🏷️ Basic Information

Make:

Kawasaki

Model:

KL650EA

Year:

2010

Chassis Code:

KL650EA

Engine Code:

KL650AE

👋 Introduction

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.

📋 Manual Details

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

Language:

English

Format:

PDF Download

📖 Manual Coverage

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.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable if generated from original digital files, allowing for quick information retrieval.

Quality:

High resolution, suitable for clear printing of text and diagrams.

Binding:

Not applicable (Digital PDF download)

Paper:

Not applicable (Digital PDF download)

⚙️ Engine Specifications

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.

🔧 Transmission

Type:

5-speed, constant mesh

Primary Drive:

Gear

Final Drive:

Sealed chain (520 O-ring seal)

Clutch Type:

Wet, multi-disc

📐 Dimensions

Length:

Approx. 2,180 mm (85.8 in)

Width:

Approx. 830 mm (32.7 in)

Height:

Approx. 1,375 mm (54.1 in)

Wheelbase:

Approx. 1,465 mm (57.7 in)

Ground Clearance:

Approx. 220 mm (8.7 in)

Dry Weight:

Approx. 172 kg (379 lbs)

Curb Weight:

Approx. 186 kg (410 lbs)

Fuel Capacity:

14 L (3.7 US gal)

🛡️ Safety Features

Crash Test Data:

Not typically rated by organizations like NHTSA or Euro NCAP as it is a motorcycle.

Brakes:

Front: Single 300 mm disc with 2-piston caliper. Rear: Single 240 mm disc with 1-piston caliper. ABS was an option on some models/markets but not standard for 2010 KL650EA.

Lighting:

Halogen headlight, LED taillight.

Ergonomics:

Upright riding position for comfort and control.

💡 Technology Features

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.

🔧 Maintenance

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.

📚 Vehicle History

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.

🏆 Awards & Recognition

Industry Acclaim:

The KLR650 platform is widely recognized for its durability, value for money, and capability as an adventure motorcycle, making it a popular choice for long-distance travel and exploration.