Kawasaki KLR650 KL650EA 2010 Workshop Repair Service Manual
Regular price
$133.00
Sale price
$133.00
Regular price
Unit price
/ per
Sale
Sold out
This manual covers the KLR650, model code KL650EA, from the 2010 model year. The KLR650 is a highly regarded dual-sport motorcycle, celebrated for its robust 652cc liquid-cooled single-cylinder engine, long-travel suspension, and durable construction, making it exceptionally versatile for both on-road commuting and off-road adventures. Its engineering prioritizes reliability and low maintenance, offering adventure riders, commuters, and off-road enthusiasts a dependable and capable machine. The KLR650 has a strong lineage, known for its go-anywhere capability and value for money within its segment. This comprehensive 477-page Workshop Repair Service Manual in English provides detailed instructions for the repair and overhaul of the 2010 KLR650. It covers all essential systems, including the engine, fuel system, transmission, cooling system, electrical system, chassis, brakes, wheels, tires, and bodywork. The manual includes scheduled maintenance procedures, troubleshooting guides with fault finding charts, step-by-step repair instructions, disassembly and assembly procedures, and adjustment guidelines. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the vehicle to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KLR650 Model Code: KL650EA Year: 2010 Product Type: Workshop Repair Service Manual 👋 Introduction Market Position Segment: Dual-sport motorcycle, known for its ruggedness and versatility Competitive Analysis Competitors: Honda XR650L, Suzuki DR650SE, Yamaha XT660R Key Features Features: Reliable single-cylinder engine, long-travel suspension, ample fuel range, durable construction Target Audience Audience: Adventure riders, commuters, off-road enthusiasts seeking a dependable and low-maintenance motorcycle 📋 Manual Details Coverage Areas Coverage: Repair and overhaul of Kawasaki KLR650 KL650EA 2010 Page Count Pages: 477 Manual Type Type: Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning Fuel System: Carburetor system, fuel pump, fuel lines, fuel tank Transmission: Clutch, gearbox, drive chain maintenance and repair Cooling System: Radiator, coolant, fan, thermostat Electrical System: Ignition system, lighting, charging system, battery, starter motor, wiring diagrams Chassis: Frame, suspension (front forks, rear shock absorber), steering Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, pads Wheels Tires: Wheel bearing service, tire pressure, installation Exhaust System: Muffler, exhaust pipe inspection and maintenance Bodywork: Fairings, seat, fuel tank, fenders, protective guards Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service Troubleshooting: Diagnostic procedures for common issues, fault finding charts Repair: Detailed step-by-step repair instructions for all major components Overhaul: Complete engine and component rebuild procedures Adjustments: Carburetor synchronization, valve clearance, clutch and brake lever adjustments Disassembly Assembly: Instructions for safe and correct disassembly and reassembly of all vehicle systems Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts Diagnostics: Includes troubleshooting guides, wiring diagrams, and component testing procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, clear text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Searchable: Yes ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 4-valve single cylinder Displacement: 652 cc Bore X Stroke: 100.0 x 83.0 mm Cooling: Liquid-cooled Compression Ratio: 8.8:1 Performance Horsepower: Approx. 48 HP @ 6500 RPM (specifications vary by market and tune) Torque: Approx. 42 lb-ft @ 5000 RPM (specifications vary by market and tune) Fuel System Fuel Delivery: Keihin CVK40 carburetor Fuel Capacity: 6.1 gal (23 L) Lubrication Oil Type: SAE 10W-40 API SG or SH Oil Capacity W Filter: Approx. 2.4 L (2.5 US qt) Ignition Ignition System: Digital CDI 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch: Wet, multiple-disc Final Drive: Sealed chain Fluid Specifications Transmission Oil Type: API GL-4, SAE 80W-90 Fluid Capacity Transmission Oil Capacity: Approx. 0.8 L (0.85 US qt) 📐 Dimensions Exterior Length: 2285 mm (89.9 in) Width: 890 mm (35.0 in) Height: 1350 mm (53.1 in) Wheelbase: 1470 mm (57.9 in) Ground Clearance: 220 mm (8.7 in) Seat Height: Approx. 860 mm (33.9 in) Weights Curb Weight: Approx. 190 kg (419 lb) Load Capacity: N/A (rider and cargo dependent) 🛡️ Safety Features Ratings Safety Standards: Compliant with applicable motorcycle safety regulations Active Features Braking System: Disc brakes front and rear Lighting: Halogen headlight, LED taillight, turn signals Passive Features Frame Construction: High-tensile steel semi-double cradle frame Protection: Handguards, skid plate (optional/standard on some trims) 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance Assistance Features: N/A Connectivity Connectivity Options: N/A Instrumentation Dashboard: Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil warning lamp, turn signal indicators 🔧 Maintenance Service Intervals Oil Change: Every 3,000 miles (5,000 km) or 6 months Air Filter Cleaning: Every 3,000 miles (5,000 km) Valve Clearance Check: Every 7,500 miles (12,000 km) Spark Plug Replacement: Every 7,500 miles (12,000 km) Drive Chain Lubrication: Every 500 miles (800 km) or after washing/rain Fluid Specifications Coolant Type: Permanent type ethylene glycol based coolant, 50% solution with demineralized water...
This manual covers the KLR650, model code KL650EA, from the 2010 model year. The KLR650 is a highly regarded dual-sport motorcycle, celebrated for its robust 652cc liquid-cooled single-cylinder engine, long-travel suspension, and durable construction, making it exceptionally versatile for both on-road commuting and off-road adventures. Its engineering prioritizes reliability and low maintenance, offering adventure riders, commuters, and off-road enthusiasts a dependable and capable machine. The KLR650 has a strong lineage, known for its go-anywhere capability and value for money within its segment.
This comprehensive 477-page Workshop Repair Service Manual in English provides detailed instructions for the repair and overhaul of the 2010 KLR650. It covers all essential systems, including the engine, fuel system, transmission, cooling system, electrical system, chassis, brakes, wheels, tires, and bodywork. The manual includes scheduled maintenance procedures, troubleshooting guides with fault finding charts, step-by-step repair instructions, disassembly and assembly procedures, and adjustment guidelines. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the vehicle to ensure optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLR650
Model Code:
KL650EA
Year:
2010
Product Type:
Workshop Repair Service Manual
👋 Introduction
Market Position
Segment:
Dual-sport motorcycle, known for its ruggedness and versatility
Competitive Analysis
Competitors:
Honda XR650L, Suzuki DR650SE, Yamaha XT660R
Key Features
Features:
Reliable single-cylinder engine, long-travel suspension, ample fuel range, durable construction
Target Audience
Audience:
Adventure riders, commuters, off-road enthusiasts seeking a dependable and low-maintenance motorcycle
📋 Manual Details
Coverage Areas
Coverage:
Repair and overhaul of Kawasaki KLR650 KL650EA 2010
Page Count
Pages:
477
Manual Type
Type:
Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, tuning
Fuel System:
Carburetor system, fuel pump, fuel lines, fuel tank
Transmission:
Clutch, gearbox, drive chain maintenance and repair
Diagnostic procedures for common issues, fault finding charts
Repair:
Detailed step-by-step repair instructions for all major components
Overhaul:
Complete engine and component rebuild procedures
Adjustments:
Carburetor synchronization, valve clearance, clutch and brake lever adjustments
Disassembly Assembly:
Instructions for safe and correct disassembly and reassembly of all vehicle systems
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
Diagnostics:
Includes troubleshooting guides, wiring diagrams, and component testing procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, clear text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Searchable:
Yes
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 4-valve single cylinder
Displacement:
652 cc
Bore X Stroke:
100.0 x 83.0 mm
Cooling:
Liquid-cooled
Compression Ratio:
8.8:1
Performance
Horsepower:
Approx. 48 HP @ 6500 RPM (specifications vary by market and tune)
Torque:
Approx. 42 lb-ft @ 5000 RPM (specifications vary by market and tune)
Fuel System
Fuel Delivery:
Keihin CVK40 carburetor
Fuel Capacity:
6.1 gal (23 L)
Lubrication
Oil Type:
SAE 10W-40 API SG or SH
Oil Capacity W Filter:
Approx. 2.4 L (2.5 US qt)
Ignition
Ignition System:
Digital CDI
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch:
Wet, multiple-disc
Final Drive:
Sealed chain
Fluid Specifications
Transmission Oil Type:
API GL-4, SAE 80W-90
Fluid Capacity
Transmission Oil Capacity:
Approx. 0.8 L (0.85 US qt)
📐 Dimensions
Exterior
Length:
2285 mm (89.9 in)
Width:
890 mm (35.0 in)
Height:
1350 mm (53.1 in)
Wheelbase:
1470 mm (57.9 in)
Ground Clearance:
220 mm (8.7 in)
Seat Height:
Approx. 860 mm (33.9 in)
Weights
Curb Weight:
Approx. 190 kg (419 lb)
Load Capacity:
N/A (rider and cargo dependent)
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with applicable motorcycle safety regulations
Active Features
Braking System:
Disc brakes front and rear
Lighting:
Halogen headlight, LED taillight, turn signals
Passive Features
Frame Construction:
High-tensile steel semi-double cradle frame
Protection:
Handguards, skid plate (optional/standard on some trims)
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance
Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
Instrumentation
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, oil warning lamp, turn signal indicators
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 miles (5,000 km) or 6 months
Air Filter Cleaning:
Every 3,000 miles (5,000 km)
Valve Clearance Check:
Every 7,500 miles (12,000 km)
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Drive Chain Lubrication:
Every 500 miles (800 km) or after washing/rain
Fluid Specifications
Coolant Type:
Permanent type ethylene glycol based coolant, 50% solution with demineralized water
Brake Fluid Type:
DOT 4
Engine Oil Viscosity Cold:
10W-40
Known Issues
Common Problems:
Stalling at idle (carburetor adjustment), oil consumption (depending on mileage and condition), doohickey failure (prevalent in earlier models, less so in later ones but still a common upgrade).
Common Issues
Doohickey Upgrade:
The output shaft balancer chain tensioner ('doohickey') is known to fail. Replacement with an improved aftermarket unit is a common preventative maintenance task.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Model Evolution
Lineage:
The KLR650 platform has a long and successful history dating back to the late 1980s, evolving with minor updates and refinements.
Production
Manufacturing Location:
Japan (primarily)
Production Years:
1987-Present (with generational updates)
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Consistently praised for its reliability, value for money, and go-anywhere capability in the dual-sport segment.
Choosing a selection results in a full page refresh.