Kawasaki · Modern chain-drive motorcycle (2000-)

Versys 650

Library entry covers 2007-2026

18 factory 32 guideline

Published source

2015 Kawasaki Versys 650 Service Manual, Periodic Maintenance Chart 2-3 to 2-4

Factory workshop manual. Covers 2015 model year service manual.

Open the source

50 items for a 2016 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2016 Kawasaki Versys 650

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 400 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain lubrication condition. Factory: Every 600 km (400 mile)

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain slack. Factory: Every 1 000 km (600 mile)

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

6 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,800 mi

1 item

Check brake pads and discs

Brakes

Factory

Manual: Brake pad wear - inspect. Factory: Every column from 6,000 km

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

6 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,600 mi or 12 months

4 items

Change engine oil

Engine

Factory

Manual: Engine oil and oil filter. Factory: Initial 1,000 km (600 mi); marks at 12/24 x1000 km; columns 1/6/12/18/24 x1000 km (0.6/3.8/7.6/11.4/15.2 mi)
Replace oil filter

Engine

Factory

Manual: Engine oil and oil filter. Factory: Replaced together with oil
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play - inspect. Factory: Year; marks at 1/6/12/24 x1000 km
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Chassis parts - lubricate. Factory: Year; marks at 12/24 x1000 km

Every 7,600 mi

3 items

Replace spark plugs

Engine

Factory

Manual: Spark plugs - change. Factory: Marks at 12/24 x1000 km
Synchronize throttle bodies

Fuel and air

Factory

Manual: Engine vacuum synchronization - inspect. Factory: Marks at 12/24 x1000 km
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear. Factory: Marks at 12/24 x1000 km

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 11,400 mi

1 item

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element - change. Factory: Single change mark at 18,000 km (11,400 mi)

Every 12,000 mi or 2 years

2 items

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,200 mi or 2 years

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearings - lubricate. Factory: 2 years; mark at 24,000 km
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (front and rear) - change. Factory: 2 years; mark at 24,000 km

Every 15,200 mi

1 item

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Valve clearance (US and CA Models). Factory: Mark at 24,000 km; other markets every 42 000 km (26 250 mile)

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 22,500 mi or 3 years

1 item

Replace coolant

Engine

Factory

Manual: Coolant, water hoses and O-rings - change. Factory: 3 years or every 36 000 km (22 500 mile)

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 4 years

1 item

Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Rubber parts of brake master cylinder and caliper - change. Factory: 4 years or every 48 000 km (30 000 mile)

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses - change. Factory: 4 years

Every 5 years

1 item

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose - change. Factory: Every 5 years

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.