Kawasaki Ninja 650R 2009 2010 2011 Workshop Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 650R Model Code: ER650 Generation Generation Name: First Generation (ER6n/ER6f) Codes Chassis Codes: ER650A, ER650C 👋 Introduction Market Position Market Segment: Middleweight...

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Taper: Motorcycle

Distributeur:

UGS: 73208

Mots clés: 2009 2010 2011 Kawasaki Misc Motorcycle Motorcycles Ninja 650R

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 650R

Model Code:

ER650

Generation

Generation Name:

First Generation (ER6n/ER6f)

Codes

Chassis Codes:

ER650A, ER650C

👋 Introduction

Market Position

Market Segment:

Middleweight Sportbike / Sport-Touring

Target Audience:

Beginner to intermediate riders seeking a versatile, affordable, and engaging sportbike experience.

Competitive Analysis

Key Competitors:

Yamaha FZ6R, Suzuki SV650, Honda CBF600S

Key Features

Engine Type:

Parallel-twin, liquid-cooled, DOHC, 8-valve

Design Philosophy:

Balanced performance, rider-friendly ergonomics, and accessible styling.

Value Proposition:

Excellent performance-to-price ratio, reliable and easy to maintain.

📋 Manual Details

Coverage Areas

Years Covered:

2009, 2010, 2011

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, and torque specifications for the 649cc parallel-twin engine.

Fuel System:

Fuel injection system (EFI) diagnosis, components, cleaning, and adjustment; fuel pump, injectors, throttle body.

Ignition System:

Ignition system components, spark plug specifications, timing, and troubleshooting.

Transmission Drivetrain:

Clutch operation, gearbox inspection, lubrication, gear replacement, and final drive maintenance (chain and sprockets).

Cooling System:

Radiator, coolant flow, thermostat operation, fan control, and fluid specifications.

Exhaust System:

Exhaust pipe and muffler inspection, repair, and potential replacement procedures.

Frame Chassis:

Frame inspection, alignment, and basic repair considerations.

Suspension Front:

Front fork disassembly, inspection, oil change, seal replacement, spring and damping adjustments.

Suspension Rear:

Rear shock absorber inspection, adjustment, linkage system maintenance, and bearing checks.

Brakes Front:

Brake caliper service, pad replacement, disc inspection, master cylinder service, and fluid bleeding.

Brakes Rear:

Rear brake caliper service, pad replacement, disc inspection, master cylinder service, and fluid bleeding.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, and wheel mounting.

Electrical System:

Wiring diagrams, component testing, battery maintenance, charging system (alternator, regulator/rectifier), lighting, starter motor.

Instrumentation:

Dashboard, speedometer, tachometer, warning lights, and sensor diagnostics.

Body Panels:

Fairing removal, installation, and minor cosmetic repair guidance.

Lubrication Points:

Identification and specification of all lubrication points throughout the motorcycle.

Procedures Included

Routine Maintenance:

Oil and filter changes, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid replacement, coolant flush.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).

Engine Repair:

Complete engine rebuild procedures, piston and cylinder inspection/replacement, valve adjustment, head gasket replacement.

Fuel System Repair:

Fuel pump replacement, injector cleaning and replacement, throttle body synchronization.

Transmission Repair:

Gearbox disassembly and reassembly, clutch plate replacement, seal replacement.

Suspension Overhaul:

Complete front fork and rear shock absorber rebuild procedures.

Brake System Service:

Brake caliper rebuild, master cylinder overhaul, brake line replacement, ABS system (if applicable) bleeding procedures.

Electrical Diagnostics:

Fault finding for starting issues, charging problems, lighting failures using wiring diagrams.

Bodywork Repair:

Fairing removal, installation, and minor damage repair techniques.

Technical Depth

Depth Level:

Comprehensive: Covers everything from routine maintenance to complete engine and chassis teardowns and rebuilds.

Diagnostic Capabilities:

Detailed diagnostic charts, symptom-to-cause analysis, and electrical troubleshooting guides.

Special Tools:

Lists and descriptions of required special tools for specific procedures.

Torque Specifications:

Precise torque values for all critical fasteners across the motorcycle.

Clearances Tolerances:

Specifications for valve clearances, bearing clearances, and other critical tolerances.

📊 Manual Specifications

File Format

File Format:

Searchable:

Print Quality

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Performance

Horsepower Peak:

Approx. 72 HP @ 8,500 rpm (claimed)

Torque Peak:

Approx. 47 lb-ft @ 7,000 rpm (claimed)

Fuel System

Fuel Delivery:

Digital Fuel Injection (DFI) with dual 38mm throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Ignition

Ignition System:

Digital CDI

Spark Plugs:

NGK CR9EIA-9 or DENSO IX27 Iridium (check manual for exact spec)

Lubrication

Oil Type:

SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil

Oil Capacity W Filter:

2.1 Liters (approx. 2.2 US qt)

Cooling System

Coolant Type:

Kawasaki Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water)

Coolant Capacity:

1.7 Liters (approx. 1.8 US qt)

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Features

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain, 15/46T sprockets (standard)

Fluid Specifications

Transmission Oil Type:

API GL-4 SAE 80W-90 Hypoid Gear Oil (refer to manual for specific type)

Transmission Oil Capacity:

Refer to manual for specific capacity, usually a fill to the lower edge of the filler plug.

📐 Dimensions

Exterior

Length:

2,095 mm (82.5 in)

Width:

760 mm (29.9 in)

Height:

1,170 mm (46.1 in)

Wheelbase:

1,410 mm (55.5 in)

Ground Clearance:

155 mm (6.1 in)

Seat Height:

805 mm (31.7 in)

Weights

Curb Weight:

Approx. 198 kg (437 lbs)

Fuel Tank Capacity:

15 Liters (4.0 US gal)

Front Tire Size:

120/70ZR17M/C (58W)

Rear Tire Size:

160/60ZR17M/C (69W)

Wheel Bolt Pattern:

N/A (Cast Wheels)

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable (motorcycle) - Refer to manufacturer specifications for specific safety features.

Active Features

Braking System:

Dual front 300mm petal discs with dual-piston calipers; Single rear 220mm petal disc with dual-piston caliper. ABS available as an option on some models.

Passive Features

Lighting:

Halogen headlight, LED taillight

Instrumentation Warnings:

Includes various warning lights for oil pressure, engine trouble, neutral, high beam, etc.

💡 Technology Features

Infotainment

Infotainment System:

N/A - Motorcycle does not feature a traditional infotainment system.

Driver Assistance

Available as an optional feature on select models within this year range.

Connectivity

Connectivity Features:

N/A - Basic motorcycle electronics.

Instrumentation

Display Type:

Digital LCD display for speedometer, odometer, trip meters, fuel gauge, clock, and warning lights. Analog tachometer.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000 miles (6,000 km) or 6 months, whichever comes first. Refer to manual for specific conditions.

Air Filter Cleaning:

Every 8,000 miles (12,000 km) or 12 months. Replacement as needed.

Spark Plug Replacement:

Every 12,000 miles (20,000 km). Refer to manual for specific type and gap.

Chain Maintenance:

Lubricate every 500 miles (800 km) or after riding in wet conditions. Adjust slack every 1,000 miles (1,600 km).

Valve Clearance Check:

Every 15,000 miles (24,000 km). Refer to manual for precise procedure and tolerances.

Fluid Specifications

Brake Fluid:

DOT 4 (refer to manual for precise specification and replacement interval).

Coolant:

Kawasaki Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water).

Known Issues

Charging System:

Early models (including some in this range) could experience premature stator or regulator/rectifier failure. Regular checks of charging voltage are recommended.

Clutch Slippage:

Can occur with high mileage or aggressive riding. Clutch plates may need replacement.

Suspension Wear:

Fork seals and rear shock bushings can wear over time, leading to leaks or a harsh ride. Regular maintenance is key.

📚 Vehicle History

Brand Heritage

Brand Origin:

Japan, established 1896

Kawasaki Legacy:

Long-standing reputation for performance motorcycles, particularly in the sportbike and racing categories.

Model Evolution

Ninja Lineage:

The Ninja 650R (ER6f) is part of Kawasaki's long-standing Ninja sportbike family, evolving from earlier parallel-twin designs.

Design Changes Period:

This generation (2009-2011) featured updated styling and minor ergonomic enhancements compared to previous models.

Production

Production Location:

Japan (Primary)

🏆 Awards & Recognition

Recognitions

Industry Accolades:

Consistently praised for its balance of performance, usability, and value in the middleweight sportbike segment.

Ratings

Rider Reviews:

Highly regarded by riders for its friendly power delivery, comfortable ergonomics for a sportbike, and overall versatility for commuting, sport riding, and light touring.

Certifications

Emissions Standards:

Compliant with applicable emissions standards for its model years.