The Kawasaki KLR650, model year 2010, is a versatile dual-sport motorcycle renowned for its ruggedness, reliability, and adaptability to both on-road commuting and off-road adventures. Powered by a 651cc single-cylinder, liquid-cooled engine with Electronic Fuel Injection (EFI), it offers a balanced blend of performance and efficiency. Its long-travel suspension, semi-double cradle frame, and upright riding position contribute to its capability and comfort during extended journeys. The KLR650 has a strong legacy, being a cornerstone in the dual-sport lineup for decades, and the 2010 model represents a significant update with modern features designed for enduring performance and rider satisfaction. This comprehensive service and repair manual provides essential information for maintaining and servicing the 2010 Kawasaki KLR650. It covers a wide array of systems, including detailed engine and transmission procedures, drivetrain, suspension, brakes, fuel system, cooling system, electrical system, and frame components. The manual includes routine maintenance schedules, troubleshooting guides, diagnostic procedures, and essential technical specifications such as torque values and fluid capacities. Its scope is designed to assist owners, mechanics, and technicians in performing everything from basic upkeep to complex repairs, ensuring the optimal performance and longevity of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Year: 2010 Codes Engine Code: EX650AE (Varies slightly by market, often referred to as a 651cc engine) 👋 Introduction Market Position Category: Dual-sport motorcycle, adventure touring Segment Appeal: Known for its ruggedness, reliability, affordability, and versatility for both on-road commuting and off-road exploration. Competitive Analysis Key Competitors 2010: Honda Transalp (varies by market), Suzuki DR650SE, Yamaha XT660R/X. Key Features Engine Type: Single-cylinder, liquid-cooled, DOHC, 4-valve Fueling: Electronic Fuel Injection (EFI) for precise fuel delivery and emissions control. Suspension Design: Long-travel telescopic front forks and adjustable rear monoshock suspension for off-road capability. Durability: Renowned for its robust construction and ability to withstand demanding conditions. Ergonomics: Upright riding position, comfortable for long-distance touring. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for the Kawasaki KLR650 (2010 model year) Secondary Coverage: Includes troubleshooting, diagnostics, specifications, wiring diagrams, and rebuild procedures Page Count Estimated Pages: Approximately 300-400 pages (typical for a full service manual of this type) Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of engine components, including cylinder head, valves, piston, crankshaft, camshaft, lubrication system, cooling system, and fuel injection. Transmission: Clutch operation, gearbox internals, gear shifting mechanism, and lubrication. Drivetrain: Chain and sprocket inspection, adjustment, and replacement; rear swingarm and bearing service. Suspension: Front fork (telescopic) disassembly, assembly, oil levels, seal replacement, and rear shock absorber service and adjustment. Brakes: Front and rear brake system diagnosis, pad replacement, caliper service, master cylinder overhaul, bleeding procedures, and hydraulic line maintenance. Electrical System: Complete wiring diagrams, charging system (stator, regulator/rectifier), ignition system, lighting, instrumentation, starting system, and battery maintenance. Fuel System: Fuel injection system (EFI) components, fuel pump, injectors, throttle body, idle speed control (ISC), and fuel tank maintenance. Cooling System: Radiator, fan, thermostat, hoses, and coolant specifications and replacement. Exhaust System: Muffler, exhaust pipe inspection, and gasket replacement. Frame And Bodywork: Chassis components, seat, fairings, fuel tank removal/installation, and fenders. Wheels And Tires: Tire inspection, replacement, wheel bearing service, and spoke tensioning (for spoked wheels). Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant replacement, spark plug checks, air filter cleaning/replacement, valve clearance checks. Troubleshooting: Diagnostic procedures for common starting, running, electrical, and braking issues. Includes flowcharts and symptom-based fault finding. Rebuild Procedures: Step-by-step guides for engine top-end rebuild (cylinder head, piston), transmission overhaul, carburetor (if applicable, though KLR650 2010 is EFI), and suspension component rebuilding. Diagnostics: Fault code retrieval (if applicable to the model's diagnostic system), electrical system testing, and fuel system pressure testing. Specifications: Torque values for all fasteners, engine timing, valve clearances, fluid capacities, electrical specifications, and dimensional data. Technical Depth Depth: Comprehensive, covering everything from basic user maintenance to advanced engine and electrical system repairs, suitable for both novice DIY mechanics and experienced technicians. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically searchable text within the PDF for quick information retrieval. Print Quality Printability: Designed to be printable, allowing users to create a physical copy for workshop use. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Quality: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, four valves Displacement: 651 cc (cubic centimeters) Bore X Stroke: 100.0 mm x 83.0 mm (approximate, typical for this generation) Compression Ratio: 8.8:1 (typical for this generation) Performance Horsepower: Approximately 46 hp @ 6500 rpm (varies slightly by market and tune) Torque: Approximately 38 lb-ft @ 5000 rpm (varies slightly by market and tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Dual throttle valves...