Kawasaki KLE650DAF 2010 Factory Service Repair Manual

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Mots clés: 2010 Kawasaki KLE650DAF Motorcycle

Variantes de produits

Description

This document provides comprehensive information for the 2010 motorcycle, also known as the Versys 650 in many markets. As an adventure sport touring motorcycle, the KLE650 is engineered for versatility, offering riders a comfortable and practical machine suitable for daily commuting, long-distance touring, and light off-road excursions. Its design philosophy emphasizes a balance between touring comfort and agile handling, powered by a liquid-cooled, parallel-twin engine with a displacement of 649 cc. The model's semi-double cradle steel frame contributes to its stability and rider-friendly ergonomics, making it a capable option in its segment. This factory service repair manual is designed to be an authoritative resource for the maintenance, troubleshooting, and repair of the 2010 motorcycle. It covers all major systems, including the engine, fuel system, ignition, cooling, transmission, drivetrain, chassis, suspension, brakes, electrical system, and instrumentation. Detailed procedures for regular maintenance, component disassembly and reassembly, adjustments, and diagnostics are included, along with critical technical specifications such as torque values and fluid capacities. This manual is an essential tool for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE650

Year:

Model Code:

KLE650DAF

Product Type:

Factory Service Repair Manual

Vehicle Type:

Motorcycle

Codes

Manual File Name Suggestion:

Kawasaki_KLE650DAF_2010_Factory_Service_Repair_Manual.pdf

👋 Introduction

Market Position

Category:

Adventure Sport Touring Motorcycle

Target Audience:

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

Competitive Analysis

Competitors 2010:

Suzuki V-Strom 650, Honda Transalp XL700V (in some markets), BMW F650GS (previous generation)

Key Features

Engine Layout:

Parallel-twin

Chassis Type:

Semi-double cradle, steel

Design Philosophy:

Combines comfort and practicality of a touring bike with some off-road capability

📋 Manual Details

Coverage Areas

Model Variants Covered:

KLE650DAF

Model Years Covered:

Page Count

Estimated Pages:

Hundreds (specific count not provided in product info)

Manual Type

Type:

Factory Service Repair Manual

Purpose:

Comprehensive repair, maintenance, and troubleshooting

Language

Language:

English (presumed, standard for factory manuals from major manufacturers)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, specifications, tuning

Fuel System:

Fuel injection, fuel pump, injectors, fuel tank, lines

Ignition System:

Ignition coils, spark plugs, ECU, sensors

Cooling System:

Radiator, fan, coolant, water pump, thermostat

Transmission:

Clutch, gearbox, shift mechanism, internal components, fluid

Drivetrain:

Chain, sprockets, rear suspension linkage

Chassis:

Frame, subframe, body panels, fairings

Suspension Front:

Front forks, seals, springs, oil, adjustments

Suspension Rear:

Rear shock absorber, linkage, adjustments

Brakes Front:

Brake calipers, discs, master cylinder, hoses, fluid, ABS (if applicable)

Brakes Rear:

Brake caliper, disc, master cylinder, hoses, fluid, ABS (if applicable)

Wheels And Tires:

Wheel bearings, tire pressures, rim specifications

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter, horn, fuses

Instrumentation And Controls:

Dashboard, switches, levers, cables

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable)

Lubrication System:

Oil pump, oil filter, oil passages

Procedures Included

Maintenance:

Regular scheduled maintenance, checks, adjustments

Troubleshooting:

Diagnostic charts, common problems and solutions

Repair:

Step-by-step disassembly and reassembly of all major components

Rebuilds:

Complete engine, transmission, and suspension rebuild procedures

Adjustments:

Valve clearance, chain tension, clutch, throttle, suspension

Diagnostics:

Fault code interpretation, electrical system testing

Specifications:

Torque values, clearances, fluid capacities, electrical data

Technical Depth

Depth:

Factory-level detail, suitable for professional mechanics and experienced DIYers

Accuracy:

Official factory data, ensuring accuracy and precision

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable if OCR'd properly

Print Quality

Printability:

Printable in entirety or selected pages

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, four valves per cylinder, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.2:1

Power Output Ps:

63 PS @ 8000 rpm (approx.)

Power Output Hp:

62 bhp @ 8000 rpm (approx.)

Torque Nm:

60 Nm @ 6000 rpm (approx.)

Torque Lb-Ft:

44 lb-ft @ 6000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (DFI)

Fuel Type:

Unleaded gasoline, 87 AKI or higher

Fuel Tank Capacity L:

15 Liters

Fuel Tank Capacity Gal:

3.96 US Gallons

Performance

Top Speed:

Approx. 110-120 mph (177-193 km/h), dependent on rider and conditions

🔧 Transmission

Standard

Type:

Constant-mesh, 6-speed

Optional

Options:

N/A (Only manual transmission offered for this model)

Features

Clutch:

Wet, multi-disc, manual operation

Final Drive:

Sealed chain, 525 V8 (DID)

📐 Dimensions

Exterior

Overall Length:

2,195 mm (86.4 in)

Overall Width:

830 mm (32.7 in)

Overall Height:

1,370 mm (53.9 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

170 mm (6.7 in)

Seat Height:

820 mm (32.3 in)

Weights

Curb Weight Kg:

206 kg (454 lbs)

Curb Weight Lbs:

454 lbs

Gross Vehicle Weight Rating:

Not specified, but rider and luggage capacity should be considered.

🛡️ Safety Features

Ratings

Safety Certifications:

Meets relevant national and international motorcycle safety standards (e.g., DOT, ECE for lights)

Active Features

Braking System:

Dual disc front, Single disc rear. ABS was optional on some models/markets, check VIN for specific features.

Lighting:

Halogen headlamp, LED tail lamp, incandescent turn signals

Passive Features

Frame Construction:

Steel semi-double cradle frame designed for stability and rider comfort.

Ergonomics:

Upright riding position for comfort during long rides.

💡 Technology Features

Infotainment

Infotainment System:

N/A (No integrated infotainment system)

Driver Assistance

ABS Availability:

Optional on certain markets and configurations for the 2010 model year.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

First Service:

1000 km or 6 months

Subsequent Service:

Every 6000 km or 6 months (whichever comes first)

Valve Clearance Check:

First at 12,000 km, then every 24,000 km

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG, SH, SJ, SL, SM or JASO MA/MA2

Engine Oil Capacity With Filter:

3.0 Liters (approx.)

Engine Oil Capacity Without Filter:

2.7 Liters (approx.)

Coolant Type:

Kawasaki Genuine Coolant or equivalent (ethylene glycol-based with corrosion inhibitors)

Brake Fluid Type:

DOT 4

Transmission Oil Type:

Kawasaki Genuine Gear Oil or equivalent SAE 80W-90 API GL-4

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals, clutch plates (depending on usage)

Potential Electrical:

Occasional rectifier/regulator issues reported on some Kawasaki models of this era, though not specific to the KLE650.

Fuel System Maintenance:

Regular cleaning of fuel injectors and checks of the fuel pump are recommended for optimal performance.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and performance-oriented motorcycles across various genres.

Model Evolution

Kle Series Origin:

The KLE designation has been used for dual-sport/adventure bikes, evolving from earlier models like the KLR series.

Kle650 Generation 1:

The KLE650 platform, including this 2010 model (often referred to as the Versys 650 in many markets), debuted in the mid-2000s, offering a more road-biased adventure-touring experience.

Production

Manufacturing Location:

Typically manufactured in Japan, with potential assembly in other regions depending on the market.

🏆 Awards & Recognition

Recognitions

Industry Awards 2010:

Specific awards for the 2010 KLE650DAF are not readily documented, but the Versys platform generally received positive reviews for its versatility and value.

Ratings

Motorcycle Reviews:

Generally praised for its comfortable riding position, smooth engine, and agility, making it a strong contender in the mid-weight adventure-touring segment.