🏷️ Basic Information

Make:

Kawasaki

Model:

KLE650

Model Code:

KLE650CAF

Year:

2010

Vin Prefix:

Begin with JKBKL...

👋 Introduction

Segment:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Owners and technicians looking for in-depth repair and maintenance information.

Comparable Models:

Suzuki V-Strom 650, Honda Transalp (earlier generations), BMW F650GS.

Vehicle Platform:

Versatile platform suitable for commuting, touring, and light off-road use.

Manual Advantage:

Provides factory-level accuracy for repairs, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Scope:

Complete Factory Service Repair Manual

Estimated Page Count:

Hundreds of pages (specific count not provided but implied to be comprehensive)

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, inspection, and repair procedures for the 650cc parallel-twin engine.

Fuel System:

Inspection and servicing of fuel injection system (EFI), throttle body, fuel pump, injectors, and fuel tank.

Cooling System:

Radiator, fan, thermostat, coolant flow, and pump inspection and repair.

Exhaust System:

Catalytic converter, mufflers, and piping inspection and replacement.

Transmission:

Clutch operation, gearbox inspection, disassembly, assembly, and shift mechanism servicing.

Drivetrain:

Final drive chain and sprockets inspection, adjustment, and replacement procedures.

Suspension Front:

Front fork disassembly, assembly, oil replacement, seal replacement, and damping adjustment.

Suspension Rear:

Rear shock absorber inspection, adjustment, and linkage servicing.

Brakes Front:

Brake caliper, master cylinder, brake lines, rotor, and pad inspection and replacement.

Brakes Rear:

Rear brake caliper, master cylinder, brake lines, rotor, and pad inspection and replacement.

Wheels Tires:

Wheel bearing inspection and replacement, tire mounting and balancing.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), ignition system (ECU, spark plugs, coils).

Lighting System:

Headlight, taillight, turn signals, brake lights, and instrument panel illumination troubleshooting.

Instruments Controls:

Speedometer, tachometer, fuel gauge, warning lights, and handlebar controls.

Bodywork:

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

Chassis:

Frame inspection, steering head bearing maintenance.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, brake fluid checks.

Troubleshooting:

Diagnostic procedures for common electrical and mechanical issues with fault codes.

Major Repairs:

Engine rebuild, transmission overhaul, suspension rebuild, brake system servicing.

Component Replacement:

Step-by-step guides for replacing wear items and major components.

Torque Specifications:

All critical fastener torque values for engine, chassis, and bodywork.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for easy troubleshooting.

Depth:

Factory-level detail for comprehensive diagnostics, repair, and maintenance.

Diagnostic Codes:

Includes information on diagnostic trouble codes (DTCs) and their interpretation.

Rebuild Procedures:

Detailed procedures for complete engine and transmission rebuilds.

📊 Manual Specifications

Format Details:

Adobe PDF, allowing for digital viewing, searching, and printing.

Quality:

High-resolution scans of original factory documentation, suitable for clear printing.

Binding Recommendation:

Printable and can be professionally bound for workshop use.

Paper Recommendation:

Standard printer paper recommended for printing.

⚙️ Engine Specifications

Engine Type:

4-stroke, Liquid-cooled, DOHC, 8-valve, Parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.2:1

Horsepower Approx:

Approx. 64 hp @ 8,000 rpm (model dependent, consult manual for exact specs)

Torque Approx:

Approx. 45 lb-ft @ 6,000 rpm (model dependent, consult manual for exact specs)

Fuel Delivery:

Digital Fuel Injection with Dual 38mm Throttle Bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane (AKI)

Ignition System:

TCBI with Digital Advance

Lubrication System:

Forced lubrication, wet sump

Starter:

Electric starter

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multiple-disc, cable operated

Gear Ratios:

Specific ratios detailed in manual for each gear.

Final Drive:

Sealed O-ring chain

📐 Dimensions

Overall Length:

Approx. 2,180 mm (85.8 in)

Overall Width:

Approx. 800 mm (31.5 in)

Overall Height:

Approx. 1,370 mm (53.9 in)

Wheelbase:

Approx. 1,465 mm (57.7 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Seat Height:

Approx. 820 mm (32.3 in)

Curb Weight:

Approx. 197 kg (434.3 lbs) (fully fueled, equipped with standard equipment)

Fuel Tank Capacity:

15 Liters (4.0 US gal)

🛡️ Safety Features

Safety Features:

Standard safety features as per motorcycle design principles; ABS was an option on some markets/variants.

Braking System:

Dual 300mm petal discs with twin-piston calipers (front), Single 240mm petal disc with twin-piston caliper (rear). Optional ABS available.

Lighting:

Multi-reflector headlights for improved visibility.

💡 Technology Features

Instrument Panel:

Digital LCD instrument cluster displaying speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and warning lamps.

ABS:

Anti-lock Braking System (ABS) was an optional feature available on certain configurations of the 2010 model.

Charging Port:

No factory-integrated USB or 12V charging port; aftermarket accessories can be installed.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact spec).

Spark Plug Replacement:

Typically every 12,000 km (7,500 miles) or 12 months (refer to manual for exact spec and type).

Air Filter Cleaning:

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

Chain Adjustment:

Inspect and adjust chain slack every 1,000 km (600 miles).

Engine Oil Type:

SAE 10W-40 API SG or SH, approved for 4-stroke motorcycle engines. Kawasaki recommends KAWASAKI's own brand of oil.

Engine Oil Capacity:

3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change (refer to manual for exact capacity).

Coolant Type:

Ethylene glycol based antifreeze with demineralized water, 50/50 mix. Kawasaki recommends KAWASAKI COOLANT TYPE 2.

Brake Fluid Type:

DOT 4

Fork Oil Type:

Show Suspension Oil 15W or equivalent (refer to manual for exact type and quantity).

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals.

Potential Issues:

Cam chain tensioner can become noisy over time. Some owners report potential issues with the regulator/rectifier under high load/heat conditions (though less common on this specific year than earlier models).

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Predecessor:

KLE500 (discontinued)

Platform Introduction:

The ER-6 platform, which the KLE650 is based on, was introduced in 2005. The Versys model (which shares the engine but has different chassis and styling) debuted in 2007, followed by the KLE650 ( വിЭരസസ് ) model.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Award Status:

While specific awards for the 2010 KLE650CAF may not be widely publicized, the model is generally well-regarded for its versatility and value within the adventure-touring segment.