Market Segment:
Middleweight Sportbike / Naked Sportbike
Target Audience:
Beginner to intermediate riders, budget-conscious enthusiasts, commuters, and sport touring riders seeking a reliable and accessible machine.
Key Competitors:
Honda CBR500R, Yamaha YZF-R6 (older models), Suzuki SV650, Ninja 500R (predecessor), Ducati Monster 696.
Engine Character:
Smooth, torquey parallel-twin engine offering a good balance of power and usability.
Handling Characteristics:
Nimble and confidence-inspiring handling, making it approachable for new riders.
Design:
Sporty fairing (Ninja 650R designation) with a naked variant (ER-6n) also available, offering a blend of sporty aesthetics and everyday comfort.
Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Regions Covered:
Global (includes variations common across major markets)
Estimated Pages:
400-600 (typical for comprehensive service manuals)
Type:
Factory Service Manual (FSM)
Powertrain:
Engine disassembly, assembly, tuning, diagnostics, cooling system, lubrication system, exhaust system.
Chassis:
Frame, front suspension (forks), rear suspension (monoshock), steering system, wheel assembly, final drive (chain).
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, ABS (if applicable to specific sub-models).
Electrical System:
Wiring diagrams, ignition system, lighting, starting system, charging system, battery, fuses, relays, ECU (Engine Control Unit) diagnosis.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, evaporative emission control system.
Bodywork And Trim:
Fairings, seat, fuel tank, fenders, instrument panel, lighting components.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain maintenance, brake pad replacement, spark plug replacement, coolant checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation, electrical system troubleshooting.
Repair And Overhaul:
Engine rebuild, transmission overhaul, suspension fork service, brake caliper rebuild, carburetor cleaning/adjustment (if applicable to earlier models, though 650R is EFI), electrical component replacement.
Disassembly And Assembly:
Step-by-step guides for removing and reinstalling major components and sub-assemblies.
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed specifications, torque values, special tool requirements, and diagnostic flowcharts.
File Type:
PDF (Portable Document Format)
Searchability:
Typically text-searchable within the PDF for quick information retrieval.
Quality:
High-resolution scans of original factory documentation, suitable for printing.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Valvetrain:
4 valves per cylinder
Horsepower Peak Approx:
70-72 hp @ 8,500 rpm (claimed)
Torque Peak Approx:
64-66 Nm @ 7,000 rpm (claimed)
Fuel Delivery:
Digital Fuel Injection (DFI) with dual 38mm Keihin throttle bodies
Fuel Type Recommended:
Unleaded gasoline, 91 octane (or higher)
Oil Type Recommended:
SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil
Coolant Type:
Kawasaki Coolant (or equivalent ethylene glycol based coolant with distilled water, 50/50 mix)
Transmission Type:
6-speed constant mesh, return shift
Clutch Type:
Wet multi-disc, manual
Final Drive:
Sealed chain drive
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.750, 2nd: 2.056, 3rd: 1.611, 4th: 1.333, 5th: 1.150, 6th: 0.967)
Transmission Oil Type:
SAE 80W-90 API GL-4 or GL-5 gear oil (if separate from engine oil, check manual for confirmation)
Crash Test Ratings:
Motorcycles are not typically subjected to standardized car-like crash tests. Safety is evaluated based on design and rider aids.
Braking System Type:
Dual front disc brakes, single rear disc brake. ABS was an option on some later models within this range.
Lighting:
Halogen headlights, LED taillight.
Frame Design:
High-tensile steel perimeter frame designed for rigidity and rider feedback.
Ergo Design:
Upright riding position for comfort and control compared to more aggressive sportbikes.
Instrument Cluster:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, coolant temperature warning.
ABS Availability:
Optional on some models and model years. The manual will specify if ABS-related procedures are included.
Connectivity Features:
None (basic motorcycle electronics for its era).
Oil Change Interval:
Every 4,000 miles (6,000 km) or 6 months, whichever comes first.
Oil Filter Change Interval:
At every oil change.
Air Filter Inspection Interval:
Every 8,000 miles (12,000 km)
Spark Plug Replacement Interval:
Every 12,000 miles (19,000 km)
Valve Clearance Check Interval:
Every 16,000 miles (26,000 km) or 24 months.
Chain Lubrication Frequency:
Every 500 miles (800 km) or after riding in rain or wet conditions.
Coolant Flush Interval:
Every 2 years.
Engine Oil Capacity W Filter:
2.7 Liters (2.9 US qt)
Engine Oil Capacity Wo Filter:
2.5 Liters (2.6 US qt)
Brake Fluid Type:
DOT 4 (or DOT 3 as minimum specification, refer to manual for precise requirement)
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires, fork seals.
Potential Electrical Issues:
Some owners have reported issues with the rectifier/regulator unit failing, leading to charging system problems. Wiring harness corrosion in specific areas can also occur with age and exposure.
Engine Performance Quirks:
Occasional issues with fuel injectors becoming clogged, requiring cleaning or replacement. Idle speed control can sometimes be sensitive to carbon buildup.
Chassis Concerns:
Rear shock absorber can lose damping over time, especially with heavy use or aggressive riding.
Kawasaki Legacy:
Kawasaki Heavy Industries, Ltd. has a long and storied history in motorcycle manufacturing, known for performance and innovation across various segments, from cruisers to superbikes and off-road machines.
Ninjafamily Introduction:
The Ninja branding has been associated with Kawasaki's sporty offerings for decades, with the Ninja 650R becoming a significant model in the middleweight sportbike category.
Predecessor:
Succeeded the Ninja 500R (EX500), offering a more modern design, increased displacement, and fuel injection.
Facelift Updates:
This generation (EX650A) received minor updates in styling and features throughout its run, but the core platform remained consistent until the next major redesign.
Manufacturing Location:
Primarily manufactured in Japan and Thailand.
Sales Performance Era:
The Ninja 650R was a strong seller globally during its production run, known for its value proposition and versatility.
