Segment:
Sportbike, middleweight class, entry-level sportbike, naked bike (ER-6n variant).
Target Audience:
New riders, commuters, sport-touring enthusiasts, budget-conscious sportbike buyers.
Key Competitors:
Suzuki SV650, Honda CBR600F, Yamaha FZ6R, Ducati Monster 696.
Design Philosophy:
Balance of performance, usability, and affordability. Known for its approachable power delivery and comfortable ergonomics for a sportbike.
Distinctive Features:
Parallel-twin engine, under-seat exhaust, strong low-to-midrange torque, distinctive Ninja styling.
Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Regions Covered:
Likely covers North American and European specifications due to common naming conventions, but always confirm specific regional variants if available.
Estimated Pages:
~500-700 (Typical for comprehensive service manuals)
Type:
Service Repair Manual
Purpose:
Professional and DIY repair, maintenance, diagnostics, and troubleshooting.
Engine:
Complete engine disassembly, assembly, timing, valve clearance, lubrication, cooling system, fuel injection (EFI) system diagnostics and repair, ignition system.
Transmission:
Clutch system, gearbox inspection and repair, shift mechanism.
Chassis And Suspension:
Front fork (telescopic, cartridge type) overhaul, rear shock absorber adjustment and replacement, swingarm, bearings, steering head bearings.
Brakes:
Hydraulic brake system (front and rear), caliper service, master cylinder overhaul, brake fluid replacement, pad and disc inspection/replacement.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter system, lighting, instrumentation, ECU (Engine Control Unit) diagnostics, sensor testing.
Fuel System:
Fuel tank, fuel pump, fuel injectors, throttle body assembly, pressure regulator.
Exhaust System:
Catalytic converter, mufflers, exhaust pipe inspection and replacement.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank cover, minor body panel repairs.
Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid flush, coolant replacement, spark plug replacement, air filter service.
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic error codes (if applicable via OBD-II or dealer tool), component testing procedures.
Repair:
Step-by-step repair instructions for major components and systems, torque specifications for all fasteners.
Overhaul:
Complete engine and suspension component overhaul procedures.
Depth:
Comprehensive: Covers basic maintenance, routine servicing, detailed component repair, and advanced diagnostics. Suitable for professional technicians and experienced enthusiasts.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Displacement:
649 cc (649cc)
Bore X Stroke:
83.0 mm x 60.0 mm
Compression Ratio:
11.3:1
Horsepower Est:
Approx. 71.2 hp (53 kW) @ 8,000 rpm (peak, may vary by region/tuning)
Torque Est:
Approx. 47.0 lb-ft (63.7 Nm) @ 6,500 rpm (peak, may vary by region/tuning)
Fuel Delivery:
Fuel Injection (EFI), DFI (Digital Fuel Injection)
Throttle Body:
Dual 38mm throttle bodies
Ignition System:
TCBI (Transistor Controlled Ignition) with electronic advance
Oil Type:
SAE 10W-40 API SG or SH with JASO MA
Oil Capacity W Filter:
3.4 US qt (3.2 L)
Oil Capacity Wo Filter:
3.0 US qt (2.8 L)
Cooling System:
Liquid-cooled
Coolant Type:
Kawasaki Coolant (50/50 mixture with distilled water)
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc
Final Drive:
O-ring sealed chain, 520 pitch
Gear Ratios:
1st: 2.750 (33/12), 2nd: 2.056 (37/18), 3rd: 1.615 (42/26), 4th: 1.333 (40/30), 5th: 1.167 (35/30), 6th: 1.045 (23/22)
Transmission Oil Type:
Kawasaki Motorcycle Gear Oil (or equivalent, check manual for spec)
Crash Test Ratings:
Motorcycles are not typically subjected to formal automotive crash test ratings like cars.
Braking System:
Dual hydraulic disc front, single hydraulic disc rear. Optional ABS (Anti-lock Braking System) available on some models/regions.
Lighting:
Halogen headlight, LED taillight.
Frame Construction:
High-tensile steel backbone frame.
Instrument Cluster:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
ABS Availability:
Optional on some models, providing enhanced braking safety.
ECU Features:
Engine Control Unit manages fuel injection, ignition timing, and idle speed control for optimal performance and emissions.
Oil Change Interval:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Oil Filter Change Interval:
At every oil change.
Chain Lubrication Interval:
Every 300 miles (500 km) or after riding in rain/wet conditions.
Chain Adjustment Interval:
Check every 3,700 miles (6,000 km), adjust as needed for 20-30mm of slack.
Air Filter Cleaning:
Every 7,500 miles (12,000 km) or annually.
Spark Plug Replacement:
Recommended every 7,500 miles (12,000 km) for standard plugs, longer for iridium.
Coolant Replacement:
Every 2 years or 15,000 miles (24,000 km).
Brake Fluid Replacement:
Every 2 years or 15,000 miles (24,000 km).
Valve Clearance Check:
Every 15,000 miles (24,000 km).
Engine Oil Filter Part Number:
Kawasaki 16099-004 (or equivalent aftermarket, e.g., HiFlofiltro HF160, K&N KN-160).
Engine Oil Specification:
SAE 10W-40 API SG or SH, JASO MA certified.
Brake Fluid Specification:
DOT 4 (or DOT 3 if specified for older models, but DOT 4 is generally preferred for its higher boiling point).
Coolant Specification:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with distilled water (50/50 mix).
Common Wear Items:
Clutch plates, brake pads and discs, chain and sprockets, fork seals, wheel bearings, regulator/rectifier (can be prone to overheating).
Potential Electrical Issues:
Regulator/rectifier failure leading to battery charging problems is a known, albeit not universal, issue on some Kawasaki models of this era. Early models might have had minor EFI tuning quirks.
Vibration:
As with many parallel-twins, some vibration can be present at higher RPMs, which is characteristic rather than a fault.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for innovation and performance in racing and street bikes.
Ninja 650R Genesis:
Introduced as a successor to models like the Ninja 500R, aimed at providing a more accessible yet sporty motorcycle with modern styling and technology. The ER-6 platform was developed concurrently for both faired (Ninja 650R) and unfaired (ER-6n) versions.
Manufacturing Location:
Primarily manufactured in Japan, with potential for assembly in other regions depending on the market.
Production Run:
The ER650A/C generation ran from model year 2006 through 2011, with minor updates during its lifecycle. A significant redesign occurred for the 2012 model year (ER650E).
Market Reception:
Generally well-received for its balance of performance, styling, and value. Popular as a first 'big bike' or for riders seeking a practical sportbike.
Magazine Reviews:
Often praised in motorcycle publications for its user-friendliness, versatile engine, and sharp looks.
