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- Assembly & Preparation Manual
Kawasaki NINJA 650R Assembly & Preparation Manual
Summary of NINJA 650R
Page 1
Ninja ® 650r er-6f er-6f abs motorcycle assembly & preparation manual.
Page 2: Foreword
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 extreme...
Page 3: Table Of Contents
Table of contents uncrating ...................................................................................... 3 opening crate ............................................................................. 3 parts check ................................................................................
Page 5: Uncrating
Uncrating 3 uncrating opening crate warning always wear protective gloves, boots and eye protection when uncrating to prevent injury. Warning be careful not to injure your body by the sharp edges of the steel crate panel plates and other sharp fasteners. • clear a space about 6 m (20 ft) square to g...
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4 uncrating 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 r...
Page 7: Assembly
Assembly 5 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). • tighten the front clamp bolts first, and then the rear clamp bolts t...
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6 assembly 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 termina...
Page 9
Assembly 7 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 t...
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8 assembly 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...
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Assembly 9 • 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. Torque: 12 n·m (1.2 kgf·m, 106 in·lb) a. Left bracket b. Flanged bolts (d = 6, l = 14) • pull the lef...
Page 12: Preparation
10 preparation a. Socket bolts (d = 5, l = 20) and plastic washers (d = 5.3) b. Upper center fairing c. Windshield brake disc cleaning • clean the front and rear brake discs using oilless solvent. Warning if not removed, the anticorrosive treat- ment applied to the brake disc surface will interfere ...
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Preparation 11 a. Seat b. Seat lock c. Ignition key d. Insert • turn 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 battery case with both hands. A. Battery b. Suitable band...
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12 preparation • 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. You will see air bubbles rising into each cell as the ports fill. Note do not tilt the electrolyte con...
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Preparation 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 to ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating fo...
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14 preparation warning never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types of fluid for use in the brakes. This lowers the brake fluid boiling point and could reduce brake ef- fectiveness. It may also ...
Page 17
Preparation 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 uppe...
Page 18
16 preparation 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. • tighten the bleed valve to the specified torque. Torque: 7.8 n·m (0.80 kgf·...
Page 19
Preparation 17 a. Socket bolt (d = 5, l = 16) and plastic washer (d = 5.3) b. Right side cover c. Stopper • loosen the locknut at the middle of the clutch cable. • turn the adjuster until the free play is correct. Warning be sure that the outer cable end at the clutch lever is fully seated in the ad...
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18 preparation 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 be within the standard value. Warning a chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, se- verely damaging the...
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Preparation 19 a. Cotter pin b. Turning clockwise • bend the cotter pin over the nut. A. Cotter pin b. Nut warning 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 spr...
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20 preparation • 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 in...
Page 23
Preparation 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 ...
Page 24
22 preparation • 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 l...
Page 25
Preparation 23 throttle grip and cable throttle 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 t...
Page 26
24 preparation rear brake light switch rear brake light switch adjustment • turn on the ignition switch. The brake light should illuminate when the brake pedal is de- pressed about 10 mm (0.39 in.) • if it does not, disconnect the rear brake light switch lead connector. • turn the rear brake light s...
Page 27
Preparation 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 ...
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26 preparation 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 ...
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Preparation 27 torque 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 cylind...
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28 preparation standard torque table 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 ...
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Model application year model name 2009 ex650c9f ninja 650r, er-6f 2009 ex650d9f er-6f abs part no. 99931-1507-01.