Kawasaki Versys (2006-11) - Repair, Service Manual and Electrical Wiring Diagrams

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KAWASAKI VERSYS (2006-11) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for motorcycles Kawasaki Versys (2006-11).
 

CONTENTS:

GENERAL INFORMATION
PERIODIC MAINTENANCE
- Fuel System (DFI)
- Cooling System
- Air Suction System
- Engine Top End
- Clutch
- Wheels/Tires
- Drive Train
- Brake System
- Suspensions
- Steering System
- Electrical System
- Others
- Replacement Parts
FUEL SYSTEM (DFI)
- DFI Servicing Precautions
- Outline
- Inquiries to Rider
- Self-diagnosis Outline
- Self-diagnosis Procedures
- Service Code Clearing Procedures
- How to Read Service Codes
- How to Erase Service Codes
- Service Code Table
- Backups
- Main Throttle Sensor Removal/Adjustment
- Main Throttle Sensor Input Voltage Inspection
- Main Throttle Sensor Output Voltage Inspection
- Main Throttle Sensor Resistance Inspection
- Intake Air Pressure Sensor Removal
- Intake Air Pressure Sensor Installation
- Intake Air Pressure Sensor Input Voltage Inspection
- Intake Air Pressure Sensor Output Voltage Inspection
- Intake Air Temperature Sensor Removal/Installation
- Intake Air Temperature Sensor Output Voltage Inspection
- Intake Air Temperature Sensor Resistance Inspection
- Water Temperature Sensor Removal/Installation
- Water Temperature Sensor Output Voltage Inspection
- Water Temperature Sensor Resistance Inspection
- Crankshaft Sensor Removal/Installation
- Crankshaft Sensor Inspection
- Speed Sensor Removal/Installation
- Speed Sensor Inspection
- Speed Sensor Input Voltage Inspection
- Speed Sensor Output Voltage Inspection
- Vehicle-down Sensor Removal
- Vehicle-down Sensor Installation
- Vehicle-down Sensor Inspection
- Subthrottle Sensor Removal/Adjustment
- Subthrottle Sensor Input Voltage Inspection
- Subthrottle Sensor Output Voltage Inspection
- Subthrottle Sensor Resistance Inspection
- Oxygen Sensor Removal/Installation
- Oxygen Sensor Inspection
- Stick Coil Removal/Installation
- Stick Coil Input Voltage Inspection
- Radiator Fan Relay Removal/Installation
- Radiator Fan Relay Inspection
- Subthrottle Valve Actuator Removal
- Subthrottle Valve Actuator Audible Inspection
- Subthrottle Valve Actuator Inspection
- Subthrottle Valve Actuator Resistance Inspection
- Subthrottle Valve Actuator Input Voltage Inspection
- Air Switching Valve Removal/Installation
- Air Switching Valve Inspection
- Oxygen Sensor Heater Removal/Installation
- Oxygen Sensor Heater Inspection
- Oxygen Sensor Removal/Installation
- Oxygen Sensor Inspection
- FI Indicator Light (LED) Inspection
- ECU Identification
- ECU Removal
- ECU Installation
- ECU Power Supply Inspection
- Fuel Pressure Inspection
- Fuel Flow Rate Inspection
- Fuel Pump Removal
- Fuel Pump Installation
- Fuel Pump Operation Inspection
- Fuel Pump Operating Voltage Inspection
- Pressure Regulator Removal
- Pump Screen, Fuel Filter Cleaning
- Removal/Installation
- Audible Inspection
- Fuel Injector Power Source Voltage Inspection
- Fuel Injector Output Voltage Inspection
- Injector Signal Test
- Injector Resistance Inspection
- Injector Unit Test
- Injector Fuel Line Inspection
- Throttle Grip Free Play Inspection
- Throttle Grip Free Play Adjustment
- Throttle Cable Installation
- Throttle Cable Lubrication
- Idle Speed Inspection
- Engine Vacuum Synchronization Inspection/Adjustment
- Throttle Body Assy Removal
- Throttle Body Assy Installation
- Throttle Body Assy Disassembly
- Throttle Body Assy Assembly
- Air Cleaner Element Removal/Installation
- Air Cleaner Element Inspection
- Air Cleaner Oil Draining
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank and Cap Inspection
- Fuel Tank Cleaning
- Parts Removal/Installation
- Canister Cover Removal
- Canister Cover Installation
- Hose Inspection
- Separator Inspection
- Separator Operation Test
- Canister Inspection
COOLING SYSTEM
- Coolant Deterioration Inspection
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Cooling System Flushing
- Coolant Reserve Tank Removal/Installation
- Water Pump Removal
- Water Pump Installation
- Water Pump Inspection
- Mechanical Seal Inspection
- Water Pump Housing Disassembly
- Water Pump Housing Assembly
- Impeller Assembly
- Pump Impeller Inspection
- Radiator and Radiator Fan Removal
- Radiator and Radiator Fan Installation
- Radiator Inspection
- Radiator Cap Inspection
- Radiator Filler Neck Inspection
- Thermostat Removal
- Thermostat Installation
- Thermostat Inspection
- Hose Installation
- Hose Inspection
- Water Temperature Sensor Removal/Installation
- Water Temperature Sensor Inspection
ENGINE TOP END
- Air Suction Valve Removal
- Air Suction Valve Installation
- Air Suction Valve Inspection
- Air Switching Valve Removal
- Air Switching Valve Installation
- Air Switching Valve Operation Test
- Air Switching Valve Unit Test
- Clean Air System Hose Inspection
- Cylinder Head Cover Removal
- Cylinder Head Cover Installation
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Camshaft Removal
- Camshaft Installation
- Camshaft, Camshaft Cap Wear
- Camshaft Runout
- Cam Wear Inspection
- Camshaft Chain Removal
- Cylinder Compression Measurement
- Cylinder Head Removal
- Cylinder Head Installation
- Cylinder Head Warp
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Valve Removal
- Valve Installation
- Valve Guide Removal
- Valve Guide Installation
- Valve-to-Guide Clearance Measurement (Wobble Method)
- Valve Seat Inspection
- Valve Seat Repair
- Cylinder Removal
- Cylinder Installation
- Piston Removal
- Piston Installation
- Cylinder Wear
- Piston Wear
- Piston Ring, Piston Ring Groove Wear
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap
- Throttle Body Assy Holder Removal
- Throttle Body Assy Holder Installation
- Muffler Body Removal
- Exhaust Pipe Removal
- Muffler Body and Exhaust Pipe Installation
CLUTCH
- Clutch Lever Free Play Inspection
- Clutch Lever Free Play Adjustment
- Clutch Cable Removal
- Clutch Cable Installation
- Clutch Cable Lubrication
- Clutch Lever Installation
- Clutch Lever Adjustment
- Clutch Cover Removal
- Clutch Cover Installation
- Release Shaft Removal
- Release Shaft Installation
- Clutch Cover Disassembly
- Clutch Cover Assembly
- Clutch Removal
- Clutch Installation
- Clutch Plate, Wear, Damage Inspection
- Clutch Plate Warp Inspection
- Clutch Spring Free Length Measurement
- Clutch Housing Finger Inspection
- Clutch Housing Spline Inspection
ENGINE LUBRICATION SYSTEM
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Replacement
- Oil Pan Removal
- Oil Pan Installation
- Oil Pressure Relief Valve Removal
- Oil Pressure Relief Valve Installation
- Oil Pressure Relief Valve Inspection
- Oil Pump Removal
- Oil Pump Installation
- Oil Pressure Measurement
- Oil Pressure Switch Removal
- Oil Pressure Switch Installation
ENGINE REMOVAL/INSTALLATION
- Engine Removal
- Engine Installation
CRANKSHAFT/TRANSMISSION
- Crankcase Splitting
- Crankcase Assembly
- Crankshaft Removal
- Crankshaft Installation
- Connecting Rod Removal
- Connecting Rod Installation
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend
- Connecting Rod Twist
- Connecting Rod Big End Side Clearance
- Connecting Rod Big End Bearing Insert/Crankpin Wear
- Crankshaft Side Clearance
- Crankshaft Runout
- Crankshaft Main Bearing Insert/Journal Wear
- Balancer Removal
- Balancer Installation
- Balancer Shaft Bearing Insert/Journal Clearance
- Shift Pedal Removal
- Shift Pedal Installation
- External Shift Mechanism Removal
- External Shift Mechanism Installation
- External Shift Mechanism Inspection
- Transmission Assy Removal
- Transmission Assy Installation
- Transmission Assy Disassembly
- Transmission Assy Assembly
- Transmission Shaft Removal
- Transmission Shaft Installation
- Transmission Shaft Disassembly
- Transmission Shaft Assembly
- Shift Drum and Fork Removal
- Shift Drum and Fork Installation
- Shift Drum Disassembly
- Shift Drum Assembly
- Shift Fork Bending
- Shift Fork/Gear Groove Wear
- Shift Fork Guide Pin/Drum Groove Wear
- Gear Dog and Gear Dog Hole Damage
- Ball and Needle Bearing Replacement
- Ball and Needle Bearing Wear
- Oil Seal Inspection
WHEELS/TIRES
- Front Wheel Removal
- Front Wheel Installation
- Rear Wheel Removal
- Rear Wheel Installation
- Wheel Inspection
- Axle Inspection
- Balance Inspection
- Balance Adjustment
- Balance Weight Removal
- Balance Weight Installation
- Air Pressure Inspection/Adjustment
- Tire Inspection
- Tire Removal
- Tire Installation
- Tire Repair
- Hub Bearing Removal
- Hub Bearing Installation
- Hub Bearing Inspection
- Hub Bearing Lubrication
FINAL DRIVE
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Wheel Alignment Inspection/Adjustment
- Drive Chain Wear Inspection
- Drive Chain Lubrication
- Drive Chain Removal (KLE650CAF/DAF)
- Drive Chain Installation (KLE650CAF/DAF)
- Drive Chain Removal (KLE650CBF/DBF)
- Drive Chain Installation (KLE650CBF/DBF)
- Engine Sprocket Removal
- Engine Sprocket Installation
- Rear Sprocket Removal
- Rear Sprocket Installation
- Coupling Installation
- Coupling Bearing Removal
- Coupling Bearing Installation
- Coupling Bearing Inspection
- Coupling Bearing Lubrication
- Coupling Damper Inspection
- Sprocket Wear Inspection
- Rear Sprocket Warp Inspection
BRAKES
- Brake Lever Position Adjustment
- Brake Pedal Position Inspection
- Brake Pedal Position Adjustment
- Brake Pedal Removal
- Brake Pedal Installation
- Front Caliper Removal
- Rear Caliper Removal
- Caliper Installation
- Front Caliper Disassembly
- Front Caliper Assembly
- Rear Caliper Disassembly
- Rear Caliper Assembly
- Caliper Fluid Seal Damage
- Rear Caliper Dust Boot and Friction Boot Damage
- Caliper Piston and Cylinder Damage
- Rear Caliper Holder Shaft Wear
- Front Brake Pad Removal
- Front Brake Pad Installation
- Rear Brake Pad Removal
- Rear Brake Pad Installation
- Brake Pad Wear Inspection
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Front Master Cylinder Disassembly
- Rear Master Cylinder Disassembly
- Master Cylinder Assembly
- Master Cylinder Inspection
- Brake Disc Removal
- Brake Disc Installation
- Brake Disc Wear
- Brake Disc Warp
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Bleeding
- Brake Hose Removal/Installation
- Brake Hose Inspection
- ABS Servicing Precautions
- ABS Troubleshooting Outline
- Inquiries to Rider
- Self-diagnosis Outline
- Self-diagnosis Procedures
- Service Code Clearing Procedures
- How to Read Service Codes
- How to Erase Service Codes
- ABS Indicator Light (LED) Inspection
- Solenoid Valve Inspection (Service Code 13,14,17,18)
- ABS Solenoid Valve Relay Inspection (Service Code 19)
- Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
- ABS Pump Motor Relay Inspection (Service Code 35)
- Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)
- Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)
- Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)
- Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)
- Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)
- Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)
- ECU Inspection (Service Code 55)
- ABS Hydraulic Unit Removal
- ABS Hydraulic Unit Installation
- ABS Hydraulic Unit Inspection
- Front Wheel Rotation Sensor Removal
- Front Wheel Rotation Sensor Installation
- Rear Wheel Rotation Sensor Removal
- Rear Wheel Rotation Sensor Installation
- Wheel Rotation Sensor Inspection
- Wheel Rotation Sensor Air Gap Inspection
- Wheel Rotation Sensor Rotor Inspection
- Brake Hose Removal/Installation
- Brake Hose Inspection
- 25 A ABS Solenoid Valve Relay Fuse Removal
- 30 A ABS Pump Motor Relay Fuse Removal
- Fuse Installation
- Fuse Inspection
SUSPENSION
- Rebound Damping Force Adjustment (Only Right Fork Leg)
- Spring Preload Adjustment
- Front Fork Removal (Each Fork Leg)
- Front Fork Installation
- Fork Oil Change
- Front Fork Disassembly
- Front Fork Assembly
- Inner Tube, Outer Tube Inspection
- Dust Seal Inspection
- Spring Tension Inspection
- Rebound Damping Force Adjustment
- Spring Preload Adjustment
- Rear Shock Absorber Removal
- Rear Shock Absorber Installation
- Rear Shock Absorber Inspection
- Swingarm Removal
- Swingarm Installation
- Swingarm Bearing Removal
- Swingarm Bearing Installation
- Swingarm Bearing, Sleeve Inspection
- Swingarm Bearing Lubrication
- Chain Guide Inspection
STEERING
- Steering Inspection
- Steering Adjustment
- Stem, Stem Bearing Removal
- Stem, Stem Bearing Installation
- Stem Bearing Lubrication
- Steering Stem Warp
- Stem Cap Deterioration, Damage
- Handlebar Removal
- Handlebar Installation
FRAME
- Seat Removal
- Seat Installation
- Lower Fairing Removal
- Lower Fairing Installation
- Lower Fairing Bracket Removal
- Lower Fairing Bracket Installation
- Middle Fairing Removal
- Middle Fairing Installation
- Upper Fairing Removal
- Upper Fairing Installation
- Upper Fairing Bracket Removal
- Upper Fairing Bracket Installation
- Side Cover Removal
- Side Cover Installation
- Seat Cover Removal
- Seat Cover Installation
- Front Fender Removal
- Front Fender Installation
- Flap and Rear Fender Rear Removal
- Flap and Rear Fender Rear Installation
- Rear Fender Front Removal
- Rear Fender Front Installation
- Frame Inspection
- Windshield Height Adjustment
- Windshield Removal
- Windshield Installation
- Sidestand Removal
- Sidestand Installation
- Front Frame Cover Removal
- Front Frame Cover Installation
- Rear Frame Cover Removal
- Rear Frame Cover Installation
- Rear View Mirrors Removal
- Rear View Mirrors Installation
ELECTRICAL SYSTEM
- Wiring Inspection
- Battery Removal
- Battery Installation
- Battery Activation
- Precautions
- Interchange
- Charging Condition Inspection
- Refreshing Charge
- Alternator Cover Removal
- Alternator Cover Installation
- Stator Coil Removal
- Stator Coil Installation
- Alternator Rotor Removal
- Alternator Rotor Installation
- Alternator Inspection
- Regulator/Rectifier Inspection
- Charging Voltage Inspection
- Starter Motor Clutch Removal/Installation
- Starter Motor Clutch Inspection
- Starter Motor Clutch Disassembly
- Starter Motor Clutch Assembly
- Crankshaft Sensor Removal
- Crankshaft Sensor Installation
- Crankshaft Sensor Inspection
- Crankshaft Sensor Peak Voltage Inspection
- Timing Rotor Removal
- Timing Rotor Installation
- Stick Coil Removal
- Stick Coil Installation
- Stick Coil Inspection
- Stick Coil Primary Peak Voltage
- Spark Plug Removal
- Spark Plug Installation
- Spark Plug Condition Inspection
- Interlock Operation Inspection
- IC Igniter Inspection
- Starter Motor Removal
- Starter Motor Installation
- Starter Motor Disassembly
- Starter Motor Assembly
- Brush Inspection
- Commutator Cleaning and Inspection
- Armature Inspection
- Brush Lead Inspection
- Right-hand End Cover Inspection
- Starter Relay Inspection
- Headlight Beam Horizontal Adjustment
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- City Light Bulb Replacement
- Headlight Cover Removal
- Headlight Cover Installation
- Headlight Removal/Installation
- Tail/Brake Light Removal
- Tail/Brake Light Installation
- License Plate Light Bulb Replacement
- Turn Signal Light Bulb Replacement
- Turn Signal Relay Inspection
- Air Switching Valve Operation Test
- Air Switching Valve Unit Test
- Fan Motor Inspection
- Meter Unit Removal
- Meter, Gauge Disassembly
- Electronic Combination Meter Unit Inspection
- Brake Light Timing Inspection
- Brake Light Timing Adjustment
- Switch Inspection
- Water Temperature Sensor Inspection
- Speed Sensor Removal
- Speed Sensor Installation
- Speed Sensor Inspection
- Fuel Level Sensor Inspection
- Oxygen Sensor Removal (Equipped Models)
- Oxygen Sensor Installation (Equipped Models)
- Oxygen Sensor Inspection (Equipped Models)
- Oxygen Sensor Heater Inspection (Equipped Models)
- Fuel Reserve Switch Inspection
- Relay Box Removal
- Relay Circuit Inspection
- Diode Circuit Inspection
- 30 A Main Fuse Removal
- Fuse Box Fuse Removal
- 15 A ECU Fuse Removal
- Fuse Installation
- Fuse Inspection
APPENDIX