This workshop service manual provides comprehensive guidance for the Ninja 650R, covering model years 2005 through 2011 (model codes EX650A/EX650C). The Ninja 650R is recognized for its accessible sportbike performance, comfortable ergonomics, and everyday usability, making it a popular choice in the entry-level to mid-range sportbike segment. Its engineering emphasizes a balance of power delivered by a liquid-cooled, 649 cc parallel-twin engine, coupled with a capable chassis and user-friendly handling. This manual details the quality and reliability inherent in the design philosophy, offering insights into the model's market position and its evolution as a versatile motorcycle. This 621-page English-language workshop service manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the Ninja 650R. It covers all essential aspects of the motorcycle, including detailed procedures for engine disassembly and assembly, fuel and cooling systems, ignition, transmission, drivetrain, brakes, suspension, and electrical systems. The manual also provides thorough guidance on routine maintenance, troubleshooting common issues, and performing complex repairs, complete with technical specifications, wiring diagrams, and diagnostic information. Its comprehensive scope ensures that all maintenance and repair needs, from basic checks to complete rebuilds, can be addressed effectively. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R Codes Model Code: EX650A / EX650C (varies by region/year) 👋 Introduction Market Position Segment: Entry-level to mid-range sportbike, popular for its balance of performance, comfort, and affordability. Competitive Analysis Competitors: Suzuki SV650, Honda CBR600F, Yamaha YZF-R6 (though R6 is higher performance), Ninja 500R. Key Features Design Philosophy: Designed to offer accessible sportbike styling and performance with everyday usability. Ergonomics: More relaxed riding position compared to supersport bikes, making it comfortable for commuting and longer rides. 📋 Manual Details Coverage Areas Applicable Years: 2005, 2006, 2007, 2008, 2009, 2010, 2011 Page Count Page Count: 621 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive engine disassembly, assembly, diagnosis, and repair for the parallel-twin engine. Fuel System: Detailed coverage of fuel injection system, throttle body, injectors, fuel pump, pressure regulator, and emissions control. Cooling System: Radiator, cooling fan, thermostat, water pump, and coolant flow paths. Ignition System: Ignition coil, spark plugs, ECU control, and timing specifications. Transmission: Clutch operation, gearbox disassembly, assembly, lubrication, and shift mechanism. Drivetrain: Chain drive, sprockets, swingarm, and rear wheel bearing maintenance. Brakes: Front and rear hydraulic disc brake systems, caliper service, master cylinder, brake fluid replacement, and bleeding procedures. Suspension: Front telescopic forks (including oil change and seal replacement) and rear monoshock absorber adjustment and service. Electrical System: Wiring diagrams, starter motor, alternator, battery, lighting, instrumentation, fuses, relays, and ECU diagnostics. Chassis: Frame inspection, steering head bearing service, and wheel specifications. Bodywork: Fairing removal and installation, seat, fuel tank, and other body panel components. Procedures Included Maintenance: Routine service checks, oil changes, filter replacements, spark plug changes, chain adjustment, brake pad inspection, fluid flushes. Troubleshooting: Diagnostic flowcharts and common issue identification for engine, electrical, and chassis problems. Repair: Step-by-step instructions for component disassembly, reassembly, and repair for all major systems. Diagnostics: Fault code interpretation (where applicable), electrical system testing, and component testing procedures. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and gearbox rebuilds. Includes detailed torque specifications, clearances, and testing procedures. 📊 Manual Specifications File Format File Format: PDF 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, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Performance Horsepower Claimed: Approximately 78.2 hp @ 8,500 rpm (varies slightly by year/region) Torque Claimed: Approximately 47.2 lb-ft @ 7,000 rpm (varies slightly by year/region) Fuel System Fuel Delivery: DFI (Digital Fuel Injection) with dual 38mm Keihin throttle bodies Fuel Type: Unleaded gasoline, 91 octane or higher recommended Fuel Capacity: 4.0 US gal (15 L) Cooling System Cooling Medium: Ethylene glycol-based coolant, 50/50 mixture with distilled water Ignition System Ignition Type: TCBI (Transistor Controlled Ignition) with digital advance 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch Type: Wet, multi-disc Final Drive: Sealed chain Features Gear Ratios: 1st: 2.750 (33/12), 2nd: 2.056 (37/18), 3rd: 1.611 (29/18), 4th: 1.333 (24/18), 5th: 1.150 (23/20), 6th: 1.042 (25/24) Transmission Oil Spec: API GL-4, SAE 10W-40 motorcycle gear oil 📐 Dimensions Exterior Length: 2,090 mm (82.3 in) Width: 750 mm (29.5 in) Height: 1,205 mm (47.4 in) Wheelbase: 1,410 mm (55.5 in) Ground Clearance: 130 mm (5.1 in) Seat Height: 805 mm (31.7 in) Weights Curb Weight: Approximately 198 kg (436.5 lbs) (wet, varies slightly by year/region) Front Tire Size: 120/70ZR17M/C (58W) Rear Tire Size: 160/60ZR17M/C (64W) Wheel Bolt Pattern: N/A (Spoked wheels with axle nuts) 🛡️ Safety Features Ratings Crash Safety: Motorcycle safety is primarily...