This manual covers the Ninja 650R, also known as the ER-6f in certain markets, for the model years 2005 through 2012. This versatile middleweight sportbike is powered by a smooth, torquey 649 cc parallel-twin engine, delivering a balanced blend of performance and everyday usability. Renowned for its nimble and confidence-inspiring handling, the Ninja 650R is an approachable machine, making it a popular choice for beginner to intermediate riders, as well as those seeking a practical option for commuting and sport touring. Its design offers a sporty aesthetic with a comfortable riding position, reflecting a legacy of engineering quality and reliable performance. This comprehensive Factory Service Manual provides detailed information essential for the maintenance, repair, and diagnosis of your Ninja 650R. It covers all major systems, including the powertrain, chassis, braking, and electrical systems, with step-by-step procedures for disassembly, assembly, and overhaul. You will find critical data such as specifications, torque values, fluid requirements, and troubleshooting guides for common issues. This manual is an indispensable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle through accurate and thorough guidance. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R Model Nickname: ER-6f (in some markets) Product Type: Service Manual / Repair Manual Generation Model Generation: First Generation (EX650A) Codes Chassis Code: EX650A 👋 Introduction Market Position Market Segment: Middleweight Sportbike / Naked Sportbike Target Audience: Beginner to intermediate riders, budget-conscious enthusiasts, commuters, and sport touring riders seeking a reliable and accessible machine. Competitive Analysis Key Competitors: Honda CBR500R, Yamaha YZF-R6 (older models), Suzuki SV650, Ninja 500R (predecessor), Ducati Monster 696. Key Features Engine Character: Smooth, torquey parallel-twin engine offering a good balance of power and usability. Handling Characteristics: Nimble and confidence-inspiring handling, making it approachable for new riders. Design: Sporty fairing (Ninja 650R designation) with a naked variant (ER-6n) also available, offering a blend of sporty aesthetics and everyday comfort. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Regions Covered: Global (includes variations common across major markets) Page Count Estimated Pages: 400-600 (typical for comprehensive service manuals) Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine disassembly, assembly, tuning, diagnostics, cooling system, lubrication system, exhaust system. Chassis: Frame, front suspension (forks), rear suspension (monoshock), steering system, wheel assembly, final drive (chain). Braking System: Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, ABS (if applicable to specific sub-models). Electrical System: Wiring diagrams, ignition system, lighting, starting system, charging system, battery, fuses, relays, ECU (Engine Control Unit) diagnosis. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, evaporative emission control system. Bodywork And Trim: Fairings, seat, fuel tank, fenders, instrument panel, lighting components. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain maintenance, brake pad replacement, spark plug replacement, coolant checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation, electrical system troubleshooting. Repair And Overhaul: Engine rebuild, transmission overhaul, suspension fork service, brake caliper rebuild, carburetor cleaning/adjustment (if applicable to earlier models, though 650R is EFI), electrical component replacement. Disassembly And Assembly: Step-by-step guides for removing and reinstalling major components and sub-assemblies. Technical Depth Depth Of Coverage: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed specifications, torque values, special tool requirements, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically text-searchable within the PDF for quick information retrieval. Print Quality Quality: High-resolution scans of original factory documentation, suitable for printing. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, parallel-twin Displacement: 649 cc Bore X Stroke: 83.0 x 60.0 mm Compression Ratio: 11.3:1 Valvetrain: 4 valves per cylinder Performance Horsepower Peak Approx: 70-72 hp @ 8,500 rpm (claimed) Torque Peak Approx: 64-66 Nm @ 7,000 rpm (claimed) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 38mm Keihin throttle bodies Fuel Type Recommended: Unleaded gasoline, 91 octane (or higher) Lubrication System Oil Type Recommended: SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil Cooling System Coolant Type: Kawasaki Coolant (or equivalent ethylene glycol based coolant with distilled water, 50/50 mix) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, return shift Clutch Type: Wet multi-disc, manual Final Drive: Sealed chain drive Features Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 2.750, 2nd: 2.056, 3rd: 1.611, 4th: 1.333, 5th: 1.150, 6th: 0.967) Transmission Oil Type: SAE 80W-90 API GL-4 or GL-5 gear oil (if separate from engine oil, check manual for confirmation) 📐 Dimensions Exterior Length: 2,090 mm (82.3 in) Width: 750 mm (29.5 in) Height: 1,170 mm (46.1 in) Wheelbase: 1,410 mm (55.5 in)...