🏷️ Basic Information

Make:

Kawasaki

Model:

KL650EA

Year:

2010

Product Type:

Workshop Service Manual

Format:

PDF Download

👋 Introduction

Vehicle Segment:

Dual-sport motorcycle, adventure touring.

Target Audience:

Owners and technicians seeking comprehensive repair and maintenance information for the KL650EA.

Competitors 1:

Honda Transalp, Suzuki V-Strom, Yamaha Ténéré.

Manual Benefit 1:

Provides the essential technical data for maintaining and repairing the KL650EA, ensuring optimal performance and longevity.

Manual Benefit 2:

Instant digital access eliminates shipping delays and costs.

📋 Manual Details

Engine:

Included

Transmission:

Included

Fuel System:

Included

Cooling System:

Included

Exhaust System:

Included

Ignition System:

Included

Starting System:

Included

Charging System:

Included

Suspension Front:

Included

Suspension Rear:

Included

Brakes Front:

Included

Brakes Rear:

Included

Wheels Tires:

Included

Steering:

Included

Electrical System Components:

Included

Lighting System:

Included

Instrumentation:

Included

Frame Chassis:

Included

Bodywork Fairings:

Included

Troubleshooting:

Included

Wiring Diagrams:

Included

Pages:

479

Type:

Workshop Service Manual

Purpose:

Repair and Maintenance

Language:

English

File Format:

PDF

Digital Delivery:

Instant Download

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly of engine components (cylinder head, pistons, crankshaft, etc.).

Engine Management:

Information on fuel injection, ignition timing, sensors, and ECU diagnostics.

Drivetrain:

Clutch operation, transmission gear inspection and replacement, final drive.

Chassis Suspension:

Fork and shock absorber servicing, linkage maintenance, bearing checks.

Braking System:

Brake fluid replacement, caliper overhaul, disc inspection, master cylinder service.

Electrical Diagnostics:

Comprehensive wiring diagrams for all circuits, troubleshooting guides for electrical faults.

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment, air filter cleaning/replacement.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon problems.

Component Replacement:

Detailed instructions for replacing individual parts and sub-assemblies.

Torque Specifications:

Precise torque values for all critical fasteners.

Depth:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.

Detail Level:

Detailed explanations of disassembly, assembly, adjustments, and diagnostics.

Diagnostic Tools:

Mentions diagnostic procedures potentially requiring specialized tools, though not explicitly listing them.

📊 Manual Specifications

File Type:

PDF

Searchable:

Likely searchable text within the PDF, allowing for quick information retrieval.

Printable:

Designed to be printable for workshop use.

Print Quality:

Assumed high quality due to being a professional workshop manual.

Binding:

N/A (PDF Digital Download)

Paper:

N/A (PDF Digital Download)

⚙️ Engine Specifications

Type:

Four-stroke, liquid-cooled, DOHC, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.0:1

Horsepower:

Approx. 64 hp @ 8000 rpm (varies by market and tuning)

Torque:

Approx. 43.5 lb-ft @ 7000 rpm (varies by market and tuning)

Induction:

Digital Fuel Injection with two 38mm Keihin throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane

Type:

Liquid-cooled

Coolant Type:

Kawasaki Specific Coolant or equivalent ethylene glycol-based antifreeze

Type:

Forced lubrication, wet sump

Oil Capacity W Filter:

3.2 US qt (3.0 L)

Oil Type Spec:

SAE 10W-40 API SG, SH, SJ, SL or SM

🔧 Transmission

Type:

6-speed, constant mesh

Clutch Type:

Wet, multi-disc, cable-actuated

Final Drive:

Sealed chain, 15/43T (example, verify with manual)

Transmission Oil:

API GL-4, SAE 80 or 90 hypoid gear oil (for separate gearbox oil, if applicable)

📐 Dimensions

Overall Length:

2,195 mm (86.4 in)

Overall Width:

800 mm (31.5 in)

Overall Height:

1,210 mm (47.6 in)

Wheelbase:

1,450 mm (57.1 in)

Ground Clearance:

170 mm (6.7 in)

Curb Weight:

Approx. 208 kg (459 lbs)

Fuel Tank Capacity:

17.0 L (4.5 US gal)

Front Tire:

90/90-21M/C 54S

Rear Tire:

130/80-17M/C 65S

Wheelbase Type:

Spoked

🛡️ Safety Features

Crash Safety:

N/A (Motorcycle, subject to specific country regulations and testing)

Brakes:

Disc brakes front and rear. ABS was an option on some models/markets, but likely not standard on the 2010 EA model without explicit mention.

Lighting:

Headlight, taillight, turn signals, brake lights.

💡 Technology Features

Display:

Analog tachometer, digital speedometer, LCD multi-function display (odometer, trip meter, clock, fuel gauge, etc.).

ABS:

ABS was an optional feature on some 2010 KL650EA models, but not universally standard. The manual will specify if ABS is present and its servicing requirements.

Usb Charging:

Not standard on this model year.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles (4,800 km) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 3,000 miles (4,800 km) or 6 months.

Spark Plug Check:

Every 6,000 miles (9,600 km).

Chain Lubrication:

Every 600 miles (1,000 km) or after riding in rain/wet conditions.

Valve Clearance Check:

Every 15,000 miles (24,000 km).

Brake Fluid:

DOT 4

Coolant Type:

Kawasaki Specific Coolant or equivalent (50/50 mix with distilled water)

Common Wear Item 1:

Clutch plates may wear over time, especially with aggressive riding.

Common Wear Item 2:

Chain and sprockets are wear items and require regular adjustment and lubrication.

Potential Issue 1:

Some models experienced doohickey (output shaft lever) issues, though Kawasaki made improvements over the years. The manual will detail inspection and replacement.

Potential Issue 2:

Exhaust system corrosion can occur in certain climates.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for innovation and performance across various segments, including off-road, sport, and touring.

Kl650 Lineage:

The KL650 platform, particularly the KLR650, has a robust heritage dating back to the 1980s, evolving as a reliable and versatile dual-sport motorcycle. The KL650EA designation refers to a specific variant within this lineage for the 2010 model year.

Manufacturing Location:

Primarily manufactured in Japan, with some global assembly.

🏆 Awards & Recognition

Kl650 Reputation:

The KLR650 (and its variants) is widely recognized for its reliability, affordability, and go-anywhere capability, making it a popular choice for adventure touring and commuting.