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Quick Reference Guide

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) 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 delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.

•Removal of the muffler(s) or any internal portion of the muffler(s).

•Removal of the air box or air box cover.

•Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

LIST OF ABBREVIATIONS

COUNTRY AND AREA CODES

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

EX650A6F (United States and Canada) Left Side View

EX650A6F (United States and Canada) Right Side View

1-8 GENERAL INFORMATION

Model Identification

EX650A6F (Europe) Left Side View

EX650A6F (Europe) Right Side View

GENERAL INFORMATION 1-9

Model Identification

EX650B6F Left Side View

EX650B6F Right Side View

1-10 GENERAL INFORMATION

General Specifications

1-12 GENERAL INFORMATION

General Specifications

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

GENERAL INFORMATION 1-13

Technical Information — Cassette Type Transmission

Cassette Type Transmission

The transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves.

The EX650A/B enables transmission to be removed from the right side of engine as an assy, without disassembling crankcase halves (see Transmission Assy Removal in the Crankshaft/Transmission chapter).

Transmission Assy: Drive Shaft [A] Output Shaft [B] Shift Rods [C] Shift Dram [D] Shift Forks [E]

Transmission Case [F]

1-14 GENERAL INFORMATION

Technical Information — Inlet Air Pressure Sensor

Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A/B. As a substitute of these sensors above, the EX650A/B recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air pressure sensor.

The ECU detects atmospheric pressure when the ignition is switched ON. While the engine is running, the ECU also presumes atmospheric pressure by analyzing the waveform of boost pressure over fixed period. The intake stroke is recognized by waveform of boost pressure, therefore the system can recognize the difference of each stroke.

GENERAL INFORMATION 1-17

Technical Information – ABS (Anti – Lock Brake System)

Related Parts and Function

1.Front Wheel Rotation Sensor

2.Front Wheel Rotation Sensor Rotor

3.Rear Wheel Rotation Sensor

4.Rear Wheel Rotation Sensor Rotor

5.ABS Indicator Light (LED)

6.ABS Hydraulic Unit

7.ABS Fuse Box

8.ABS Kawasaki Self-diagnosis System Connector

Wheel Rotation Sensor

The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulic unit. The wheel rotation sensor is installed to the front fork and rear caliper bracket, and the sensor rotor is pressed into the brake disc. The number of teeth on the front and rear sensor rotor is 50.

ABS Indicator Light (LED)

The condition or the failure of the ABS system is indicated by various patterns of the ABS indicator light (LED) blinking.

1-18 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

ABS Hydraulic Unit

The outlet and inlet solenoid valves, reservoir, pump motor, solenoid valve relay, motor relay, and ECU are built in the ABS hydraulic unit.

1.Brake Lever

2.Brake Pedal

3.Pump Motor

4.Rear Inlet Solenoid Valve

5.Rear Outlet Solenoid Valve

6.Rear Reservoir

7.Rear Caliper

8.Front Inlet Solenoid Valve

9.Front Outlet Solenoid Valve

10.Front Caliper

11.Front Reservoir

12.Orifice

13.Filter

14.Check Valve

GENERAL INFORMATION 1-19

Technical Information – ABS (Anti – Lock Brake System)

Inlet Solenoid Valve

Inlet solenoid valves control the brake pressure of each wheel by combining the operation of the outlet solenoid valve. The ECU changes the electric current in the solenoids of the inlet solenoid valve (2 way, 2 position electromagnetic valve) to move the tappet and change the fluid pressure to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1.Increase Mode

2.Hold and Decrease Mode

3.Tappet

4.Valve Body

5.From Master Cylinder

Outlet Solenoid Valve

Outlet solenoid valves control the brake pressure of each wheel by combining the operation of the inlet solenoid valve. The ECU changes the electric current in the solenoids of the outlet solenoid valve (2 way, 2 position electromagnetic valve) to move the armature and change the fluid pressure to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1.Decrease Mode

2.Increase and Hold Mode

3.Armature

4.Valve

5.To Reservoir

1-20 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

Reservoir

When the passage opens between the caliper and the reservoir with the outlet solenoid valve in “Decrease Mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporarily, and then returns to the master cylinder. With the outlet solenoid valve “Increase or Hold Mode”, the pump returns the remaining brake fluid in the reservoir to the master cylinder.

1.From Outlet Solenoid Valve

2.To Pump

Pump Motor

The pump motor operates the pump, supply or return the brake fluid from the pump.

Pump

The pump operates continuously when the ABS is activated. The pump is driven by the motor and supply the brake fluid to the caliper or return the brake fluid in the reservoir to the master cylinder. The piston is reciprocated by the eccentric cam [A] on the end of the motor shaft and the pump sucks in or discharge the brake fluid.

When the pump pulls fluid in, the piston [B] is moved right by the force of the spring [C]. At this time, the spring [D] is compressed by the pressure of the brake fluid in the reservoir to open the inlet valve [E] and the brake fluid flows into the cylinder [F]. The outlet valve [G] is held closed by the force of the spring [H].

When the pump discharges the brake fluid, the inlet valve [E] is closed by the spring [D], and the piston [B] is moved left by the cam [A], producing pressure in the cylinder [F]. The pressure pushes the spring [H], opens the outlet valve [G], and the brake fluid returns to the master cylinder.

Spring [C]

GENERAL INFORMATION 1-21

Technical Information – ABS (Anti – Lock Brake System)

ABS Solenoid Valve Relay

ABS solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves.

ABS Motor Relay

ABS motor relay supply or intercept the power to the pump motor.

ECU

ECU inputs the sensor signal.

ECU calculates the wheel condition for the slip.

ECU controls the hydraulic unit.

ECU sends the actuating signals to the ABS indicator light (LED).

GENERAL INFORMATION 1-23

Technical Information – ABS (Anti – Lock Brake System)

(Hold Mode)

When the caliper fluid pressure is to be hold, the tappet of inlet solenoid valve closes, and the passage (master cylinder side) to the valve body is intercepted. No matter how hard the brake lever is pulled, the brake fluid pressure in the caliper is maintained at a given level.

1.Brake Lever

2.Front Inlet Solenoid Valve

3.Pump Motor

4.Pump

5.Front Reservoir

6.Front Outlet Solenoid Valve

7.Front Caliper

1-24 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

(Decrease Mode)

When the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and the passage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operation of the armature, and the brake fluid flows to the reservoir. ECU operates pump, and the pump returns the brake fluid in the reservoir to the master cylinder. The brake fluid pressure is decreased, and the wheel is prevented from locking.

1.Brake Lever

2.Front Inlet Solenoid Valve

3.Pump Motor

4.Pump

5.Front Reservoir

6.Front Outlet Solenoid Valve

7.Front Caliper

1-26 GENERAL INFORMATION

Technical Information – ABS (Anti – Lock Brake System)

Riding Characteristics of ABS

ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.

Brake control function is identical to that of a conventional motorcycle. The brake lever is used for the front brake and the brake pedal for the rear brake.

Although the ABS provides stability while stopping by preventing wheel lock-up, remember the following characteristics:

○ABS cannot compensate for adverse road conditions, misjudgement or improper application of brakes. You must take the same care as with motorcycles not equipped with ABS.

○ABS is not designed to shorten the braking distance. On loose, uneven or downhill surfaces, the stopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle without ABS. Use special caution in such areas.

○ABS will help prevent wheel lock-up during straight-up braking, but it cannot control wheel slip which may be caused by braking during cornering. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner.

○The ECU integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended tires can affect wheel speed, they may confuse the ECU, which can extend braking distance.

WARNING

Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking distance. The rider could have an accident as a result. Always use recommended standard tires for this motorcycle.

NOTE

○When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal. You need not suspend applying brakes.

○Immediately after turning the ignition switch on, you may hear a click of the relay operating. This is the sound of self-checking and is quite normal.

○ABS does not function at the speed of approx. 6 km/h or below. ○ABS does not function if the battery is discharged.

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.

L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

R:Replacement Parts

S:Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).

SS:Apply silicone sealant.

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

The table below, relating tightening torque to thread diameter, lists the basic torque for the 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.

Basic Torque for General Fasteners