The Kawasaki ER-6f, also known as the Ninja 650R in certain markets, represents a significant offering in the middleweight sportbike category, produced from 2005 through 2011. This model was engineered to provide a balanced blend of performance, comfort, and style, making it an appealing choice for a wide spectrum of riders, from daily commuters to those seeking a more spirited riding experience. Its core engineering features a robust 649cc parallel-twin engine, known for its tractable power delivery and reliability, complemented by a user-friendly chassis and accessible ergonomics. The ER-6f's design prioritizes a comfortable riding position and sharp styling, contributing to its reputation as a versatile and enjoyable motorcycle that offers substantial value within its class.
This comprehensive workshop service manual serves as an indispensable resource for maintaining and repairing the Kawasaki ER-6f models from 2005 to 2011. It meticulously details a vast array of systems and procedures, including engine mechanicals, fuel and ignition systems, cooling, lubrication, and exhaust, as well as the clutch, transmission, and drive chain. Furthermore, it covers suspension, steering, braking systems, and the complete electrical system, complete with wiring diagrams. The manual offers in-depth guidance on routine maintenance, engine overhauls, troubleshooting, and diagnostic procedures, ensuring owners and technicians have the necessary information to keep the motorcycle in optimal condition.
Model Code:
EX650A / EX650C (depending on market and specific updates)
Generation Code:
First Generation (Ninja 650R/ER-6f)
Chassis Codes:
EX650A (initial), EX650C (later revisions)
Market Position:
The Kawasaki ER-6f (also known as the Ninja 650R in some markets) was positioned as a versatile, accessible, and sporty middleweight motorcycle. It appealed to a broad range of riders, from commuters seeking practicality and comfort to newer riders looking for an engaging yet manageable sportbike experience, and even experienced riders who appreciated its balanced performance and reliability.
Competitive Analysis:
Competed directly with models such as the Suzuki SV650, Honda CBF600, Yamaha FZ6R, and Kawasaki's own Ninja 650. Its blend of a parallel-twin engine, comfortable ergonomics, and sporty styling set it apart by offering a more approachable package compared to inline-four competitors, while providing a more modern and fuel-injected option against some older V-twin designs.
Key Features:
Durable and torquey 649cc parallel-twin engine, accessible seat height, comfortable riding position, sharp and modern styling (especially the faired ER-6f), robust chassis for predictable handling, fuel injection for smooth throttle response and economy.
Covered Years:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Manual Type:
Workshop Service Manual
Language:
English (assumed based on typical market availability for this manual)
Systems Covered:
Engine Mechanical, Engine Control System (ECU, FI), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch System, Transmission System, Drive Chain, Suspension (Front & Rear), Steering System, Brake System (Front & Rear), Electrical System (Wiring Diagrams, Lighting, Starting, Charging), Chassis, Frame, Bodywork, Wheels & Tires, Special Tools, Troubleshooting, Diagnostic Procedures.
Procedures Included:
Routine Maintenance (oil changes, filter replacement, chain adjustment, brake pad inspection), Engine Overhaul & Rebuild, Carburetor/Fuel Injection System Diagnosis & Repair, Ignition System Testing, Electrical Troubleshooting, Suspension Overhaul, Brake System Service, Clutch Adjustment & Replacement, Transmission Inspection & Repair, Wheel Bearing Replacement, Chassis Component Inspection, Body Panel Removal & Installation, Diagnostic Codes Interpretation, Torque Specifications for all fasteners.
Technical Depth:
Comprehensive, covering basic to advanced repair and overhaul procedures. Includes detailed diagnostic flowcharts and troubleshooting guides for all major systems. Suitable for professional technicians and experienced DIY mechanics.
File Format:
PDF (Portable Document Format)
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Searchable text within the PDF for efficient navigation.
Binding Type:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Valve Train:
DOHC, 8 valves (2 per cylinder)
Horsepower Peak:
Approx. 71.1 hp (53 kW) @ 8,500 rpm (variation by market/tune)
Torque Peak:
Approx. 65.7 Nm (48.5 lb-ft) @ 7,000 rpm (variation by market/tune)
Fuel Induction:
Fuel Injection (EFI) with dual 38mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON)/2
Fuel Capacity:
17 Liters (4.5 US gal)
Lubrication Type:
Forced lubrication, wet sump
Oil Type Capacity:
SAE 10W-40 API SG or SH, Jaso MA. Capacity: 2.4 L (2.5 US qt) for regular change; 2.7 L (2.9 US qt) for filter change; 3.0 L (3.2 US qt) for overhaul.
Transmission Type:
6-speed constant mesh
Optional Transmission:
N/A
Clutch Type:
Wet, multi-disc, manual
Final Drive:
Sealed chain (525-pitch)
Overall Length:
2,120 mm (83.5 in)
Overall Width:
760 mm (30.0 in)
Overall Height:
1,215 mm (47.8 in)
Wheelbase:
1,410 mm (55.5 in)
Ground Clearance:
145 mm (5.7 in)
Seat Height:
790 mm (31.1 in)
Curb Weight:
Approx. 204 kg (450 lbs)
Dry Weight:
Approx. 190 kg (419 lbs)
Safety Ratings:
Not applicable in the same manner as automobiles. Focus is on rider safety through design and features.
Active Features:
Dual-piston front brake calipers with large-diameter petal discs, single-piston rear caliper with petal disc. Optional ABS (Anti-lock Braking System) available on certain models/markets.
Passive Features:
High-tensile steel backbone frame for rigidity, 3-way adjustable front suspension, 4-way adjustable rear suspension, halogen headlights, LED tail light.
Infotainment Features:
Basic LCD instrument cluster displaying speed, RPM, odometer, trip meters, fuel level, clock, and warning lights. No advanced infotainment features like Bluetooth or navigation.
Driver Assistance:
Optional ABS (Anti-lock Braking System) for enhanced braking safety. Otherwise, relies on rider skill and the motorcycle's inherent design for stability and control.
Initial Service:
First service at 1,000 km (600 miles) or 6 months, whichever comes first. Includes oil and filter change, chain inspection/adjustment, general inspection.
Subsequent Service Intervals:
Every 6,000 km (3,750 miles) or 12 months. Key checks include engine oil and filter, valve clearance (every 12,000 km or 7,500 miles), spark plugs, brake fluid, coolant, chain slack, tire pressure, and general bolt torque.
Engine Oil:
SAE 10W-40 API SG or SH, Jaso MA
Coolant:
Mixture of high-quality ethylene glycol base antifreeze and distilled water (50:50 ratio). Kawasaki recommends their specific coolant or equivalent.
Brake Fluid:
DOT 4 (FMVSS No. 116 DOT 4)
Clutch Fluid:
DOT 4 (FMVSS No. 116 DOT 4) - Hydraulic clutch
Common Issues:
Some early models may experience occasional FI warning light illumination (often related to sensor issues). Stator output can degrade over time. Cam chain tensioner can sometimes become noisy if not properly maintained. Rear shock absorber can lose damping effectiveness over extended use and mileage. Chain and sprockets wear is typical for chain-driven bikes.
Maintenance Tips:
Regular chain lubrication and adjustment are critical. Proper coolant level and quality ensure engine longevity. Checking valve clearances at recommended intervals prevents potential engine damage. Keeping battery voltage healthy is important for the EFI system.
Brand Heritage:
Kawasaki Heavy Industries, Motorcycle & Engine division, has a long-standing reputation for performance, reliability, and innovation in motorcycle manufacturing, dating back to the early 1960s. Known for iconic models across various segments.
Model Evolution:
The ER-6f (and its naked sibling, the ER-6n, and the U.S. Ninja 650R) was introduced in 2005 as a completely new platform for Kawasaki. It replaced older models like the ER-5. This first generation (2005-2011) received minor updates for styling and electronics but retained its core parallel-twin engine and chassis design. A significant redesign occurred for the 2012 model year.
Production Location:
Primarily manufactured in Thailand, with some assembly or production potentially occurring in other Kawasaki facilities depending on the market.
Recognitions:
While specific awards for the 2005-2011 ER-6f are not widely publicized, the model series was consistently praised by motorcycle media for its value, usability, and sporty yet accessible performance, often being recommended as a strong contender in its class.
User Ratings:
Generally high user satisfaction due to its reliability, ease of use, and enjoyable riding characteristics for its segment.
Certifications:
Compliant with emission standards relevant to its production years and markets (e.g., Euro 3 in Europe).
