The 2010 Kawasaki KL650EA is a versatile dual-sport motorcycle, renowned for its robust engineering and go-anywhere capability, making it a popular choice for adventure touring and everyday commuting. Building on Kawasaki's extensive heritage in motorcycle manufacturing, the KL650EA variant offers a blend of performance and reliability, stemming from a lineage that dates back to the 1980s. Its design prioritizes durability and practicality, equipped with a 649cc parallel-twin engine, a 6-speed transmission, and a capable chassis that handles both paved roads and light off-road conditions with confidence. This comprehensive workshop service manual provides essential technical data for the maintenance and repair of the 2010 Kawasaki KL650EA. It covers a wide array of systems, including detailed procedures for the engine, transmission, fuel, cooling, exhaust, ignition, starting, charging, suspension, brakes, wheels, tires, steering, and electrical systems. The manual includes step-by-step guides for routine maintenance, major repairs, troubleshooting, and component replacement, along with critical torque specifications and wiring diagrams, ensuring optimal performance and longevity for owners and technicians alike. 🏷️ Basic Information Identification Make: Kawasaki Model: KL650EA Year: 2010 Product Type: Workshop Service Manual Format: PDF Download 👋 Introduction Market Position Vehicle Segment: Dual-sport motorcycle, adventure touring. Target Audience: Owners and technicians seeking comprehensive repair and maintenance information for the KL650EA. Competitive Analysis Competitors 1: Honda Transalp, Suzuki V-Strom, Yamaha Ténéré. Key Features Manual Benefit 1: Provides the essential technical data for maintaining and repairing the KL650EA, ensuring optimal performance and longevity. Manual Benefit 2: Instant digital access eliminates shipping delays and costs. 📋 Manual Details Coverage Areas Engine: Included Transmission: Included Fuel System: Included Cooling System: Included Exhaust System: Included Ignition System: Included Starting System: Included Charging System: Included Suspension Front: Included Suspension Rear: Included Brakes Front: Included Brakes Rear: Included Wheels Tires: Included Steering: Included Electrical System Components: Included Lighting System: Included Instrumentation: Included Frame Chassis: Included Bodywork Fairings: Included Troubleshooting: Included Wiring Diagrams: Included Page Count Pages: 479 Manual Type Type: Workshop Service Manual Purpose: Repair and Maintenance Language Language: English Format File Format: PDF Digital Delivery: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, and reassembly of engine components (cylinder head, pistons, crankshaft, etc.). Engine Management: Information on fuel injection, ignition timing, sensors, and ECU diagnostics. Drivetrain: Clutch operation, transmission gear inspection and replacement, final drive. Chassis Suspension: Fork and shock absorber servicing, linkage maintenance, bearing checks. Braking System: Brake fluid replacement, caliper overhaul, disc inspection, master cylinder service. Electrical Diagnostics: Comprehensive wiring diagrams for all circuits, troubleshooting guides for electrical faults. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain adjustment, air filter cleaning/replacement. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair. Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon problems. Component Replacement: Detailed instructions for replacing individual parts and sub-assemblies. Torque Specifications: Precise torque values for all critical fasteners. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Detail Level: Detailed explanations of disassembly, assembly, adjustments, and diagnostics. Diagnostic Tools: Mentions diagnostic procedures potentially requiring specialized tools, though not explicitly listing them. 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text within the PDF, allowing for quick information retrieval. Printable: Designed to be printable for workshop use. Print Quality: Assumed high quality due to being a professional workshop manual. Binding Type Binding: N/A (PDF Digital Download) Paper Type Paper: N/A (PDF Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, liquid-cooled, DOHC, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 64 hp @ 8000 rpm (varies by market and tuning) Torque: Approx. 43.5 lb-ft @ 7000 rpm (varies by market and tuning) Fuel System Induction: Digital Fuel Injection with two 38mm Keihin throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane Cooling System Type: Liquid-cooled Coolant Type: Kawasaki Specific Coolant or equivalent ethylene glycol-based antifreeze Lubrication System Type: Forced lubrication, wet sump Oil Capacity W Filter: 3.2 US qt (3.0 L) Oil Type Spec: SAE 10W-40 API SG, SH, SJ, SL or SM 🔧 Transmission Standard Type: 6-speed, constant mesh Features Clutch Type: Wet, multi-disc, cable-actuated Final Drive: Sealed chain, 15/43T (example, verify with manual) Fluid Type Transmission Oil: API GL-4, SAE 80 or 90 hypoid gear oil (for separate gearbox oil, if applicable) 📐 Dimensions Exterior Overall Length: 2,195 mm (86.4 in) Overall Width: 800 mm (31.5 in) Overall Height: 1,210 mm (47.6 in) Wheelbase: 1,450 mm (57.1 in) Ground Clearance: 170 mm (6.7 in) Weights Curb Weight: Approx. 208 kg (459 lbs) Fuel Tank Capacity: 17.0 L (4.5 US gal) Wheels Tires Front Tire: 90/90-21M/C 54S Rear Tire: 130/80-17M/C 65S Wheelbase Type: Spoked 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle, subject to specific country regulations and testing) Active Features Brakes: Disc brakes front and rear. 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