Segment:
Dual-sport motorcycle, often categorized with adventure touring or enduro platforms.
Target Audience:
Riders seeking a reliable and capable motorcycle for commuting, light off-road exploration, and general touring.
Competitors:
BMW G 650 GS Sertao, Honda Transalp, Suzuki V-Strom 650 (though larger), Yamaha XT660R.
Versatility:
Designed for both on-road comfort and off-road capability, making it a versatile choice.
Durability:
Known for its robust construction and reliable engine, often used in demanding conditions.
Sections Covered:
Engine, Fuel System, Ignition System, Electrical System, Transmission, Chassis, Suspension, Brakes, Cooling System, Lubrication System, Frame, Bodywork, Maintenance, Troubleshooting, Specifications, Diagrams.
Estimated Pages:
Hundreds (exact count not specified, but typical for comprehensive factory manuals)
Type:
Workshop Service Repair Manual
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly of the engine, including cylinder head, pistons, crankshaft, connecting rods, valves, camshafts, and timing components.
Fuel System:
Carburetor (if applicable) or Fuel Injection system (EFI) diagnostics, cleaning, adjustment, and component replacement; fuel pump, fuel filter, injectors.
Ignition System:
Ignition coil, spark plugs, CDI unit, troubleshooting and testing of ignition components.
Electrical System:
Wiring diagrams, battery, starter motor, charging system (alternator/stator), lighting system, switches, fuses, relays, and instrument panel diagnostics.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, chain and sprocket maintenance and replacement.
Chassis Suspension:
Front fork (telescopic) disassembly, inspection, fluid changes, and seal replacement; rear shock absorber inspection and replacement; swingarm and linkage maintenance.
Braking System:
Front and rear brake caliper inspection and overhaul, brake pad replacement, brake fluid flush and bleeding, brake line inspection, master cylinder service.
Cooling System:
Radiator, coolant, thermostat, water pump, hoses, and fan operation checks and service.
Lubrication System:
Oil pump, oil filter, oil passages, and oil change procedures.
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, fenders, and fairings.
Scheduled Maintenance:
Detailed procedures for routine checks, adjustments, and replacements at specified intervals (e.g., oil changes, filter replacements, chain lubrication, valve clearance checks).
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical issues, often presented in a flowchart format.
Component Overhaul:
Complete step-by-step instructions for disassembling, cleaning, inspecting, repairing, and reassembling major components like the engine, transmission, forks, and brake calipers.
Electrical Diagnostics:
Guidance on using multimeters and interpreting wiring diagrams to diagnose electrical faults.
Torque Specifications:
Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.
Depth:
Comprehensive; covers everything from basic pre-ride checks and routine maintenance to complete engine rebuilds, complex electrical diagnostics, and chassis component overhauls.
User Level:
Suitable for experienced DIY mechanics and professional service technicians.
Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
652 cc (39.8 cu in)
Bore X Stroke:
100.0 x 83.0 mm (3.94 x 3.27 in)
Cooling System:
Liquid-cooled
Horsepower:
Approximately 48 hp @ 6,500 rpm (may vary by market/tuning)
Torque:
Approximately 53 Nm (39.1 lb-ft) @ 5,000 rpm (may vary by market/tuning)
Induction:
Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON+MON)/2
Oil Capacity With Filter:
Approx. 2.7 L (2.8 US qt)
Oil Type:
API SG, SF, SH, SJ, SL, SM or higher, SAE 10W-40 motorcycle specific oil recommended.
Display:
Analog speedometer and tachometer, digital odometer, trip meters, and clock. Indicator lights for turn signals, high beam, neutral, oil pressure, and engine trouble.
ABS:
Optional on some markets, but not standard on the 2010 KL650EA.
Gps Integration:
No integrated connectivity features; aftermarket GPS units can be mounted.
Oil Change:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first. Refer to manual for exact interval based on severe/normal use.
Air Filter:
Inspect every 6,000 km (3,700 mi), clean or replace as needed.
Spark Plug:
Replace every 12,000 km (7,500 mi) or annually.
Valve Clearance:
Check every 12,000 km (7,500 mi) or annually.
Chain Lubrication:
Lubricate every 1,000 km (600 mi) or after riding in the rain/wet conditions.
Engine Oil:
SAE 10W-40 API SG or higher, motorcycle-specific.
Coolant:
Permanent type anti-freeze coolant, 50% solution with distilled water.
Brake Fluid:
DOT 4 recommended.
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, brake pads, and wheel bearings are common wear items that may require replacement due to usage.
Specific Concerns:
Some users have reported potential issues with the charging system (stator) on earlier KLR models; the 2010 is generally more reliable but still susceptible. Regular inspection of the Doohickey (cam chain tensioner lever) is also a common topic among KLR owners.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Reputation:
Known for robust engineering, reliable engines, and a strong presence in off-road and dual-sport segments.
Lineage:
The KL650 platform has a long history, evolving from models like the KLR600. The KL650EA designation is specific to a particular iteration and market configuration.
Key Updates:
The KL650EA model year 2010 typically incorporates updates from previous generations, focusing on refinements in fuel delivery, emissions, and sometimes suspension or braking components. The transition to fuel injection was a significant evolutionary step for this platform.
Manufacturing Location:
Likely manufactured in Japan or Thailand by Kawasaki.
