The KLE650CAF, a 2010 model, represents a versatile adventure touring motorcycle designed for a wide range of riding conditions, from daily commuting to extended touring and light off-road excursions. Building on the robust ER-6 platform, this model offers a balanced combination of performance and practicality. Its 649 cc parallel-twin engine provides ample power and torque, supported by a reliable chassis and suspension system. Known for its adaptability and value, the KLE650 has been a competent competitor in its segment, offering a compelling alternative to models like the V-Strom 650 and Transalp. This comprehensive Factory Service Repair Manual in English provides in-depth guidance for the maintenance and repair of your 2010 KLE650CAF. It covers all major systems, including the engine, fuel system, cooling system, transmission, drivetrain, suspension, brakes, wheels, tires, and electrical systems. Detailed procedures for routine maintenance, troubleshooting, major repairs, and component replacement are included, along with essential technical specifications, torque values, and wiring diagrams. This manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance, reliability, and longevity of their motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLE650 Model Code: KLE650CAF Year: 2010 Codes Vin Prefix: Begin with JKBKL... 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Motorcycle Target Audience: Owners and technicians looking for in-depth repair and maintenance information. Competitive Analysis Comparable Models: Suzuki V-Strom 650, Honda Transalp (earlier generations), BMW F650GS. Key Features Vehicle Platform: Versatile platform suitable for commuting, touring, and light off-road use. Manual Advantage: Provides factory-level accuracy for repairs, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Coverage Scope: Complete Factory Service Repair Manual Page Count Estimated Page Count: Hundreds of pages (specific count not provided but implied to be comprehensive) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair procedures for the 650cc parallel-twin engine. Fuel System: Inspection and servicing of fuel injection system (EFI), throttle body, fuel pump, injectors, and fuel tank. Cooling System: Radiator, fan, thermostat, coolant flow, and pump inspection and repair. Exhaust System: Catalytic converter, mufflers, and piping inspection and replacement. Transmission: Clutch operation, gearbox inspection, disassembly, assembly, and shift mechanism servicing. Drivetrain: Final drive chain and sprockets inspection, adjustment, and replacement procedures. Suspension Front: Front fork disassembly, assembly, oil replacement, seal replacement, and damping adjustment. Suspension Rear: Rear shock absorber inspection, adjustment, and linkage servicing. Brakes Front: Brake caliper, master cylinder, brake lines, rotor, and pad inspection and replacement. Brakes Rear: Rear brake caliper, master cylinder, brake lines, rotor, and pad inspection and replacement. Wheels Tires: Wheel bearing inspection and replacement, tire mounting and balancing. Electrical System: Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), ignition system (ECU, spark plugs, coils). Lighting System: Headlight, taillight, turn signals, brake lights, and instrument panel illumination troubleshooting. Instruments Controls: Speedometer, tachometer, fuel gauge, warning lights, and handlebar controls. Bodywork: Fairing, fuel tank, seat, fenders, and luggage rack removal and installation. Chassis: Frame inspection, steering head bearing maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, brake fluid checks. Troubleshooting: Diagnostic procedures for common electrical and mechanical issues with fault codes. Major Repairs: Engine rebuild, transmission overhaul, suspension rebuild, brake system servicing. Component Replacement: Step-by-step guides for replacing wear items and major components. Torque Specifications: All critical fastener torque values for engine, chassis, and bodywork. Wiring Diagrams: Comprehensive electrical wiring diagrams for easy troubleshooting. Technical Depth Depth: Factory-level detail for comprehensive diagnostics, repair, and maintenance. Diagnostic Codes: Includes information on diagnostic trouble codes (DTCs) and their interpretation. Rebuild Procedures: Detailed procedures for complete engine and transmission rebuilds. 📊 Manual Specifications File Format Format Details: Adobe PDF, allowing for digital viewing, searching, and printing. Print Quality Quality: High-resolution scans of original factory documentation, suitable for clear printing. Binding Type Binding Recommendation: Printable and can be professionally bound for workshop use. Paper Type Paper Recommendation: Standard printer paper recommended for printing. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, 8-valve, Parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.2:1 Performance Horsepower Approx: Approx. 64 hp @ 8,000 rpm (model dependent, consult manual for exact specs) Torque Approx: Approx. 45 lb-ft @ 6,000 rpm (model dependent, consult manual for exact specs) Fuel System Fuel Delivery: Digital Fuel Injection with Dual 38mm Throttle Bodies Fuel Type: Unleaded gasoline, minimum 87 octane (AKI) Ignition Ignition System: TCBI with Digital Advance Lubrication Lubrication System: Forced lubrication, wet sump Starting Starter: Electric starter 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multiple-disc, cable operated Features Gear Ratios: Specific ratios detailed in manual for each gear. Final Drive: Sealed O-ring chain 📐 Dimensions Exterior Overall Length: Approx. 2,180 mm (85.8 in) Overall Width: Approx. 800...