Kawasaki KLE650DAF 2010 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLE650 Year: 2010 Model Code: KLE650DAF Product Type: Factory Service Repair Manual Vehicle Type: Motorcycle Codes Manual File Name Suggestion: Kawasaki_KLE650DAF_2010_Factory_Service_Repair_Manual.pdf 👋 Introduction Market Position Category: Adventure Sport Touring Motorcycle Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and light off-road use Competitive Analysis Competitors 2010: Suzuki V-Strom 650, Honda Transalp XL700V (in some markets), BMW F650GS (previous generation) Key Features Engine Layout: Parallel-twin Chassis Type: Semi-double cradle, steel Design Philosophy: Combines comfort and practicality of a touring bike with some off-road capability 📋 Manual Details Coverage Areas Model Variants Covered: KLE650DAF Model Years Covered: 2010 Page Count Estimated Pages: Hundreds (specific count not provided in product info) Manual Type Type: Factory Service Repair Manual Purpose: Comprehensive repair, maintenance, and troubleshooting Language Language: English (presumed, standard for factory manuals from major manufacturers) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, specifications, tuning Fuel System: Fuel injection, fuel pump, injectors, fuel tank, lines Ignition System: Ignition coils, spark plugs, ECU, sensors Cooling System: Radiator, fan, coolant, water pump, thermostat Transmission: Clutch, gearbox, shift mechanism, internal components, fluid Drivetrain: Chain, sprockets, rear suspension linkage Chassis: Frame, subframe, body panels, fairings Suspension Front: Front forks, seals, springs, oil, adjustments Suspension Rear: Rear shock absorber, linkage, adjustments Brakes Front: Brake calipers, discs, master cylinder, hoses, fluid, ABS (if applicable) Brakes Rear: Brake caliper, disc, master cylinder, hoses, fluid, ABS (if applicable) Wheels And Tires: Wheel bearings, tire pressures, rim specifications Electrical System: Wiring diagrams, battery, charging system, lighting, starter, horn, fuses Instrumentation And Controls: Dashboard, switches, levers, cables Exhaust System: Exhaust pipes, muffler, catalytic converter (if applicable) Lubrication System: Oil pump, oil filter, oil passages Procedures Included Maintenance: Regular scheduled maintenance, checks, adjustments Troubleshooting: Diagnostic charts, common problems and solutions Repair: Step-by-step disassembly and reassembly of all major components Rebuilds: Complete engine, transmission, and suspension rebuild procedures Adjustments: Valve clearance, chain tension, clutch, throttle, suspension Diagnostics: Fault code interpretation, electrical system testing Specifications: Torque values, clearances, fluid capacities, electrical data Technical Depth Depth: Factory-level detail, suitable for professional mechanics and experienced DIYers Accuracy: Official factory data, ensuring accuracy and precision 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if OCR'd properly Print Quality Printability: Printable in entirety or selected pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, four valves per cylinder, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.2:1 Power Output Ps: 63 PS @ 8000 rpm (approx.) Power Output Hp: 62 bhp @ 8000 rpm (approx.) Torque Nm: 60 Nm @ 6000 rpm (approx.) Torque Lb-Ft: 44 lb-ft @ 6000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (DFI) Fuel Type: Unleaded gasoline, 87 AKI or higher Fuel Tank Capacity L: 15 Liters Fuel Tank Capacity Gal: 3.96 US Gallons Performance Top Speed: Approx. 110-120 mph (177-193 km/h), dependent on rider and conditions 🔧 Transmission Standard Type: Constant-mesh, 6-speed Optional Options: N/A (Only manual transmission offered for this model) Features Clutch: Wet, multi-disc, manual operation Final Drive: Sealed chain, 525 V8 (DID) 📐 Dimensions Exterior Overall Length: 2,195 mm (86.4 in) Overall Width: 830 mm (32.7 in) Overall Height: 1,370 mm (53.9 in) Wheelbase: 1,465 mm (57.7 in) Ground Clearance: 170 mm (6.7 in) Seat Height: 820 mm (32.3 in) Weights Curb Weight Kg: 206 kg (454 lbs) Curb Weight Lbs: 454 lbs Gross Vehicle Weight Rating: Not specified, but rider and luggage capacity should be considered. 🛡️ Safety Features Ratings Safety Certifications: Meets relevant national and international motorcycle safety standards (e.g., DOT, ECE for lights) Active Features Braking System: Dual disc front, Single disc rear. ABS was optional on some models/markets, check VIN for specific features. Lighting: Halogen headlamp, LED tail lamp, incandescent turn signals Passive Features Frame Construction: Steel semi-double cradle frame designed for stability and rider comfort. Ergonomics: Upright riding position for comfort during long rides. 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system) Driver Assistance ABS Availability: Optional on certain markets and configurations for the 2010 model year. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals First Service: 1000 km or 6 months Subsequent Service: Every 6000 km or 6 months (whichever comes first) Valve Clearance Check: First at 12,000 km, then every 24,000 km Fluid Specifications Engine Oil Type: SAE 10W-40 API SG, SH, SJ, SL, SM or JASO MA/MA2 Engine Oil Capacity With Filter: 3.0 Liters (approx.) Engine Oil Capacity Without Filter: 2.7 Liters (approx.) Coolant Type: Kawasaki Genuine Coolant or equivalent (ethylene glycol-based with corrosion inhibitors) Brake Fluid Type: DOT 4 Transmission Oil Type: Kawasaki Genuine Gear Oil or equivalent SAE 80W-90 API GL-4 Known Issues Common Wear Items: Chain and sprockets, brake pads,...
Fault code interpretation, electrical system testing
Specifications:
Torque values, clearances, fluid capacities, electrical data
Technical Depth
Depth:
Factory-level detail, suitable for professional mechanics and experienced DIYers
Accuracy:
Official factory data, ensuring accuracy and precision
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if OCR'd properly
Print Quality
Printability:
Printable in entirety or selected pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four valves per cylinder, parallel-twin
Displacement:
649 cc
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.2:1
Power Output Ps:
63 PS @ 8000 rpm (approx.)
Power Output Hp:
62 bhp @ 8000 rpm (approx.)
Torque Nm:
60 Nm @ 6000 rpm (approx.)
Torque Lb-Ft:
44 lb-ft @ 6000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (DFI)
Fuel Type:
Unleaded gasoline, 87 AKI or higher
Fuel Tank Capacity L:
15 Liters
Fuel Tank Capacity Gal:
3.96 US Gallons
Performance
Top Speed:
Approx. 110-120 mph (177-193 km/h), dependent on rider and conditions
🔧 Transmission
Standard
Type:
Constant-mesh, 6-speed
Optional
Options:
N/A (Only manual transmission offered for this model)
Features
Clutch:
Wet, multi-disc, manual operation
Final Drive:
Sealed chain, 525 V8 (DID)
📐 Dimensions
Exterior
Overall Length:
2,195 mm (86.4 in)
Overall Width:
830 mm (32.7 in)
Overall Height:
1,370 mm (53.9 in)
Wheelbase:
1,465 mm (57.7 in)
Ground Clearance:
170 mm (6.7 in)
Seat Height:
820 mm (32.3 in)
Weights
Curb Weight Kg:
206 kg (454 lbs)
Curb Weight Lbs:
454 lbs
Gross Vehicle Weight Rating:
Not specified, but rider and luggage capacity should be considered.
🛡️ Safety Features
Ratings
Safety Certifications:
Meets relevant national and international motorcycle safety standards (e.g., DOT, ECE for lights)
Active Features
Braking System:
Dual disc front, Single disc rear. ABS was optional on some models/markets, check VIN for specific features.
Lighting:
Halogen headlamp, LED tail lamp, incandescent turn signals
Passive Features
Frame Construction:
Steel semi-double cradle frame designed for stability and rider comfort.
Ergonomics:
Upright riding position for comfort during long rides.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No integrated infotainment system)
Driver Assistance
ABS Availability:
Optional on certain markets and configurations for the 2010 model year.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
First Service:
1000 km or 6 months
Subsequent Service:
Every 6000 km or 6 months (whichever comes first)
Valve Clearance Check:
First at 12,000 km, then every 24,000 km
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ, SL, SM or JASO MA/MA2
Engine Oil Capacity With Filter:
3.0 Liters (approx.)
Engine Oil Capacity Without Filter:
2.7 Liters (approx.)
Coolant Type:
Kawasaki Genuine Coolant or equivalent (ethylene glycol-based with corrosion inhibitors)
Brake Fluid Type:
DOT 4
Transmission Oil Type:
Kawasaki Genuine Gear Oil or equivalent SAE 80W-90 API GL-4
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals, clutch plates (depending on usage)
Potential Electrical:
Occasional rectifier/regulator issues reported on some Kawasaki models of this era, though not specific to the KLE650.
Fuel System Maintenance:
Regular cleaning of fuel injectors and checks of the fuel pump are recommended for optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries Motorcycle & Engine division has a long history of producing reliable and performance-oriented motorcycles across various genres.
Model Evolution
Kle Series Origin:
The KLE designation has been used for dual-sport/adventure bikes, evolving from earlier models like the KLR series.
Kle650 Generation 1:
The KLE650 platform, including this 2010 model (often referred to as the Versys 650 in many markets), debuted in the mid-2000s, offering a more road-biased adventure-touring experience.
Production
Manufacturing Location:
Typically manufactured in Japan, with potential assembly in other regions depending on the market.
🏆 Awards & Recognition
Recognitions
Industry Awards 2010:
Specific awards for the 2010 KLE650DAF are not readily documented, but the Versys platform generally received positive reviews for its versatility and value.
Ratings
Motorcycle Reviews:
Generally praised for its comfortable riding position, smooth engine, and agility, making it a strong contender in the mid-weight adventure-touring segment.