e Gasoline brake fluid and coolant will damage the finish of painted and plastic surfaces wash them off im mediately e Avoid wire brushes steel wool and all other abrasive pads or brushes e Use care when washing the wind shield headlight lens and other plastic parts as they can easily be scratched e Avoid using pressure washers wa ter can penetrate seals and electrical Kawasaki Versys 650 Owner s Manual 158 MAINTENANCE AND ADJUSTMENT components and damage your mo torcycle e Avoid spraying water in delicate areas such as in air intakes fuel system brake components electri cal components muffler outlets and fuel tank openings Washing Your Motorcycle Rinse your bike with cold water from a garden hose to remove any loose dirt e Mix a mild neutral detergent de signed for motorcycles or automo biles and water in a bucket Use a soft cloth or sponge to wash your motorcycle If needed use a mild de greaser to remove any oil or grease which build up e After washing rinse your motorcy cle thoroughly with clean water to re move any residue residue from the detergent can damage parts of your motorcycle Use a soft cloth to dry your motorcy cle As you dry inspect your mot
96. und damping force adjuster from the fully seated position as the ad justing mechanism may be dam aged Kawasaki Versys 650 Owner s Manual 136 MAINTENANCE AND ADJUSTMENT Rear Shock Absorber The rear shock absorber operation and oil leakage should be checked in accordance with the Periodic Mainte nance Chart Rear Shock Absorber Inspection e Press down on the seat several times to inspect the stroke e Visually inspect the rear shock ab sorber for oil leakage e f there is any doubt about the rear shock absorber it should be checked by an authorized Kawasaki dealer ak TK20041 A Rear Shock Absorber The rear shock absorber can be ad justed by changing the spring preload and rebound damping force for various riding and loading conditions Kawasaki Versys 650 Owner s Manual Spring Preload Adjustment The spring preload adjuster on the rear shock absorber has 7 positions TK20042B G A Spring Preload Adjuster B Wrench In accordance with the following ta ble turn the preload adjuster with the wrench from the tool kit MAINTENANCE AND ADJUSTMENT 137 Postion 2 3 4 s o 7 The standard setting position for an average build rider of 68 kg 150 Ib with no passenger and no accessories is No 5 NOTICE Be careful not to damage the motorcycle parts when adjust ing the spring preload Rebound Damping Force Adjustment The rebound damping force adjuster
97. wasaki dealer Kawasaki Versys 650 Owner s Manual 126 MAINTENANCE AND ADJUSTMENT Lubrication e Apply oil to the sides of the rollers so Lubrication is also necessary after that it will penetrate to the rollers and riding through rain or on wet roads or bushings Apply oil to the O rings so any time that the chain appears dry A that the O rings will be coated with heavy oil such as SAE 90 is preferred oil Wipe off any excess oil to a lighter oil because it will stay on the chain longer and provide better lubrica tion TK16011BZ2 C f the chain is especially dirty clean it using diesel oil or kerosine and then apply oil as described above Kawasaki Versys 650 Owner s Manual Brakes Brake Wear Inspection Inspect the brakes for wear For each front and rear disc brake caliper if the thickness of either pad is less than 1 mm 0 04 in replace both pads in the caliper as a set Pad replace ment should be done by an authorized Kawasaki dealer TK17159B S A Lining Thickness B 1 mm 0 04 in MAINTENANCE AND ADJUSTMENT 127 Brake Fluid In accordance with the Periodic Main tenance Chart inspect the brake fluid level in both the front and rear brake fluid reservoirs and change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Fluid Requirement Use heavy duty brake fluid only from a container marked DOT4 NOTICE Do not spill brake fluid
98. y TG23013R G A Wellnuts B Rivets Kawasaki Versys 650 Owner s Manual GENERAL INFORMATION 49 Windshield Position 1 Windshield Position 2 JA g 16238002 P ag 1G23B003 P A Windshield A Windshield B Bolts B Bolts C Wellnuts C Wellnuts D Rivets D Rivets Kawasaki Versys 650 Owner s Manual 50 GENERAL INFORMATION Windshield Position 3 1G23B004 P A Windshield B Bolts C Wellnuts NOTE O Keep the uninstalled rivets in a safe place Kawasaki Versys 650 Owner s Manual BREAK IN 51 BREAK IN The first 1 600 km 1 000 miles that the motorcycle is ridden is designated as the break in period If the motorcycle is not used carefully during this period you may very well end up with a broken down instead of a broken in motorcycle after a few thousand kilometers The following rules should be observed during the break in period e The table shows maximum recommended engine speed during the break in pe riod Distance traveled Maximum engine speed 0 800 km 0 500 miles 4 000 r min rpm 800 1 600 km 500 1 000 miles 6 000 r min rpm NOTE O When operating on public roadways keep maximum speed under traffic law lim its e Do not start moving or race the engine immediately after starting it even if the engine is already warm Run the engine for two or three minutes at idle speed to give the oil a chance to work up into all the engine parts e Do not race t
99. y Kawasaki dealer for warranty repairs Your Kawasaki dealer will inspect your vehi cle and give you the results of the inspection The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty Kawasaki Versys 650 Owner s Manual 174 YOUR WARRANTY OWNER SATISFACTION Kawasaki will work with your dealer to resolve any warranty issues No autho rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer What if am not Satisfied With My Warranty Service If you aren t satisfied with your dealership s repair work or operations it is best to discuss the situation with the appropriate dealership manager If you have already done this then contact the dealership s owner or general manager to request a review of the issue lf you are unable to resolve a problem after consulting with the dealership man agement and need further assistance contact Kawasaki Motors Corp U S A at the address below Please be certain to provide the model vehicle identification number VIN mileage or hours of use accessories dates that events occurred and what action has been taken by both you and your dealer Include the name and address of the dealership To assist us in resolving your inquiry please include copies of related receipts and any other pertinent information including the name of the dealership personnel with whom you have been working Upon receip
100. y routed or they may be damaged Be sure to correct any of these conditions before riding A WARNING Operation with damaged cables could result in an unsafe riding condition Replace damaged control cables before operation Kawasaki Versys 650 Owner s Manual 116 MAINTENANCE AND ADJUSTMENT Clutch Due to friction plate wear and clutch cable stretch over a long period of use the clutch operation should be checked each day before riding the motorcycle and in accordance with the Periodic Maintenance Chart Inspection e Check that the clutch lever operates properly and that the inner cable slides smoothly If there is any irreg ularity have the clutch cable checked by an authorized Kawasaki dealer e Check the clutch lever play as shown in the figure TK15B054 P A Locknut B Clutch Lever Play C Adjuster Clutch Lever Play 2 3 mm 0 08 0 12 in lf the play is incorrect adjust the lever play as follows Kawasaki Versys 650 Owner s Manual Adjustment A WARNING Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or death When adjusting the clutch cable be sure the upper end of the outer cable is fully seated in its fitting so that it doesn t slip into place later and create excessive cable play MAINTENANCE AND ADJUSTMENT 117 e Loosen the locknut and turn the ad juster at the clutch lever so that the clutch lever will
101. ystem ac cumulates rust and scale in the water jacket and radiator This will clog up the coolant passages and consider ably reduce the efficiency of the cooling system A WARNING Coolant containing corrosion inhibitors for alminum engines and radiators include harmful chemicals for human body Drinking coolant can result in serious injury or death Use coolant in accordance with the instructions of the manufacturer Soft or distilled water must be used with the antifreeze see below for an tifreeze in the cooling system Kawasaki Versys 650 Owner s Manual NOTICE If hard water is used in the sys tem it causes scale accumula tion in the water passages and considerably reduces the effi ciency of the cooling system If the lowest ambient temperature en countered falls below the freezing point of water use permanent antifreeze in the coolant to protect the cooling sys tem against engine and radiator freeze up as well as from rust and corrosion Use a permanent type of antifreeze soft water and ethylene glycol plus cor rosion and rust inhibitor chemicals for aluminum engines and radiators in the cooling system On the mixture ratio of coolant choose the suitable one re ferring to the relation between freezing point and strength directed on the con tainer MAINTENANCE AND ADJUSTMENT 101 NOTICE Permanenttypes of antifreeze on the market have anti corrosion and anti rust properties When

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