🏷️ Basic Information

Make:

Kawasaki

Model:

KLR650

Year:

2010

Engine Code:

EX650AE (Varies slightly by market, often referred to as a 651cc engine)

👋 Introduction

Category:

Dual-sport motorcycle, adventure touring

Segment Appeal:

Known for its ruggedness, reliability, affordability, and versatility for both on-road commuting and off-road exploration.

Key Competitors 2010:

Honda Transalp (varies by market), Suzuki DR650SE, Yamaha XT660R/X.

Engine Type:

Single-cylinder, liquid-cooled, DOHC, 4-valve

Fueling:

Electronic Fuel Injection (EFI) for precise fuel delivery and emissions control.

Suspension Design:

Long-travel telescopic front forks and adjustable rear monoshock suspension for off-road capability.

Durability:

Renowned for its robust construction and ability to withstand demanding conditions.

Ergonomics:

Upright riding position, comfortable for long-distance touring.

📋 Manual Details

Primary Coverage:

Comprehensive service, repair, and maintenance for the Kawasaki KLR650 (2010 model year)

Secondary Coverage:

Includes troubleshooting, diagnostics, specifications, wiring diagrams, and rebuild procedures

Estimated Pages:

Approximately 300-400 pages (typical for a full service manual of this type)

Type:

Full Service & Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed breakdown of engine components, including cylinder head, valves, piston, crankshaft, camshaft, lubrication system, cooling system, and fuel injection.

Transmission:

Clutch operation, gearbox internals, gear shifting mechanism, and lubrication.

Drivetrain:

Chain and sprocket inspection, adjustment, and replacement; rear swingarm and bearing service.

Suspension:

Front fork (telescopic) disassembly, assembly, oil levels, seal replacement, and rear shock absorber service and adjustment.

Brakes:

Front and rear brake system diagnosis, pad replacement, caliper service, master cylinder overhaul, bleeding procedures, and hydraulic line maintenance.

Electrical System:

Complete wiring diagrams, charging system (stator, regulator/rectifier), ignition system, lighting, instrumentation, starting system, and battery maintenance.

Fuel System:

Fuel injection system (EFI) components, fuel pump, injectors, throttle body, idle speed control (ISC), and fuel tank maintenance.

Cooling System:

Radiator, fan, thermostat, hoses, and coolant specifications and replacement.

Exhaust System:

Muffler, exhaust pipe inspection, and gasket replacement.

Frame And Bodywork:

Chassis components, seat, fairings, fuel tank removal/installation, and fenders.

Wheels And Tires:

Tire inspection, replacement, wheel bearing service, and spoke tensioning (for spoked wheels).

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant replacement, spark plug checks, air filter cleaning/replacement, valve clearance checks.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and braking issues. Includes flowcharts and symptom-based fault finding.

Rebuild Procedures:

Step-by-step guides for engine top-end rebuild (cylinder head, piston), transmission overhaul, carburetor (if applicable, though KLR650 2010 is EFI), and suspension component rebuilding.

Diagnostics:

Fault code retrieval (if applicable to the model's diagnostic system), electrical system testing, and fuel system pressure testing.

Specifications:

Torque values for all fasteners, engine timing, valve clearances, fluid capacities, electrical specifications, and dimensional data.

Depth:

Comprehensive, covering everything from basic user maintenance to advanced engine and electrical system repairs, suitable for both novice DIY mechanics and experienced technicians.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Printability:

Designed to be printable, allowing users to create a physical copy for workshop use.

Binding:

N/A (Digital Download - PDF)

Paper Quality:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, DOHC, four valves

Displacement:

651 cc (cubic centimeters)

Bore X Stroke:

100.0 mm x 83.0 mm (approximate, typical for this generation)

Compression Ratio:

8.8:1 (typical for this generation)

Horsepower:

Approximately 46 hp @ 6500 rpm (varies slightly by market and tune)

Torque:

Approximately 38 lb-ft @ 5000 rpm (varies slightly by market and tune)

Fuel Delivery:

Electronic Fuel Injection (EFI), Dual throttle valves (DTV) for improved throttle response.

Fuel Type:

Unleaded gasoline, minimum octane rating 87 (AKI)

Cooling Method:

Liquid-cooled

Oil Type Spec:

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

Oil Capacity W Filter:

Approx. 2.4 L (2.5 US qt)

🔧 Transmission

Type:

5-speed constant mesh, return type

Clutch Type:

Wet, multi-plate

Transmission Options:

N/A (Standard 5-speed manual)

Gear Ratios:

Specific gear ratios are detailed within the manual for each gear.

Final Drive:

O-ring sealed chain, 525 series

Transmission Oil Spec:

Same as engine oil: SAE 10W-40 API SG, SH, SJ, SL, SM or SN, JASO MA or MA2

Transmission Oil Capacity:

Approx. 2.2 L (2.3 US qt)

📐 Dimensions

Length:

2,245 mm (88.4 in)

Width:

910 mm (35.8 in)

Height:

1,365 mm (53.7 in)

Wheelbase:

1,470 mm (57.9 in)

Ground Clearance:

210 mm (8.3 in)

Seat Height:

865 mm (34.1 in)

Curb Weight:

Approx. 194 kg (428 lb)

Fuel Tank Capacity:

18 L (4.7 US gal)

🛡️ Safety Features

Safety Features Overview:

Primarily passive safety features inherent to motorcycle design. No formal crash ratings like cars. Focus is on rider control and system reliability.

Braking System:

Disc brakes front and rear. Optional ABS was available on some later models, but likely not standard on 2010 KLR650.

Lighting:

Halogen headlight, LED taillight, turn signals.

Frame Construction:

Semi-double cradle frame for stability and durability.

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle instrumentation)

Assistance Features:

None (standard motorcycle)

Connectivity Features:

None (standard motorcycle)

Dashboard Display:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, clock, and indicator lights.

🔧 Maintenance

Oil Change Interval:

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

Air Filter Check Interval:

Inspect every 6,000 km (3,700 mi), clean/replace as needed. More frequent in dusty conditions.

Valve Clearance Check Interval:

Every 24,000 km (15,000 mi) or 24 months.

Chain Maintenance Interval:

Lubricate and adjust every 1,000 km (600 mi) or more frequently as needed.

Coolant Type:

Kawasaki Coolant 50/50 (or equivalent ethylene glycol-based antifreeze with distilled water).

Brake Fluid Type:

DOT 4

Common Wear Items:

Clutch plates, fork seals, wheel bearings, drive chain and sprockets are typical wear items requiring periodic inspection and replacement.

Fuel Pump Reliability:

Some reports of early fuel pump failures, though generally robust. Manual provides diagnostic steps.

Charging System Inspection:

Regular inspection of the regulator/rectifier and stator is recommended, especially for high-mileage bikes or those used in extreme conditions.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and innovation across various segments.

Klr Lineage:

The KLR650 platform has been a cornerstone for Kawasaki in the dual-sport market since its introduction in the mid-1980s, undergoing gradual refinements over the years rather than radical redesigns.

2010 Update Context:

The 2010 model represents a significant update to the original KLR650 design, incorporating electronic fuel injection, a larger fuel tank, improved suspension, and updated styling. This generation is often referred to as the 'second generation' KLR650.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Award Status:

While the KLR650 itself hasn't won specific automotive awards like cars, it has consistently been recognized within the motorcycle press and by owners as a highly reliable, value-for-money, and capable dual-sport machine. It's often lauded for its longevity and low cost of ownership.