Segment:
Mid-size sportbike/naked bike derivative, popular for commuting, sport touring, and entry-level sport riding.
Target Audience:
New riders, experienced riders seeking a versatile and affordable sportbike, urban commuters.
Key Competitors:
Suzuki SV650, Honda CBR600F, Yamaha FZ6 (all within similar displacement and performance classes).
Design Philosophy:
Balanced performance, approachable handling, distinctive styling with a focus on user-friendliness and versatility.
Distinctive Elements:
Under-seat exhaust, distinctive angled headlights, approachable ergonomics for a sportbike.
Covered Model Years:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Engine Variants Covered:
649cc Parallel-Twin (ER650C)
Estimated Page Count:
~500+ pages (typical for this type of manual)
Type:
Workshop Service and Repair Manual
Powertrain:
Engine (assembly, disassembly, lubrication, cooling, fuel system, ignition), Transmission (clutch, gearbox, final drive), Exhaust System
Chassis:
Frame, Suspension (front fork, rear shock), Wheels, Tires, Brakes (front and rear systems, ABS if equipped), Steering
Electrical:
Ignition system, Starting system, Charging system, Lighting, Instruments, Wiring diagrams, ECU (Engine Control Unit) diagnosis
Bodywork And Trim:
Fairings, Seat, Fuel Tank, Handlebars, Footpegs, Body panels removal and installation
Maintenance:
Scheduled maintenance, Oil changes, Filter replacement, Spark plug replacement, Chain adjustment and lubrication, Brake pad inspection/replacement, Coolant flush
Troubleshooting:
Diagnostic procedures for common issues, Fault code interpretation (if applicable), Electrical system troubleshooting, Engine performance issues
Repair:
Engine rebuild procedures, Transmission overhaul, Suspension component replacement, Brake system bleeding and component replacement, Electrical component testing and replacement
Assembly Disassembly:
Detailed step-by-step instructions for major component removal and reinstallation with torque specifications
Depth:
Comprehensive, covering basic to advanced diagnostics and repairs. Suitable for professional mechanics and experienced DIY enthusiasts.
File Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text content for efficient information retrieval.
Image Resolution:
High resolution for clear diagrams, illustrations, and text.
Binding For Download:
N/A (Digital format)
Paper Type For Printout:
N/A (Digital format, user chooses print paper)
Engine Type:
4-stroke, Liquid-cooled, DOHC, 8-valve, Parallel-twin
Displacement:
649 cc (39.6 cu. in.)
Bore X Stroke:
83.0 x 60.0 mm
Compression Ratio:
11.3:1
Max Power:
Approx. 72 hp @ 8,000 rpm (varies slightly by region/model year)
Max Torque:
Approx. 65 Nm (47.9 lb-ft) @ 6,000 rpm (varies slightly by region/model year)
Fuel Delivery:
Fuel injection with two 38mm Keihin throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON + MON)/2 / 91 AKI
Oil Type Recommendation:
API SG, SH, SJ, SL or SM, JASO MA certified 10W-40 semi-synthetic or synthetic motorcycle oil
Coolant Type:
Kawasaki Genuine 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, cable operated
Final Drive:
Sealed chain, 525-pitch
Gear Ratios:
1st: 2.750 (33/12), 2nd: 2.056 (37/18), 3rd: 1.650 (33/20), 4th: 1.409 (31/22), 5th: 1.250 (30/24), 6th: 1.042 (25/24)
Transmission Oil Type:
API GL-4 or GL-5 SAE 80W-90 gear oil
Transmission Oil Capacity:
Approx. 2.2 L (2.3 US qt) for disassembly, 1.8 L (1.9 US qt) for regular change
Overall Length:
Approx. 2,090 mm (82.3 in)
Overall Width:
Approx. 750 mm (29.5 in)
Overall Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Ground Clearance:
Approx. 155 mm (6.1 in)
Seat Height:
Approx. 805 mm (31.7 in)
Curb Weight:
Approx. 207 kg (456.4 lbs)
Fuel Tank Capacity:
17 Liters (4.5 US gal)
ABS Availability:
Optional (depending on model year and specific market configuration)
Braking System Front:
Dual 300mm petal discs with hydraulic dual-piston calipers
Braking System Rear:
Single 220mm petal disc with hydraulic single-piston caliper
Lighting System:
Dual Halogen headlights, LED taillight
Chassis Design:
High-tensile steel backbone frame for rigidity and light weight
Instrumentation:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
ABS System:
Optional Anti-lock Braking System (ABS) for enhanced braking control.
Diagnostic Ports:
Diagnostic connectors for accessing ECU data and fault codes.
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Brake Fluid:
DOT 4 specification (for both front and rear systems)
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol based coolant (50/50 mix with distilled water)
Engine Oil Capacity:
2.4 L (2.5 US qt) with filter change, 2.2 L (2.3 US qt) without filter change
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (depending on usage).
Potential Electrical Gremlins:
Occasional issues with rectifier/regulator overheating, or loose electrical connectors requiring inspection. Fuel pump can be a wear item.
Engine Performance Notes:
While generally reliable, some riders report a slight dip in power delivery around 5,000-6,000 RPM, often mitigated by exhaust and ECU remapping. Regular maintenance is key for optimal performance.
Suspension Notes:
Stock suspension can be perceived as basic. Upgrades are common for more demanding riding.
Manufacturer History:
Kawasaki Heavy Industries is a renowned Japanese multinational corporation with a long history in motorcycle manufacturing, known for performance and innovation.
Ninja 650R Lineage:
The ER-6f/Ninja 650R was introduced as a versatile middleweight sportbike, bridging the gap between smaller displacement bikes and larger liter-class machines. It was also offered in an unfaired version (ER-6n).
Production Period For This Manual:
2005-2011 (This generation was succeeded by an updated model for 2012).
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions depending on market.
