The Kawasaki KL650EA, produced in 2010, is a versatile dual-sport motorcycle renowned for its ruggedness and reliability. Built upon a legacy of robust engineering, this model offers a balanced platform suitable for both on-road commuting and off-road exploration. Its design emphasizes practicality and durability, featuring a capable 651cc liquid-cooled engine, a comfortable riding position, and ample ground clearance for tackling varied terrain. As part of Kawasaki's long-standing KLR650 lineage, the KL650EA embodies a commitment to providing dependable performance and value within the adventure motorcycle segment, making it a popular choice for riders seeking a go-anywhere capability. This comprehensive workshop repair service manual provides essential information for the maintenance and repair of your 2010 Kawasaki KL650EA. It covers all major systems, including detailed procedures for the engine, fuel system, ignition, lubrication, cooling, transmission, clutch, drivetrain, frame, suspension, steering, and brakes. Additionally, the manual offers guidance on the electrical system, bodywork, and troubleshooting common issues. With step-by-step instructions, technical specifications, and diagnostic aids, this manual serves as an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KL650EA Year: 2010 Vehicle Type: Dual-sport Motorcycle Codes Chassis Code: KL650EA 👋 Introduction Market Position Segment: Dual-sport / Adventure Motorcycle, known for its ruggedness and reliability. Competitive Analysis Competitors: Suzuki DR650SE, Honda XR650L, Yamaha XT660R. Key Features Features: Versatile for both on-road and off-road use, simple and robust engine design, comfortable ergonomics for longer rides. Target Audience Audience: Owners of the Kawasaki KL650EA seeking to perform maintenance, repairs, or understand the technical aspects of their motorcycle. 📋 Manual Details Coverage Areas Systems Covered Summary: Engine, Fuel System, Ignition, Lubrication, Cooling, Transmission, Clutch, Drivetrain, Frame, Suspension, Steering, Brakes, Electrical System, Bodywork, Troubleshooting, Specifications. Page Count Estimated Page Count: 300-400 Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, repair, and overhaul procedures for the 651cc liquid-cooled, four-stroke, SOHC, four-valve engine. Fuel System: Carburetor tuning, cleaning, and overhaul (likely Keihin CVK40 for this model), fuel pump operation, fuel filter replacement. Ignition System: CDI system troubleshooting, spark plug specifications, ignition timing adjustment. Lubrication System: Oil pump inspection, oil filter replacement, oil change intervals, oil capacity, lubrication points. Cooling System: Radiator inspection, coolant type and capacity, fan operation, thermostat testing, water pump overhaul. Transmission: Gearbox inspection, clutch assembly removal and installation, clutch adjustment, transmission fluid type and capacity. Drivetrain: Chain and sprocket inspection, adjustment, and replacement; rear hub bearing maintenance. Frame And Suspension: Front fork disassembly, seal replacement, oil type and level; rear shock absorber inspection and adjustment; swingarm and linkage bearing maintenance. Steering: Steering head bearing adjustment and replacement, handlebar installation. Brakes: Front and rear brake system inspection, pad replacement, caliper overhaul, master cylinder servicing, brake fluid type and bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, horn, instrument panel. Bodywork: Fairing, tank, seat, fenders, and luggage rack removal and installation. Procedures Included Maintenance: Regular scheduled maintenance checks, oil changes, filter replacements, chain lubrication and adjustment, brake fluid changes, coolant flushes. Troubleshooting: Diagnostic flowcharts and guides for common problems related to starting, running, electrical issues, and performance. Repair: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Diagnostics: Methods for identifying and resolving mechanical and electrical faults using diagnostic charts and specifications. Overhaul: Comprehensive procedures for engine rebuilds, carburetor overhauls, and suspension component servicing. Technical Depth Depth: Comprehensive coverage suitable for both home mechanics and professional technicians, including detailed torque specifications, clearances, and assembly procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if properly digitized. Print Quality Quality: Varies based on original manual and digitization process, typically clear diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, single cylinder Displacement: 651 cc (40.1 cu in) Bore X Stroke: 100.0 x 83.0 mm (3.94 x 3.27 in) Compression Ratio: 9.5:1 Valve Train: SOHC, 4 valves Performance Horsepower Estimated: Approx. 45-48 HP (at crankshaft, depending on specific tuning) Torque Estimated: Approx. 52 Nm (38.4 lb-ft) (at crankshaft) Fuel System Fuel Delivery: Carburetor (likely Keihin CVK40) Fuel Type: Unleaded gasoline, minimum 87 octane Ignition Ignition System: Digital CDI Spark Plug Type: NGK CR9E or equivalent Lubrication Oil Capacity W Filter Change: Approx. 2.4 Liters (2.5 US qt) Recommended Oil Viscosity: SAE 10W-40 (API SG or higher, JASO MA) Cooling Cooling System Type: Liquid-cooled Coolant Capacity: Approx. 1.7 Liters (1.8 US qt) Recommended Coolant: Ethylene glycol-based coolant, 50/50 mix with distilled water 🔧 Transmission Standard Type: Constant mesh 5-speed Final Drive: Sealed chain, 525 Features Clutch Type: Wet, multi-plate Transmission Oil Type: API GL-1 or GL-4 gear oil (specific viscosity may be detailed...