Segment:
Sportbike/Naked Sportbike
Target Audience:
New riders, commuters, sport touring enthusiasts
Competitors:
Suzuki SV650, Honda CBF600, Yamaha FZ6
Engine Configuration:
Parallel-twin
Design Philosophy:
Balanced performance, comfort, and economy
Covered Model Years:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Estimated Page Count:
Hundreds
Type:
Factory Service Repair Manual
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
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
Depth:
Comprehensive, covering basic maintenance to complete engine and chassis rebuilds
Engine Type:
4-stroke, Liquid-cooled, DOHC, Parallel-twin
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Horsepower Est:
78.2 HP @ 8,000 RPM (approx.)
Torque Est:
63.7 Nm @ 6,000 RPM (approx.)
Fuel Delivery:
Fuel Injection
Throttle Body:
Dual 38mm Keihin
Oil Capacity W Filter:
3.0 L (approx.)
Coolant Capacity:
1.7 L (approx.)
Crash Test Ratings:
Not applicable to motorcycles in traditional automotive sense
Braking System:
Dual hydraulic disc front, Single hydraulic disc rear (ABS optional on some models/markets)
Lighting:
Halogen headlamp, LED taillight
Frame Construction:
High-tensile steel perimeter frame
Display Type:
Digital LCD instrument cluster
Features:
Speedometer, tachometer, fuel gauge, clock, odometer, trip meters, coolant temperature indicator
ABS:
Optional on certain models and markets
Features:
N/A (basic instrumentation)
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)
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)
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)
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)
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Predecessor:
Varied, evolved from earlier Kawasaki parallel-twins
Successor:
Ninja 650 (ER650J onwards)
Production Start Year:
2005
Production End Year:
2011 (for this specific generation/variant)
Manufacturing Locations:
Japan (primarily), other international facilities
