Segment:
Entry-level to mid-range sportbike/naked bike (depending on fairing configuration)
Target Audience:
New riders, commuters, sportbike enthusiasts seeking a balance of performance and affordability.
Key Competitors:
Honda CBR500R, Suzuki SV650, Yamaha MT-07 (later model), Ninja 500R (previous generation).
Engine Layout:
Parallel-twin, liquid-cooled, DOHC, 8-valve
Frame Type:
Trellis frame
Styling:
Aggressive sportbike styling (Ninja 650R) or naked bike styling (ER-6n/ER-6f in some markets).
Applicable Years:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Estimated Page Count:
400-500
Type:
Full Service Repair Manual
Engine:
Complete overhaul, component testing, tuning, fuel injection system, ignition system, lubrication system, cooling system
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication
Chassis:
Frame inspection, swingarm, suspension (front forks and rear shock), steering system
Brakes:
Front and rear brake system diagnosis, caliper servicing, master cylinder overhaul, hydraulic system bleeding, ABS components (if applicable)
Electrical:
Wiring diagrams, battery system, charging system, lighting, ignition system, starter motor, sensors, ECU diagnostics, instrument cluster
Fuel System:
Fuel pump, fuel injectors, fuel pressure regulator, evaporative emission control system (EVAP)
Exhaust System:
Exhaust pipe inspection, catalytic converter, muffler maintenance
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, body panel servicing
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid flush, coolant flush
Troubleshooting:
Diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting guides
Repair:
Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension repairs, and electrical system fixes
Disassembly And Assembly:
Detailed instructions for dismantling and reassembling all parts of the motorcycle
Torque Specifications:
Precise torque values for all fasteners and critical components
Wiring Diagrams:
Comprehensive and easy-to-read electrical schematics for all circuits
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
Engine Type:
Four-stroke, liquid-cooled, DOHC, parallel-twin
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Horsepower Estimated:
Approx. 70-72 hp @ 8,000 rpm
Torque Estimated:
Approx. 47-48 lb-ft @ 7,000 rpm
Fuel Delivery:
Fuel Injection (DFI) with dual 38mm Keihin throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 RON)
Ignition System:
Digital CDI with electronic advance
Lubrication System:
Forced lubrication, wet sump
Cooling System:
Liquid-cooled
Overall Length:
Approx. 2,115 mm (83.3 in)
Overall Width:
Approx. 750 mm (29.5 in)
Overall Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Ground Clearance:
Approx. 130 mm (5.1 in)
Dry Weight:
Approx. 174 kg (383.6 lbs)
Curb Weight:
Approx. 197 kg (434.3 lbs)
Fuel Tank Capacity:
17 Liters (4.5 US gal)
Safety Certification:
Compliance with national and international safety standards for motorcycles.
Braking System:
Dual semi-floating 300mm petal discs with dual-piston calipers (front), Single 220mm petal disc with dual-piston caliper (rear). ABS was an optional feature on some models.
Lighting:
Halogen headlights, LED taillight.
Frame Construction:
High-tensile steel trellis frame designed for rigidity and optimal mass centralization.
Instrument Cluster:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
ABS:
Optional Anti-lock Braking System (ABS) available on select models.
ECU:
Engine Control Unit (ECU) manages fuel injection and ignition timing.
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months
Oil Filter Replacement Interval:
Every 3,750 miles (6,000 km) or 6 months (concurrent with oil change)
Air Filter Cleaning Interval:
Every 7,500 miles (12,000 km)
Spark Plug Replacement Interval:
Every 7,500 miles (12,000 km)
Coolant Flush Interval:
Every 15,000 miles (24,000 km) or 2 years
Brake Fluid Flush Interval:
Every 2 years (regardless of mileage)
Chain Maintenance:
Lubricate and adjust every 500-600 miles (800-1000 km)
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified
Engine Oil Capacity:
3.2 Liters (3.4 US qt) without filter change; 3.4 Liters (3.6 US qt) with filter change
Coolant Type:
High-quality ethylene glycol-based coolant, 50/50 mix with distilled water
Clutch Fluid Type:
DOT 4 (if hydraulic clutch, check specific market configuration)
Common Wear Items:
Brake pads, tires, chain and sprockets, clutch plates (high mileage).
Potential Faults:
Minor electrical connector corrosion in humid climates, occasional throttle body synchronization issues if not maintained.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Predecessor:
Kawasaki Ninja 500R (EX500)
Introduction Year:
2006 model year (introduced in late 2005).
Major Updates Within Period:
Minor styling updates and emissions control improvements over the 2005-2012 period. ABS became available as an option.
Manufacturing Location:
Japan (primarily)
