Kawasaki 650R Ninja ER-6f 2005-2011 Workshop Service Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R ER-6f Model Code: ER650C (for relevant years) Generation Generation Designation: First Generation (ER-6f/Ninja 650R) Codes Vin Prefix Example: JKB (check specific year/region) 👋 Introduction Market Position Segment: Mid-size sportbike/naked bike derivative, popular for commuting, sport touring, and entry-level sport riding. Target Audience: New riders, experienced riders seeking a versatile and affordable sportbike, urban commuters. Competitive Analysis Key Competitors: Suzuki SV650, Honda CBR600F, Yamaha FZ6 (all within similar displacement and performance classes). Key Features Design Philosophy: Balanced performance, approachable handling, distinctive styling with a focus on user-friendliness and versatility. Distinctive Elements: Under-seat exhaust, distinctive angled headlights, approachable ergonomics for a sportbike. 📋 Manual Details Coverage Areas Covered Model Years: 2005, 2006, 2007, 2008, 2009, 2010, 2011 Engine Variants Covered: 649cc Parallel-Twin (ER650C) Page Count Estimated Page Count: ~500+ pages (typical for this type of manual) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (assembly, disassembly, lubrication, cooling, fuel system, ignition), Transmission (clutch, gearbox, final drive), Exhaust System Chassis: Frame, Suspension (front fork, rear shock), Wheels, Tires, Brakes (front and rear systems, ABS if equipped), Steering Electrical: Ignition system, Starting system, Charging system, Lighting, Instruments, Wiring diagrams, ECU (Engine Control Unit) diagnosis Bodywork And Trim: Fairings, Seat, Fuel Tank, Handlebars, Footpegs, Body panels removal and installation Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacement, Spark plug replacement, Chain adjustment and lubrication, Brake pad inspection/replacement, Coolant flush Troubleshooting: Diagnostic procedures for common issues, Fault code interpretation (if applicable), Electrical system troubleshooting, Engine performance issues Repair: Engine rebuild procedures, Transmission overhaul, Suspension component replacement, Brake system bleeding and component replacement, Electrical component testing and replacement Assembly Disassembly: Detailed step-by-step instructions for major component removal and reinstallation with torque specifications Technical Depth Depth: Comprehensive, covering basic to advanced diagnostics and repairs. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically searchable text content for efficient information retrieval. Print Quality Image Resolution: High resolution for clear diagrams, illustrations, and text. Binding Type Binding For Download: N/A (Digital format) Paper Type Paper Type For Printout: N/A (Digital format, user chooses print paper) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, 8-valve, Parallel-twin Displacement: 649 cc (39.6 cu. in.) Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Performance Max Power: Approx. 72 hp @ 8,000 rpm (varies slightly by region/model year) Max Torque: Approx. 65 Nm (47.9 lb-ft) @ 6,000 rpm (varies slightly by region/model year) Fuel System Fuel Delivery: Fuel injection with two 38mm Keihin throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane (RON + MON)/2 / 91 AKI Lubrication Oil Type Recommendation: API SG, SH, SJ, SL or SM, JASO MA certified 10W-40 semi-synthetic or synthetic motorcycle oil Cooling System Coolant Type: Kawasaki Genuine Coolant or equivalent ethylene glycol based coolant with distilled water (50/50 mix) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, return shift Clutch Type: Wet, multi-disc, cable operated Final Drive: Sealed chain, 525-pitch Features Gear Ratios: 1st: 2.750 (33/12), 2nd: 2.056 (37/18), 3rd: 1.650 (33/20), 4th: 1.409 (31/22), 5th: 1.250 (30/24), 6th: 1.042 (25/24) Transmission Oil Type: API GL-4 or GL-5 SAE 80W-90 gear oil Transmission Oil Capacity: Approx. 2.2 L (2.3 US qt) for disassembly, 1.8 L (1.9 US qt) for regular change 📐 Dimensions Exterior Overall Length: Approx. 2,090 mm (82.3 in) Overall Width: Approx. 750 mm (29.5 in) Overall Height: Approx. 1,170 mm (46.1 in) Wheelbase: Approx. 1,410 mm (55.5 in) Ground Clearance: Approx. 155 mm (6.1 in) Seat Height: Approx. 805 mm (31.7 in) Weights Curb Weight: Approx. 207 kg (456.4 lbs) Fuel Tank Capacity: 17 Liters (4.5 US gal) 🛡️ Safety Features Ratings ABS Availability: Optional (depending on model year and specific market configuration) Active Features Braking System Front: Dual 300mm petal discs with hydraulic dual-piston calipers Braking System Rear: Single 220mm petal disc with hydraulic single-piston caliper Passive Features Lighting System: Dual Halogen headlights, LED taillight Chassis Design: High-tensile steel backbone frame for rigidity and light weight 💡 Technology Features Infotainment Instrumentation: Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights. Driver Assistance ABS System: Optional Anti-lock Braking System (ABS) for enhanced braking control. Connectivity Diagnostic Ports: Diagnostic connectors for accessing ECU data and fault codes. 🔧 Maintenance Service Intervals Oil And Filter Change: Every 6,000 km (3,700 miles) or 6 months, whichever comes first. Air Filter Inspection: Every 6,000 km (3,700 miles) Spark Plug Replacement: Every 12,000 km (7,500 miles) Valve Clearance Check: Every 24,000 km (15,000 miles) Fluid Specifications Brake Fluid: DOT 4 specification (for both front and rear systems) Coolant Type: Kawasaki Genuine Coolant or equivalent ethylene glycol based coolant (50/50 mix with distilled water) Engine Oil Capacity: 2.4...
Approx. 2.2 L (2.3 US qt) for disassembly, 1.8 L (1.9 US qt) for regular change
📐 Dimensions
Exterior
Overall Length:
Approx. 2,090 mm (82.3 in)
Overall Width:
Approx. 750 mm (29.5 in)
Overall Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Ground Clearance:
Approx. 155 mm (6.1 in)
Seat Height:
Approx. 805 mm (31.7 in)
Weights
Curb Weight:
Approx. 207 kg (456.4 lbs)
Fuel Tank Capacity:
17 Liters (4.5 US gal)
🛡️ Safety Features
Ratings
ABS Availability:
Optional (depending on model year and specific market configuration)
Active Features
Braking System Front:
Dual 300mm petal discs with hydraulic dual-piston calipers
Braking System Rear:
Single 220mm petal disc with hydraulic single-piston caliper
Passive Features
Lighting System:
Dual Halogen headlights, LED taillight
Chassis Design:
High-tensile steel backbone frame for rigidity and light weight
💡 Technology Features
Infotainment
Instrumentation:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
Driver Assistance
ABS System:
Optional Anti-lock Braking System (ABS) for enhanced braking control.
Connectivity
Diagnostic Ports:
Diagnostic connectors for accessing ECU data and fault codes.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Fluid Specifications
Brake Fluid:
DOT 4 specification (for both front and rear systems)
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol based coolant (50/50 mix with distilled water)
Engine Oil Capacity:
2.4 L (2.5 US qt) with filter change, 2.2 L (2.3 US qt) without filter change
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (depending on usage).
Potential Electrical Gremlins:
Occasional issues with rectifier/regulator overheating, or loose electrical connectors requiring inspection. Fuel pump can be a wear item.
Engine Performance Notes:
While generally reliable, some riders report a slight dip in power delivery around 5,000-6,000 RPM, often mitigated by exhaust and ECU remapping. Regular maintenance is key for optimal performance.
Suspension Notes:
Stock suspension can be perceived as basic. Upgrades are common for more demanding riding.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Kawasaki Heavy Industries is a renowned Japanese multinational corporation with a long history in motorcycle manufacturing, known for performance and innovation.
Model Evolution
Ninja 650R Lineage:
The ER-6f/Ninja 650R was introduced as a versatile middleweight sportbike, bridging the gap between smaller displacement bikes and larger liter-class machines. It was also offered in an unfaired version (ER-6n).
Production
Production Period For This Manual:
2005-2011 (This generation was succeeded by an updated model for 2012).
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions depending on market.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards are not widely publicized for this model, it consistently received positive reviews for its value, performance, and versatility in motorcycle media throughout its production run.