This document provides comprehensive technical information for the motorcycle, covering the 2009, 2010, and 2011 model years. As part of an esteemed line, this model is recognized for its balanced performance, rider-friendly ergonomics, and accessible styling, making it a popular choice for beginner to intermediate riders seeking a versatile sportbike experience. Engineered with a liquid-cooled, 649cc parallel-twin engine, this model offers a compelling blend of performance and value, building upon a legacy of producing reliable and engaging motorcycles. This workshop service manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the motorcycle. It offers detailed guidance on a wide range of systems, including engine mechanicals, fuel and ignition systems, transmission, cooling, brakes, suspension, and electrical components. The manual covers routine maintenance, in-depth troubleshooting, complete engine and chassis overhauls, and specific repair procedures, providing essential technical data, torque specifications, and diagnostic charts to ensure the longevity and optimal performance of the motorcycle. 🏷️ 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:...