Page 2 - Foreword; WARNING; NOTE
Foreword In order to ship Kawasaki vehicles as effi- ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly removed parts have a direct bear-ing on a vehicle’s reliability and safety, consci-entious pre-sale assembly and preparation be-comes extremely im...
Page 3 - Table of Contents; Uncrating
Table of Contents Uncrating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check ................................................................................
Page 5 - UNCRATING 3; Opening Crate; CAUTION; C. Steering Stem Support Bracket
UNCRATING 3 Uncrating Opening Crate WARNING Always wear protective gloves, bootsand eye protection when uncrating toprevent injury. WARNING Be careful not to injure your body bythe sharp edges of the steel crate panelplates and other sharp fasteners. • Clear a space about 6 m (20 ft) square to givey...
Page 6 - UNCRATING; Parts Check; Part Name
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...
Page 7 - ASSEMBLY 5; Assembly; Handlebar; Handlebar Installation
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...
Page 8 - Front Brake Master Cylinder
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...
Page 9 - ASSEMBLY 7; Cables, Harness and Hoses Routing; Right Side View
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...
Page 10 - ASSEMBLY; Left Switch Housing; A. Left Switch Housing; Clutch Cable
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...
Page 11 - Windshield
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...
Page 12 - Brake Disc Cleaning; Preparation; Battery Service; Battery Removal; Battery Model Name for; A. Model Name of the Electrolyte; Each
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...
Page 13 - PREPARATION 11; Battery Specifications; Battery Activation; Filling the Battery with Electrolyte
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 • ...
Page 14 - 2 PREPARATION; Initial Charge; Optimate III
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...
Page 15 - PREPARATION 13; Battery Installation; Front Brake Fluid; Front Brake Fluid Level Inspection; A. Front Brake Fluid Reservoir
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...
Page 16 - 4 PREPARATION; Front Brake Line Air Bleeding; B. Quickly open and close the bleed valve.; Rear Brake Fluid; Rear Brake Fluid Level Inspection
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...
Page 17 - Rear Brake Line Air Bleeding
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...
Page 18 - Seat Installation; Clutch Lever and Cable; Clutch Lever Free Play Inspection; Clutch Lever Free Play:; Clutch Lever Free Play Adjustment
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, ...
Page 19 - PREPARATION 17; Drive Chain; Drive Chain Slack and Wheel Alignment
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...
Page 20 - Drive Chain Slack Adjustment
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...
Page 21 - PREPARATION 19; Rear Shock Absorber; Spring Preload Adjustment; B. Spring Preload Adjuster; Tire Air Pressures; A. Tire Air Pressure Gauge; Fuel
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...
Page 22 - 0 PREPARATION; Coolant; Coolant Level Inspection; B. Right Upper Fairing; Coolant Filling; A. City Light Lead Connector
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...
Page 23 - Engine Oil Level Inspection; Engine Oil Drain Plug Torque:
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...
Page 24 - Recommended Engine Oil; Idle Speed Adjustment; A. Idle Adjusting Screw
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 ...
Page 25 - PREPARATION 23; Throttle Grip and Cable; Throttle Grip Free Play Inspection; Throttle Grip Free Play:; Throttle Grip Free Play Adjustment
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...
Page 26 - 4 PREPARATION; Rear Brake Light Switch; Rear Brake Light Switch Adjustment; A. Rear Brake Light Switch; Headlight Aim; Horizontal Adjustment; A. Horizontal Adjuster; Vertical Adjustment
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...
Page 27 - Digital Meter; Check the Km/Mile Display in the
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...
Page 28 - 6 PREPARATION; Fastener Check
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...
Page 30 - 8 PREPARATION; Standard Torque Table; Engine Stop Switch Works:
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...
Page 32 - MODEL APPLICATION
MODEL APPLICATION Year Model Name 2009 EX650C9F Ninja 650R, ER-6f 2009 EX650D9F ER-6f ABS Part No. 99931-1507-01
