Motorcycle engine repair Kawasaki KLE 650 Versys (2007-2025)

Exploded View of Engine top end
No.FastenerTorqueRemarks Nmkgf·m ft·lb 1Air Suction Valve Cover Bolts9.81.087 in·lb 2Baffle Plate Bolts5.90.6052 in·lb 3Camshaft Cap Bolts121.2106 in·lbS 4Camshaft Chain Tensioner Cap Bolt202.015 5Camshaft Chain Tensioner Mounting Bolts9.81.087...

Exhaust System Identification
Exhaust System KLE650A7F, KLE650B7F Full: Full Power H: Honeycomb Type Catalyst Silencer [A] with Hole [B] for Oxygen Sensor [C] Muffler Body Mark Position [A] Manifold Mark Position [A]

Specifications of Engine top end
ItemStandardService Limit Camshafts Cam Height: Exhaust35.343 ∼ 35.457 mm (1.3915 ∼ 1.3959 in.)35.24 mm (1.387 in.) Inlet35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.)35.74 mm (1.407 in.) Camshaft Journal, Camshaft0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028...

Special Tools and Sealant
Compression Gauge, 20 kgf/cm²: 57001-221 Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter, 45° - ∅35: 57001-1116 Valve Seat Cutter, 32° - ∅30: 57001-1120 Valve Seat Cutter, 32° - ∅35: Valve Seat Cutter, 60° - ∅30: 57001-1123 Valve Seat...

Clean Air System
Air Suction Valve Removal Remove: Air Switching Valve (See Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Clamp [B] Air Suction Valve Cover [C] Remove the air suction valve [A]. Air Suction Valve Installation Install the air suction...

Cylinder Head Cover
Cylinder Head Cover Removal Remove: Fuel Tank (See Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (See Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Suction Valve (See Air Suction Valve Removal) Stick...

Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal Caution: This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing...

Camshaft, Camshaft Chain
Camshaft Removal Remove: Cylinder Head Cover (See Cylinder Head Cover Removal) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the timing rotor...

Cylinder Head
Cylinder Compression Measurement Note: Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove: Fuel Tank (See Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (See Air Cleaner Housing...

Removing and installing the valves
Valve Clearance Inspection Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal Remove cylinder head (See...

Removing and Installing Cylinder, Pistons
Remove: Cylinder Head (See Cylinder Head Removal) Front Engine Mounting Bolts (Both Sides) [A] (See Engine Removal in the Engine Removal/Installation chapter) Front Engine Brackets (Both Sides) [B] (See Engine Removal in the Engine...

Throttle Body Assy Holder
Throttle Body Assy Holder Removal Remove: Fuel Tank (See Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (See Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (See Throttle Body Assy Removal in...

Removing muffler
Muffler Body Removal Warning: To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Remove: Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter) Lower Fairings (See...

Exploded View of Engine removal/installation
No.FastenerTorqueRemarks Nmkgf·m ft·lb 1Engine Mounting Bracket Bolts252.518S 2Front Engine Mounting Bolts444.532S 3Rear Engine Mounting Nuts444.532S 4. Collar 5. Engine Mounting Brackets S: Follow the specified tightening sequence.

Engine Removal/Installation
Engine Removal Support the rear part of the swingarm with a stand. Squeeze the brake lever slowly and hold it with a band [A]. Warning: Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an...