- •General Information
- •Before Servicing
- •Model Identification
- •General Specifications
- •Unit Conversion Table
- •Periodic Maintenance
- •Periodic Maintenance Chart
- •Torque and Locking Agent
- •Specifications
- •Special Tools
- •Periodic Maintenance Procedures
- •Fuel System (DFI)
- •Throttle Control System Inspection
- •Engine Vacuum Synchronization Inspection
- •Idle Speed Inspection
- •Idle Speed Adjustment
- •Fuel Hose Inspection (fuel leak, damage, installation condition)
- •Cooling System
- •Coolant Level Inspection
- •Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)
- •Engine Top End
- •Valve Clearance Inspection
- •Valve Clearance Adjustment
- •Air Suction System Damage Inspection
- •Clutch
- •Clutch Operation Inspection
- •Wheels/Tires
- •Air Pressure Inspection
- •Wheel/Tire Damage Inspection
- •Tire Tread Wear Inspection
- •Wheel Bearing Damage Inspection
- •Final Drive
- •Drive Chain Lubrication Condition Inspection
- •Drive Chain Slack Inspection
- •Drive Chain Slack Adjustment
- •Wheel Alignment Inspection
- •Drive Chain Wear Inspection
- •Chain Guide Wear Inspection
- •Brakes
- •Brake Fluid Leak (Brake Hose and Pipe) Inspection
- •Brake Hose and Pipe Damage and Installation Condition Inspection
- •Brake Fluid Level Inspection
- •Brake Pad Wear Inspection
- •Brake Operation Inspection
- •Brake Light Switch Operation Inspection
- •Suspension
- •Front Forks/Rear Shock Absorber Operation Inspection
- •Front Fork Oil Leak Inspection
- •Rear Shock Absorber Oil Leak Inspection
- •Rocker Arm Operation Inspection
- •Tie-Rod Operation Inspection
- •Steering
- •Steering Play Inspection
- •Steering Play Adjustment
- •Steering Stem Bearing Lubrication
- •Steering Damper Oil Leak Inspection
- •Electrical System
- •Lights and Switches Operation Inspection
- •Headlight Aiming Inspection
- •Sidestand Switch Operation Inspection
- •Engine Stop Switch Operation Inspection
- •Others
- •Chassis Parts Lubrication
- •Bolts, Nuts and Fasteners Tightness Inspection
- •Replacement Parts
- •Air Cleaner Element Replacement
- •Fuel Hose Replacement
- •Coolant Change
- •Radiator Hose and O-ring Replacement
- •Engine Oil Change
- •Oil Filter Replacement
- •Brake Hose and Pipe Replacement
- •Brake Fluid Change
- •Master Cylinder Rubber Parts Replacement
- •Caliper Rubber Parts Replacement
- •Spark Plug Replacement
- •Fuel System (DFI)
- •Exploded View
- •DFI System
- •DFI Parts Location
- •Specifications
- •Special Tools and Sealant
- •DFI Servicing Precautions
- •DFI Servicing Precautions
- •Troubleshooting the DFI System
- •Outline
- •Inquiries to Rider
- •DFI System Troubleshooting Guide
- •Self-Diagnosis
- •Self-diagnosis Outline
- •Self-diagnosis Procedures
- •Service Code Reading
- •Service Code Erasing
- •Backups
- •Main Throttle Sensor (Service Code 11)
- •Main Throttle Sensor Removal/Adjustment
- •Main Throttle Sensor Input Voltage Inspection
- •Main Throttle Sensor Output Voltage Inspection
- •Main Throttle Sensor Resistance Inspection
- •Inlet Air Pressure Sensor #1 (Service Code 12)
- •Inlet Air Pressure Sensor #1 Removal
- •Inlet Air Pressure Sensor #1 Installation
- •Inlet Air Pressure Sensor #1 Output Voltage Inspection
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Removal/Installation
- •Inlet Air Temperature Sensor Resistance Inspection
- •Water Temperature Sensor (Service Code 14)
- •Water Temperature Sensor Removal/Installation
- •Water Temperature Sensor Resistance Inspection
- •Inlet Air Pressure Sensor #2 (Service Code 16)
- •Inlet Air Pressure Sensor #2 Removal
- •Inlet Air Pressure Sensor #2 Installation
- •Inlet Air Pressure Sensor #2 Output Voltage Inspection
- •Crankshaft Sensor (Service Code 21)
- •Crankshaft Sensor Removal/Installation
- •Crankshaft Sensor Resistance Inspection
- •Crankshaft Sensor Peak Voltage Inspection
- •Speed Sensor (Service Code 24)
- •Speed Sensor Removal/Installation
- •Speed Sensor Inspection
- •Speed Sensor Input Voltage Inspection
- •Speed Sensor Output Voltage Inspection
- •Gear Position Switch (Service Code 25)
- •Gear Position Switch Removal/Installation
- •Gear Position Switch Resistance Inspection
- •Gear Position Switch Output Voltage Inspection
- •Vehicle-down Sensor (Service Code 31)
- •Vehicle-down Sensor Removal
- •Vehicle-down Sensor Installation
- •Vehicle-down Sensor Input Voltage Inspection
- •Vehicle-down Sensor Output Voltage Inspection
- •Subthrottle Sensor (Service Code 32)
- •Subthrottle Sensor Removal/Adjustment
- •Subthrottle Sensor Input Voltage Inspection
- •Subthrottle Sensor Output Voltage Inspection
- •Subthrottle Sensor Resistance Inspection
- •Oxygen Sensor - not activated (Service Code 33 (Equipped Models))
- •Oxygen Sensor Removal/Installation
- •Oxygen Sensor Inspection
- •Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
- •Exhaust Butterfly Valve Actuator Sensor Removal/Installation
- •Immobilizer Amplifier (Service Code 35 (Equipped Models))
- •Antenna Resistance Inspection
- •Amplifier Input Voltage Inspection
- •Blank Key Detection (Service Code 36 (Equipped Models))
- •User Key Inspection
- •ECU Communication Error (Service Code 39)
- •ECU Communication Line Inspection
- •Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
- •Stick Coil Removal/Installation
- •Stick Coil Primary Winding Resistance Inspection
- •Stick Coil Input Voltage Inspection
- •Radiator Fan Relay (Service Code 56)
- •Radiator Fan Relay Removal/Installation
- •Radiator Fan Relay Inspection
- •Subthrottle Valve Actuator (Service Code 62)
- •Subthrottle Valve Actuator Removal
- •Subthrottle Valve Actuator Inspection
- •Subthrottle Valve Actuator Resistance Inspection
- •Exhaust Butterfly Valve Actuator (Service Code 63)
- •Exhaust Butterfly Valve Actuator Removal
- •Exhaust Butterfly Valve Actuator Installation
- •Exhaust Butterfly Valve Actuator Inspection
- •Air Switching Valve (Service Code 64)
- •Air Switching Valve Removal/Installation
- •Air Switching Valve Inspection
- •Oxygen Sensor Heater (Service Code 67 (Equipped Models))
- •Oxygen Sensor Heater Removal/Installation
- •Oxygen Sensor Heater Resistance Inspection
- •Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models))
- •Oxygen Sensor Removal/Installation
- •Oxygen Sensor Inspection
- •Warning Indicator Light (LED)
- •Light (LED) Inspection
- •ECU Identification
- •ECU Removal
- •ECU Installation
- •ECU Power Supply Inspection
- •DFI Power Source
- •ECU Fuse Removal
- •ECU Fuse Installation
- •ECU Fuse Inspection
- •ECU Main Relay Removal/Installation
- •ECU Main Relay Inspection
- •Fuel Line
- •Fuel Pressure Inspection
- •Fuel Flow Rate Inspection
- •Fuel Pump
- •Fuel Pump Removal
- •Fuel Pump Installation
- •Fuel Pump Operation Inspection
- •Fuel Pump Operating Voltage Inspection
- •Pressure Regulator Removal
- •Fuel Filter Cleaning
- •Fuel Injectors
- •Primary Fuel Injector Removal/Installation
- •Secondary Fuel Injector Removal/Installation
- •Fuel Injector Audible Inspection
- •Fuel Injector Resistance Inspection
- •Fuel Injector Power Source Voltage Inspection
- •Fuel Injector Output Voltage Inspection
- •Fuel Injector Fuel Line Inspection
- •Throttle Grip and Cables
- •Free Play Inspection
- •Free Play Adjustment
- •Cable Installation
- •Cable Lubrication
- •Throttle Body Assy
- •Idle Speed Inspection/Adjustment
- •Synchronization Inspection/Adjustment
- •Throttle Body Assy Removal
- •Throttle Body Assy Installation
- •Throttle Body Assy Disassembly
- •Throttle Body Assy Assembly
- •Nozzle Assy
- •Nozzle Assy Removal
- •Nozzle Assy Installation
- •Nozzle Assy Disassembly
- •Nozzle Assy Assembly
- •Air Cleaner
- •Air Cleaner Element Removal/Installation
- •Air Cleaner Element Inspection
- •Air Cleaner Oil Draining
- •Air Cleaner Housing Removal
- •Air Cleaner Housing Installation
- •Air Cleaner Housing Disassembly
- •Air Cleaner Housing Assembly
- •Air Line
- •Air Inlet Duct Removal
- •Air Inlet Duct Installation
- •Fuel Tank
- •Fuel Tank Removal
- •Fuel Tank Installation
- •Fuel Tank Inspection
- •Fuel Tank Cleaning
- •Evaporative Emission Control System (CAL, SEA and TH Models)
- •Parts Removal/Installation
- •Hose Inspection
- •Separator Inspection
- •Separator Operation Test
- •Canister Inspection
- •Cooling System
- •Exploded View
- •Coolant Flow Chart
- •Specifications
- •Special Tools
- •Coolant
- •Coolant Deterioration Inspection
- •Coolant Level Inspection
- •Coolant Draining
- •Coolant Filling
- •Pressure Testing
- •Cooling System Flushing
- •Coolant Reserve Tank Removal
- •Coolant Reserve Tank Installation
- •Water Pump
- •Water Pump Removal
- •Water Pump Installation
- •Water Pump Inspection
- •Water Pump Impeller Disassembly/Assembly
- •Water Pump Impeller Inspection
- •Water Pump Housing Disassembly
- •Water Pump Housing Assembly
- •Mechanical Seal Inspection
- •Radiator
- •Radiator and Radiator Fan Removal
- •Radiator and Radiator Fan Installation
- •Radiator Inspection
- •Radiator Cap Inspection
- •Radiator Filler Neck Inspection
- •Thermostat
- •Thermostat Removal
- •Thermostat Installation
- •Thermostat Inspection
- •Hoses and Pipes
- •Hose Installation
- •Hose Inspection
- •Water Temperature Sensor
- •Water Temperature Sensor Removal/Installation
- •Water Temperature Sensor Inspection
- •Engine Top End
- •Exploded View
- •Exhaust System Identification
- •Specifications
- •Special Tools and Sealant
- •Clean Air System
- •Air Suction Valve Removal
- •Air Suction Valve Installation
- •Air Suction Valve Inspection
- •Air Switching Valve Removal
- •Air Switching Valve Installation
- •Air Switching Valve Operation Test
- •Air Switching Valve Unit Test
- •Clean Air System Hose Inspection
- •Cylinder Head Cover
- •Cylinder Head Cover Removal
- •Cylinder Head Cover Installation
- •Camshaft Chain Tensioner
- •Camshaft Chain Tensioner Removal
- •Camshaft Chain Tensioner Installation
- •Camshaft, Camshaft Chain
- •Camshaft Removal
- •Camshaft Installation
- •Camshaft, Camshaft Cap Wear Inspection
- •Camshaft Runout Inspection
- •Cam Wear Inspection
- •Camshaft Chain Removal
- •Cylinder Head
- •Cylinder Compression Measurement
- •Cylinder Head Removal
- •Cylinder Head Installation
- •Cylinder Head Warp Inspection
- •Valves
- •Valve Clearance Inspection
- •Valve Removal
- •Valve Installation
- •Valve Guide Removal
- •Valve Guide Installation
- •Valve-to-Guide Clearance Measurement (Wobble Method)
- •Valve Seat Inspection
- •Valve Seat Repair
- •Throttle Body Assy Holder
- •Throttle Body Assy Holder Removal
- •Throttle Body Assy Holder Installation
- •Muffler
- •Muffler Body Removal
- •Muffler Body Installation
- •Premuffler Chamber Removal
- •Premuffler Chamber Installation
- •Exhaust Pipe Removal
- •Exhaust Pipe Installation
- •Exhaust Butterfly Valve Cable Removal
- •Exhaust Butterfly Valve Cable Installation
- •Clutch
- •Exploded View
- •Specifications
- •Special Tool and Sealant
- •Clutch Lever and Cable
- •Clutch Lever Free Play Inspection
- •Clutch Lever Free Play Adjustment
- •Cable Removal
- •Cable Installation
- •Cable Lubrication
- •Clutch Lever Installation
- •Clutch Cover
- •Clutch Cover Removal
- •Clutch Cover Installation
- •Release Shaft Removal
- •Release Shaft Installation
- •Clutch Cover Disassembly
- •Clutch Cover Assembly
- •Clutch
- •Clutch Removal
- •Clutch Installation
- •Spring Plate Free Play Measurement
- •Spring Plate Free Play Adjustment
- •Clutch Plate, Wear, Damage Inspection
- •Clutch Plate Warp Inspection
- •Clutch Spring Free Length Measurement
- •Clutch Housing Finger Inspection
- •Clutch Housing Spline Inspection
- •Damper Cam Inspection
- •Engine Lubrication System
- •Exploded View
- •Engine Oil Flow Chart
- •Specifications
- •Special Tools and Sealant
- •Engine Oil and Oil Filter
- •Oil Level Inspection
- •Engine Oil Change
- •Oil Filter Replacement
- •Oil Pan Removal
- •Oil Pan Installation
- •Oil Pressure Relief Valve
- •Oil Pressure Relief Valve Removal
- •Oil Pressure Relief Valve Installation
- •Oil Pressure Relief Valve Inspection
- •Oil Pump
- •Oil Pump Removal
- •Oil Pump Installation
- •Oil Pump Drive Gear Removal
- •Oil Pump Drive Gear Installation
- •Oil Pump Drive Gear Shaft Removal
- •Oil Pump Drive Gear Shaft Installation
- •Oil Cooler
- •Oil Cooler Removal
- •Oil Cooler Installation
- •Oil Cooler/Oil Filter Case Removal
- •Oil Cooler/Oil Filter Case Installation
- •Oil Pressure Measurement
- •Oil Pressure Measurement
- •Oil Pressure Switch
- •Oil Pressure Switch Removal
- •Oil Pressure Switch Installation
- •Engine Removal/Installation
- •Exploded View
- •Special Tool
- •Engine Removal/Installation
- •Engine Removal
- •Engine Installation
- •Crankshaft/Transmission
- •Exploded View
- •Specifications
- •Special Tools and Sealants
- •Crankcase
- •Crankcase Splitting
- •Crankcase Assembly
- •Crankshaft and Connecting Rods
- •Crankshaft Removal
- •Crankshaft Installation
- •Connecting Rod Removal
- •Connecting Rod Installation
- •Crankshaft/Connecting Rod Cleaning
- •Connecting Rod Bend Inspection
- •Connecting Rod Twist Inspection
- •Connecting Rod Big End Side Clearance Inspection
- •Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
- •Crankshaft Side Clearance Inspection
- •Crankshaft Runout Inspection
- •Pistons
- •Piston Removal
- •Piston Installation
- •Cylinder (Upper Crankcase) Wear Inspection
- •Piston Wear Inspection
- •Piston Ring, Piston Ring Groove Wear Inspection
- •Piston Ring Groove Width Inspection
- •Piston Ring Thickness Inspection
- •Piston Ring End Gap Inspection
- •Starter Idle Gear and Starter Clutch
- •Starter Idle Gear Removal
- •Starter Idle Gear Installation
- •Starter Clutch Removal
- •Starter Clutch Installation
- •Starter Clutch Disassembly
- •Starter Clutch Assembly
- •Starter Clutch Inspection
- •Transmission
- •Transmission Assy Removal
- •Transmission Assy Disassembly
- •Transmission Assy Assembly
- •Transmission Assy Installation
- •Transmission Shaft Removal
- •Transmission Shaft Installation
- •Transmission Shaft Disassembly
- •Transmission Shaft Assembly
- •Shift Drum and Fork Removal
- •Shift Drum and Fork Installation
- •Shift Drum Disassembly
- •Shift Drum Assembly
- •Shift Fork Bending Inspection
- •Shift Fork/Gear Groove Wear Inspection
- •Shift Fork Guide Pin/Drum Groove Wear Inspection
- •Gear Dog and Gear Dog Hole Damage Inspection
- •External Shift Mechanism
- •Shift Pedal Removal
- •Shift Pedal Installation
- •External Shift Mechanism Removal
- •External Shift Mechanism Installation
- •External Shift Mechanism Inspection
- •Wheels/Tires
- •Exploded View
- •Specifications
- •Special Tools
- •Wheels (Rims)
- •Front Wheel Removal
- •Front Wheel Installation
- •Rear Wheel Removal
- •Rear Wheel Installation
- •Wheel Inspection
- •Axle Inspection
- •Balance Inspection
- •Balance Adjustment
- •Balance Weight Removal
- •Balance Weight Installation
- •Tires
- •Air Pressure Inspection/Adjustment
- •Tire Inspection
- •Tire Removal
- •Tire Installation
- •Tire Repair
- •Hub Bearing
- •Hub Bearing Removal
- •Hub Bearing Installation
- •Hub Bearing Inspection
- •Hub Bearing Lubrication
- •Final Drive
- •Exploded View
- •Specifications
- •Special Tools
- •Drive Chain
- •Drive Chain Slack Inspection
- •Drive Chain Slack Adjustment
- •Wheel Alignment Inspection/Adjustment
- •Drive Chain Wear Inspection
- •Drive Chain Lubrication
- •Drive Chain Guide Wear Inspection
- •Drive Chain Removal
- •Sprocket, Coupling
- •Engine Sprocket Removal
- •Engine Sprocket Installation
- •Rear Sprocket Removal
- •Rear Sprocket Installation
- •Coupling Installation
- •Coupling Bearing Removal
- •Coupling Bearing Installation
- •Coupling Bearing Inspection
- •Coupling Bearing Lubrication
- •Coupling Damper Inspection
- •Sprocket Wear Inspection
- •Rear Sprocket Warp Inspection
- •Brakes
- •Exploded View
- •Specifications
- •Special Tools
- •Brake Lever, Brake Pedal
- •Brake Lever Position Adjustment
- •Brake Pedal Position Inspection
- •Brake Pedal Position Adjustment
- •Brake Pedal Removal
- •Brake Pedal Installation
- •Calipers
- •Front Caliper Removal
- •Rear Caliper Removal
- •Caliper Installation
- •Front Caliper Disassembly
- •Front Caliper Assembly
- •Rear Caliper Disassembly
- •Rear Caliper Assembly
- •Caliper Fluid Seal Damage Inspection
- •Caliper Dust Seal Damage Inspection
- •Caliper Piston and Cylinder Damage Inspection
- •Rear Caliper Holder Shaft Wear Inspection
- •Brake Pads
- •Front Brake Pad Removal
- •Front Brake Pad Installation
- •Rear Brake Pad Removal
- •Rear Brake Pad Installation
- •Brake Pad Wear Inspection
- •Master Cylinder
- •Front Master Cylinder Removal
- •Front Master Cylinder Installation
- •Rear Master Cylinder Removal
- •Rear Master Cylinder Installation
- •Front Master Cylinder Disassembly
- •Rear Master Cylinder Disassembly
- •Master Cylinder Assembly
- •Master Cylinder Inspection (Visual Inspection)
- •Brake Disc
- •Brake Disc Removal
- •Brake Disc Installation
- •Brake Disc Wear Inspection
- •Brake Disc Warp Inspection
- •Brake Fluid
- •Brake Fluid Level Inspection
- •Brake Fluid Change
- •Brake Line Bleeding
- •Brake Hose
- •Brake Hose Removal/Installation
- •Brake Hose Inspection
- •Suspension
- •Exploded View
- •Specifications
- •Special Tools
- •Front Fork
- •Rebound Damping Force Adjustment
- •Compression Damping Force Adjustment
- •Spring Preload Adjustment
- •Front Fork Removal (Each Fork Leg)
- •Front Fork Installation (Each Fork Leg)
- •Front Fork Oil Change
- •Front Fork Disassembly
- •Front Fork Assembly
- •Inner Tube Inspection
- •Dust Seal Inspection
- •Spring Tension Inspection
- •Rear Shock Absorber
- •Rebound Damping Force Adjustment
- •Compression Damping Force Adjustment
- •Spring Preload Adjustment
- •Rear Shock Absorber Removal
- •Rear Shock Absorber Installation
- •Rear Shock Absorber Inspection
- •Rear Shock Absorber Scrapping
- •Swingarm
- •Swingarm Removal
- •Swingarm Installation
- •Swingarm Bearing Removal
- •Swingarm Bearing Installation
- •Swingarm Bearing, Sleeve Inspection
- •Swingarm Bearing Lubrication
- •Tie-Rod, Rocker Arm
- •Tie-Rod Removal
- •Tie-Rod Installation
- •Rocker Arm Removal
- •Rocker Arm Installation
- •Tie-Rod and Rocker Arm Bearing Removal
- •Tie-Rod and Rocker Arm Bearing Installation
- •Tie-Rod/Rocker Arm Bearing, Sleeve Inspection
- •Tie-Rod/Rocker Arm Bearing Lubrication
- •Steering
- •Exploded View
- •Specifications
- •Special Tools
- •Steering
- •Steering Inspection
- •Steering Adjustment
- •Steering Damper
- •Damping Force Adjustment
- •Steering Damper Removal
- •Steering Damper Installation
- •Steering Damper Oil Leak Inspection
- •Steering Stem
- •Stem, Stem Bearing Removal
- •Stem, Stem Bearing Installation
- •Steering Stem Bearing Lubrication
- •Steering Stem Warp Inspection
- •Stem Cap Deterioration, Damage Inspection
- •Handlebar
- •Handlebar Removal
- •Handlebar Installation
- •Frame
- •Exploded View
- •Seats
- •Front Seat Removal
- •Front Seat Installation
- •Rear Seat Removal
- •Rear Seat Installation
- •Fairings
- •Lower Fairing Removal
- •Lower Fairing Installation
- •Lower Inner Fairing Removal
- •Lower Inner Fairing Installation
- •Upper Fairing Assembly Removal
- •Upper Fairing Assembly Installation
- •Center Fairing Removal
- •Center Fairing Installation
- •Upper Fairing Removal
- •Upper Fairing Installation
- •Upper Center Fairing Removal
- •Upper Center Fairing Installation
- •Upper Inner Fairing Removal
- •Upper Inner Fairing Installation
- •Center Inner Fairing Removal
- •Center Inner Fairing Installation
- •Inner Fairing Removal
- •Inner Fairing Installation
- •Fairing Cover Removal
- •Fairing Cover Installation
- •Side Covers
- •Side Cover Removal
- •Side Cover Installation
- •Seat Covers
- •Seat Cover Removal
- •Seat Cover Installation
- •Upper Seat Cover Installation (Only on Ninja ZX-6R MONSTER ENERGY® Model)
- •Fenders
- •Front Fender Removal
- •Front Fender Installation
- •Flap and Rear Fender Removal
- •Flap and Rear Fender Installation
- •Frame
- •Rear Frame Rear Removal
- •Rear Frame Rear Installation
- •Rear Frame Front Removal
- •Rear Frame Front Installation
- •Frame Inspection
- •Windshield
- •Windshield Removal
- •Windshield Installation
- •Guard
- •Mud Guard Removal
- •Mud Guard Installation
- •Sidestand
- •Sidestand Removal
- •Sidestand Installation
- •Electrical System
- •Exploded View
- •Specifications
- •Special Tools and Sealant
- •Parts Location
- •Wiring Diagram (US, CAL and CA Models)
- •Wiring Diagram (Other than US, CAL and CA Models)
- •Precautions
- •Electrical Wiring
- •Wiring Inspection
- •Battery
- •Battery Removal
- •Battery Installation
- •Battery Activation
- •Precautions
- •Interchange
- •Charging Condition Inspection
- •Refreshing Charge
- •Charging System
- •Alternator Cover Removal
- •Alternator Cover Installation
- •Stator Coil Removal
- •Stator Coil Installation
- •Alternator Rotor Removal
- •Alternator Rotor Installation
- •Charging Voltage Inspection
- •Alternator Inspection
- •Regulator/Rectifier Inspection
- •Ignition System
- •Crankshaft Sensor Removal
- •Crankshaft Sensor Installation
- •Crankshaft Sensor Inspection
- •Crankshaft Sensor Peak Voltage Inspection
- •Stick Coil Removal
- •Stick Coil Installation
- •Stick Coil Inspection
- •Stick Coil Primary Peak Voltage Inspection
- •Spark Plug Removal
- •Spark Plug Installation
- •Spark Plug Condition Inspection
- •Interlock Operation Inspection
- •IC Igniter Inspection
- •Electric Starter System
- •Starter Motor Removal
- •Starter Motor Installation
- •Starter Motor Disassembly
- •Starter Motor Assembly
- •Brush Inspection
- •Commutator Cleaning and Inspection
- •Armature Inspection
- •Brush Lead Inspection
- •Right-hand End Cover Assembly Inspection
- •Starter Relay Inspection
- •Lighting System
- •Headlight Beam Horizontal Adjustment
- •Headlight Beam Vertical Adjustment
- •Headlight Bulb Replacement
- •City Light Bulb Replacement
- •Headlight Removal/Installation
- •Tail/Brake Light (LED) Removal/Installation
- •License Plate Light Bulb Replacement
- •Turn Signal Light Bulb Replacement
- •Turn Signal Relay Inspection
- •Air Switching Valve
- •Air Switching Valve Operation Test
- •Air Switching Valve Unit Test
- •Radiator Fan System
- •Fan Motor Inspection
- •Meter, Gauge, Indicator Unit
- •Meter Unit Removal/Installation
- •Meter Unit Disassembly
- •Electronic Unit (Combination Meter) Inspection
- •Immobilizer System (Equipped Models)
- •Operational Cautions
- •Key Registration
- •Immobilizer System Parts Replacement
- •Immobilizer System Inspection
- •Switches and Sensors
- •Brake Light Timing Inspection
- •Brake Light Timing Adjustment
- •Switch Inspection
- •Water Temperature Sensor Inspection
- •Speed Sensor Removal
- •Speed Sensor Installation
- •Speed Sensor Inspection
- •Fuel Reserve Switch Inspection
- •Oxygen Sensor Removal (Equipped Models)
- •Oxygen Sensor Installation (Equipped Models)
- •Oxygen Sensor Inspection (Equipped Models)
- •Oxygen Sensor Heater Inspection (Equipped Models)
- •Gear Position Switch Removal
- •Gear Position Switch Installation
- •Gear Position Switch Inspection
- •Relay Box
- •Relay Box Removal
- •Relay Circuit Inspection
- •Diode Circuit Inspection
- •Fuse
- •30 A Main Fuse Removal
- •Fuse Box Fuse Removal
- •10 A ECU Fuse Removal
- •Fuse Installation
- •Fuse Inspection
- •Appendix
- •Cable, Wire, and Hose Routing
- •Troubleshooting Guide
Ninja ZX-6R
Motorcycle
Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure.
•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.
•Refer to the sectional table of contents for the exact pages to locate the specific topic required.
General Information |
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Periodic Maintenance |
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Fuel System (DFI) |
3 |
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Cooling System |
4 |
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Engine Top End |
5 |
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Clutch |
6 |
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Engine Lubrication System |
7 |
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Engine Removal/Installation |
8 |
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Crankshaft/Transmission |
9 |
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Wheels/Tires |
10 |
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Final Drive |
11 |
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Brakes |
12 |
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Suspension |
13 |
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Steering |
14 |
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Frame |
15 |
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Electrical System |
16 |
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Appendix |
17 |
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Ninja ZX-6R
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2008 Kawasaki Heavy Industries, Ltd. |
First Edition (1) : Oct. 31, 2008 (M) |
LIST OF ABBREVIATIONS
A |
ampere(s) |
lb |
pound(s) |
|
ABDC |
after bottom dead center |
m |
meter(s) |
|
AC |
alternating current |
min |
minute(s) |
|
ATDC |
after top dead center |
N |
newton(s) |
|
BBDC |
before bottom dead center |
Pa |
pascal(s) |
|
BDC |
bottom dead center |
PS |
horsepower |
|
BTDC |
before top dead center |
psi |
pound(s) per square inch |
|
°C |
degree(s) Celsius |
r |
revolution |
|
DC |
direct current |
rpm |
revolution(s) per minute |
|
F |
farad(s) |
TDC |
top dead center |
|
°F |
degree(s) Fahrenheit |
TIR |
total indicator reading |
|
ft |
foot, feet |
V |
volt(s) |
|
g |
gram(s) |
W |
watt(s) |
|
h |
hour(s) |
Ω |
ohm(s) |
|
L |
liter(s) |
|
|
|
|
|
|
|
COUNTRY AND AREA CODES
AT |
Austria |
GB |
United Kingdom |
AU |
Australia |
MY |
Malaysia |
BR |
Brazil |
SEA |
Southeast Asia |
CA |
Canada |
TH |
Thailand |
CAL |
California |
US |
United States |
CH |
Switzerland |
WVTA |
WVTA Model with Honeycomb |
|
|
(FULL H) |
Catalytic Converter (Full Power) |
DE |
Germany |
GB WVTA |
WVTA Model with Honeycomb Catalytic |
|
|
(FULL H) |
Converter (Left Side Traffic Full |
|
|
|
Power) |
EUR |
Europe |
WVTA |
WVTA Model with Honeycomb Catalytic |
|
|
(78.2 H) |
Converter (Restricted Power) |
|
|
|
|
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”
NOTE
○The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.
1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2.Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.
•Removal of the muffler(s) or any internal portion of the muffler(s).
•Removal of the air box or air box cover.
•Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your vehicle.
•Follow the Periodic Maintenance Chart in the Service Manual.
•Be alert for problems and non-scheduled maintenance.
•Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
•Follow the procedures in this manual carefully. Don’t take shortcuts.
•Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
•Indicates a procedural step or work to be done.
○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information |
|
Table of Contents |
|
|
1 |
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-9 |
Unit Conversion Table ............................................................................................................ |
1-12 |
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
Electrical Wires
A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.