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General| Engine Type | Liquid-cooled, 4-stroke Parallel Twin |
|---|---|
| Fuel System | Fuel injection: ø38 mm x 2 (Keihin) |
| Ignition | Digital |
| Frame Type | Diamond, high-tensile steel |
| Front Suspension | 41 mm telescopic fork |
| Front Tire | 120/70ZR17M/C (58W) |
| Rear Tire | 160/60ZR17M/C (69W) |
| Displacement | 649 cc |
| Bore x Stroke | 83.0 mm x 60.0 mm |
| Transmission | 6-speed, return |
| Final Drive | Chain |
| Rear Suspension | Offset laydown single-shock with adjustable preload |
| Front Brakes | Dual 300 mm petal discs |
| Rear Brakes | Single 220 mm petal disc |
| Wheelbase | 1, 410 mm |
| Fuel Capacity | 15.5 L |
| Maximum Power | 53 kW {72 PS} / 8, 500 rpm |
| Maximum Torque | 66 Nm (6.7 kgf·m) @ 7, 000 rpm |
Precautions and general procedures before starting inspection or disassembly.
Visual identification of the motorcycle model through side views.
Key technical specifications including dimensions, engine, drive train, frame, and electrical equipment.
Details on the transmission system and its removal from the engine.
Explanation of the inlet air pressure sensor and its role in engine management.
Outline of the ABS system, its components, and how it controls brake fluid pressure.
Table for converting various units of measurement used in the manual.
Scheduled maintenance tasks categorized by frequency and odometer reading.
Schedule for replacing parts based on time intervals or odometer readings.
List of tightening torques and recommended locking agents for major fasteners.
Illustrated breakdown of DFI system components and their assembly.
Overview of the Digital Fuel Injection system.
Visual guide to the location of DFI system components on the motorcycle.
Detailed standard and service limit specifications for DFI system components.
List of specialized tools and sealants for DFI system servicing.
Important safety and handling precautions to be followed when servicing the DFI system.
Guide for diagnosing and resolving common problems within the DFI system.
Procedures for accessing and interpreting diagnostic trouble codes from the ECU.
Illustrated breakdown of cooling system components.
Standard values and service limits for cooling system components.
List of specialized tools for cooling system maintenance.
Information on coolant properties, inspection, draining, filling, and pressure testing.
Procedures for removing, installing, and inspecting the water pump and its components.
Steps for removing, installing, and inspecting the radiator and its related parts.
Procedures for removing, installing, and inspecting the thermostat.
Instructions for installing and inspecting hoses and pipes within the cooling system.
Procedures for removing, installing, and inspecting the water temperature sensor.
Illustrated breakdown of engine top end components.
Technical specifications for camshafts, cylinder head, valves, and pistons.
List of specialized tools and sealants for engine top end work.
Procedures for removing, installing, and inspecting air suction and switching valves.
Steps for removing and installing the cylinder head cover.
Procedures for removing and installing the camshaft chain tensioner.
Detailed instructions for camshaft removal, installation, and inspection.
Procedures for measuring cylinder compression and removing/installing the cylinder head.
Steps for inspecting, adjusting, removing, and installing valves, guides, and seats.
Procedures for cylinder removal/installation, piston inspection, and ring measurements.
Installation procedure for the throttle body holder.
Steps for removing and installing the muffler body and exhaust pipe.
Illustrated breakdown of clutch components.
Standard and service limit specifications for clutch components.
List of specialized tools and sealants for clutch service.
Procedures for inspecting and adjusting clutch lever free play and cable.
Steps for removing and installing the clutch cover, release shaft, and related components.
Detailed procedures for clutch removal, installation, and inspection of plates, springs, and housing.
Illustrated breakdown of engine lubrication system components.
Diagram illustrating the flow of engine oil through the lubrication system.
Standard specifications for engine oil grade, viscosity, capacity, and oil pressure.
List of specialized tools and sealants for engine lubrication system service.
Procedures for checking oil level, changing oil, and replacing the oil filter.
Steps for removing and installing the oil pan and its related components.
Procedures for removing, installing, and inspecting the oil pressure relief valve.
Detailed procedures for removing and installing the oil pump assembly.
Method for measuring engine oil pressure using specialized tools.
Procedures for removing, installing, and testing the oil pressure switch.
Illustrated breakdown of engine mounting components.
Step-by-step instructions for safely removing the engine from the motorcycle.
Step-by-step instructions for correctly installing the engine back into the motorcycle.
Illustrated breakdown of crankshaft and transmission components.
Standard and service limit specifications for crankshaft, connecting rods, and transmission parts.
List of specialized tools and sealants for crankshaft and transmission service.
Procedures for separating the crankcase halves.
Detailed instructions for removing, installing, inspecting, and measuring crankshaft and connecting rod components.
Procedures for removing, installing, and inspecting the balancer shaft and its bearings.
Procedures for removing, installing, disassembling, and assembling the transmission system.
Illustrated breakdown of wheel and tire components.
Standard and service limit specifications for wheels (rims) and tires.
List of specialized tools for wheel and tire service.
Procedures for removing, installing, inspecting, and balancing wheels.
Steps for inspecting tire pressure, tread depth, and performing tire removal and installation.
Procedures for removing, installing, inspecting, and lubricating hub bearings.
Illustrated breakdown of final drive components.
Standard and service limit specifications for drive chain and sprockets.
List of specialized tools for final drive service.
Procedures for inspecting, adjusting, lubricating, removing, and installing the drive chain.
Steps for installing engine and rear sprockets, and inspecting coupling components.
Illustrated breakdown of front brake system components.
Standard and service limit specifications for brake lever, pedal, pads, discs, and fluid.
List of specialized tools for brake system service.
Procedures for adjusting and removing/installing brake lever and pedal.
Steps for removing, installing, disassembling, and inspecting brake calipers.
Procedures for removing, installing, and inspecting brake pads.
Procedures for removing, installing, disassembling, and inspecting master cylinders.
Steps for removing, installing, inspecting wear, and checking warp of brake discs.
Procedures for inspecting fluid level, changing fluid, and bleeding brake lines.
Procedures for removing, installing, and inspecting brake hoses.
Information on ABS system parts location, wiring, troubleshooting, and self-diagnosis.
Illustrated breakdown of front fork components.
Standard specifications for front fork and rear shock absorber.
List of specialized tools for suspension service.
Procedures for removing, installing, changing oil, disassembling, and assembling front forks.
Procedures for adjusting spring preload, removing, installing, and inspecting the rear shock absorber.
Steps for removing, installing, and inspecting swingarm bearings and lubrication.
Inspection of the drive chain guide for wear or damage.
Illustrated breakdown of steering system components.
List of specialized tools for steering system service.
How to inspect steering play and adjust it for proper operation.
Procedures for removing, installing, lubricating, and inspecting the steering stem and its bearings.
Steps for removing and installing the handlebar and related components.
Illustrated breakdown of frame components.
Procedures for removing and installing the seat.
Steps for removing and installing lower, center, upper, and inner fairings, as well as windshields.
Procedures for removing and installing front and rear fenders.
Inspection of the frame for damage like cracks, dents, or warping.
Procedures for removing and installing the sidestand and its switch.
Steps for removing and installing frame covers.
Illustrated breakdown of electrical system components.
Standard electrical system specifications for battery, charging, ignition, starter, and sensors.
List of specialized tools and sealants for electrical system service.
Visual guide to the location of electrical system components on the motorcycle.
Electrical wiring diagram for European models.
Electrical wiring diagram for US, Canada, and Taiwan models.
Electrical wiring diagram for Australian and Malaysian models.
Electrical wiring diagram specific to EX650B models.
General safety and handling precautions for servicing electrical systems.
Procedures for inspecting wiring and connectors for damage or continuity.
Procedures for battery removal, installation, activation, charging, and testing.
Information on alternator, stator coil, regulator/rectifier, and charging voltage inspection.
Procedures for removing, installing, inspecting, and disassembling the starter motor clutch.
Troubleshooting and inspection procedures for crankshaft sensor, timing rotor, stick coils, and spark plugs.
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