Kawasaki Versys (2006) User Manual [ru]

Versys

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

This quick reference guide will assist
you in locating a desired topic or pro­cedure.

•Bend the pages back to match the
black tab of the desired chapter num­ber with the black tab on the edge at
each table of contents page.

•Refer to the sectional table of contents
for the exact pages to locate the spe­cific topic required.

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

Versys

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted i n any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1) : Aug. 21, 2006 (K)

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

PS

psi

r revolution

horsepower

pound(s) per square inch

COUNTRY AND AREA CODES

AT Austria GB United Kingdom

CA Canada MY Malaysia

CH Sw

DE

Germany

itzerland

WVTA Whole Vehicle Type Approval

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his o wn basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce­dures must be understood in order to carry out
maintenance and repair satisfactorily. When­ever the owner has insufficient experience or
doubts his ability to do the work, all adjust­ments, maintenance, and repair should be car­ried out only by qualified mechanics.

In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor­oughly familiarize yourself with the procedures
before starting work, and then do the work care­fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad­versely affect safe operation.

For the duration of the warranty period,

we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta­ble of Contents.

For example, if you want ignition coil informa­tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap­ter to find the Ignition Coil section.

Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa­tion.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows.

In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec­ified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery cables from the battery to prevent the en­gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca­ble to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve­hicle disassembly can cause excessive wear and decrease
performance of the vehicle.

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

GENERAL INFORMATION 1-3

Inspection

Reuse of worn or damaged parts may lead to serious ac­cident. Visually inspect removed parts for corrosion, discol­oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be­yond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins m ust be replaced with
new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassem­bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se­quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar­ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.

Force

Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam­age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per­formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces­sively. Excessive application can clog oil passages and
cause serious damage.

Before Servicing

Press

For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con­tact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri­cation points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro­tate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires

A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor­oughly before using the meter. Incorrect values may lead
to improper adjustments.

Model Identification

KLE650B7F Left Side View

GENERAL INFORMATION 1-7

KLE650B7F Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

General Specifications

Items KLE650A7F, KLE650B7F

Dimensions

Overall Length 2 125 mm (83.7 in.)

Overall Width 840 mm (33.1 in.)

Overall Height 1 315 mm (51.8 in.)

Wheelbase

Road Clearance 180 mm (7.1 in.)

Seat Height 840 mm (33.1 in.)

Dry Mass:

KLE650A7F 181 kg (399 lb)

KLE650B7F 184 kg (405 lb)

Curb Mass:

Front:

KLE650A7F 103 kg (227 lb)

KLE650B7F 103 kg (227 lb)

Rear:

KLE650A7F 105 kg (232 lb)

KLE650B7F 104 kg (229 lb)

Fuel Tank Capacity 19 L (5.0 US gal)

Performance

Minimum Turning Radius

Engine

Type 4-stroke, DOHC, 2-cylinder

Cooling System

Bore and Stroke 83 × 60 mm (3.3 × 2.4 in.)

Displacement 649 cm³ (39.6 cu in.)

Compression Ratio 10.6 : 1

Maximum Horsepower 47.0 kW (64 PS) @8 000 r/min (rpm),

Maximum Torque

Carburetion System FI (Fuel injection), KEIHIN TTK38 × 2

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically advanced (digital igniter in ECU)

Ignition Timing

Spark Plug NGK CR9EIA-9

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

1 415 mm (55.7 in.)

2.7 m (8.8 ft)

Liquid-cooled

(MY) 44.0kW (60 PS) @7 000 r/min (rpm),
(CA) – – –

61 N·m (6.2 kgf·m, 114 ft·lb) @6 800 r/min (rpm),
(MY)61 N·m (6.2 kgf·m, 114 ft·lb) @6 000 r/min (rpm),
(CA) – – –

From 10° BTDC @1 300 r/min (rpm) to From 33° BTDC @5 000
r/min (rpm)

GENERAL INFORMATION 1-9

General Specifications

Items KLE650A7F, KLE650B7F

Valve Timing:

Inlet:

Open 25° (BTDC)

Close 54° (ABDC)

Duration

Exhaust:

Open 47° (BBDC)

Close 25° (ATDC)

Duration 252°

Lubrication System Forced lubrication (sem-dry sump)

Engine Oil:

Type API SE, SF or SG

Viscosity

Capacity 2.4 L (2.5 US qt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 2.095 (88/42)

Clutch Type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear Ratios:

1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

Final Drive System:

Type Chain drive

Reduction Ratio

Overall Drive Ratio 5.473 @Top gear

Frame

Type Tubular,diamond

Caster (Rake Angle) 25°

Trail 108 mm (4.2 in.)

Front Tire:

Type Tubeless

Size 120/70 ZR17 MC (58W)

Rear Tire:

Type Tubeless

Size 160/60 ZR17 MC (69W)

260°

API SH, SJ or SL with JASO MA

SAE 10W-40

1.333 (32/24)

3.067 (46/15)

1-10 GENERAL INFORMATION

General Specifications

Items KLE650A7F, KLE650B7F

Rim Size:

Front 17 × 3.50

Rear 17 × 4.50

Front Suspension:

Type Telescopic fork (upside-down)

Wheel Travel 150 mm (5.9 in.)

Rear Suspension:

Type

Wheel Travel 145 mm (5.7 in.)

Brake Type:

Front Dual discs

Rear Single disc

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

Bulb

Tail/Brake Light 12 V 0.5/3.7 W (LED)

Alternator:

Type

Rated Output 8 A/14 V @4 000 r/min (rpm)

Swingarm (uni-trak)

12 V 55 W/55W (Hi/Lo)

Three-phase AC

Specifications are subject to change without notice, and may not apply to every country.

Unit Conversion Table

GENERAL INFORMATION 1-11

Prefixes fo r Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units o f Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 =

L × 0.2200 =

L × 1.057 = qt (US)

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 =

mL × 0.02816 =

mL × 0.06102 = cu in

gal (US)

gal (imp)

oz (US)

oz (imp)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = k gf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m

kgf·m

kgf·m

× 9.807 = N·m

×7.233=

× 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 =

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW × 1.360 =

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-6

Specifications ......................................................................................................................... 2-11

Special Tools .......................................................................................................................... 2-13

Periodic Maintenance Procedures.......................................................................................... 2-14

Fuel System (DFI)................................................................................................................ 2-14

Air Cleaner Element Cleaning........................................................................................... 2-14

Throttle Control System Inspection................................................................................... 2-15

Engine Vacuum Synchronization Inspection ..................................................................... 2-16

Idle Speed Inspection ....................................................................................................... 2-18

Idle Speed Adjustment...................................................................................................... 2-18

Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-18

Cooling System.................................................................................................................... 2-19

Coolant Level Inspection ................................................................................................... 2-19

Radiator Hose Damage and Installation Condition Inspection.......................................... 2-19

Air Suction System .............................................................................................................. 2-20

Air Suction System Damage Inspection............................................................................ 2-20

Engine Top End ................................................................................................................... 2-20

Valve Clearance Inspection .............................................................................................. 2-20

Valve Clearance Adjustment ............................................................................................. 2-21

Clutch................................................................................................................................... 2-25

Clutch Operation Inspection.............................................................................................. 2-25

Wheels/Tires........................................................................................................................ 2-25

Air Pressure Inspection..................................................................................................... 2-25

Wheel/Tire Damage Inspection......................................................................................... 2-26

Tire Tread Wear, Abnormal Wear Inspection.................................................................... 2-26

Wheel Bearing Damage Inspection .................................................................................. 2-27

Drive Train ........................................................................................................................... 2-27

Drive Chain Lubrication Condition Inspection................................................................... 2-27

Drive Chain Slack Inspection ............................................................................................ 2-28

Drive Chain Slack Adjustment .......................................................................................... 2-28

Wheel Alignment Inspection ............................................................................................. 2-29

Drive Chain Wear Inspection ............................................................................................ 2-30

Chain Guide Inspection..................................................................................................... 2-30

Brake System ...................................................................................................................... 2-31

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-31

Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-31

Brake Operation Inspection .............................................................................................. 2-32

Brake Fluid Level Inspection............................................................................................. 2-32

Brake Pad Wear Inspection .............................................................................................. 2-33

Brake Light Switch Operation Inspection .......................................................................... 2-33

Suspensions ........................................................................................................................ 2-34

Front Forks/Rear Shock Absorber Operation Inspection.................................................. 2-34

Front Fork Oil Leak Inspection.......................................................................................... 2-34

Rear Shock Absorber Oil Leak Inspection........................................................................ 2-34

Steering System ..................................................................................................................2-35

Steering Play Inspection ................................................................................................... 2-35

Steering Play Adjustment.................................................................................................. 2-35

Steering Stem Bearing Lubrication ................................................................................... 2-36

Electrical System ................................................................................................................. 2-37

2

2-2 PERIODIC MAINTENANCE

Lights and Switches Operation Inspection........................................................................ 2-37

Headlight Aiming Inspection ............................................................................................. 2-39

Sidestand Switch Operation Inspection ............................................................................ 2-40

Engine Stop Switch Operation Inspection......................................................................... 2-41

Others.................................................................................................................................. 2-42

Chassis Parts Lubrication ................................................................................................. 2-42

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-43

Replacement Parts .............................................................................................................. 2-44

Air Cleaner Element Replacement.................................................................................... 2-44

Fuel Hose Replacement ................................................................................................... 2-44

Coolant Change................................................................................................................ 2-45

Radiator Hose and O-ring Replacement........................................................................... 2-47

Engine Oil Change............................................................................................................ 2-48

Oil Filter Replacement ...................................................................................................... 2-48

Brake Hose and Pipe Replacement.................................................................................. 2-49

Brake Fluid Change .......................................................................................................... 2-50

Master Cylinder Rubber Parts Replacement .................................................................... 2-52

Caliper Rubber Parts Replacement .................................................................................. 2-53

Spark Plug Replacement .................................................................................................. 2-55

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in

good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

FREQUENCY Whichever

comes

first

INSPECTION Every

Fuel System

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

* ODOMETER READING

(× 1 000 mile)

1

× 1 000 km

See

Page

Air cleaner element - clean

Throttle control system (play, smooth return,
no drag) - inspect

Engine vacuum synchronization - inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect year

Fuel hose and pipe damage - inspect year

Fuel hose and pipe installation condition ­inspect

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) ­inspect

Radiator hose damage - inspect year

Radiator hose installation condition - inspect year

Air Suction System

Air suction system damage - inspect

Engine Top End

Valve clearance

- inspect

Clutch

Clutch operation (play, disengagement,
engagement) - inspect

Wheels and Tires

CA Model

Other than CA Model Every 42 000 km (26 000 mile)

year

year

year

• • •

• • • •

• • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • •

•

• • • •

2-14

2-15

2-16

2-18

2-18

2-18

2-18

2-19

2-19

2-19

2-19

2-20

2-20

2-25

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearing damage - inspect year

Drive Train

Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-27

Drive chain slack - inspect # Every 1 000 km (600 mile) 2-28

Drive chain wear - inspect #

Drive chain guide wear - inspect

Brake System

Brake fluid leak (brake hose and pipe) ­inspect

year

• • • • • • •

• • •

• • •

• • •

• • •

• • •

• • •

2-25

2-26

2-26

2-27

2-30

2-30

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

INSPECTION Every

Brake hose and pipe damage - inspect year

Brake hose and pipe installation condition ­inspect

Brake operation (effectiveness, play, n o
drag) - inspect

Brake fluid level - inspect 6months

Brake pad wear - inspect #

Brake light switch operation - inspect

Suspensions

Front forks/rear shock absorber operation
(damping and smooth stroke) - inspect

Front forks/rear shock absorber oil leak ­inspect

Steering System

year

year

year

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1

(0.6)6(4)12(7.5)18(12)24(15)30(20)36(24)

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • •

• • • • • • •

• • •

• • •

See

Page

2-31

2-31

2-32

2-32

2-33

2-33

2-34

2-34

Steering play - inspect year

Steering stem bearings - lubricate

Electrical System

Lights and switches operation - inspect year

Headlight aiming - inspect year

Sidestand switch operation - inspect year

Engine stop switch operation - inspect year

Others

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2 years

• • • •

•

• • •

• • •

• • •

• • •

• • •

• • • •

2-35

2-36

2-37

2-39

2-40

2-41

2-42

2-43

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

CHANGE/REPLACE ITEM Every

Air cleaner element # 2 years 2-44

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1

(0.6)12(7.5)24(15)36(24)48(30)

See

Page

Fuel hose 4 years

Coolant

Radiator hose and O-ring 3 years

Engine oil # year

Oil filter year

Brake hose and pipe 4 years

Brake fluid 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

3 years

•

•

• • • • •

• • • • •

• •

• • • •

•

•

•

2-44

2-45

2-47

2-48

2-48

2-49

2-50

2-52,

2-53

2-55

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

EO: Apply engine oil.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant.

Fastener

Fuel System (DFI)

Fuel Pump Bolts 9.8 1.0 87 in·lb L, S

Right Switch Housing Screws 3.5 0.36 31 in·lb

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

Crankshaft Sensor Bolts 6.0 0.61 53 in·lb

Oxygen Sensor (Europe Models) 44.1 4.5 33

Spark Plugs

Speed Sensor Bolt 7.8 0.80 69 in·lb

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor

Cooling System

Baffle Plate Bolts 5.9 0.60 52 in·lb

Radiator Bolt 15 1.5 11

Radiator Hose Clamp Screws 2.0 0.20 18 in·lb

Thermostat Housing Bolts 9.8 1.0 87 in·lb

Water Pump Cover Bolts

Water Pump Drain Bolt 9.8 1.0 87 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Water Temperature Sensor 12 1.2 106 in·lb

Engine Top End

Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb

Baffle Plate Bolts 5.9 0.60 52 in·lb

Camshaft Cap Bolts 12 1.2 106 in·lb S

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts

Camshaft Sprocket Bolts 15 1.5 11 L

Cylinder Head Bolts (M10) 56 5.7 41 MO, S

Cylinder Head Bolts (M6) 12 1.2 106 in·lb S

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

Rear Camshaft Chain Guide Bolts 20 2.0 15 L

Spark Plugs

N·m kgf·m ft·lb

15 1.5 11

12 1.2 106 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

15 1.5 11

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Throttle Body Assy Holder Bolts 12 1.2 106 in·lb

Cylinder Bolt (M8) 27.5 2.8 20 MO,S

Cylinder Nut (M10) 49 5.0 36 MO, S

Cylinder Bolts (M6)

Exhaust Pipe Manifold Holder Nuts 17 1.7 12

Muffler Body Mounting Bolt (Front) 20 2.0 15

Muffler Body Mounting Bolt (Rear) 20 2.0 15

Clutch

Clutch Cable Clamp Bolt 9.8 1.0 87 in·lb

Clutch Cable Holder Bolts

Clutch Cover Mounting Bolts 9.8 1.0 87 in·lb

Clutch Hub Nut 130 13.3 96

Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S

Clutch Spring Bolts 9.8 1.0 87 in·lb

Timing Rotor Bolt Cap 4.9 0.50 43 in·lb

Oil Filler Plug

Oil Pump Chain Guide Bolts 12 1.2 106 in·lb L(1)

Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh

Timing Inspection Cap 3.9 0.40 35 in·lb

Engine Lubrication System

Engine Oil Drain Bolt 30 3.1 22

Filter Plate Bolts 9.8 1.0 87 in·lb L

Holder Mounting Bolt 25 2.5 18 L

Lower Fairing Bracket Bolts 12 1.2 106 in·lb L

Oil Filter

Oil Pan Bolts 12 1.2 106 in·lb

Oil Passage Plug 20 2.0 15 L

Oil Pipe Plate Bolt 9.8 1.0 87 in·lb L

Oil Plate Bolts 9.8 1.0 87 in·lb L

Oil Pressure Relief Valve 15 1.5 11 L

Oil Pressure Switch

Oil Pump Chain Guide Bolts 12 1.2 106 in·lb L(1)

Oil Pump Cover Bolts 9.8 1.0 87 in·lb L

Oil Pump Sprocket Bolt 12 1.2 106 in·lb L, Lh

Engine Removal/Installation

Engine Mounting Bracket Bolts 25 2.5 18 S

Front Engine Mounting Bolts 44 4.5 32

Rear Engine Mounting Nuts 44 4.5 32 S

Crankshaft/Transmission

Breather Plate Bolts 9.8 1.0 87 in·lb L

Race Holder Screw 4.9 0.50 43 in·lb L

Connecting Rod Big End Nuts see Text ← ←

Crankcase Bolt (M8, L = 110 mm) 27.5 2.8 20 S

N·m kgf·m ft·lb

12 1.2 106 in·lb

9.8 1.0 87 in·lb L

– – – Hand-tighten

17.5 1.8 13

15 1.5 11

Torque

Remarks

EO, R

SS

S

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Crankcase Bolt (M6, L = 32 mm)

Crankcase Bolts (M6, L = 38 mm) 19.6 2.0 14 S

Crankcase Bolts (M6, L = 45 mm) 19.6 2.0 14 S

Crankcase Bolts (M8, L = 50 mm) 27.5 2.8 20 S

Crankcase Bolts (M8, L = 60 mm) 35 3.6 26 MO, S

Crankcase Bolts (M8, L = 73 mm) 35 3.6 26 MO, S

Crankcase Bolts (M9, L = 113 mm)

Crankcase Bolts (M9, L = 83 mm) 44 4.5 32 MO, S

Upper Crankcase Bolt (M8, L = 120 mm) 27.5 2.8 20 S

Upper Crankcase Bolts (M8, L = 110 mm) 27.5 2.8 20 S

Oil Pipe Bolts 9.8 1.0 87 in·lb L

Oil Plate Bolts 9.8 1.0 87 in·lb L

Shift Shaft Return Spring Pin

Timing Rotor Bolt 40 4.1 30

Drive Shaft Bearing Holder Screw 4.9 0.50 43 in·lb L

Gear Positioning Lever Bolt

Neutral Switch 15 1.5 11

Neutral Switch Holder Screw 4.9 0.50 43 in·lb L

Oil Jet Nozzle 2.9 0.30 26 in·lb L

Shift Drum Bearing Holder Screws 4.9 0.50 43 in·lb L

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Shift Lever Bolt

Shift Rod Plate Bolt 9.8 1.0 87 in·lb L

Shift Shaft Cover Bolts 9.8 1.0 87 in·lb L(3)

Shift Shaft Cover Screw 4.9 0.50 43 in·lb L

Transmission Case Bolts 20 2.0 15

Wheels/Tires

Front Axle 108 11.0 80

Front Axle Clamp Bolt 20 2.0 15

Rear Axle Nut 108 11.0 80

Final Drive

Engine Sprocket Nut 125 12.7 92 MO

Rear Axle Nut 108 11.0 80

Rear Sprocket Nuts

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Speed Sensor Bracket Bolts 9.8 1.0 87 in·lb

Brakes

Bleed Valve 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

Front Brake Disc Mounting Bolts 27 2.8 20 L

Front Brake Light Switch Screw

N·m kgf·m ft·lb

19.6 2.0 14

44 4.5 32

29 3.0 21 L

12 1.2 106 in·lb L

12 1.2 106 in·lb L

59 6.0 44

1.0 0.10 9in·lb

Torque

Remarks

MO, S

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Front Brake Reservoir Cap Screws

Front Caliper Mounting Bolts 34 3.5 25

Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb

Bleed Valve 7.8 0.80 69 in·lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Pedal Bolt 8.8 0.90 78 in·lb

Rear Brake Disc Mounting Bolts 27 2.8 20 L

Rear Caliper Mounting Bolts 25 2.5 18

Rear Master Cylinder Mounting Bolts 25 2.5 18

Rear Master Cylinder Push Rod Locknut 18 1.8 13

Brake Pipe Joint Nuts (KLE650B Models) 18 1.8 13

Suspension

Front Axle Clamp Bolt

Front Fork Bottom Allen Bolts 20 2.0 15

Front Fork Clamp Bolts (Lower) 29 3.0 21 AL

Front Fork Clamp Bolts (Upper)

Front Fork Top Plugs 35 3.6 26

Piston Rod Nuts 20 2.0 15

Rear Shock Absorber Bolt (Upper) 59 6.0 44

Rear Shock Absorber Nut (Lower) 59 6.0 44

Swingarm Pivot Shaft Nut 108 11. 0 80

Steering

Front Fork Clamp Bolts (Lower) 29 3.0 21 AL

Front Fork Clamp Bolts (Upper) 20 2.0 15

Upper Handlebar Holder Bolts 25 2.5 18 S

Lower Handlebar Holder Bolts 25 2.5 18

Left Switch Housing Screws 3.5 0.36 31 in·lb

Right Switch Housing Screws 3.5 0.36 31 in·lb

Steering Stem Head Bolt 108 11.0 80

Steering Stem Nut 20 2.0 15

Frame

Footpeg Holder Bolts 34 3.5 25 L

Front Footpeg Stay Bolts 25 2.5 18

Rear Footpeg Stay Bolts 25 2.5 18

Sidestand Bolt 44 4.5 32

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

Lower Fairing Mounting Bolts 8.8 0.90 78 in·lb

Windshield Mounting Bolts 0.40 0.041 3.5 in·lb

Tandem Grip Mounting Bolts 25 2.5 18

Electrical System

Tail/Brake Light Mounting Bolts 1.2 0.12 11 in· lb

License Plate Light Cover Screws 0.90 0.090 8in·lb

License Plate Light Mounting Screws

N·m kgf·m ft·lb

1.5 0.15 13 in·lb

20 2.0 15

20 2.0 15

1.2 0.12 11 in·lb

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Turn Signal Light Lens Screws

Alternator Cover Bolts 9.8 1.0 87 in·lb

Alternator Lead Holding Plate Bolt 9.8 1.0 87 in·lb L

Alternator Rotor Bolt 155 15.8 114

Engine Ground Cable Terminal Bolt 9.8 1.0 87 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Left Switch Housing Screws 3.5 0.36 31 in·lb

Right Switch Housing Screws 3.5 0.36 31 in·lb

Sidestand Switch Bolt 3.9 0.40 35 in·lb L

Starter Motor Cable Terminal Nut

Starter Motor Clutch Bolts 34 3.5 25 L

Starter Motor Mounting Bolts 9.8 1.0 87 in·lb L

Starter Motor Terminal Locknut 11 1.1 97 in·lb

Starter Motor Through Bolts 4.9 0.50 43 in·lb

Stator Coil Bolts 12 1.2 106 in·lb L

Crankshaft Sensor Bolts

Neutral Switch 15 1.5 11

Oil Pressure Switch 15 1.5 11 SS

Oxygen Sensor (Europe Models) 44.1 4.50 32.5

Spark Plugs 15 1.5 11

Speed Sensor Bolt 7.8 0.80 69 in·lb L

Timing Rotor Bolt 40 4.1 30

Water Temperature Sensor 12 1.2 106 in·lb

Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L

N·m kgf·m ft·lb

1.0 0.10 9in·lb

6.0 0.61 53 in·lb

6.0 0.61 53 in·lb

Torque

Remarks

MO

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads D

(mm)

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

iameter

N·m kgf·m ft·lb

Torque