Things That Break on the Versys 650 - Kawasaki Versys Forum
 
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post #1 of 18 (permalink) Old 11-29-2014, 10:27 AM Thread Starter
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Things That Break on the Versys 650

I got this idea from another model specific forum. A list of "common" issues with the bike. This way you can order stuff ahead, support your local dealer, add more parts to an order so you can get free shipping, or just have the peace of mind of knowing that you already have the spare at home. For some of us, that live far away from a Kawasaki dealership, or in a country with poor dealership support, waiting for a part to come to the dealership means waiting for several days, if not weeks.

So, what are the common issues on this bike? I'm thinking:

1. Clutch cable. I've already had one break on my '10 Versys with only 6,000kms. I've seen other posters that have had issues with their clutch cables too.

2. Regulator / Rectifier.

3. Stator - you need the stator cover gasket too.

4. Radiator cap. My '10 started with coolant dripping and over time the coolant boiled. My '14 has just had the dripping. Got a replacement for the '10 in Autozone, can 't recall which car it fit. But from another post, from user Invader, http://www.kawasakiversys.com/forums...3&postcount=12 we can use: Stant's 10233 or Prestone's RR-33. I cross referenced the Prestone.

5. Air filter. Just including this one as it seems many people are not aware that, even though it is reusable, it has to be replaced every 2 years.

I guess the rattling fairings are a common issue too, but no spares would fix that and not all of us really care about them.

So what else am I missing? Have you had wheel bearing failures, steering head bearing failures, broken brackets holding something or other?
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post #2 of 18 (permalink) Old 11-29-2014, 11:25 AM
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On my last trip to the North, those parts are the exact same parts I brought back with me for spares. The only additional parts I have are a set of bearings and seals for both wheels. I bought the electrical parts used on a low mileage wrecked V for about 150 total.
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post #3 of 18 (permalink) Old 11-29-2014, 11:45 AM
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FWIW - w/ my '08 at 52,5xx miles, and my '09 at 52,xxx kms, I have NOT (so far...) had ANY of those failures, and my '08 is STILL on its original chain.

I DO suggest that new owners change the clutch 'take-up' point from where the lever is FAR from the handle bars, to somewhat closer, so you're NOT trying to pull the cable apart when you pull the lever closer to the bars (as in waiting in gear at a light).


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post #4 of 18 (permalink) Old 11-29-2014, 02:50 PM
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Mode buttons

On the day I bought my V, the mode buttons on the dash went out. The previous owner had replaced the dash under warranty at 13k miles, and not it has 25k miles. Do they often fail at 13k? So, my dash is stuck on the clock setting, can't change it to the ODO or trip meters.
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post #5 of 18 (permalink) Old 11-29-2014, 07:04 PM
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2012, 3 years old with 24k km
it has only broken the rear axel nut split pin
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post #6 of 18 (permalink) Old 11-29-2014, 07:47 PM
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Here's an alternative to the OEM filter that I have been using for a year with good results,

Uni-filter Angled Pod filter>

http://www.ebay.com/itm/UNI-UNIVERSA...f333a5&vxp=mtr

Much better filtering than the skimpy OEM filter.
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post #7 of 18 (permalink) Old 11-29-2014, 08:17 PM
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No it's not. I'm guess you butchered the airbox.
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post #8 of 18 (permalink) Old 11-29-2014, 08:39 PM
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The clutch cables break on these things? Whaaaaa?
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post #9 of 18 (permalink) Old 11-29-2014, 09:46 PM
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Quote:
Originally Posted by waltermitty View Post
No it's not. I'm guess you butchered the airbox.
No the air box is fine, search JDrocks build thread and you can see photos of his installation. I did not have to alter my airbox.
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post #10 of 18 (permalink) Old 11-30-2014, 06:17 AM Thread Starter
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Quote:
Originally Posted by jdrocks View Post
what would the incident rate have to be for a failure to become "common"?

.01%, .05%, 1%, 5%, 10%? i haven't had any of the supposed common problems you mention. i did upgrade steering bearings, but it wasn't because the OEM bearings failed.
I've yet to have any of those on my '14:

Clutch:
http://www.kawasakiversys.com/forums...ad.php?t=11414
http://www.kawasakiversys.com/forums...ad.php?t=50754
http://www.kawasakiversys.com/forums...ad.php?t=39425
http://www.kawasakiversys.com/forums...ad.php?t=21893
http://www.kawasakiversys.com/forums...ad.php?t=14708

Ongoing stator thread:
http://www.kawasakiversys.com/forums...ad.php?t=16774

Radiator cap woes:
http://www.kawasakiversys.com/forums...ad.php?t=57426
http://www.kawasakiversys.com/forums...ad.php?t=57146
http://www.kawasakiversys.com/forums...ad.php?t=16368
http://www.kawasakiversys.com/forums...ead.php?t=7676

How many threads have you seen about broken throttle cables? How many threads about regulators falling off?
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post #11 of 18 (permalink) Old 11-30-2014, 06:19 AM Thread Starter
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Quote:
Originally Posted by kiko View Post
On my last trip to the North, those parts are the exact same parts I brought back with me for spares. The only additional parts I have are a set of bearings and seals for both wheels. I bought the electrical parts used on a low mileage wrecked V for about 150 total.
You know how I feel about freaking Motomex

When I had the clutch cable break on my '10 they said "none on stock, you have to order it, it will take 20 to 30 working days to get here". I commute on my bike...
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post #12 of 18 (permalink) Old 11-30-2014, 06:52 AM
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Susser Tod, must have taken some time to track down all those threads. Thanks for that.
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post #13 of 18 (permalink) Old 11-30-2014, 07:30 AM
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Only have replaced my air filter on that list. But Ive replaced swing arm bearings (under warranty deemed defective). Two chains, two front sprockets, changed rear sprocket to supersprox 44t. Valve shims. Oil and tires - 30,000 miles.

Ill add that the two chain replacing is sorta my fault, I beat the oem one pretty bad, long trips no lube no cleaning, got 18k out of it with all the abuse. Next chain got the same treatment and I took it off and still have it, I just got a slamming deal on another chain and got it and put 'er on!

Dave
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2015 Ducati Scrambler Urban Enduro / M-10
2017 Versys X300 / M-12
1966 Honda CT90

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post #14 of 18 (permalink) Old 11-30-2014, 10:20 AM
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One of the first things I did after getting my V this year was start taking it apart.

I had the airbox off to run some wiring, and I'm glad I did. I don't know why it happened, but there was a bunch of fibers from the air filter on the "bad" side, meaning in the airbox. Glad I caught it.

Something to check for all you DIYers who haven't taken it apart, yet.

2014 Versys ABS
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post #15 of 18 (permalink) Old 11-30-2014, 01:30 PM
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Quote:
Originally Posted by kiko View Post
Here's an alternative to the OEM filter that I have been using for a year with good results,

Uni-filter Angled Pod filter>

http://www.ebay.com/itm/UNI-UNIVERSA...f333a5&vxp=mtr

Much better filtering than the skimpy OEM filter.
Thanks for link!

Dave
1983 Honda XL600R / M-6
2015 Ducati Scrambler Urban Enduro / M-10
2017 Versys X300 / M-12
1966 Honda CT90

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post #16 of 18 (permalink) Old 12-01-2014, 10:21 AM
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air filter is one of those maintenance items that I haven't been able to get to since buying my bike in august. its on my list along with the valve adjustment.
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post #17 of 18 (permalink) Old 12-01-2014, 12:35 PM
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I guess I am lucky. None of those failures on my '11 with close to 30,000 miles.

My Versys Travels:


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post #18 of 18 (permalink) Old 12-01-2014, 12:57 PM
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radiator fan on mine died, "upgraded" with a 07 ninja fan
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