Kawasaki KLE650CAF 2010 Service Repair Manual

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The KLE650CAF, produced in 2010, is a versatile adventure touring motorcycle designed for riders who desire a blend of on-road comfort and capability for varied terrain. This model draws upon...

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Typ: Motorcycle

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Art.-Nr: 92965

Stichworte: 2010 Kawasaki KLE650CAF Misc Motorcycle Motorcycles

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Beschreibung

The KLE650CAF, produced in 2010, is a versatile adventure touring motorcycle designed for riders who desire a blend of on-road comfort and capability for varied terrain. This model draws upon the reliable parallel-twin engine platform shared with the popular ER-6 series, known for its smooth power delivery and user-friendly nature. Its engineering emphasizes a balance between performance and practicality, making it suitable for daily commuting, longer touring excursions, and navigating unpaved roads. The KLE650's design offers an upright riding position and a chassis built for stability and rigidity, reflecting a legacy of producing dependable and enjoyable motorcycles. This comprehensive Service Repair Manual provides detailed information for the maintenance, repair, and troubleshooting of your 2010 KLE650CAF. It covers all essential systems, including the engine mechanicals, fuel injection, ignition, transmission, drivetrain, electrical systems, suspension, brakes, cooling system, and chassis. Within its pages, you will find step-by-step instructions for regular maintenance, component overhauls, and adjustments, along with critical torque specifications. The manual also offers guidance on diagnosing and resolving common issues, ensuring that owners, mechanics, and technicians have the necessary resources to keep this motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE650

Model Code:

KLE650CAF

Year:

Codes

Chassis Code:

ER650A

Engine Code:

ER650AE

👋 Introduction

Market Position

Vehicle Segment:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.

Competitive Analysis

Key Competitors:

BMW F650GS, Suzuki V-Strom DL650, Honda NC700X (later models), Yamaha XT660Z Ténéré.

Key Features

Engine Platform:

Utilizes the same reliable parallel-twin engine as the popular ER-6f/ER-6n series, known for its smoothness and user-friendliness.

Versatility:

Designed for both on-road comfort and the capability to handle unpaved roads, offering a balanced adventure riding experience.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

Page Count

Estimated Page Count:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, internal components, cylinder head, piston, crankshaft, lubrication system, cooling system.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel filter, fuel tank.

Ignition System:

Ignition coils, spark plugs, ECU control, timing.

Transmission Drivetrain:

Clutch operation and maintenance, gearbox assembly, shift mechanism, final drive (chain and sprockets).

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starting system, fuses, relays, ECU.

Suspension:

Front fork (telescopic, cartridge type) overhaul and adjustment, rear shock absorber, linkage system.

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, bleeding procedure.

Cooling System:

Radiator, coolant, water pump, thermostat, cooling fan, hoses.

Chassis Frame:

Frame inspection, steering head bearing maintenance, wheel bearings.

Bodywork Fittings:

Fairings, seat, fuel tank removal/installation, instrument panel.

Procedures Included

Regular Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, brake pad checks, tire pressure checks, general inspection.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and mechanical issues. Fault code interpretation (if applicable).

Component Overhaul:

Detailed step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components.

Adjustment:

Throttle cable, clutch cable, idle speed (if applicable), suspension preload.

Replacement:

Gaskets, seals, bearings, filters, spark plugs, brake pads, bulbs.

Torque Specifications:

Essential torque values for all critical fasteners to ensure proper assembly and prevent damage.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes diagnostic information.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing quick access to specific topics.

Print Quality

Clarity:

High-resolution, ensuring clear text and legible diagrams/illustrations.

Binding Type

Format Type:

Digital Download (PDF)

Paper Type

Format Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Valve Train:

DOHC, 8 valves (2 per cylinder)

Performance

Horsepower Ps:

Approx. 72 PS @ 8,000 rpm (EU spec, may vary slightly by region)

Torque Nm:

Approx. 64 Nm @ 7,000 rpm (EU spec, may vary slightly by region)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Fuel Type:

Unleaded gasoline

Fuel Capacity:

15 Liters (3.3 Gallons)

Cooling System

Coolant Type:

Ethylene glycol based coolant (e.g., Kawasaki Coolant Type 2 or equivalent)

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multi-disc

Features

Drive Type:

Sealed chain, 525 pitch

Fluid Specifications

Transmission Oil:

API GL-4, SAE 80W-90 hypoid gear oil

📐 Dimensions

Exterior

Length:

2,195 mm (86.4 in)

Width:

800 mm (31.5 in)

Height:

1,330 mm (52.4 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

170 mm (6.7 in)

Seat Height:

800 mm (31.5 in)

Weights

Dry Weight:

192 kg (423 lbs)

Curb Weight:

Approx. 209 kg (461 lbs) (fully fueled)

Front Tire:

110/80-19 M/C 59S

Rear Tire:

130/80-17 M/C 65S

Wheel Bolt Pattern:

N/A (Cast wheels)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not typically rated in the same manner as automobiles. Safety relies on rider skill and adherence to maintenance.

Active Features

Braking System:

Dual disc front brakes, single disc rear brake. Optional ABS available on some models/markets.

Lighting:

Halogen headlights, LED taillight.

Passive Features

Frame Construction:

High-tensile steel backbone frame designed for stability and rigidity.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD display with speedometer, tachometer, fuel gauge, odometer, trip meters, clock, and indicator lights.

Driver Assistance

ABS Availability:

Optional Anti-lock Braking System (ABS) may be fitted to some specific configurations of the 2010 model.

Connectivity

Connectivity Features:

N/A (Motorcycle technology of this era typically focuses on core performance and safety features, not advanced connectivity.)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 6,000 km (3,700 miles) or annually.

Air Filter Cleaning:

Every 6,000 km (3,700 miles), replace as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Chain Adjustment:

Check every 1,000 km (600 miles).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified (e.g., Kawasaki Genuine Oil 10W-40)

Engine Oil Capacity:

Approx. 2.0 Liters (2.1 US qt) without filter change, 2.3 Liters (2.4 US qt) with filter change.

Coolant Capacity:

Approx. 1.6 Liters (1.7 US qt)

Brake Fluid:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, brake pads, fork seals (typical motorcycle wear items).

Potential Concerns:

Some owners report a slight vibration at certain RPMs, characteristic of parallel-twin engines. Regular chain maintenance is crucial for drivetrain longevity.

Part Numbers

Oil Filter Example:

Kawasaki part number 16099-004 (or equivalent aftermarket)

Air Filter Example:

Kawasaki part number 11013-0007 (or equivalent aftermarket)

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing reliable and performance-oriented motorcycles, particularly in the sportbike and off-road segments. The KLE lineage represents their entry into the versatile adventure-touring market.

Model Evolution

Kle Series:

The KLE650 Versys shares its platform and engine with the successful ER-6 series, offering a more upright riding position and longer-travel suspension suitable for touring and varied terrain. It evolved from earlier Kawasaki dual-purpose models.

Production

Manufacturing Location:

Primarily manufactured in Thailand.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 2010 KLE650CAF are not widely publicized, the ER-6 platform it shares has generally received positive reviews for its value, reliability, and user-friendliness.