🏷️ Basic Information

Make:

Kawasaki

Model:

ER-6N

Model Variant:

ER-6N ABS

Year:

2009, 2010

Vehicle Type:

Motorcycle

Body Style:

Naked Sportbike

Manual Product Name:

Kawasaki ER-6N & ER-6N ABS Motorcycle Complete Workshop Service Repair Manual 2009 2010 PDF Download

👋 Introduction

Segment:

Mid-weight naked sportbike

Target Audience:

Commuters, urban riders, beginner to intermediate sportbike enthusiasts.

Key Competitors:

Yamaha FZ6R, Suzuki SV650, Honda CBF600.

Engine Configuration:

Liquid-cooled, four-stroke, DOHC, parallel-twin.

Design Philosophy:

User-friendly, accessible performance, stylish naked design.

ABS Availability:

Optional Anti-lock Braking System (ABS) for enhanced safety.

📋 Manual Details

Manual Coverage Scope:

Complete Service and Repair Procedures

Estimated Page Count:

300-500 pages (typical for this model and detail level)

Manual Category:

Workshop Service Repair Manual

Language:

English

File Format:

PDF (Downloadable)

📖 Manual Coverage

Engine System:

Complete engine disassembly, assembly, tuning, diagnostics, and repair for the 649cc parallel-twin engine.

Fuel System:

Fuel injection system, throttle bodies, fuel pump, fuel filter, and emissions control systems.

Cooling System:

Radiator, cooling fan, coolant circulation, and related components.

Exhaust System:

Exhaust pipes, catalytic converter, muffler, and lambda sensor replacement.

Transmission System:

Clutch operation, gear shifting mechanism, gearbox internals, and lubrication.

Chassis Frame:

Frame inspection, alignment, and associated brackets.

Suspension System:

Front fork (telescopic) servicing, adjustment, and rear shock absorber replacement and adjustment.

Braking System:

Hydraulic front and rear disc brakes, brake pad replacement, caliper servicing, master cylinder, and ABS system operation and diagnostics.

Wheel Tire System:

Wheel bearing replacement, tire removal and installation, wheel balancing, and spoke tension (if applicable).

Electrical System:

Battery, starter motor, alternator, ignition system, lighting, horn, and wiring diagrams.

Instrumentation Controls:

Dashboard, switches, levers, and control cable adjustments.

Bodywork Fairings:

Removal, installation, and repair of plastic panels, seats, and fuel tank.

Preventative Maintenance:

Routine checks, fluid changes, filter replacements, chain adjustment, and lubrication schedules.

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).

Engine Repair Rebuild:

Detailed instructions for engine disassembly, component inspection, critical torque specifications, and reassembly for full engine overhauls.

Transmission Overhaul:

Complete procedures for gearbox disassembly, gear inspection, and reassembly.

Suspension Service:

Fork oil changes, seal replacement, and rear shock absorber servicing.

Brake System Overhaul:

Bleeding procedures, caliper rebuilds, and master cylinder replacement.

Electrical Component Replacement:

Ignition coil, stator, regulator/rectifier, and starter motor replacement.

ABS System Maintenance:

ABS sensor cleaning, brake fluid bleeding with ABS considerations.

Wiring Diagram Interpretation:

Detailed electrical schematics for troubleshooting and component identification.

Depth Level:

Comprehensive (from basic maintenance to full engine and transmission rebuilds)

Diagnostic Capability:

Advanced diagnostics for all major systems, including fuel injection and ignition.

Repair Methodology:

Detailed, step-by-step repair instructions with illustrations and torque specifications.

📊 Manual Specifications

PDF Quality:

High-resolution, searchable PDF for clear viewing and printing.

Printability:

Printable pages allowing users to create a physical copy.

Physical Copy Binding:

N/A (Digital Download)

Digital File Type:

PDF Document

⚙️ Engine Specifications

Engine Code:

ER650A (typical, check VIN for exact)

Engine Type:

Liquid-cooled, four-stroke, DOHC, 4 valves per cylinder, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Valve Clearance Intake:

0.10 - 0.15 mm (cold)

Valve Clearance Exhaust:

0.15 - 0.20 mm (cold)

Claimed Horsepower:

Approx. 72 hp @ 8,500 rpm

Claimed Torque:

Approx. 60 Nm (44.3 lb-ft) @ 7,000 rpm

Fuel Delivery:

Fuel Injection with Digital Fuel Injection (DFI)

Fuel Type:

Unleaded gasoline (minimum 91 octane recommended)

Throttle Body Size:

38 mm

Ignition Type:

TCBI (Transistor Controlled Ignition) with digital advance

Spark Plug Type:

NGK CR9EIA-9 or DENSO VUH27A

🔧 Transmission

Transmission Type:

6-speed constant mesh, return type

Clutch Type:

Wet multi-disc, cable operated

Optional Transmission:

N/A

Final Drive:

Sealed chain, RK525MS0 (or equivalent)

📐 Dimensions

Overall Length:

2,105 mm (82.9 in)

Overall Width:

760 mm (29.9 in)

Overall Height:

1,090 mm (42.9 in)

Wheelbase:

1,410 mm (55.5 in)

Ground Clearance:

150 mm (5.9 in)

Seat Height:

805 mm (31.7 in)

Curb Weight:

Approx. 200 kg (441 lbs) for ABS model

Dry Weight:

Approx. 191 kg (421 lbs) for non-ABS model

Front Tire Size:

120/70ZR17M/C (58W)

Rear Tire Size:

160/60ZR17M/C (64W)

Wheel Bolt Pattern:

N/A (Cast Wheels)

Fuel Tank Capacity:

16 L (4.2 US gal)

🛡️ Safety Features

Safety Certification:

Meets applicable national/regional safety standards for motorcycles.

ABS:

Available Anti-lock Braking System (ABS) on specific models for improved stopping control.

Braking System:

Dual front disc brakes, single rear disc brake provide strong stopping power.

Lighting:

Halogen headlamp and LED taillight for visibility.

Frame Construction:

High-tensile steel backbone frame for rigidity and rider feedback.

💡 Technology Features

Display Type:

Digital LCD instrument cluster.

Instrumentation Features:

Speedometer, tachometer, odometer, trip meters, fuel gauge, clock, coolant temperature warning lamp, fuel injection warning lamp, neutral indicator.

ABS:

Optional Anti-lock Braking System (ABS) contributes to rider safety by preventing wheel lock-up during heavy braking.

Connectivity Features:

N/A (Basic motorcycle electronics, no integrated Bluetooth or Wi-Fi).

🔧 Maintenance

First Service:

1,000 km (600 miles) or 6 months, whichever comes first. Includes oil change, filter check, chain adjustment, and general inspection.

Subsequent Service:

Every 6,000 km (3,700 miles) or 12 months, whichever comes first. Includes oil change, filter replacement, spark plug replacement (at higher intervals), valve clearance checks, coolant change, brake fluid flush, etc., as per the manual schedule.

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified.

Engine Oil Capacity W Filter:

3.0 L (3.2 US qt)

Engine Oil Capacity Wo Filter:

2.7 L (2.9 US qt)

Coolant Type:

High-quality ethylene glycol based coolant with distilled water (50/50 mixture recommended).

Coolant Capacity:

Approx. 1.7 L (1.8 US qt)

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified for ABS)

Fork Oil Type:

Show 45 (or equivalent 5W-10W suspension fluid, check manual for precise weight).

Fork Oil Level:

130 mm (5.1 in)

Final Drive Chain Lubricant:

High-quality motorcycle chain lubricant.

Engine Idling Issues:

Some owners report occasional rough idling or stalling, often related to throttle body synchronization or fuel injection system cleanliness.

Suspension Harshness:

The stock suspension can be perceived as slightly firm for some riders, leading to a less comfortable ride on rough surfaces. Tuning or aftermarket upgrades are common solutions.

Clutch Lever Feel:

Some users find the clutch lever pull to be slightly heavy; cable adjustment or lubrication can help mitigate this.

Chain Wear:

Regular chain maintenance (cleaning, lubrication, adjustment) is crucial to prevent premature wear and ensure smooth power delivery.

📚 Vehicle History

Kawasaki Motorcycle Legacy:

Kawasaki has a long-standing reputation for performance and reliability in the motorcycle industry, dating back to its early beginnings in motorcycle production in the 1950s.

Er6N Genesis:

The ER-6N (and its faired sibling, the ER-6F Ninja 650) was introduced in 2005, designed to offer accessible performance and a modern, aggressive aesthetic in the mid-weight sportbike category. It quickly gained popularity for its user-friendly nature and versatile capabilities.

2009 2010 Updates:

The 2009-2010 models represent a significant update over the first generation, featuring revised styling, improved suspension, updated fuel injection, and enhanced ergonomics. The introduction of the ABS option further broadened its appeal.

Manufacturing Location:

Primarily manufactured in Japan, with potential assembly in other global locations depending on market.

🏆 Awards & Recognition

Segment Popularity:

The ER-6N has consistently been praised in motorcycle reviews for its value proposition, ease of use, and versatile performance, making it a popular choice in its segment.