This manual covers the Ninja 650R and ER-6F models, including the ER-6F ABS variant, produced for the 2009 and 2010 model years. These motorcycles are characterized by their aggressive Ninja styling combined with comfortable, upright ergonomics, making them versatile for daily commuting, spirited riding, and light touring. Powered by a 649 cc parallel-twin engine, they offer a balanced blend of performance and efficiency, with an available ABS option enhancing braking safety. The engineering quality and reliability of the ER-6 platform have made it a popular choice in the mid-weight sport-touring segment. This comprehensive Workshop Service Repair Manual provides detailed information for the maintenance, diagnosis, and repair of your Ninja 650R / ER-6F. It covers all major systems, including the engine, drivetrain, chassis, brakes, and electrical systems, with specific procedures for overhaul, component replacement, and adjustments. The manual includes scheduled maintenance guidelines, troubleshooting charts for common issues, detailed technical specifications, and clear wiring diagrams. This resource is essential for owners and technicians seeking to ensure the optimal performance, longevity, and safety of their motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R / ER-6F Model Variants: ER-6F, ER-6F ABS Year: 2009, 2010 Codes Internal Model Codes: ER650C (non-ABS), ER650CB (ABS) 👋 Introduction Market Position Category: Mid-weight sport-touring motorcycle Target Audience: Riders seeking a balance of performance, comfort, and value for commuting and touring Competitive Analysis Key Competitors: Suzuki SV650S, Yamaha FZ6R, Honda CBR500R (later models) Key Features Styling: Aggressive Ninja sportbike styling with a more upright and comfortable ergonomics Versatility: Suitable for daily commuting, sport riding, and light touring ABS: Available ABS variant for enhanced braking safety Manual Usefulness Value Proposition: Essential resource for owners and technicians to maintain, diagnose, and repair the motorcycle, saving time and money 📋 Manual Details Coverage Areas Coverage: Complete Workshop Service and Repair Page Count Estimated Page Count: 700-900 pages (typical for comprehensive manuals of this era and type) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine overhaul, fuel injection, ignition, lubrication, cooling, starting system Drivetrain: Clutch, transmission, final drive (chain, sprockets) Chassis: Frame, suspension (front forks, rear shock), steering, wheels, tires Brakes: Hydraulic system, calipers, master cylinders, ABS unit (if equipped), bleeding procedures Electrical: Wiring diagrams, lighting, instrumentation, battery, charging system, starter, ECU diagnostics Bodywork: Fairings, body panels, seat, fuel tank, exhaust system Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement, fluid checks Troubleshooting: Diagnostic charts, common fault finding, symptom-based troubleshooting Repair: Component removal and installation, rebuild procedures, specific adjustments Technical Data: Torque specifications, clearances, electrical resistance values, diagnostic trouble codes (DTCs) Technical Depth Depth: Comprehensive, from basic user maintenance to full engine and chassis rebuilds 📊 Manual Specifications File Format Compatibility: PDF readers (Adobe Acrobat, etc.), viewable on PC, Mac, tablet, smartphone Print Quality Clarity: High-resolution scans, clear text and diagrams, printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Valve Train: DOHC, 8 valves (4 per cylinder) Performance Horsepower Est Peak: Approx. 70-75 hp @ 8000 rpm (varies slightly by market and tune) Torque Est Peak: Approx. 47-50 lb-ft @ 6500 rpm (varies slightly by market and tune) Fuel System Fuel Delivery: Fuel Injection (DFI) with dual 38mm throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane (AKI) Cooling System Coolant Type: Kawasaki Coolant 50% or equivalent ethylene glycol based coolant Lubrication System Oil Type: SAE 10W-40 API SG or SH with JASO MA Oil Capacity Oil Capacity W Filter Change: 2.7 L (2.8 US qt) Oil Capacity W O Filter Change: 2.5 L (2.6 US qt) Oil Capacity Engine Washout: 3.2 L (3.4 US qt) 🔧 Transmission Standard Type: Constant mesh, 6-speed sequential Features Clutch Type: Wet, multi-disc, cable operated Final Drive: Sealed chain, 15T front sprocket, 46T rear sprocket (typical) Fluid Type Transmission Oil Type: Kawasaki Genuine Gear Oil GL-4 (SAE 75W-85) or equivalent Fluid Capacity Transmission Oil Capacity: 0.7 L (0.7 US qt) 📐 Dimensions Exterior Length Overall: Approx. 2,105 mm (82.9 in) Width Overall: Approx. 760 mm (29.9 in) Height Overall: Approx. 1,165 mm (45.9 in) Wheelbase: Approx. 1,410 mm (55.5 in) Ground Clearance: Approx. 150 mm (5.9 in) Seat Height: Approx. 805 mm (31.7 in) Weights Dry Weight: Approx. 172 kg (379.2 lbs) Curb Weight ABS: Approx. 177 kg (390.2 lbs) Fuel Capacity Fuel Tank Capacity: 15.5 L (4.1 US gal) 🛡️ Safety Features Ratings ABS Availability: Available as an optional feature Active Features Braking System Front: Dual semi-floating 300 mm petal discs, dual piston calipers Braking System Rear: Single 220 mm petal disc, single piston caliper Passive Features Lighting: Dual multi-reflector headlights 💡 Technology Features Infotainment...
This manual covers the Ninja 650R and ER-6F models, including the ER-6F ABS variant, produced for the 2009 and 2010 model years. These motorcycles are characterized by their aggressive Ninja styling combined with comfortable, upright ergonomics, making them versatile for daily commuting, spirited riding, and light touring. Powered by a 649 cc parallel-twin engine, they offer a balanced blend of performance and efficiency, with an available ABS option enhancing braking safety. The engineering quality and reliability of the ER-6 platform have made it a popular choice in the mid-weight sport-touring segment.
This comprehensive Workshop Service Repair Manual provides detailed information for the maintenance, diagnosis, and repair of your Ninja 650R / ER-6F. It covers all major systems, including the engine, drivetrain, chassis, brakes, and electrical systems, with specific procedures for overhaul, component replacement, and adjustments. The manual includes scheduled maintenance guidelines, troubleshooting charts for common issues, detailed technical specifications, and clear wiring diagrams. This resource is essential for owners and technicians seeking to ensure the optimal performance, longevity, and safety of their motorcycle.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Ninja 650R / ER-6F
Model Variants:
ER-6F, ER-6F ABS
Year:
2009, 2010
Codes
Internal Model Codes:
ER650C (non-ABS), ER650CB (ABS)
👋 Introduction
Market Position
Category:
Mid-weight sport-touring motorcycle
Target Audience:
Riders seeking a balance of performance, comfort, and value for commuting and touring
Comprehensive, from basic user maintenance to full engine and chassis rebuilds
📊 Manual Specifications
File Format
Compatibility:
PDF readers (Adobe Acrobat, etc.), viewable on PC, Mac, tablet, smartphone
Print Quality
Clarity:
High-resolution scans, clear text and diagrams, printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Displacement:
649 cc
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Valve Train:
DOHC, 8 valves (4 per cylinder)
Performance
Horsepower Est Peak:
Approx. 70-75 hp @ 8000 rpm (varies slightly by market and tune)
Torque Est Peak:
Approx. 47-50 lb-ft @ 6500 rpm (varies slightly by market and tune)
Fuel System
Fuel Delivery:
Fuel Injection (DFI) with dual 38mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane (AKI)
Cooling System
Coolant Type:
Kawasaki Coolant 50% or equivalent ethylene glycol based coolant
Lubrication System
Oil Type:
SAE 10W-40 API SG or SH with JASO MA
Oil Capacity
Oil Capacity W Filter Change:
2.7 L (2.8 US qt)
Oil Capacity W O Filter Change:
2.5 L (2.6 US qt)
Oil Capacity Engine Washout:
3.2 L (3.4 US qt)
🔧 Transmission
Standard
Type:
Constant mesh, 6-speed sequential
Features
Clutch Type:
Wet, multi-disc, cable operated
Final Drive:
Sealed chain, 15T front sprocket, 46T rear sprocket (typical)
Fluid Type
Transmission Oil Type:
Kawasaki Genuine Gear Oil GL-4 (SAE 75W-85) or equivalent
Fluid Capacity
Transmission Oil Capacity:
0.7 L (0.7 US qt)
📐 Dimensions
Exterior
Length Overall:
Approx. 2,105 mm (82.9 in)
Width Overall:
Approx. 760 mm (29.9 in)
Height Overall:
Approx. 1,165 mm (45.9 in)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Ground Clearance:
Approx. 150 mm (5.9 in)
Seat Height:
Approx. 805 mm (31.7 in)
Weights
Dry Weight:
Approx. 172 kg (379.2 lbs)
Curb Weight ABS:
Approx. 177 kg (390.2 lbs)
Fuel Capacity
Fuel Tank Capacity:
15.5 L (4.1 US gal)
🛡️ Safety Features
Ratings
ABS Availability:
Available as an optional feature
Active Features
Braking System Front:
Dual semi-floating 300 mm petal discs, dual piston calipers
Braking System Rear:
Single 220 mm petal disc, single piston caliper
Passive Features
Lighting:
Dual multi-reflector headlights
💡 Technology Features
Infotainment
Instrument Cluster:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, gear position indicator (on some versions)
Driver Assistance
ABS:
Bosch Anti-lock Braking System (optional)
Connectivity
Diagnostic Port:
Under-seat diagnostic connector for ECU access
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 6,000 km (3,700 mi) or 6 months
Air Filter Inspection:
Every 6,000 km (3,700 mi)
Spark Plug Replacement:
Every 12,000 km (7,500 mi)
Coolant Change:
Every 24,000 km (15,000 mi) or 2 years
Chain Lubrication And Adjustment:
Every 1,000 km (600 mi) or after riding in rain/wet conditions
Fluid Specifications
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (hydraulic clutch system)
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires due to relatively aggressive riding profile
Potential Issues:
Stalling at low RPMs (can be related to FI mapping, air filter condition, or throttle body sync), regulator/rectifier failures (common on many Kawasakis of this era, though less prevalent on this model compared to some others)
Kawasaki Heavy Industries Motorcycle & Engine Company
Model Evolution
Predecessor:
ER-5 (in some markets)
Lineage:
Part of Kawasaki's successful ER series, building on the ER-6n platform
Production
Production Years Range:
2005-2016 (for the ER-6F/Ninja 650R platform, with significant updates over the years)
Manufacturing Locations:
Japan (primarily), some assembly may occur in other regions
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2009-2010 model year are not widely documented, the ER-6 platform consistently received positive reviews for its value, usability, and performance in the sport-touring segment.
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