🏷️ Basic Information Identification Make: Kawasaki Model: KLE650 Model Variant: CAF Year: 2010 Product Type: Workshop Repair Service Manual 👋 Introduction Market Position Category: Adventure Sport Touring / Dual-Sport Motorcycle Target Audience: Owners seeking to perform their own maintenance, repairs, and modifications. Competitive Analysis Segment: Competes with models like the Suzuki V-Strom 650, BMW F650GS (twin), Honda NC700X/DCT (later years). Key Features Vehicle Engine Type: Parallel-twin, DOHC, 8-valve, liquid-cooled. Styling: Dual-sport aesthetic with a comfortable upright riding position and wind protection from the fairing and windscreen. Key Features Manual Utility: Essential for maintaining peak performance, reliability, and safety of the KLE650CAF. Value Proposition: Enables significant cost savings on maintenance and repairs compared to dealership services. 📋 Manual Details Coverage Areas All Models Engines Trims: True Page Count Estimated Pages: Approximately 500+ Manual Type Manual Type: Comprehensive Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, assembly, and tuning of the 650cc parallel-twin engine. Fuel System: Fuel injection system, fuel pump, injectors, throttle body, evaporative emission control system. Ignition System: Ignition coil, spark plugs, ECU control, ignition timing. Cooling System: Radiator, coolant, water pump, thermostat, cooling fan operation. Exhaust System: Exhaust pipes, catalytic converter, muffler, exhaust emissions control. Transmission Drivetrain: Clutch operation, gearbox (6-speed), shift mechanism, final drive (chain and sprockets). Suspension Front: Front fork (telescopic, non-adjustable or adjustable depending on specific sub-model), steering system, wheel bearings. Suspension Rear: Rear shock absorber (adjustable preload/rebound), swingarm, linkage system, rear wheel bearings. Brakes Front: Dual disc brakes, calipers, master cylinder, brake fluid, hoses, ABS (if equipped). Brakes Rear: Single disc brake, caliper, master cylinder, brake fluid, hoses, ABS (if equipped). Wheels Tires: Wheel specifications, tire pressure, rim removal/installation, tire changing. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, tail light, indicators), horn. Instrumentation: Instrument panel, gauges (speedometer, tachometer, fuel gauge), warning lights. Chassis Frame: Frame construction, steering head, subframe, body panels, fairings. Bodywork Cosmetics: Fairings, fenders, seat, fuel tank, mounting points, panel removal/installation. Diagnostic Procedures: Troubleshooting charts, fault codes (if applicable for EFI systems), common problem diagnosis. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake pad inspection, tire checks. Engine Overhaul: Complete engine teardown, component measurement, rebuild procedures. Suspension Rebuild: Front fork seal replacement, rear shock absorber servicing. Brake System Service: Brake fluid flush and bleed, caliper overhaul, master cylinder replacement. Electrical Troubleshooting: Wiring diagrams, circuit testing, component testing. Fuel System Diagnosis: Checking fuel pressure, injector pulse width, throttle position sensor (TPS) adjustment. Valve Adjustment: Procedure for checking and adjusting valve clearances. Troubleshooting Guides: Systematic approaches to diagnose and fix common and uncommon issues. Technical Depth Depth Level: Expert-level, covering all aspects from basic maintenance to complete engine and chassis rebuilds. Diagnostic Capabilities: Detailed diagnostic procedures, wiring diagrams, and component testing methods. Rebuild Specifications: Includes all necessary torque specifications, clearances, and measurements for internal engine and gearbox components. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Printability: High-resolution, printable pages. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: ER650AE (approximate, check VIN) Displacement: 649 cc Bore X Stroke: 83.0 mm x 60.0 mm Compression Ratio: 11.5:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Peak: Approx. 72 HP @ 8500 RPM (spec varies slightly by region/tuning) Torque Peak: Approx. 46 lb-ft @ 7000 RPM (spec varies slightly by region/tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 91 octane (RON+MON)/2 minimum Fuel Tank Capacity: 15 Liters (3.96 US gal) 🔧 Transmission Standard Transmission Type: 6-Speed Constant Mesh Clutch Type: Wet, Multiple Disc Final Drive: Sealed Chain Drive 📐 Dimensions Exterior Overall Length: 2,105 mm (82.9 in) Overall Width: 780 mm (30.7 in) Overall Height: 1,170 mm (46.1 in) Wheelbase: 1,415 mm (55.7 in) Ground Clearance: 170 mm (6.7 in) Seat Height: 820 mm (32.3 in) Weights Curb Weight: Approx. 192 kg (423 lbs) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle specific safety ratings not typically published in the same way as cars) Active Features ABS: Available as an option on certain models/trims (check specific VIN). Passive Features Lighting: Multi-reflector headlight, LED taillight. Braking Performance: Dual front discs and single rear disc provide strong stopping power. 💡 Technology Features Infotainment Instrument Cluster: Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, and various warning indicators. Driver Assistance ABS Availability: Anti-lock Braking System (ABS) available as an optional feature, enhancing braking safety. Connectivity ECU Control: Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km (3,700 miles) or 6 months, whichever comes first. Oil Filter Replacement: At every engine oil change. Air Filter Inspection: Every...