Segment:
Middleweight sportbike / sport-touring motorcycle.
Target Audience:
Riders seeking a balance of sporty performance, everyday usability, and affordability. Popular for commuting, sport touring, and general recreational riding.
Competitors:
Honda CBR600F, Yamaha FZ6, Suzuki SV650/GSX650F, Triumph Daytona 675 (older models).
Engine Configuration:
Parallel-twin engine, known for its broad powerband and user-friendliness.
Design Philosophy:
Designed to offer exciting performance in a comfortable, versatile package, bridging the gap between entry-level and supersport motorcycles.
Ergonomics:
More upright riding position compared to pure supersports, enhancing comfort for longer rides.
Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Estimated Pages:
Approximately 300-400 pages (typical for this model and manual type)
Type:
Service Repair Workshop Manual
Engine:
Complete engine disassembly, assembly, inspection, lubrication, cooling system, fuel injection system (EFI), exhaust system.
Transmission:
Clutch, gearbox, gear shift mechanism, lubrication, internal inspection and repair.
Chassis And Suspension:
Front fork (including oil type and level), rear shock absorber, swingarm, bearings, steering system.
Brakes:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, discs, bleeding procedures, ABS system (if applicable to specific variants).
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting, starting system, instrumentation, ECU (Engine Control Unit).
Fuel System:
Fuel pump, fuel injectors, fuel filter, fuel tank, evaporative emission control system (EVAP).
Cooling System:
Radiator, fan, water pump, thermostat, coolant type and capacity, bleeding.
Body And Frame:
Fairings, seat, fuel tank removal, frame inspection, sub-frame.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks and replacement, chain adjustment and lubrication, brake fluid replacement, coolant checks.
Troubleshooting:
Diagnostic charts, common problems and their solutions, fault codes (if applicable).
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly.
Tune Up:
Idle speed adjustment, ignition timing checks (if adjustable), fuel mixture adjustments (if applicable).
Diagnostics:
EFI system diagnostics, sensor testing, wiring continuity checks.
Depth:
Comprehensive; covers everything from basic scheduled maintenance to complete engine and transmission overhauls, electrical system diagnostics, and chassis component repair.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Displacement:
649 cc (650cc class)
Bore X Stroke:
83.0 mm x 60.0 mm
Compression Ratio:
11.4:1
Valve Train:
DOHC, 8 valves (2 per cylinder)
Horsepower Peak:
Approximately 78.2 hp (58.3 kW) @ 8,500 rpm (specifications may vary slightly by year/market)
Torque Peak:
Approximately 47.0 lb-ft (63.7 Nm) @ 7,000 rpm (specifications may vary slightly by year/market)
Fuel Delivery:
Digital Fuel Injection (DFI) with dual 38mm Keihin throttle bodies.
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
4.1 US gallons (15.5 Liters)
Type:
6-speed, constant mesh
Clutch:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain, 15T front / 46T rear sprockets (typical)
Gear Ratios:
Typical ratios: 1st: 2.733 (41/15), 2nd: 2.052 (39/19), 3rd: 1.619 (34/21), 4th: 1.333 (32/24), 5th: 1.150 (23/20), 6th: 1.040 (26/25).
Transmission Fluid:
Refer to manual for specific type (typically SAE 10W-40 or 20W-50 motorcycle oil, API SG or higher, JASO MA compliant).
Length:
Approx. 80.1 inches (2035 mm)
Width:
Approx. 30.1 inches (765 mm)
Height:
Approx. 44.1 inches (1120 mm)
Wheelbase:
Approx. 55.1 inches (1400 mm)
Ground Clearance:
Approx. 4.7 inches (120 mm)
Dry Weight:
Approx. 386 lbs (175 kg)
Curb Weight:
Approx. 423 lbs (192 kg) (includes all necessary operating consumables and a full tank of fuel)
Gross Vehicle Weight Rating Gvwr:
Refer to chassis decal and manual (typically around 800 lbs / 363 kg).
Crash Test Ratings:
N/A (Motorcycles are not typically rated by standard automotive crash safety organizations like NHTSA or IIHS).
Braking System:
Dual front 300mm petal discs with dual-piston calipers; Single rear 220mm petal disc with dual-piston caliper. ABS was an optional feature on some models/markets.
Lighting:
Halogen headlights, LED taillight.
Frame Construction:
High-tensile steel perimeter frame for strength and rigidity.
Instrumentation:
Digital speedometer, analog tachometer, fuel gauge, clock, trip meters.
Display:
Analog tachometer, digital LCD multi-function display (speedometer, odometer, trip meters, clock, fuel gauge, coolant temperature).
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on select models and markets during this generation.
ECU Capabilities:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. Diagnostic capabilities for ECU fault codes are covered in the manual.
Oil Change:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 7,500 miles (12,000 km) or 12 months. Can be done concurrently with oil changes.
Air Filter Cleaning/Replacement:
Inspect every 3,700 miles (6,000 km), clean or replace as needed. Replacement typically recommended around 7,500-15,000 miles (12,000-24,000 km) depending on conditions.
Spark Plug Replacement:
Typically every 7,500 miles (12,000 km).
Chain Lubrication And Adjustment:
Lubricate every 500 miles (800 km) or after riding in wet conditions. Adjust chain slack every 1,200 miles (2,000 km).
Brake Fluid Replacement:
Every 24 months or 15,000 miles (24,000 km).
Coolant Replacement:
Every 24 months or 15,000 miles (24,000 km).
Engine Oil:
SAE 10W-40 or 20W-50, API SG or higher, JASO MA compliant. Capacity: 2.4 L (2.5 US qt) with filter change; 2.2 L (2.3 US qt) without filter change.
Coolant:
High-quality ethylene glycol-based antifreeze coolant mixed with distilled water (50/50 ratio). Capacity: Approx. 1.5 L (1.6 US qt).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Refer to manual for specific type and quantity (often 0W-20 or 10W, approx. 470-480ml per fork leg).
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals, regulator/rectifier (can overheat), clutch plates (under heavy use).
Engine Reliability:
Generally considered reliable. Issues can arise from poor maintenance or neglect. Some owners report occasional regulator/rectifier failures due to heat buildup.
Electrical Quirks:
Occasional electrical connection issues, particularly in humid environments. Battery health is crucial for the EFI system.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, dating back to the 1950s, known for innovation and performance across various motorcycle segments.
Ninja Lineage:
The Ninja 650R (often referred to as the ER-6f in some markets) was introduced as a more accessible and versatile sportbike, succeeding models like the Ninja 500R. It aimed to provide a balance of performance and practicality.
Design Change Over Years:
The 2005-2008 models shared a common platform. Minor cosmetic updates and feature tweaks occurred in later years (e.g., 2009 onwards saw slight revisions to fairings and instrumentation), but the core mechanicals remained largely consistent throughout this generation.
Manufacturing Location:
Primarily manufactured in Thailand and Japan.
