® Ninja 650R ER-6f ER-6f ABS Motorcycle Assembly & Preparation Manual
Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
Table of Contents Uncrating ...................................................................................... Opening Crate ............................................................................. Parts Check ................................................................................. Assembly ...................................................................................... Handlebar....................................................................................
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. remove the lower bolts (D = 8, L = 16) • First, at the steering stem and discard them. the upper bolts (D = 8, L = 22) to • Remove take off the steering stem support bracket and • • discard them.
4 UNCRATING Parts Check the parts box, and check the parts against the illustrations. There may be minor differences • Open between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. No.
ASSEMBLY 5 Assembly Handlebar Handlebar Installation the handlebar so that its punched mark is • Set aligned with the upper rear edge of the lower handlebar clamp and install the upper handlebar clamp and bolts (D = 8, L = 30). Tighten the front clamp bolts first, and then the rear clamp bolts to the specified torque. There will be a gap at the rear part of the clamp after tightening. Torque: 25 N·m (2.5 kgf·m, 18 ft·lb) • A. Throttle Grip B. Cable Tips : Apply Grease. C. Rear Half D.
6 ASSEMBLY A. Right Switch Housing B. Screw (D = 5, L = 25) C. Screw (D = 5, L = 40) Front Brake Master Cylinder the right switch housing lead con• Connect nectors to the front brake light switch terminals on the front brake master cylinder. A. Front Master Cylinder B. Brake Light Switch Terminals C. Connectors and Dust Covers the front master cylinder with its clamp • Install and the two bolts (D = 6, L = 22).
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 F. Left Switch Housing Harness B. Throttle Cable (Accelerator) G. Clutch Cable C. Throttle Cable (Decelerator) H. Run the clutch cable and left switch D. Front Brake Hose housing harness through the guide. E. From the inside sequentially, run the right switch I.
8 ASSEMBLY Left Switch Housing the left switch housing connector to • Connect the starter lock-out switch on the clutch lever assembly. A. Left Switch Housing B. Screws (D = 5, L = 25) Clutch Cable A. Clutch Lever Assy B. Starter Lock-out Switch C. Connector the two halves of the left switch housing • Fit together so that the small projection on the front half fits into the hole in the handlebar. A. B. C. D.
ASSEMBLY 9 the left bracket on the lower left side • Install 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) the left upper fairing outward to clear the • Pull stopper. the socket bolts (D = 5, L = 16) (3) and • Install plastic washers (D = 5.3) (3). the socket bolt (D = 6, L = 14) and • Install plastic washer (D = 6.5). A.
10 PREPARATION CAUTION Incorrect Battery Activation will reduce battery performance and service life. Be sure to strictly follow the Battery Service instructions in this Manual. sure to use the electrolyte packed in the • Make crate with the unit. sure that the model name of the elec• Make trolyte container matches the model name of the battery. These names must be the same. Battery Model Name for A. Socket Bolts (D = 5, L = 20) and Plastic Washers (D = 5.3) B. Upper Center Fairing C.
PREPARATION 11 Battery Activation Filling the Battery with Electrolyte CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. A. B. C. D. the battery on a level surface. • Place Check see that the sealing sheet [A] has no • peeling,totears, or holes in it. Remove the sealing sheet [A]. • Seat Seat Lock Ignition Key Insert NOTE The battery is vacuum sealed.
12 PREPARATION the electrolyte container upside down • Place 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 container. the electrolyte flow. • Check If no air [A] are coming up from the • filler ports,bubbles or if the container cells have not emptied completely, tap the container [B] a few times.
PREPARATION 13 Front Brake Fluid Front Brake Fluid Level Inspection the front brake fluid reservoir held hori• With zontal, check that the fluid level is above the lower level line. CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery. NOTE To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds.
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 effectiveness. It may also cause the rubber brake parts to deteriorate. Don’t leave the reservoir cap off for any length of time to prevent moisture contamination of the fluid.
PREPARATION 15 A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line fluid level in the reservoir is lower than • Ifthethelower 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. WARNING Be sure to hold the front brake during the bleeding operation, or the motorcycle may fall over. It could cause an accident and injury. A. B. C. D.
16 PREPARATION the hook at the rear of the seat into the • Insert latch, and push down the rear part of seat until • the lock clicks. Pull up the rear end of seat to make sure it is securely locked. NOTE If there is difficulty removing the ignition key from the seat lock, turn it lightly counterclockwise while pulling it out. A. Hold the brake pedal applied. B. Quickly open and close the bleed valve. C. Release the brake pedal.
PREPARATION 17 A. Socket Bolt (D = 5, L = 16) and Plastic Washer (D = 5.3) B. Right Side Cover C. Stopper the locknut at the middle of the clutch • Loosen cable. • Turn the adjuster until the free play is correct. A. Right Side Cover B. Projections C. Grommets D. Tabs E. Slots the bolt and plastic washer, • Reinstall tighten the bolt.
18 PREPARATION the chain is too loose, turn in the left and • Ifright chain adjusting nuts evenly. If the chain is too tight, turn out the left and • right chain adjusting nuts evenly. Turn both chain nuts evenly until the • drive chain has adjusting the correct amount of slack. To keep the chain and wheel properly aligned, the left wheel alignment indicator should align with the same swingarm mark that the right indicator aligns with. A. 25 a 35 mm (1.0 a 1.4 in.
PREPARATION 19 A. Cotter Pin B. Turning Clockwise • Bend the cotter pin over the nut. A. Wrench B. Spring Preload Adjuster C. No.4 Position the preload adjuster to the No.4 position • Turn with the wrench in the tool kit. Tire Air Pressures Tire Air Pressures prevent flat-spotting during shipment, the • To tires are over-inflated before crating. Adjust the pressures to the specified values in the front and rear, and make sure to tighten the caps securely. Tire Air Pressure [when cold]: A.
20 PREPARATION the fuel tank cap, and check for debris • Open in the fuel tank. the fuel tank with one gallon or four liters • Fill 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 Research Octane Number (RON) and the Motor Octane Number (MON), as shown in the table. Minimum Octane Rating Method Rating Research Octane Number (RON) 91 • Close the fuel tank cap.
PREPARATION 21 the cap. • Install Reinstall upper fairing and meter cover in • the reversetheorder of the removal procedure. Connect the city light lead connectors, head • light lead connectors and turn signal light lead • • A. Dust Cover B. Meter Unit Connector C. Flanged Bolts (D = 6, L= 12) the upper fairing outward to clear the • Pull stoppers on both sides. • Remove the upper fairing forward. connectors on both sides.
22 PREPARATION the engine and run it for several minutes • Start at idle speed. Stop the engine, then wait sev- • eral minutes until the oil settles. With the motorcycle held level, check the engine oil level through the oil level sight gauge. The oil level should come up between the upper and lower level lines next to the gauge. Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.
PREPARATION 23 Throttle Grip and Cable Throttle Grip Free Play Inspection the throttle grip free play. If the free • Inspect play is incorrect, adjust the throttle cables. Throttle Grip Free Play: 2 a 3 mm (0.08 a 0.12 in.) that the throttle grip moves smoothly • Check from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.
24 PREPARATION Rear Brake Light Switch Rear Brake Light Switch Adjustment on the ignition switch. The brake light • Turn 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 switch body as required. Connect the connector. A. Horizontal Adjuster Vertical Adjustment the vertical adjuster in or out to adjust • Turn the headlight vertically. A. Rear Brake Light Switch B.
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. the ignition key to “ON”. • Turn Push button to display the odometer • in the MODE digital meter. km/mile display shifts by pushing the RE• The SET button while the MODE button pushed in. A. Km/Mile Display • The km/mile display shifts as follows.
26 PREPARATION Fastener Check torque values listed are for assembly and preparation items only, see the appropriate Service • The 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.
PREPARATION 27 No.
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 Fasteners: Threads dia. mm 5 6 8 10 12 14 16 18 20 N·m 3.4 a 4.9 5.9 a 7.8 14 a 19 25 a 34 44 a 61 73 a 98 115 a 155 165 a 225 225 a 325 Torque kgf·m 0.35 a 0.50 0.60 a 0.80 1.4 a 1.9 2.6 a 3.5 4.5 a 6.2 7.
MODEL APPLICATION Year 2009 2009 Model EX650C9F EX650D9F Name Ninja 650R, ER-6f ER-6f ABS Part No.
