🏷️ Basic Information

Make:

Kawasaki

Model:

ER-6f

Year:

2009-2011

Chassis Code:

ER650C

Engine Code:

ER650AE00001 onwards (specific to model years)

👋 Introduction

Segment:

Mid-weight sport-touring / naked sportbike platform

Target Audience:

New and experienced riders seeking a versatile, reliable, and affordable motorcycle.

Competitors:

Yamaha FZ6/Fazer, Suzuki SV650/SV650S, Honda CBF600.

Key Selling Points:

Smooth parallel-twin engine, balanced chassis, accessible ergonomics, stylish full-fairing design (ER-6f).

Engine Layout:

Parallel-twin cylinder, liquid-cooled, DOHC, 4-valve per cylinder.

Fairing Design:

Full fairing with integrated dual headlights contributing to a sporty and aerodynamic profile.

Ergonomics:

Comfortable rider triangle suitable for commuting and longer rides.

📋 Manual Details

Engine:

Yes

Transmission:

Yes

Chassis And Suspension:

Yes

Electrical System:

Yes

Fuel System:

Yes

Braking System:

Yes

Cooling System:

Yes

Exhaust System:

Yes

Bodywork And Fairings:

Yes

Wheels And Tires:

Yes

Lighting System:

Yes

Troubleshooting:

Yes

Total Pages:

622

Type:

Workshop Service Manual

Purpose:

Repair and Maintenance

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for the 649cc parallel-twin engine, including cylinder head, pistons, crankshaft, connecting rods, valves, and timing components.

Engine Management:

Coverage of EFI system, sensors (throttle position, crank angle, coolant temperature, oxygen), fuel injectors, ECU diagnosis, and emission control.

Transmission And Clutch:

In-depth information on the 6-speed sequential gearbox, clutch operation (wet multi-plate), clutch cover removal, and gearbox disassembly/assembly.

Fuel And Exhaust:

Fuel tank removal and installation, fuel pump testing, fuel filter replacement, catalytic converter inspection, and exhaust system component torque specifications.

Cooling System:

Radiator, fan, thermostat, water pump, coolant specifications, flushing procedures, and leak testing.

Lubrication System:

Oil pump, oil filter replacement (e.g., 16099-003), oil capacity (approx. 2.8L with filter change), and lubrication point diagrams.

Braking System:

Front and rear brake caliper servicing, brake pad replacement, brake fluid type (DOT 4), bleeding procedures, master cylinder maintenance, and ABS system (if equipped).

Suspension And Steering:

Front telescopic forks (including oil type, level, and seal replacement), rear monoshock absorber, swingarm, steering head bearing service, and wheel bearing replacement.

Electrical And Ignition:

Wiring diagrams, battery specifications (e.g., YTX9-BS or equivalent), charging system (stator, rectifier/regulator), starter motor, ignition coil testing, and lighting system troubleshooting.

Chassis And Frame:

Frame inspection, sub-frame removal, footpeg and control lever adjustments, and mounting point torque specifications.

Body And Fairings:

Removal and installation of front and side fairings, seat, fuel tank cover, and other trim components.

Scheduled Maintenance:

Detailed intervals for oil changes, filter replacements, valve clearance checks (every 4000-6000 miles or as specified), chain lubrication, brake inspection, and coolant changes.

Engine Rebuild:

Complete step-by-step instructions for engine disassembly, component inspection, part replacement, and reassembly with precise torque values.

Suspension Overhaul:

Front fork seal and oil replacement, rear shock absorber servicing (if applicable), and linkage maintenance.

Brake System Service:

Fluid flushing, bleeding, pad and disc replacement, and caliper overhaul.

Electrical Diagnostics:

Troubleshooting common electrical faults, testing components, and interpreting wiring diagrams.

Fuel System Cleaning:

Cleaning of fuel injectors and throttle bodies for optimal performance.

Wheel And Tire Service:

Tire mounting/dismounting, balancing, chain adjustment, and wheel bearing replacement.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners and engine components.

Troubleshooting Guides:

Systematic diagnostic procedures for common performance issues, starting problems, and electrical faults.

Depth:

Comprehensive workshop level, covering everything from basic fluid changes to full engine and transmission rebuilds.

Diagnostic Capabilities:

Includes guidance for diagnosing EFI system faults, ignition issues, and charging system problems.

Special Tools:

Mentions necessary special tools for specific procedures, such as valve spring compressors or engine timing tools.

📊 Manual Specifications

Format:

PDF

Searchability:

Typically text-searchable if properly created

Quality:

High-resolution scans suitable for clear printing

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, DOHC, parallel-twin

Displacement:

649 cc

Bore X Stroke:

83.0 x 60.0 mm

Compression Ratio:

11.3:1

Valve Train:

DOHC, 8 valves

Horsepower:

Approx. 72 hp @ 8,500 rpm (may vary slightly by market)

Torque:

Approx. 64 Nm @ 7,000 rpm (may vary slightly by market)

Fuel Delivery:

Fuel Injection (DFI) with dual 38mm throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane (RON+MON)/2

Fuel Tank Capacity:

15.5 Liters (4.1 US gal)

🔧 Transmission

Transmission Type:

6-speed, constant mesh, sequential manual

Transmission Type:

N/A (No automatic option available)

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Overall Length:

2,105 mm (82.9 in)

Overall Width:

760 mm (30.0 in)

Overall Height:

1,170 mm (46.1 in)

Wheelbase:

1,410 mm (55.5 in)

Ground Clearance:

145 mm (5.7 in)

Seat Height:

805 mm (31.7 in)

Curb Weight:

Approx. 208 kg (458.6 lbs)

Front Tire Size:

120/70ZR17M/C (58W)

Rear Tire Size:

160/60ZR17M/C (64W)

Wheel Bolt Pattern:

N/A (Cast wheels, hub mounted)

Front Brakes:

Dual semi-floating 300 mm petal discs with 2-piston calipers

Rear Brakes:

Single 220 mm petal disc with 1-piston caliper

🛡️ Safety Features

Safety Features:

ABS (Anti-lock Braking System) was an optional feature on some models/markets.

Braking:

Powerful dual front discs and responsive rear disc; ABS option enhances stability under heavy braking.

Lighting:

Dual multi-reflector headlights for improved visibility.

Frame Construction:

Rigid perimeter frame design for stability.

Fairing:

Provides rider protection from wind and elements.

💡 Technology Features

Display:

Digital LCD instrument cluster including speedometer, tachometer, fuel gauge, clock, trip meter, and indicator lights.

ABS:

Available as an optional feature on certain models, enhancing braking safety.

Lighting:

Halogen headlights and LED taillight.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement Interval:

Every 12,000 km (7,400 miles) or 12 months.

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles) or 6 months; replacement as needed.

Spark Plug Replacement Interval:

Every 12,000 km (7,400 miles) or 12 months.

Valve Clearance Check Interval:

Every 12,000 km (7,400 miles) or 12 months (adjust as needed).

Engine Oil Type:

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

Engine Oil Capacity:

2.8 L (2.9 US qt) with filter change; 2.6 L (2.7 US qt) without filter change.

Coolant Type:

Kawasaki All-Season Motorcycle Coolant or equivalent ethylene glycol based coolant with distilled water (50/50 mix).

Brake Fluid Type:

DOT 4

Fork Oil Type:

10W (refer to manual for specific Kawasaki part number or equivalent)

Fork Oil Level:

120 mm (4.7 in) from top of inner tube with spring removed and suspension fully compressed.

Common Problems:

Occasional reports of regulator/rectifier failures (heat related), chain wear, and clutch slave cylinder leaks. Regular maintenance mitigates most issues.

Common Problems Diagnosis:

The manual provides diagnostic steps for electrical issues including regulator/rectifier function checks.

📚 Vehicle History

Brand:

Kawasaki Heavy Industries Motorcycle & Engine Company is a renowned Japanese manufacturer with a long history of producing high-performance and reliable motorcycles.

Generation:

The ER-6f (also known as Ninja 650R in some markets) was part of Kawasaki's ER series, designed to offer a balance of performance, comfort, and affordability. The 2009-2011 models represent a specific iteration of this platform, often featuring minor styling updates or component refinements over earlier versions.

Manufacturing Location:

Primarily manufactured in Japan.

Sales Performance:

The ER-6 platform was popular globally, particularly in Europe and North America, for its versatility and competitive pricing.

🏆 Awards & Recognition

Awards:

While specific awards for the 2009-2011 ER-6f are not widely publicized, the ER-6 platform has consistently received praise from motorcycle publications for its value, performance, and usability.