Page 3 - ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED; BASIC WORKS IN INSTALLING KIT PARTS
Congratulation on your purchase of racing kit parts for the 2008 Ninja ZX-6R. IMPORTANT This manual provides how to install racing kit parts for the 2008 Ninja ZX-6R and how to tune up basically. As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-6R (P/No. 99924-1382-02). ...
Page 4 - Dummy page
Page 5 - Table of Contents
Table of Contents General Specifications ...................................................................................................... 4 Racing Kit Service Data .................................................................................................... 6 Periodic Maintenance Chart ...
Page 6 - General Specifications; Item; Transmission Gear Table
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...
Page 7 - Gear Identification Slit Number Table
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...
Page 8 - Racing Kit Service Data; Item Standard; Spark
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...
Page 9 - Periodic Maintenance Chart; motorcycle in good running condition.
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...
Page 11 - Preparation; Before Installing; Modify the parts based on your race regulation.; Racing Kit Parts; Air Intake Parts
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...
Page 12 - Remove the oil receiver and plug the hole.
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. ...
Page 13 - Cylinder Head; Smooth the inside of the intake port and exhaust port.; NOTE
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 ...
Page 14 - Camshaft Chain Tensioner; Tighten the rock nut after adjustment.; tensioner and may damage to the chain guide.
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...
Page 15 - Camshafts, Sprockets
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...
Page 16 - Valve Timing (when the round bolt holes are used); Valve Springs; Squish Measurement
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...
Page 17 - Cylinder Head Gasket
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
Page 18 - Crankshaft Main Journal and Connecting Rod Big End Bushings
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)...
Page 21 - Selection Table; Connecting Rod Bolts; determine the bolt stretch.; Bolt Stretch
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...
Page 25 - Standard Selection of Spring Retainers
• 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...
Page 26 - Standard Selection of Shim; Transmission
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...
Page 27 - Cover Gaskets
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...
Page 28 - Muffler; Web Site; Water Temperature Sensor
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...
Page 29 - Radiator Installation; Machine the original cowl to meet the outline of radiator.
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...
Page 31 - Sensor; Reserve Tank Installation; Position of the hose to a reserve tank.
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...
Page 32 - Oil Catch Tank Installation
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...
Page 34 - Assemble hoses as shown below
Assemble hoses as shown below 5. Fitting (92005-0080) 32
Page 35 - Frame Parts Installation
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...
Page 36 - Front Brake Pads; (Steering angle should be controlled by the regulation)
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...
Page 37 - ) Recommended Steering Damper; Set the steering damper to the holder as shown.; Seat Height Adjustment; Rear Suspension Condition of Seat Height Adjustment
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...
Page 39 - The optional front fork springs are available for racing.; ) Front Fork Specifications; Coil; ) Front Fork Spring Replacement
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...
Page 40 - Fork Spring Installation
Page 41 - Electric Parts Installation; Battery; Use the original battery or a battery with 12 V 7 Ah or more capacity.
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...
Page 42 - Bolt
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...
Page 43 - Main Harness Combination Parts Table
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 ○ × × ...
Page 44 - Wiring Routing
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...
Page 48 - Wiring Diagram (with Original Meter Assembly)
Page 50 - Dummy Page
Page 51 - Racing Kit Parts List
Page 55 - Engine
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...
Page 65 - Chassis
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...
