Kawasaki KLE650DAF 2010 Workshop Service Repair Manual

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Mots clés: 2010 Kawasaki KLE650DAF Motorcycle

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Description

This manual pertains to the KLE650 DAF, a 2010 model year adventure touring motorcycle. Known for its parallel-twin, liquid-cooled engine and high-tensile steel perimeter frame, the KLE650 DAF offers a blend of on-road comfort and off-road capability. Its upright riding position and long-travel suspension contribute to its versatility, making it suitable for commuting, touring, and light trail riding. The motorcycle features a 6-speed transmission, wet multi-disc clutch, and a sealed chain final drive, underpinned by a reputation for engineering quality and reliability. The KLE650 DAF 2010 Workshop Service Repair Manual provides comprehensive factory-level technical information essential for the maintenance and repair of this motorcycle. It covers a wide array of systems, including engine overhaul, fuel and cooling systems, drivetrain, suspension, brakes, and the electrical system. Detailed procedures for routine maintenance, troubleshooting common malfunctions, component repair, and technical specifications are included. This manual serves as an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance, longevity, and safe operation of the KLE650 DAF.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE650 DAF

Year:

Chassis Code:

ER650EFA

Codes

Engine Code:

ER650AE

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Target Audience:

Motorcyclists seeking a versatile, reliable, and capable machine for commuting, touring, and light off-road use

Competitive Analysis

Key Competitors:

Honda NC700X/VFR800X, Yamaha XT660R/Tenere, Suzuki V-Strom 650

Key Features

Engine Type:

Parallel-twin, liquid-cooled

Frame Type:

Perimeter frame

Suspension Setup:

Long-travel front forks and rear monoshock for versatile performance

Ergonomics:

Upright riding position, comfortable for long distances

Versatility:

Suitable for both on-road touring and moderate off-road excursions

📋 Manual Details

Coverage Areas

Manual Title:

Kawasaki KLE650DAF 2010 Workshop Service Repair Manual

Primary Coverage:

Complete official full factory service repair manual

Model Coverage:

KLE650DAF 2010

Page Count

Estimated Pages:

Hundreds of pages

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures

Fuel System:

Fuel injection system, throttle body, fuel pump, injectors, fuel filter maintenance and diagnostics

Cooling System:

Radiator, cooling fan, thermostat, coolant flow, maintenance, and troubleshooting

Exhaust System:

Muffler, catalytic converter, exhaust pipe inspection and replacement

Transmission Clutch:

Clutch operation, hydraulic system, gearbox inspection, maintenance, and repair

Drivetrain:

Chain drive, sprockets inspection, adjustment, and replacement

Suspension:

Front forks (oil change, seal replacement, spring specifications), rear shock absorber inspection and adjustment

Brakes:

Brake fluid replacement, caliper overhaul, pad replacement, disc inspection, ABS system diagnostics (if applicable)

Wheels Tires:

Wheel bearing inspection, tire pressure recommendations, rim inspection

Steering:

Handlebar, steering stem bearings inspection and adjustment

Electrical System:

Battery maintenance, charging system (alternator, regulator/rectifier), starter motor, ignition system (spark plugs, coils), lighting, wiring diagrams

Instrumentation:

Dashboard, indicators, speedometer, tachometer troubleshooting

Body Frame:

Fairings, seat, fuel tank removal/installation, chassis inspection, frame integrity

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, brake inspections

Troubleshooting:

Diagnostic charts and procedures for common malfunctions across all systems

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair

Engine Tuning:

Idle speed adjustment, throttle cable adjustment, ignition timing (if adjustable)

Electrical Diagnostics:

Testing of charging system, ignition system, and lighting circuits using multimeters and specified procedures

Suspension Servicing:

Front fork oil and seal replacement, rear shock pre-load adjustment

Brake System Maintenance:

Brake fluid flush and bleed, pad and caliper servicing

Technical Depth

Depth:

Comprehensive factory-level technical information for all repair and maintenance tasks

Diagnostic Capability:

Detailed diagnostic procedures, fault codes (if applicable), and troubleshooting trees

Rebuild Information:

Full engine and transmission rebuild specifications, clearances, and torques

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text within the PDF, allowing quick navigation to specific topics

Print Quality

Quality:

Designed for high-quality printing, ensuring clarity of diagrams and text

Binding Type

Digital Binding:

N/A (Digital PDF)

Paper Type

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 8-valve, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.0:1

Performance

Horsepower:

Approx. 62.6 hp @ 7500 rpm (claimed)

Torque:

Approx. 43.4 lb-ft @ 6000 rpm (claimed)

Fuel System

Fuel Delivery:

DFI (Digital Fuel Injection) with Keihin throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane or higher

Fuel Tank Capacity:

15 Liters (approx. 3.96 US gallons)

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh, return shift

Features

Clutch Type:

Wet, multi-disc, cable operated

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

2,195 mm (86.4 in)

Width:

800 mm (31.5 in)

Height:

1,365 mm (53.7 in)

Wheelbase:

1,465 mm (57.7 in)

Ground Clearance:

170 mm (6.7 in)

Weights

Curb Weight:

208 kg (459 lbs)

Weight Distribution:

Typically balanced for stability

🛡️ Safety Features

Ratings

Optional ABS (Anti-lock Braking System) on certain models/regions

Active Features

Braking System:

Dual 300 mm petal discs with dual-piston calipers (front), Single 240 mm petal disc with dual-piston caliper (rear)

Lighting:

Halogen headlight, LED taillight

Passive Features

Frame Construction:

High-tensile steel perimeter frame for rigidity and strength

Rider Protection:

Handlebar, bodywork, and seating position designed for rider control and comfort

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle does not feature a traditional infotainment system)

Driver Assistance

ABS Availability:

Available as an option on certain model variants, enhancing braking safety.

Connectivity

Connectivity Features:

N/A (Motorcycle does not feature modern connectivity features like Bluetooth or smartphone integration)

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Oil Filter Replacement:

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

Air Filter Cleaning Replacement:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Recommended at 12,000 km (7,500 miles) or based on condition.

Valve Clearance Check:

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

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ, SL or SM; SAE 10W-40 or SAE 20W-50

Engine Oil Capacity:

3.2 L (3.4 US qt) with filter change; 2.8 L (3.0 US qt) without filter change.

Coolant Type:

High-quality ethylene glycol-based coolant, 50/50 mix with distilled water

Brake Fluid Type:

DOT 4

Clutch Fluid Type:

DOT 4 (Hydraulic clutch)

Chain Lube:

Recommended motorcycle chain lubricant

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals.

Potential Concerns:

Some owners report a slightly buzzy feel at higher RPMs. Regular chain maintenance is crucial for drivetrain longevity.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various categories, including sportbikes, cruisers, and off-road models.

Model Evolution

Kle Series Origin:

The KLE series has evolved from earlier dual-purpose motorcycles, focusing on blending on-road comfort with off-road capability. The KLE650 Ninja/Versys platform shares its engine with the ER-6n/ER-6f models, demonstrating Kawasaki's modular design approach.

Production

Manufacturing Location:

Likely manufactured in Japan or Thailand by Kawasaki Heavy Industries.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2010 KLE650DAF model may not be widely publicized, the Versys platform (which this manual covers) generally received positive reviews for its value, versatility, and accessible performance.

Ratings

Performance Reviews:

Often praised for its usable powerband and comfortable ergonomics, making it a popular choice for commuting and light touring.