This workshop service repair manual covers the Ninja 650R models produced between 2005 and 2012, identified by internal codes ER650A for 2005-2008 and ER650C for 2009-2012. Known for its versatile performance and comfortable ergonomics, the Ninja 650R is a middleweight sportbike powered by a liquid-cooled, 4-stroke, DOHC parallel-twin engine with a displacement of 649 cc. This engine delivers smooth power delivery and tractable torque, making it suitable for both beginner and intermediate riders. The model features a 6-speed sequential transmission, hydraulic wet multi-disc clutch, and a sealed chain final drive. Safety is enhanced with petal disc brakes, and optional ABS was available on select models. The Ninja 650R has been recognized for its balance of performance, affordability, and everyday usability, positioning it as a strong competitor in its segment. This comprehensive manual provides detailed information essential for the maintenance, repair, and troubleshooting of your Ninja 650R. It covers all major systems, including the engine, fuel system (carburetor or fuel injection depending on model year), transmission, electrical system, suspension, brakes, cooling system, exhaust system, chassis, and bodywork. Included are step-by-step procedures for routine maintenance, component overhauls, rebuilds, and adjustments, along with diagnostic charts and high-resolution wiring diagrams. This resource is designed to assist owners, mechanics, and technicians in keeping the motorcycle in optimal condition, ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R Generation Production Years: 2005-2012 Codes Internal Model Codes: ER650A (2005-2008), ER650C (2009-2012) 👋 Introduction Market Position Segment: Middleweight Sportbike / Naked Sportbike Target Audience: Beginner to intermediate riders seeking a sporty yet versatile motorcycle for commuting and recreational riding. Competitive Analysis Key Competitors: Suzuki SV650, Honda CBR600F, Yamaha FZ6 Key Features Versatility: Appeals to both sportbike enthusiasts and those preferring a more upright riding position due to its performance and comfortable ergonomics. Engine Character: Parallel-twin engine known for its smooth power delivery and tractable torque. 📋 Manual Details Coverage Areas Covered Years: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Page Count Estimated Pages: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, disassembly, assembly, overhaul, tuning Fuel System: Carburetor (2005-2008), Fuel Injection (2009-2012), fuel pump, injectors, lines Transmission: Clutch, gearbox, shift mechanism, lubrication, troubleshooting Electrical System: Ignition, charging system, starting system, lighting, instrumentation, wiring diagrams, ECU diagnostics Suspension: Front forks (preload, damping), rear shock absorber, linkages, adjustment Brakes: Front and rear disc brakes, brake pads, calipers, master cylinders, fluid bleeding, ABS (if equipped) Cooling System: Radiator, cooling fan, thermostat, coolant types and capacities Exhaust System: Muffler, catalytic converter (if applicable), exhaust headers Chassis And Frame: Frame inspection, steering head bearings, swingarm, drive chain Bodywork: Fairings, seat, fuel tank, removal and installation procedures Procedures Included Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant checks, spark plug replacement Troubleshooting: Diagnostic charts for common problems, electrical fault finding Repair: Component overhaul, part replacement, reassembly instructions Rebuilds: Engine top-end and bottom-end rebuilds, transmission rebuilds Adjustments: Carburetor synchronization, throttle cable adjustment, clutch cable adjustment, suspension setup Wiring Diagrams: Comprehensive, color-coded wiring diagrams for all electrical systems Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, printable pages with clear diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ 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: 11.2:1 Performance Horsepower: Approx. 71-77 hp @ 8000-8500 rpm (model dependent) Torque: Approx. 48-50 lb-ft @ 6000-6500 rpm (model dependent) Fuel System Fuel Delivery: Carburetor (2005-2008), Digital Fuel Injection (DFI) with 34mm throttle bodies (2009-2012) Fuel Type: Unleaded gasoline, minimum 87 octane (91 AKI) Fuel Capacity: 15.0 L (3.96 US gal) 🔧 Transmission Standard Type: Constant mesh 6-speed sequential Clutch: Wet, multi-disc, manual Features Final Drive: Sealed chain, 525 O-ring Gear Ratios: 1st: 2.750 (33/12), 2nd: 2.056 (37/18), 3rd: 1.611 (29/18), 4th: 1.333 (24/18), 5th: 1.167 (21/18), 6th: 1.045 (23/22) 📐 Dimensions Exterior Length: 2,095 mm (82.5 in) Width: 750 mm (29.5 in) Height: 1,170 mm (46.1 in) Wheelbase: 1,405 mm (55.3 in) Ground Clearance: 155 mm (6.1 in) Seat Height: 805 mm (31.7 in) Weights Curb Weight: Approx. 195 kg (430 lbs) (model dependent) Front Tire: 120/70ZR17 M/C (58W) Rear Tire: 160/60ZR17 M/C (69W) Wheel Type: 3-spoke cast alloy 🛡️ Safety Features Ratings ABS: Optional on some models/markets during this period. Active Features Braking System: Dual 300mm petal discs with 2-piston calipers (front), Single 220mm petal disc with 1-piston caliper (rear). Passive Features Lighting: Halogen headlight, LED taillight. 💡 Technology Features Infotainment Instrument Cluster: Digital LCD display featuring speedometer, tachometer, odometer, trip meters, clock, fuel gauge (FI models), and...