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Kawasaki Ninja 650R Service Manual 2006 2008

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$133.00
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$133.00
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This manual covers the Ninja 650R, ER-6f, and ER-6f ABS models, produced between 2006 and 2008. As part of the first generation of this popular mid-weight sportbike and naked sportbike segment, these motorcycles are known for their liquid-cooled, 4-stroke parallel-twin 649 cc engine, delivering approximately 76 HP and 47 lb-ft of torque. The Ninja 650R series offers a blend of performance and user-friendliness, making it a competitive choice against rivals like the Suzuki SV650 and Honda CBR600F. With a focus on reliability and engineering quality, these bikes are designed for both everyday riding and spirited performance. This comprehensive service and repair manual provides professional-level guidance for owners and technicians. It details all major mechanical and electrical systems, including the fuel system, engine top end, clutch, lubrication, cooling, transmission, wheels, tires, brakes, suspension, steering, and frame. Extensive coverage is given to maintenance, service, diagnosis, and repair procedures, with clear instructions for engine rebuilds, electrical diagnostics, and component replacement. The manual includes high-resolution, searchable text, exploded view diagrams, step-by-step illustrations, and critical torque specifications, ensuring accurate and efficient upkeep of your motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R / ER-6f / ER-6f ABS Model Codes: EX650A6F, EX650B6F Generation: First Generation 👋 Introduction Market Position Market Segment: Mid-weight sportbike / naked sportbike Competitive Analysis Key Competitors: Suzuki SV650, Honda CBR600F, Yamaha FZ6 Key Features Value Proposition: Provides comprehensive, professional-grade information for DIY maintenance and repair, saving time and money. Target Audience: DIY mechanics, aspiring motorcycle technicians, owners seeking to understand and maintain their Kawasaki Ninja 650R. 📋 Manual Details Coverage Applicable Years: 2006-2008 Format File Format: PDF Language Language: English Type Manual Type: Service / Repair / Workshop Manual Compatibility Operating Systems: All Versions of Windows & Mac Requirements Software Requirements: PDF Reader Coverage Areas Manual Scope: Comprehensive coverage of all major mechanical and electrical systems. 📖 Manual Coverage Systems Systems Covered: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams Procedures Procedures Included: Maintenance, Service, Diagnosis, Repair, Troubleshooting Depth Technical Depth: Professional level, equivalent to dealership technicians Specific Procedures Engine Rebuild: Complete engine disassembly, inspection, and reassembly procedures for top end, crankshaft, and transmission. Electrical Diagnostics: Detailed wiring diagrams, troubleshooting charts for electrical system faults, sensor testing, and component checks. Fuel System Maintenance: Detailed instructions for cleaning fuel injectors, checking fuel pressure, and fuel pump operation. Electrical System Components: Guidance on testing and replacing ignition coils, battery, alternator, starter motor, and all sensors. Suspension Tuning Suspension Adjustments: Information on front fork and rear shock preload, compression, and rebound adjustments (where applicable). Frame Chassis Frame Maintenance: Procedures for inspecting and maintaining frame components, steering head bearings, and swingarm. Technical Details Torque Specifications: Includes critical torque values for all fasteners and engine components. Illustrations: High-quality exploded view diagrams and step-by-step illustrations for procedures. Systems Covered Bodywork And Trim: Instructions for removing and installing fairings, body panels, and trim pieces. Chassis Components: Detailed coverage of suspension, steering, wheels, and final drive maintenance and repair. 📊 Manual Specifications File Details File Quality: High-resolution, clear diagrams and text Searchability: Searchable text for quick information retrieval. Delivery Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke Parallel-twin Displacement Engine Displacement: 649 cc Bore Stroke Bore X Stroke: 83.0 x 60.0 mm Compression Ratio Compression Ratio: 11.3:1 Fuel System Fuel Delivery: Fuel Injection (DFI) with dual 38mm throttle bodies Ignition Ignition System: Digital CDI Lubrication Lubrication System: Forced lubrication, wet sump Performance Horsepower: Approx. 76 HP (56 kW) @ 9000 RPM (figures may vary slightly by region/tuning) Torque: Approx. 64 Nm (47 lb-ft) @ 7000 RPM (figures may vary slightly by region/tuning) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Clutch Type: Wet, multi-disc Final Drive Final Drive: Sealed chain 📐 Dimensions Weights Curb Weight: Approx. 190 kg (419 lbs) for ABS model Dry Weight: Approx. 172 kg (379 lbs) for non-ABS model Maximum Load: Refer to owner's manual for specific load limits and recommendations. Fuel Capacity Fuel Tank Capacity: 15 Liters (3.96 US gal) 🛡️ Safety Features Braking System Front Brake: Dual semi-floating 300mm petal discs, dual opposed 2-piston calipers Rear Brake: Single 220mm petal disc, single-piston caliper Abs ABS Availability: Optional (ER-6f ABS model) Tire Specifications Front Tire Size: 120/70ZR17 M/C (58W) Rear Tire Size: 160/60ZR17 M/C (64W) 💡 Technology Features Engine Management Efi System: Digital Fuel Injection (DFI) with dual throttle valves for precise fuel delivery and throttle response. Instrumentation Dashboard Type: Digital LCD with analog tachometer 🔧 Maintenance Service Intervals First Service: 1000 km (600 miles) or 6 months Major Service Intervals: Every 12,000 km (7,500 miles) for valve clearance checks, spark plug replacement, etc. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG...
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SKU: 44327
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Kawasaki Ninja 650R Service Manual 2006 2008Kawasaki Ninja 650R Service Manual 2006 2008Kawasaki Ninja 650R Service Manual 2006 2008Kawasaki Ninja 650R Service Manual 2006 2008
This manual covers the Ninja 650R, ER-6f, and ER-6f ABS models, produced between 2006 and 2008. As part of the first generation of this popular mid-weight sportbike and naked sportbike segment, these motorcycles are known for their liquid-cooled, 4-stroke parallel-twin 649 cc engine, delivering approximately 76 HP and 47 lb-ft of torque. The Ninja 650R series offers a blend of performance and user-friendliness, making it a competitive choice against rivals like the Suzuki SV650 and Honda CBR600F. With a focus on reliability and engineering quality, these bikes are designed for both everyday riding and spirited performance. This comprehensive service and repair manual provides professional-level guidance for owners and technicians. It details all major mechanical and electrical systems, including the fuel system, engine top end, clutch, lubrication, cooling, transmission, wheels, tires, brakes, suspension, steering, and frame. Extensive coverage is given to maintenance, service, diagnosis, and repair procedures, with clear instructions for engine rebuilds, electrical diagnostics, and component replacement. The manual includes high-resolution, searchable text, exploded view diagrams, step-by-step illustrations, and critical torque specifications, ensuring accurate and efficient upkeep of your motorcycle.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Ninja 650R / ER-6f / ER-6f ABS
Model Codes:
EX650A6F, EX650B6F
Generation:
First Generation
👋 Introduction
Market Position
Market Segment:
Mid-weight sportbike / naked sportbike
Competitive Analysis
Key Competitors:
Suzuki SV650, Honda CBR600F, Yamaha FZ6
Key Features
Value Proposition:
Provides comprehensive, professional-grade information for DIY maintenance and repair, saving time and money.
Target Audience:
DIY mechanics, aspiring motorcycle technicians, owners seeking to understand and maintain their Kawasaki Ninja 650R.
📋 Manual Details
Coverage
Applicable Years:
2006-2008
Format
File Format:
PDF
Language
Language:
English
Type
Manual Type:
Service / Repair / Workshop Manual
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software Requirements:
PDF Reader
Coverage Areas
Manual Scope:
Comprehensive coverage of all major mechanical and electrical systems.
📖 Manual Coverage
Systems
Systems Covered:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams
Procedures
Procedures Included:
Maintenance, Service, Diagnosis, Repair, Troubleshooting
Depth
Technical Depth:
Professional level, equivalent to dealership technicians
Specific Procedures
Engine Rebuild:
Complete engine disassembly, inspection, and reassembly procedures for top end, crankshaft, and transmission.
Electrical Diagnostics:
Detailed wiring diagrams, troubleshooting charts for electrical system faults, sensor testing, and component checks.
Fuel System Maintenance:
Detailed instructions for cleaning fuel injectors, checking fuel pressure, and fuel pump operation.
Electrical System Components:
Guidance on testing and replacing ignition coils, battery, alternator, starter motor, and all sensors.
Suspension Tuning
Suspension Adjustments:
Information on front fork and rear shock preload, compression, and rebound adjustments (where applicable).
Frame Chassis
Frame Maintenance:
Procedures for inspecting and maintaining frame components, steering head bearings, and swingarm.
Technical Details
Torque Specifications:
Includes critical torque values for all fasteners and engine components.
Illustrations:
High-quality exploded view diagrams and step-by-step illustrations for procedures.
Systems Covered
Bodywork And Trim:
Instructions for removing and installing fairings, body panels, and trim pieces.
Chassis Components:
Detailed coverage of suspension, steering, wheels, and final drive maintenance and repair.
📊 Manual Specifications
File Details
File Quality:
High-resolution, clear diagrams and text
Searchability:
Searchable text for quick information retrieval.
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke Parallel-twin
Displacement
Engine Displacement:
649 cc
Bore Stroke
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio
Compression Ratio:
11.3:1
Fuel System
Fuel Delivery:
Fuel Injection (DFI) with dual 38mm throttle bodies
Ignition
Ignition System:
Digital CDI
Lubrication
Lubrication System:
Forced lubrication, wet sump
Performance
Horsepower:
Approx. 76 HP (56 kW) @ 9000 RPM (figures may vary slightly by region/tuning)
Torque:
Approx. 64 Nm (47 lb-ft) @ 7000 RPM (figures may vary slightly by region/tuning)
Cooling System
Cooling Method:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch
Clutch Type:
Wet, multi-disc
Final Drive
Final Drive:
Sealed chain
📐 Dimensions
Weights
Curb Weight:
Approx. 190 kg (419 lbs) for ABS model
Dry Weight:
Approx. 172 kg (379 lbs) for non-ABS model
Maximum Load:
Refer to owner's manual for specific load limits and recommendations.
Fuel Capacity
Fuel Tank Capacity:
15 Liters (3.96 US gal)
🛡️ Safety Features
Braking System
Front Brake:
Dual semi-floating 300mm petal discs, dual opposed 2-piston calipers
Rear Brake:
Single 220mm petal disc, single-piston caliper
Abs
ABS Availability:
Optional (ER-6f ABS model)
Tire Specifications
Front Tire Size:
120/70ZR17 M/C (58W)
Rear Tire Size:
160/60ZR17 M/C (64W)
💡 Technology Features
Engine Management
Efi System:
Digital Fuel Injection (DFI) with dual throttle valves for precise fuel delivery and throttle response.
Instrumentation
Dashboard Type:
Digital LCD with analog tachometer
🔧 Maintenance
Service Intervals
First Service:
1000 km (600 miles) or 6 months
Major Service Intervals:
Every 12,000 km (7,500 miles) for valve clearance checks, spark plug replacement, etc.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH, JASO MA certified
Coolant Type:
Kawasaki Genuine Coolant or equivalent (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4
Transmission Oil Type:
SAE 80 API GL-4 or GL-5
Clutch Fluid Type:
DOT 4 (if hydraulic clutch)
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (with high mileage).
Potential Faults:
Occasional issues with starter relay or fuel pump at higher mileage, some reported clutch lever free play adjustments needed.
Tune Up Procedures
Spark Plug Type:
NGK CR9EIA-9 (Iridium)
Valve Clearance:
Intake: 0.14-0.24 mm, Exhaust: 0.24-0.34 mm
📚 Vehicle History
Model Evolution
Introduction Year:
2005 (globally)
Era Context:
Represents Kawasaki's successful entry into the mid-weight, user-friendly sportbike market.
Brand Heritage
Kawasaki Motorcycles:
Long-standing reputation for performance and reliability in sportbikes and motorcycles.
Production
Manufacturing Origin:
Japan
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