This manual covers the 2010 KLE650 CAF, a versatile adventure sport-touring motorcycle renowned for its comfortable upright riding position, effective wind protection, and the proven reliability of its liquid-cooled, parallel-twin engine. Building on extensive heritage in motorcycle engineering, the KLE650 platform offers a balanced blend of performance and practicality, making it suitable for both daily commuting and longer journeys. Its dual-sport aesthetic and robust construction allow riders to confidently tackle various road conditions, embodying a commitment to delivering dependable and enjoyable riding experiences. This comprehensive service and repair manual provides detailed information essential for the maintenance, diagnosis, and repair of your 2010 KLE650 CAF. It encompasses all major systems, including the engine mechanicals, fuel injection, ignition, cooling, transmission, drivetrain, suspension, braking, and electrical systems. Within its approximately 500+ pages, you will find step-by-step procedures for routine maintenance, component overhauls, troubleshooting common issues, and detailed technical specifications. This resource is designed to empower owners, mechanics, and technicians with the knowledge required to keep the motorcycle in optimal condition, ensuring its longevity and peak performance. 🏷️ 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)...