🏷️ Basic Information

Make:

Kawasaki

Model:

KL650EA

Year:

2010

Vehicle Type:

Dual-sport Motorcycle

Chassis Code:

KL650EA

👋 Introduction

Segment:

Dual-sport / Adventure Motorcycle, known for its ruggedness and reliability.

Competitors:

Suzuki DR650SE, Honda XR650L, Yamaha XT660R.

Features:

Versatile for both on-road and off-road use, simple and robust engine design, comfortable ergonomics for longer rides.

Audience:

Owners of the Kawasaki KL650EA seeking to perform maintenance, repairs, or understand the technical aspects of their motorcycle.

📋 Manual Details

Systems Covered Summary:

Engine, Fuel System, Ignition, Lubrication, Cooling, Transmission, Clutch, Drivetrain, Frame, Suspension, Steering, Brakes, Electrical System, Bodywork, Troubleshooting, Specifications.

Estimated Page Count:

300-400

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, inspection, repair, and overhaul procedures for the 651cc liquid-cooled, four-stroke, SOHC, four-valve engine.

Fuel System:

Carburetor tuning, cleaning, and overhaul (likely Keihin CVK40 for this model), fuel pump operation, fuel filter replacement.

Ignition System:

CDI system troubleshooting, spark plug specifications, ignition timing adjustment.

Lubrication System:

Oil pump inspection, oil filter replacement, oil change intervals, oil capacity, lubrication points.

Cooling System:

Radiator inspection, coolant type and capacity, fan operation, thermostat testing, water pump overhaul.

Transmission:

Gearbox inspection, clutch assembly removal and installation, clutch adjustment, transmission fluid type and capacity.

Drivetrain:

Chain and sprocket inspection, adjustment, and replacement; rear hub bearing maintenance.

Frame And Suspension:

Front fork disassembly, seal replacement, oil type and level; rear shock absorber inspection and adjustment; swingarm and linkage bearing maintenance.

Steering:

Steering head bearing adjustment and replacement, handlebar installation.

Brakes:

Front and rear brake system inspection, pad replacement, caliper overhaul, master cylinder servicing, brake fluid type and bleeding procedures.

Electrical System:

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

Bodywork:

Fairing, tank, seat, fenders, and luggage rack removal and installation.

Maintenance:

Regular scheduled maintenance checks, oil changes, filter replacements, chain lubrication and adjustment, brake fluid changes, coolant flushes.

Troubleshooting:

Diagnostic flowcharts and guides for common problems related to starting, running, electrical issues, and performance.

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Diagnostics:

Methods for identifying and resolving mechanical and electrical faults using diagnostic charts and specifications.

Overhaul:

Comprehensive procedures for engine rebuilds, carburetor overhauls, and suspension component servicing.

Depth:

Comprehensive coverage suitable for both home mechanics and professional technicians, including detailed torque specifications, clearances, and assembly procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable if properly digitized.

Quality:

Varies based on original manual and digitization process, typically clear diagrams and text.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, DOHC, single cylinder

Displacement:

651 cc (40.1 cu in)

Bore X Stroke:

100.0 x 83.0 mm (3.94 x 3.27 in)

Compression Ratio:

9.5:1

Valve Train:

SOHC, 4 valves

Horsepower Estimated:

Approx. 45-48 HP (at crankshaft, depending on specific tuning)

Torque Estimated:

Approx. 52 Nm (38.4 lb-ft) (at crankshaft)

Fuel Delivery:

Carburetor (likely Keihin CVK40)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Ignition System:

Digital CDI

Spark Plug Type:

NGK CR9E or equivalent

Oil Capacity W Filter Change:

Approx. 2.4 Liters (2.5 US qt)

Recommended Oil Viscosity:

SAE 10W-40 (API SG or higher, JASO MA)

Cooling System Type:

Liquid-cooled

Coolant Capacity:

Approx. 1.7 Liters (1.8 US qt)

Recommended Coolant:

Ethylene glycol-based coolant, 50/50 mix with distilled water

🔧 Transmission

Type:

Constant mesh 5-speed

Final Drive:

Sealed chain, 525

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

API GL-1 or GL-4 gear oil (specific viscosity may be detailed in manual)

📐 Dimensions

Length:

Approx. 2180 mm (85.8 in)

Width:

Approx. 840 mm (33.1 in)

Height:

Approx. 1190 mm (46.9 in)

Wheelbase:

Approx. 1465 mm (57.7 in)

Ground Clearance:

Approx. 220 mm (8.7 in)

Seat Height:

Approx. 860 mm (33.9 in)

Curb Weight:

Approx. 176 kg (388 lbs)

Fuel Tank Capacity:

18 Liters (4.8 US gal)

Front Tire Size:

80/90-21M/C 48S

Rear Tire Size:

4.60-17M/C 62S

Front Wheel Type:

Spoked, 21-inch

Rear Wheel Type:

Spoked, 17-inch

🛡️ Safety Features

Crash Safety Ratings:

N/A (Motorcycle safety is typically assessed through rider skill and component integrity, not standardized crash tests like cars).

Braking System:

Front: Single 300mm disc with dual-piston caliper. Rear: Single 240mm disc with dual-piston caliper.

Lighting:

Halogen headlight, LED tail light, incandescent turn signals.

Frame Construction:

High-tensile steel semi-double cradle frame.

💡 Technology Features

Infotainment System:

Basic analog instrumentation (speedometer, tachometer, odometer, trip meters), basic warning lights. No integrated infotainment system.

Assistance Features:

None (focus on mechanical simplicity).

Connectivity Features:

None (focus on mechanical simplicity).

Headlight Type:

Halogen

🔧 Maintenance

Oil Change Interval:

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

Air Filter Inspection:

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

Spark Plug Replacement:

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

Valve Clearance Check:

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

Chain Adjustment:

Check slack every 1,000 km (600 miles) or after extended periods of inactivity; adjust as needed.

Engine Oil:

SAE 10W-40, API SG or higher, JASO MA.

Coolant:

50/50 mix of ethylene glycol-based coolant and distilled water.

Brake Fluid:

DOT 4.

Transmission Oil:

API GL-1 or GL-4 gear oil (specific viscosity to be confirmed in manual).

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, wheel bearings, balancer chain tensioner (on older models, may be improved in 2010).

Potential Faults:

Carburetor jetting may require adjustment for altitude or modifications; some owners report balancer chain rattle on high-mileage units.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long history in motorcycle manufacturing, known for performance and durability, dating back to the 1960s.

Kl650 Lineage:

The KL650 platform, often known as the KLR650, has a lineage tracing back to the original 1987 model. It has undergone evolutionary updates rather than radical redesigns, maintaining its core dual-sport identity.

Manufacturing Location:

Japan (typically).

Production Years For Model:

The KL650EA designation specifically refers to the 2010 model year, but the KLR650 model has been in continuous production with minor updates for many years.

🏆 Awards & Recognition

Industry Recognition:

The KLR650 line is consistently recognized for its value, versatility, and long-term reliability in the dual-sport segment.

Owner Satisfaction:

Generally high owner satisfaction for its intended purpose, often praised for its durability and low cost of ownership.