Kawasaki MOTORCYCLE Owner's manual

ENGLISH j

Motorcycle

Owner’s Manual

Whenever you see the symbols

shown below, heed their instructions!

Always follow safe operating and main-

tenance practices.

WARNING

This warning symbol identifies

special instructions or proce-

dures which, if not correctly fol-

lowed, could result in personal

injury, or loss of life.

CAUTION

This caution symbol identifies

special instructions or proce-

dures which, if not strictly ob-

served, could result in damage

to or destruction of equipment.

NOTE

○

This note symbol indicates points of

particular interest for more efficient

and convenient operation.

NOTICE

THIS PRODUCT HAS BEEN

MANUFACTURED FOR USE IN A

REASONABLE AND PRUDENT

MANNER BY A QUALIFIED OP-

ERATOR AND AS A VEHICLE

ONLY.

(Australian model only)

TAMPERING W ITH NOISE CONTROL SYSTEM

PROHIBITED

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes

of maintenance, repair or replacement, of any device or element of design

incorporated into any new vehicle for the purpose of noise control prior to

its sale or deliver y to the ultimate purchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been re-

moved or rendered inoperative by any person.

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 be

thoroughly familiar with th e proper operation of your motorcycle’s con tro ls, its fea-

tures, capabilities, and limitations. This manual offers man y safe riding tips, but its

purpose is not to provide instruction in all the te chniques and skills required to ride

a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-

cle enroll in a motorcycle rider training program to atta in awareness of the mental

and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and

maintenance described in this manual. For those who would like more detailed in-

formation on their Kawasaki Motorcycle, a Service Manual is available for purchase

from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-

tailed disassembly and maintenance information. Those who plan to do their own

work should, of course, be competent mechanics and possess the special tools

described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can

refer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and should

remain with th e motorcycle whe n it is sold.

prior written permission.

This publication includes the latest information available at the time of printing.

However, ther e may be minor differences b etween the actual product and illustra-

tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company

TABLE OF CONTENTS

SPECIFICATIONS ............................... 10

LOCATION OF PARTS ....................... 14

LOADING AND ACCESSORIES

INFORMATION ................................ 17

GENERAL INFORMATION................. 20

Meter Instruments ............................ 20

Tachometer Gauge: ...................... 21

LCD (Speedometer, Clock,

Odometer, Trip Meters, Warning

Symbols): .................................. 22

Warning/Indicator Lights: .............. 28

Key................................................... 33

Ignition Switch/Steering Lock........... 33

Right Handlebar Switches................ 35

Engine Stop Switch: ..................... 35

Starter Button: .............................. 36

Left Handlebar Switches .................. 36

Dimmer Switch: ............................ 36

Turn Signal Switch:....................... 37

Horn Button: ................................. 37

Passing Button: ............................ 37

Hazard Switch: ............................. 37

Brake/Clutch Lever Adjusters........... 38

Fuel Tank Cap.................................. 39

Fuel Tank ......................................... 40

Fuel Requirement: ........................ 41

Stand................................................ 42

Seat Lock ......................................... 43

Helmet Holding Cable ...................... 45

Tool Kit/U-Shaped Lock

Compartment................................ 46

Rear View Mirror .............................. 48

Tying Hooks ..................................... 49

BREAK-IN ........................................... 50

HOW TO RIDE THE MOTORCYCLE .52

Starting the Engine .......................... 52

Jump Starting ................................... 54

Moving Off........................................ 56

Shifting Gears .................................. 57

Braking............................................. 58

Anti-lock Brake System (ABS) for

only on ER650B............................ 60

ABS Indicator Light:...................... 61

Stopping the Engine......................... 62

Stopping the Motorcycle in an

Emergency ................................... 63

Parking............................................. 64

Catalytic Converter........................... 65

SAFE OPERATION............................. 67

Safe Riding Technique ..................... 67

Daily Safety Checks......................... 69

Additional Consideration s for H igh

Speed Operation .......................... 71

MAINTENANCE AND ADJUSTMENT 73

Periodic Maintenance Chart............. 74

Engine Oil ........................................ 83

Cooling System ................................ 89

Spark Plugs...................................... 94

Kawasaki Clean Air System ............. 96

Valve Clearance ............................... 97

Air Cleaner ....................................... 97

Throttle Control System ................... 99

Engine Vacuum Synchronization ..... 101

Idle Speed ........................................ 102

Clutch............................................... 103

Drive Chain ...................................... 105

Brakes.............................................. 113

Brake Light Switches........................ 117

Front Fork......................................... 119

Rear Shock Absorbers..................... 120

Wheels ............................................. 122

Battery.............................................. 128

Headlight Beam................................ 133

Rear Turn Signal Light ..................... 135

Fuses ............................................... 135

Cleaning Your Motorcycle ................ 137

STORAGE........................................... 142

ENVIRONMENTAL PROTECTION..... 145

LOCATION OF LABELS..................... 146

10 SPEC IFICATIONS

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)

63.2N·m(6.4kgf·m,46.6ft·lb)@6500r/min(rpm)

Minimum Turning Radius

2.7 m (106.3 in.)

DIMENSIONS

Overall Length 2 100 m m (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

(A) 174 kg (384 lb)

178 kg (392 lb)

SPECIFICATIO NS 11

ENGINE

Type

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

Displacement

649 cm

3

(39.6 cu in.)

Bore × Stroke 83 × 60 mm (3.27 × 2.36 in.)

Compression Ratio

11.3 : 1

Starting System

Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order

1-2

Carburetion 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-9

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil

Type :

API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

12 SPEC IFICATIONS

Capacity: 2.4L(2.5USqt)

Coolant Capacity 1.2 L (1.3 US q t)

TRANSMISSION

Transmission Type

6-speed, return shift

Clutch Type

Wet, multi disc

Driving System Chain drive

Primary 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)

FRAME

Castor 24.5°

SPECIFICATIONS 13

Trail

102mm(4.0in.)

Tire Size:

Front

120/70ZR17 M/C (58 W) Tubeless

Rear

160/60ZR17 M/C (69 W) Tubeless

Rim Size:

Front 17 × 3.50

Rear 17 × 4.50

Fuel Tank Capacity 15.5 L (4.1 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 10 Ah

Headlight

12V55W/55W(Hi/Lo)

Tail/Brake Light 12 V 5/21 W

(MY): Malaysian model

(A): ER650A

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

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Left Handlebar Switches

3. Meter Instruments

4. Brake Fluid Reservoir (Front)

5. Right Handleb ar Sw itch es

6. Front Brake Lever

7. Throttle Grip

8. Ignition Switch/Steering Lock

LOCATION OF PARTS 15

9. Wheel

10. Headlight

11. Turn Signal Light

12. Spark Plugs

13. Air Cleaner

14. Main Fuse

15. Battery

16. Seat

17. Tool Kit/Sto rage

Compartments

18. Helmet Holding Cable

19. Tying Hooks

20. Seat Lock

21. Front Fork

22. Brake Disc

23. Brake Calip er

24. Shift Pe dal

25. Side Stan d

26. Drive C hain

16 LOCATION OF PARTS

27. License Plate Light

28. Tail/Brake Light

29. Brake Fluid R eservoir

(Rear)

30. Fuel Tank

31. Fuel Tank Cap

32. Muffler

33. Rear Brake Light

Switch

34. Rear Brake Pedal

35. Oil Level Gauge

36. Rear Shock Absorber

37. Rebound Damping

Force Adjuster

38. Idle Adjusting Screw

39. Coolant Reserve Tank

LOADING AND ACCESSORIES INFORMATION 17

LOADING AND ACCESSORIES INFORMATION

WARNING

Incorrect loading, improper in-

stallation or use of accessories,

or modification of your motorcy-

cle may result in an unsafe rid-

ing condition. Before you ride

the motorcycle, make sure that

the motorcycle is not overloaded

and that you have followed these

instructions.

With the exception of genuine

Kawasaki Parts and Accessories,

Kawasaki has no control over the

design or application of accessories.

In som e cases, improper installation

or use of accessories, or m otorcycle

modification, will void the motorcycle

warranty, can negatively affect per-

formance, and can even be illegal.

In selectin g and using accessories,

and in loading the motorcycle, you are

personally responsible for your own

safety and the safety of other persons

involved.

NOTE

○

Kawasaki Parts and Accessories

have been specially designed for

use on Kawasaki motorcycle s. We

strongly recommend that all parts

and accessories you add to your

motorcycle be genuine Kawasaki

components.

Because a motorcycle is s en sitive to

changes in weight and aerodynamic

forces, you must take extreme care

18 LOADING AND ACCESSOR IES INFORMATION

in carrying cargo, passengers and/or

in the fitting of additional accessories.

The following general guidelines have

been prepared to assist you in making

your determinations.

1. Any passenger should be thor-

oughly fa milia r with motorc ycle op-

eration. The passenger can affect

control of the motorcycle by im-

proper positioning during cornering

and sudden movements. It is impor-

tant that the passenger sit s till while

the motorcycle is in motion and not

interfere with the operation of the

motorcycle. Do not carry animals

on your motorcycle.

2. You should instruct any passenger

before riding to keep his feet on the

passenger footpegs and hold on to

the opera tor, sea t st rap or g rab ra il.

Do not ca rry a passenge r unless he

or she is tall enough to reach the

footpegs and footpegs are provided.

3. All baggage should be carried as

low a s possible to reduce the effect

on the motorcycle center of gravity.

Baggage weight should also be dis-

tributed equally on both sides of the

motorcycle. Avoid carrying baggage

that extends beyond the rear of the

motorcycle.

4. Baggage should be securely at-

tached. M ake sure that the baggage

will not m o ve around while you are

riding. Recheck baggage security

as often as possible (not while the

motorcycle is in m o tion) and adjust

as necessary.

5. Do not carry heavy or bulky items on

a luggage rack. They are designed

for light items, and overloading can

affect handling due to changes in

weight distribution and aerodynamic

forces.

LOADING AND ACCESSORIES INFORMATION 19

6. Do not install accessories or carry

baggage that impairs the perfor-

mance of the motorcycle. Make

sure that you have not adversely

affected any lighting components,

road clea ran ce , banking capability

(i.e., lean angle), control operation,

wheel travel, front fork movement,

or any othe r aspect of the m ot orcy-

cle’s operation.

7. Weight attached to the handlebar or

front fork will increase the mass of

thesteeringassemblyandcanre-

sult in an unsafe riding condition.

8. Fairings, windshields, backrests,

and other large items have the ca-

pability o f adversely affecting stabil-

ity and handling of the motorcycle,

not only because of their weight, but

also due to the aerodynamic forces

acting on these surfaces while the

motorcycle is in op e ra tio n . Po orly

designed or installed items can re-

sult in an unsafe riding condition.

9. This motorcycle was not intended

to be equipped with a sidecar or to

be used to tow any trailer or other

vehicle. Kawasaki does not manu-

facture sidecars or trailers for m o-

torcycles and cannot predict the ef-

fects of such accessories on han-

dling or stability, but can only warn

thattheeffectscanbeadverseand

that Kawasaki cannot assume re-

sponsib ility for the results of suc h

unintended use of the motorcycle.

Furthermore, any adverse effects on

motorcycle components caused by

the use of such accessories will not

be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,

and accessories must not exceed 180 kg

(397 lb).

20 GENERAL INFORMATION

GENERAL INFORMATION

Meter Instruments

A. MODE Button

B. Neutral Indicator Light

C. Left Turn Signal Indica tor

Light

D. Tachometer

E. ABS Indicator Light (Only

on ER650-B)

F. FI Indicator Light

G. Fuel Level Warning Light

H. Warning Light

I. Red Zone

J. Right Turn Signal Indicator

Light

K. High Beam Indicator Light

L. RESET Button

M. LCD (Speedometer, Clock,

Trip meter A/B, Odometer,

Warning S ymbols)

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Kawasaki MOTORCYCLE Owner's manual

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