- •Foreword
- •General Information Table of Contents
- •Inspection
- •Instrument
- •Model Identification
- •Technical Information - Cassette Type Transmission
- •Technical Information - Inlet Air Pressure Sensor
- •Inlet Solenoid Valve
- •Unit Conversion Table Prefixes for Units:
- •Units of Power:
- •Periodic Maintenance Table of Contents
- •Idle Speed Inspection ....................................................................................................... 2-18
- •Idle Speed Adjustment...................................................................................................... 2-18
- •Valve Clearance Inspection .............................................................................................. 2-21
- •Valve Clearance Adjustment............................................................................................. 2-23
- •Periodic Inspection
- •Basic Torque for General Fasteners
- •Specifications
- •Special Tools
- •Inside Circlip Pliers: 57001-143
- •Fuel System (dfi)
- •Idle Speed Inspection
- •Idle Speed
- •Idle Speed Adjustment
- •Evaporative Emission Control System (California Model)
- •Cooling System
- •Air Suction System
- •Engine Top End
- •Valve Clearance Inspection
- •Valve clearance adjustment chart inlet valve
- •Valve clearance adjustment chart exhaust valve
- •Wheels/Tires
- •(Over 130 km/h (80 mph))
- •Drive Train
- •Brake System
- •Suspensions
- •Steering System
- •Electrical System
- •Replacement Parts
- •Viscosity: sae 10w-40
- •1.9 L (2.0 us qt) (when filter is removed)
- •2.4 L (2.5 us qt) (when engine is completely dry) note
- •It does not reach to this tightening torque.
- •Fuel System (dfi) Table of Contents
- •Inquiries to Rider.................................................................................................................. 3-26
- •Inquiries to Rider............................................................................................................... 3-26
- •Terminal Names
- •Dfi Parts Location
- •Specifications
- •Special Tools and Sealant
- •Dfi Servicing Precautions
- •Dfi Servicing Precautions
- •Inquiries to Rider
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Engine Doesn’t Start, Starting Difficulty
- •Self-diagnosis Procedures
- •Service Code Clearing Procedures
- •How to Erase Service Codes
- •Backups
- •Idle Speed Standard: 1 300 ±50 r/min (rpm)
- •Inlet Air Pressure Sensor Removal
- •Inlet Air Pressure Sensor Installation
- •Inlet Air Pressure Sensor Input Voltage Inspection note
- •Inlet Air Pressure Sensor Input Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Inspection note
- •Inlet Air Pressure Sensor Output Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Connection to Adapter
- •Inlet Air Pressure Sensor Circuit
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Removal/Installation
- •Inlet Air Temperature Sensor Output Voltage Inspection note
- •Inlet Air Temperature Sensor Output Voltage Connections to ecu Connector
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Resistance Inspection
- •Inlet Air Temperature Sensor Circuit
- •Water Temperature Sensor (Service Code 14)
- •Water Temperature Sensor (Service Code 14)
- •Crankshaft Sensor (Service Code 21)
- •Speed Sensor (Service Code 24, 25)
- •Speed Sensor (Service Code 24, 25)
- •Vehicle-down Sensor (Service Code 31)
- •Vehicle-down Sensor Output Voltage Connections to Sensor
- •Vehicle-down Sensor Circuit
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Stick Coil Removal/Installation
- •Input Voltage at ecu
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Radiator Fan Relay (Service Code 56)
- •Subthrottle Valve Actuator (Service Code 62)
- •Subthrottle Valve Actuator (Service Code 62)
- •Input Voltage at Actuator
- •Air Switching Valve (Service Code 64)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Fi Indicator Light (led)
- •Inspection Flow Chart
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Ignition Switch off: Terminal 16 (br/w): 0 V
- •Needle Adapter Set: 57001-1457
- •Standard: Battery Voltage (12.8 V or more) for 3 seconds, and then 0 V.
- •Injector Output Voltage Connections to Injector #1
- •Injector Wiring Inspection
- •Injector Signal Test
- •Injector Resistance Inspection
- •Injector Resistance Connections to Injector
- •#1: W/r ←→ bl/r Terminal #2: w/r ←→ bl/g Terminal
- •Injector Unit Test
- •Injector Fuel Line Inspection
- •Injector Fuel Line Maximum Pressure Standard: 333 kPa (3.4 kgf/cm², 48 psi)
- •Idle Speed Inspection
- •Throttle Body Assy
- •Throttle Body Assy
- •Air Cleaner
- •Air Cleaner
- •Evaporative Emission Control System (California Model)
- •Evaporative Emission Control System (California Model)
- •Cooling System Table of Contents
- •Exploded View
- •Coolant Flow Chart
- •Specifications
- •Coolant
- •Coolant
- •Water Pump
- •Impeller Assembly
- •Thermostat
- •Thermostat
- •Hose and Pipes
- •Water Temperature Sensor
- •Engine Top End Table of Contents
- •Exhaust System
- •Exhaust System
- •Specifications
- •Special Tools and Sealant
- •Clean Air System
- •Clean Air System
- •Cylinder Head Cover
- •Cylinder Head Cover
- •Camshaft Chain Tensioner
- •Inlet 36.44 mm (1.4346 in.)
- •Valve Guide Removal
- •Valve Guide Installation
- •Valve-to-Guide Clearance Measurement (Wobble Method)
- •Throttle Body Holder
- •Muffler
- •Muffler
- •Clutch Table of Contents
- •Exploded View
- •Specifications
- •Clutch Lever and Cable
- •Clutch Lever and Cable
- •Clutch Cover
- •Engine Lubrication System Table of Contents
- •Exploded View
- •Engine Oil Flow Chart
- •Engine Oil and Oil Filter
- •Oil Pressure Relief Valve
- •Oil Pump
- •Oil Pump
- •Oil Pressure Measurement
- •Oil Pressure Switch
- •Engine Removal/Installation Table of Contents
- •Exploded View
- •Crankshaft/Transmission Table of Contents
- •Balancer
- •Balancer
- •Balancer Shaft Bearing Insert Selection
- •Ball Bearing, Needle Bearing, and Oil Seal
- •Wheels/Tires Table of Contents
- •Exploded View
- •Specifications
- •Service Limit:
- •Hub Bearing
- •Hub Bearing
- •Final Drive Table of Contents
- •Exploded View
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brakes Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brake Lever, Brake Pedal
- •Brake Disc
- •Brake Fluid
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Service Code Table
- •Suspension Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Special Tools
- •Viscosity: kayaba khl34-g10 or equivalent
- •Inner Tube Inspection
- •Rear Shock Absorber
- •Special Tools - Jack: 57001-1238
- •Rear Shock Absorber
- •Jack Attachment: 57001-1608
- •Steering Table of Contents
- •Exploded View
- •Special Tools
- •Steering
- •Handlebar
- •Handlebar
- •Frame Table of Contents
- •Inner Fairing Removal
- •Inner Fairing Installation
- •Side Covers
- •Seat Covers
- •Fenders
- •Fenders
- •Sidestand
- •Frame Cover
- •Electrical System Table of Contents
- •Specifications
- •Parts Location
- •Parts Location
- •Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)
- •Precautions
- •Electrical Wiring
- •Initial Charge
- •Interchange
- •Rotor Holder: 57001-1658
- •Interlock Operation Inspection
- •1St Check
- •2Nd Check
- •3Rd Check
- •Ic Igniter Inspection
- •Ignition System Circuit
- •Air Switching Valve
- •Air Switching Valve
- •Radiator Fan System
- •Indicator Lights Inspection
- •12 V 3.4 w Bulb (Other Side) → bl Lead Terminal Battery (–) → bk Lead Terminal
- •30 A Main Fuse Removal
- •15 A ecu Fuse Removal
- •Appendix Table of Contents
- •Engine Doesn’t Start, Starting Difficulty:
- •Poor Running at Low Speed:
- •Poor Running or No Power at High Speed:
- •Overheating:
- •Over Cooling:
- •Clutch Operation Faulty:
- •Gear Shifting Faulty:
- •Abnormal Engine Noise:
- •Valve noise:
- •Abnormal Drive Train Noise:
- •Battery Trouble:
- •Model application
Instrument
Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thor- oughly before using the meter. Incorrect values may lead to improper adjustments.
EX650A6F (United States and Canada) Left Side View
EX650A6F
(United States and Canada) Right Side View
Model Identification
EX650A6F (Europe) Left Side View
EX650A6F
(Europe) Right Side View
EX650B6F
Left Side View
EX650B6F Right Side View
Frame Number Engine Number
Items |
EX650A6F, EX650B6F |
Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass: EX650A6F
EX650B6F Curb Mass: Front: EX650A6F EX650B6F Rear: EX650A6F
EX650B6F Fuel Tank Capacity |
2 105 mm (82.9 in.) |
760 mm (29.9 in.) |
|
1 210 mm (47.6 in.) |
|
1 410 mm (55.5 in.) |
|
145 mm (5.7 in.) |
|
790 mm (31.1 in.) |
|
178 kg (392.5 lb) |
|
(CAL) 178.5 kg (393.6 lb) |
|
182 kg (401.3 lb) |
|
101 kg (222.7 lb) |
|
103 kg (227.1 lb) |
|
99 kg (216.1 lb) |
|
(CAL) 99.5 kg (219.4 lb) |
|
101 kg (222.7 lb) |
|
15.5 L (4.1 US gal.) |
|
Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing
Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration |
2.7 m (8.9 ft) |
4-stroke, DOHC, 2-cylinder |
|
Liquid-cooled |
|
83 × 60 mm (3.3 × 2.4 in.) |
|
649 cm³ (39.60 cu in.) |
|
11.3 : 1 |
|
53 kW (72 PS) @8 500 r/min (rpm), |
|
66 N·m (6.7 kgf·m, 49 ft·lb) @7 000 r/min (rpm), |
|
FI (Fuel Injection) KEIHIN TTK38 × 2 |
|
Electric starter |
|
Battery and coil (transistorized) |
|
Electronically advanced (digital igniter) |
|
From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 800 |
|
r/min (rpm) |
|
NGK CR9EIA-9 |
|
Left to right, 1-2 |
|
1-2 |
|
31° BTDC |
|
61° ABDC |
|
272° |
General Specifications
Items |
EX650A6F, EX650B6F |
Exhaust: Open Close Duration Lubrication System Engine Oil: Type
Viscosity Capacity |
50° BBDC 30° ATDC 260° Forced lubrication (semi-dry sump)
API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 2.4 L (2.5 US qt) |
Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio |
Gear |
2.095 (88/42) |
|
Wet multi disc |
|
6-speed, constant mesh, return shift |
|
2.438 (39/16) |
|
1.714 (36/21) |
|
1.333 (32/24) |
|
1.111 (30/27) |
|
0.966 (28/29) |
|
0.852 (23/27) |
|
Chain drive |
|
3.067 (46/15) |
|
5.473 @Top gear |
|
Frame Type Caster (Rake Angle) Trail Front Tire: Type Size Rim Size Rear Tire: Type Size Rim Size Front Suspension: Type Wheel Travel Rear Suspension: |
Tubular, diamond |
25° |
|
106 mm (4.2 in.) |
|
Tubeless |
|
120/70 ZR17 M/C (58W) |
|
17 × 3.50 |
|
Tubeless |
|
160/60 ZR17 M/C (69W) |
|
17 × 4.50 |
|
Telescopic fork |
|
120 mm (4.7 in.) |
Items |
EX650A6F, EX650B6F |
Type |
Swingarm |
Wheel Travel |
125 mm (4.9 in.) |
Brake Type: |
|
Front |
Dual discs |
Rear |
Single disc |
Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light Alternator: Type Rated Output |
12 V 10 Ah |
Semi-sealed beam |
|
12 V 55 W × 2/55 W (Hi/Lo) |
|
12 V 5/21 W |
|
Three-phase AC |
|
24 A/14 V @5 000 r/min (rpm) |
Specifications are subject to change without notice, and may not apply to every country.
