Segment:
Dual-sport motorcycle, known for its versatility in commuting, touring, and light off-road use.
Competitors:
BMW F650GS, Suzuki V-Strom 650, Honda Transalp (older models), Kymco Venox 250.
Features:
Robust single-cylinder engine, comfortable ergonomics, long-travel suspension, ample luggage capacity (with optional accessories), legendary reliability.
Value:
Empowers owners to perform a wide range of maintenance and repair tasks, saving money and ensuring the longevity and optimal performance of their KLR650.
Coverage:
Complete service, repair, maintenance, troubleshooting, and diagnostics for the 2010 Kawasaki KLR650.
Pages:
Approximately 300-400 pages (typical for comprehensive service manuals of this era).
Type:
Service and Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine Mechanical:
Engine disassembly, assembly, inspection, maintenance, troubleshooting, cylinder head, valves, piston, crankshaft, lubrication system, cooling system, oil system.
Fuel System:
Carburetor (Keihin CVK40) removal, inspection, cleaning, adjustment, fuel tank, fuel pump, fuel lines, emission controls.
Transmission:
Clutch operation, gearbox removal, disassembly, inspection, assembly, lubrication, troubleshooting.
Drivetrain:
Final drive chain maintenance, adjustment, replacement; sprocket inspection and replacement.
Chassis Suspension:
Front fork (telescopic) disassembly, service, fluid replacement, seal replacement; rear shock absorber (monoshock) inspection, adjustment, removal; swingarm and linkage maintenance.
Braking System:
Front and rear disc brake systems, caliper inspection, pad replacement, fluid bleeding, master cylinder service.
Electrical System:
Ignition system (CDI), charging system (alternator, regulator/rectifier), starting system (starter motor, battery), lighting (headlight, taillight, turn signals), instrumentation, wiring diagrams, troubleshooting electrical faults.
Bodywork:
Fairing, fuel tank, seat, fenders, luggage rack, and other body panel removal and installation.
Scheduled Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustments, brake inspections, valve clearance checks.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues across all systems.
Repair Procedures:
Detailed instructions for component disassembly, repair, rebuilding, and reassembly.
Component Identification:
Clear identification of all parts and components with diagrams.
Depth:
Comprehensive (from basic adjustments to full engine rebuilds and electrical system diagnostics).
Format Details:
PDF (Portable Document Format), allowing for easy viewing, searching, and printing.
Quality:
High-resolution scans ensuring clarity of text and diagrams.
Binding:
Not applicable (digital download).
Paper:
Not applicable (digital download).
Type:
Four-stroke, DOHC, single-cylinder
Displacement:
651 cc (651 cubic centimeters)
Bore X Stroke:
100.0 mm x 83.0 mm
Cooling System:
Liquid-cooled
Horsepower:
Approximately 32.4 kW (44 hp) @ 6000 rpm (approximate, actual may vary)
Torque:
Approximately 51.7 Nm (38.1 lb-ft) @ 4500 rpm (approximate, actual may vary)
Carburetor:
Keihin CVK40 (Constant Velocity Carburetor)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Valve Actuation:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Crash Test Data:
Motorcycle safety is typically assessed through rider experience and component durability, not standardized crash tests like automobiles.
Braking:
Disc brakes front and rear for effective stopping power.
Lighting:
Halogen headlight, LED taillight, and turn signals for visibility.
Frame:
Semi-double cradle frame constructed from high-tensile steel for strength and rigidity.
Ergonomics:
Upright riding position and comfortable seating for rider fatigue reduction on long journeys.
Audio System:
Not applicable (basic motorcycle instrumentation).
Features:
ABS (Anti-lock Braking System) was an optional feature on some international models, but typically not standard on the 2010 US market model. This manual will cover standard braking system components.
Features:
Not applicable.
Dashboard:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, warning lights (neutral, oil pressure, high beam, turn signal).
Oil Change:
Every 3,000-6,000 km (1,800-3,700 miles) or 6-12 months, depending on riding conditions. Refer to manual for exact recommendation.
Air Filter Cleaning:
Inspect every 3,000 km (1,800 miles), clean or replace as needed.
Valve Clearance Check:
Every 6,000 km (3,700 miles) or annually.
Chain Maintenance:
Lubricate and adjust chain tension every 1,000 km (600 miles) or as needed.
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil. (e.g., Kawasaki Genuine Oil, Motul 5100 10W-40).
Engine Oil Capacity:
2.4 L (2.5 US qt) without filter change; 2.5 L (2.6 US qt) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed with distilled water in a 50/50 ratio. (e.g., Kawasaki Super Coolant).
Common Problems:
Doohickey failure (a spring inside the countershaft sprocket hub), excessive oil consumption on high-mileage examples, potential doohickey spring breakage leading to catastrophic engine damage if not addressed. Some models may experience carburetor icing in cold, humid conditions. Subframe cracking on early models (less common on 2008+ revisions). Coolant hose leaks over time.
Doohickey Upgrade:
The manual will cover the inspection and potential replacement of the 'doohickey,' a common upgrade for KLR650 owners to enhance reliability.
