Category:
Dual-sport motorcycle, adventure touring
Segment Appeal:
Known for its ruggedness, reliability, affordability, and versatility for both on-road commuting and off-road exploration.
Key Competitors 2010:
Honda Transalp (varies by market), Suzuki DR650SE, Yamaha XT660R/X.
Engine Type:
Single-cylinder, liquid-cooled, DOHC, 4-valve
Fueling:
Electronic Fuel Injection (EFI) for precise fuel delivery and emissions control.
Suspension Design:
Long-travel telescopic front forks and adjustable rear monoshock suspension for off-road capability.
Durability:
Renowned for its robust construction and ability to withstand demanding conditions.
Ergonomics:
Upright riding position, comfortable for long-distance touring.
Engine:
Detailed breakdown of engine components, including cylinder head, valves, piston, crankshaft, camshaft, lubrication system, cooling system, and fuel injection.
Transmission:
Clutch operation, gearbox internals, gear shifting mechanism, and lubrication.
Drivetrain:
Chain and sprocket inspection, adjustment, and replacement; rear swingarm and bearing service.
Suspension:
Front fork (telescopic) disassembly, assembly, oil levels, seal replacement, and rear shock absorber service and adjustment.
Brakes:
Front and rear brake system diagnosis, pad replacement, caliper service, master cylinder overhaul, bleeding procedures, and hydraulic line maintenance.
Electrical System:
Complete wiring diagrams, charging system (stator, regulator/rectifier), ignition system, lighting, instrumentation, starting system, and battery maintenance.
Fuel System:
Fuel injection system (EFI) components, fuel pump, injectors, throttle body, idle speed control (ISC), and fuel tank maintenance.
Cooling System:
Radiator, fan, thermostat, hoses, and coolant specifications and replacement.
Exhaust System:
Muffler, exhaust pipe inspection, and gasket replacement.
Frame And Bodywork:
Chassis components, seat, fairings, fuel tank removal/installation, and fenders.
Wheels And Tires:
Tire inspection, replacement, wheel bearing service, and spoke tensioning (for spoked wheels).
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant replacement, spark plug checks, air filter cleaning/replacement, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and braking issues. Includes flowcharts and symptom-based fault finding.
Rebuild Procedures:
Step-by-step guides for engine top-end rebuild (cylinder head, piston), transmission overhaul, carburetor (if applicable, though KLR650 2010 is EFI), and suspension component rebuilding.
Diagnostics:
Fault code retrieval (if applicable to the model's diagnostic system), electrical system testing, and fuel system pressure testing.
Specifications:
Torque values for all fasteners, engine timing, valve clearances, fluid capacities, electrical specifications, and dimensional data.
Depth:
Comprehensive, covering everything from basic user maintenance to advanced engine and electrical system repairs, suitable for both novice DIY mechanics and experienced technicians.
Engine Type:
Four-stroke, single-cylinder, DOHC, four valves
Displacement:
651 cc (cubic centimeters)
Bore X Stroke:
100.0 mm x 83.0 mm (approximate, typical for this generation)
Compression Ratio:
8.8:1 (typical for this generation)
Horsepower:
Approximately 46 hp @ 6500 rpm (varies slightly by market and tune)
Torque:
Approximately 38 lb-ft @ 5000 rpm (varies slightly by market and tune)
Fuel Delivery:
Electronic Fuel Injection (EFI), Dual throttle valves (DTV) for improved throttle response.
Fuel Type:
Unleaded gasoline, minimum octane rating 87 (AKI)
Cooling Method:
Liquid-cooled
Oil Type Spec:
SAE 10W-40 API SG, SH, SJ, SL, SM or SN, JASO MA or MA2
Oil Capacity W Filter:
Approx. 2.4 L (2.5 US qt)
Type:
5-speed constant mesh, return type
Clutch Type:
Wet, multi-plate
Transmission Options:
N/A (Standard 5-speed manual)
Gear Ratios:
Specific gear ratios are detailed within the manual for each gear.
Final Drive:
O-ring sealed chain, 525 series
Transmission Oil Spec:
Same as engine oil: SAE 10W-40 API SG, SH, SJ, SL, SM or SN, JASO MA or MA2
Transmission Oil Capacity:
Approx. 2.2 L (2.3 US qt)
Oil Change Interval:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Air Filter Check Interval:
Inspect every 6,000 km (3,700 mi), clean/replace as needed. More frequent in dusty conditions.
Valve Clearance Check Interval:
Every 24,000 km (15,000 mi) or 24 months.
Chain Maintenance Interval:
Lubricate and adjust every 1,000 km (600 mi) or more frequently as needed.
Coolant Type:
Kawasaki Coolant 50/50 (or equivalent ethylene glycol-based antifreeze with distilled water).
Common Wear Items:
Clutch plates, fork seals, wheel bearings, drive chain and sprockets are typical wear items requiring periodic inspection and replacement.
Fuel Pump Reliability:
Some reports of early fuel pump failures, though generally robust. Manual provides diagnostic steps.
Charging System Inspection:
Regular inspection of the regulator/rectifier and stator is recommended, especially for high-mileage bikes or those used in extreme conditions.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and innovation across various segments.
Klr Lineage:
The KLR650 platform has been a cornerstone for Kawasaki in the dual-sport market since its introduction in the mid-1980s, undergoing gradual refinements over the years rather than radical redesigns.
2010 Update Context:
The 2010 model represents a significant update to the original KLR650 design, incorporating electronic fuel injection, a larger fuel tank, improved suspension, and updated styling. This generation is often referred to as the 'second generation' KLR650.
Manufacturing Location:
Primarily manufactured in Japan.
