Elements of transmission motorcycle Kawasaki KLE 650 Versys (2007-2025)

Exploded View of Clutch
No.FastenerTorqueRemarks Nmkgf·m ft·lb 1Clutch Cable Clamp Bolt9.81.087 in·lb 2Clutch Cable Holder Bolts9.81.087 in·lbL 3Clutch Cover Mounting Bolts9.81.087 in·lb 4Clutch Hub Nut13013.396 5Clutch Lever Clamp Bolts7.80.8069 in·lbS 6Clutch Spring...

Specifications of Clutch
ItemStandardService Limit Clutch Lever Free Play2-3 mm (0.08-0.12 in.)— Clutch Friction Plate Thickness2.92-3.08 mm (0.115-0.121 in.)2.8 mm (0.110 in.) Friction Plate Warp0.15 mm (0.16 in.) or less0.3 mm (0.012 in.) Steel Plate Warp0.2 mm (0.008...

Special Tool and Sealant
Clutch Holder: 57001-1243 Kawasaki Bond (Silicone Sealant): 92104-0004

Clutch Lever and Cable
Clutch Lever Free Play Inspection Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal...

Clutch Cover — removal and installation
Clutch Cover Removal Drain the engine oil (See Engine Oil Change in the Periodic Maintenance chapter). Remove: Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter) Right Lower Fairing (See Lower Fairing Removal in the Frame...

Removing and installing clutch
Clutch Removal Remove: Clutch Cover (See Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with bearing) Pusher [C] Remove: Friction Plates Steel Plates Hold the clutch hub [A] steady with the clutch holder [B],...

Exploded View of Crankshaft/transmission
No.FastenerTorqueRemarks Nmkgf·m ft·lb 1Breather Plate Bolts9.81.087 in·lbL 2Race Holder Screw4.90.5043 in·lbL 3Connecting Rod Big End Nutssee Text←← 4Crankcase Bolt (M8, L = 110 mm)27.52.820S 5Crankcase Bolt (M6, L = 32 mm)19.62.014S 6Crankcase...

Specifications of Crankshaft/transmission
ItemStandardService Limit Crankshaft, Connecting Rods Connecting Rod Bend—TIR 0.2/100 mm Connecting Rod Twist—(0.008/3.94 in.) TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)0.58 mm (0.023...

Special Tools and Sealants
Outside Circlip Pliers: 57001-144 Bearing Driver Set: 57001-1129 Kawasaki Bond (Silicone Sealant): 92104-0004 Kawasaki Bond: 92104-1064

Crankcase Splitting
Crankcase Splitting Remove the engine (See Engine Removal in the Engine Removal/Installation chapter) Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Cylinder Head (See Cylinder Head Removal in the...

Crankshaft and Connecting Rods
Crankshaft Removal Split the crankcase (See Crankcase Splitting). Remove: Camshaft Chain [A] Crankshaft [B] Crankshaft Installation Note: Olf the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main...

Removing and installing balancer
Balancer Removal Split the crankcase (See Crankcase Splitting). Pull the balancer shaft [A] with the balancer gear out of the crankcase. Balancer Installation Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing...

Transmission — removal and installation
Shift Pedal Removal Remove: Shift Lever Bolt [A] Shift Lever [B] Bolts [C] Left Front Footpeg Stay [D] with Shift Pedal [E] Remove: Footpeg Holder Bolt [A] Footpeg [B] Shift Pedal [C] Shift Pedal Installation When the new oil seals [A] are installed...

Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement Caution: Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. Using a press or puller, remove the ball bearing and/or needle bearings. Note: In the absence of the above...

Exploded View of Final drive
No.FastenerTorqueRemarks Nmkgf·m ft·lb 1Engine Sprocket Nut12512.792MO 2Rear Axle Nut10811.080 3Rear Sprocket Nuts596.044 4Speed Sensor Bolt7.80.8069 in·lbL 5Speed Sensor Bracket Bolts9.81.087 in·lb G: Apply grease. HG: Apply high-temperature...

Specifications of Final drive
ItemStandardService Limit Drive Chain Drive Chain Slack25-35 mm (1.0-1.4 in.)— Drive Chain Wear (20-link Length)317.5-318.2 mm (12.50-12.53 in.)323 mm (12.7 in.) Standard Chain: MakeENUMA— TypeEK520MVXL1— Link114 links— Sprockets Rear Sprocket...

Special Tools of Final drive
Inside Circlip Pliers: 57001-143 Bearing Driver Set: 57001-1129

Drive Chain — removal and installation
Drive Chain Slack Inspection Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment...

Sprocket, Coupling
Engine Sprocket Removal Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. Note: When...