Kawasaki NINJA 650R, NINJA ER-6F ABS, NINJA ER-6F User Manual
®
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.
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