Kawasaki ZX-6R - Manuals

General Specifications Item 2008 Ninja ZX-6R Racing Engine: Ignition timing 12.5°BTDC @1 300 r/min (rpm) Fuel (Recommended) Racing gasoline Engine oil (Recommended): Racing oil Level Between upper and lower levels of oil level gauge. Drive Train: Primary drive reduction ratio 1.900 (76/40) Transmiss...

Input 3rd/4th Gear Selection Table 4th Gear A B C D A 13262-0506 13262-0529 13262-0679 3rd Gear B 13262-0680 13262-0681 13262-0682 Gear Identification Slit Number Table STD (Type A) Type B Type C Type D In 0 1 1 1st Out 0 1 2 In 0 1 2 3 2nd Out 0 1 2 3 In 0 1 3rd Out 0 1 In 0 1 2 3 4th Out 0 1 2 3 I...

Racing Kit Service Data Item Standard Cylinder Head, Valves: Duration: Intake 288° Exhaust 266° Camshaft timing (cam lift center): Intake 105° (ATDC) Exhaust 110° (BTDC) Valve clearance: Intake 0.16 mm Exhaust 0.28 mm Valve to piston clearance: Intake 0.80 mm (Minimum) @12°ATDC Exhaust 1.40 mm (Mini...

Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQENCY OPERATION Each Race (300 km) Every 3 races (1 000 km) Every 5 races (1 500 km) (3 000 km) Every 10 races As Required Engine Clutch plate - - chec...

Preparation Before Installing Modify the parts based on your race regulation. To avoid misuse keep the parts replaced with the kit parts separate. When reusing parts, clean them and check them for damage or deterioration. Main Removal Parts: Lights Rear View Mirrors Side Stand Starter Lockout Switch...

Remove the secondary valves of cylinder head and relational parts, then plug the each holes. Remove the oil receiver and plug the hole. Remove the air cleaner element or cut the cleaner element off remaining punched plate to reduce the air flow resistance. 1. Remove the parts. 2. Plug the holes. 3. ...

Cylinder Head Grind off the stepped portions of the ports and smooth the inside of ports to make intake/exhaust gas flow more smooth. Grind off the stepped portion only at the mating surface between the carburetor holder and the intake port. Do not port it. To extend the intake port, air flow speed ...

The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners (Round them to about R1). Chamfer the machining edge of the cylinder head where the valve seat is installed, also smooth the dome of the combustion chamber with the valves installed. Exc...

A. Tensioner B. Tensioner Rod C. O-ring D. O-ring E. Lock nut Camshafts, Sprockets Camshafts, Sprockets: Adjust the valve clearance within the specified value, but more performance is expected when adjusted from middle value to upper limit between adjustable range. Original Timing Cam Lift Valve Cle...

If you don’t adjust the valve timing for racing, install the camshaft sprocket to the kit camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-6R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range...

Cylinder Head Gasket Part No. Thickness Note 11004-0071 0.45 mm KIT 11004-0070 0.50 mm KIT 11004-0069 0.55 mm KIT 11004-0068 0.60 mm KIT 11004-0057 0.65 mm Original 11004-0067 0.70 mm KIT 1. Squish, Front/Rear 2. Squish, Left/Right 15

Crankshaft Main Journal and Connecting Rod Big End Bushings To adjust clearance of crankshaft main journal you can select proper bush in accordance with the marks. The kit bushings are improved in anti-seizuring characteristics as well as in wear-resistance as compared with the standard bushings. 1)...

Selection Table Connecting Rod Big End Inside Diameter Crankpin Diameter Mark Size Color Part Number (STD) Part Number (KIT) None ○ (33.000 mm ~ 33.008 mm) (29.992 mm ~ 30.000 mm) brown 92139-0167 92139-0196 None None (33.000 mm ~ 33.008 mm) (29.984 mm ~ 29.992 mm) black 92139-0166 92139-0195 ○ ○ (3...

• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub). • To measure the effective stroke of clutch spring plate, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The difference between the highest and l...

Standard Selection of Shim Total Thickness of Clutch Plates Size of Shim Remarks Approx. 40.7 mm 2.0 mm P/No. 92180-0149 Original Setting 40.2 mm 1.5 mm P/No. 92026-1590 39.5 ~ 40 mm 1.2 mm 92025-1137 Transmission Remove the three steel balls (600A0500) from the output shaft assembly. Take kit and o...

Generator (Option) To quicken response by reducing the flywheel mass and to reduce the weight, use the optional inner rotor generator. Select using the optional generator or original generator according to the situation. Use the optional regulator and optional generator cover set when using the opti...

Muffler With recommended muffler engine performance can be improved. Recommended muffler: Beet NASSERT-R 1002-E02-00 Web Site : http://www.beet.co.jp/(beetjapan) * For further information contact the manufacturer of muffler directly. Water Temperature Sensor The original water temperature sensor ins...

Radiator Installation Use the radiator stay (35063-0439) and bracket (11054-1818) belong to kit, and fasten the radiator to the Crankcase by bolts as shown in the figure. Stay has several installation holes. Install position is adjustable for proper position of radiator. Some muffler may interfere w...

1. Water Hose 39062-0219 4. Sensor 21176-1099 2. Ground Wire 26011-0071 5. Lead Wire 26011-1779 3. Water Hose 39062-0166 (Standard) 6. Clamp 92171-0179 Reserve Tank Installation When using the radiator (Kit), the original reserve tank cannot be used. Prepare a suitable substitue. Reserve Tank should...

Oil Catch Tank Installation Fasten the Bracket (E) to the Engine Hanger by using bolt (D). Fasten Oil Catch Tank (A) to the Bracket (E) by using bolt (F) and nut (I). Connect Air Cleaner, Crankcase and Oil Catch Tank by using hose1 (B) and hose2 (C). A) Oil Catch Tank (52001-0004) B) Hose1 (Air Clea...

Assemble hoses as shown below 5. Fitting (92005-0080) 32

Frame Parts Installation Throttle Parts (Kit) The following throttle cases, grip and reels are available as optional parts. These optional parts quicken throttle response to the twist grip. 1) Throttle Case Parts P/No. Throttle Case, Upper 32099-0004 Throttle Case, Lower 32099-0005 Bolts (2) 120S062...

1) Drive Chain #520 Joint endless drive chain is available as an optional parts. 2) Chain Guard 1. Guard: 55020-0028 2. Bolt: 130J1020 3. Swingarm (Left Side) Brake Pads (Kit) The front and rear brake pads for racing use are available. The front pads are for higher braking force, and the rear pads a...

1) Recommended Steering Damper OHLINS SD121 Set the steering damper to the holder as shown. 2) Stroke(s) SD121: 68 mm 1. Steering Damper: OHLINS SD121 2. Bracket: 11054-1816 3. Bracket: 11054-1817 4. Collar: 92152-0589 5. Ring: 670 B 2012 6. Washer: 410 B 0800 7. Bolt, Socket: 120 CA0630 8. Bolt, So...

Front Fork Springs (Kit) The optional front fork springs are available for racing. 1) Front Fork Specifications Items Original Rebounded damping setting (Upper) 1 1/2 turns out from the fully clockwise position Compression damping setting (Lower) 1 1/2 turns out from the fully clockwise position For...

Electric Parts Installation Battery Use the original battery or a battery with 12 V 7 Ah or more capacity. Main Harness and Sub Harness (Kit) Main harness and sub harness are available for racing use as optional parts. Select one of them in accordance with your race regulation. Main Harness (with Op...

Meter (Kit) Installation 1. Tachometer with Water Temperature Gauge (Optional): 25031-1142 2. Collar (Optional): 92152-0058 3. Pad (Optional): 39156-0098 4. Bracket (Optional): 11053-1749 5. Rivet (Optional): 92039-1106 6. Nut (Optional): 92015-1233 7. Collar (Optional): 92152-1074 8. Bolt (Optional...

Main Harness Combination Parts Table Main Harness and Kit Part Combination Table ○ : need × : no need. Harness Part Harness for Kit Meter 26031-0559 Harness for Original Meter 26031-0558 Sub Harness 26031-0327 Meter Assembly (Kit) × ○ ○ Tachometer with Water Temperature Gauge (Kit) 25031-1142 ○ × × ...

Wiring Routing 1. Vehicle-down Sensor 12. Main Throttle Sensor 2. Meter Assembly 13. Injector, Secondary 3. Shift Up Indicator Light 14. Injector, Primary 4. Right Handlebar Switch 15. Coolant Temperature Sensor 5. Left Handlebar Bar Switch 16. Speed Sensor 6. Intake Air Temperature Sensor 17. Crank...

This catalog co v ers: GRID NO . This g rid co v ers: ’08 ZX600P8FR Engine B-6 T ransmission(TYPE-B) Quantity-ZX600 ’08 Ref . No . P a rt No . Descr iption Spec Code P8FR 13127 13127-0055 SHAFT-TRANSMISSION INPUT ,14T 1 (OPTION) 13144 13144-0047 SPR OCKET-OUTPUT ,16T 1 (OPTION) 13144A 13144-0048 SPR...

This catalog co v ers: GRID NO . This g rid co v ers: ’08 ZX600P8FR Chassis C-6 Meter(s) Quantity-ZX600 ’08 Ref . No . P a rt No . Descr iption Spec Code P8FR 11053 11053-1749 BRA CKET ,KIT METER 1 (OPTION) 23016 23016-0006 LAMP-ASSY ,INDICA T O R 1 (OPTION) 25031 25031-1142 METER-ASSY 1 (OPTION) 39...