2009-2011 Kawasaki Ninja 650R ER-6f ABS ER-6f Workshop Service Repair Manual Download 09 10 11 PDF
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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R ER-6f Model Code: ER650C/ER650E (ABS) Sub Model: ABS Variant Body Style: Sportbike / Naked Sportbike (ER-6f designation often implies faired version, but Ninja 650R is consistently faired) Generation Generation: Second Generation (2009-2011) Codes Chassis Code: ER650C ABS Chassis Code: ER650E 👋 Introduction Market Position Segment: Middleweight Sportbike / Entry-Level Sportbike Target Audience: New riders, sportbike enthusiasts seeking a balance of performance, comfort, and affordability, commuters. Competitive Analysis Key Competitors: Suzuki SV650/SFV650 Gladius, Honda CBR500R, Yamaha YZF-R6 (slightly higher class), Ninja 500R (previous generation). Key Features Engine Type: Parallel-twin, liquid-cooled, DOHC, 8-valve Design Philosophy: Balanced performance, user-friendliness, comfortable ergonomics for a sportbike, accessible styling. ABS Availability: Optional ABS system for enhanced braking safety. 📋 Manual Details Coverage Areas Applicable Years: 2009, 2010, 2011 Applicable Models: Kawasaki Ninja 650R, ER-6f, ER-6f ABS Page Count Estimated Pages: Approx. 400-500 pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine teardown, assembly, inspection, tuning, and troubleshooting; including cooling system, lubrication system, fuel injection, ignition system, emissions control. Transmission: Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication, troubleshooting. Chassis And Suspension: Frame inspection, front fork (telescopic, cartridge type) disassembly, assembly, and servicing; rear shock absorber (monoshock) servicing and replacement; swingarm, linkage system (if applicable), and wheel bearings. Brakes: Front and rear brake system servicing, including disc replacement, caliper maintenance, brake fluid bleeding (including ABS bleed procedures), master cylinder overhaul, and ABS unit specific maintenance. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), instrumentation, horn, ignition coils, ECUs, fuses, relays, and diagnostic procedures. Fuel System: Fuel tank removal and installation, fuel pump, fuel filter, fuel injectors, throttle bodies, EVAP system, and fuel pressure testing. Cooling System: Radiator, cooling fan, water pump, thermostat, coolant hoses, and coolant specifications. Bodywork And Trim: Fairing removal and installation, seat, fuel tank cover, fenders, and other cosmetic components. ABS System: Detailed diagnosis, bleeding procedures, component testing, and troubleshooting specific to the Anti-lock Braking System. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, brake pad inspection and replacement, coolant flushes, spark plug replacement, air filter cleaning/replacement. Repair: Step-by-step instructions for component removal, installation, and overhaul for all major systems. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for electrical, mechanical, and fuel system issues. Specifications: Torque specifications, clearances, tolerances, fluid capacities, electrical values, and performance data. Special Tools: Identification of Kawasaki-specific tools required for certain procedures. Technical Depth Depth: Comprehensive; covers from basic maintenance and fluid changes to complete engine rebuilds, gearbox overhauls, and detailed electrical system diagnostics. Diagnostic Capabilities: Advanced diagnostic procedures, including understanding error codes (if applicable via diagnostics port) and component-level testing. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable: Yes (typically, if created from original digital source or scanned with OCR) Print Quality Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download - PDF format) Paper Type Paper Type: N/A (Digital Download - PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, parallel-twin Displacement: 649 cc (39.6 cu in) Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Valve Train: DOHC, 8 valves (4 per cylinder) Ignition: Digital CDI with electronic advance Performance Horsepower Peak: Approx. 72 hp @ 8,500 rpm (at crank) Torque Peak: Approx. 47 lb-ft @ 7,000 rpm (at crank) Fuel System Fuel Delivery: DFI (Digital Fuel Injection) with dual 38mm Keihin throttle bodies Fuel Type: Unleaded gasoline, 87 octane or higher Fuel Tank Capacity: 15 Liters (3.96 US gal) Lubrication System Type: Forced lubrication, wet sump Cooling System Type: Forced air and liquid cooling, with radiator and fan 🔧 Transmission Standard Type: 6-speed, constant mesh, return type Optional Type: N/A Features Clutch: Wet, multiple-disc, manual operation Final Drive: Sealed chain drive Fluid Specifications Transmission Oil Type: API GL-4, SAE 80W-90 (Kawasaki recommends specific gearbox oil; consult manual for exact specification and part number) Fluid Capacities Transmission Oil Capacity: Approx. 1.8 L (1.9 US qt) when disassembled; 1.5 L (1.6 US qt) for normal change (refer to manual for precise amounts) 📐 Dimensions Exterior Length: 2,090 mm (82.3 in) Width: 760 mm (29.9 in) Height: 1,170 mm (46.1 in) Wheelbase: 1,410 mm (55.5 in) Ground Clearance: 145 mm (5.7 in) Seat Height: 805 mm (31.7 in) Weights Curb Weight: Approx. 206 kg (454 lbs) for ABS model Dry Weight: Approx. 193 kg (425 lbs) for non-ABS model Wheels And Tires Front Tire: 120/70ZR17M/C (58W) Rear Tire: 160/60ZR17M/C (69W) Front Wheel: 17 x MT3.50 Rear Wheel: 17 x MT4.50 Bolt Pattern: N/A (cast wheels) 🛡️ Safety Features Ratings ABS Rating: Available on select models for enhanced braking stability. Active Features Braking...
Balanced performance, user-friendliness, comfortable ergonomics for a sportbike, accessible styling.
ABS Availability:
Optional ABS system for enhanced braking safety.
📋 Manual Details
Coverage Areas
Applicable Years:
2009, 2010, 2011
Applicable Models:
Kawasaki Ninja 650R, ER-6f, ER-6f ABS
Page Count
Estimated Pages:
Approx. 400-500 pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine teardown, assembly, inspection, tuning, and troubleshooting; including cooling system, lubrication system, fuel injection, ignition system, emissions control.
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication, troubleshooting.
Chassis And Suspension:
Frame inspection, front fork (telescopic, cartridge type) disassembly, assembly, and servicing; rear shock absorber (monoshock) servicing and replacement; swingarm, linkage system (if applicable), and wheel bearings.
Brakes:
Front and rear brake system servicing, including disc replacement, caliper maintenance, brake fluid bleeding (including ABS bleed procedures), master cylinder overhaul, and ABS unit specific maintenance.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), instrumentation, horn, ignition coils, ECUs, fuses, relays, and diagnostic procedures.
Fuel System:
Fuel tank removal and installation, fuel pump, fuel filter, fuel injectors, throttle bodies, EVAP system, and fuel pressure testing.
Cooling System:
Radiator, cooling fan, water pump, thermostat, coolant hoses, and coolant specifications.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank cover, fenders, and other cosmetic components.
ABS System:
Detailed diagnosis, bleeding procedures, component testing, and troubleshooting specific to the Anti-lock Braking System.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, brake pad inspection and replacement, coolant flushes, spark plug replacement, air filter cleaning/replacement.
Repair:
Step-by-step instructions for component removal, installation, and overhaul for all major systems.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for electrical, mechanical, and fuel system issues.
Identification of Kawasaki-specific tools required for certain procedures.
Technical Depth
Depth:
Comprehensive; covers from basic maintenance and fluid changes to complete engine rebuilds, gearbox overhauls, and detailed electrical system diagnostics.
Diagnostic Capabilities:
Advanced diagnostic procedures, including understanding error codes (if applicable via diagnostics port) and component-level testing.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchable:
Yes (typically, if created from original digital source or scanned with OCR)
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download - PDF format)
Paper Type
Paper Type:
N/A (Digital Download - PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, parallel-twin
Displacement:
649 cc (39.6 cu in)
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Valve Train:
DOHC, 8 valves (4 per cylinder)
Ignition:
Digital CDI with electronic advance
Performance
Horsepower Peak:
Approx. 72 hp @ 8,500 rpm (at crank)
Torque Peak:
Approx. 47 lb-ft @ 7,000 rpm (at crank)
Fuel System
Fuel Delivery:
DFI (Digital Fuel Injection) with dual 38mm Keihin throttle bodies
Fuel Type:
Unleaded gasoline, 87 octane or higher
Fuel Tank Capacity:
15 Liters (3.96 US gal)
Lubrication System
Type:
Forced lubrication, wet sump
Cooling System
Type:
Forced air and liquid cooling, with radiator and fan
🔧 Transmission
Standard
Type:
6-speed, constant mesh, return type
Optional
Type:
N/A
Features
Clutch:
Wet, multiple-disc, manual operation
Final Drive:
Sealed chain drive
Fluid Specifications
Transmission Oil Type:
API GL-4, SAE 80W-90 (Kawasaki recommends specific gearbox oil; consult manual for exact specification and part number)
Fluid Capacities
Transmission Oil Capacity:
Approx. 1.8 L (1.9 US qt) when disassembled; 1.5 L (1.6 US qt) for normal change (refer to manual for precise amounts)
📐 Dimensions
Exterior
Length:
2,090 mm (82.3 in)
Width:
760 mm (29.9 in)
Height:
1,170 mm (46.1 in)
Wheelbase:
1,410 mm (55.5 in)
Ground Clearance:
145 mm (5.7 in)
Seat Height:
805 mm (31.7 in)
Weights
Curb Weight:
Approx. 206 kg (454 lbs) for ABS model
Dry Weight:
Approx. 193 kg (425 lbs) for non-ABS model
Wheels And Tires
Front Tire:
120/70ZR17M/C (58W)
Rear Tire:
160/60ZR17M/C (69W)
Front Wheel:
17 x MT3.50
Rear Wheel:
17 x MT4.50
Bolt Pattern:
N/A (cast wheels)
🛡️ Safety Features
Ratings
ABS Rating:
Available on select models for enhanced braking stability.
Active Features
Braking System:
Dual 300mm petal discs with 2-piston calipers (front), Single 220mm petal disc with 1-piston caliper (rear). Optional ABS module.
Lighting:
Multi-reflector headlight, LED taillight.
Passive Features
Chassis Design:
Under-seat exhaust system for improved mass centralization and styling.
Frame Construction:
High-tensile steel backbone frame for rigidity and feedback.
💡 Technology Features
Infotainment
Display Type:
Digital LCD instrument cluster.
Instrumentation:
Includes speedometer, tachometer, fuel gauge, clock, trip meters, odometer, engine temperature indicator, gear position indicator (on some models/regions), and ABS indicator light.
Driver Assistance
ABS:
Optional Anti-lock Braking System for enhanced safety.
Connectivity
Ports:
N/A (No USB or Bluetooth connectivity on this model year).
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Change:
Every 12,000 km (7,500 miles) or 12 months, or at every oil change.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or 6 months. Replace if damaged or excessively dirty.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Chain Adjustment Lubrication:
Every 1,000 km (600 miles) or after washing/riding in rain.
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or SH, or JASO MA (Kawasaki recommends KAWASAKI GENUINE OIL or equivalent)
Engine Oil Capacity:
Approx. 2.9 L (3.1 US qt) for oil change only; 3.2 L (3.4 US qt) with filter change; 3.7 L (3.9 US qt) when engine is disassembled.
Coolant:
High-quality permanent type engine coolant (ethylene glycol based), typically a 50/50 mixture with distilled water. Consult manual for specific Kawasaki coolant part number.
Brake Fluid:
DOT 4 brake fluid (for both front and rear systems, including ABS)
Known Issues
Stalling At Low Rpm:
Can sometimes occur due to fuel mapping or dirty throttle bodies; manual addresses diagnosis.
Suspension Harshness:
Some riders find the stock suspension a bit firm; manual provides adjustment and upgrade guidance.
Clutch Feel:
Can feel slightly heavy for some; proper adjustment is key.
ABS System Diagnosis:
The manual's detailed ABS troubleshooting is invaluable for any ABS-related indicator lights or performance issues.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long and storied history in motorcycle manufacturing, known for performance, innovation, and iconic sportbikes like the Ninja series.
Model Evolution
Ninja 650R Lineage:
The Ninja 650R (ER-6f) was introduced as a versatile middleweight sportbike, bridging the gap between entry-level and supersport categories. It emphasized approachability, everyday usability, and comfortable sport riding.
Second Generation Updates:
The 2009-2011 models represent the second generation, featuring updated styling, improved aerodynamics, revised suspension tuning, and often enhanced fuel injection mapping compared to the first generation (2006-2008).
Production
Manufacturing Location:
Primarily manufactured in Japan and Thailand.
🏆 Awards & Recognition
Recognitions
Award History:
While specific awards for the 2009-2011 model might be scarce, the Ninja 650R platform has consistently been praised for its value, versatility, and performance in its class by various motorcycle publications over its lifespan.