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

Exploded View of Clutch
No. Fastener Torque Remarks Nm kgf·m ft·lb 1 Clutch Cable Clamp Bolt 9.8 1.0 87 in·lb 2 Clutch Cable Holder Bolts 9.8 1.0 87 in·lb L 3 Clutch Cover Mounting Bolts 9.8 1.0 87 in·lb 4 Clutch Hub Nut 130 13.3 96 5 Clutch Lever Clamp Bolts 7.8 0.80 69...

Specifications of Clutch
Item Standard Service Limit Clutch Lever Free Play 2-3 mm (0.08-0.12 in.) — Clutch Friction Plate Thickness 2.92-3.08 mm (0.115-0.121 in.) 2.8 mm (0.110 in.) Friction Plate Warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) Steel Plate Warp 0.2 mm...

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. Fastener Torque Remarks Nm kgf·m ft·lb 1 Breather Plate Bolts 9.8 1.0 87 in·lb L 2 Race Holder Screw 4.9 0.50 43 in·lb L 3 Connecting Rod Big End Nuts see Text ← ← 4 Crankcase Bolt (M8, L = 110 mm) 27.5 2.8 20 S 5 Crankcase Bolt (M6, L = 32 mm)...

Specifications of Crankshaft/transmission
Item Standard Service 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 Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm...

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. Fastener Torque Remarks Nm kgf·m ft·lb 1 Engine Sprocket Nut 125 12.7 92 MO 2 Rear Axle Nut 108 11.0 80 3 Rear Sprocket Nuts 59 6.0 44 4 Speed Sensor Bolt 7.8 0.80 69 in·lb L 5 Speed Sensor Bracket Bolts 9.8 1.0 87 in·lb G: Apply grease. HG:...

Specifications of Final drive
Item Standard Service Limit Drive Chain Drive Chain Slack 25-35 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: Make ENUMA — Type EK520MVXL1 — Link 114 links — Sprockets Rear...

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...