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

ELECTRICAL SYSTEM 16-43

Ignition System

Interlock Operation Inspection

•

Raise the rear wheel off the ground with a stand.

1st Check

•

Start the engine to the following conditions.

Condition

Transmission Gear

→

1st Position

Clutch Lever

→

Release

Sidestand

→

Down or Up

○

Turn the ignition switch ON and push the starter button.

○

Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
neutral switch and relay box.
If their parts are normality, replace the ECU.

2nd Check

•

Start the engine to the following conditions.

Condition

Transmission Gear

→

1st Position

Clutch Lever

→

Pulled in

Sidestand

→

○

Turn the ignition switch ON and push the starter button.

○

Then the starter motor should turn when the starter sys-
tem circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, neutral switch and relay box.
If their parts are normality, replace the ECU.

3rd Check

•

Inspect the engine for its secure stop after the following
operations are completed.

•

Run the engine to the following conditions.

Condition

Transmission Gear

→

1st Position

Clutch Lever

→

Pulled in

Sidestand

→

•

Set the sidestand on the ground, then the engine will stop.
If whichever may not be stopped, inspect the neutral
switch, starter lockout switch, sidestand switch and relay
box.
If their parts are normality, replace the ECU.

16-46 ELECTRICAL SYSTEM

Ignition System

Ignition System Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Spark Plugs
4. Stick Coils
5. Speed Sensor
6. Subthrottle Sensor
7. Main Throttle Sensor
8. Water-proof Joint D
9. Vehicle-down Sensor

10. Water-proof Joint E

11. Water Temperature Sensor

12. Neutral Switch
13. Crankshaft Sensor
14. Oxygen

Sensor

(Equipped

Models)

15. Frame Ground
16. Water-proof Joint C
17. Meter Unit
18. Water-proof Joint B
19. Starter Lockout Switch
20. Oxygen Sensor Heater Fuse

10 A

21. ECU Fuse 15 A
22. Ignition Fuse 10 A
23. Fuse Box
24. ECU Main Relay
25. Relay Box
26. Main Fuse 30 A
27. Battery 12 V 10 Ah
28. Frame Ground
29. Sidestand Switch
30. Joint Connector
31. ECU

ELECTRICAL SYSTEM 16-47

Electric Starter System

Starter Motor Removal

CAUTION

Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)

•

Slide out the rubber cap [A].

•

Remove the starter motor cable terminal nut [B].

•

Remove the mounting bolts [C].

•

Pull out the starter motor [D].

Starter Motor Installation

CAUTION

Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

•

When installing the starter motor, clean the starter mo-
tor legs [A] and crankcase [B] where the starter motor is
grounded.

•

Replace the O-ring [A] with a new one.

•

Apply grease to the O-ring.

•

Apply a non-permanent locking agent to the threads of
the bolts and tighten the bolts.

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install the starter motor cable [A] as shown.

About 20° [B]
Front [C]

•

Tighten:

Torque - Starter Motor Terminal Nut: 6.0 N·m (0.61 kgf·m,

53 in·lb)

•

Slide back the rubber cap to the original position.

16-48 ELECTRICAL SYSTEM

Electric Starter System

Starter Motor Disassembly

•

Remove the starter motor (see Starter Motor Removal).

•

Take off the starter motor through bolts [A] and remove
the both end covers [B].

•

Pull out the armature [A] out of the yoke [B].

NOTE

○

Do not remove the circlip [C] from the shaft.

•

Remove the starter motor terminal locknut [A].

•

Pull out the brushes from the brush holder [A].

•

Remove:

Brush Springs [B]
Starter Motor Terminal [C]
Positive Brush Assembly [D]
Screw [E]
Negative Brush Assembly [F]
Brush Holder

Starter Motor Assembly

•

Be sure that the stopper [A] is in position.

•

Align the hole [B] of the brush holder [C] to the boss [D]
of the right-hand end cover [E].

ELECTRICAL SYSTEM 16-49

Electric Starter System

•

Align the stoppers [A] of the negative brush assembly [B]
to the grooves [C] of the brush holder [D].

•

Tighten the screw securely.

•

Align the stoppers [A] of the positive brush assembly [B]
to the grooves [C] of the brush holder [D].

•

Install the starter motor terminal.

•

Replace the O-ring [A] with a new one.

•

Install the following parts to the starter motor terminal [B].

New O-ring
Collar [C]
Washer [D]
Starter Motor Terminal Locknut [E]

○

Install the collar so that stepped side faces outward.

•

Tighten:

Torque - Starter Motor Terminal Locknut:

11 N·m (1.1

kgf·m, 97 in·lb)

•

Install the brush springs [A] and insert the brushes [B].

•

Apply thin coat of grease to the oil seal [A].

16-50 ELECTRICAL SYSTEM

Electric Starter System

•

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

•

Insert the armature [B] so that commutator side [C] faces
hollow side [D] of the yoke [E].

•

Align the marks [A] to assembly the yoke and the end
covers [B].

•

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

•

Tighten the through bolts [B].

Torque - Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m,

44 in·lb)

Brush Inspection

•

Measure the length of each brush [A].
If any is worn down to the service limit, replace the brush
assembly.

Starter Motor Brush Length

Standard:

12 mm (0.47 in.)

Service Limit: 6.5 mm (0.26 in.)

Commutator Cleaning and Inspection

•

Clean the metallic debris off the between commutator
segments [A].

NOTE

○

Do not use emery or sand paper on the commutator.

•

Check the commutator for damage or abnormal wear.
Replace the starter motor with a new one if there is any
damage or wear.

•

Visually inspect the commutator segments for discol-
oration.
Replace the starter motor with a new one if discoloration
is noticed.

ELECTRICAL SYSTEM 16-51

Electric Starter System

Armature Inspection

•

Using the × 1

Ω

hand tester range, measure the resis-

tance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (

∞

) between any

two segments, a winding is open and the starter motor
must be replaced.

•

Using the highest hand tester range, measure the resis-
tance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.

NOTE

○

Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.

Brush Lead Inspection

•

Using the × 1

Ω

hand tester range, measure the resis-

tance as shown.

Terminal Bolt and Positive Brushes [A]
Right-hand End Cover and Negative Brushes [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an
open. Replace the brush assembly.

Right-hand End Cover Inspection

•

Using the highest tester range, measure the resistance
as shown.

Terminal Bolt and Right-hand End Cover [A]
Terminal Bolt and Negative Brushes [B]

Special Tool - Hand Tester: 57001-1394

If there is any reading, the brush assy and/or terminal bolt
assy have a short. Replace the starter motor.

Starter Relay Inspection

•

Remove:

Battery Negative (–) Cable (see Battery Removal)
Bolt [A]
Cover [B]

16-52 ELECTRICAL SYSTEM

Electric Starter System

•

Disconnect:

Connector [A]
Starter Motor Cable [B]
Battery Positive (+) Cable [C]

•

Remove the starter relay.

CAUTION

The battery positive (+) cable with the rubber cap is
connected directly to the battery positive (+) termi-
nal even when the ignition switch off, so take care
not to short the removed cable to chassis ground.

•

Connect the hand tester [A] and 12 V battery [B] to the
starter relay [C] as shown.

Special Tool - Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defec-
tive. Replace the relay.

Testing Relay

Tester Range:

× 1

Ω

range

Criteria:

When battery is connected

→

Ω

When battery is disconnected

→ ∞ Ω

16-54 ELECTRICAL SYSTEM

Lighting System

This motorcycle adopt the daylight system and have a

headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.

Headlight Beam Horizontal Adjustment

•

Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.

Headlight Beam Vertical Adjustment

•

Refer to the Headlight Aiming Inspection in the Periodic
Maintenance chapter.

Headlight Bulb Replacement

•

Remove:

Headlight Connector [A]
Headlight Bulb Dust Cover [B]

•

Release the hook [A], and pull out the headlight bulb [B].

CAUTION

When handling the quartz-halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.

NOTE

○

Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.

•

Replace the headlight bulb with a new one.

•

Fit the projection [A] of the bulb in the hollow [B] of the
headlight.

•

Install the hook [C].

ELECTRICAL SYSTEM 16-55

Lighting System

•

Fit the dust cover [A] firmly onto the bulb so that the TOP
mark [B] is aligned with the arrow mark [C] on the head-
light.

•

After installation, adjust the headlight aim (see Headlight
Aiming Inspection in the Periodic Maintenance chapter).

City Light Bulb Replacement

•

Pull out the socket [A] together with the bulb.

•

Pull the bulb [A] out of the socket [B].

CAUTION

Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.

Do not use bulb rated for

greater wattage then the specified bulb.

•

Replace the bulb with a new one.

Headlight Removal

•

Remove:

Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Bolts [A]
Headlight [B]

Headlight Installation

•

Installation is the reverse of removal.

16-56 ELECTRICAL SYSTEM

Lighting System

Tail/Brake Light (LED) Removal

•

Remove:

Seat Cover (see Seat Cover Removal in the Frame
chapter)

•

Disconnect the tail/brake light lead connector [A]

•

Remove the nuts [A] and washers.

•

Remove the tail/brake light mounting bolts [A], and take
off the tail/brake light unit [B].

Tail/Brake Light (LED) Installation

•

Installation is the reverse of removal; note the following.

○

Tighten:

Clamp [A]

Torque - Tail/Brake Light Mounting Bolts [B]: 8.8 N·m (0.90

kgf·m, 78 in·lb)

License Plate Light Bulb Replacement

•

Remove:

Screws [A]
License Plate Light Cover [B]

ELECTRICAL SYSTEM 16-57

Lighting System

•

Pull the bulb [A] out of the socket [B].

CAUTION

Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.

Do not use bulb rated for

greater wattage then the specified valve.

•

Replace the bulb with a new one.

•

Install the license plate light cover.

Headlight/Tail Light Circuit

1. Ignition Switch
2. Frame Ground
3. Water-proof Joint C
4. Meter Unit
5. Water-proof Joint B
6. Water-proof Joint A
7. Right City Light
8. Headlight (High Beam)
9. Headlight (Low Beam)

10. Left City Light

11. Dimmer Switch

12. Passing Button (Equipped Models)
13. Fuse Box

14. Headlight Fuse 10 A
15. Tail Light Fuse 10 A
16. Headlight Circuit Relay
17. Relay Box
18. Starter Relay
19. Main Fuse 30 A
20. Battery 12 V 10 Ah
21. Frame Ground
22. Tail/Brake Light (LED)
23. License Plate Light
24. Joint Connector
25. Alternator

16-58 ELECTRICAL SYSTEM

Lighting System

Turn Signal Light Bulb Replacement

•

Unscrew the screw [A] and remove the lens [B].

•

Remove the bulb [A].

○

Push and turn counterclockwise the bulb.

•

Insert the new bulb [A] by aligning its pins [B] with the
grooves [C] in the socket, and turn the bulb clockwise.

•

Install the lens.

Turn Signal Relay Inspection

•

Remove:

Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Turn Signal Relay [A]

ELECTRICAL SYSTEM 16-59

Lighting System

•

Connect one 12 V battery and turn signal lights as indi-
cated in the figure, and count how may times the lights
flash for one minute.

Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]

If the lights do not flash as specified, replace the turn sig-
nal relay.

Testing Turn Signal Relay

Load

The Number of Turn

Signal Lights

Wattage (W)

Flashing Times

(c/m*)

1**

140

∼

250

∼

(*): Cycle(s) per minute

(**): Corrected to “one light burned out”.

ELECTRICAL SYSTEM 16-61

Air Switching Valve

Air Switching Valve Operation Test

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

Pull the air switching valve hose [A] out of the air cleaner
base.

•

Take the air switching valve hose end outside of the
frame.

•

Reinstall the fuel tank (see Fuel Tank Installation in the
Fuel System (DFI) chapter).

•

Start the engine and run it at idle speed.

•

Plug the air switching valve hose end [A] with your finger
and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve (see
Air Switching Valve Unit Test).

•

Apply a soap and water solution or rubber lubricant to the
end of the air switching valve hose and install the hose on
the fitting.

Air Switching Valve Unit Test

•

Remove the air switching valve (see Air Switching Valve
Removal in the Engine Top End chapter).

•

Set the hand tester [A] to the ×

Ω

range and connect it to

the air switching valve terminals as shown.

Special Tool - Hand Tester: 57001-1394

Air Switching Valve Resistance

Standard:

∼

Ω

at 20°C (68°F)

If the resistance reading is except the specified value, re-
place it with a new one.

•

Connect the 12 V battery [A] to the air switching valve
terminals as shown.

16-62 ELECTRICAL SYSTEM

Air Switching Valve

•

Blow the air to the inlet air duct [A], and make sure does
not flow the blown air from the outlet air duct [B].

•

Disconnect the 12 V battery.

•

Blow the air to the inlet air duct [A] again, and make sure
flow the blown air from the outlet air duct [B].
If the air switching valve does not operate as described,
replace it with a new one.

NOTE

○

To check air flow through the air switching valve, just
blow through the air cleaner hose [C].

ELECTRICAL SYSTEM 16-63

Radiator Fan System

Fan Motor Inspection

•

Disconnect the connector [A].

•

Using an auxiliary leads, supply battery power to the fan
motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.

Radiator Fan Circuit

1. Ignition Switch
2. Frame Ground
3. Water-proof Joint C
4. Water-proof Joint B
5. Water-proof Joint A
6. Fuse Box
7. Fan Fuse 15 A
8. ECU Fuse 15 A
9. Relay Box

10. Radiator Fan Relay

11. ECU Main Relay

12. Main Fuse 30 A
13. Battery 12 V 10 Ah
14. Frame Ground
15. Joint Connector
16. ECU
17. Water Temperature Sensor
18. Water-proof Joint E
19. Radiator Fan

16-64 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Meter Unit Removal/Installation

•

Remove:

Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Upper Fairing Covers (see Upper Fairing Cover Re-
moval in the Frame chapter)
Bolt [A] (Both Sides)

•

Remove:

Windshield (see Windshield Removal in the Frame
chapter)
Quick Rivets [A]
Meter Cover [B]

•

Slide out the dust cover [A], and disconnect the connector.

•

Remove the screws [B], and take off the center inner fair-
ing together with the meter unit.

•

Remove the screws [A] and washers, and separate the
meter unit [B] and the center inner fairing [C].

CAUTION

Place the meter unit so that the face is up. If a meter
unit is left upside down or sideways for any length
of time, it will malfunction.

•

Installation is the reverse of removal.

•

Tighten:

Torque - Meter Cover Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)

ELECTRICAL SYSTEM 16-65

Meter, Gauge, Indicator Unit

Meter, Gauge Disassembly

•

Remove:

Meter Unit (see Meter Unit Removal)
Screws [A]
Lower Meter Cover [B]

•

Separate the meter assembly [A] and upper meter cover
[B].

Electronic Combination Meter Unit Inspection

•

Remove the meter unit [A] (see Meter Unit Removal).

[1] High Beam Indicator Light (LED) (+)
[2] FI Indicator Light (LED) (–)
[3] Speed Sensor Signal
[4] Tachometer Signal
[5] ABS Indicator Light (LED) (EX650D Models)
[6] Oil Pressure Warning Indicator Light (LED) (–)
[7] Battery (+)
[8] Ground (–)
[9] Neutral Indicator Light (LED) (–)

[10] Right Turn Signal Indicator Light (LED) (+)

[11] Fuel Level Gauge

[12] Fuel Reserve Switch
[13] Left Turn Signal Indicator Light (LED) (+)
[14] Water Temperature Sensor
[15] Speed Sensor Supply Voltage
[16] Ignition

CAUTION

Do not drop the meter unit. Place the meter unit so
that it faces upward. If the meter unit is left upside
down or sideways for a long time or dropped, it will
malfunction. Do not short each terminals.

16-66 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Liquid Crystal Display (LCD) Segments Check

•

Using the auxiliary leads, connect the 12 V battery to the
meter unit connector as follows.

○

Connect the battery positive terminal to the terminal [7].

○

Connect the battery negative terminal to the terminal [8].

○

Anything does not happen, it is normal.

•

Connect the terminal [16] to the terminal [7].

○

When the terminals are connected, all the LCD segments
[A] and water temperature warning indicator light [B] ap-
pear for 3 seconds.

○

For models equipped with an ABS, the ABS indicator light
[C] appears.
If the LCD segments and water temperature warning in-
dictor light will not appear, replace the meter assembly.

•

Disconnect the terminal [16].

○

All the LCD segments disappear.
If the segments do not disappear, replace the meter as-
sembly.

ELECTRICAL SYSTEM 16-67

Meter, Gauge, Indicator Unit

MODE AND RESET BUTTON Operation Check

•

Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.

•

Check that the display change to the ODO, TRIP A
and TRIP B displays each time the MODE button [A] is
pressed.

○

If the fuel level gauge flashed, display change to FUEL,
ODO, TRIP A and TRIP B.
If the display function does not work, replace the meter
assembly.

•

Indicate the ODO mode.

•

Check that when the RESET button [A] in ODO mode
is pushed for more than two seconds, the meter display
turns to the clock set mode.

○

Both the hour and minute display start flashing.

•

In the HOUR/MINUTE setting mode, press the RESET
button again to effect the HOUR setting mode.

○

The hour display flashes on the display.

•

Press the MODE button to set the hour.

16-68 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

•

In the HOUR setting mode, press the RESET button to
effect the MINUTE setting mode.

○

The minute display flashes on the display.

•

Press the MODE button to set the minute.

•

In the MINUTE setting mode, press the RESET button to
return to the HOUR/MINUTE setting mode.

•

Press the MODE button to complete the time setting
process.

○

The clock starts counting the seconds as soon as the
MODE button is pressed.

•

Indicate the ODO mode.

•

Check that the display [A] change to the mile and km dis-
play each time by pushing the RESET button while MODE
button pushed in.

NOTE

○

Mile/Km display can alternate between English and
metric modes (mile and km) in the digital meter. Make
sure that km or mile according to local regulations is
correctly displayed before riding.

If the display function does not work and adjust, replace
the meter assembly.

Speedometer Check

•

Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.

•

The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave (illustrated as shown)
would be input into the terminal [3].

○

Indicates approximately 60 mph in case the input fre-
quency would be approximately 172.6 Hz.

○

Indicates approximately 60 km/h in case the input fre-
quency would be approximately 107.9 Hz.

•

If the oscillator is not available, the speedometer can be
checked as follows.

○

Install the meter unit.

○

Raise the rear wheel off the ground with stand.

○

Turn on the ignition switch.

○

Rotate the rear wheel by hand.

○

Check that the speedometer shows the speed.
If the speedometer does not work, check the speed sen-
sor electric source voltage and speed sensor.
If the electric source voltage and speed sensor are nor-
mal, replace the meter assembly.

ELECTRICAL SYSTEM 16-69

Meter, Gauge, Indicator Unit

Speed Sensor Electric Source Check

•

Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.

•

Set the hand tester to the DC 25 V range and connect it
to the terminals [15] and [8].

Special Tool - Hand Tester: 57001-1394

If the voltage is less than 9 V, replace the meter assembly.

Odometer Check

•

Check the odometer with the speedometer in the same
way.
If value indicated in the odometer is not added, replace
the meter assembly.

NOTE

○

The data is maintained even if the battery is discon-
nected.

○

When the figures come to 999999, they are stopped and
locked.

Trip A/B Meter Check

•

Check the trip A or B meters with the speedometer in the
same way.
If value indicated in the trip A/B meters is not added, re-
place the meter assembly.

•

Check that when the RESET button is pushed for more
than two seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the me-
ter assembly.

Tachometer Check

•

Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.

•

The revolutions per minute (rpm) equivalent to the input
frequency is indicated in the oscillator [A] if the square
wave (illustrated as shown) would be input into the termi-
nal [4].

○

Indicates approximately 4 000 rpm in case the input fre-
quency would be approximately 133.3 Hz.

16-70 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

•

If the oscillator is not available, the tachometer can be
checked as follows.

○

Connect the 12 V battery and terminals in the same man-
ner as specified in the "Liquid Crystal Display (LCD) Seg-
ments Check".

○

When the terminals are connected, the tachometer goes
and disappears from minimum to the maximum reading
momentarily. It goes again, and then the tachometer dis-
appears.
If the tachometer segments function does not work, re-
place the meter assembly.

○

Using the insulated auxiliary lead, quickly open and con-
nect the terminal [16] to the terminal [4] repeatedly.

○

Then the tachometer segments [A] should flick [B].
If the hand does not flick, replace the meter assembly.

Fuel Level Gauge Check

•

Connect the 12 V battery and terminals in the same man-
ner way as specified in the “Liquid Crystal Display (LCD)
Segments Check”.

•

Connect the variable rheostat [A] to the terminal [11] as
shown.

•

Check that the number of segments [A] matches the re-
sistance value of the variable rheostat.

○

When the terminal [11] is connected, one segment in the
fuel level gauge should appear about every 15 seconds.

Variable Rheostat

Resistance (

Ω

)

Display Segments

110

200

If the display function does not work, replace the meter
assembly.

Fuel Level Warning Check

•

Connect the 12 V battery and terminals in the same man-
ner way as specified in the “Liquid Crystal Display (LCD)
Segments Check”.

•

Connect the variable rheostat [A] to the terminal [12] as
shown.

•

Adjust the resistance value to the approximately 100

Ω

ELECTRICAL SYSTEM 16-71

Meter, Gauge, Indicator Unit

•

Check that one segment [A] in the fuel gauge starts flash-
ing.

•

Check that the FUEL segments [B] flashes in the LCD.
If the display function does not work, replace the meter
assembly.

Indicator Lights Inspection

•

Connect the 12 V battery and terminals in the same man-
ner as specified in the “Liquid Crystal Display (LCD) Seg-
ments Check”.

Left Turn Signal Indicator Light (LED) [A]
Right Turn Signal Indicator Light (LED) [B]
Neutral Indicator Light (LED) [C]
High Beam Indicator Light (LED) [D]
ABS Indicator Light (LED) (EX650D Models) [E]
Oil Pressure Warning Indicator Light (LED) [F]
FI Indicator Light (LED) [G]
Water Temperature Warning Indicator Light (LED) [H]

•

Using the auxiliary leads, connect a 12 V battery to the
meter unit connector as follows.

Water Temperature Warning Indicator Light (LED)

Battery Negative (–) Terminal to Terminal [14]

Oil Pressure Warning Indicator Light (LED)

Battery Negative (–) Terminal to Terminal [6]

16-72 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

High Beam Indicator Light (LED)

Battery Positive (+) Terminal to Terminal [1]

Neutral Indicator Light (LED)

Battery Negative (–) Terminal to Terminal [9]

Right and Left Turn Signal Indicator Light (LED)

For Right Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [10]

For Left Turn Signal Indicator Light (LED)
Battery Positive (+) Terminal to Terminal [13]

FI Indicator Light (LED)

Battery Negative (–) Terminal to Terminal [2]

If each lights (LED) does not go on, replace the meter
assembly.

ELECTRICAL SYSTEM 16-73

Meter, Gauge, Indicator Unit

EX650D Models
ABS Indicator Light (LED)

Battery Negative (–) Terminal to Terminal [5]

If the light (LED) keeps going on, replace the meter as-
sembly.

Meter Circuit

1. Ignition Switch
2. ABS Hydraulic Unit (ABS Equipped Models)
3. Frame Ground
4. Water-proof Joint C
5. Meter Unit
6. Fuse Box
7. ECU Fuse 15 A
8. Ignition Fuse 10 A
9. Main Fuse 30 A

10. Battery 12 V 10 Ah

11. Frame Ground

12. Fuel Reserve Switch
13. ECU
14. Oil Pressure Switch
15. Neutral Switch
16. Water Temperature Sensor
17. Water-proof Joint E
18. Speed Sensor
19. Fuel Level Sensor

16-74 ELECTRICAL SYSTEM

Switches and Sensors

Brake Light Timing Inspection

•

Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.

Brake Light Timing Adjustment

•

Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.

Switch Inspection

•

Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).

○

For the switch housings and the ignition switch, refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.

Special Tool - Hand Tester: 57001-1394

Rear Brake Light Switch Connections

Sidestand Switch Connections

Neutral Switch Connections

Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition.

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 17