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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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🏷️ 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:
622
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:
PDF
Searchable:
Yes
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
ABS:
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.