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

BRAKES 12-5

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Front Brake Reservoir Cap Screws

1.5

0.15

13 in·lb

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Front Master Cylinder Clamp Bolts

1.1

97 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Brake Hose Banjo Bolts

2.5

Caliper Bleed Valve

7.8

0.80

69 in·lb

Front Caliper Mounting Bolts

3.5

Brake Disc Mounting Bolts

2.8

10. Other than EUR and MY Models

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-7

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Brake Hose Banjo Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.7

Brake Pedal Bolt

8.8

0.90

78 in·lb

Caliper Bleed Valve

7.8

0.80

69 in·lb

Rear Caliper Mounting Bolts

2.5

Brake Disc Mounting Bolts

2.8

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-9

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Front Brake Reservoir Cap Screws

1.5

0.15

13 in·lb

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Front Master Cylinder Clamp Bolts

1.1

97 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Brake Hose Banjo Bolts

2.5

Brake Pipe Joint Nuts

1.8

Front Caliper Mounting Bolts

3.5

Caliper Bleed Valve

7.8

0.80

69 in·lb

10 Brake Disc Mounting Bolts

2.8

Front Wheel Rotation Sensor Bolt

2.0

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-11

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.7

Brake Hose Banjo Bolts

2.5

Brake Pipe Joint Nuts

1.8

Caliper Bleed Valve

7.8

0.80

69 in·lb

Rear Caliper Mounting Bolts

2.5

Brake Disc Mounting Bolts

2.8

Brake Pedal Bolt

8.8

0.90

78 in·lb

Rear Wheel Rotation Sensor Bolt

2.0

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

12-12 BRAKES

Specifications

Item

Standard

Service Limit

Brake Lever, Brake Pedal

Lever Position

5-way adjustable (to suit rider)

– – –

Lever Free Play

Non-adjustable

– – –

Pedal Position

About 40 mm (1.6 in.) below top of footpeg

– – –

Pedal Free Play

Non-adjustable

– – –

Brake Pads

Lining Thickness:

Front

4.5 mm (0.18 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Discs

Thickness:

Front

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

4.5 mm (0.18 in.)

Rear

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

4.5 mm (0.18 in.)

Runout

TIR 0.15 mm (0.0059 in.) or less

TIR 0.3 mm (0.01 in.)

Brake Fluid

Grade

DOT4

– – –

12-14 BRAKES

Brake Lever, Brake Pedal

Brake Lever Position Adjustment

The brake lever adjuster has 5 positions so that the brake

lever position can be adjusted to suit the operator’s hand.

•

Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B] on the lever holder.

○

The distance from the grip to the lever is minimum at num-
ber 5 and maximum at number 1.

Brake Pedal Position Inspection

•

Measure the brake pedal position [A].

Pedal Position

Standard:

About 40 mm (1.6 in.) below top of footpeg
[B]

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE

○

Usually it is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.

•

Remove:

Right Footpeg Stay (see Footpeg Stay Removal in the
Frame chapter)

•

Loosen the locknut [A] and turn the push rod with the hex
head [B] to achieve the correct pedal position.
If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the
pedal position will be within the standard range.

•

Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m

(1.7 kgf·m, 13 ft·lb)

•

Install the right footpeg stay (see Footpeg Stay Installation
in the Frame chapter).

•

Check the brake light switch operation (see Brake Light
Switch Operation Inspection in the Periodic Maintenance
chapter).

Brake Pedal Removal

•

Remove:

Right Footpeg Stay (see Footpeg Stay Removal in the
Frame chapter)
Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]

•

Remove the mounting bolt [E] and take out the brake
pedal.

BRAKES 12-15

Brake Lever, Brake Pedal

Brake Pedal Installation

•

Apply grease to the pivot shaft [A].

•

Install:

Washer [B]
Brake Pedal [C]
Washer [D]

•

Tighten:

Torque - Brake Pedal Bolt [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install the following parts as shown in the figure.

Return Spring [A]
Rear Brake Light Switch Spring [B]

•

Install the joint pin [A].

•

Replace the cotter pin with a new one.

•

Insert the cotter pin [B] and bend the pin ends as shown.

•

Install the right footpeg stay (see Footpeg Stay Installation
in the Frame chapter).

•

Check the brake pedal position (see Brake Pedal Position
Inspection).

12-16 BRAKES

Calipers

Caliper Removal

CAUTION

Immediately wipe up any brake fluid that spilled.

NOTE

○

If the caliper is to be disassembled after removal and
compressed air is not available, disassemble the caliper
before brake hose removal (see Caliper Rubber Parts
Replacement in the Periodic Maintenance chapter).

Front Brake

•

Loosen the banjo bolt [A] so as not to spill brake fluid.

•

Remove the caliper mounting bolts [B].

•

Remove the banjo bolt and take off the brake hoses from
the caliper.

Rear Brake

•

Loosen the banjo bolt [A] so as not to spill brake fluid.

•

Remove the caliper mounting bolts [B].

•

Remove the banjo bolt and take off the brake hose from
the caliper.

Caliper Installation

•

Install the caliper(s), and tighten the bolts.

Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

Rear Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

•

Install the brake hose lower end.

○

Replace the washers [A] on each side of hose fitting [B]
with new ones.

•

Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

BRAKES 12-17

Calipers

•

Check the fluid level in the brake reservoirs (see Brake
Fluid Level Inspection in the Periodic Maintenance chap-
ter).

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

WARNING

Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal and the pads are against the
disc. The brakes will not function on the first appli-
cation of the lever or pedal if this is not done.

Front Caliper Disassembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Front Caliper Assembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Rear Caliper Disassembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Rear Caliper Assembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Caliper Fluid Seal Damage Inspection

The fluid seal (piston seal) [A] is placed around the pis-

ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem-
perature of the discs or the brake fluid to increase.

•

Replace the fluid seal(s) if it exhibits any of the conditions
listed below.

○

Brake fluid leakage around the pad.

○

Brakes overheat.

○

Considerable difference in inner and outer pad wear.

○

Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal(s) [B] as
well. Also, replace all seals every other time the pads are
changed.

12-18 BRAKES

Calipers

Caliper Dust Seal Damage Inspection

•

Check that the dust seal(s) [A] are not cracked, worn,
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.

Piston(s) [B]
Fluid Seal(s) [C]

Caliper Dust Boot and Friction Boot Damage
Inspection

•

Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.

BRAKES 12-19

Calipers

Caliper Piston and Cylinder Damage Inspection

•

Visually inspect the piston(s) [A] and cylinder surface(s)
[B].
Replace the caliper if the cylinder and piston are badly
scores or rusty.

Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder

shaft [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.

•

Check to see that the caliper holder shaft is not badly worn
or stepped, and that the friction boot [B] is not damaged.
If the friction boot is damaged, replace the friction boot. To
replace the friction boot, remove the pads and the caliper
holder.
If the caliper holder shaft is damage, replace the caliper
holder.

12-20 BRAKES

Brake Pads

Front Brake Pad Removal

•

Remove the front caliper with the hose installed (see
Caliper Removal).

•

Draw out the holder shaft pin [A], and take off the holder
shaft [B].

•

Remove the pad [C] from the holder shaft [D].

•

Remove the other side pad [E].

Front Brake Pad Installation

•

Push the caliper pistons in by hand as far as they will go.

•

Install the pad spring in its correct position.

•

Install the pad on the piston side first, then install the other
pad on the holder.

•

Install the front caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.

Rear Brake Pad Removal

•

Remove the rear caliper with the hose installed (see
Caliper Removal).

•

Draw out the holder shaft pin [A], and take off the holder
shaft [B].

•

Remove the pad [C] from the holder shaft [D].

•

Remove the other side pad [E].

Rear Brake Pad Installation

•

Push the caliper piston in by hand as far as it will go.

•

Install the pad spring in its correct position.

•

Install the pad on the piston side first, then install the other
pad on the holder.

•

Install the rear caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
and the pads are against the disc. The brake will not
function on the first application of the pedal if this
is not done.

Brake Pad Wear Inspection

•

Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.

BRAKES 12-21

Master Cylinder

Front Master Cylinder Removal

•

Remove the banjo bolt [A] to disconnect the brake hose
from the master cylinder [B].

•

Disconnect the front brake light switch connectors [A].

•

Unscrew the clamp bolts [B], and take off the master cylin-
der as an assembly with the reservoir, brake lever and
brake switch installed.

CAUTION

Immediately wipe up any brake fluid that spilled.

•

Remove:

Brake Lever Pivot Bolt [A] and Locknut [B]
Brake Lever [C]
Front Brake Light Switch [D]

Front Master Cylinder Installation

•

Install the front master cylinder.

○

Align the punch mark [A] of the handlebar with the mating
surface [B] of the master cylinder clamp.

•

Tighten the upper clamp bolt [A] first, and then the lower
clamp bolt [B]. There will be a gap at the lower part of the
clamp after tightening.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1

kgf·m, 97 in·lb)

•

Connect the front brake light switch connectors [C].

•

Replace the washers on each side of the hose fitting with
new ones.

•

Tighten:

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

12-22 BRAKES

Master Cylinder

Rear Master Cylinder Removal

•

Unscrew the brake hose banjo bolt [A] on the master cylin-
der.

•

Unscrew the master cylinder mounting bolts [A].

•

Remove the cotter pin [B].

•

Pull off the joint pin [C] while pressing down the brake
pedal.

•

Pull off the reservoir hose lower end [D], and drain the
brake fluid into a container.

•

Remove the master cylinder.

Rear Master Cylinder Installation

•

Install the joint pin.

•

Replace the cotter pin with a new one.

•

Insert the cotter pin, and bend the pin ends.

•

Replace the washers on each side of hose fitting with new
ones.

•

Tighten:

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

Front Master Cylinder Disassembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

Master Cylinder Assembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

BRAKES 12-23

Master Cylinder

Master Cylinder Inspection

•

Remove the master cylinders (see Front/Rear Master
Cylinder Removal).

•

Disassemble the front and rear master cylinders.

•

Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.

•

Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.

•

Check the dust covers [E] for damage.
If they are damaged, replace them.

•

Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.

•

Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.

Front Master Cylinder [J]
Rear Master Cylinder [K]

12-24 BRAKES

Brake Disc

Brake Disc Removal

•

Remove the wheel (see Front/Rear Wheel Removal in the
Wheels/Tires chapter).

•

Unscrew the mounting bolts [A], and take off the disc.

•

For front brake disc, remove the gaskets.

Brake Disc Installation

•

For front brake disc, replace the gaskets with new ones.

•

Install the brake disc on the wheel so that the marked side
[A] faces out.

•

Apply a non-permanent locking agent to the threads of
the front and rear brake disc mounting bolts.

•

Tighten:

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear Inspection

•

Measure the thickness of each disc at the point where it
has worn the most.
If the disc has worn past the service limit, replace it.

Measuring Area [A]

Disc Thickness

Standard:

Front

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

Rear

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

Service Limit:

Front

4.5 mm (0.18 in.)

Rear

4.5 mm (0.18 in.)

Brake Disc Warp

•

Raise the wheel off the ground (see Front/Rear Wheel
Removal in the Wheels/Tires chapter).

○

For front disc inspection, turn the handlebar fully to one
side.

•

Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.

Disc Runout

Standard:

TIR 0.15 mm (0.0059 in.) or less

Service Limit:

TIR 0.3 mm (0.01 in.)

BRAKES 12-25

Brake Fluid

Brake Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.

Brake Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.

WARNING

Be sure to bleed the air from the brake line when-
ever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or when-
ever a brake line fitting has been loosened for any
reason.

NOTE

○

The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.

•

Remove the reservoir cap and diaphragm.

•

Fill the reservoir with fresh brake fluid to the upper level
line [A].

•

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.

○

Bleed the air completely from the master cylinder by this
operation.

•

Remove the rubber cap [A] on the caliper.

•

Attach a clear plastic hose [B] to the bleed valve [C], and
run the other end of the hose into a container.

12-26 BRAKES

Brake Fluid

•

Bleed the brake line and the caliper.

○

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

○

The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.

○

Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.

○

Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.

•

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13in·lb)

•

For rear brake, follow the procedure below to install the
rear reservoir cap correctly.

○

First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

•

Tighten the bleed valve, and install the rubber cap.

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).

•

After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.

BRAKES 12-27

Brake Fluid

WARNING

When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in

the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of

time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong

wind is blowing.

6. Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterio-
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful that

no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.

8. Brake fluid quickly ruins painted surfaces; any

spilled fluid should be completely wiped up imme-
diately.

9. If any of the brake line fittings or the bleed valve is

opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.

BRAKES 12-31

Anti-Lock Brake System (Equipped Models)

ABS System Wiring Diagram

1. Ignition Switch
2. ABS Hydraulic Unit
3. ABS Self-diagnosis Terminal
4. ABS Kawasaki Diagnostic System Connec-

tor

5. Front Wheel Rotation Sensor
6. Rear Wheel Rotation Sensor
7. ABS Solenoid Valve Relay Fuse 25 A
8. ABS Motor Relay Fuse 30 A

9. Frame Ground

10. Water-proof Joint C

11. Meter Unit

12. Front Brake Light Switch
13. Ignition Fuse 10 A
14. Main Fuse 30 A
15. Battery 12 V 10 Ah
16. Frame Ground
17. Rear Brake Light Switch

○

Color Codes:

BK: Black

BL: Blue

BR: Brown

G: Green

GY: Gray

O: Orange

P: Pink

R: Red

W: White

Y: Yellow

12-32 BRAKES

Anti-Lock Brake System (Equipped Models)

Terminal Names

1. Ground to Motor
2. Power Supply to ABS Motor Relay
3. Power Supply to ABS Solenoid Valve Relay
4. Ground
5. Front Wheel Rotation Sensor Signal
6. Unused
7. Power Supply to Rear Wheel Rotation Sensor
8. Unused
9. Unused

10. Unused

11. ABS Kawasaki Diagnostic System Terminal

12. ABS Indicator Light (LED)
13. Unused
14. Unused
15. Unused
16. Power Supply to Front Wheel Rotation Sensor
17. Unused
18. Power Supply
19. Rear Wheel Rotation Sensor Signal
20. Front Brake Light Switch
21. Rear Brake Light Switch
22. Unused
23. Unused
24. Unused
25. ABS Self-diagnosis Terminal
26. Unused

BRAKES 12-33

Anti-Lock Brake System (Equipped Models)

ABS Servicing Precautions

There are a number of important precautions that should

be followed servicing the ABS system.

○

This ABS system is designed to be used with a 12 V
sealed battery as its power source.

Do not use any

other battery except for a 12 V sealed battery as a power
source.

○

Do not reverse the battery cable connections. This will
damage the ABS hydraulic unit.

○

To prevent damage to the ABS parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON or while the engine is
running.

○

Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.

○

Do not turn the ignition switch ON while any of the ABS
electrical connectors are disconnected.

The ABS hy-

draulic unit memorizes service codes.

○

Do not spray water on the electrical parts, ABS parts, con-
nectors, leads and wiring.

○

If a transceiver is installed on the motorcycle, make sure
that the operation of the ABS system is not influenced
by electric wave radiated from the antenna. Locate the
antenna as far as possible away from the ABS hydraulic
unit.

○

Whenever the ABS electrical connections are to be dis-
connected, first turn off the ignition switch.

○

The ABS parts should never be struck sharply, as with
a hammer, or allowed to fall on a hard surface. Such a
shock to the parts can damage them.

○

The ABS parts cannot be disassembled. Even if a fault is
found, do not try to disassemble and repair the ABS parts,
replace it.

○

The ABS has many brake lines, pipes, and leads. And
the ABS cannot detect problems with the conventional
braking system (brake disc wear, unevenly worn brake
pad, and other mechanical faults). To prevent trouble,
check the brake lines and pipes for correct routing and
connection, the wiring for correct routing, and the brakes
for proper braking power. Be sure to check for fluid leak-
age, and bleed the brake line thoroughly.

WARNING

If any of the brake line fittings, including the ABS
hydraulic unit joint nuts, or the bleed valve is
opened at any time, the air must be bled completely
from the brake line.

CAUTION

Do not ride the motorcycle with air in the brake line,
or the ABS could malfunction.

12-34 BRAKES

Anti-Lock Brake System (Equipped Models)

○

The ABS indicator light (LED) [A] may light if the tire pres-
sure is incorrect, a non-recommended tire is installed, or
the wheel is deformed. If the indicator light lights, remedy
the problem and clear the service code.

WARNING

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

○

The ABS indicator light (LED) may come on if the engine
is run with the motorcycle on its stand and the transmis-
sion in gear. If the indicator light comes on, just turn the
ignition switch OFF, then clear service code 42, which in-
dicates a “Faulty front wheel rotation sensor”.

○

When the ABS operates, the ABS makes noise and the
rider feels the reaction force on the brake lever and brake
pedal. This is a normal condition. It informs the rider that
the ABS is operating normally.

○

Service codes detected once by the ABS hydraulic unit
will be memorized in the ABS hydraulic unit. Therefore,
after maintenance work is finished, be sure to erase the
service codes. Do not erase the service codes during
troubleshooting. Wait until all the checks and repair work
are finished to prevent duplication of previous service
codes and unnecessary maintenance work.

○

Before delivering the motorcycle to the customer, be
sure to erase any service codes which might be stored
in the ABS hydraulic unit.

Using the self-diagnosis

feature, make sure that only start code 12 is shown. A
fully charged battery is a must for conducting reliable
self-diagnosis.

Test run the motorcycle at a speed of

more than 20 km/h (12 mph) to see that the ABS indicator
light (LED) does not come on. Finally, test run the mo-
torcycle at a speed of more than 30 km/h (20 mph) and
brake suddenly to see that the motorcycle stops without
loss of steering control and the ABS operates normally
(The reaction force generated is felt in the brake lever
and pedal.). This completes the final inspection.

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 12