Kawasaki KLR650 2010 Repair Service Manual

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Tipo: Motorcycle

Proveedor:

SKU: 58347

Etiquetas: 2010 Kawasaki KLR650 Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This manual pertains to the 2010 Kawasaki KLR650, a versatile dual-purpose motorcycle renowned for its robust engineering and enduring reliability. Combining on-road comfort with off-road capability, the KLR650 is powered by a 652 cc liquid-cooled single-cylinder engine and features a durable semi-double cradle frame. Its design prioritizes practicality and longevity, making it a favored choice for adventure touring, commuting, and general riding. The model's lineage, dating back to 1987, is marked by a proven platform that emphasizes dependable performance and ease of maintenance, reflecting a legacy of producing high-quality, durable motorcycles. The English-language Repair Service Manual provided herein offers comprehensive guidance for maintaining and repairing the 2010 Kawasaki KLR650. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, cooling, exhaust, transmission, drivetrain, chassis, suspension, braking, wheels, tires, and electrical systems. Furthermore, the manual includes step-by-step instructions for routine maintenance, troubleshooting common issues, disassembly and reassembly, and precise torquing specifications. This resource is designed to empower professional motorcycle technicians and advanced home mechanics with the in-depth technical knowledge required to ensure the KLR650 operates at peak performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLR650

Year:

👋 Introduction

Market Position

Target Audience:

Professional motorcycle technicians and advanced home mechanics.

Value Proposition:

Enables comprehensive maintenance, repair, and troubleshooting of the Kawasaki KLR650, reducing reliance on dealership services.

Competitive Analysis

Comparison:

Provides in-depth technical data often not found in owner's manuals or basic repair guides, crucial for complex jobs.

Key Features

Content Focus:

Detailed procedures, specifications, and troubleshooting for all motorcycle systems.

Benefit:

Empowers users with the knowledge to maintain their KLR650 to factory standards.

📋 Manual Details

Coverage Areas

Manual Type:

Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, top-end and bottom-end rebuild, cylinder, piston, camshaft, valve train, crankshaft, connecting rods, lubrication system.

Fuel System:

Carburetor disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines, vacuum operated petcock operation.

Ignition System:

CDI unit, ignition coils, spark plug specifications, timing procedures, troubleshooting.

Cooling System:

Radiator, fan operation, coolant types, bleeding procedures, thermostat.

Exhaust System:

Muffler and pipe inspection, gasket replacement.

Transmission Drivetrain:

Clutch operation, gear selection, shift mechanism, chain and sprockets inspection and replacement, final drive lubrication.

Chassis Frame:

Frame inspection, headstock bearings, swingarm and linkage lubrication and bearing replacement.

Suspension Front:

Fork disassembly, seal replacement, oil type and level, spring specifications, damping adjustments.

Suspension Rear:

Shock absorber inspection, linkage maintenance, spring preload adjustment.

Braking System:

Front and rear brake caliper service, pad replacement, master cylinder overhaul, brake fluid type and bleeding, rotor specifications.

Wheels Tires:

Spoke tensioning and truing, wheel bearing replacement, tire pressure specifications, tire wear limits.

Electrical System:

Battery testing and maintenance, charging system (stator, regulator/rectifier), lighting system, horn, starter motor, wiring diagrams.

Instrumentation Controls:

Speedometer, tachometer, indicator lights, handlebar controls, throttle and clutch cable adjustments.

Bodywork Fairings:

Panel removal and installation, graphics, windshield.

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, lubrication points, valve clearance checks, chain adjustment.

Troubleshooting:

Diagnostic procedures for common problems, electrical system faults, engine performance issues.

Repair:

Step-by-step repair instructions for all major components and systems.

Disassembly Reassembly:

Detailed instructions for taking apart and putting back together various assemblies.

Torquing Specifications:

Precise torque values for all critical fasteners.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers full rebuilds and advanced diagnostics.

📊 Manual Specifications

File Format

File Format:

Searchability:

Text-searchable, allowing for quick information retrieval.

Printability:

Printable pages for hands-on use in the workshop.

Image Quality:

High-resolution images and diagrams for clarity.

Page Count Estimate:

Typically 400-600 pages for a full service manual (exact count not provided in product info, but standard for this type).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, single-cylinder, liquid-cooled

Displacement:

652 cc (40.0 cu in)

Bore X Stroke:

100.0 x 83.0 mm (3.9 x 3.3 in)

Compression Ratio:

8.8:1

Performance

Horsepower Approx:

32.7 kW (43.9 hp) @ 6,000 rpm (claimed)

Torque Approx:

53.4 N·m (39.4 lb·ft) @ 4,500 rpm (claimed)

Fuel System

Carburetor:

Mikuni BSR32 (CV type)

Fuel Capacity:

18 L (4.8 US gal)

Lubrication System

Oil Capacity With Filter Change:

2.1 L (2.2 US qt)

Oil Type Recommended:

SAE 10W-40 API SG or SH

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 5-speed

Clutch Type:

Wet, multi-disc

Features

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

2,255 mm (88.8 in)

Width:

910 mm (35.8 in)

Height:

1,375 mm (54.1 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

210 mm (8.3 in)

Weights

Curb Weight:

194 kg (427.7 lbs)

Seat Height:

860 mm (33.9 in)

🛡️ Safety Features

Ratings

Safety Features Note:

Motorcycles of this era typically do not have formal crash ratings like automobiles. Safety is primarily passive through design.

Active Features

Brakes:

Front: Hydraulic disc; Rear: Hydraulic disc

Lighting:

Halogen headlight, LED tail light, turn signals

Passive Features

Frame Construction:

Semi-double cradle, high-tensile steel

Ergonomics:

Upright riding position for rider control and visibility

💡 Technology Features

Infotainment

Infotainment Features:

Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high beam indicator, oil warning lamp.

Driver Assistance

Assist Features:

N/A (No electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-4,000 miles or 6 months (refer to manual for exact recommendation)

Valve Clearance Check:

Every 7,500 miles or 12 months

Air Filter Cleaning:

Every 7,500 miles or as needed based on conditions

Chain Lubrication Adjustment:

Every 600 miles or as needed

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or SH

Coolant:

Permanent type antifreeze coolant (ethylene glycol based) with distilled water, 50:50 mixture

Brake Fluid:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, fork seals, wheel bearings, head stock bearings, cam chain tensioner (later models may have updated auto tensioner, but manual covers original design).

Potential Problems:

Carburetor jetting can be sensitive to altitude; some owners report issues with the stock cam chain tensioner over time, though this is often addressable with proper maintenance or aftermarket parts.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing reliable and versatile motorcycles, known for performance and durability.

Model Evolution

Klr650 Lineage:

The KLR650 platform, introduced in 1987, is renowned for its dual-purpose capability, blending on-road comfort with off-road prowess. The 2010 model represents a significant evolution with fuel injection and other updates, though the core design remains largely consistent due to its proven success.

Production

Manufacturing Location:

Japan (primary)

🏆 Awards & Recognition

Recognitions

Model Recognition:

The KLR650 platform is consistently recognized for its durability, versatility, and value, making it a popular choice for adventure touring and commuting.