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Kawasaki Versys 650 (KLE650, 2007-2014, Gen 1 and Gen 2) Maintenance Schedule and Service Intervals

2013 Honda Versys 650 white 2nd gen

This is the maintenance schedule with associated service intervals for the Kawasaki Versys 650 from 2007 to 2014. It was launched in 2007 in Europe, and in 2008 in the US.

The Versys 650 has gone through a few distinct upgrades in its lifelong period, but the engine and fundamental architecture have stayed the same (though a few parts have changed).

  • Gen 1-2 2007-2009 Kawasaki Versys 650: The 2007-2009 Versys 650 was the original! A well-received bike, just thought of as a little buzzy. The 2010-2014 update got a new fairing (still a stacked headlight), rubber engine mounts and foot-pegs to reduce vibration. Optional (standard in some markets) ABS and heated grips.
  • Gen 3 2015+ Kawasaki Versys 650: Re-tuned engine for 3 more kW (5 more hp), new look (twin headlights) with adjustable windscreen, updated front Showa suspension and rear KYB shock with remote pre-load adjuster, standard ABS, updated front Nissin brakes and 30mm larger rear disc.

All models of the Kawasaki Versys 650 have been based around the same engine — a 649cc parallel twin that makes about 50 kW or 70 hp under 10,000 rpm. It’s the same engine you’ll find in the Ninja 650, for example. It’s not a ton of power, but it’s a lot more than you’d get from a big thumper of similar displacement, for example.

The Gen 1 and Gen 2 are based around a similar enough platform to warrant having their maintenance schedules together. The Gen 3 had enough changes to its chassis (despite having a basically identical engine) to warrant keeping the maintenance schedule separate.

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What you need to service the Kawasaki Versys 650

If you’re servicing the Kawasaki Versys 650, you need the following consumables and parts.

Versys 650 owners are pretty dedicated home maintenance types, but if you’re short on basic tools, check out this list of maintenance tools to see what else you might need.

PartKawasaki Versys 650 Spec
OilYou need 1.6-1.8L of SAE 10W-40 engine oil “with API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 rating”, preferably Kawasaki 10W-40 Engine Oil.

Don’t over-torque the drain bolt (spec is 30 Nm/22 lb-ft per the manual) — use a torque wrench if you don’t have experience with how much torque is enough.
Oil filterOil filter is part 16097-0008, or you can use Hiflofiltro HF303RC. Torque for oil filter is 17.5 Nm (12.9 ft-lb) (use a torque wrench, and it’s easier on the K&N one)
Front brake padsGet double-sintered EBC brake pads for better bite and wear. FA229HH, FA231HH (1 each).
Rear brake padsGet double-sintered EBC brake pads for better bite and wear — FA192HH.
Spark plugsNGK CR9EIA-9, with a spark plug gap of 0.8-0.9mm (use a spark plug gapping tool), torqued to 15 Nm or 11 ft-lb (use a torque wrench)
Air filterUse the K&N drop-in equivalent. Part number for 07-14 is HF3675.
Cable lubricantRemember to lubricate your clutch cable (and brake cables if you have them) with a cable lubricant. Protect All Cable Life is a good general-purpose lubricant.
Chain lubricantThe chain needs to be lubricated every 600 km/400 miles (or more, if it gets wet/dirty). Motul chain paste is cheap and well-loved.
Brake fluidSpec is to use DOT-4 brake fluid, e.g. Castrol DOT 4.
CoolantUse nitrate-free, phosphate-free, ethylene glycol-based coolant with anti-corrosion inhibitors, e.g. Valvoline Zerex G05 or Pro Honda Coolant.
GreaseUse a lithium soap-based grease for all the important greasing points.
Consumables for servicing the Kawasaki Versys 650 motorcycle (gen 1-2)

Maintenance Schedule for Kawasaki Versys 650

Below is the maintenance schedule for the Kawasaki Versys 650. It has been simplified a bit for display and to reduce unnecessary complexity.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

The maintenance for the Kawasaki Versys 650 is broken into three sections:

  1. Change/Replacement Items
  2. Engine Related Items
  3. Chassis Related Items

Notes

  • For higher odometer readings, repeat at the frequency interval established here.
  • # (air filter, chain, oil etc.): Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.

Versys 650 Replacement Parts

km x 1000112243648
mi x 1000Every0.67.51522.530
Air cleaner element – replace # (e) (HF3675)2 year
Engine oil – change # (Kawasaki 10W-40 Engine Oil)year
Oil filter – replace (HF303RC)year
Fuel hoses – replace5 years
Coolant – change (Valvoline Zerex G05)3 years
Radiator hoses and O-rings – replace3 years
Brake hoses – replace4 years
Brake fluid (front and rear) – change (Castrol DOT 4)2 years
Rubber parts of master cylinder and caliper – replace4 years
Spark plug (e) – replace (NGK CR9EIA-9)
Kawasaki Versys 650 — parts to replace during maintenance

Engine maintenance

km x 1000161218243036
mi x 1000Every0.63.757.511.251518.7522.5
Air cleaner element – clean
Valve clearance – inspect
Throttle control system – inspectyear
Engine vacuum synchronization – inspect
Idle speed – inspect
Fuel leak (fuel hose and pipe) – inspectyear
Fuel hoses damage – inspectyear
Fuel hoses installation condition – inspectyear
Coolant level – inspect
Coolant leak – inspectyear
Radiator hose damage – inspectyear
Radiator hoses installation condition – inspectyear
Evaporative emission control system – inspect (California model only)
Air suction system damage – inspect
Kawasaki Versys 650 Engine Maintenance

Chassis maintenance

km x 1000161218243036
mi x 1000Every0.63.757.511.251518.7522.5
Clutch operation (play, engagement, disengagement) – inspect
Drive chain lubrication condition – inspect # (lubricate with Motul chain paste)600 km (400 mile)
Drive chain slack – inspect #1000 km (600 mile)
Drive chain wear – inspect #
Drive chain guide wear – inspect
Tire air pressure – inspectyear
Wheels/tires damage – inspect
Tire tread wear, abnormal wear – inspect
Wheel bearings damage – inspectyear
Brake fluid leak – inspectyear
Brake hoses and pipe damage – inspectyear
Brake pad wear – inspect #
Brake hose installation condition – inspectyear
Brake fluid level – inspect6 months
Brake operation (effectiveness, play, drag) – inspectyear
Brake light switch operation – inspect
Front forks/rear shock absorber operation – inspect
Front forks/rear shock absorber oil leak – inspectyear
Steering play – inspectyear
Steering stem bearings – lubricate2 years
Lights and switches operation – inspectyear
Headlight aiming – inspectyear
Side stand switch operation – inspectyear
Engine stop switch operation – inspectyear
Chassis parts – lubricateyear
Bolts and nuts tightness – inspect
Kawasaki Versys 650 Chassis Maintenance

Tyre size and tyre pressure for the Kawasaki Versys 650

The Kawasaki Versys 650 has the following tyres, tyre sizes, and pressures:

TyreSizeBrand(s)Tyre pressure
Front120/70 ZR17 M/C (58W)DUNLOP, SPORTMAX RADIAL “D221FAG”
PIRELLI, SCORPION SYNC FRONT
225 kPa/32psi
Rear160/60 ZR17 M/C (69W)DUNLOP SPORTMAX “D221G”
PIRELLI, SCORPION SYNC RADIAL
250 kPa/36psi
Tyres and tyre pressures

The original Versys 650 shipped with either Dunlop Sportmax D221G or Pirelli Scorpion Sync tyres. These days, re-fit any sport touring tyres and you’re good to go.

General information about the Kawasaki Versys 650

The Kawasaki Versys 650 (model number KLE650) is a middleweight adventure touring motorcycle, the smaller sibling to the Kawasaki Versys 1000, but with quite a different engine — a parallel twin rather than four. Both bikes are so named as a portmanteau of the words “versatile” and “system”.

“Wait,” cry the Versys 650 faithful. “The Versys 650 not just a smaller Versys 1000!” And no, of course it isn’t… in many ways, the smaller Versys is a totally different bike.

The Versys 650’s engine is based on the Kawasaki Ninja 650’s parallel twin platform — although again, it’s quite a different bike to the Ninja 650. Some people might choose between the two — but they’d be just as likely to choose between a Versys 650 and a V-Strom 650, or a Versys 650 and a Honda VFR800X.

The Versys 650 differs in riding position, rear subframe, suspension components, and engine tuning. But it’s not just a Ninja in different clothing. Owners and reviewers of the Versys says that it feels like an entirely different motorcycle, and one who doesn’t like the Ninja might end up falling in love with the Versys.

The Versys’ 650 cc liquid-cooled, four-stroke, parallel-twin engine has been retuned for more bottom-end and mid-range torque compared to the Ninja, but it was always a midrange-focused engine (even in the Ninja).

The torquey twin delivers a broad powerband, starting low and letting it rev up high, making the Versys a great commuter and relaxed traveling companion. With its big, 5-gallon fuel tank, you can go a long way between fill-ups. This is partly why in the US, later models are available in an LT version — LT standing for “Light Touring”.

The long-travel suspension is an important part of the Versys’ multi-role mission. A Showa rear shock with two-stage damping firms up progressively as the wheel moves through its stroke, providing an initially plush ride that firms to near sportbike levels as suspension loads escalate. An adjustable, long-travel 41mm tapered-tube inverted fork soaks up bumps big and small, and like the rear end, firms up as you ride the Versys 650 more quickly.

With petal-style disc brakes and dual two-piston calipers in front and a single petal disc with a single-piston caliper in the back, the Versys 650 has plenty of stopping power.

The Kawasaki Versys 650 is commonly pitted against the V-Strom 650 (this is the earlier gen one). While the V-Strom, or “Wee Strom”, is a cult classic among people who travel long distances, many consider the Versys to be the better bike for road work, and the Versys better for going off-road sometimes.

Both bikes play in similar territory though and you’re unlikely to be unhappy with either.

Manual for the Kawasaki Versys 650 1st gen (2007-2014)

The above maintenance schedule comes directly from the user’s manual for the Kawasaki Versys 650, which is available here.

It’s the same across 2007-2014 models with the same items and schedules, though with different layout in each manual across the years.

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