®
Ninja 650R
ER-6f
ER-6f ABS
Motorcycle
Assembly & Preparation
Manual
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Table of Contents
Uncrating ......................................................................................
Opening Crate .............................................................................
Parts Check.................................................................................
Assembly ......................................................................................
Handlebar....................................................................................
Throttle Grip and Right Switch Housing ......................................
Front Brake Master Cylinder .......................................................
Cables, Harness and Hoses Routing ..........................................
Left Switch Housing.....................................................................
Clutch Cable................................................................................
Lower Fairing...............................................................................
Windshield...................................................................................
3
3
4
5
5
5
6
7
8
8
8
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
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UNCRATING 3
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.
•
•
Uncrating
Opening Crate
WARNING
Always wear protective gloves, boots
and eye protection when uncrating to
prevent injury.
•
•
WARNING
Be careful not to injure your body by
the sharp edges of the steel crate panel
plates and other sharp fasteners.
A. Lower Bolts (D = 8, L = 16)
B. Upper Bolts (D = 8, L = 22)
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)
H. Front Master Cylinder Support Bracket
Take out all the bolts and screws and remove
the top and sides of the crate.
•
NOTE
PRoll the vehicle off the crate base after in-
stalling the handlebar and front master cylin-
der.
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 compo-
nents with the crate bracket.
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4 UNCRATING
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.
1
Part Name
Handlebar with Grips, Weights and Clutch Lever Assy
Clamp, Handlebar
Qty
1
1
Remarks
Socket Bolt, Clamp, Handlebar
Clamp, Front Master Cylinder
Socket Bolt, Clamp, Front Master Cylinder
Left Bracket, Lower Fairing
Flanged Bolt with Non-permanent Locking Agent, Left Bracket
Lower Fairing, LH & RH
4
1
2
1
2
2
D = 8, L = 30
D = 6, L = 22
D = 6, L = 14
2
Socket Bolt, Lower Fairing
Plastic Washer, Lower Fairing
Socket Bolt, Lower Fairing
Plastic Washer, Lower Fairing
Plastic Rivet, Lower Fairing
Windshield
6
6
2
2
3
1
D = 5, L = 16
D = 5.3
D = 6, L = 14
D = 6.5
3
Socket Bolt, Windshield
Plastic Washer, Windshield
4
4
D = 5, L = 20
D = 5.3
4
5
Battery Electrolyte, FTX12-BS
Owner’s Manual
1
1
12 V 10 Ah
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ASSEMBLY 5
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 handle-
bar 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.
A. Throttle Grip
B. Cable Tips : Apply Grease.
C. Rear Half
Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)
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.
•
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. Gap
A. Rear Half
B. Hole
C. Projection
D. Front Half
Throttle Grip and Right Switch
Housing
Apply a light coat of grease on the exposed
•
Insert the two screws (D = 5, L = 25) (D = 5,
•
portion of the throttle inner cables.
Fit both throttle cable tips into the nearest
L = 40) and tighten them.
•
socket in the throttle grip.
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6 ASSEMBLY
A. Right Switch Housing
B. Screw (D = 5, L = 25)
C. Screw (D = 5, L = 40)
A. Front Master Cylinder
B. Clamp
C. Punched Mark
D. Bolts (D = 6, L = 22)
Tighten the upper clamp bolt first and then the
•
Front Brake Master Cylinder
lower clamp bolt to the specified torque.
Connect the right switch housing lead con-
•
Torque: 11 N·m (1.1 kgf·m, 97 in·lb)
nectors to the front brake light switch termi-
nals on the front brake master cylinder.
A. Front Master Cylinder
B. Brake Light Switch Terminals
C. Connectors and Dust Covers
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 cylin-
der clamps align with the punched mark on
the handlebar.
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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 Harness
B.Throttle Cable (Accelerator)
C.Throttle Cable (Decelerator)
D.Front Brake Hose
F.Left Switch Housing Harness
G.Clutch Cable
H.Run the clutch cable and left switch
housing harness through the guide.
E.From the inside sequentially, run the right switch I.Run the left switch housing harness
housing harness, front brake hose, throttle ca-
ble (decelerator) and throttle cable (accelerator)
through the guides.
through the guide.
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8 ASSEMBLY
Left Switch Housing
Connect the left switch housing connector to
the starter lock-out switch on the clutch lever
assembly.
•
A. Left Switch Housing
B. Screws (D = 5, L = 25)
Clutch Cable
A. Clutch Lever Assy
B. Starter Lock-out Switch
C. Connector
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
Fit the two halves of the left switch housing
•
•
lever socket, slide the inner cable through the
slots, and release the outer cable into the ad-
juster.
together so that the small projection on the
front half fits into the hole in the handlebar.
A. Rear Half
B. Hole
C. Projection
D. Front Half
A. Clutch Cable
B. Adjuster
C. Locknut
D. Cable Tip
E. Clutch Lever
Insert the two screws (D = 5, L = 25) and
tighten them securely.
•
Lower Fairing
NOTE
PIt 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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ASSEMBLY 9
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.
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).
•
•
•
Torque: 12 N·m (1.2 kgf·m, 106 in·lb)
A. Socket Bolts (D = 5, L = 16) and Plastic
Washers (D = 5.3)
A. Left Bracket
B. Socket Bolt (D = 6, L = 14) and Plastic
B. Flanged Bolts (D = 6, L = 14)
Washer (D = 6.5)
Pull the left upper fairing outward to clear the
•
Install the right lower fairing in the same man-
stopper.
•
•
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
A. Plastic Rivets
B. Left and Right Lower Fairings
Insert the tabs into the slots to fit the left lower
fairing on the inside of the left upper fairing.
•
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.
A. Tabs
B. Slots
C. Left Upper Fairing
D. Left Lower Fairing
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10 PREPARATION
CAUTION
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
Make sure to use the electrolyte packed in the
crate with the unit.
Make sure that the model name of the elec-
trolyte container matches the model name of
the battery. These names must be the same.
•
•
Battery Model Name for
EX650C/D: FTX12-BS
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 using
oilless solvent.
•
WARNING
If not removed, the anticorrosive treat-
ment applied to the brake disc surface
will interfere with brake action, and an
unsafe riding condition could result.
A. Model Name of the Electrolyte
B. Model Name of the Battery
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.
•
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, fill-
ing the battery with electrolyte, and charging.
Read the electrolyte safety label and the follow-
ing procedures carefully before battery activa-
tion.
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PREPARATION 11
Battery Activation
Filling the Battery with Electrolyte
CAUTION
Do not remove the aluminum sealing
sheet [A] from the filler ports [B] until
just prior to use. Be sure to use the ded-
icated electrolyte container for correct
electrolyte volume.
Place the battery on a level surface.
•
Check to see that the sealing sheet [A] has no
•
peeling, tears, or holes in it.
Remove the sealing sheet [A].
A. Seat
•
B. Seat Lock
C. Ignition Key
D. Insert
NOTE
PThe battery is vacuum sealed. If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.
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.
•
•
•
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.
A. Battery
NOTE
B. Suitable Band
PDo not pierce or otherwise open the sealed
cells [B] of the electrolyte container. Do not
attempt to separate individual cells.
Clean the terminals.
Battery Specifications
Make
•
Furukawa
FTX12-BS
12 V 10 Ah
0.60 L
Battery Type
Battery Capacity
Electrolyte Capacity
Battery/Electrolyte Set P/No.
26012-0109
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12 PREPARATION
Place the electrolyte container upside down
NOTE
•
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.
PCharging the battery immediately after filling
can shorten service life. Let the battery sit for
at least 30 minutes after filling.
Initial Charge
Place the strip of caps [A] loosely over the
•
NOTE
filler ports.
PDo not tilt the electrolyte container.
Newly activated sealed batteries require an
•
initial charge.
Check the electrolyte flow.
•
Standard Charge: 1.2 A × 5 ꢀ 10 hours
If no air bubbles [A] are coming up from the
•
filler ports, or if the container cells have not
emptied completely, tap the container [B] a
few times.
If using a recommended battery charger, fol-
low the charger’s instructions for newly acti-
vated sealed battery.
•
Kawasaki-recommended chargers:
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
If the above chargers are not available, use
equivalent one.
•
NOTE
PCharging rates will vary depending on how
long the battery has been stored, tempera-
ture, 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.
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.
After charging is completed, press down
•
CAUTION
firmly with both hands to seat the strip of
caps [A] into the battery (don’t pound or ham-
mer). When properly installed, the strip of the
caps will be level with the top of the battery.
Removal of the container before it is
completely empty can shorten the ser-
vice life of the battery. Do not remove
the electrolyte container until it is com-
pletely 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.
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PREPARATION 13
Front Brake Fluid
Front Brake Fluid Level Inspection
With the front brake fluid reservoir held hori-
zontal, check that the fluid level is above the
lower level line.
•
CAUTION
Once the strip of the caps [A] is installed
onto the battery, never remove the caps,
nor add water or electrolyte to the bat-
tery.
A. Front Brake Fluid Reservoir
B. Lower Level Line
NOTE
PTo ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.6 volts
repeat the charging cycle and load test. If still
below 12.6 volts the battery is defective.
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.
Battery Installation
Turn the ignition switch OFF.
•
Place the battery into the battery case.
•
Route the battery cables as shown, and first
•
connect the red capped cable to the positive
terminal (+), and then connect the negative
cable to the negative terminal (–).
Put a light coat of grease on the terminals to
•
•
prevent corrosion.
Cover the positive terminal (+) with its protec-
tive cap.
A. Front Brake Fluid Reservoir
B. Upper Level Line
A. Battery
B. Positive Cable (+)
C. Negative Cable (–)
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14 PREPARATION
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 counterclock-
wise) 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.
WARNING
Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time.
Do not mix two types of fluid for use in
the brakes. This lowers the brake fluid
boiling point and could reduce brake ef-
fectiveness. It may also cause the rub-
ber brake parts to deteriorate.
Don’t leave the reservoir cap off for any
length of time to prevent moisture con-
tamination of the fluid.
Don’t add or change brake fluid in the
rain or during conditions of blowing dust
or debris.
•
•
•
CAUTION
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi-
ately.
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.
A. Hold the brake lever applied.
B. Quickly open and close the bleed valve.
C. Release the brake lever.
Front Brake Line Air Bleeding
Remove the reservoir cap and diaphragm,
•
and check that there is plenty of fluid in the
reservoir.
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.
NOTE
PThe 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.
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.
•
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PREPARATION 15
A. Reservoir
B. Cap
C. Clockwise
D. 1/6 turn
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.
•
Operate the brake pedal several times.
•
•
•
•
If it feels spongy, there might be air in the
Remove the reservoir cap and diaphragm,
and fill the reservoir to the upper level line with
DOT4 brake fluid.
brake line.
•
If necessary, bleed the air in the rear brake
line.
Also check for fluid leakage around the fit-
tings.
WARNING
Be sure to hold the front brake during
the bleeding operation, or the motorcy-
cle may fall over. It could cause an acci-
dent and injury.
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
CAUTION
PThe 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.
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi-
ately.
NOTE
PFirst, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap is seated on the reser-
voir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
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 bub-
bles 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 counter-
clockwise) 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.
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16 PREPARATION
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
PIf there is difficulty removing the ignition key
from the seat lock, turn it lightly counterclock-
wise while pulling it out.
Clutch Lever and Cable
A. Hold the brake pedal applied.
B. Quickly open and close the bleed valve.
C. Release the brake pedal.
Clutch Lever Free Play Inspection
Check that the clutch lever has the specified
•
amount of free play as shown in the figure.
When air bleeding is finished, check that the
•
Clutch Lever Free Play:
fluid level is between the upper and lower
level lines.
2 ꢀ 3 mm (0.08 ꢀ 0.12 in.)
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
PFirst, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap is seated on the reser-
voir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
A. Locknut
B. 2 ꢀ 3 mm (0.08 ꢀ 0.12 in.)
C. Adjuster
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.
If the free play is incorrect, adjust the free
•
•
play.
Clutch Lever Free Play Adjustment
Turn the adjuster so that the clutch lever will
•
have 2 ꢀ 3 mm (0.08 ꢀ 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
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PREPARATION 17
A. Socket Bolt (D = 5, L = 16) and Plastic
Washer (D = 5.3)
B. Right Side Cover
C. Stopper
A. Right Side Cover
B. Projections
C. Grommets
D. Tabs
E. Slots
Loosen the locknut at the middle of the clutch
•
•
cable.
Reinstall the bolt and plastic washer, and
tighten the bolt.
•
Turn the adjuster until the free play is correct.
WARNING
NOTE
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.
PAfter the adjustment is made, start the engine
and check that the clutch does not slip and
PFthoartmitirneoler acsoerrsecptrioopnesr,lyu.se 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.
WARNING
Misalignment of the wheel will result in
abnormal wear, and may result in an un-
safe riding condition.
A. Locknut
B. Adjuster
C. Clutch Cable
Tighten the locknut.
•
Rotate the rear wheel to find the position
•
Insert the projections of the right side cover
into the grommets.
•
•
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.
Insert the tabs of the right side cover into the
slots.
Drive Chain Slack:
25 ꢀ 35 mm (1.0 ꢀ 1.4 in.)
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18 PREPARATION
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. 25 ꢀ 35 mm (1.0 ꢀ 1.4 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.
•
WARNING
A chain that breaks or jumps off the
sprockets could snag on the engine
sprocket or lock the rear wheel, se-
verely damaging the motorcycle and
causing it to go out of control.
A. Chain Adjuster Alignment Marks
B. Indicator
C. Drive Chain Adjusting Nut
D. Drive Chain Adjuster Locknut
Drive Chain Slack Adjustment
Loosen the left and right chain adjuster lock-
•
•
nuts.
Remove the cotter pin, and loosen the rear
axle nut.
NOTE
PWheel alignment can also be checked using
the straightedge or string method.
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.
•
A. Rear Axle Nut
NOTE
B. Cotter Pin
C. Drive Chain Adjusting Nut
D. Drive Chain Adjuster Locknut
PWhen 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
PaItlisghnomueldntb.e within 30 degrees.
PLoosen once and tighten again when the slot
goes past the nearest hole.
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PREPARATION 19
A. Cotter Pin
A. Wrench
B. Turning Clockwise
B. Spring Preload Adjuster
C. No.4 Position
Bend the cotter pin over the nut.
•
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)
A. Cotter Pin
B. Nut
WARNING
If the rear axle nut is not securely tight-
ened or the cotter pin is not installed, an
unsafe riding condition may result.
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.
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20 PREPARATION
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 Re-
search Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.
Minimum
Octane Rating Method
Rating
A. Socket Bolts (D = 6, L = 14)
Research Octane Number (RON)
91
Free the turn signal light lead from the clamp.
Close the fuel tank cap. Check for any leaks.
•
•
Disconnect the city light lead connector, head
light lead connector and turn signal light lead
connector.
•
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 in-
side the right upper fairing. The coolant level
should be above the L (Low) level line.
NOTE
PCheck the level when the engine is cold (room
or atmospheric temperature).
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).
A. Quick Rivets
B. Meter Cover
Remove the left side cover in the same man-
•
•
ner as the right side cover.
Remove the socket bolts (D = 6, L = 14) (4)
Slide the dust cover and disconnect the meter
•
•
on both sides of the upper fairing.
unit connector.
Remove the flanged bolts (D = 6, L= 12) (3).
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PREPARATION 21
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.
NOTE
A. Dust Cover
B. Meter Unit Connector
C. Flanged Bolts (D = 6, L= 12)
PA permanent type of antifreeze is installed in
the cooling system when shipped. It is col-
ored green and contains ethylene glycol. It is
mixed at 50% and has the freezing point of
–35 °C (–31 °F).
Pull the upper fairing outward to clear the
•
•
stoppers on both sides.
Remove the upper fairing forward.
Engine Oil (4-stroke)
Engine Oil Level Inspection
NOTE
PThis vehicle’s engine is filled with 20W-40 oil
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain plug tightness.
Engine Oil Drain Plug Torque:
30 N·m (3.1 kgf·m, 22 ft·lb)
A. Upper Fairing
B. Stoppers
C. Remove the Upper Fairing Forward.
Remove the cap from the reserve tank and
add coolant through the filler opening to the 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.
A. Reserve Tank
B. Cap
C. F (Full) Level Line
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22 PREPARATION
Start the engine and run it for several minutes
Although 10W-40 engine oil is the recom-
mended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.
•
at 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 level lines next to the gauge.
Idle Speed Adjustment
Start the engine and warm it up thoroughly.
A. Oil Level Sight Gauge
B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap
•
Adjust the idle speed to 1 250 ꢀ 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 sy-
ringe 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:
API SE, SF or SG
API SH, SJ, SL or SM with
JASO MA, MA1 or MA2
A. Idle Adjusting Screw
Open and close the throttle grip a few times
•
to make sure that the idle speed does not
change.
Viscosity: SAE 10W-40
Capacity: 1.7 L (1.8 US qt)
With the engine idling, turn the handlebar to
•
each side. If handlebar movement changes
idle speed, check the throttle cable routing
and free play.
[when filter is not removed]
1.9 L (2.0 US qt)
[when filter is removed]
2.4 L (2.5 US qt)
WARNING
Operation with improperly routed, or
damaged throttle cable could result in
an unsafe riding condition.
[when engine is completely
dry]
NOTE
Check for any exhaust leaks and correct if
necessary.
•
PDo 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.
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PREPARATION 23
Throttle Grip and Cable
Throttle Grip Free Play Inspection
Inspect the throttle grip free play. If the free
•
play is incorrect, adjust the throttle cables.
Throttle Grip Free Play:
2 ꢀ 3 mm (0.08 ꢀ 0.12 in.)
Check that the throttle grip moves smoothly
•
from full open to close, and the throttle closes
quickly and completely in all steering posi-
tions by the return spring. If the throttle grip
does not return properly, check the throttle ca-
ble routing, grip free play, and for possible ca-
ble damage. Then lubricate the throttle ca-
bles.
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 com-
pletely closed. Tighten the locknut.
•
•
A. Throttle Grip
B. 2 ꢀ 3 mm (0.08 ꢀ 0.12 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 condi-
tion.
A. Adjuster
B. Locknut
C. Decelerator Cable
Throttle Grip Free Play Adjustment
Loosen the locknut at the throttle grip, and
Turn out the accelerator cable adjuster until 2
•
•
turn the cable adjuster until the specified
amount of play is obtained.
Tighten the locknut.
ꢀ 3 mm (0.08 ꢀ 0.12 in.) of throttle grip play is
obtained. Tighten the locknut.
Reinstall the right side cover.
•
•
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24 PREPARATION
Rear Brake Light Switch
Rear Brake Light Switch Adjustment
Turn on the ignition switch. The brake light
•
should illuminate when the brake pedal is de-
pressed about 10 mm (0.39 in.)
If it does not, disconnect the rear brake light
•
switch lead connector.
Turn the rear brake light switch body as re-
•
quired.
Connect the connector.
•
A. Horizontal Adjuster
Vertical Adjustment
Turn the vertical adjuster in or out to adjust
the headlight vertically.
•
A. Rear Brake Light Switch
B. Adjusting Nut
C. Lights sooner.
D. Lights later.
A. Vertical Adjuster
For US and Canadian model
NOTE
POn 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.
Headlight Aim
The headlight beam is adjustable both hori-
zontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as on-
coming 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.
For other than US and Canadian models
Horizontal Adjustment
NOTE
Turn the horizontal adjuster in or out until the
•
POn 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.
beam points straight ahead.
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PREPARATION 25
CAUTION
Turn the ignition key to “ON”.
•
•
•
Push MODE button to display the odometer
in the digital meter.
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.
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
Digital Meter
C. Push RESET Button with MODE Button
Check the Km/Mile Display in the
Digital Meter:
in
Km/Mile Display can alternate between Eng-
lish and metric modes (km and mile) in the dig-
ital meter. Make sure that km or mile according
to local regulations is correctly displayed before
sale.
NOTE
PThe data is maintained even if the battery is
disconnected.
NOTE
PDo not operate the vehicle with the digital me-
ter displaying in the wrong unit (km or mile) of
the digital meter. Shift the km/mile display in
the digital meter as follows.
A. MODE Button
B. RESET Button
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26 PREPARATION
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.
•
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PREPARATION 27
Torque
kgf·m
No.
Fastener
Remarks
ft·lb
N·m
Steering
1
Handlebar clamp bolt
25
2.5
18
S
S
Brake
2
3
4
5
6
7
Front master cylinder clamp bolt
Front brake bleed valve (Left and Right)
Front caliper mounting bolt (Left and Right)
Rear master cylinder mounting bolt
Rear brake bleed valve
11
7.8
34
25
7.8
25
1.1
97 in·lb
0.80 69 in·lb
3.5
2.5
0.80 69 in·lb
2.5
25
18
Rear caliper mounting bolt
18
Wheel
8
9
Front axle
Front axle clamp bolt (Right)
108
34
11
3.5
80
25
Suspension
10 Front fork clamp bolt (Upper) (Left and Right)
11 Rear shock absorber mounting bolt (Upper)
12 Rear shock absorber mounting bolt (Lower)
Other
20
59
59
2.0
6.0
6.0
15
44
44
13 Footpeg bracket bolt (Left and Right)
Engine Oil Drain Plug
14 Engine oil drain plug
25
30
2.5
3.1
18
22
Cotter Pin or Circlip
15 Front footpeg pin circlip (Left and Right)
16 Rear footpeg pin circlip (Left and Right)
17 Rear axle nut cotter pin
–
–
–
–
–
–
–
–
–
–
–
–
18 Rear master cylinder rod cotter pin
S: Follow the specific tightening sequence.
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28 PREPARATION
Electrical System:
Headlight - check high and low beams.
Taillight - check operation.
Brake Light - check operation.
Turn Signal Lights - check operation.
Horn - check operation.
Instrument Lights and Indicator Lights –
check operation.
Standard 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:
Engine Stop Switch Works:
Starter Interlock Switch Works:
No Unusual Noises:
Threads
dia. mm
Torque
kgf·m
N·m
ft·lb
5
3.4 ꢀ 4.9 0.35 ꢀ 0.50 30 ꢀ 43 in·lb
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
6
8
5.9 ꢀ 7.8 0.60 ꢀ 0.80 52 ꢀ 69 in·lb
14 ꢀ 19
25 ꢀ 34
44 ꢀ 61
1.4 ꢀ 1.9 10.0 ꢀ 13.5
10
12
14
16
18
20
2.6 ꢀ 3.5
19.0 ꢀ 25
33 ꢀ 45
54 ꢀ 72
PREPARATION COMPLETE.
4.5 ꢀ 6.2
73 ꢀ 98 7.4 ꢀ 10.0
WARNING
115 ꢀ 155 11.5 ꢀ 16.0 83 ꢀ 115
165 ꢀ 225 17.0 ꢀ 23.0 125 ꢀ 165
New tires are slippery and may cause
loss of control and injury. A break-in pe-
riod of 160 km (100 miles) is necessary
to establish normal tire traction. During
break-in, avoid sudden and maximum
braking and acceleration, and hard cor-
nering.
225 ꢀ 325 23 ꢀ 33
165 ꢀ 240
Test Ride the Motorcycle
Complete the test ride checklist.
Control Cables: Throttle cables must work
•
without binding in any
steering position.
Action is free from
lock-to-lock.
Check operation front
and rear.
A&P Check List
Complete the A & P Check List.
Steering:
•
Suspension:
Engine:
Electric starter works
properly and engine
starts promptly. Good
throttle response and
return.
Transmission
and Clutch:
Smooth operation.
Brakes:
Adequate, smooth
stopping power, No
drag.
Speedometer
and Tachometer:
Check operation.
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MODEL APPLICATION
Year
2009
2009
Model
Name
Ninja 650R, ER-6f
ER-6f ABS
EX650C9F
EX650D9F
Part No. 99931-1507-01
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