Periodic service of motorcycle Kawasaki KLE 650 (Versys, 2007-2025)
See this section in russian language
List of abbreviations
A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center...
A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center...
Country and area codes
AT Austria GB United Kingdom CA Canada MY Malaysia CH Switzerland WVTA Whole Vehicle Type Approval DE Germany
AT Austria GB United Kingdom CA Canada MY Malaysia CH Switzerland WVTA Whole Vehicle Type Approval DE Germany
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference. Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own...
In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference. Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own...
General information about maintenance — inspection
Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions,...
Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions,...
Model Identification
KLE650B7F Left Side View KLE650B7F Right Side View Frame Number Engine Number
KLE650B7F Left Side View KLE650B7F Right Side View Frame Number Engine Number
General Specifications
Items KLE650A7F, KLE650B7F Dimensions Overall Length 2 125 mm (83.7 in.) Overall Width 840 mm (33.1 in.) Overall Height 1 315 mm (51.8 in.) Wheelbase 1 415 mm (55.7 in.) Road Clearance 180 mm (7.1 in.) Seat Height 840 mm (33.1 in.) Dry Mass:...
Items KLE650A7F, KLE650B7F Dimensions Overall Length 2 125 mm (83.7 in.) Overall Width 840 mm (33.1 in.) Overall Height 1 315 mm (51.8 in.) Wheelbase 1 415 mm (55.7 in.) Road Clearance 180 mm (7.1 in.) Seat Height 840 mm (33.1 in.) Dry Mass:...
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY, INSPECTION Whichever comes...
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY, INSPECTION Whichever comes...
Periodic Replacement Parts
FREQUENCY, CHANGE/REPLACE ITEM Whichever comes first → * ODOMETER READING x 1 000 km (x 1 000 mile) See Page Every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) Air cleaner element #2 years 2-44 Fuel hose 4 years • 2-44 Coolant 3 years • 2-45 Radiator...
FREQUENCY, CHANGE/REPLACE ITEM Whichever comes first → * ODOMETER READING x 1 000 km (x 1 000 mile) See Page Every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) Air cleaner element #2 years 2-44 Fuel hose 4 years • 2-44 Coolant 3 years • 2-45 Radiator...
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to...
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to...
Specifications of periodic maintenance
Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 2-3 mm (0.08-0.12 in.) — Idle Speed 1 300±50 r/min (rpm) — Bypass Screws (Turn Out) 0-2 1/2 (for reference) — Engine Vacuum 37.9±1.3 kPa (285±10 mmHg) — Air Cleaner Element...
Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 2-3 mm (0.08-0.12 in.) — Idle Speed 1 300±50 r/min (rpm) — Bypass Screws (Turn Out) 0-2 1/2 (for reference) — Engine Vacuum 37.9±1.3 kPa (285±10 mmHg) — Air Cleaner Element...
Special Tools
Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Oil Filter Wrench: 57001-1249 Vacuum Gauge: 57001-1369 Throttle Sensor Setting Adapter: 57001-1538 Extension Tube: 57001-1578 Pilot Screw Adjuster, E: 57001-1603
Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Oil Filter Wrench: 57001-1249 Vacuum Gauge: 57001-1369 Throttle Sensor Setting Adapter: 57001-1538 Extension Tube: 57001-1578 Pilot Screw Adjuster, E: 57001-1603
Air Cleaner Element Cleaning
Note: OIn dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or on muddily roads, the element should be cleaned immediately. Warning: If dirt or dust is allowed to pass through into...
Note: OIn dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or on muddily roads, the element should be cleaned immediately. Warning: If dirt or dust is allowed to pass through into...
Throttle Control System Inspection
Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and completely by the return spring in all steering positions. If the throttle grip doesn't return properly, check the throttle cable routing,...
Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and completely by the return spring in all steering positions. If the throttle grip doesn't return properly, check the throttle cable routing,...
Engine Vacuum Synchronization Inspection
Note: These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. Situate the motorcycle so that it is vertical. Pull off the rubber caps [A] from the fitting of each throttle body....
Note: These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. Situate the motorcycle so that it is vertical. Pull off the rubber caps [A] from the fitting of each throttle body....
Idle Speed Inspection
Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to...
Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to...
Idle Speed Adjustment
Start the engine and warm it up thoroughly. Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
Start the engine and warm it up thoroughly. Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
Fuel Hose Inspection (fuel leak, damage, installation condition)
OIf the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (See Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the...
OIf the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (See Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the...
Coolant Level Inspection
Note: Check the level when the engine is cold (room orambi-ent temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (do not use the sidestand). If the coolant level is lower than the "L" level line...
Note: Check the level when the engine is cold (room orambi-ent temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (do not use the sidestand). If the coolant level is lower than the "L" level line...
Radiator Hose Damage and Installation Condition Inspection
The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and...
The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and...
Air Suction System Damage Inspection
Remove: Fuel Tank (See Fuel Tank Removal in the Fuel System chapter) Fuel Hose (See Fuel Hose Replacement ) Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool -...
Remove: Fuel Tank (See Fuel Tank Removal in the Fuel System chapter) Fuel Hose (See Fuel Hose Replacement ) Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool -...
Valve Clearance Inspection
Note: Valve clearance must be checked and adjusted when the engine is cold (room temperature). Remove: Cylinder Head Cover (See Cylinder Head Cover Removal in the Engine Top End chapter) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Check the...
Note: Valve clearance must be checked and adjusted when the engine is cold (room temperature). Remove: Cylinder Head Cover (See Cylinder Head Cover Removal in the Engine Top End chapter) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Check the...
Valve Clearance Adjustment
To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note: Mark and record the valve lifter and shim locations so they can be reinstalled in their...
To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note: Mark and record the valve lifter and shim locations so they can be reinstalled in their...
Valve clearance adjustment chart inlet valve
PRESENT SHIM Example PART No. (92180-) 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 MARK 50 55 60 65 70 75 80 85 90 95 00 05 10 15 20 25 30 35 40 45 50 THICKNESS (mm) 2. 50 2. 55 2. 60 2....
PRESENT SHIM Example PART No. (92180-) 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 MARK 50 55 60 65 70 75 80 85 90 95 00 05 10 15 20 25 30 35 40 45 50 THICKNESS (mm) 2. 50 2. 55 2. 60 2....
Valve clearance adjustment chart exhaust valve
PRESENT SHIM Example PART No. (92180-) 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 MARK 50 55 60 65 70 75 80 85 90 95 00 05 10 15 20 25 30 35 40 45 50 THICKNESS (mm) 2. 50 2. 55 2. 60 2....
PRESENT SHIM Example PART No. (92180-) 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 1054 MARK 50 55 60 65 70 75 80 85 90 95 00 05 10 15 20 25 30 35 40 45 50 THICKNESS (mm) 2. 50 2. 55 2. 60 2....
Clutch Operation Inspection
Pull the clutch lever just enough to take up the free play [A]. Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either...
Pull the clutch lever just enough to take up the free play [A]. Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either...
Air Pressure Inspection
Remove the air valve cap. Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Install the air valve cap. Adjust the tire...
Remove the air valve cap. Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Install the air valve cap. Adjust the tire...
Wheel/Tire Damage Inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread. Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Visually inspect...
Remove any imbedded stones [A] or other foreign particles [B] from tread. Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Visually inspect...
Tire Tread Wear, Abnormal Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires...
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires...
Wheel Bearing Damage Inspection
Raise the front wheel off the ground with jack (See Front Wheel Removal in the Wheels/Tires chapter). Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin...
Raise the front wheel off the ground with jack (See Front Wheel Removal in the Wheels/Tires chapter). Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin...
Drive Chain Lubrication Condition Inspection
If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. Caution:...
If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. Caution:...
Drive Chain Slack Inspection
Note: Check the slack with the motorcycle setting on its sidestand. Clean the chain if it is dirty, and lubricate it if it appears dry. Check the wheel alignment (See Wheel Alignment Inspection ). Rotate the rear wheel to find the position where the...
Note: Check the slack with the motorcycle setting on its sidestand. Clean the chain if it is dirty, and lubricate it if it appears dry. Check the wheel alignment (See Wheel Alignment Inspection ). Rotate the rear wheel to find the position where the...
Drive Chain Slack Adjustment
Raise the rear wheel off the ground with the stand. Remove the cotter pin [A], and loosen the axle nut [B]. Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the right and left chain adjusters [D] evenly. If the chain...
Raise the rear wheel off the ground with the stand. Remove the cotter pin [A], and loosen the axle nut [B]. Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the right and left chain adjusters [D] evenly. If the chain...
Wheel Alignment Inspection
Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (See Drive...
Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (See Drive...
Drive Chain Wear Inspection
Remove the chain cover (See Swingarm Removal in the Suspension chapter). Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain...
Remove the chain cover (See Swingarm Removal in the Suspension chapter). Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain...
Chain Guide Inspection
Remove the swingarm (See Swingarm Removal in the Suspension chapter). Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage.
Remove the swingarm (See Swingarm Removal in the Suspension chapter). Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage.
Brake Fluid Leak (Brake Hose and Pipe) Inspection
For models equipped with an ABS, remove the rear fender front (See Rear Fender Front Removal in the Frame chapter). Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped models) [B] and...
For models equipped with an ABS, remove the rear fender front (See Rear Fender Front Removal in the Frame chapter). Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped models) [B] and...
Brake Hose and Pipe Damage and Installation Condition Inspection
For models equipped with an ABS, remove the rear fender front (See Rear Fender Front Removal in the Frame chapter). Inspect the brake hoses, fittings and pipes (ABS equipped models) for deterioration, cracks and signs of leakage. The high pressure...
For models equipped with an ABS, remove the rear fender front (See Rear Fender Front Removal in the Frame chapter). Inspect the brake hoses, fittings and pipes (ABS equipped models) for deterioration, cracks and signs of leakage. The high pressure...
Brake Operation Inspection
Inspect the operation of the front and rear brake by running the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. Warning: When inspecting by running the vehicle, note a surrounding traffic situation enough...
Inspect the operation of the front and rear brake by running the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. Warning: When inspecting by running the vehicle, note a surrounding traffic situation enough...
Brake Fluid Level Inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. Note: Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line,...
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. Note: Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line,...
Brake Pad Wear Inspection
Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: Front: 4.5 mm (0.18 in.) Rear: 5.0 mm...
Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: Front: 4.5 mm (0.18 in.) Rear: 5.0 mm...
Brake Light Switch Operation Inspection
Turn on the ignition switch. The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch. Disconnect the connector [A]. Turn the brake...
Turn on the ignition switch. The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch. Disconnect the connector [A]. Turn the brake...
Front Forks/Rear Shock Absorber Operation Inspection
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (See Front fork ) Oil Change in the Suspension chapter). Pump the seat down and up...
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (See Front fork ) Oil Change in the Suspension chapter). Pump the seat down and up...
Front Fork Oil Leak Inspection
Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary.
Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
Steering Play Inspection
Raise the front wheel off the ground with jack (See Front Wheel Removal in the Wheels/Tires chapter). With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the...
Raise the front wheel off the ground with jack (See Front Wheel Removal in the Wheels/Tires chapter). With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the...
Steering Play Adjustment
Remove the steering stem head (See Stem, Stem Bearing Removal ). Bend the claws [A] of the claw washer straighten. Remove the steering stem locknut [B] and claw washer [C]. Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100...
Remove the steering stem head (See Stem, Stem Bearing Removal ). Bend the claws [A] of the claw washer straighten. Remove the steering stem locknut [B] and claw washer [C]. Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100...
Steering Stem Bearing Lubrication
Remove the steering stem (See Stem, Stem Bearing Removal in the Steering chapter). Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame...
Remove the steering stem (See Stem, Stem Bearing Removal in the Steering chapter). Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame...
Lights and Switches Operation Inspection
First Step Turn on the ignition switch. The following lights should goon according to below table. City Lights [A] goes on Taillight [B] goes on License Plate Light [C] goes on Meter Panel Illumination Light (LED) [D] goes on Meter Panel LCD [E]...
First Step Turn on the ignition switch. The following lights should goon according to below table. City Lights [A] goes on Taillight [B] goes on License Plate Light [C] goes on Meter Panel Illumination Light (LED) [D] goes on Meter Panel LCD [E]...
Headlight Aiming Inspection
Inspect the headlight beam for aiming. If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment Turn the horizontal adjuster [A] on the headlight with the screwdriver [B]...
Inspect the headlight beam for aiming. If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment Turn the horizontal adjuster [A] on the headlight with the screwdriver [B]...
Sidestand Switch Operation Inspection
Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up...
Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up...
Engine Stop Switch Operation Inspection
First step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect or replace the following item. Engine Stop Switch...
First step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect or replace the following item. Engine Stop Switch...
Chassis Parts Lubrication
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant. Note: Whenever the vehicle has been operated under wet or rainy...
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant. Note: Whenever the vehicle has been operated under wet or rainy...
Bolts, Nuts and Fasteners Tightness Inspection
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note: For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are...
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note: For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are...
Bolt, Nut and Fastener to be checked
Engine: Clutch Lever Pivot Nut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Brake Lever Pivot Nut Brake Pedal...
Engine: Clutch Lever Pivot Nut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Brake Lever Pivot Nut Brake Pedal...
Air Cleaner Element Replacement
Refer to the Air Cleaner Element Cleaning . Fuel Hose Replacement Caution: When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made...
Refer to the Air Cleaner Element Cleaning . Fuel Hose Replacement Caution: When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made...
Coolant Change
Warning: To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash...
Warning: To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash...
Engine Oil Change
Situate the motorcycle so that it is vertical after warming up the engine. Unscrew the oil filler plug [A]. Place on oil pan beneath the engine. Remove the engine oil drain bolt [A] to drain the oil. The oil in the oil filter can be drained by...
Situate the motorcycle so that it is vertical after warming up the engine. Unscrew the oil filler plug [A]. Place on oil pan beneath the engine. Remove the engine oil drain bolt [A] to drain the oil. The oil in the oil filter can be drained by...
Oil Filter Replacement
Drain the engine oil (See Engine Oil Change ). Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 Replace the filter with a new one. Apply engine oil to the gasket [A] before installation. Tighten...
Drain the engine oil (See Engine Oil Change ). Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 Replace the filter with a new one. Apply engine oil to the gasket [A] before installation. Tighten...
Brake Hose and Pipe Replacement
Caution: Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove the banjo bolts [A]. When removing the brake hose, take care not to spill the brake fluid on the painted or plastic...
Caution: Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove the banjo bolts [A]. When removing the brake hose, take care not to spill the brake fluid on the painted or plastic...
Brake Fluid Change
Note: The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove the reservoir cap and diaphragm. Remove the rubber cap from the bleed valve...
Note: The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove the reservoir cap and diaphragm. Remove the rubber cap from the bleed valve...
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly Remove the front master cylinder (See Front Master Cylinder Removal in the Brakes chapter). Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. Unscrew the locknut and pivot bolt, and...
Front Master Cylinder Disassembly Remove the front master cylinder (See Front Master Cylinder Removal in the Brakes chapter). Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. Unscrew the locknut and pivot bolt, and...
Caliper Rubber Parts Replacement
Front Caliper Disassembly Remove: Front Caliper (See Front Caliper Removal in the Brakes chapter) Brake Pads (See Front Brake Pad Removal in the Brakes chapter) Using compressed air, remove the pistons. Cover the piston area with a clean, thick...
Front Caliper Disassembly Remove: Front Caliper (See Front Caliper Removal in the Brakes chapter) Brake Pads (See Front Brake Pad Removal in the Brakes chapter) Using compressed air, remove the pistons. Cover the piston area with a clean, thick...
Spark Plug Replacement
Remove: Stick Coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter) Remove the spark plugs using the 16 mm plug wrench [A]. Owner's Tool - Spark Plug Wrench, 16 mm: 92110-1132 Replace the spark...
Remove: Stick Coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter) Remove the spark plugs using the 16 mm plug wrench [A]. Owner's Tool - Spark Plug Wrench, 16 mm: 92110-1132 Replace the spark...
Troubleshooting Guide of Motorcycle
Note: Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the...
Note: Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the...
Similar subsections of other motorcycle models
Maintenance motorcycle Aprilia Shiver SL 750 (2007-2016)
Maintenance motorcycle Ducati Monster 696 (2007-2014)
- Information for owner
- Maintenance
- Engine and systems
- Engine repair
- Fuel system
- Cooling system
- Lubrication system
- Transmission
- Running gear and frame
- Frame and hinged elements
- Suspension
- Handlebar
- Brake system
- ABS (anti-lock brake system)
- Wheels and tires
- Electric equipment
- Equipment and devices
- Starting and charging system
Aprilia: RS-series Shiver (map) BMW: F-series R-series K-series (map) Ducati: ST series Monster (map) Harley: Street Sportster V-Rod (map) Honda: Africa Twin CB series VTX series (map) Kawasaki: ZX-6R Versys Vulcan (map) Suzuki: DR-Z V-Strom Boulevard (map) Triumph: Rocket Street Triple Tiger (map) Yamaha: Fazer DragStar R1 (map)