Kawasaki 650R Ninja ER-6f 2005-2011 Factory Repair Manual

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Mots clés: 2005 2006 2007 2008 2009 2010 2011 650R Ninja ER-6f Kawasaki Misc Motorcycle Motorcycles

Variantes de produits

Description

Introducing the Ninja 650R ER-6f, a versatile sportbike produced from 2005 to 2011, recognized for its balanced performance, comfort, and economy. This model, featuring a 649 cc parallel-twin engine, has been lauded by motorcycle publications for its usability and value, making it a popular choice for new riders, commuters, and sport touring enthusiasts. Engineered with a high-tensile steel perimeter frame and equipped with a digital LCD instrument cluster, the Ninja 650R ER-6f offers a reliable and enjoyable riding experience. This comprehensive Factory Service Repair Manual provides detailed guidance for the Ninja 650R ER-6f, covering model years 2005 through 2011. Within its hundreds of pages, you will find extensive information on engine overhaul, transmission servicing, chassis maintenance, brake system repairs, and electrical system diagnostics. The manual includes step-by-step instructions for disassembly and assembly, routine maintenance procedures, troubleshooting guides for common issues, and essential technical specifications, ensuring owners and technicians can effectively maintain and repair this machine.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 650R ER-6f

Codes

Chassis Code:

ER650A

Engine Code Prefix:

ER650AE

Generation

First Generation Years:

2005-2011

👋 Introduction

Market Position

Segment:

Sportbike/Naked Sportbike

Target Audience:

New riders, commuters, sport touring enthusiasts

Competitive Analysis

Competitors:

Suzuki SV650, Honda CBF600, Yamaha FZ6

Key Features

Engine Configuration:

Parallel-twin

Design Philosophy:

Balanced performance, comfort, and economy

📋 Manual Details

Coverage Areas

Covered Model Years:

2005, 2006, 2007, 2008, 2009, 2010, 2011

Page Count

Estimated Page Count:

Hundreds

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, lubrication, cooling system, fuel system, ignition system, exhaust system

Transmission:

Clutch operation, gearbox disassembly and assembly, gear inspection, shift mechanism

Chassis:

Frame inspection, suspension (front forks, rear shock), steering system, wheel bearings, swingarm

Brakes:

Front and rear brake system servicing, hydraulic components, pad replacement, fluid bleeding, ABS system (if applicable)

Electrical:

Wiring diagrams, lighting system, ignition switch, battery, charging system, starter motor, ECU diagnostics, sensor troubleshooting

Bodywork:

Fairing removal and installation, seat, fuel tank, fenders, body panel alignment, fasteners

Procedures Included

Maintenance:

Regular service checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks

Troubleshooting:

Diagnostic flowcharts, common problem identification, error code interpretation, electrical system faults

Repair:

Component-specific repair instructions, assembly and disassembly steps, torque specifications, seal replacement

Disassembly Assembly:

Detailed step-by-step instructions for major components and sub-assemblies

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and chassis rebuilds

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Liquid-cooled, DOHC, Parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Performance

Horsepower Est:

78.2 HP @ 8,000 RPM (approx.)

Torque Est:

63.7 Nm @ 6,000 RPM (approx.)

Fuel System

Fuel Delivery:

Fuel Injection

Throttle Body:

Dual 38mm Keihin

Lubrication

Oil Capacity W Filter:

3.0 L (approx.)

Cooling System

Coolant Capacity:

1.7 L (approx.)

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Features

Clutch:

Wet, multi-disc

Fluid Specifications

Transmission Oil Type:

API GL-4, SAE 10W-40

📐 Dimensions

Exterior

Length Overall:

2,115 mm (83.3 in)

Width Overall:

770 mm (30.3 in)

Height Overall:

1,190 mm (46.9 in)

Wheelbase:

1,410 mm (55.5 in)

Ground Clearance:

150 mm (5.9 in)

Weights

Dry Weight Est:

174 kg (383.6 lbs)

Curb Weight Est:

190 kg (418.9 lbs)

Fuel Capacity

Fuel Tank Capacity:

15.5 L (4.1 US gal)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable to motorcycles in traditional automotive sense

Active Features

Braking System:

Dual hydraulic disc front, Single hydraulic disc rear (ABS optional on some models/markets)

Lighting:

Halogen headlamp, LED taillight

Passive Features

Frame Construction:

High-tensile steel perimeter frame

💡 Technology Features

Infotainment

Display Type:

Digital LCD instrument cluster

Features:

Speedometer, tachometer, fuel gauge, clock, odometer, trip meters, coolant temperature indicator

Driver Assistance

Optional on certain models and markets

Connectivity

Features:

N/A (basic instrumentation)

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Valve Clearance Interval:

Every 12,000 km (7,500 miles) or 12 months

Air Filter Cleaning:

Every 6,000 km (3,700 miles)

Fluid Specifications

Engine Oil Type:

API SG/SH/SJ/SL/SM or JASO MA, SAE 10W-40

Coolant Type:

Kawasaki All-Season coolant or equivalent (50/50 mix of ethylene glycol and distilled water)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Item:

Clutch plates, chain and sprockets, brake pads

Potential Faults:

Stalling at low RPMs (can be related to ECU mapping or TPS adjustment), fuel pump relay issues (less common)

Torque Values

Engine Oil Drain Plug:

22 Nm (16.2 lb-ft)

Front Axle Nut:

58 Nm (43 lb-ft)

Rear Axle Nut:

113 Nm (83 lb-ft)

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Model Evolution

Predecessor:

Varied, evolved from earlier Kawasaki parallel-twins

Successor:

Ninja 650 (ER650J onwards)

Production

Production Start Year:

Production End Year:

2011 (for this specific generation/variant)

Manufacturing Locations:

Japan (primarily), other international facilities

🏆 Awards & Recognition

Recognitions

Market Acclaim:

Praised for its usability, balance, and value for money by motorcycle publications

Ratings

Owner Satisfaction:

Generally high, especially for its intended purpose as a versatile all-rounder