Kawasaki NINJA 650R Manuals

One-Year WarrantY Your new Kawasaki motorcycle comes with a 12-month/unlimited mileage limited factory warranty. Read the next paragraph to find out how you can extend your coverage inexpensively, or ask your dealer for details about the factory warranty and available extended coverage. Up tO FOUr Years additiOnal COverage* Let Kawasaki protect your new machine for years to come* with the exclusive Good Times™ Protection Plan. This plan repairs or replaces most components free of charge if found defective in material or workmanship. Everything about the plan is easy: There’s no deductible. It’s honored at every authorized Kawasaki motorcycle dealer nationwide. It’s transferable to another owner with no fee. Just ask your dealer how you can buy additional coverage of 12, 24, 36 or 48 months depending on the model. Imagine, for just pennies a day, you can ride with no worry and no hassle. Just tell your dealer you want the Good Times Protection Plan. * Depending on the program purchased. ride With ZerO dOWn** We offer up to 100% instant financing on most Kawasaki products with the Good Times™ Credit Plan† or Good Times™ Credit Card. Qualified buyers can ride away on a brand-new Kawasaki with no down payment. In most cases, the computerized credit approval takes just minutes. You can even add insurance, accessories and the Good Times Protection Plan to your contract. Ask your participating dealer for details. **Qualified Buyers. † Good Times Credit Plan not available in Canada. Specifications subject to change without notice. Availability may be limited. Always wear a helmet and appropriate apparel. Call 1-800-446-9227 for the Motorcycle Safety Foundation beginner or expert course near you. You won’t even need a motorcycle−your course sponsor will provide one courtesy of your local dealer. saFe riding’s MOre FUn ride responsibly. Kawasaki believes safety begins with us and continues with you. always wear a helmet, eye protection, and proper apparel. passengers, too. ride defensively. if riding off-highway, use authorized areas only. Obey the Basic speed law. never ride under the influence of drugs or alcohol. riding is more fun on a well-maintained motorcycle... follow the instructions in your owner’s manual. remember, riding safe is smart. For more information, visit our Web site at: kawasaki.com For the nearest Kawasaki dealer, call: 1-800-661-ride To purchase accesories, see your dealer or visit our Web site. P/N 99969-3386 Printed in U.S.A. Kawasaki Motors Corp., U.S.A. 9950 Jeronimo Road, Irvine, California 92618 ©2008 Kawasaki Motors Corp., U.S.A Action Photography: Professional riders on a closed course. ® Professional rider on a closed course. ® SUPERSPORT SPORT availaBle COlOrs * liMe Green * MetalliC DiaBlO BlaCK / Flat sUper BlaCK * CanDY sUrF BlUe / Flat sUper BlaCK * MOnster enerGY ® (Shown on right) the champion in you On the track, you’re either the quickest guy in the 600 supersport pack or you’re toast. Which is exactly why the all-new 2009 ninja® ZX™-6r motorcycle boasts a potent 599cc DOHC liquid-cooled In-Line Four with chrome-moly camshafts and ultra-precise digital fuel injection for superior bottom-end, midrange and peak horsepower, along with 22 pounds less mass for an improved power-to-weight ratio. The new inverted big-piston fork likewise improves cornering feel and agility, while a first-in- class steering damper, sharpened handling and ergonomics, and aggressive new bodywork serve notice that the new ZX-6R means business – the business of winning. Professional rider on a closed course. sharing multiple compon with the lightweight new ZX-10r swingarm, the aluminum ZX-6r unit is now both lighter and mo rigid. swingarm includes rear race-stand bosses f convenient track-side or garage support. 1 2 the first production use of showa’s new Big pisto Fork (BpF) utilizes simple internal damper construc for lighter weight, better feedback and smoother fork action for better overall handling. 2 extremely compact and li weight, the DOHC in-line engine dramatically impro handling response and le angles, while huge 43mm throttle bodies and secon fuel injectors dramatically boost top-end horsepower race-spec twin-tube Öhlin steering damper is adjusta for street or track use. standard equipment and designed especially for th ZX-10r, the damper provid highly uniform steering damping performance eve under race conditions. Professional rider on a closed course. Action shot depicts motorcycle in Track-Day Form, with the removal of turn indicators and mirrors. 1 Built for the track and civilized for the street – that‘s the focus of the new 2009 ninja® ZX™-10r motorcycle. As a direct beneficiary of Kawasaki’s factory superbike racing experience, the ZX-10R has an extremely compact and potent 998cc liquid-cooled DOHC In-Line Four engine with two digital fuel injectors per cylinder for earth-shaking low-end torque and stratospheric top-end performance. The new 10R is just as comfortable on the street as it is on the track, thanks to nimble handling, superb machine-to-rider interfaces, and aggressive styling that sets it apart from any other machine. the race track availaBle COlOrs * liMe green / MetalliC DiaBlO BlaCK * CanDY BUrnt Orange / Flat sUper BlaCK * eBOnY(Shown on right)

Ninja 650R ER-6f ER-6f ABS Motorcycle Service Manual http://mototh.com http://mototh.com This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 j Periodic Maintenance 2 j Fuel System (DFI) 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j Engine Removal/Installation 8 j Crankshaft/Transmission 9 j Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix 17 j http://mototh.com http://mototh.com

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 prevent needless warranty claims and give customers a greater sense of confi- dence in Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual ex- plains step by step procedures of the following items for the Kawasaki Ninja 650R, ER-6f and ER-6f ABS. 1. Uncrating 2. Assembly 3. Preparation The selling dealer assumes sole responsibil- ity for any unauthorized modifications prior to sale. Refer to your Service Binder for any Ser- vice Bulletins specifying Factory Directed Mod- ifications (Special Claims) which must be per- formed before the vehicle is ready for sale. Whenever you see the following symbols heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not correctly followed, could result in dam- age to, or destruction of equipment. NOTE This note symbol indicates points of particular interest for more efficient and convenient op- eration. Kawasaki Heavy Industries, Ltd. accepts no liability for any inaccuracies or omissions in this publication, although every possible measure has been taken to make it as complete and ac- curate as possible. All procedures and specifi- cations subject to change without notice. © 2008 Kawasaki Heavy Industries, Ltd. Dec., 2008 Table of Contents Uncrating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check................................................................................. 4 Assembly ...................................................................................... 5 Handlebar.................................................................................... 5 Throttle Grip and Right Switch Housing ...................................... 5 Front Brake Master Cylinder ....................................................... 6 Cables, Harness and Hoses Routing .......................................... 7 Left Switch Housing..................................................................... 8 Clutch Cable................................................................................ 8 Lower Fairing............................................................................... 8 Windshield................................................................................... 9 Brake Disc Cleaning.................................................................... 10 Preparation ................................................................................... 10 Battery Service ............................................................................ 10 Front Brake Fluid......................................................................... 13 Rear Brake Fluid ......................................................................... 14 Clutch Lever and Cable............................................................... 16 Drive Chain.................................................................................. 17 Rear Shock Absorber .................................................................. 19 Tire Air Pressures........................................................................ 19 Fuel ............................................................................................. 19 Coolant ........................................................................................ 20 Engine Oil (4-stroke) ................................................................... 21 Idle Speed Adjustment ................................................................ 22 Throttle Grip and Cable ............................................................... 23 Rear Brake Light Switch.............................................................. 24 Headlight Aim .............................................................................. 24 Digital Meter ................................................................................ 25 Fastener Check ........................................................................... 26 Standard Torque Table ................................................................ 28 Test Ride the Motorcycle ............................................................. 28 A&P Check List ........................................................................... 28

Kawasaki Ninja 650R / ER-6F (EX650A6F) User Guide and Installation Instructions for Cowling Panel Vibration Damper Kit (99999-0093 and 99999-0095) This guide was started for the Kawasaki Ninja 650R / ER-6F Forum (http://www.ninja650.com) to solve the “fairing buzz” being experienced by many members. If you have any comments or corrections please email or PM me on the forum (Kiwi_ER-6F) and I will update the guide. Shane ([email protected]) Parts Required The Kawasaki Factory Authorized Repair (FAR) consists of installation paperwork (pictures of where install the self adhesive foam dampers and two kits (part numbers - 99999-0093 & 99999- 0095). The contents of both these kits are listed below: Kit 99999-0093 Part No Description Qty 92161-0401 Damper 1 92161-0402 Damper 2 92161-0403 Damper 2 92161-0404 Damper 2 92161-1315 Damper 2 92160-1099 Damper 2 Kit 99999-0095 Part No Description Qty 92161-1315 Damper 2 92160-1099 Damper 2 Some of these dampers are available separately through your Kawasaki Dealer. If you intend carrying out the “fix” yourself without the Kawasaki parts then substitute the dampers with self adhesive foam tape (I used door weather strip or draught stop foam tape) available from any hardware store and the loop side of 1 inch self adhesive Velcro tape. Tools Required Flat Blade Screwdriver #1 Phillips Screwdriver #2 Phillips Screwdriver 4 mm Hex Allen Key 8 mm Socket or Spanner 10 mm Socket or Spanner Before You Start Remove components in the following order: 1. Windshield 2. Belly Pan (Both halves) 3. Cowling Upper Trim Panels 4. Meter Cover 5. Rear View Mirrors 6. Upper Cowling (After disconnecting the turn signal wires and headlamp connectors) 7. Main Cowling Panels left and right side 8. Main Cowling Inner Panels left and right side 9. Headlight Assembly The pictures in the Modification section of this guide are taken from Kawasaki FAR; it’s a good place to start. If you have the kits, install them as per the pictures. Unfortunately for some people (myself included) just installing the kit did not completely eliminate the problem. If you want to carry out further work and be sure of a complete cure, then follow the suggestions in the Additional Information section of this guide. Keep all hardware (hex screws, washers, spacers, nuts and bolts) in order, separated and labeled, some parts although similar in appearance are in fact of different lengths (bolts) and thicknesses (washers). Use care with painted and plastic parts, they are easily damaged. Work inside in a clear and well lit area. Store items carefully and out of harms way when they are not being worked on. 1. Windshield Remove the four hex screws and clear plastic washers that secure the windshield to the upper cowling. Tilt the windshield forward to disengage the tang at the front. 2. Belly Pan Remove the three plastic clips which secure the two halves of the belly pan. First pull the centre pin to it’s out position using a flat blade screwdriver, use a spanner or another screwdriver shaft wrapped in a rag to act as a pivot point. Care should be taken not to damage the surrounding paint. With the centre pin pulled out, the clip can be removed by hand. Remove the two hex screws and clear plastic washers on each side that secure belly pan to the left and right main cowling panels. Note these hex screws are longer than all other hex screws used, take care not to mix. Remove the lower rear hex screw, stepped washer and clear plastic washer on each side and remove the belly pan. The left and right main cowling panels have tangs which locate into their respective belly pan halves.