🏷️ Basic Information

Make:

Kawasaki

Model:

KLE650

Variant:

CAF

Year:

2010

Product Type:

Workshop Service Repair Manual

👋 Introduction

Segment:

Adventure Touring / Sport Touring Motorcycle

Target Audience:

Owners seeking to perform their own maintenance and repairs, or independent motorcycle repair shops.

Competitors:

Suzuki V-Strom DL650, Honda NC700X/NC750X (in later years).

Vehicle Highlights:

Versatile parallel-twin engine, comfortable ergonomics for long-distance riding, capable on various road surfaces.

Benefit To Owner:

Empowers owners to maintain their KLE650CAF, saving money on dealership service, increasing understanding of the motorcycle, and ensuring longevity through proper care.

📋 Manual Details

General Coverage:

Complete factory service and repair information for the 2010 Kawasaki KLE650CAF.

Estimated Pages:

Hundreds of pages (specific count not provided, but implies comprehensive documentation).

Type:

Workshop Service Repair Manual

Language:

English (assumed based on typical product offerings for this market).

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed diagnosis, repair, and overhaul procedures for the 650cc parallel-twin engine.

Fuel System:

Fuel injection system, injectors, fuel pump, fuel filter, evaporative emission control system.

Ignition System:

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

Cooling System:

Radiator, cooling fan, thermostat, coolant flow, pressure testing.

Exhaust System:

Exhaust pipes, catalytic converter, mufflers, O2 sensors.

Transmission:

Clutch operation, gearbox, internal components, lubrication, troubleshooting.

Drivetrain:

Final drive chain and sprockets, adjustment, inspection.

Suspension:

Front fork (telescopic, USD or conventional), rear shock absorber, linkage, adjustment, overhaul.

Brakes:

Front and rear brake systems (disc brakes), brake pads, calipers, master cylinders, brake lines, fluid replacement, bleeding procedures.

Wheels And Tires:

Wheel bearings, tire pressure, tire replacement, wheel balancing.

Electrical System:

Battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor), lighting, horn, fuses, relays.

Instrumentation:

Speedometer, tachometer, fuel gauge, indicator lights, diagnostic codes.

Frame And Bodywork:

Chassis inspection, frame components, fairings, seat, fuel tank, fenders, removal and installation.

Controls:

Throttle, clutch lever, brake lever, handlebar, footpegs, cables.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common problems and solutions.

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, spark plug replacement, air filter cleaning/replacement, brake checks.

Engine Repair:

Top-end rebuild (cylinder head, piston), bottom-end overhaul (crankshaft, connecting rods), valve clearance adjustment.

Transmission Repair:

Gearbox disassembly and assembly, clutch replacement, shifting mechanism repair.

Suspension Overhaul:

Fork seal replacement, damper rod service, rear shock absorber servicing.

Brake System Service:

Brake fluid flush and bleed, caliper piston service, master cylinder rebuild.

Electrical Diagnostics:

Wiring diagrams, circuit testing, fault finding for starting, charging, and ignition systems.

Fuel System Diagnostics:

Fuel pressure testing, injector pulse width measurement, idle speed control adjustment.

Bodywork Repair:

Fairing removal and installation, decal application, panel repair.

Wheel And Tire Service:

Wheel bearing replacement, tire mounting and balancing.

Depth Level:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics and electrical schematics.

📊 Manual Specifications

Digital Format:

PDF

Printability:

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

Binding Options:

Digital (PDF), user printable to their preferred binding.

Paper Recommendation:

Standard copy paper for printing; consider heavier stock for a bound manual.

⚙️ Engine Specifications

Engine Type:

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

Displacement:

649 cc (39.6 cu. in.)

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Horsepower Claimed:

Approx. 67 hp @ 8000 rpm (actual figures may vary slightly by region)

Torque Claimed:

Approx. 46 lb-ft @ 6000 rpm (actual figures may vary slightly by region)

Fuel Delivery:

Digital Fuel Injection (DFI) with dual 38mm throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane

Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil

Oil Capacity With Filter:

3.0 L (3.2 US qt)

Ignition Type:

TCBI (Transistor Controlled Ignition) with digital advance

Spark Plug Type:

NGK CR9EIA-9 or DENSO VUH27A (check manual for exact fitment)

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multi-disc

Transmission Oil Type:

Kawasaki Genuine Transmission Oil, SAE 80 (API GL-4) or equivalent (check manual for specific recommendations).

Final Drive:

Sealed chain, 525

📐 Dimensions

Length:

2,195 mm (86.4 in)

Width:

800 mm (31.5 in)

Height:

1,410 mm (55.5 in)

Wheelbase:

1,415 mm (55.7 in)

Ground Clearance:

170 mm (6.7 in)

Seat Height:

800 mm (31.5 in)

Curb Weight:

Approx. 209 kg (460.6 lbs)

Fuel Tank Capacity:

15 L (4.0 US gal)

🛡️ Safety Features

Safety Certification:

CE (for European markets), EPA (for US markets) - adherence to emissions and safety standards.

Braking System:

Dual front disc brakes, single rear disc brake. ABS was an optional feature on some models/markets but not standard on all 2010 KLE650CAF variants.

Lighting:

Halogen headlamp, LED tail lamp and brake lights, turn signals.

💡 Technology Features

Display Type:

Digital/Analog combination instrument cluster featuring a digital speedometer, analog tachometer, LCD multi-function display (fuel level, clock, odometer, trip meters).

ABS Availability:

Anti-lock Braking System (ABS) was optional on some 2010 models, typically indicated by an 'ABS' badge on the motorcycle. The manual would detail ABS-specific components and diagnostics if equipped.

🔧 Maintenance

Oil And Filter Change:

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

Chain Adjustment:

Inspect every 1,000 km (600 miles) or sooner if slack is felt; adjust as needed.

Valve Clearance:

Every 24,000 km (15,000 miles).

Air Filter:

Clean every 12,000 km (7,500 miles), replace as needed.

Brake Fluid:

DOT 4.

Coolant:

Kawasaki Coolant (50/50 mixture of ethylene glycol and deionized water) or equivalent.

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, and bearings are common wear items on higher mileage bikes. Some owners report occasional issues with the fuel pump or regulator/rectifier, though generally reliable.

Diagnostic Emphasis:

The manual provides detailed guidance on diagnosing issues related to the EFI system, electrical faults, and mechanical component wear, enabling owners to pinpoint problems effectively.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.

Kle Series Origin:

The KLE series, particularly the Versys line, evolved from Kawasaki's desire to create a versatile, sporty, and adventure-capable machine. The 650cc parallel-twin engine platform is shared with the popular Ninja 650.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Motorcycle Reviews:

While specific awards for the 2010 model are not cited, the Kawasaki Versys platform has consistently received positive reviews for its versatility, performance, and value in the sport-touring segment.