🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R Model Code: ER650 Generation Generation Name: First Generation (ER6n/ER6f) Codes Chassis Codes: ER650A, ER650C 👋 Introduction Market Position Market Segment: Middleweight Sportbike / Sport-Touring Target Audience: Beginner to intermediate riders seeking a versatile, affordable, and engaging sportbike experience. Competitive Analysis Key Competitors: Yamaha FZ6R, Suzuki SV650, Honda CBF600S Key Features Engine Type: Parallel-twin, liquid-cooled, DOHC, 8-valve Design Philosophy: Balanced performance, rider-friendly ergonomics, and accessible styling. Value Proposition: Excellent performance-to-price ratio, reliable and easy to maintain. 📋 Manual Details Coverage Areas Years Covered: 2009, 2010, 2011 Page Count Page Count: 622 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, assembly, inspection, and torque specifications for the 649cc parallel-twin engine. Fuel System: Fuel injection system (EFI) diagnosis, components, cleaning, and adjustment; fuel pump, injectors, throttle body. Ignition System: Ignition system components, spark plug specifications, timing, and troubleshooting. Transmission Drivetrain: Clutch operation, gearbox inspection, lubrication, gear replacement, and final drive maintenance (chain and sprockets). Cooling System: Radiator, coolant flow, thermostat operation, fan control, and fluid specifications. Exhaust System: Exhaust pipe and muffler inspection, repair, and potential replacement procedures. Frame Chassis: Frame inspection, alignment, and basic repair considerations. Suspension Front: Front fork disassembly, inspection, oil change, seal replacement, spring and damping adjustments. Suspension Rear: Rear shock absorber inspection, adjustment, linkage system maintenance, and bearing checks. Brakes Front: Brake caliper service, pad replacement, disc inspection, master cylinder service, and fluid bleeding. Brakes Rear: Rear brake caliper service, pad replacement, disc inspection, master cylinder service, and fluid bleeding. Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, and wheel mounting. Electrical System: Wiring diagrams, component testing, battery maintenance, charging system (alternator, regulator/rectifier), lighting, starter motor. Instrumentation: Dashboard, speedometer, tachometer, warning lights, and sensor diagnostics. Body Panels: Fairing removal, installation, and minor cosmetic repair guidance. Lubrication Points: Identification and specification of all lubrication points throughout the motorcycle. Procedures Included Routine Maintenance: Oil and filter changes, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid replacement, coolant flush. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable). Engine Repair: Complete engine rebuild procedures, piston and cylinder inspection/replacement, valve adjustment, head gasket replacement. Fuel System Repair: Fuel pump replacement, injector cleaning and replacement, throttle body synchronization. Transmission Repair: Gearbox disassembly and reassembly, clutch plate replacement, seal replacement. Suspension Overhaul: Complete front fork and rear shock absorber rebuild procedures. Brake System Service: Brake caliper rebuild, master cylinder overhaul, brake line replacement, ABS system (if applicable) bleeding procedures. Electrical Diagnostics: Fault finding for starting issues, charging problems, lighting failures using wiring diagrams. Bodywork Repair: Fairing removal, installation, and minor damage repair techniques. Technical Depth Depth Level: Comprehensive: Covers everything from routine maintenance to complete engine and chassis teardowns and rebuilds. Diagnostic Capabilities: Detailed diagnostic charts, symptom-to-cause analysis, and electrical troubleshooting guides. Special Tools: Lists and descriptions of required special tools for specific procedures. Torque Specifications: Precise torque values for all critical fasteners across the motorcycle. Clearances Tolerances: Specifications for valve clearances, bearing clearances, and other critical tolerances. 📊 Manual Specifications File Format File Format: PDF Searchable: Yes Print Quality Print Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Performance Horsepower Peak: Approx. 72 HP @ 8,500 rpm (claimed) Torque Peak: Approx. 47 lb-ft @ 7,000 rpm (claimed) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 38mm throttle bodies Fuel Type: Unleaded gasoline, 87 octane (minimum) Ignition Ignition System: Digital CDI Spark Plugs: NGK CR9EIA-9 or DENSO IX27 Iridium (check manual for exact spec) Lubrication Oil Type: SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil Oil Capacity W Filter: 2.1 Liters (approx. 2.2 US qt) Cooling System Coolant Type: Kawasaki Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water) Coolant Capacity: 1.7 Liters (approx. 1.8 US qt) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Features Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain, 15/46T sprockets (standard) Fluid Specifications Transmission Oil Type: API GL-4 SAE 80W-90 Hypoid Gear Oil (refer to manual for specific type) Transmission Oil Capacity: Refer to manual for specific capacity, usually a fill to the lower edge of the filler plug. 📐 Dimensions Exterior Length: 2,095 mm (82.5 in) Width: 760 mm (29.9 in) Height: 1,170 mm (46.1 in) Wheelbase: 1,410 mm (55.5 in) Ground Clearance: 155 mm (6.1 in) Seat Height: 805 mm (31.7 in) Weights Curb Weight: Approx. 198 kg (437 lbs) Fuel Tank Capacity: 15 Liters (4.0 US...