Segment:
Dual-sport / Adventure motorcycle
Target Audience:
Owners seeking to perform their own maintenance and repairs, professional mechanics
Alternatives:
Other manufacturers' dual-sport models like BMW GS series, Suzuki V-Strom, Honda Africa Twin (though KL650EA is a different class)
Vehicle Attributes:
Reliable, versatile, suitable for both on-road and light off-road use, known for its durability
Benefit:
Enables cost savings on maintenance, empowers owners with knowledge for repairs, ensures proper upkeep for longevity
Advantage Over Paper:
Instant access, searchable text, portability, environmentally friendly
Engine:
Complete engine overhaul, diagnostics, and tune-up procedures
Transmission:
Clutch, gearbox, and final drive maintenance and repair
Chassis:
Frame, suspension (front and rear), steering, and wheels
Brakes:
Front and rear brake system inspection, service, and repair, including fluid replacement
Electrical:
Ignition system, lighting, charging system, starter system, and instrumentation
Fuel System:
Fuel injection system, fuel pump, injectors, and fuel tank servicing
Cooling System:
Radiator, cooling fan, hoses, and thermostat maintenance
Exhaust System:
Muffler, exhaust pipe inspection and replacement
Bodywork:
Fairings, seat, fenders, and minor body panel repair
Troubleshooting:
Diagnostic charts and procedures for common problems
Type:
Service Repair Manual
Engine Mechanical:
Cylinder head, piston, crankshaft, lubrication system, valve train
Fuel And Emission:
Fuel pump, fuel pressure regulator, evaporative emission control system
Ignition And Charging:
Ignition coils, spark plugs, alternator, battery, regulator/rectifier
Suspension And Steering:
Front fork (including oil changes and seal replacement), rear shock absorber, steering head bearings
Brake System:
Brake fluid type (DOT 4), pad inspection and replacement, caliper service, master cylinder overhaul
Wheel And Tire:
Tire pressure specifications, wheel bearing maintenance, spoke tightening (if applicable)
Electrical Diagrams:
Complete wiring diagrams for all circuits
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning/replacement, spark plug gap and replacement, chain adjustment
Component Removal Installation:
Engine removal and installation, transmission disassembly and reassembly, fork disassembly
Diagnostic Procedures:
Troubleshooting common electrical and mechanical faults, fuel system diagnostics
Special Tool Requirements:
Identification and usage of specialized tools for specific repair tasks
Torque Specifications:
Detailed torque values for all critical fasteners
Adjustments:
Carburetor (if applicable, though KL650EA is FI), throttle cable, clutch cable, idle speed
Depth:
Comprehensive, covering routine maintenance to full engine and transmission rebuilds
Diagnostic Level:
Advanced, including fault code interpretation and sensor data analysis
Type:
Four-stroke, SOHC, four-valve, single-cylinder
Displacement:
651 cc (39.7 cu. in.)
Bore X Stroke:
100.0 x 83.0 mm (3.94 x 3.27 in.)
Horsepower Approx:
42 hp @ 6,000 rpm (stock, may vary)
Torque Approx:
38 lb-ft @ 4,500 rpm (stock, may vary)
Induction:
Electronic Fuel Injection (EFI) with Dual Throttle Valves (DTV)
Fuel Type:
Unleaded gasoline
Type:
Forced lubrication, wet sump
Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change
Type:
Digital CDI with electronic advance
Type:
5-speed constant mesh
Clutch Type:
Wet, multiple-disc, cable operated
Final Drive:
Sealed chain
Gear Ratios:
Specific ratios provided in the manual
Transmission Oil:
API GL-4, SAE 80W-90 gear oil
Crash Safety:
N/A (Motorcycle specific safety is through design and rider skill)
Braking System:
Optional ABS (Anti-lock Braking System)
Lighting:
Halogen headlight, LED taillight
Frame Construction:
Robust semi-double cradle frame designed for stability
Ergonomics:
Upright riding position for rider control and comfort
Features:
Basic instrumentation: speedometer, tachometer, odometer, trip meter, clock, coolant temperature warning light, fuel injection warning light.
ABS:
Optional Anti-lock Braking System (ABS)
Features:
N/A (Motorcycle specific, no advanced connectivity features)
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Change:
With every oil change
Air Filter Cleaning:
Every 6,000 km (3,700 miles), replace as needed
Spark Plug Inspection:
Every 12,000 km (7,500 miles)
Chain Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions
Valve Clearance Inspection:
Every 24,000 km (15,000 miles)
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ, SL, SM, SN or JASO MA
Coolant Type:
Kawasaki Genuine Coolant or equivalent (50/50 mixture with distilled water)
Fork Oil Type:
SAE 10W (specific amount and viscosity detailed in manual)
Common Complaints:
Some models may experience excessive vibration at certain RPMs; cam chain noise; potential weak balancer drive sprocket (though less common on later models). The manual provides troubleshooting for these.
Common Fixes:
Proper chain tensioning, vibration damping solutions, oil viscosity selection. Manual details specific diagnostic and repair procedures.
Heritage:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and reliability.
Kl Series Lineage:
The KL650 platform, originating from the KLR650, has been a staple in Kawasaki's lineup for decades, evolving with fuel injection and other modernizations.
Kl650Ea Specifics:
The 'EA' designation often refers to a specific market or configuration of the KLR650 model for a given year.
Manufacturing Location:
Japan (primary)
Production Years:
The KLR650 platform has been in continuous production since the late 1980s, with the KL650EA being a variant for the 2010 model year.
Awards History:
While specific awards for the 2010 KL650EA might be limited, the KLR650 platform is widely recognized for its value, reliability, and long-distance capability by motorcycle publications and riders.
Durability Reputation:
High, known for enduring long journeys and challenging conditions.
