The KL650EA, a robust dual-sport motorcycle produced in 2010, is engineered for adventure riders, long-distance tourers, and off-road enthusiasts. Building on a legacy of reliable and performance-oriented machines, this model offers exceptional versatility for both on-road and off-road exploration. Its design philosophy prioritizes durability and dependability, making it a capable companion for diverse riding conditions. Powered by a liquid-cooled, 651 cc single-cylinder engine featuring fuel injection, the KL650EA delivers consistent performance, supported by a durable semi-double cradle steel frame for enhanced rigidity. This comprehensive factory service repair manual provides complete guidance for maintaining and repairing the 2010 KL650EA. It covers all essential systems, including detailed procedures for engine diagnostics, fuel system servicing, ignition system troubleshooting, transmission overhauls, chassis and suspension adjustments, brake system maintenance, and electrical system diagnostics. The manual also includes preventative maintenance schedules, troubleshooting charts, and critical technical specifications such as torque values and clearances. This resource is invaluable for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their KL650EA. 🏷️ Basic Information Identification Make: Kawasaki Model: KL650EA Year: 2010 Product Type: Factory Service Repair Manual Format: PDF Download 👋 Introduction Market Position Vehicle Type: Dual-sport / Adventure Motorcycle Target Audience: Adventure riders, long-distance tourers, off-road enthusiasts Competitive Analysis Competitors: BMW G 650 GS Sertão, Suzuki V-Strom 650, Honda Transalp Key Features Design Philosophy: Durable, reliable, and versatile for on-road and off-road use 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service and Repair Page Count Estimated Pages: Hundreds Manual Type Type: Service Repair Manual Language Language: English Format Digital Format: Searchable PDF 📖 Manual Coverage Systems Covered Engine: Full engine diagnostics, repair, and overhaul procedures Fuel System: Fuel injection system, fuel pump, injectors, sensors, and fuel tank servicing Ignition System: Ignition coils, spark plugs, ECU control, and troubleshooting Transmission: Gearbox operation, internal components, clutch, and lubrication Chassis: Frame, swingarm, suspension (front and rear), and steering assembly Brakes: Brake caliper, master cylinder, brake lines, bleeding procedures, and pad replacement Electrical System: Wiring diagrams, charging system, lighting, starter system, and ECU diagnostics Cooling System: Radiator, fan, water pump, coolant specifications, and pressure testing Exhaust System: Muffler, catalytic converter, and pipework inspection and replacement Bodywork: Fairings, body panels, seat, and luggage system removal and installation Procedures Included Preventative Maintenance: Scheduled maintenance tasks, checks, and adjustments Troubleshooting: Diagnostic charts and symptom-based problem solving Repair: Step-by-step disassembly and reassembly instructions for all major components Rebuilds: Complete engine and transmission rebuild procedures Specifications: Torque values, clearances, and critical measurements Wiring Diagrams: Detailed electrical schematics for all systems Technical Depth Depth: Comprehensive, from basic maintenance to full engine rebuilds 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High-resolution, suitable for printing individual pages or the entire manual Binding Type Digital Binding: N/A (Downloadable PDF) Paper Type Digital Paper Type: N/A (Digital Document) Searchability Text Search: Yes, fully searchable text content ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 1 cylinder Displacement: 651 cc Bore X Stroke: 100.0 mm x 83.0 mm Cooling Method: Liquid-cooled Performance Horsepower: Approximately 48 HP (35.8 kW) @ 6,500 rpm (model dependent, check manual for exact specs) Torque: Approximately 41.4 lb-ft (56.1 Nm) @ 5,000 rpm (model dependent, check manual for exact specs) Fuel System Fuel Delivery: Fuel Injection (EFI) with dual throttle valves Fuel Type: Unleaded gasoline, minimum 87 octane Ignition System Ignition: Digital CDI with electronic advance Lubrication Oil Type: SAE 10W-40 API SG, JASO MA (check manual for exact specifications and alternatives) Starting System Starter: Electric starter 🔧 Transmission Standard Transmission Type: Constant mesh 5-speed Clutch Type: Wet multi-disc, manual operation Drive Method: Sealed chain drive Features Gear Ratios: Detailed in manual, important for performance tuning Lubrication Transmission Oil Type: API GL-4, SAE 80 (check manual for exact specifications) 📐 Dimensions Exterior Length: Approx. 2,180 mm (85.8 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1,155 mm (45.5 in) Wheelbase: Approx. 1,465 mm (57.7 in) Ground Clearance: Approx. 195 mm (7.7 in) Weights Curb Weight: Approx. 172 kg (379 lbs) Fuel Capacity: 17 Liters (4.5 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA/IIHS) Active Features Braking System: Disc brakes, front and rear (ABS optional on some markets/variants) Lighting: Halogen headlight, LED taillight Passive Features Frame Construction: Semi-double cradle, steel tubing for rigidity and durability 💡 Technology Features Infotainment Infotainment System: Basic analogue/digital combination instrumentation (speedometer, tachometer, odometer, trip meters, fuel gauge, clock). Driver Assistance ABS Availability: Optional on select markets/trim levels, not standard on all 2010 KL650EA models. Connectivity Connectivity Features: None (standard motorcycle technology for this era) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 4,000 miles or 6 months (refer to manual for precise interval based on usage) Air Filter Cleaning: Every 6,000 miles or 12 months, or more...