Kawasaki KLE650DAF 2010 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 92966

Tags: 2010 Kawasaki KLE650DAF Motorcycle

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Description

This manual covers the, a versatile Adventure Sport Touring Motorcycle produced in 2010. Designed for riders seeking a capable machine for commuting, touring, and light off-road excursions, the KLE650 DAF is known for its reliable and fuel-efficient parallel-twin engine, comfortable upright riding position, and balanced performance. Building on heritage of dual-purpose capability, this model offers a practical and enjoyable riding experience. This comprehensive English-language Service Repair Manual provides detailed information for the maintenance, repair, and troubleshooting of your 2010. It covers all major systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, suspension, brakes, electrical system, and bodywork. With step-by-step instructions, diagnostic charts, and technical specifications, this manual is an essential resource for owners and technicians to ensure optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLE650 DAF

Year:

Product Type:

Service Repair Manual

👋 Introduction

Market Position

Category:

Adventure Sport Touring Motorcycle

Target Audience:

Riders seeking a versatile, reliable motorcycle for commuting, touring, and light off-road excursions.

Competitive Analysis

Segment:

Light to mid-weight adventure touring segment.

Key Competitors:

BMW F650GS/F700GS (older generations), Suzuki V-Strom 650, Honda Transalp.

Key Features

Versatility:

Balanced performance for both on-road comfort and light off-road capability.

Engine Type:

Reliable and fuel-efficient parallel-twin engine.

Ergonomics:

Comfortable upright riding position suitable for long distances.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service, repair, troubleshooting, and maintenance for the Kawasaki KLE650 DAF model year 2010.

Page Count

Estimated Pages:

Several hundred (typical for a comprehensive service manual).

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed internal and external engine components, diagnosis, repair, and overhaul procedures.

Fuel System:

Fuel injection system, fuel pump, injectors, throttle body, fuel tank, and lines.

Ignition System:

Ignition coils, spark plugs, ECU control, and timing.

Cooling System:

Radiator, fan, coolant, thermostat, hoses, and water pump.

Exhaust System:

Exhaust pipes, catalytic converter, mufflers, and sensors.

Transmission:

Clutch, gearbox, internal transmission components, lubrication, and adjustment.

Drivetrain:

Final drive, chain, sprockets, wheel bearings.

Suspension:

Front forks (telescopic, cartridge type), rear shock absorber, linkages, and adjustments.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, pads, rotors, ABS (if equipped).

Wheels Tires:

Wheel specifications, tire mounting, balancing, and pressure recommendations.

Steering:

Handlebar, steering stem, bearings, and lubrication.

Electrical System:

Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, ignition, and instrument cluster.

Lighting:

Headlight, taillight, brake light, turn signals, and related wiring.

Instruments Indicators:

Speedometer, tachometer, fuel gauge, warning lights, and their diagnostics.

Chassis Frame:

Frame inspection, welding, and component mounting.

Bodywork Fairings:

Removal, installation, and repair of fairings, plastics, and trim.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common and uncommon issues.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication points, valve clearance checks.

Engine Overhaul:

Complete engine disassembly, inspection, reassembly, and torque specifications.

Transmission Repair:

Gearbox disassembly, clutch replacement, and seal renewal.

Suspension Rebuild:

Front fork seal replacement, oil changes, rear shock absorber servicing.

Brake System Service:

Brake fluid replacement, caliper overhaul, pad replacement, and bleeding procedures.

Electrical Diagnostics:

Wiring diagrams, component testing, and troubleshooting electrical faults.

Fuel System Cleaning:

Injector cleaning, throttle body synchronization, and fuel filter replacement.

Wheel Tire Service:

Tire mounting/dismounting, wheel balancing, and spoke tensioning.

Bodywork Repair:

Panel removal/installation, minor cosmetic repairs.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text, allowing for quick access to specific information.

Print Quality

Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Format:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Type:

Liquid-cooled, four-stroke, DOHC, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.2:1

Performance

Horsepower:

Approximately 62.6 hp @ 8,000 rpm (claimed, may vary slightly by region/testing)

Torque:

Approximately 43.4 lb-ft @ 6,000 rpm (claimed, may vary slightly by region/testing)

Fuel System

Induction:

Fuel injection with two 38mm throttle bodies

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approximately 15 liters (3.96 US gal)

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Clutch:

Wet, multi-disc, manual

Optional

Type:

Features

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

Approximately 2,180 mm (85.8 in)

Width:

Approximately 800 mm (31.5 in)

Height:

Approximately 1,400 mm (55.1 in)

Wheelbase:

Approximately 1,465 mm (57.7 in)

Ground Clearance:

Approximately 150 mm (5.9 in)

Seat Height:

Approximately 820 mm (32.3 in)

Weights

Curb Weight:

Approximately 199 kg (439 lbs)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not typically rated by consumer safety organizations like NHTSA/Euro NCAP for crashworthiness in the same manner as cars.

Active Features

Optional (ABS variant available, check specific model code DAF).

Brakes:

Dual discs front, single disc rear (ABS may be integrated).

Passive Features

Lighting:

Halogen headlight, LED taillight, conspicuity lighting.

💡 Technology Features

Infotainment

Features:

Basic dashboard instrumentation, typically including speedometer, tachometer, fuel gauge, and essential warning lights. No advanced infotainment systems.

Driver Assistance

Features:

Optional ABS braking system.

Connectivity

Features:

No integrated connectivity features like Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change:

Recommended every 6,000 miles (9,600 km) or 6 months, whichever comes first.

Oil Filter Change:

Recommended with every oil change.

Air Filter Check:

Recommended every 12,000 miles (19,200 km).

Spark Plug Replacement:

Recommended every 12,000 miles (19,200 km).

Valve Clearance Check:

Recommended every 12,000 miles (19,200 km) or 24,000 miles (38,400 km), refer to manual for specific interval.

Chain Adjustment:

Recommended every 2,000 miles (3,200 km).

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ, SL or SM, JASO MA, MA1 or MA2, SAE 10W-40 or 20W-50 (depending on climate).

Engine Oil Capacity:

Approximately 2.4 liters (2.5 US qt) without filter change; 2.6 liters (2.7 US qt) with filter change.

Coolant Type:

Ethylene glycol-based coolant, 50/50 mixture with distilled water.

Brake Fluid Type:

DOT 4

Transmission Oil Type:

SAE 80W-90 API GL-4 gear oil (for final drive, if applicable or gearbox if different).

Known Issues

Common Complaints:

Occasional reports of clutch judder, minor vibration at certain RPMs, and potential issues with the regulator/rectifier if not properly managed.

Preventative Measures:

Regular maintenance, ensuring proper cooling system function, and verifying electrical charging system health are crucial.

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company, a division of Kawasaki Heavy Industries, Ltd.

Model Evolution

Lineage:

The KLE650 Versys is part of Kawasaki's lineage of versatile, multi-purpose motorcycles, building on the spirit of dual-purpose capability.

Previous Generations:

The Versys platform debuted in 2007, with updates and refinements in subsequent years leading up to this 2010 model.

Production

Manufacturing Location:

Typically manufactured in Thailand or Japan for global markets.

🏆 Awards & Recognition

Recognitions

Awards Received:

The Kawasaki Versys line has generally received positive reviews from motorcycle journalists and riders for its versatility and value, though specific awards for the 2010 model are not widely publicized.