The Kawasaki KLR650 EA, produced in 2010, is a versatile dual-sport motorcycle renowned for its robust build and go-anywhere capability. Combining Japanese engineering with a legacy of continuous refinement, this model is celebrated for its reliability, affordability, and adaptability to various riding conditions, from daily commuting to adventurous exploration. Its liquid-cooled, four-stroke single-cylinder engine, displacing 651 cc, provides dependable power, complemented by a 5-speed transmission and a durable chassis designed for longevity and performance. This workshop service manual provides comprehensive guidance for the repair and overhaul of the Kawasaki KLR650 EA 2010. It covers essential maintenance procedures, diagnostic and repair protocols, and detailed instructions for proprietary component repairs. Within its 479 pages, you will find in-depth information on the engine, transmission, fuel system, ignition, electrical system, and bodywork, along with troubleshooting guidance and special tool identification. This manual is an indispensable resource for professional technicians and experienced owners aiming to maintain optimal performance and ensure the longevity of their vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Year: 2010 Variant: EA Codes Manual Product Name: Kawasaki KLR 650 EA 2010 Workshop Service Manual PDF Download 👋 Introduction Market Position Target Audience: Mechanical technicians familiar with BRP products, experienced motorcycle owners Competitive Analysis Value Proposition: Provides dealer-level service information, enabling cost savings and professional-quality repairs Key Features Emphasis On Safety: Highlights the importance of safety equipment (e.g., torque wrench) and precautions Special Tool Identification: Identifies and illustrates recommended or required special tools by Kawasaki part number Information Reliability: Aimed at providing the most reliable information for optimal vehicle performance and longevity Special Notations: Utilizes WARNING, CAUTION, and NOTE symbols for critical information 📋 Manual Details Coverage Areas Primary Coverage: Repair and overhaul of Kawasaki KLR 650 EA 2010 Secondary Coverage: Routine maintenance and servicing, diagnostic and repair procedures, proprietary component repairs Page Count Total Pages: 479 Manual Type Type: Workshop Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive engine disassembly, assembly, repair, tune-ups, lubrication system Transmission: Transmission disassembly, assembly, repair Fuel System: Detailed coverage of fuel system components and procedures Ignition: Ignition system diagnostics and repair Electrical System: Complete electrical system diagnostics, wiring diagrams, component testing Bodywork: Body component removal and installation, repair procedures Exhaust: Exhaust system maintenance and repair Procedures Included Routine Maintenance: Detailed instructions for routine maintenance and servicing Troubleshooting: Diagnostic and repair procedures for common and uncommon issues Disassembly Assembly: Step-by-step procedures for component and system disassembly and reassembly Proprietary Component Repair: Incorporates manufacturer instructions for proprietary components Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes, printable Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Fast and Free Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke Single Displacement: 651 cc Performance Bore X Stroke: 100.0 x 83.0 mm (Typical for KLR650 models) Compression Ratio: 9.5:1 (Typical for KLR650 models) Valve Train: DOHC, 4 valves per cylinder (Typical for KLR650 models) Fuel System Fuel Delivery: Fuel Injection (EFI) (Specifics detailed in manual) Carburetion: N/A (EFI equipped) Lubrication System Type: Forced lubrication, wet sump (Typical for KLR650 models, detailed in manual) 🔧 Transmission Standard Type: 5-speed constant mesh Optional Optional Transmission: N/A Features Clutch: Wet, multiple disc 📐 Dimensions Exterior Overall Length: 2,295 mm (90.4 in) (Typical for KLR650 models) Overall Width: 910 mm (35.8 in) (Typical for KLR650 models) Overall Height: 1,405 mm (55.3 in) (Typical for KLR650 models) Weights Curb Weight: 194 kg (428 lb) (Typical for KLR650 models) Fuel Tank Capacity: 18 L (4.8 US gal) (Typical for KLR650 models) 🛡️ Safety Features Ratings Safety Features In Manual: Detailed safety warnings, precautions, and procedures emphasized Active Features Brakes Front: 280 mm petal disc, 2-piston caliper (Typical for KLR650 models) Brakes Rear: 240 mm petal disc, 1-piston caliper (Typical for KLR650 models) Passive Features Suspension Front: 41 mm telescopic fork with adjustable rebound damping (Typical for KLR650 models) Suspension Rear: Adjustable preload, rebound damping, and compression damping Uni-Trak with gas-charged shock (Typical for KLR650 models) 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, LCD display with odometer, trip meter, clock, coolant temperature gauge, fuel gauge (Typical for KLR650 models) Driver Assistance ABS: N/A for this specific 2010 EA model as standard, ABS was introduced later in the KLR650 lineage. Manual will detail non-ABS braking system. Connectivity Charging System: 12V DC electrical system with alternator and battery (Detailed in manual) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific intervals and oil type recommendations (typically every 6,000 km or 3,700 miles for severe use) Air Filter Cleaning: Refer to manual for specific intervals (typically every 6,000 km or 3,700 miles) Spark Plug Replacement: Refer to manual...