Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year)

FUEL SYSTEM (DFI) 3-103

Throttle Body Assy

Throttle Body Assy Disassembly

CAUTION

Do not remove, disassemble or adjust the main
throttle sensor [A], subthrottle sensor [B], sub-
throttle valve actuator [C], throttle link mechanism
[D] and throttle body assy [E], because they are
adjusted or set at the manufacturer. Adjustment
of these parts could result in poor performance,
requiring replacement of the throttle body assy.

CAUTION

Never drop the throttle body assy , especially on a
hard surface. Such a shock to the body assy can
damage it.

•

Remove:

Throttle Body Assy (see Throttle Body Assy Removal)
Screws [A]
Delivery Pipe [B]
Fuel Injectors [C]

Throttle Body Assy Assembly

•

Replace the O-rings [A] and seals [B] with the new ones.

•

Before assembling, blow away dirt or dust from the throttle
body and delivery pipe by applying compressed air.

•

Apply engine oil to the new O-rings of each injector [C],
insert them into the delivery pipe and confirm whether the
injectors turn smoothly or not.

•

Install the injectors along with the delivery pipe assy into
the throttle bodies.

•

Install the throttle body assy (see Throttle Body Assy In-
stallation).

3-104 FUEL SYSTEM (DFI)

Air Cleaner

Air Cleaner Element Removal/Installation

•

Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.

Air Cleaner Element Inspection

•

Remove the air cleaner element (see Air Cleaner Element
Replacement in the Periodic Maintenance chapter).

•

Visually inspect the element [A] for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment with a new one.

Air Cleaner Oil Draining

A drain hose is connected to the bottom of the air cleaner

to drain water or oil accumulated in the cleaner part.

•

Visually inspect the drain hose [A] for accumulation of wa-
ter or oil.
If any water or oil accumulates in the hose, remove the
plug [B] from the drain hose and drain it.

WARNING

Be sure to reinstall the plug in the drain hose after
draining. Oil on tires will make them slippery and
can cause an accident and injury.

Air Cleaner Housing Removal

•

Remove:

Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)
Inlet Air Temperature Sensor Connector [A]
Screws [B]
Cover [C]

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the breather hose [A] on the upper crankcase.

3-106 FUEL SYSTEM (DFI)

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF
and disconnect the battery (–) terminal.
To avoid fire, do not remove the fuel tank when the
engine is still hot. Wait until it cools down.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.

•

Turn the ignition switch and engine stop switch OFF.

•

Wait until the engine cools down.

•

Open the fuel tank cap [A] to lower the pressure in the
tank.

○

During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.

•

Remove:

Side Covers (see Side Cover Removal in the Frame
chapter)
Fuel Tank Bolts [A]

•

Draw the fuel out from the fuel tank with a commercially
available pump [A].

○

Use a soft plastic hose [B] as a pump inlet hose in order
to insert the hose smoothly.

○

Put the hose through the fill opening [C] into the tank and
draw the fuel out.

Front [D]

WARNING

The fuel could not be removed completely from the
fuel tank. Be careful for remained fuel spillage.

FUEL SYSTEM (DFI) 3-107

Fuel Tank

•

Disconnect:

Fuel Pump Lead Connector [A]
Fuel Level Sensor Lead Connector [B]

•

Remove the fuel tank breather hose and the fuel drain
hose from the fuel tank.

•

Be sure to place a piece of cloth around the fuel hose joint.

•

Insert a minus screwdriver [A] into the slit [B] on the joint
lock.

•

Turn the driver [A] to disconnect the joint lock [B].

•

Pull [C] the fuel hose joint [D] out of the outlet pipe.

CAUTION

When removing the fuel hose joint, do not apply
strong force to the outlet pipe on the fuel pump. The
pipe made from resin could be damaged.

WARNING

Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.

•

Close the fuel tank cap.

•

Remove the fuel tank [A], and place it on planks [B].

○

Do not apply the load to the fuel pump outlet portion [C]
especially the outlet pipe made from resin.

3-108 FUEL SYSTEM (DFI)

Fuel Tank

Fuel Tank Installation

•

Note the WARNING on the previous page (see Fuel Tank
Removal).

•

Route the hoses correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

•

Check that the rubber dampers [A] are on the frame and
the fuel tank.
If the dampers are damaged or deteriorated, replace
them.

•

Install the trim [A] on the fuel tank.

○

Align the trim end [A] with the hollow [B] of the fuel tank
as shown in the figure.

•

Insert [A] the fuel hose joint [B] straight onto the delivery
pipe until the hose joint clicks.

CAUTION

When installing the fuel hose joint, do not apply
strong force to the outlet pipe on the fuel pump. The
pipe made from resin could be damaged.

•

Push the joint lock [C] until it clicks.

•

Push and pull [A] the hose joint [B] back and forth more
than two times and make sure it is locked and does not
come off.

WARNING

Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.

If it comes off, reinstall the hose joint.

•

Connect the fuel pump lead, the fuel level sensor lead
connectors and the battery (–) cable terminal.

FUEL SYSTEM (DFI) 3-109

Fuel Tank

Fuel Tank and Cap Inspection

•

Visually inspect the gasket [A] on the tank cap for any
damage.
Replace the gasket if it is damaged.

•

Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank is not clogged. check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes
[D] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNING

Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger or
highly flammable liquids, do not use gasoline or
low-flash point solvents to clean the tank.

•

Remove:

Fuel Pump (see Fuel Pump Removal)

•

Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.

•

Draw the solvent out of the fuel tank.

•

Dry the tank with compressed air.

•

Install:

Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)

3-110 FUEL SYSTEM (DFI)

Evaporative Emission Control System (CAL and SEA Models)

The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Al-
though no adjustments are required, a thorough visual in-
spection must be made at the intervals specified by the Pe-
riodic Maintenance Chart.

Parts Removal/Installation

WARNING

CAUTION

If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.

•

To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.

•

Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.

Hose Inspection

•

Refer to the Evaporative Emission Control System In-
spection in the Periodic Maintenance chapter.

Separator Inspection

•

Refer to the Evaporative Emission Control System In-
spection in the Periodic Maintenance chapter.

FUEL SYSTEM (DFI) 3-111

Evaporative Emission Control System (CAL and SEA Models)

Separator Operation Test

WARNING

Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Do not smoke.
Turn the ignition switch OFF. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.

•

Connect the hoses to the separator, and install the sepa-
rator on the motorcycle.

•

Disconnect the breather hose from the separator, and in-
ject about 20 mL (0.68 US oz.) of gasoline [A] into the
separator [B] through the hose fitting.

•

Disconnect the fuel return hose [C] from the fuel tank [D].

•

Run the open end of the return hose into the container
and hold it level with the tank top [E].

•

Start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
with a new one.

Canister Inspection

•

Refer to the Evaporative Emission Control System In-
spection in the Periodic Maintenance chapter.

COOLING SYSTEM 4-1

Cooling System

Table of Contents

Exploded View........................................................................................................................

4-2

Coolant Flow Chart.................................................................................................................

4-4

Specifications .........................................................................................................................

4-6

Special Tools ..........................................................................................................................

4-7

Coolant ...................................................................................................................................

4-8

Coolant Deterioration Inspection.......................................................................................

4-8

Coolant Level Inspection...................................................................................................

4-8

Coolant Draining ...............................................................................................................

4-8

Coolant Filling ...................................................................................................................

4-8

Pressure Testing ...............................................................................................................

4-8

Cooling System Flushing ..................................................................................................

4-9

Coolant Reserve Tank Removal/Installation .....................................................................

4-9

Water Pump............................................................................................................................

4-10

Water Pump Removal .......................................................................................................

4-10

Water Pump Installation ....................................................................................................

4-10

Mechanical Seal Inspection ..............................................................................................

4-11

Water Pump Housing Disassembly ..................................................................................

4-11

Water Pump Housing Assembly .......................................................................................

4-12

Impeller Assembly.............................................................................................................

4-12

Pump Impeller Inspection .................................................................................................

4-12

Radiator ..................................................................................................................................

4-13

Radiator and Radiator Fan Removal ................................................................................

4-13

Radiator and Radiator Fan Installation .............................................................................

4-14

Radiator Inspection ...........................................................................................................

4-15

Radiator Cap Inspection ...................................................................................................

4-15

Radiator Filler Neck Inspection .........................................................................................

4-16

Thermostat .............................................................................................................................

4-17

Thermostat Removal.........................................................................................................

4-17

Thermostat Installation......................................................................................................

4-17

Thermostat Inspection ......................................................................................................

4-18

Hose and Pipes ......................................................................................................................

4-19

Hose Installation ...............................................................................................................

4-19

Hose Inspection ................................................................................................................

4-19

Water Temperature Sensor ....................................................................................................

4-20

Water Temperature Sensor Removal/Installation .............................................................

4-20

Water Temperature Sensor Inspection .............................................................................

4-20

COOLING SYSTEM 4-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Baffle Plate Bolts

5.9

0.60

52 in·lb

Radiator Bolt

1.5

Water Hose Clamp Screws

2.0

0.20

18 in·lb

Thermostat Housing Bolts

9.8

1.0

87 in·lb

Water Pump Cover Bolts

9.8

1.0

87 in·lb

Water Pump Drain Bolt

9.8

1.0

87 in·lb

Water Pump Impeller Bolt

9.8

1.0

87 in·lb

Water Temperature Sensor

1.2

106 in·lb

G: Apply grease.

HG: Apply high-temperature grease.

R: Replacement Parts

W: Apply water.

COOLING SYSTEM 4-5

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The

thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 80.5

∼

83.5°C (177

∼

182°F), the thermostat closes so that the

coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
When coolant temperature is more than 80.5

∼

83.5°C, the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 104°C (219°F), the radiator fan relay conducts to

operate the radiator fan. The radiator fan draws air through the radiator core when there is not suffi-
cient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
temperature is below 99°C (210°F), the fan relay opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine op-

erates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles

which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system

when the engine is running. When the pressure exceeds 112.3

∼

141.7 kPa (1.15

∼

1.45 kgf/cm²,

16.3

∼

20.5 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon

as pressure escapes, the valve closes, and keeps the pressure at 112.3

∼

141.7 kPa (1.15

∼

1.45

kgf/cm², 16.3

∼

20.5 psi). When the engine cools down, another small valve (vacuum valve) in the

cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum
valve opens and allows the coolant from the reserve tank to enter the radiator.

4-6 COOLING SYSTEM

Specifications

Item

Standard

Coolant Provided when Shipping

Type (Recommended)

Permanent type of antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)

Color

Green

Mixed Ratio

Soft water 50%, coolant 50%

Freezing Point

−35°C (−31°F)

Total Amount

1.2 L (1.3 US qt) (reserve tank full level, including radiator
and engine)

Radiator Cap

Relief Pressure

112.3

∼

141.7 kPa (1.15

∼

1.45 kgf/cm², 16.3

∼

20.5 psi)

Thermostat

Valve Opening Temperature

80.5

∼

83.5°C (177

∼

182°F)

Valve Full Opening Lift

8 mm (0.31 in.) or more at 95°C (203°F)

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•

Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).

•

Visually inspect the coolant [A] in the reserve tank.
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded.

If the coolant is

brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.

Coolant Level Inspection

•

Refer to the Coolant Level Inspection in the Periodic Main-
tenance chapter.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

Pressure Testing

•

Remove the radiator cap (see Coolant Change in the Pe-
riodic Maintenance chapter), and install a cooling system
pressure tester [A] on the filler neck [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

•

Build up pressure in the system carefully until the pres-
sure reaches 141.7 kPa (1.45 kgf/cm², 20.5 psi).

CAUTION

During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 141.7 kPa (1.45 kgf/cm², 20.5 psi).

•

Watch the gauge for at least 6 seconds.
If the pressure holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.

•

Remove the pressure tester, replenish the coolant, and
install the radiator cap.

COOLING SYSTEM 4-9

Coolant

Cooling System Flushing

Over a period of time, the cooling system accumulates

rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.

•

Drain the cooling system (see Coolant Change in the Pe-
riodic Maintenance chapter).

•

Fill the cooling system with fresh water mixed with a flush-
ing compound.

CAUTION

Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.

•

Warm up the engine, and run it at normal operating tem-
perature for about ten minutes.

•

Stop the engine, and drain the cooling system.

•

Fill the system with fresh water.

•

Warm up the engine and drain the system.

•

Repeat the previous two steps once more.

•

Fill the system with a permanent type coolant and bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).

Coolant Reserve Tank Removal/Installation

•

The coolant reserve tank is removed and installed dur-
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).

4-10 COOLING SYSTEM

Water Pump

Water Pump Removal

•

Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).

•

Remove:

Water Hose [A]
Water Pump Cover Bolts [B]
Water Pump Cover [C]

•

Shift the transmission into 1st gear.

•

While applying the rear brake, remove the water pump
impeller bolt [A].

•

Remove:

Impeller [B]
Water Pump Housing [C]

Water Pump Installation

•

Replace the water pump housing oil seal with a new one.

○

Press in the oil seal until it is bottomed.

○

Apply high-temperature grease to the outer circumfer-
ence of the oil seal.

•

Replace the O-rings [A] on the water pump housing with
new ones.

•

Apply grease to the O-rings and the lips of the oil seal [B].

•

Be sure that the dowel pin [A] is in position.

•

Install the water pump housing.

•

Install the impeller.

○

Apply water to the inside of the mechanical seal.

•

When installing the water pump impeller bolt, shift the
transmission into 1st gear and apply the rear brake.

•

Tighten:

Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

•

Replace the O-ring [A] on the water pump cover with a
new one and apply grease to it.

COOLING SYSTEM 4-11

Water Pump

•

Install the two dowel pins [A].

•

Install the water pump cover.

•

Tighten:

Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

•

Align the line [A] of the water pump cover and the white
paint mark [B] of the water hose.

•

Install the water hose clamp [C] so that the screw head
faces the front.

•

Tighten:

Torque - Water Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

•

Fill the radiator with the coolant (see Coolant Change in
the Periodic Maintenance chapter).

Mechanical Seal Inspection

•

Remove the impeller (see Water Pump Removal).

•

Visually inspect the mechanical seal.
If any one of the parts is damaged, replace the mechani-
cal seal as a unit.

○

The sealing seat and rubber seal may be removed easily
by hand.

Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal Diaphragm [C]

Water Pump Housing Disassembly

CAUTION

Be careful not to damage the sealing surface of the
mechanical seal.

•

Remove the water pump housing (see Water Pump Re-
moval).

•

Take the oil seal [A] out of the housing [B] with a hook [C].

•

Press the mechanical seal [A] out of the housing with a
bearing driver [B].

Special Tool - Bearing Driver Set: 57001-1129

4-12 COOLING SYSTEM

Water Pump

Water Pump Housing Assembly

•

Apply grease [A] to the new oil seal [B].

•

Press the oil seal into the housing with a bearing driver so
that the seal surface is flush [C] with the end of the hole.

○

Apply high-temperature grease to the outer circum-
ference [D] of the oil seal so that it will go into place
smoothly.

•

Press the new mechanical seal into the housing with the
oil seal driver [E] until its flange [F] touches the surface
[G] of the housing.

Special Tool - Oil Seal Driver: 57001-1660

Impeller Assembly

•

Clean the sliding surface of the mechanical seal with a
high-flash point solvent, and apply a little coolant to the
sliding surface to give the mechanical seal initial lubrica-
tion.

•

Apply coolant to the surfaces of the rubber seal [A] and
sealing seat [B], and install the rubber seal and sealing
seat into the impeller by pressing them by hand until the
seat stops at the bottom of the hole.

Pump Impeller Inspection

•

Remove the water pump cover (see Water Pump Re-
moval).

•

Visually check the impeller [A].
If the surface is corroded, or if the blades are damaged,
replace the impeller (see Water Pump Removal).

COOLING SYSTEM 4-15

Radiator

Radiator Inspection

•

Remove the radiator (see Radiator and Radiator Fan Re-
moval).

•

Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed,

carefully

straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.

CAUTION

When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage:
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface.
Run the steam gun, following the core fin direction.

Radiator Cap Inspection

•

Remove the radiator cap (see Coolant Change in the Pe-
riodic Maintenance chapter).

•

Check the condition of the bottom [A] and top [B] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.

•

Install the cap [A] on a cooling system pressure tester [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

•

Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and mea-
sure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

Standard:

112.3

∼

141.7 kPa (1.15

∼

1.45 kgf/cm², 16.3

∼

20.5 psi)

If the cap can not hold the specified pressure or if it holds
too much pressure, replace it with a new one.

4-18 COOLING SYSTEM

Thermostat

•

Align the line [A] of the thermostat housing and the white
paint mark [B] of the water hose [C].

•

Install the water hose clamp [D] as shown.

•

Tighten:

Torque - Water Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

•

Fill the radiator with coolant (see Coolant Change in the
Periodic Maintenance chapter).

Thermostat Inspection

•

Remove the thermostat (see Thermostat Removal), and
inspect the thermostat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.

•

To check valve opening temperature, suspend the ther-
mostat [A] in a container of water and raise the tempera-
ture of the water.

○

The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curate thermometer [B] in the water so that the heat sen-
sitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.

Thermostat Valve Opening Temperature

80.5

∼

83.5°C (177

∼

182°F)