®
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.
This Assembly and Preparation Manual explains step by step procedures of the following
items for the Kawasaki Ninja 650R, ER-6f and
ER-6f ABS.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
correctly followed, could result in damage to, or destruction of equipment.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
NOTE
This note symbol indicates points of particular
interest for more efficient and convenient operation.
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 accurate as possible. All procedures and specifications subject to change without notice.
© 2008 Kawasaki Heavy Industries, Ltd. Dec., 2008
Table of Contents
crating ......................................................................................
Un
Opening Crate ............................................................................. 3
Parts Check ................................................................................. 4
sembly ......................................................................................
As
Handlebar.................................................................................... 5
Throttle Grip and Right Switch Housing ...................................... 5
ront Brake Master Cylinder .......................................................
F
Cables, Harness and Hoses Routing .......................................... 7
Left Switch Housing..................................................................... 8
lutch Cable ................................................................................
C
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
3
5
6
8
Uncrating
Opening Crate
WARNING
Always
and eye protection when uncrating to
prevent injury.
wear protective gloves, boots
UNCRATI
First, remove the lower bolts (D = 8, L = 16)
•
at the steering stem and discard them.
Remove the upper bolts (D = 8, L = 22) to
•
take off the steering stem support bracket and
discard them.
Remove the lower bolts (D = 6, L = 12) and
•
washer to take off the front master cylinder.
Remove the upper bolt (D = 8, L = 16) to take
•
off the front master cylinder support bracket
and discard it.
NG 3
WARNING
Be careful not to injure your body by
the sharp edges of the steel crate panel
tes and other sharp fasteners.
pla
Clear a space about 6 m (20 ft) square to give
•
yourself plenty of space to work.
Place the crate upright on its base.
•
Remove the cardboard cover.
•
Remove the handlebar and the parts box.
•
CAUTION
When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other components with the crate bracket.
A. Lower Bolts (D = 8, L = 16)
Upper Bolts (D = 8, L = 22)
B.
C. Steering Stem Support Bracket
D. Lower Bolt (D = 6, L = 12) and Washer
E. Lower Bolt (D = 6, L = 12)
F. Front Master Cylinder
G. Upper Bolt (D = 8, L = 16)
. Front Master Cylinder Support Bracket
H
Take out all the bolts and screws and remove
•
the top and sides of the crate.
NOTE
Roll the vehicle off the crate base after in-
stalling the handlebar and front master cylin-
der.
4 UNCRAT
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
1 Handlebar with Grips, Weights and Clutch Lever Assy 1
Clamp, Handlebar 1
Socket Bolt, Clamp, Handlebar 4 D = 8, L = 30
Clamp, Front Master Cylinder 1
ocket Bolt, Clamp, Front Master Cylinder
S
2
Left Bracket, Lower Fairing
Flanged Bolt with Non-permanent Locking Agent, Left Bracket 2 D = 6, L = 14
Lower Fairing, LH & RH 2
Socket Bolt, Lower Fairing 6 D = 5, L = 16
Plastic Washer, Lower Fairing 6 D=5.3
Socket Bolt, Lower Fairing 2 D = 6, L = 14
Plastic Washer, Lower Fairing 2 D=6.5
Plastic Rivet, Lower Fairing 3
3 Windshield 1
Socket Bolt, Windshield 4 D = 5, L = 20
Plastic Washer, Windshield 4 D=5.3
4 Battery Electrolyte, FTX12-BS 1 12 V 10 Ah
5 Owner’s Manual 1
Qty
2 D = 6, L = 22
1
Remarks
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 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)
ASSEMBL
A. Throttle Grip
B. Cable Tips : Apply Grease.
C. Rear Half
D. Throttle Cable (Decelerator)
E. Throttle Cable (Accelerator)
Fit the two halves of the right switch housing
•
so that the projection on the front half fits into
the hole in the handlebar.
Y5
A. Handlebar Clamp (Upper)
B. Front Bolts (D = 8, L = 30)
C. Rear Bolts (D = 8, L = 30)
D. Punched Mark
E. No Gap
F. G a p
Throttle Grip and Right Switch
Housing
Apply a light coat of grease on the exposed
•
portion of the throttle inner cables.
Fit both throttle cable tips into the nearest
•
socket in the throttle grip.
A. Rear Half
B. Hole
C. Projection
D. Front Half
Insert the two screws (D = 5, L = 25) (D = 5,
•
L = 40) and tighten them.
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 terminals on the front brake master cylinder.
A. Front Master Cylinder
B. Brake Light Switch Terminals
C. Connectors and Dust Covers
A. Front Master Cylinder
B. Clamp
C. Punched Mark
D. Bolts (D = 6, L = 22)
Tighten the upper clamp bolt first and then the
•
lower clamp bolt to the specified torque.
Torque: 11 N·m (1.1 kgf·m, 97 in·lb)
Install the front master cylinder with its clamp
•
and the two bolts (D = 6, L = 22).
Position the master cylinder so that the mat-
•
ing surface of the front and rear master cylinder clamps align with the punched mark on
the handlebar.
Cables, Harness and Hoses Routing
Check that the cables, wiring leads and hoses are routed correctly.
•
Right Side View
ASSEMBL
Y7
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 hose, throttle cable (decelerator) and throttle cable (accelerator)
through the guides.
F. Left Switch Housing Harness
G. Clutch Cable
H. Run the clutch cable and left switch
housing harness through the guide.
I. Run the left switch housing harness
through the guide.
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. Left Switch Housing
B.Screws(D=5,L=25)
Clutch Cable
Apply a light coat of grease on the clutch inner
•
cable.
Line up the slots on the clutch lever, locknut,
•
and adjuster.
Fit the tip of the clutch inner cable into the
•
lever socket, slide the inner cable through the
slots, and release the outer cable into the adjuster.
A. Rear Half
B. Hole
C. Projection
D. Front Half
Insert the two screws (D = 5, L = 25) and
•
tighten them securely.
A. Clutch Cable
B. Adjuster
C. Locknut
D. Cable Tip
E. Clutch Lever
Lower Fairing
NOTE
It is recommended that the lower fairing
should be installed after completing the steps
in the “Coolant” section on page 20 in the
PREPARATION chapter.
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.
Torque:
A. Left Bracket
B. Flanged Bolts (D = 6, L = 14)
Pull the left upper fairing outward to clear the
•
stopper.
12 N·m (1.2 kgf·m, 106 in·lb)
Install the socket bolts (D = 5, L = 16) (3) and
•
plastic washers (D = 5.3) (3).
Install the socket bolt (D = 6, L = 14) and
•
plastic washer (D = 6.5).
A. Socket Bolts (D = 5, L = 16) and Plastic
Washers (D = 5.3)
B.
Socket Bolt (D = 6, L = 14) and Plastic
her (D = 6.5)
Was
Install the right lower fairing in the same man-
•
ner as the left lower fairing.
Fasten the left and right lower fairings with
•
three plastic rivets.
A. Clear the stopper.
B. Left Upper Fairing
Insert the tabs into the slots to fit the left lower
•
fairing on the inside of the left upper fairing.
A. Tabs
B. Slots
C. Left Upper Fairing
D. Left Lower Fairing
A. Plastic Rivets
B.
Left and Right Lower Fairings
Tighten the socket bolts (D = 5, L = 16).
•
Tighten the socket bolts (D = 6, L = 14) to the
•
specified torque.
Torque: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Windshield
Install the windshield on the upper center fair-
•
ing with the socket bolts (D = 5, L = 20) (4) and
plastic washers (D = 5.3) (4), and tighten the
bolts.
10 PREPA
RATION
CAUTION
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
A.
Socket Bolts (D = 5, L = 20) and Plastic
Washers (D = 5.3)
B.
C.
er Center Fairing
Upp
Windshield
Brake Disc Cleaning
Clean the front and rear brake discs using
•
oilless solvent.
WARNING
If not removed, the anticorrosive treatment applied to the brake disc surface
will interfere with brake action, and an
unsafe riding condition could result.
Make s
•
crate with the unit.
Make sure that the model name of the elec-
•
trol
the battery. These names must be the same.
Battery Model Name for
A. Model Name of the Electrolyte
B. Model Name of the Battery
uretousetheelectrolytepackedinthe
yte container matches the model name of
0C/D: FTX12-BS
EX65
Preparation
Battery Service
Battery Removal
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.
Activating the battery requires two steps, filling the battery with electrolyte, and charging.
Read the electrolyte safety label and the following procedures carefully before battery activation.
CAUTION
Sealed battery electrolyte has a higher
concentration of sulfuric acid. Each
container contains the proper amount
of electrolyte for its specific battery.
Insufficient or incorrect electrolye will
reduce battery performance and service
life. Electrolyte over capacity can lead
to battery cranking or leaking and result
in corrosion damage to the vehicle.
Insert the ignition key into the seat lock, lo-
•
cated under the seat cover.
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.
PREPARA
TION 11
Battery Activation
g the Battery with Electrolyte
Fillin
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.
Place the battery on a level surface.
•
Check to see that the sealing sheet [A] has no
•
ing, tears, or holes in it.
peel
Remove the sealing sheet [A].
•
NOTE
The battery is vacuum sealed. If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.
A. Battery
B. Suitable Band
Clean the terminals.
•
Battery Specifications
Make Furukawa
Battery Type FTX12-BS
Battery Capacity 12 V 10 Ah
Electrolyte Capacity 0.60 L
Battery/Electrolyte Set P/No. 26012-0109
Remove the electrolyte container from the
•
vinyl bag.
Detach the strip of caps [A] from the container
•
and set aside, these will be used later to seal
the battery.
NOTE
o not pierce or otherwise open the sealed
D
cells [B] of the electrolyte container. Do not
attempt to separate individual cells.
12 PREPA
a
RATION
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 container.
Check the electrolyte flow.
•
If no air bubbles [A] are coming up from the
•
ller ports, or if the container cells have not
fi
emptied completely, tap the container [B] a
few times.
NOTE
Charging the battery immediately after filling
can sho
at least 30 minutes after filling.
Initial Charge
Place
•
filler ports.
New
•
initial charge.
Standard Charge: 1.2 A × 5
If using a recommended battery charger, fol-
•
low the charger’s instructions for newly activatedsealedbattery.
Kawasaki-recommended chargers:
rten service life. Let the battery sit for
the strip of caps [A] loosely over the
ly activated sealed batteries require an
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
10 hours
Keep the container in place for 20 minutes or
•
more. Don’t remove the container from the
battery until it’s empty, the battery requires all
the electrolyte from the container for proper
operation.
CAUTION
Removal of the container before it is
completely empty can shorten the service life of the battery. Do not remove
the electrolyte container until it is completely empty and 20 minutes have
elapsed.
Gently remove the container from the battery.
•
Let the battery sit for 30 minutes prior to
•
charging to allow the electrolyte to permeate
into the plates for optimum performance.
If the above chargers are not available, use
•
equivalent one.
NOTE
Charging rates will vary depending on how
long the battery has been stored, temperature, and the type of charger used. Let battery
sit 30 minutes after initial charge, then check
voltage using a voltmeter. If it is not at least
12.6 volts, repeat charging cycle.
After charging is completed, press down
•
firmly with both hands to seat the strip of
caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the
caps will be level with the top of the battery.
Front Brake Fluid
PREPARA
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 battery.
NOTE
To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
d tested at three times its amp-hour rating
loa
for 15 seconds.
Re-check voltage and if less than 12.6 volts
peat the charging cycle and load test. If still
re
below 12.6 volts the battery is defective.
Battery Installation
rn the ignition switch OFF.
Tu
•
Place the battery into the battery case.
•
Route the battery cables as shown, and first
•
onnect the red capped cable to the positive
c
terminal (+), and then connect the negative
cable to the negative terminal (–).
ut a light coat of grease on the terminals to
P
•
prevent corrosion.
Cover the positive terminal (+) with its protec-
•
tive cap.
Front B
With the front brake fluid reservoir held hori-
•
zontal, check that the fluid level is above the
lower l
A. Front Brake Fluid Reservoir
B. Lower Level Line
If the fluid level in the reservoir is lower than
•
the lower level line, check for fluid leaks in the
front brake lines and fill the reservoir.
Remove the screws to take off the front brake
•
fluid reservoir cap and diaphragm.
Fill the reservoir to the upper level line with
•
DOT4 brake fluid. Inside the front brake
reservoir is a stepped line showing the upper
level line.
rake Fluid Level Inspection
evel line.
A. Battery
B. Positive Cable (+)
C. Negative Cable (–)
A. Front Brake Fluid Reservoir
B. Upper Level Line
14 PREPA
RATION
WARNING
Never reuse old brake fluid.
Do not use fluid from a container that
has bee
open for a long time.
Do not mix two types of fluid for use in
the bra
boiling point and could reduce brake effectiveness. It may also cause the rubber br
Don’t leave the reservoir cap off for any
length of time to prevent moisture contamin
Don’t add or change brake fluid in the
rain or during conditions of blowing dust
or deb
n left unsealed or that has been
kes. This lowers the brake fluid
ake parts to deteriorate.
ation of the fluid.
ris.
CAUTION
Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immedi-
y.
atel
Operate the brake lever several times.
•
If it feels spongy, there might be air in the
•
brake line.
If necessary, bleed the air in the front brake
•
lines.
Also check for fluid leakage around the fit-
•
tings.
Front Brake Line Air Bleeding
move the reservoir cap and diaphragm,
Re
•
and check that there is plenty of fluid in the
reservoir.
NOTE
The fluid level must be checked several times,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
Attach a clear plastic hose to the bleed valve
•
on each front brake caliper and run the other
end of the hose into a container.
With the reservoir cap off, slowly pump the
•
brake lever several times until no air bubbles
can be seen rising up through the fluid from
the holes at the bottom of the reservoir. This
bleeds the air from the brake master cylinder
end of the line.
Pump the brake lever a few times until it
•
becomes hard and then, holding the lever
squeezed, quickly open (turn counterclockwise) and close the bleed valve. Then release
the lever. Repeat this operation until no more
air can be seen coming out into the plastic
hose.
A. Hold the brake lever applied.
B. Quickly open and close the bleed valve.
C. Release the brake lever.
Repeat the previous step one more time for
•
the other front disc brake.
When air bleeding is finished, check that the
•
fluid level is between the upper and lower
level lines.
Install the diaphragm and reservoir cap.
•
Tighten the bleed valves to the specified
•
torque.
Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Apply the brake forcefully for a few seconds,
•
and check for fluid leakage around the fittings.
Rear Brake Fluid
Rear Brake Fluid Level Inspection
With the rear brake fluid reservoir held hor-
•
izontal, check that the fluid level is between
the upper and lower level lines.
PREPARA
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.
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.
CAUTION
Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately.
NOTE
First, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap is seated on the reservoir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
A. Reservoir
B. Cap
C. Clockwise
D. 1/6 turn
Operate the brake pedal several times.
•
If it feels spongy, there might be air in the
•
brake line.
If necessary, bleed the air in the rear brake
•
line.
Also check for fluid leakage around the fit-
•
tings.
Rear Brake Line Air Bleeding
Remove the rear brake reservoir cap and di-
•
aphragm, and check that there is plenty of
fluid in the reservoir.
NOTE
The fluid level must be checked several time,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
Attach a clear plastic hose to the bleed valve
•
on the rear brake caliper and run the other
end of the hose into a container.
With the reservoir cap off, slowly pump the
•
brake pedal several times until no air bubbles can be seen rising up through the fluid
from the holes at the bottom of the reservoir.
This bleeds the air from the rear brake master
cylinder end of the line.
Pump the brake pedal a few times until it
•
becomes hard and then, holding the pedal
pushed down, quickly open (turn counterclockwise) and close the bleed valve. Then
release the pedal. Repeat this operation until
no more air can be seen coming up into the
plastic hose.
16 PREPA
a
RATION
Insert the hook at the rear of the seat into the
•
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 the
re 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.
Release the brake pedal.
C.
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·m, 69 in·lb)
Install the diaphragm and reservoir cap.
•
NOTE
First, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap is seated on the reservoir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
Apply the brake forcefully for a few seconds,
•
and check for fluid leakage around the fittings.
Seat Installation
Insert the three tabs on the seat into the slots.
•
Clutch Lever and Cable
Clutch Lever Free Play Inspection
Check that the clutch lever has the specified
•
amount of free play as shown in the figure.
h Lever Free Play:
Clutc
2a3 mm (0.08a0.12 in.)
A. Locknut
B. 2
C.
•
Clutch Lever Free Play Adjustment
•
•
•
•
3mm(0.08a0.12 in.)
Adjuster
If the free play is incorrect, adjust the free
play.
Turn the adjuster so that the clutch lever will
have 2 a 3 mm (0.08 a 0.12 in.) of free play.
If it cannot be done, use the adjuster at the
middle of the clutch cable.
Remove the socket bolt (D = 5, L = 16) and
plastic washer (D = 5.3).
Pull the right side cover outward to clear the
stopper, and then remove the right side cover.
A. Seat
B. Tabs
C. Slots
D. Hook
E. Latch
PREPARA
TION 17
A.
Socket Bolt (D = 5, L = 16) and Plastic
Washer (D = 5.3)
B.
ht Side Cover
Rig
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 adjuster
at the clutch lever, or it could slip into
place later, creating enough cable play
to prevent clutch disengagement.
A. Right Side Cover
B. Projections
ommets
C. Gr
D. Tabs
E. Slots
Reinstall the bolt and plastic washer, and
•
tighten the bolt.
NOTE
After the adjustment is made, start the engine
and check that the clutch does not slip and
that it releases properly.
For minor corrections, use the adjuster at the
clutch lever.
Drive Chain
Drive Chain Slack and Wheel Alignment
Inspection
Set the motorcycle up on its side stand.
•
Make sure that the drive chain has the speci-
•
fied amount of play, and that the left and right
notches (marks) on the swingarm points to
the same marks on the left and right drive
chain adjusters.
A. Locknut
B. Adjuster
C. Clutch Cable
Tighten the locknut.
•
Insert the projections of the right side cover
•
into the grommets.
Insert the tabs of the right side cover into the
•
slots.
WARNING
Misalignment of the wheel will result in
abnormal wear, and may result in an unsafe riding condition.
Rotate the rear wheel to find the position
•
where the chain is tightest, and measure
the maximum chain slack by pulling up and
pushing down in the chain midway between
the engine sprocket and rear wheel sprocket.
Drive Chain Slack:
25a35 mm (1.0a1.4 in.)
18 PREPA
A. 25a35 mm (1.0a1.4 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.
RATION
WARNING
A chain that breaks or jumps off the
sprockets could snag on the engine
sprocket or lock the rear wheel, severely damaging the motorcycle and
causing it to go out of control.
Drive Chain Slack Adjustment
Loosen the left and right chain adjuster lock-
•
nuts.
Remove the cotter pin, and loosen the rear
•
axle nut.
If the chain is too loose, turn in the left and
•
right chain adjusting nuts evenly.
If the chain is too tight, turn out the left and
•
right chain adjusting nuts evenly.
Turn both chain adjusting nuts evenly until the
•
drive chain has 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. Chain Adjuster Alignment Marks
B. Indicator
C. Drive Chain Adjusting Nut
D. Drive Chain Adjuster Locknut
NOTE
Wheel alignment can also be checked using
the straightedge or string method.
A. Rear Axle Nut
B. Cotter Pin
C. Drive Chain Adjusting Nut
D. Drive Chain Adjuster Locknut
Tighten both chain adjuster locknuts.
•
Tighten the rear axle nut to the specified
•
torque.
Torque: 108 N·m (11.0 kgf·m, 80 ft·lb)
Rotate the wheel, measure the chain slack
•
again at the tightest position, and readjust if
necessary.
Install a new cotter pin.
•
NOTE
When inserting the cotter pin, if the slots in the
nut do not align with the cotter pin hole in the
axle, tighten the nut clockwise up to the next
alignment.
It should be within 30 degrees.
Loosen once and tighten again when the slot
goes past the nearest hole.
PREPARA
TION 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 tightened or the cotter pin is not installed, an
unsafe riding condition may result.
A. Wrench
B. Spring Preload Adjuster
.4 Position
C. No
Turn the preload adjuster to the No.4 position
•
with the wrench in the tool kit.
Tire Air Pressures
Tire Air Pressures
To prevent flat-spotting during shipment, the
•
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]:
Front: 225 kPa (2.25 kgf/cm², 32 psi)
Rear: 250 kPa (2.50 kgf/cm², 36 psi)
Check the rear brake effectiveness.
•
Rear Shock Absorber
Spring Preload Adjustment
Check the position of the spring preload ad-
•
juster on the rear shock absorber.
STD Spring Preload: No.4 position
A. Tire Air Pressure Gauge
Fuel
WARNING
Fill the tank in a well-ventilated area, and
take ample care that there are no sparks
or open flames anywhere near the work
area.
20 PREPA
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 Research Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.
Research Octane Number (RON) 91
RATION
Octane Rating Method
Minimum
Rating
A. Socket Bolts (D = 6, L = 14)
Close the fuel tank cap. Check for any leaks.
•
Coolant
Coolant Level Inspection
Situate the motorcycle so that it is perpendic-
•
ular to the ground.
Check the coolant level through the coolant
•
level gauge on the reserve tank located inside the right upper fairing. The coolant level
should be above the L (Low) level line.
NOTE
Check the level when the engine is cold (room
or atmospheric temperature).
Free the turn signal light lead from the clamp.
•
Disconnect the city light lead connector, head
•
light lead connector and turn signal light lead
connector.
A. City Light Lead Connector
B. Head Light Lead Connector
C. Turn Signal Light Lead Connector
Disconnect the connectors on the left side in
•
the same manner.
Remove the quick rivets to take off the meter
•
cover.
A. L (Low) Level Line
B. Right Upper Fairing
If the amount of coolant is insufficient, add
•
coolant into the reserve tank.
Coolant Filling
Remove the right side cover (see the “Clutch
•
Lever and Cable” section on page 16 in the
Preparation chapter).
Remove the left side cover in the same man-
•
ner as the right side cover.
Remove the socket bolts (D = 6, L = 14) (4)
•
on both sides of the upper fairing.
A. Quick Rivets
B. Meter Cover
Slide the dust cover and disconnect the meter
•
unit connector.
Remove the flanged bolts (D = 6, L= 12) (3).
•
PREPARA
Install the cap.
•
Reinstall the upper fairing and meter cover in
•
the reverse order of the removal procedure.
Connect the city light lead connectors, head
•
light lead connectors and turn signal light lead
connectors on both sides.
Reinstall the right side cover (see the “Clutch
•
Lever and Cable” section on page 16 in the
Preparation chapter).
Reinstall the left side cover in the same man-
•
ner as the right side cover.
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.
NOTE
A per
Eng
manent type of antifreeze is installed in
the cooling system when shipped. It is colored green and contains ethylene glycol. It is
ed at 50% and has the freezing point of
mix
–35 °C (–31 °F).
ine Oil (4-stroke)
Engine Oil Level Inspection
NOTE
s vehicle’s engine is filled with 20W-40 oil
Thi
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
in plug tightness.
dra
Engine Oil Drain Plug Torque:
30 N·m (3.1 kgf·m, 22 ft·lb)
Remove the cap from the reserve tank and
•
add coolant through the filler opening to the F
(Full) level line.
A. Reserve Tank
B. Cap
C. F (Full) Level Line
A. Oil Drain Plug
Park the vehicle on level ground.
•
Before starting the engine, check that the en-
•
gine has oil.
With the motorcycle held level, check that the
•
engine has oil through the oil level sight gauge
in the lower right side of the engine.
CAUTION
If the engine is run without oil, it will be
severely damaged.
22 PREPA
a
RATION
Start the engine and run it for several minutes
•
at idle speed. Stop the engine, then wait several 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 upper and lower level lines next to the gauge.
A. Oil Level Sight Gauge
B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap
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.
Idle Speed Adjustment
Start the engine and warm it up thoroughly.
•
Adjust the idle speed to 1 250 a 1 350 r/min
•
(rpm) by turning the idle adjusting screw.
Idle Speed: 1 250
1 350 r/min (rpm)
If the oil level is too high, remove the excess
•
oil through the oil filler opening, using a syringe or some other suitable device.
If the oil level is too low, add oil to reach the
•
correct level. Use the same type oil that is
already in the engine.
When replacing the cap, be sure the O-ring is
•
in place, and tighten the cap in finger tight.
Recommended Engine Oil
Type:
Viscosity: SAE 10W-40
Capacity: 1.7 L (1.8 US qt)
API SE, SF or SG
API SH, SJ, SL or SM with
JASO MA, MA1 or MA2
[when filter is not removed]
1.9 L (2.0 US qt)
[when filter is removed]
2.4 L (2.5 US qt)
[when engine is completely
dry]
A. Idle Adjusting Screw
Open and close the throttle grip a few times
•
to make sure that the idle speed does not
change.
With the engine idling, turn the handlebar to
•
each side. If handlebar movement changes
idle speed, check the throttle cable routing
and free play.
WARNING
Operation with improperly routed, or
damaged throttle cable could result in
an unsafe riding condition.
NOTE
Do not add any chemical additive to the oil.
Oils fulfilling the above requirements are fully
formulated and provide adequate lubrication
for both the engine and the clutch.
Check for any exhaust leaks and correct if
•
necessary.
Throttle Grip and Cable
a
PREPARA
TION 23
Thrott
•
Throttle Grip Free Play:
•
le Grip Free Play Inspection
Inspect the throttle grip free play. If the free
play is incorrect, adjust the throttle cables.
2a3 mm (0.08a0.12 in.)
Check that the throttle grip moves smoothly
from full open to close, and the throttle closes
quickly and completely in all steering positions by the return spring. If the throttle grip
does not return properly, check the throttle cable routing, grip free play, and for possible cable damage. Then lubricate the throttle cables.
A. Locknut
B. Adjuster
C. Throttle Cable (Accelerator)
If the throttle cable can not be adjusted by
•
using the cable adjuster at the throttle grip,
use the cable adjuster near the cylinder head.
Remove the right side cover (see the “Clutch
•
Lever and Cable” section on page 16 in the
Preparation chapter).
Loosen the locknut at the throttle grip and turn
•
in the adjuster fully.
Tighten the locknut.
•
Turn out the decelerator cable adjuster until
•
there is no play when the throttle grip is completely closed. Tighten the locknut.
A. Throttle Grip
B. 2
•
3 mm (0.08a0.12 in.)
Run the engine at idle speed, and turn the
handlebar all the way to the right and left to
ensure that the idle speed does not change.
If the idle speed increases, check the throttle
grip free play.
WARNING
Operation with an improperly adjusted,
incorrectly routed, or damaged cables
could result in an unsafe riding condition.
Throttle Grip Free Play Adjustment
Loosen the locknut at the throttle grip, and
•
turn the cable adjuster until the specified
amount of play is obtained.
Tighten the locknut.
•
A. Adjuster
B. Locknut
C. Decelerator Cable
Turn out the accelerator cable adjuster until 2
•
a 3 mm (0.08 a 0.12 in.) of throttle grip play is
obtained. Tighten the locknut.
Reinstall the right side cover.
•
24 PREPA
RATION
Rear Brake Light Switch
Rear Br
Turn on the ignition switch. The brake light
•
should illuminate when the brake pedal is depresse
If it does not, disconnect the rear brake light
•
switch lead connector.
Turn t
•
quired.
Connect the connector.
•
A. R
B. Adjusting Nut
C. Lights sooner.
D. Lights later.
ake Light Switch Adjustment
d about 10 mm (0.39 in.)
he rear brake light switch body as re-
ear Brake Light Switch
A. Horizontal Adjuster
Vertical Adjustment
Turn the vertical adjuster in or out to adjust
•
the headlight vertically.
Headlight Aim
The headlight beam is adjustable both horizontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as oncoming drivers. In most areas it is illegal to ride
with an improperly adjusted headlights.
The left and right (high beam and low beam)
headlight aim can be adjusted individually. The
following explains the procedure for adjusting
the left headlight aim, and the right headlight
aim can be adjusted in the same manner.
Horizontal Adjustment
Turn the horizontal adjuster in or out until the
•
beam points straight ahead.
A. Vertical Adjuster
For US and Canadian model
NOTE
On high beam, the brightest point should be
slightly below horizontal. The proper angle is
0.4 degrees below horizontal. This is a 50 mm
(2 in.) drop at 7.6 m (25 ft) measured from the
center of the headlight, with the motorcycle on
its wheels and the rider seated.
For other than US and Canadian models
NOTE
On high beam, the brightest point should be
slightly below horizontal with the motorcycle
on its wheels and the rider seated. Adjust
the headlight to the proper angle according to
local regulation.
PREPARA
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 English and metric modes (km and mile) in the digital meter. Make sure that km or mile according
to local regulations is correctly displayed before
sale.
Turn the ignition key to “ON”.
•
Push MODE button to display the odometer
•
in the digital meter.
The km/mile display shifts by pushing the RE-
•
SET button while the MODE button pushed in.
A. Km/Mile Display
The km/mile display shifts as follows.
•
A. Mile Display
B. Km Display
C.PushRESETButtonwithMODEButton
in
NOTE
The data is maintained even if the battery is
disconnected.
NOTE
Do not operate the vehicle with the digital me-
ter displaying in the wrong unit (km or mile) of
e digital meter. Shift the km/mile display in
th
the digital meter as follows.
A. MODE Button
B. RESET Button
26 PREPA
RATION
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.
PREPARA
TION 27
No. Fastener
N·m kgf·m ft·lb
Torq ue
Remarks
Steering
1 Handlebar clamp bolt 25 2.5 18
Brake
2 Front master cylinder clamp bolt 11 1.1 97 in·lb S
3
4
brake bleed valve (Left and Right)
Front
Front caliper mounting bolt (Left and Right)
7.8 0.80 69 in·lb
34 3.5 25
5 Rear master cylinder mounting bolt 25 2.5 18
6 Rear brake bleed valve 7.8 0.80 69 in·lb
7 Rear caliper mounting bolt 25 2.5 18
Wheel
8 Front axle 108 11 80
9 Front axle clamp bolt (Right) 34 3.5 25
Suspension
10
11
fork clamp bolt (Upper) (Left and Right)
Front
Rear shock absorber mounting bolt (Upper)
20 2.0 15
59 6.0 44
12 Rear shock absorber mounting bolt (Lower) 59 6.0 44
Other
13 Footpeg bracket bolt (Left and Right) 25 2.5 18
Engine Oil Drain Plug
14 Engine oil drain plug 30 3.1 22
Cotter Pin or Circlip
15 Front footpeg pin circlip (Left and Right) – – –
16
footpeg pin circlip (Left and Right)
Rear
– – –
17 Rear axle nut cotter pin – – –
18 Rear master cylinder rod cotter pin – – –
S
S: Follow the specific tightening sequence.
28 PREPA
RATION
Stand ard 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 Torque
dia. mm N·m kgf·m ft·lb
5 3.4 a 4.9 0.35 a 0.50 30 a 43 in·lb
6 5.9 a 7.80.60 a 0
8 14 a 19 1.4 a 1.9 10.0 a 13.5
10 25 a 34 2.6 a 3.5 19.0 a 25
12 44 a 61 4.5 a 6.
14 73 a 98 7.4 a 10.0 54 a 72
16 115 a 155 11.5 a 16.0 83 a 115
18 165 a 225 17.0 a 23.0125 a 165
20 225 a 325 23 a 33 165 a 240
.80
2
52 a 69 i
n·lb
33 a 45
Test Ride the Motorcycle
Complete the test ride checklist.
•
Control Cables:
Steering: Action is free from
Suspension: Check operation front
Engine: Electric starter works
Transmission
and Clutch:
Brakes: Adequate, smooth
Speedometer
and Tachometer:
Throttle cables must work
without binding in any
steering position.
lock-to-lock.
and rear.
properly and engine
starts promptly. Good
throttle response and
return.
Smooth operation.
stopping power, No
drag.
Check operation.
ical System:
Electr
Headlight - check high and low beams.
Taillight - check operation.
Brake Li
Turn Signal Lights - check operation.
Horn - check operation.
Instrument Lights and Indicator Lights –
check operation.
Engine Stop Switch Works:
Starter Interlock Switch Works:
No Unusual Noises:
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
PREPARATION COMPLETE.
ght - check operation.
WARNING
New tires are slippery and may cause
loss of control and injury. A break-in period of 160 km (100 miles) is necessary
to establish normal tire traction. During
break-in, avoid sudden and maximum
braking and acceleration, and hard cornering.
A&P Check List
CompletetheA&PCheckList.
•
MODEL APPLICATION
Year Model Name
2009 EX650C9F Ninja 650R, ER-6f
2009 EX650D9F ER-6f ABS
Part No. 99931-1507-01
Loading...