Kawasaki Ninja 650R ER-6F ER-6F ABS Motorcycle Complete Workshop Service Repair Manual 2009 2010

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This manual covers the Ninja 650R and ER-6F models, including the ER-6F ABS variant, produced for the 2009 and 2010 model years. These motorcycles are characterized by their aggressive Ninja...

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Typ: Motorcycle

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Art.-Nr: 94762

Stichworte: 2009 2010 ER-6F ER-6F ABS Kawasaki Misc Motorcycle Motorcycles Ninja 650R

Produktvarianten

Beschreibung

This manual covers the Ninja 650R and ER-6F models, including the ER-6F ABS variant, produced for the 2009 and 2010 model years. These motorcycles are characterized by their aggressive Ninja styling combined with comfortable, upright ergonomics, making them versatile for daily commuting, spirited riding, and light touring. Powered by a 649 cc parallel-twin engine, they offer a balanced blend of performance and efficiency, with an available ABS option enhancing braking safety. The engineering quality and reliability of the ER-6 platform have made it a popular choice in the mid-weight sport-touring segment. This comprehensive Workshop Service Repair Manual provides detailed information for the maintenance, diagnosis, and repair of your Ninja 650R / ER-6F. It covers all major systems, including the engine, drivetrain, chassis, brakes, and electrical systems, with specific procedures for overhaul, component replacement, and adjustments. The manual includes scheduled maintenance guidelines, troubleshooting charts for common issues, detailed technical specifications, and clear wiring diagrams. This resource is essential for owners and technicians seeking to ensure the optimal performance, longevity, and safety of their motorcycle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 650R / ER-6F

Model Variants:

ER-6F, ER-6F ABS

Year:

2009, 2010

Codes

Internal Model Codes:

ER650C (non-ABS), ER650CB (ABS)

👋 Introduction

Market Position

Category:

Mid-weight sport-touring motorcycle

Target Audience:

Riders seeking a balance of performance, comfort, and value for commuting and touring

Competitive Analysis

Key Competitors:

Suzuki SV650S, Yamaha FZ6R, Honda CBR500R (later models)

Key Features

Styling:

Aggressive Ninja sportbike styling with a more upright and comfortable ergonomics

Versatility:

Suitable for daily commuting, sport riding, and light touring

Available ABS variant for enhanced braking safety

Manual Usefulness

Value Proposition:

Essential resource for owners and technicians to maintain, diagnose, and repair the motorcycle, saving time and money

📋 Manual Details

Coverage Areas

Coverage:

Complete Workshop Service and Repair

Page Count

Estimated Page Count:

700-900 pages (typical for comprehensive manuals of this era and type)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, fuel injection, ignition, lubrication, cooling, starting system

Drivetrain:

Clutch, transmission, final drive (chain, sprockets)

Chassis:

Frame, suspension (front forks, rear shock), steering, wheels, tires

Brakes:

Hydraulic system, calipers, master cylinders, ABS unit (if equipped), bleeding procedures

Electrical:

Wiring diagrams, lighting, instrumentation, battery, charging system, starter, ECU diagnostics

Bodywork:

Fairings, body panels, seat, fuel tank, exhaust system

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement, fluid checks

Troubleshooting:

Diagnostic charts, common fault finding, symptom-based troubleshooting

Repair:

Component removal and installation, rebuild procedures, specific adjustments

Technical Data:

Torque specifications, clearances, electrical resistance values, diagnostic trouble codes (DTCs)

Technical Depth

Depth:

Comprehensive, from basic user maintenance to full engine and chassis rebuilds

📊 Manual Specifications

File Format

Compatibility:

PDF readers (Adobe Acrobat, etc.), viewable on PC, Mac, tablet, smartphone

Print Quality

Clarity:

High-resolution scans, clear text and diagrams, printable

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital 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

Valve Train:

DOHC, 8 valves (4 per cylinder)

Performance

Horsepower Est Peak:

Approx. 70-75 hp @ 8000 rpm (varies slightly by market and tune)

Torque Est Peak:

Approx. 47-50 lb-ft @ 6500 rpm (varies slightly by market and tune)

Fuel System

Fuel Delivery:

Fuel Injection (DFI) with dual 38mm throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane (AKI)

Cooling System

Coolant Type:

Kawasaki Coolant 50% or equivalent ethylene glycol based coolant

Lubrication System

Oil Type:

SAE 10W-40 API SG or SH with JASO MA

Oil Capacity

Oil Capacity W Filter Change:

2.7 L (2.8 US qt)

Oil Capacity W O Filter Change:

2.5 L (2.6 US qt)

Oil Capacity Engine Washout:

3.2 L (3.4 US qt)

🔧 Transmission

Standard

Type:

Constant mesh, 6-speed sequential

Features

Clutch Type:

Wet, multi-disc, cable operated

Final Drive:

Sealed chain, 15T front sprocket, 46T rear sprocket (typical)

Fluid Type

Transmission Oil Type:

Kawasaki Genuine Gear Oil GL-4 (SAE 75W-85) or equivalent

Fluid Capacity

Transmission Oil Capacity:

0.7 L (0.7 US qt)

📐 Dimensions

Exterior

Length Overall:

Approx. 2,105 mm (82.9 in)

Width Overall:

Approx. 760 mm (29.9 in)

Height Overall:

Approx. 1,165 mm (45.9 in)

Wheelbase:

Approx. 1,410 mm (55.5 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Seat Height:

Approx. 805 mm (31.7 in)

Weights

Dry Weight:

Approx. 172 kg (379.2 lbs)

Curb Weight ABS:

Approx. 177 kg (390.2 lbs)

Fuel Capacity

Fuel Tank Capacity:

15.5 L (4.1 US gal)

🛡️ Safety Features

Ratings

ABS Availability:

Available as an optional feature

Active Features

Braking System Front:

Dual semi-floating 300 mm petal discs, dual piston calipers

Braking System Rear:

Single 220 mm petal disc, single piston caliper

Passive Features

Lighting:

Dual multi-reflector headlights

💡 Technology Features

Infotainment

Instrument Cluster:

Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, gear position indicator (on some versions)

Driver Assistance

Bosch Anti-lock Braking System (optional)

Connectivity

Diagnostic Port:

Under-seat diagnostic connector for ECU access

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 6,000 km (3,700 mi) or 6 months

Air Filter Inspection:

Every 6,000 km (3,700 mi)

Spark Plug Replacement:

Every 12,000 km (7,500 mi)

Coolant Change:

Every 24,000 km (15,000 mi) or 2 years

Chain Lubrication And Adjustment:

Every 1,000 km (600 mi) or after riding in rain/wet conditions

Fluid Specifications

Brake Fluid Type:

DOT 4

Clutch Fluid Type:

DOT 4 (hydraulic clutch system)

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires due to relatively aggressive riding profile

Potential Issues:

Stalling at low RPMs (can be related to FI mapping, air filter condition, or throttle body sync), regulator/rectifier failures (common on many Kawasakis of this era, though less prevalent on this model compared to some others)

Diagnostic Tools

Required Tools:

Standard metric tool set, torque wrench, multimeter, diagnostic connector (for ECU reading)

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Model Evolution

Predecessor:

ER-5 (in some markets)

Lineage:

Part of Kawasaki's successful ER series, building on the ER-6n platform

Production

Production Years Range:

2005-2016 (for the ER-6F/Ninja 650R platform, with significant updates over the years)

Manufacturing Locations:

Japan (primarily), some assembly may occur in other regions

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2009-2010 model year are not widely documented, the ER-6 platform consistently received positive reviews for its value, usability, and performance in the sport-touring segment.