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Manuals
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Kawasaki Manuals
Motorcycle
Ninja ZX-6RR
Service manual
Kawasaki ninja zx-6rr Service Manual Page 541
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Also See for ninja zx-6rr
Service manual
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519 pages
Instruction manual
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51 pages
Model information
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9 pages
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Page 1
Page 2
Page 3 - GENERAL INFORMATION
Page 4
Page 5
Page 6
Page 7 - Emission control information
Page 8
Page 9 - How to use this manual
Page 10
Page 11
Page 12 - Before Servicing
Page 13
Page 14
Page 15
Page 16
Page 17 - Model Identification
Page 18
Page 19 - General Specifications
Page 20
Page 21
Page 22 - Unit Conversion Table
Page 23 - Table Of Contents
Page 24
Page 25 - Periodic Maintenance Chart (United State...
Page 26 - Periodic Maintenance Chart
Page 27
Page 28
Page 29
Page 30
Page 31 - Torque and Locking Agent
Page 32
Page 33
Page 34
Page 35
Page 36
Page 37 - Specifications
Page 38
Page 39 - Special Tools
Page 40 - Maintenance Procedure
Page 41
Page 42
Page 43 - Idle Speed Inspection
Page 44 - Idle Speed Adjustment
Page 45 - Cooling System
Page 46 - Water Hose Damage and Installation Condi...
Page 47 - Valve Clearance Adjustment
Page 48
Page 49
Page 50 - Air Suction System Damage Inspection
Page 51 - Wheels/Tires
Page 52 - Wheel/Tire Damage Inspection
Page 53 - Wheel Bearing Damage Inspection
Page 54 - Drive Chain Slack Inspection
Page 55 - Drive Chain Slack Adjustment
Page 56 - Wheel Alignment Inspection
Page 57 - Chain Guide Wear Inspection
Page 58 - Brake Fluid Level Inspection
Page 59 - Brake Light Switch Operation Inspection
Page 60 - Front Fork Oil Leak Inspection
Page 61 - Steering
Page 62 - Steering Stem Bearing Lubrication
Page 63 - Lights and Switches Operation Inspection
Page 64
Page 65 - Headlight Aiming Inspection
Page 66 - Side Stand Switch Operation Inspection
Page 67 - Engine Stop Switch Operation Inspection
Page 68 - Others
Page 69 - Bolts, Nuts and Fasteners Tightness Insp...
Page 70 - Replacement Parts
Page 71
Page 72 - Coolant Change
Page 73
Page 74 - Radiator Hose and O-ring Replacement
Page 75 - Engine Oil Change
Page 76 - Brake Hose and Pipe Replacement
Page 77
Page 78 - Master Cylinder Rubber Parts Replacement
Page 79 - Caliper Rubber Parts Replacement
Page 80
Page 81
Page 82 - Spark Plug Replacement
Page 83
Page 84
Page 85 - Exploded View
Page 86
Page 87
Page 88
Page 89
Page 90
Page 91
Page 92 - Specifications
Page 93
Page 94 - Special Tools and Sealant
Page 95
Page 96 - DFI Parts Location
Page 97
Page 98 - DFI System
Page 99
Page 100
Page 101
Page 102
Page 103 - DFI Servicing Precautions
Page 104 - Troubleshooting the DFI System
Page 105
Page 106
Page 107
Page 108 - Inquiries to Rider
Page 109
Page 110
Page 111 - DFI System Troubleshooting Guide
Page 112
Page 113
Page 114
Page 115
Page 116 - Poor running or no power at high speed
Page 117
Page 118
Page 119 - Self-Diagnosis
Page 120 - Service Code Clearing Procedures
Page 121
Page 122 - Service Code Reading
Page 123
Page 124 - Backups
Page 125
Page 126 - Main Throttle Sensor (Service Code 11)
Page 127 - Main Throttle Sensor Output Voltage Insp...
Page 128
Page 129 - Main Throttle Sensor Resistance Inspecti...
Page 130 - Inlet Air Pressure Sensor (Service Code ...
Page 131 - Inlet Air Temperature Sensor Output Volt...
Page 132
Page 133
Page 134
Page 135 - Inlet Air Temperature Sensor (Service Co...
Page 136 - Inlet Air Temperature Sensor Resistance ...
Page 137
Page 138 - Water Temperature Sensor (Service Code 1...
Page 139 - Water Temperature Sensor Resistance Insp...
Page 140 - Atmospheric Pressure Sensor (Service Cod...
Page 141 - Atmospheric Pressure Sensor Output Volta...
Page 142
Page 143
Page 144 - Crankshaft Sensor (Service Code 21)
Page 145 - Camshaft Position Sensor (Service Code 2...
Page 146 - Speed Sensor (Service Code 24)
Page 147
Page 148 - Vehicle-down Sensor (Service Code 31)
Page 149
Page 150
Page 151 - Subthrottle Sensor (Service Code 32)
Page 152 - Subthrottle Sensor Output Voltage Inspec...
Page 153
Page 154 - Subthrottle Sensor Resistance Inspection
Page 155 - Exhaust Butterfly Valve Actuator Sensor ...
Page 156 - Stick Coils #1, #2, #3, #4: (Service Cod...
Page 157
Page 158 - Inspection
Page 159 - Subthrottle Valve Actuator Input Voltage...
Page 160 - Exhaust Butterfly Valve Actuator (Servic...
Page 161 - Exhaust Butterfly Valve Actuator Inspect...
Page 162 - Exhaust Butterfly Valve Actuator Output ...
Page 163 - ECU
Page 164 - ECU Power Supply Inspection
Page 165
Page 166 - DFI Power Source
Page 167 - FI Indicator Light (LED)
Page 168 - Fuel Line
Page 169 - Fuel Flow Rate Inspection
Page 170
Page 171 - Fuel Pump
Page 172 - Fuel Pump Operation Inspection
Page 173
Page 174 - Fuel Injectors
Page 175 - Fuel Injector Resistance Inspection
Page 176 - Fuel Injector Unit Test
Page 177
Page 178 - Fuel Injector Fuel Line Inspection
Page 179
Page 180 - Throttle Grip and Cables
Page 181 - Throttle Body Assy
Page 182 - Throttle Body Assy Installation
Page 183 - Throttle Body Assy Disassembly
Page 184 - Throttle Body Assy Assembly
Page 185 - Nozzle Assy
Page 186 - Nozzle Assy Assembly
Page 187
Page 188 - Air Cleaner
Page 189 - Air Cleaner Housing Installation
Page 190 - Air Cleaner Housing Disassembly
Page 191 - Fuel Tank
Page 192
Page 193 - Fuel Tank Installation
Page 194 - Fuel Tank and Cap Inspection
Page 195 - Evaporative Emission Control System (Cal...
Page 196 - Separator Operation Test
Page 197
Page 198 - Exploded View
Page 199
Page 200 - Specifications
Page 201 - Special Tools and Sealant
Page 202 - Coolant Flow Chart
Page 203
Page 204 - Coolant
Page 205 - Cooling System Flushing
Page 206 - Water Pump
Page 207 - Water Pump Housing Assembly
Page 208 - Radiator
Page 209 - Radiator and Radiator Fan Installation
Page 210
Page 211
Page 212 - Radiator Inspection
Page 213 - Radiator Cap Inspection
Page 214 - Thermostat
Page 215 - Thermostat Inspection
Page 216 - Hoses and Pipes
Page 217 - Water Temperature Sensor
Page 218
Page 219
Page 220 - Exploded View
Page 221
Page 222
Page 223
Page 224
Page 225 - Specifications
Page 226
Page 227
Page 228
Page 229 - Air Suction Valve Removal
Page 230 - Vacuum Switch Valve Removal
Page 231 - Clean Air System Hose Inspection
Page 232 - Cylinder Head Cover
Page 233
Page 234 - Camshaft Chain Tensioner
Page 235 - Camshaft, Camshaft Chain
Page 236
Page 237 - Camshaft, Camshaft Cap Wear Inspection
Page 238 - Cam Wear Inspection
Page 239 - Cylinder Head
Page 240 - Cylinder Head Removal
Page 241 - Cylinder Head Warp Inspection
Page 242 - Valves
Page 243 - Valve Guide Installation
Page 244 - Valve Seat Inspection
Page 245
Page 246
Page 247
Page 248
Page 249 - Cylinder, Pistons
Page 250 - Piston Removal
Page 251 - Cylinder Wear Inspection
Page 252 - Piston Ring, Piston Ring Groove Wear Ins...
Page 253 - Piston Ring End Gap Inspection
Page 254 - Throttle Body Holder
Page 255 - Muffler
Page 256 - Muffler Body Installation
Page 257 - Exhaust Pipe Manifold Removal
Page 258 - Exhaust Pipe Manifold Installation
Page 259 - Exhaust Butterfly Valve Cable Removal
Page 260
Page 261
Page 262
Page 263
Page 264 - Exploded View
Page 265
Page 266 - Specifications
Page 267 - Special Tool and Sealant
Page 268 - Clutch Lever and Cable
Page 269 - Clutch Cover
Page 270 - Release Shaft Installation
Page 271 - Clutch Removal
Page 272
Page 273
Page 274 - Spring Plate Free Play Measurement
Page 275 - Spring Plate Play Adjustment
Page 276 - Clutch Plate, Wear, Damage Inspection
Page 277
Page 278 - Exploded View
Page 279
Page 280 - Specifications
Page 281 - Special Tools and Sealant
Page 282 - Engine Oil Flow Chart
Page 283
Page 284 - Engine Oil and Oil Filter
Page 285 - Oil Pan
Page 286
Page 287 - Oil Pressure Relief Valve
Page 288 - Oil Pump
Page 289 - Oil Pump Drive Gear Removal
Page 290 - Oil Pump Drive Gear Installation
Page 291 - Oil Cooler
Page 292 - Oil Pressure Measurement
Page 293 - Oil Pressure Switch
Page 294
Page 295
Page 296 - Exploded View
Page 297
Page 298 - Special Tool
Page 299 - Engine Removal/Installation
Page 300
Page 301 - Engine Installation
Page 302
Page 303
Page 304 - Exploded View
Page 305
Page 306
Page 307
Page 308 - Specifications
Page 309
Page 310 - Special Tools and Sealant
Page 311 - Crankcase Splitting
Page 312 - Crankcase Splitting
Page 313
Page 314
Page 315 - Crankshaft and Connecting Rods
Page 316
Page 317
Page 318
Page 319 - Crankshaft/Connecting Rod Cleaning
Page 320 - Connecting Rod Big End Bearing Insert/Cr...
Page 321 - Crankshaft Side Clearance Inspection
Page 322 - Crankshaft Runout Inspection
Page 323
Page 324 - Transmission
Page 325 - External Shift Mechanism Removal
Page 326 - Transmission Shaft Removal
Page 327 - Transmission Shaft Assembly
Page 328
Page 329
Page 330 - Shift Drum and Fork Removal
Page 331 - Shift Fork/Gear Groove Wear Inspection
Page 332
Page 333
Page 334 - Exploded View
Page 335
Page 336 - Specifications
Page 337 - Special Tools
Page 338 - Wheels (Rims)
Page 339 - Rear Wheel Removal
Page 340 - Rear Wheel Installation
Page 341 - Wheel Inspection
Page 342 - Axle Inspection
Page 343 - Balance Adjustment
Page 344
Page 345 - Tires
Page 346
Page 347 - Tire Repair
Page 348 - Hub Bearing
Page 349 - Hub Bearing Lubrication
Page 350
Page 351
Page 352 - Exploded View
Page 353
Page 354 - Specifications
Page 355 - Special Tools
Page 356 - Drive Chain
Page 357 - Drive Chain Installation
Page 358
Page 359
Page 360 - Sprocket, Coupling
Page 361 - Rear Sprocket Removal
Page 362 - Coupling Bearing Removal
Page 363 - Coupling Bearing Inspection
Page 364 - Rear Sprocket Warp Inspection
Page 365
Page 366 - Exploded View
Page 367
Page 368
Page 369
Page 370 - Specifications
Page 371 - Special Tools
Page 372 - Brake Lever, Brake Pedal
Page 373 - Brake Pedal Installation
Page 374 - Calipers
Page 375 - Front Caliper Disassembly
Page 376 - Rear Caliper Dust Boot and Rubber Boot D...
Page 377 - Brake Pads
Page 378 - Rear Brake Pad Removal
Page 379 - Master Cylinder
Page 380 - Rear Master Cylinder Removal
Page 381
Page 382 - Brake Disc
Page 383 - Brake Fluid
Page 384
Page 385
Page 386
Page 387 - Brake Hose
Page 388
Page 389
Page 390 - Exploded View
Page 391
Page 392
Page 393
Page 394 - Specifications
Page 395 - Special Tools
Page 396
Page 397 - Front Fork
Page 398 - Spring Preload Adjustment
Page 399 - Front Fork Installation
Page 400
Page 401
Page 402
Page 403 - Front Fork Disassembly
Page 404 - Front Fork Assembly
Page 405 - Dust Seal Inspection
Page 406 - Rear Shock Absorber
Page 407 - Spring Preload Adjustment
Page 408 - Rear Shock Absorber Removal
Page 409 - Rear Shock Absorber Inspection
Page 410 - Swingarm
Page 411 - Swingarm Installation
Page 412 - Swingarm Bearing Removal
Page 413 - Swingarm Bearing Installation
Page 414 - Chain Guide Inspection
Page 415 - Tie-Rod, Rocker Arm
Page 416 - Rocker Arm Installation
Page 417
Page 418 - Rocker Arm/Tie-Rod Bearing, Sleeve Inspe...
Page 419
Page 420 - Exploded View
Page 421
Page 422 - Special Tools
Page 423 - Steering Inspection
Page 424 - Steering Stem
Page 425 - Steering Stem, Steering Stem Bearing Ins...
Page 426
Page 427 - Steering Stem Bearing Lubrication
Page 428 - Handlebar
Page 429
Page 430
Page 431
Page 432 - Exploded View
Page 433
Page 434
Page 435
Page 436
Page 437
Page 438 - Seats
Page 439 - Fairings
Page 440 - Center Fairing Installation
Page 441 - Upper Fairing Disassembly
Page 442 - Upper Fairing Installation
Page 443 - Right and Left Inner Fairing Removal
Page 444 - Side Covers
Page 445 - Seat Cover
Page 446 - Fenders
Page 447 - Flap and Rear Fender Rear Installation
Page 448 - Rear Fender Front Removal
Page 449 - Frame
Page 450 - Side Stand
Page 451
Page 452
Page 453 - Parts Location
Page 454 - Exploded View
Page 455
Page 456
Page 457
Page 458
Page 459
Page 460 - Wiring Diagram (United States and Canada...
Page 461
Page 462 - Wiring Diagram (Other than United States...
Page 463
Page 464 - Wiring Diagram (Australia)
Page 465
Page 466 - Specifications
Page 467 - Special Tools and Sealant
Page 468 - Precautions
Page 469
Page 470 - Electrical Wiring
Page 471 - Battery
Page 472
Page 473
Page 474 - Precautions
Page 475 - Charging Condition Inspection
Page 476
Page 477 - Charging System
Page 478 - Alternator Rotor Removal
Page 479 - Alternator Inspection
Page 480
Page 481 - Regulator/Rectifier Removal
Page 482
Page 483 - Charging Voltage Inspection
Page 484
Page 485 - Starter Motor Clutch Removal/Installatio...
Page 486 - Ignition System
Page 487 - Crankshaft Sensor Removal
Page 488 - Crankshaft Sensor Installation
Page 489 - Timing Rotor Removal
Page 490 - Stick Coil (Ignition Coil together with ...
Page 491 - Stick Coil Primary Peak Voltage
Page 492 - Spark Plug Clean and Inspection
Page 493 - Camshaft Position Sensor Peak Voltage In...
Page 494 - Interlock Operation Inspection
Page 495 - IC Igniter Inspection
Page 496
Page 497 - Electric Starter System
Page 498 - Brush Inspection
Page 499 - Commutator Cleaning and Inspection
Page 500 - Right-hand End Cover Assembly Inspection
Page 501
Page 502 - Lighting System
Page 503 - City Light Bulb Replacement (Europe Mode...
Page 504 - Tail/Brake Light (LED) Removal
Page 505 - Turn Signal Light Bulb Replacement
Page 506
Page 507 - Turn Signal Relay Inspection
Page 508
Page 509
Page 510 - Radiator Fan System
Page 511 - Meter, Gauge, Indicator Unit
Page 512 - Electronic Combination Meter Unit Inspec...
Page 513
Page 514
Page 515
Page 516
Page 517
Page 518
Page 519
Page 520 - Switches and Sensors
Page 521 - Switch Inspection
Page 522 - Water Temperature Sensor Inspection
Page 523 - Speed Sensor Inspection
Page 524 - Relay Box
Page 525 - Diode Circuit Inspection
Page 526
Page 527 - Fuse
Page 528 - Fuse Installation
Page 529
Page 530 - Cable, Wire, and Hose Routing
Page 531
Page 532 - Cable, Wire, and Hose Routing (US Model)
Page 533
Page 534 - Cable, Wire, and Hose Routing (Other the...
Page 535
Page 536 - Cable, Wire, and Hose Routing
Page 537
Page 538
Page 539
Page 540
Page 541
Page 542
Page 543
Page 544
Page 545
Page 546
Page 547
Page 548
Page 549
Page 550
Page 551
Page 552
Page 553
Page 554
Page 555
Page 556
Page 557
Page 558 - Troubleshooting Guide
Page 559
Page 560 - Over cooling
Page 561 - Abnormal drive train noise
Page 562
Page 563
/
563
Contents
Table of contents
Troubleshooting
Bookmarks
Advertisement
Cable, Wire, and Hose Routing
1. Reserve Return Hose
2. Clamp
3. Starter Motor Cable
4. Main Harness
5. Run the harnesses under the breather hose.
6. Clamp
7. Clamp
8. Speed Sensor
9. Force the harness into between the bosses of the upper crankcase.
10. Regulator/Rectifier Lead
11. Side Stand Switch Lead
12. Alternator Lead
13. Neutral Switch Lead
14. Reserve Tank Over Flow Hose
15. Clamp the regulator/rectifier lead together with the fuel tank drain hose and reserve tank over
flow hose.
16. Clamp the side stand switch lead.
17. Adjust the clamp position so that the side stand lead does not loosen.
18. Run the alternator lead under the starter motor cable.
APPENDIX 17-13
Table of
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Emission control information
Before Servicing
Engine Top End
Wheels/Tires
Unit Conversion Table
Fuel System
Cooling System
Air Pressure Inspection
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Chapters
Table Of Contents
11
Periodic Maintenance
23
Fuel System (dfi)
83
Cooling System
197
Engine Top End
219
Clutch
263
Engine Lubrication System
277
Table Of Contents
295
Crankshaft/transmission
303
Wheels/tires
333
Final Drive
351
Brakes
365
Suspension
389
Steering
419
Frame
431
Electrical System
451
Table of Contents
Troubleshooting
Troubleshooting the DFI System
104
DFI System Troubleshooting Guide
111
Troubleshooting Guide
558
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