Kawasaki Ninja 650 ABS 2013 Owner's manual

Quick Reference Guide

This Quick Reference Guide will assist you in finding the information you’re looking for.

A Table of Contents is included after the Foreword.

GENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

NOTICE

NOTICE is used to address practices not related to personal injury.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNING indicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

NOTE

NOTE indicates information that may

○

help or guide you in the operation or service of the vehicle.

WARNING

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

NOTICE

THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance.

Please read this Owner ’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, c apabilities, and limita tio ns. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training p ro gram to attain awareness of the mental and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and should

remain with th e motorcycle whe n it is sold.

prior written permission.

This publication includes the latest information available at the time of printing. However, there may be minor differences between the actual product and illustrations and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CO NTE NTS

SPECIFICATIONS............................... 9

SERIAL NUMBER L OCATIONS......... 13

LOCATION OF PARTS....................... 14

LOADING AND ACCESSORIES

INFORMATION ................................ 17

GENERAL INFORMATION................. 20

Meter Instruments ............................ 20

Tachometer................................... 21

Multifunction Meter........................... 22

Multifunction Display..................... 24

Warning/Indicator Lights: .............. 31

Keys ................................................. 34

Ignition Switch/Steering Lock ........... 35

Right Handlebar Switches ................ 37

Engine Stop Switch: ..................... 37

Starter Button: .............................. 38

Left Handlebar Switches .................. 38

Dimmer Switch: ............................ 38

Turn Signal Switch:....................... 39

Horn Button: ................................. 39

Passing Button: ............................ 39

Hazard Switch: ............................. 39

Brake/Clutch Lever Adjusters........... 40

Fuel Tank Cap .................................. 41

Fuel Tank ......................................... 42

Fuel Requirement ......................... 43

Stand................................................ 47

Seats................................................ 48

Helmet Hooks................................... 50

Tool Kit ............................................. 51

Tying Hooks ..................................... 52

Windshield........................................ 52

BREAK-IN ........................................... 54

HOW TO RIDE THE MOTORCYCLE .56

Starting the Engine .......................... 56

Jump Starting ................................... 58

Moving Off........................................ 61

Shifting Gears .................................. 62

Braking............................................. 64

Anti-lock Brake System (ABS) for

models equipped with ABS........... 65

Yellow ABS Indicator Light:........... 67

Stopping the Engine ......................... 68

Stopping the Motorcycle in an

Emergency ................................... 69

Parking............................................. 70

Catalytic Converter........................... 72

SAFE OPERATION............................. 74

Safe Riding Technique ..................... 74

Daily Checks .................................... 77

Additional Considerations for High

Speed Operation .......................... 80

MAINTENANCE AND ADJUSTMENT 82

Periodic Maintenance Chart ............. 87

Engine Oil ........................................ 99

Cooling System ................................ 105

Spark Plugs...................................... 113

Evaporative Emission Control

System (California model only)..... 114

Kawasaki Clean Air System ............. 115

Valve Clearance ............................... 116

Air Cleaner ....................................... 117

Throttle Control System ................... 118

Engine Vacuum Synchronization ..... 121

Idle Speed ........................................ 121

Clutch............................................... 123

Drive Chain ...................................... 125

Brakes.............................................. 132

Brake Light Switches........................ 136

Front Fork......................................... 139

Rear Shock Absorber ....................... 140

Wheels ............................................. 143

Battery.............................................. 148

Headlight Beam................................ 153

Fuses ............................................... 155

General Lubrication.......................... 157

Cleaning Your Motorcycle ................ 159

Bolt and Nut Tightening.................... 164

STORAGE........................................... 166

TROUBLESHOOTING GUIDE............ 169

YOUR WARRANTY/OWNER

SATISFACTION ........................... 170

REPORTING SAFETY DEFECTS ...... 176

ENVIRONMENTAL PROTECTION ..... 177

MAINTENANCE RECORD ................. 178

LOCATION OF LABELS..................... 186

SPECIFICATIONS

SPECIFICATIONS 9

PERFORMAN

Minimum Turning Radius

DIMENSIO

Overall L

Overall W

Overall H

ength

idth

eight

Wheelbase

Road Clearance

Curb Mass

ENGINE

Type

Displacement

Bore × S

Compr

troke

ession Ratio 10.8 : 1

2.7 m (106.

2110mm(8

770 mm (30

1 180 mm (4

1 410 mm (

130 mm (5

(E) 209 kg (4

(F) 211 kg (4

3in.)

3.07 in.)

.31 in.)

6.46 in.)

55.51 in.)

.12 in.)

61 lb)

65 lb)

DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled

649 cm

83.0 × 6

(39.6 cu in.)

0.0 mm (3.27 × 2.36 in.)

10 SPECIFICATIONS

Starting System Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing 10° BTDC @1 300 r/min (rpm) ∼

(Electronically advan ced) 37° BTDC @5 000 r/min (rpm)

Spark Plugs NGK CR9EIA-9

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil

Coolant Capacity 1.2 L (1.3 US qt)

TRANSMISSION

Transmission Type

Clutch Type

Type :

Viscosity:

Capacity: 2.3 L (2.4 US qt)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

6-speed, constant mesh, return shift

Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio 2.095 (88/42)

Final R eduction Ratio 3.067 (46/15)

Overall D rive Rati o 5.473 (Top gear)

Gear Ratio 1st 2.438 (39/16)

2nd 1.714 (36/21)

3rd 1.333 (32/24)

4th 1.111 (30/27)

5th 0.966 (28/29)

6th 0.852 (23/27)

FRAME

Castor 25°

Trail 110 mm (4.3 in.)

Tire Size: Front 120/70ZR17 M/C (58 W)

Rear 160/60ZR17 M/C (69 W)

Rim Size: Front J17M/C × MT3.50

Rear J17M/C × MT4.50

SPECIFICATIONS 11

12 SPECIFICATIONS

Fuel Tank Capacity 16 L (4.2 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 10 Ah

Headlight 12 V 55 W/55 W (Hi/Lo)

Tail/Brake Light LED

Even if one of LED (Light Emitting Diode) tail/brake light does not go on, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice.

(E): EX650E (F): EX650F

SERIAL NUMBER LOCATIONS 13

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them id entify it.

Frame No.

A. Frame Number

Engine N o.

A. Engine Number

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Left Handlebar S witches

3. Meter Instruments

4. Brake Fluid Reservoir (Front)

5. R ight Handlebar Switches

6. Fr on t Brake Lever

7. T hro ttle Grip

8. Ig nit ion Switch/Steering Lock

LOCATION OF PARTS 15

1. Headlight

2. Turn Signal Light

3. Spark Plugs

4. Air Cleaner

5. Battery

6. Rider’s Seat

7. H elmet Holding Hooks

8. Tool Kit

9. Seat Lock

10. Passeng er ’s Seat

11. Tying Hooks

12. Brake Disc

13. Front Fork

14. Brake Caliper

15. Shift Pedal

16. Side Stand

17. Drive Chain

16 LOCATION OF PARTS

1. License Plate Light

2. Turn Signal Light

3. Tail/Brake L igh t

4. Brake Fluid Reservoir (R ear)

5. Rear Shock Absorber

6. Spring Preload Adjuster

7. Fuel Tank

8. Fuel Tank Cap

9. C oo lant Reserve Tank

10. R ear Brake Light Swi tch

11. Mu ff ler

12. R ear Brake Pedal

13. Oil Level Inspection Window

14. Id le Adjusting Screw

LOADING AND ACCESSORIES INFORMATION 17

LOADING AND ACCESSORIES INFORMATION

WARNING

Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure it is not overloaded and that you have followed these instructions.

With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or motorcycle modification, will void the motorcycle warranty, can negatively affect performance, and can even be illegal.

In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other persons involved.

NOTE

Kawasaki Parts and Accessories

○

have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components.

Because a motorcycle is s en sitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in

18 LOADING AND ACCESSORIES INFORMATION

fitting additional accessories. The following general guidelines have been prepared to assist you in making your determinations.

1. Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper positioning during cornering and sudden movements. It is important that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle.

2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator or seat strap. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided.

3. All baggage should be carried as low as possible to r educe the effect on the motorcycle center of gravity. Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle.

4. Baggage should be securely attached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary.

5. Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces.

LOADING AND ACCESSORIES INFORMATION 19

6. Do not install accessories or carry baggage that impairs the performance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle’s operation.

7. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can r esult in an unsafe riding condition.

8. Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly

designed or installed items can result in an unsafe riding condition.

9. This motorcycle is not intended to be equipped with a sidecar or to be used to tow any tr ailer or other vehicle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the effects of such accessories on handling or stability, but can only warn thattheeffectscanbeadverseand that Kawasaki cannot assume responsibility for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage, and accessories must not exceed 200 kg (441 lb).

20 GENERAL INFORMATION

Meter Instruments

A. MODE Button B. Green Left Turn Sign al

Indicator Light C. Tachometer D. Red Zone E. Green Right Turn Signal

Indicator Light F. Yellow ABS Indicator Light

(Only on ABS model) G. Yellow Engine Warning

Indicator Light H. Red Battery Voltage

Warning Indicator Light I. RESET Button J. Multifunction Meter K. Green Neutral Indicator

Light L. Blue High Beam Indicator

Light M. Red Coolant Temperature

Warning Indicator Light N. Red Oil Pressure Warning

Indicator Light

GENERAL INFORMATION

NOTE

For safety, do not operate the instru-

○

ment buttons while riding the motorcycle.

Tachometer

The tachometer shows the engine speed in revolutions per m in ute (r/min, rpm). On the right side of the tachometer face is a portion called th e “red zone”. Engine r/ min (rpm) in the red zone is above maximum recommended engine speed and is also above the range for good performance.

NOTICE

Engine r/min (rpm) should not

be allowed to enter the red zone;

operation in the red zone will

overstress the engine and may

cause serious engine damage.

GENERAL INFORMATION 21

A. Tachometer B. Red Zone

When the ignition key is turned to “ON”, the tachometer needle momentarily goes from the minimum to the maximum, then goes back from the maximum to the minimum reading to check its operation. If the tachometer does not operate correctly, have it checked by an authorized Kawasaki dealer.

22 GENERAL INFORMATION

Multifunction Meter

The multifunction meter displays the

following functions.

A. Fuel Gauge B. Speedometer C. Economical Riding

Indicator D. Fuel Level Warning Symbol E. Multifunction Display

Odometer Trip meter A Trip meter B Current Mileage Average Mileage Cruising Range

F. C l o c k

When the ignition key is turned to “ON”, all LCD segments are displayed with opening display functions for few seconds, then the multifunction meter turns to operational mode.

GENERAL INFORMATION 23

Speedometer -

The speedometer shows the speed

of the vehicle in digital values.

Unit Setting -

The unit setting in the m eter instrument can be changed according to local regulations. Make sure the unit setting is correctly displayed before riding.

A. Speedometer B. Speed Unit C. Mileage Unit

NOTE

Do not operate the motorcycle with

○

wrong unit (mph or km/h) of the speedometer.

To change the meter display units in

the meter instrument as follows:

Display the od ometer in the multi-

•

function display. Refer to the Multifunction Display section. Push the RESET button while push-

•

ing the MODE button to select the display units.

L/100km (km/h) → km/L (km/h) → MPG US (mph) → MP G UK (mph) → L/100km (km/h)...

The display units on the multifunction

•

meter can be changed depending on the selected mileage unit as shown.

24 GENERAL INFORMATION

Mileage Units

L/100km

km/L

MPG US

MPG UK

Multifunction Display

The following display modes can be

shifted by pushing the M ODE button.

Odometer → Trip meter A → Trip meter B → Current Mileage → Average Mileage → Cruis ing Range → Odometer...

Speed Units

km/h km

mph mile

Distance Units

NOTE

For safety, do not operate the instru-

○

ment bu ttons while riding the motorcycle. The multifunction display is dis-

○

played in the unit depending on the

unit mode setting, refer to the “Unit Setting” item in this sec tio n.

Odometer -

The odometer shows the total distance in kilometers or miles that the vehicle has been ridden. This meter cannot be reset.

A. Odometer B. “ODO”

NOTE

The data is maintained even if the

○

battery is disconnected. When the figures come to 999999,

○

they are stopped and locked.

GENERAL INFORMATION 25

Tri p Meter -

The trip meters show the distance in kilometers (miles) traveled since they were last reset to zero.

TRIP A: 0.0 ∼ 9999.9

TRIP B: 0.0 ∼ 9999.9

A. Trip A B. Trip B

To r e se t th e tr i p m e t er :

PushtheMODEbuttontodisplaythe

•

trip meter A or B.

Push the RESET button and hold it

•

in. After two seconds, the figure display

•

turns to 0.0, and then starts cou nting when the vehicle is operated. The meter counts until it is reset.

NOTE

The data is maintained by the back

○

-up power if the ignition key is turned off. When the trip meter reaches 9999.9

○

while running, the m eters reset to 0.0 and continues counting. When the battery is disconnected,

○

the meter display resets to 0.0.

Current Mileage -

This display mode shows the current mileage by numerical value. The current mileage display is renewed every 4 seconds.

26 GENERAL INFORMATION

A. Current Mileage B. “km/L”

NOTE

The display unit modes can be

○

changed, refer to the “Unit Setting” item in this section. Thenumericalvalueshows“––.–”

○

until 4 seconds have passed and the speedometer is rises to above 5 km/h (3 mph).

Average Mileage -

This display mode shows the average mileage by numerical value counted from the start of measuring to present time. The average mileage

display is renewed every 4 ∼ 6sec-

onds.

A. Average Mileage B. “AV km/L”

While the average mileag e is dis-

•

played, push the R ESET button and hold it in until the average mileage values resets to “– –. –”.

NOTE

The display un it modes can be

○

changed, refer to the “Unit Setting” item in this section. After resetting the average mileage,

○

the numerical value is not displayed until 5 mL (0.2 US oz.) of fuel has

GENERAL INFORMATION 27

been used and 100 m (328 ft) has been traveled. The data is maintained by back up

○

power if the ignition switch is turned “OFF”. When the battery is disconnected,

○

the data resets to “– –.–”.

Cruising Range -

This display shows the cruising range by numerical value and indicates the cruising range from the remaining fuel in the fuel tank. This cruising range display is renewed every 20 seconds.

A. Cruising Range B. "RANGE"

The cruising range value displays "-

- -" when the fuel warning symbol ( blinks in the multifunction meter.

A."---"display B. "RANGE"

NOTE

The display unit modes can be

○

changed, refer to the “Unit Setting” in this section. The display range for cruising range

○

is 0 ~ 999. The cruising range value may not

○

indicate the actual value. Use this value for your reference only.

)

28 GENERAL INFORMATION

Clock -

To adjust hours and minutes, do the followings while the motorcycle is a t a stop.

Turn the ignition switch to “ON”.

•

Display the odometer in the multi-

•

function dis pla y. Refer to the “Multifunction Displa y” item in this section. Push the RESET button for more

•

than 2 seconds. Both the hour and minute displays start blinking.

Push the RESET button. The hour

•

display only b links. Push the MO DE button to advance the hours.

Push the RESET button. The hour

•

display stops blinking and the minute display starts blin king. Push the MODE button to advance the minutes.

Push the RESET button. Both the

•

hour and minute displays start blinking again. Push the MODE button. The dis-

•

plays stop blinking and the clock starts working.

NOTE

Pushing the MODE button momen-

○

tarily advances the hour or minute step by step. Pushing and holding the button advances the hour or minute continuously. The clock works n ormally by the back

○

-up power while the ignition switch is turned “OFF”. When the battery is disconnected,

○

theclockisresetto1:00andstarts working again when the battery is connected.

Economical Riding Indicator -

When the operator is driving the motorcycle for optimum fuel-efficiency, the economical riding indicator appears on the multifunction meter to indicate favorable fuel consumption. Monitoring the economical riding indicator can help the rider maximize fuel efficiency.

GENERAL INFORMATION 29

A. Economical Riding Indicator

WARNING

Failing to properly observe the road ahead increases the chance of an accident resulting in severe injury or death. Do not concentrate on the economical riding indicator by taking your eyes off the road; observe using peripheral vision.

+ 165 hidden pages