Kawasaki ER-6F ABS - Manuals

4 UNCRATING Parts Check • Open the parts box, and check the parts against the illustrations. There may be minor differencesbetween 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 Rem...

ASSEMBLY 5 Assembly Handlebar Handlebar Installation • Set the handlebar so that its punched mark isaligned with the upper rear edge of the lowerhandlebar clamp and install the upper handle-bar clamp and bolts (D = 8, L = 30). • Tighten the front clamp bolts first, and thenthe rear clamp bolts to th...

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 Terminals...

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 HarnessB. Throttle Cable (Accelerator) C. Throttle Cable (Decelerator)D. Front Brake Hose E. From the inside sequentially, run the...

8 ASSEMBLY Left Switch Housing • Connect the left switch housing connector tothe starter lock-out switch on the clutch leverassembly. A. Clutch Lever Assy B. Starter Lock-out Switch C. Connector • Fit the two halves of the left switch housingtogether so that the small projection on thefront half fit...

ASSEMBLY 9 • Install the left bracket on the lower left sideof 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 BracketB. Flanged Bolts (D = 6, L = 14) • Pull the left up...

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 usingoilless solvent. WARNING If not removed, the anticorrosive treat-ment applied to the brake disc surfacewill interfere wit...

PREPARATION 11 A. Seat B. Seat Lock C. Ignition Key D. Insert • Turn the key clockwise while pulling the rearend of the seat. • Remove the seat backward. • Run the suitable band into the positive termi-nal (+). • Pull the battery out of the battery case withboth hands. A. Battery B. Suitable Band • ...

12 PREPARATION • Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pushdown to break the seals of all six cells. Youwill see air bubbles rising into each cell as theports fill. NOTE Do not tilt the electrolyte containe...

PREPARATION 13 CAUTION Once the strip of the caps [A] is installedonto the battery, never remove the caps,nor add water or electrolyte to the bat-tery. NOTE To ensure maximum battery life and customersatisfaction, it is recommended the battery beload tested at three times its amp-hour ratingfor 15 s...

14 PREPARATION WARNING Never reuse old brake fluid.Do not use fluid from a container thathas been left unsealed or that has beenopen for a long time.Do not mix two types of fluid for use inthe brakes. This lowers the brake fluidboiling point and could reduce brake ef-fectiveness. It may also cause t...

PREPARATION 15 A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line • If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thebrake line, and fill the reservoir. • Remove the reservoir cap and diaphragm,and fill the reservoir to the upper l...

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 thefluid level is between the upper and lowerlevel lines. • Tighten the bleed valve to the specifiedtorque. Torque: 7.8 N·m (0.80 kgf·m, ...

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 clutchcable. • Turn the adjuster until the free play is correct. WARNING Be sure that the outer cable end at theclutch lever is fully seated in the adju...

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 thestandard value. WARNING A chain that breaks or jumps off thesprockets could snag on the enginesprocket or lock the rear wheel, se-verely damaging the moto...

PREPARATION 19 A. Cotter Pin B. Turning Clockwise • Bend the cotter pin over the nut. A. Cotter PinB. Nut WARNING If the rear axle nut is not securely tight-ened or the cotter pin is not installed, anunsafe riding condition may result. • Check the rear brake effectiveness. Rear Shock Absorber Spring...

20 PREPARATION • Open the fuel tank cap, and check for debrisin the fuel tank. • Fill the fuel tank with one gallon or four litersof unleaded gasoline. Use gasoline with aminimum antiknock index rating according tothe recommendation of your country. Refer tothe following table. The antiknock index i...

PREPARATION 21 A. Dust Cover B. Meter Unit Connector C. Flanged Bolts (D = 6, L= 12) • Pull the upper fairing outward to clear thestoppers 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 andad...

22 PREPARATION • Start the engine and run it for several minutesat 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 lower ...

PREPARATION 23 Throttle Grip and Cable Throttle Grip Free Play Inspection • Inspect the throttle grip free play. If the freeplay 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 smoothlyfrom full open to close, and the...

24 PREPARATION Rear Brake Light Switch Rear Brake Light Switch Adjustment • Turn on the ignition switch. The brake lightshould illuminate when the brake pedal is de-pressed about 10 mm (0.39 in.) • If it does not, disconnect the rear brake lightswitch lead connector. • Turn the rear brake light swit...

PREPARATION 25 CAUTION When handling the quartz-halogen bulbs, never touch the glass portionwith bare hands. Always use a clean cloth. Oil contamination from hands ordirty rags can reduce bulb life or causethe bulb to explode. Digital Meter Check the Km/Mile Display in the Digital Meter: Km/Mile Dis...

26 PREPARATION Fastener Check • The torque values listed are for assembly and preparation items only, see the appropriate ServiceManual for a more comprehensive list. Check tightness of all fasteners that are in the table beforeretail delivery. Also check to see that each cotter pin or circlip is in...

28 PREPARATION Standard Torque Table This table relating tightening torque to thread diameter, lists the basic torque for bolts andnuts. Use this table for only the bolts and nutswhich do not require a specific torque value.All of the values are for use with dry solvent-cleaned threads. General Fast...

MODEL APPLICATION Year Model Name 2009 EX650C9F Ninja 650R, ER-6f 2009 EX650D9F ER-6f ABS Part No. 99931-1507-01