This manual covers the ER-6f, also known as the Ninja 650R in North America, produced between the 2005 and 2011 model years. This versatile middleweight sportbike features a liquid-cooled, 649cc parallel-twin engine housed within a high-tensile steel backbone frame, offering a balance of approachable performance and sporty aesthetics with its semi-faired design. Praised for its user-friendliness and affordability, the ER-6f is a popular choice for riders seeking a capable machine for various riding styles, from daily commuting to recreational touring. Its engineering emphasizes reliability and accessible power delivery, making it a strong contender in its segment. This comprehensive factory service repair manual provides detailed guidance for the maintenance, diagnosis, and repair of the ER-6f across its covered production years. It encompasses all essential systems, including in-depth engine mechanicals, fuel and ignition systems, cooling, exhaust, transmission, chassis, suspension, brakes, wheels, tires, steering, and the complete electrical system with wiring diagrams. The manual offers step-by-step procedures for routine maintenance, engine overhauls, suspension servicing, brake system work, and electrical component testing, along with critical technical specifications, torque values, and troubleshooting guidance, enabling owners and technicians to effectively maintain and repair the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: ER-6f Model Nickname: Ninja 650R (North American market variant name) Product Type: Workshop Service Repair Manual Codes Manual Part Number Indicator: Factory Official 👋 Introduction Market Position Segment: Middleweight sportbike / naked sportbike (ER-6n sibling) Target Audience: Riders seeking a versatile, approachable, and sporty motorcycle for commuting, touring, and recreational riding. Competitive Analysis Key Competitors: Suzuki SV650, Honda CBF600, Yamaha FZ6R. Key Features Engine Layout: Parallel-twin, liquid-cooled, DOHC. Frame Design: High-tensile steel backbone frame. Styling: Semi-faired design providing some wind protection and sporty aesthetics. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011 Specific Models Covered: Kawasaki ER-6f (all variants for the specified years) Page Count Estimated Pages: Hundreds (exact count not specified in product info, but implies comprehensive) Manual Type Type: Complete Factory Service Repair Manual Language Language: English (typical for factory manuals unless otherwise specified) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, specifications, torque values, timing, valve clearances, piston/cylinder assembly, crankshaft, connecting rods, lubrication system. Fuel System: Fuel injection system (EFI), injectors, throttle body, fuel pump, fuel pressure regulator, fuel tank, lines, troubleshooting. Ignition System: Ignition coils, spark plugs, ECU control, timing, troubleshooting. Cooling System: Radiator, fan, coolant, water pump, thermostat, hoses, diagnosis. Exhaust System: Catalytic converter, mufflers, pipes, mounting. Transmission Drivetrain: Clutch operation, gear shifting mechanism, gearbox components, lubrication, troubleshooting. Chassis Frame: Frame inspection, rigidity, component mounting points, welding integrity. Suspension Front: Front fork (telescopic), oil type and level, seals, springs, damping adjustments, disassembly, reassembly. Suspension Rear: Monoshock rear suspension, linkage, swingarm, adjustment, bearing service, lubrication. Braking System Front: Dual disc brakes, calipers, pads, rotors, master cylinder, fluid type and bleeding, troubleshooting. Braking System Rear: Single disc brake, caliper, pad, rotor, master cylinder, fluid type and bleeding, troubleshooting. Wheels Tires: Wheel bearing service, tire pressure, rim specifications, balancing. Steering System: Handlebar, steering stem bearings, lubrication, adjustment, geometry. Electrical System Components: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays. Electronics ECU: ECU diagnosis, sensor inputs (MAP, TPS, IAT, Crankshaft Position), output control. Bodywork Fairings: Fairing removal and installation, seat, fuel tank cover, fenders, trim pieces, fasteners. Procedures Included Preventative Maintenance: Scheduled maintenance checks, lubrication points, fluid changes, filter replacements. Troubleshooting Diagnostics: Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable). Engine Rebuild: Complete engine disassembly, inspection, repair, and reassembly instructions. Suspension Service: Front fork oil change, seal replacement, rear shock absorber inspection. Brake System Service: Brake pad replacement, rotor inspection, caliper service, brake fluid flush and bleeding. Electrical Component Testing: Testing of stator, regulator/rectifier, starter, battery, lights, switches, and sensors using multimeters. Fuel System Cleaning: Injector cleaning, throttle body cleaning procedures. Wiring Diagram Interpretation: Detailed electrical schematics for all systems. Technical Depth Depth Level: Comprehensive, covering everything from basic maintenance to complete engine and component overhauls. Diagnostic Capability: Advanced diagnostic procedures, including electrical system testing and potential fault finding for EFI components. Repair Procedures: Detailed, step-by-step instructions for virtually all repair and replacement operations. Specifications Data: Includes critical torque specifications, clearances, fluid capacities, and performance data. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable: Typically yes for factory PDF manuals, allowing keyword searches. Print Quality Quality: High resolution, designed for clear printing of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, 2-cylinder, DOHC, 8 valves Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Cooling Method: Liquid-cooled Performance Max Power: Approx. 72.1 hp (53.7 kW) @ 8000 rpm (specifications may vary slightly by region/year) Max...