🏷️ Basic Information

Make:

Kawasaki

Model:

KL650E (KLR650)

Year:

2010

Model Code:

KL650EA

👋 Introduction

Segment:

Dual-sport motorcycle, known for its versatility and ruggedness for adventure touring and commuting.

Competitors 2010:

Honda XR650L, Suzuki DR650SE, Yamaha XT660R.

Engine Type:

Liquid-cooled, single-cylinder, DOHC, 4-stroke.

Frame Type:

Semi-double cradle steel frame.

Suspension Type:

Long-travel conventional telescopic front forks and single shock rear suspension (Uni-Trak).

Durability:

Renowned for its robust construction and reliability, suitable for demanding conditions.

📋 Manual Details

General Coverage:

Complete service and repair for the Kawasaki KL650EA (KLR650) model year 2010.

Estimated Pages:

Approximately 400-500 pages (typical for comprehensive workshop manuals).

Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, tuning, valve clearance, piston, rings, crankshaft, connecting rods, cylinder head, oil pump, lubrication system.

Fuel System:

Carburetor (Mikuni VM26SS type for this era) disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable), vapor canister system.

Ignition System:

Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams specific to ignition.

Cooling System:

Radiator, cooling fan, hoses, thermostat, coolant type and capacity.

Transmission:

Clutch operation, gearbox disassembly and assembly, gear selection, lubrication, maintenance.

Drive Train:

Chain and sprockets inspection and replacement, swingarm, rear shock absorber, linkage maintenance.

Suspension Front:

Front fork disassembly, inspection, seal replacement, oil type and level, spring rates, adjustment procedures.

Brakes Front:

Brake caliper disassembly, piston, seals, brake pads, rotor inspection and replacement, brake fluid specifications, bleeding procedures.

Brakes Rear:

Rear brake caliper, brake pads, rotor inspection and replacement, brake fluid specifications, bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting, instrumentation, horn.

Chassis Frame:

Frame inspection, headstock bearings, steering assembly maintenance.

Bodywork Trim:

Fairings, plastics, seat, fuel tank removal and installation, graphics.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain adjustment, lubrication points, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based fault finding, electrical system diagnostics.

Engine Rebuild:

Complete engine overhaul, including detailed steps for disassembling and reassembling all internal components.

Suspension Overhaul:

Full rebuild of front forks and rear shock absorber.

Brake System Service:

Service and replacement of brake components, including bleeding.

Electrical Diagnosis:

Troubleshooting electrical faults using wiring diagrams and specified test procedures.

Carburetor Tuning:

Adjustment of idle speed, mixture, and float level.

Depth:

Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick access to specific topics.

Quality:

High resolution, designed for clear reproduction of diagrams and text.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, 1-cylinder, SOHC, 4-valve

Displacement:

651 cc (651 cubic centimeters)

Bore X Stroke:

100.0 mm x 83.0 mm

Compression Ratio:

8.3:1

Horsepower Estimated:

Approx. 35-40 HP (at crankshaft)

Torque Estimated:

Approx. 39-42 Nm (at crankshaft)

Carburetor:

Mikuni VM26SS (36mm) with K-TRIC (Kawasaki Throttle Response Ignition Control).

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Oil Capacity W Filter:

3.1 L (3.3 US qt)

Oil Type Recommended:

SAE 10W-40 API SG or SH motorcycle oil

Ignition System:

Digital CDI with electronic advance

Spark Plug Type:

NGK CR9E or DPR9EA-9

Cooling Method:

Liquid-cooled

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-disc, manual

Gear Ratios:

Detailed ratios available in the manual (e.g., 1st: 2.667, 2nd: 1.750, 3rd: 1.333, 4th: 1.045, 5th: 0.857)

Final Drive:

Sealed chain drive (525 O-ring type)

Transmission Oil Capacity:

0.9 L (0.95 US qt)

Transmission Oil Type:

SAE 80W-90 API GL-4 hypoid gear oil

📐 Dimensions

Overall Length:

2,255 mm (88.8 in)

Overall Width:

905 mm (35.6 in)

Overall Height:

1,205 mm (47.4 in)

Wheelbase:

1,450 mm (57.1 in)

Ground Clearance:

210 mm (8.3 in)

Seat Height:

870 mm (34.3 in)

Curb Weight:

Approx. 192 kg (423 lbs)

Fuel Tank Capacity:

18 L (4.8 US gal)

Front Tire Size:

80/90-21 M/C 48P

Rear Tire Size:

130/80-17 M/C 65P

Front Wheel Type:

Spoked

Rear Wheel Type:

Spoked

🛡️ Safety Features

Safety Features:

N/A (Motorcycle safety ratings are not standardized like cars).

Braking System:

Disc brakes front and rear, offering strong and reliable stopping power.

Lighting:

Halogen headlamp, LED tail light, front and rear turn signals.

Frame Construction:

Robust semi-double cradle frame for stability.

Ergonomics:

Upright riding position providing good visibility and control.

💡 Technology Features

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, tachometer (on some models/versions), neutral indicator, high-beam indicator, turn signal indicators.

Driver Assistance Features:

None. This era of KLR650 is mechanically focused.

Connectivity Features:

None. Primarily analog systems.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months.

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Air Filter Cleaning:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet conditions.

Coolant Type:

High-quality ethylene glycol-based coolant, 50% mixture with distilled water.

Brake Fluid Type:

DOT 4

Common Wear Items:

Clutch plates, brake pads, fork seals, chain and sprockets are common wear items due to the nature of dual-sport riding.

Potential Modifications:

Many owners opt for aftermarket exhaust systems, improved seats, and luggage racks to enhance touring capability. Carburetor jetting adjustments might be needed for specific altitude or atmospheric conditions.

Schedule:

The manual provides a detailed schedule covering all checks, adjustments, fluid changes, and component replacements at specified intervals for optimal performance and longevity.

📚 Vehicle History

Brand:

Kawasaki Heavy Industries Motorcycle & Engine Company, known for reliable and performance-oriented motorcycles.

Klr650 Lineage:

The KLR650 line has a long history, with the fundamental design proving so effective that it saw minimal changes for many years, emphasizing its durable and functional nature. The 2010 model is part of the robust 'E' generation which largely carried forward the established platform.

Manufacturing Location:

Japan (primary manufacturing)

🏆 Awards & Recognition

Industry Recognition:

The KLR650 platform is widely recognized for its 'go-anywhere' capability, reliability, and value for money in the dual-sport segment, often lauded by motorcycle publications and riders for its adventure-touring prowess.