Kawasaki NINJA 650R manual

Ninja ® 650R ER-6f ER-6f ABS Motorcycle Assembly & Preparation Manual[...]

Foreword In order to ship Kawasaki vehicles as effi- ciently as possible, they are partially disassem- bled before crating. Since some of the most commonly removed parts have a direct bear- ing on a vehicle’ s reliability and safety , consci- entious pre-sale assembly and preparation be- comes extremely important. Good setup pro- cedures can prev[...]

T able of Contents Un crating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check ................................................................................. 4 As sembly ...............................[...]

[...]

UNCRA TI NG 3 Uncrating Opening Crate WA R N I N G Always wear protective gloves, boots and eye protection when uncrating to prevent injury . WA R N I N G Be careful not to injure your body by the sharp edges of the steel crate panel pla tes and other sharp fasteners. • Clear a space about 6 m (20 ft) square to give yourself plenty of space to wo[...]

4 UNCRA T ING Parts Check • Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. No. Part Name Qty Remarks 1 Handlebar with Grips, Weights and Clu[...]

ASSEMBL Y5 Assembly Handlebar Handlebar Installation • Set the handlebar so that its punched mark is aligned with the upper rear edge of the lower handlebar clamp and install the upper handle- bar clamp and bolts (D = 8, L = 30). • T ighten the front clamp bolts first, and then the rear clamp bolts to the specified torque. There will be a gap a[...]

6 ASSEMB LY A. Right Switch Housing B. Screw (D = 5, L = 25) C. Screw (D = 5, L = 40) Front Brake Master Cylinder • Connect the right switch housing lead con- nectors to the front brake light switch termi- nals on the front brake master cylinder . A. Front Master Cylinder B. Brake Light Switch T erminals C. Connectors and Dust Covers • Install [...]

ASSEMBL Y7 Cables, Harness and Hoses Routing • Check that the cables, wiring leads and hoses are routed correctly . Right Side View Left Side View A. Right Switch Housing Harness B. Throttle Cable (Accelerator) C. Throttle Cable (Decelerator) D. Front Brake Hose E. From the inside sequentially , run the right switch housing harness, front brake h[...]

8 ASSEMB LY Left Switch Housing • Connect the left switch housing connector to the starter lock-out switch on the clutch lever assembly . A. Clutch Lever Assy B. Starter Lock-out Switch C. Connector • Fit the two halves of the left switch housing together so that the small projection on the front half fits into the hole in the handlebar . A. Re[...]

ASSEMBL Y9 • Install the left bracket on the lower left side of the engine with the flanged bolts (D = 6, L = 14) (2) with non-permanent locking agent, and tighten the bolts to the specified torque. T orque: 12 N·m (1.2 kgf·m, 106 in·lb) A. Left Bracket B. Flanged Bolts (D = 6, L = 14) • Pull the left upper fairing outward to clear the stopp[...]

10 PREP A RA TION A. Socket Bolts (D = 5, L = 20) and Plastic W ashers (D = 5.3) B. Upp er Center Fairing C. Windshield Brake Disc Cleaning • Clean the front and rear brake discs using oilless solvent. WA R N I N G If not removed, the anticorrosive treat- ment applied to the brake disc surface will interfere with brake action, and an unsafe ridin[...]

PREP ARA TION 1 1 A. Seat B. Seat Lock C. Ignition Key D. Insert • T urn the key clockwise while pulling the rear end of the seat. • Remove the seat backward. • Run the suitable band into the positive termi- nal (+). • Pull the battery out of the batt ery case with both hands. A. Battery B. Suitable Band • Clean the terminals. Battery Spe[...]

12 PREP A RA TION • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery . Hold the container level, push down to break the seals of all six cells. Y ou will see air bubbles rising into each cell as the ports fill. NOTE  Do not tilt the electrolyte container . • Check the electrolyte flow[...]

PREP ARA TION 13 CAUTION Once the strip of the caps [A] is installed onto the battery , never remove the caps, nor add water or electrolyte to the bat- tery . NOTE  T o ensure maximum battery life and customer satisfaction, it is recommended the battery be loa d tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if le[...]

14 PREP A RA TION WA R N I N G Never reuse old brake fluid. Do not use fluid from a container that has bee n left unsealed or that has been open for a long time. Do not mix two types of fluid for use in the bra kes. This lowers the brake fluid boiling point and could reduce brake ef- fectiveness. It may also cause the rub- ber br ake parts to deter[...]

PREP ARA TION 15 A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line • If the fluid level in the reservoir is lower than the lower level line, check for fluid leaks in the brake line, and fill the reservoir . • Remove the reservoir cap and diaphragm, and fill the reservoir to the upper level line with DOT4 brake fluid. WA R N [...]

16 PREP A RA TION A. Hold the brake pedal applied. B. Quickly open and close the bleed valve. C. Release the brake pedal. • When air bleeding is finished, check that the fluid level is between the upper and lower level lines. • T ighten the bleed valve to the specified torque. T orque: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Install the diaphragm[...]

PREP ARA TION 17 A. Socket Bolt (D = 5, L = 16) and Plastic W asher (D = 5.3) B. Rig ht Side Cover C. Stopper • Loosen the locknut at the middle of the clutch cable. • T urn the adjuster until the free play is correct. WA R N I N G Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever , or it c[...]

18 PREP A RA TION A. 25 a 35 mm (1.0 a 1.4 in.) • If the drive chain is too tight or too loose, ad- just it so that the chain slack will b e within the standard value. WA R N I N G A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, se- verely damaging the motorcycle and causing it to go out of[...]

PREP ARA TION 19 A. Cotter Pin B. T urning Clockwise • Bend the cotter pin over the nut. A. Cotter Pin B. Nut WA R N I N G If the rear axle nut is not securely tight- ened or the cotter pin is not installed, an unsafe riding condition may result. • Check the rear brake effectiveness. Rear Shock Absorber Spring Preload Adjustment • Check the p[...]

20 PREP A RA TION • Open the fuel tank cap, and check for debris in the fuel tank. • Fill the fuel tank with one gallon or four liters of unleaded gasoline. Use gasoline with a minimum antiknock index rating according to the recommendation of your country . Refer to the following table. The antiknock index is an average of the Re- search Octane[...]

PREP ARA TION 21 A. Dust Cover B. Meter Unit Connector C. Flanged Bolts (D = 6, L= 12) • Pull the upper fairing outward to clear the stoppers on both sides. • Remove the upper fairing forward. A. Upper Fairing B. Stoppers C. Remove the Upper Fairing Forward. • Remove the cap from the reserve tank and add coolant through the filler opening to [...]

22 PREP A RA TION • Start the engine and run it for several minutes at idle speed. Stop the engine, then wait sev- eral minutes until the oil settles. • With the motorcycle held level, check the en- gine oil level through the oil level sight gauge. The oil level should come up between the up - per and lower level lines next to the gauge. A. Oil[...]

PREP ARA TION 23 Throttle Grip and Cable Thrott le Grip Free Play Inspection • Inspect the throttle grip free play . If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play: 2 a 3 mm (0.08 a 0.12 in.) • Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely [...]

24 PREP A RA TION Rear Brake Light Switch Rear Br ake Light Switch Adjustment • T urn on the ignition switch. The brake light should illuminate when the brake pedal is de- presse d about 10 mm (0.39 in.) • If it does not, disconnect the rear brake light switch lead connector . • Tu r n t he rear brake light switch body as re- quired. • Conn[...]

PREP ARA TION 25 CAUTION When handling the quartz-halogen bulbs, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. Digital Meter Check the Km/Mile Display in the Digital Meter: Km/Mile Display can alternate between Eng- lish and metr[...]

26 PREP A RA TION Fastener Check • The torque values listed are for assembly and preparation items only , see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery . Also check to see that each cotter pin or circlip is in place.[...]

PREP ARA TION 27 To r q u e No. Fastener N·m kgf·m ft·lb Remarks Steering 1 Handlebar clamp bolt 25 2.5 18 S Brake 2 Front master cylinder clamp bolt 11 1.1 97 in·lb S 3 Front brake bleed valve (Left and Right) 7.8 0.80 69 in·lb 4 Front caliper mounting bolt (Left and Right) 34 3.5 25 5 Rear master cylinder mounting bolt 25 2.5 18 6 Rear brake[...]

28 PREP A RA TION S t a n d a r d To r q u e Ta b l e This table relating tightening torque to thread diameter , lists the basic torque for bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent -cleaned threads. General Fasteners: Threads T orque dia. [...]

[...]

MODEL APPLICA TION Y ear Model Name 2009 EX650C9F Ninja 650R, ER-6f 2009 EX650D9F ER-6f ABS Part No. 99931-1507-01[...]