Kawasaki ER-6N 650 Owners Maintenance Manual 2006-08

ER-6n

Whenever you see the symbolsshown below, heed their instructions!Always follow safe operating and main-tenance practices.

WARNINGThis warning symbol identifiesspecial instructions or proce-dures which, if not correctly fol-lowed, could result in personalinjury, or loss of life.

CAUTIONThis caution symbol identifiesspecial instructions or proce-dures which, if not strictly ob-served, could result in damageto or destruction of equipment.

NOTEThis note symbol indicates points ofparticular interest for more efficientand convenient operation.

NOTICETHIS PRODUCT HAS BEENMANUFACTURED FOR USE IN AREASONABLE AND PRUDENTMANNER BY A QUALIFIED OP-ERATOR AND AS A VEHICLEONLY.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-torcycle is the product of Kawasaki�s advanced engineering, exhaustive testing,and continuous striving for superior reliability, safety and performance.

Please read this Owner�s Manual carefully before riding so that you will bethoroughly familiar with the proper operation of your motorcycle�s controls, its fea-tures, capabilities, and limitations. This manual offers many safe riding tips, but itspurpose is not to provide instruction in all the techniques and skills required to ridea motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-cle enroll in a motorcycle rider training program to attain awareness of the mentaland physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care andmaintenance described in this manual. For those who would like more detailed in-formation on their Kawasaki Motorcycle, a Service Manual is available for purchasefrom any authorized Kawasaki motorcycle dealer. The Service Manual contains de-tailed disassembly and maintenance information. Those who plan to do their ownwork should, of course, be competent mechanics and possess the special toolsdescribed in the Service Manual.

Keep this Owner�s Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.

TABLE OF CONTENTS

SPECIFICATIONS............................... 8LOCATION OF PARTS ....................... 12GENERAL INFORMATION ................. 15Meter Instruments ............................ 15Tachometer Gauge: ...................... 16LCD (Speedometer, Clock,Odometer, Trip Meters, WarningSymbols): .................................. 17

Warning/Indicator Lights: .............. 23Key................................................... 27Ignition Switch/Steering Lock ........... 27Right Handlebar Switches................ 29Engine Stop Switch: ..................... 29Starter Button: .............................. 30

Left Handlebar Switches .................. 30Dimmer Switch: ............................ 30Turn Signal Switch: ....................... 31Horn Button: ................................. 31Passing Button: ............................ 31Hazard Switch: ............................. 31

Brake/Clutch Lever Adjusters........... 32Fuel Tank Cap.................................. 33Fuel Tank ......................................... 34Fuel Requirement: ........................ 35

Stand................................................ 36Seat Lock ......................................... 37Helmet Holding Cable ...................... 39Tool Kit/U-Shaped LockCompartment................................ 40

Rear View Mirror .............................. 42Tying Hooks ..................................... 43

BREAK-IN ........................................... 44HOW TO RIDE THE MOTORCYCLE . 46Starting the Engine .......................... 46Jump Starting ................................... 48Moving Off ........................................ 50Shifting Gears .................................. 51Braking............................................. 52Stopping the Engine......................... 54

Stopping the Motorcycle in anEmergency ................................... 54

Parking ............................................. 55Catalytic Converter........................... 56

SAFE OPERATION............................. 58Daily Safety Checks ......................... 58Additional Considerations for HighSpeed Operation .......................... 60

MAINTENANCE ANDADJUSTMENT 62Periodic Maintenance Chart............. 63Engine Oil ........................................ 72Cooling System................................ 78Spark Plugs...................................... 83Kawasaki Clean Air System............. 85Valve Clearance............................... 86Air Cleaner ....................................... 86Throttle Control System ................... 88

Engine Vacuum Synchronization ..... 90Idle Speed........................................ 91Clutch ............................................... 92Drive Chain ...................................... 94Brakes .............................................. 102Brake Light Switches........................ 106Front Fork......................................... 108Rear Shock Absorbers ..................... 109Wheels ............................................. 111Battery.............................................. 117Headlight Beam................................ 122Rear Turn Signal Light ..................... 124Fuses ............................................... 124Cleaning Your Motorcycle ................ 126

STORAGE ........................................... 131ENVIRONMENTAL PROTECTION..... 134LOCATION OF LABELS..................... 135

8 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Maximum Horsepower 53 kW (72 PS) @8 500 r/min (rpm)(MY) 46 kW (62.5 PS) @7 000 r/min (rpm)

Maximum Torque 66 N·m (6.7 kgf·m, 48.7 ft·lb) @7 000 r/min (rpm)(MY) 63.2 N·m (6.4 kgf·m, 46.6 ft·lb) @6 500 r/min (rpm)

Minimum Turning Radius 2.7 m (106.3 in.)DIMENSIONSOverall Length 2 100 mm (82.68 in.)Overall Width 760 mm (29.92 in.)Overall Height 1 095 mm (43.11 in.)Wheelbase 1 405 mm (55.31 in.)Road Clearance 140 mm (5.51 in.)Dry Weight 174 kg (384 lb)

ENGINEType DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled

SPECIFICATIONS 9

Displacement 649 cm3 (39.6 cu in.)Bore x Stroke 83 x 60 mm (3.27 x 2.36 in.)Compression Ratio 11.3 : 1Starting System Electric starterCylinder Numbering Method Left to right, 1-2Firing Order 1-2Carburetion System Fi (Fuel Injection)Ignition System Battery and coil (transistorized ignition)Ignition Timing 10° BTDC @1 300 r/min (rpm)(Electronically advanced) 35° BTDC @4 800 r/min (rpm)Spark Plugs NGK CR9EIA-9Lubrication System Forced lubrication (semi-dry sump)Engine Oil Type : API SE, SF or SG

API SH, SJ or SL with JASO MASAE 10W-40

Capacity : 2.4 L (2.5 US qt)Coolant Capacity 1.2 L (1.3 US qt)

10 SPECIFICATIONS

TRANSMISSIONTransmission Type 6-speed, return shiftClutch Type Wet, multi discDriving System Chain drivePrimary Reduction Ratio 2.095 (88/42)Final Reduction Ratio 3.067 (46/15)Overall Drive Ratio 5.473 (Top gear)Gear Ratio 1st 2.438 (39/16)

2nd 1.714 (36/21)3rd 1.333 (32/24)4th 1.111 (30/27)5th 0.966 (28/29)6th 0.852 (23/27)

FRAMECastor 24.5°Trail 102 mm (4.0 in.)Tire Size: Front 120/70ZR17 M/C (58 W) Tubeless

SPECIFICATIONS 11

Rear 160/60ZR17 M/C (69 W) TubelessRim Size: Front 17 × 3.50

Rear 17 × 4.50Fuel Tank Capacity 15.5 L (4.1 US gal)

ELECTRICAL EQUIPMENTBattery 12 V 10 AhHeadlight 12 V 55 W/55 W (Hi/Lo)Tail/Brake Light 12 V 5/21 W

(MY): Malaysian model

Specifications subject to change without notice, and may not apply to every country.

12 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever2. Left Handlebar Switches3. Meter Instruments4. Brake Fluid Reservoir (Front)

5. Right Handlebar Switches6. Front Brake Lever7. Throttle Grip8. Ignition Switch/Steering Lock

LOCATION OF PARTS 13

9. Wheel10. Headlight11. Turn Signal Light12. Spark Plugs13. Air Cleaner14. Main Fuse15. Battery

16. Seat17. Tool Kit/Storage

Compartments18. Helmet Holding Cable19. Tying Hooks20. Seat Lock21. Front Fork

22. Brake Disc23. Brake Caliper24. Shift Pedal25. Side Stand26. Drive Chain

14 LOCATION OF PARTS

27. License Plate Light28. Tail/Brake Light29. Brake Fluid Reservoir

(Rear)30. Fuel Tank31. Fuel Tank Cap

32. Muffler33. Rear Brake Light

Switch34. Rear Brake Pedal35. Oil Level Gauge36. Rear Shock Absorber

37. Rebound DampingForce Adjuster

38. Idle Adjusting Screw39. Coolant Reserve Tank

GENERAL INFORMATION 15GENERAL INFORMATION

Meter Instruments

A. MODE ButtonB. Neutral Indicator LightC. Left Turn Signal Indicator

LightD. TachometerE. FI Indicator LightF. Fuel Level Warning LightG. Warning LightH. Red ZoneI. Right Turn Signal Indicator

LightJ. High Beam Indicator LightK. RESET ButtonL. LCD (Speedometer, Clock,

Trip meter A/B, Odometer,Warning Symbols)

16 GENERAL INFORMATION

Tachometer Gauge:The tachometer shows the engine

speed in revolutions per minute (r/min,rpm). On the right side of the tachome-ter face is a portion called the "redzone". Engine r/min (rpm) in thered zone is above maximum recom-mended engine speed and is alsoabove the range for good performance.When ignition key is turned to �ON�,

the tachometer needle momentarilypoint to the last reading to check its op-eration. If the tachometer needle does

not operate correctly, have it inspectedby an authorized Kawasaki dealer.

CAUTIONEngine r/min (rpm) should notbe allowed to enter the red zone;operation in the red zone willoverstress the engine and maycause serious engine damage.

GENERAL INFORMATION 17

LCD (Speedometer, Clock,Odometer, Trip Meters, WarningSymbols):

The LCD (Liquid Crystal Display) lo-cated in the tachometer face is usedto display the speedometer, Clock,odometer, Trip Meters A/B, and the fol-lowing Warning Symbols: oil pressure( ), coolant temperature ( ), andfuel injection (FI). Pushing the MODEbutton shifts the display through thefollowing four modes: CLOCK, ODO,and TRIP A/B. When the ignition key isturned to �ON�, all the LCD segmentsare displayed for three seconds, thenthe clock or meters operate normallydepending on the mode selected.

A. ClockB. OdometerC. Trip Meter AD. Trip Meter BE. Push MODE Button

NOTEFor safe operation do not press theMODE button while riding.


Digital Meter

A. SpeedometerB. Clock, Trip Meter A/B, OdometerC. FI Warning SymbolD. Coolant Temperature Warning SymbolE. Oil Pressure Warning Symbol

NOTEDo not shift the digital meter displaywhile riding for safe operation.

Mile/Km Display -Mile/Km Display can alternate be-

tween English and metric modes (mileand km) in the digital meter. Make surethat km or mile according to local reg-ulations is correctly displayed beforeriding.

NOTEDo not operate the vehicle with thedigital meter displaying in the wrongunit (km or mile). Shift the km/miledisplay in the digital meter as follows.

� Display the odometer in the digitalmeter.


� The km/mile display shifts by pushingthe RESET button while the MODEbutton pushed in.

A. Km/Mile Display

� The km/mile display shifts as follows.

A. Mile DisplayB. Km DisplayC. Push RESET Button with MODE Button in

NOTEThe data is maintained even if thebattery is disconnected.

Speedometer -The speedometer shows the speed

of the vehicle in digital value.


Clock -To adjust the hours and minutes:

� Turn the ignition key to "ON".� Push the "MODE" button to displaythe clock.

� Push the "RESET" button for morethan two seconds. Both the hour andminute displays start flashing.

� Push the "RESET" button. Thehour display only flashes. Pushthe "MODE" button to advance thehours.

� Push the "RESET" button. Thehour display stops flashing and theminute display starts flashing. Pushthe "MODE" button to advance theminutes.


� Push the "RESET" button. Both thehour and minute displays start flash-ing again.

� Push the "MODE" button. The dis-plays stop flashing and the clockstarts working.

NOTEPushing the �MODE� button momen-tarily advances the hour or minutestep by step. Pushing and hold-ing the button advance the hour orminute continuously.The clock works normally from theback-up power while the ignitionswitch is turned off.When the battery is disconnected,the clock resets to 1:00 and startsworking again when the battery isconnected.

Odometer -The odometer shows the total dis-

tance in kilometers or miles that the ve-hicle has been ridden. This meter can-not be reset.

NOTEThe data is maintained even if thebattery is disconnected.When the figures come to 999999,they are stopped and locked.


Trip Meter -The trip meters show the distance in

kilometers (miles) traveled since theywere last reset to zero.TRIP A: 0.0 999.9TRIP B: 0.0 9999.9To reset the trip meter:

� Push the �MODE� button to displaythe trip meter A or B.

� Push the �RESET� button and hold itin.

� After two seconds, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. Themeter counts until it is next reset.


NOTEThe data is maintained by the back-up power if the ignition key is turnedoff.When the trip meter is reset while thevehicle is stopped, it starts countingas soon as the vehicle starts moving.When the trip meter reaches 999.9(TRIP A) or 9999.9 (TRIP B) whilerunning, the meters reset to 0.0 andcontinues counting.When the battery is disconnected,the meter display resets to 0.0.

Warning/Indicator Lights:: The fuel level warning light in

the tachometer goes on and �FUEL�flashes in the digital meter when only3.5 L (0.9 US gal) of fuel remains. Re-fuel at the earliest opportunity whenthe fuel level warning light goes on and�FUEL� flashes.

A. Fuel Level Warning LightB. Flash


NOTEWhen pushing the MODE buttonwhile �FUEL� is displayed, the dis-play can be shifted to odometer, tripmeter, or clock mode.

N: When the transmission is in neutral,the neutral indicator light is lit.

: When the headlight is on highbeam, the high beam indicator light islit.

: When the turn signal switch ispushed to the left or right, the cor-responding turn signal indicator lightflashes.

: The oil pressure warning light inthe tachometer and symbol in the LCDgoes on whenever the oil pressure isdangerously low or the ignition key isin the ON position with the engine notrunning, and goes off when the engineoil pressure is high enough. Refer totheMaintenance and Adjustment chap-ter for more detailed engine oil informa-tion.

A. Oil Pressure Warning LightB. Oil Pressure Warning Symbol


FI: The fuel injection (FI) indicator lightin the tachometer and symbol in theLCD goes on when the ignition key isturned to �ON� and goes off soon afterensuring that its circuit functions prop-erly. The indicator light also goes onwhenever the troubles occur in digitalfuel injection system (DFI). If the indica-tor light comes on, have the DFI systemchecked by an authorized Kawasakidealer,When the indicator light flashes, firstturn the ignition key to �OFF� and thenback to �ON�.

A. FI Indicator LightB. FI Warning Symbol


: The coolant temperature warninglight in the tachometer and symbol inthe LCD goes on whenever the coolanttemperature rises to 115°C (239°F)when the motorcycle is in operation.This warns the operator that the coolanttemperature is too high. If the warn-ing light goes on stop the engine andcheck the coolant level in the reservetank after the engine cools down.

CAUTIONDo not let the engine continuerunning when the warning lightflashes. Prolonged engine oper-ation will result in severe dam-age from overheating.

A. Coolant Temperature Warning LightB. Coolant Temperature Warning Symbol


KeyThis motorcycle has a combination

key, which is used for the ignitionswitch/steering lock, seat lock, and fueltank cap.Blank keys are available at your

Kawasaki dealers. Ask your dealer tomake any additional spare keys youmay need, using your original key as amaster.

Ignition Switch/Steering LockThis is a four-position, key-operated

switch. The key can be removed fromthe switch when it is in the OFF, LOCK,or P (Park) position.

A. Ignition Switch/Steering LockB. ON positionC. OFF positionD. LOCK positionE. P (Park) position


OFF Engine off. All electricalcircuits off.

ON Engine on. All electricalequipment can be used.

LOCK Steering locked. Engine off.All electrical circuits off.

P(Park)

Steering locked. Engine off.License plate, tail, and citylights on and turn signals canbe used. All other electricalcircuits cut off.

NOTEThe city, tail and license plate lightsare on whenever the ignition key isin the ON position. One headlightgoes on when the starter button isreleased after starting the engine. Toavoid battery discharge, always start

the engine immediately after turningthe ignition key to �ON�.If you leave the P (Park) position onfor a long time (one hour), the batterymay become totally discharged.


Right Handlebar SwitchesEngine Stop Switch:In addition to the ignition switch,

the engine stop switch must be inthe position for the motorcycle tooperate.The engine stop switch is for emer-

gency use. If some emergency re-quires stopping the engine, move theengine stop switch to the position.

NOTEAlthough the engine stop switchstops the engine, it does not turn offall the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.

A. Engine Stop SwitchB. Starter Button


Starter Button:The starter button operates the elec-

tric starter when the transmission is inneutral.Refer to the Starting the Engine sec-

tion of the "How to Ride the Motorcycle"chapter for starting instructions.

Left Handlebar SwitchesDimmer Switch:High or low beam can be selected

with the dimmer switch. When theheadlight is on high beam ( ), thehigh beam indicator light is lit.High beam.......( )Low beam.......( )


NOTEWhen the headlight is on high beam,both head lights are lit. When theheadlight is on low beam, only oneheadlight is lit.

A. Dimmer SwitchB. Turn Signal SwitchC. Horn ButtonD. Passing ButtonE. Hazard

Turn Signal Switch:When the turn signal switch is turned

to the left ( ) or right ( ), thecorresponding turn signal flashes onand off.To stop flashing, push the switch in.

Horn Button:When the horn button is pushed, the

horn sounds.

Passing Button:When the passing button is pushed,

the headlight high beam (passingbeam) comes on to signal the driver ofthe vehicle ahead that you are about topass him. The passing light shuts offas soon as the button is released.

Hazard Switch:If an emergency requires you to park

on the highway shoulder, turn on thehazard lights to warn other drivers ofyour location.


Push in the hazard switch with theignition switch in the ON or P (Park)position. All the turn signals and turnsignal indicator lights will flash on andoff.

CAUTIONIf you leave the switch on for along time, the battery may be-come totally discharged. So becareful not to use the hazardlights for more than 30 minutes.

Brake/Clutch Lever AdjustersThere is an adjuster on both the

brake and clutch levers. Each adjusterhas 5 positions so that the releasedlever position can be adjusted to suitthe operator�s hands. Push the leverforward and turn the adjuster to alignthe number with the arrow mark on thelever holder.


The distance from the grip to the re-leased lever is minimum at Number 5and maximum at Number 1.

A. AdjusterB. Mark

Fuel Tank CapTo open the fuel tank cap, pull up the

key hole cover. Insert the ignition keyinto the fuel tank cap and turn the keyto the right.To close the cap, push it down into

place with the key inserted. The keycan be removed by turning it to the leftto the original position.

NOTEThe fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.


NOTEDo not push on the key to close thecap, or the cap cannot be locked.

A. Key Hole CoverB. Ignition KeyC. Fuel Tank Cap

Fuel TankAvoid filling the tank in the rain or

where heavy dust is blowing so that thefuel does not get contaminated.

A. Tank CapB. Fuel TankC. Top LevelD. Filler Neck


WARNINGGasoline is extremely flammableand can be explosive under cer-tain conditions. Turn the igni-tion key to �OFF�. Do not smoke.Make sure the area is well ven-tilated and free from any sourceof flame or sparks; this includesany appliance with a pilot light.Never fill the tank so the fuellevel rises into the filler neck. Ifthe tank is overfilled, heat maycause the fuel to expand andoverflow through the vents inthe tank cap.After refueling, make sure thefuel tank cap is closed securely.If gasoline is spilled on the fueltank, wipe it off immediately.

Fuel Requirement:Your Kawasaki engine is designed to

use only unleaded gasoline.

CAUTIONDo not use leaded gasoline, asthis will destroy the catalyticconverter. (For further infor-mation, refer to the �CatalyticConverter� section in the �Howto Ride the Motorcycle� chap-ter.)

Octane RatingThe octane rating of a gasoline is a

measure of its resistance to detona-tion or "knocking." The term commonlyused to describe a gasoline�s octanerating is the Research Octane Number(RON). Always use a gasoline with anoctane rating equal to, or higher than,RON 91.


NOTEIf �knocking� or �pinging� occurs, usea different brand of gasoline or higheroctane rating.

StandThe motorcycle is equipped with a

side stand.

A. Side Stand

NOTEWhen using the side stand, turn thehandlebar to the left.


Whenever the side stand is used,make it a practice to kick the stand fullyup before sitting on the motorcycle.

NOTEThe motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does notstart if the transmission is in gear andthe side stand is down.

Seat LockSeat RemovalInsert the ignition key into the seat

lock, located under the rear cowling.Turn the key clockwise while pulling

on the rear end of the seat.

A. SeatB. Seat LockC. Ignition KeyD. Insert


NOTEIf there is difficulty removing the seat,be sure to insert the key all the wayand to push down strongly on therear end of the seat while turning thekey clockwise.

Seat InstallationInstall seats in the reverse order of

removal.� Place the tabs into the matching slotand receptacles.

A. Seat D. ReceptacleB. Slot E. HookC. Tab F. Lock

� Insert the hook at the rear of the seatinto the lock on the frame.


� Push down the rear part of the seatuntil the lock clicks.

� Pull up the rear end of the seat tomake sure it is securely locked.

NOTEIf there is difficulty removing the ig-nition key from the seat lock, turn itlightly counterclockwise while pullingit out.

Helmet Holding CableHelmets can be secured to the motor-

cycle using the helmet holding cableslocated under the seat.

A. Helmet Holding Cable


WARNINGDo not ride the motorcycle witha helmet attached to the cable.The helmet could cause an acci-dent by distracting the operatoror interfering with normal vehi-cle operation.

Tool Kit/U-Shaped LockCompartment

The tool kit is stored under the seat.The kit contains tools that can be help-ful in making roadside repairs, adjust-ments, and some maintenance proce-dures explained in this manual.Also under the seat, there is a lock

strap which holds a U-Shaped lock.


Install the U-shaped part and lockseparately and secure them each withits strap.

A. Tool KitB. Lock StrapC. U-Shaped Lock

� Fit the lock with the holes.

A. LockB. Hole


Rear View MirrorRear View Mirror Adjustment� Adjust the rear view mirror by slightlymoving only the mirror portion of theassembly.

� If the rear visibility can not be as-sured by moving the mirror, turn thestay by hand.

A. StayB. Rear View Mirror

CAUTIONDo not force to tighten and/orloosen the upper hexagonalarea with a pair of spannersor wrench. Forcible looseningand/or tightening may damagethe upper hexagonal area and/orthe turning mechanism of thestay


A. Lower Hexagonal Area for TighteningB. Upper Hexagonal AreaC. Rear View Mirror

Tying HooksWhen tying up light loads to the seat,

use the tying hooks located on the leftand right sides of the rear fairing.

A. Tying Hooks

U5FB15E0.book Page 3 Tuesday, May 11, 2004 3:55 AM

PARTS & ACCESSORIES

OEM parts & online schematics (US)

OEM parts & online schematics (EU)

Click on links below

Free Shipping at Motorcycle Superstore

CheapCycleParts.com - Save Up To 30% On OEM Kawasaki Parts

http://www.anrdoezrs.net/1i103mu2-u1HLLKKQIOHJILPIOLP

http://www.kqzyfj.com/jt82biroiq59988E6C576E8C8FD

http://www.jdoqocy.com/6i104uoxuowBFFEEKCIBDCHHLIIL

http://www.anrdoezrs.net/3977xdmjdl04433917021A19964

Documents

Kawasaki ER-6N 650 Owners Maintenance Manual 2006-08