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Kawasaki Ninja ZX-6R Service Manual

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Ninja ZX-6R
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  Summary of Contents for Kawasaki Ninja ZX-6R

  • Page 1 Ninja ZX-6R Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 5 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. © 1999 Kawasaki Heavy Industries, Ltd. 7th Edition (1):Jun. 26, 2007 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 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.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    General Specifications......................Periodic Maintenance Chart (United States and Canada Models) ......... Periodic Maintenance Chart (Other than United States and Canada Models) ....... 1-11 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)......1-13 Technical Information - Non-Contact Hall IC-Type Speed Sensor.......... 1-22 Technical Information - Alternator Made from Rare Magnet...........
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13: General Information

    GENERAL INFORMATION 1-3 Before Servicing (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent...
  • Page 15: Model Identification

    GENERAL INFORMATION 1-5 Model Identification ZX600-J1 Left Side View ZX600-J1 Right Side View...
  • Page 16: General Specifications

    1-6 GENERAL INFORMATION General Specifications ZX600-J3 ∼ Items ZX600-J1, J2 Dimensions Overall Length 2 030 mm (79.9 in.), (PN) 2 060 mm (81.1 in.) ← Overall Width 730 mm (28.7 in.) ← Overall Height 1 175 mm (46.3 in.) ← Wheelbase 1 400 mm (55.1 in.) ←...
  • Page 17 GENERAL INFORMATION 1-7 General Specifications ZX600-J3 ∼ Items ZX600-J1, J2 Exhaust: Open 61° BBDC ← Close 33° ATDC ← Duration 274° ← Lubrication System Forced lubrication (wet sump with cooler) ← Engine Oil: Grade API SE, SF or SG ← API SH, SJ with JASO MA (ZX600J1 ∼...
  • Page 18 1-8 GENERAL INFORMATION General Specifications ZX600-J3 ∼ Items ZX600-J1, J2 Front Suspension: Type Telescopic fork ← Wheel Travel 120 mm (4.7 in.) ← Rear Suspension: Type Swingarm (uni-trak) ← Wheel Travel 135 mm (5.3 in.) ← Brake Type: Front Dual discs ←...
  • Page 19: Periodic Maintenance Chart (United States And Canada Models)

    GENERAL INFORMATION 1-9 Periodic Maintenance Chart (United States and Canada Models) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes...
  • Page 20 1-10 GENERAL INFORMATION Periodic Maintenance Chart (United States and Canada Models) FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) marks (0.6) (7.5) (12) (15) (20) (24) OPERATION Every Coolant filter - clean year #: Service more frequently when operating in severe conditions;...
  • Page 21: Periodic Maintenance Chart (Other Than United States And Canada Models)

    GENERAL INFORMATION 1-11 Periodic Maintenance Chart (Other than United States and Canada Models) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes...
  • Page 22 1-12 GENERAL INFORMATION Periodic Maintenance Chart (Other than United States and Canada Models) #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed, or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here. †: Replace, add, adjust, clean, or torque if necessary.
  • Page 23: Technical Information-Kleen (Kawasaki Low Exhaust Emission)

    Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) The ZX600J have catalytic converters. The secondary air injection system [A] helps Kawasaki keep motorcycle exhaust gases below the established emission regulation limits. This system draws air into the exhaust ports, dilutes and burns harmful ingredients in the exhaust gas in order to reduce them.
  • Page 24 1-14 GENERAL INFORMATION Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) 1. Exhaust Purification System The burned gas, which goes out from the combustion chamber, is injected with secondary air (adding necessary oxygen), and is cleaned up while passing through the small precatalytic converters in the joint pipe and the main catalytic converter in the silencer, and then goes out to the atmosphere.
  • Page 25: Catalytic Converters

    GENERAL INFORMATION 1-15 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) Catalytic Converters 2. Catalyst Protection System When excessive unburned gasoline flows more than the allowable amount into the exhaust gas dur- ing running, the temperature of the catalysts rises abnormally because the unburned gasoline reacts with heated catalysts (at the activation temperature or higher).
  • Page 26 1-16 GENERAL INFORMATION Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) old fuel may gum up the fuel cut valves which remain seated in the float bowls. To cope with, the IC igniter test-operates the fuel cut valves when starting the engine and prevents lock of the valves.
  • Page 27 GENERAL INFORMATION 1-17 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) Engine Ignition Protection Fuel No Running Condition Stop Remedy (Action) Switch System Cutvalve Switch Abnormal (no spark) OPEN • • Short of the ignition Inspect and replace switch the ignition switch.
  • Page 28 1-18 GENERAL INFORMATION Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) • When the ignition switch [A] is turned off, the fuel cut valves [B] do not work. So, avoid coasting with the ignition switch OFF. • Do not run the engine nor coast the motorcycle under the misfire which occurs by defects such as a bad connection with the spark plug at the secondary wiring of the stick coil [C].
  • Page 29 GENERAL INFORMATION 1-19 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) • Do not run overspeed limiter too much from the standpoint to protect the engine. (Overspeed limiter has a protection system that applies ignition cut method and fuel cut method together. Conventional system applies fuel-on method.)
  • Page 30 1-20 GENERAL INFORMATION Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) Secondary Air Injection System 1. Air Cleaner Housing 6. Exhaust Valve 2. Air Hose 7. Carburetors 3. Inlet Silencer 8. Inlet Pipe 4. Vacuum Switch Valve 9. Inlet Valve 5. Air Suction Valve 2) Operation of Three-way Catalytic Converter The three-way catalysts are used for the catalytic converters and the main catalytic converter.
  • Page 31 GENERAL INFORMATION 1-21 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION) 3) Property of Catalyst Most catalysts are powders of metal or of metallic compounds, and they increase the rate of a chemical reaction. Catalysts are supposed to act in some way to loosen the bonds of the reacting substances. In other words, they lower the energy of activation, thus allowing the reaction to proceed more rapidly.
  • Page 32: Technical Information - Non-Contact Hall Ic-Type Speed Sensor

    1-22 GENERAL INFORMATION Technical Information - Non-Contact Hall IC-Type Speed Sensor Details The electronic combination meter unit, superior to the conventional type in weight and durability is installed on the ZX600-J. The hall IC-type speed sensor is installed on the ZX600-J together with it, which needs no cable and speedometer gears.
  • Page 33 GENERAL INFORMATION 1-23 Technical Information - Non-Contact Hall IC-Type Speed Sensor • In the internal system of the Hall IC, the switch is operated in accordance with the magnetic induction alternator. This makes the square wave equal to the pulse of the rotor nut output.
  • Page 34: Technical Information - Alternator Made From Rare Magnet

    1-24 GENERAL INFORMATION Technical Information - Alternator Made from Rare Magnet Rare Magnet Material Sintered metal made from mainly neodium (Nd), ferric magnet (Fe), and boron (B). Main Characters Rare magnet used and assembled in the alternator for the ZX600-J model has six (6) times higher performance than that of the traditional use ferrite magnet.
  • Page 35: Torque And Locking Agent

    GENERAL INFORMATION 1-25 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. LG: Apply grease to the threads.
  • Page 36 1-26 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Baffle Plate Bolts 87 in·lb Muffler Body and Exhaust Pipe Connecting Nuts Exhaust Pipe Mounting Bolt Clutch Clutch Cover Bolts 104 in·lb L (2, Front) Clutch Cover Damper Bolts 0.60 52 in·lb Clutch Spring Bolts...
  • Page 37 GENERAL INFORMATION 1-27 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Neutral Switch Shift Drum Bearing Holder Bolt 104 in·lb Shift Drum Bearing Holder Screw 43 in·lb Shift Drum Cam Bolt 104 in·lb Oil Pipe Holder Bolts 104 in·lb Crankshaft Sensor Cover Bolts 104 in·lb L (1)
  • Page 38 1-28 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts (Upper and Lower) Rear Shock Absorber Upper Bracket Nut Swingarm Pivot Shaft Nut Uni-Trak: Rocker Arm Nut Tie-Rod Nuts Steering Steering Stem Head Nut Steering Stem Locknut 43 in·lb Steering Stem Nut...
  • Page 39 GENERAL INFORMATION 1-29 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Throttle Sensor Mounting Screws 0.35 30 in·lb Side Stand Switch Bolt 0.90 78 in·lb...
  • Page 40 1-30 GENERAL INFORMATION Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 41: Special Tools And Sealant

    GENERAL INFORMATION 1-31 Special Tools and Sealant Bearing Puller: Valve Spring Compressor Assembly: 57001-135 57001-241 Inside Circlip Pliers: Bearing Puller Adapter: 57001-143 57001-317 Outside Circlip Pliers: Piston Pin Puller Assembly: 57001-144 57001-910 Oil Pressure Gauge, 10 kgf/cm²: Fuel Level Gauge: 57001-164 57001-1017 Compression Gauge, 20 kgf/cm²:...
  • Page 42 1-32 GENERAL INFORMATION Special Tools and Sealant Head Pipe Outer Race Press Shaft: Valve Seat Cutter, 32° - 28: 57001-1075 57001-1119 Steering Stem Nut Wrench: Valve Seat Cutter, 32° - 30: 57001-1100 57001-1120 Hook Wrench R37.5, R42: Valve Seat Cutter, 60° - 30: 57001-1101 57001-1123 Valve Seat Cutter, 45°...
  • Page 43 GENERAL INFORMATION 1-33 Special Tools and Sealant Valve Spring Compressor Adapter, 20: Pilot Screw Adjuster, A: 57001-1154 57001-1239 Valve Spring Compressor Adapter, 22: Clutch Holder: 57001-1202 57001-1243 Fork Outer Tube Weight: Oil Filter Wrench: 57001-1218 57001-1249 Front Fork Oil Seal Driver: Spark Plug Wrench, Hex 16: 57001-1219 57001-1262...
  • Page 44 1-34 GENERAL INFORMATION Special Tools and Sealant Valve Guide Arbor, 4: Fork Oil Level Gauge: 57001-1273 57001-1290 Valve Guide Reamer, 4: Flywheel Holder: 57001-1274 57001-1313 Valve Seat Cutter Holder, 4: Compression Gauge Adapter, M10 × 1.0: 57001-1275 57001-1317 Oil Pressure Gauge Adapter, M18 × 1.5: Valve Seat Cutter, 60°...
  • Page 45 GENERAL INFORMATION 1-35 Special Tools and Sealant □ Steering Stem Bearing Driver Adapter, 41.5: Fork Cylinder Holder, Hex 24 × 19.5: 57001-1345 57001-1406 Bearing Remover Head, 25 × 28: Peak Voltage Adapter: 57001-1346 57001-1415 Bearing Remover Shaft, 13: Head Pipe Outer Race Driver, 55: 57001-1377 57001-1446 Hand Tester:...
  • Page 46 1-36 GENERAL INFORMATION Special Tools and Sealant Engine Mount Nut Wrench: Flywheel & Pulley Holder: 57001-1450 57001-1605 Needle Adapter Set: Kawasaki Bond (Silicone Sealant): 57001-1457 56019-120 Throttle Sensor Setting Adapter: Kawasaki Bond (Liquid Gasket - Gray): 57001-1521 92104-1063...
  • Page 47: Cable, Wire, And Hose Routing

    GENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing 1. Choke Cable 2. Clutch Cable 3. Throttle Cables 4. Front Fork 5. Coolant Reserve Tank Hose 6. Coolant By-pass Hose 7. To Main Harness 8. Air Intake Duct 9. Turn Signal Light Lead 10.
  • Page 48 1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Meter Lead 2. Headlight/Turn Signal Light Lead 3. Headlight Relay Lead 4. Left Handlebar Switch Lead 5. Right Handlebar Switch Lead 6. Ignition Switch Lead 7. Front Fork 8. Radiator Fan Motor Lead 9.
  • Page 49 GENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing 1. Rear Brake Switch Lead 2. Battery 3. Alternator Lead Connector 4. Battery (–) Cable 5. Starter Relay 6. Junction Box 7. IC Igniter 8. Fuel Pump Relay 9. Headlight Fuse Lead 10.
  • Page 50 1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Headlight/Turn Signal 12. Fuel Pump Relay 19. Engine (Battery) Ground Light Lead 13. Regulator/Rectifier Cable 2. Headlight Relay Lead 14. Rear Brake Light Switch 20. Clamp 3. Horn 15. Starter Relay 21.
  • Page 51 GENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing 1. Radiator 11. Face the white mark outward. 2. Radiator Fan Switch 12. Face the white mark forward. 3. Coolant Reserve Tank 13. Align the marks. 4. Reserve Tank Overflow Hose 14. Drain Hose (California model only) 5.
  • Page 52 1-42 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Coolant By-pass Hose 9. Other than US, CA Models 2. Align the mark on the hose with the pro- 10. To #4 Carburetor jection on the thermostat cover. 11. To #1 Carburetor 3.
  • Page 53 GENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing 1. Air Vent Filter 11. To Radiator 2. Align the mark on the hose with the mark 12. Install the clamps with the baffle plate. on the filter. 13. Baffle Plate 3. To Carburetors 14.
  • Page 54 1-44 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Brake Hose Joint 2. Front Brake Reservoir 3. Front Brake Master Cylinder 4. Clamp (Installed to the front fender) 5. Front Brake Caliper 6. Clamp 7. Clamp 8. Rear Brake Caliper 9.
  • Page 55 GENERAL INFORMATION 1-45 Cable, Wire, and Hose Routing 1. Vacuum Valve 12. Vacuum Hoses (To #2, #3 20. Breather Hose (To Canis- 2. To Air Vent Filter Carburetor Holder) ter, Blue) 3. Carburetor Vent Hose 13. Fitting (4 Way) 21. Breather Hose (To Fuel 4.
  • Page 56 1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Tank 10. Purge Hose (Green) 2. Return Hose (To Fuel Tank, Red) 11. To Right Turn Signal Light 3. Breather Hose (To Fuel Tank, Blue) 12. Canister 4. Through the cut portion of Rear Fender 13.
  • Page 57: Cable, Wire And Hose Routing (Zx600-J4)

    GENERAL INFORMATION 1-47 Cable, Wire and Hose Routing (ZX600-J4) Evaporative Emission Control System (California Model) 1. Main Harness 10. Fuel Hose 2. Regulator/Rectifier Lead 11. Carburetor Vent Hose (Yellow) 3. Purge Hose (green) 12. Breather Hose (Blue) (To Fuel Tank) 4.
  • Page 59 FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View........Coolant Valve Inspection (Other Specifications ........than United States and Canada Throttle Grip and Cables ....Models) ........2-17 Throttle Grip Play Inspection..Air Cleaner......... 2-18 Throttle Cable Installation .... Element Removal......
  • Page 60: Exploded View

    2-2 FUEL SYSTEM Exploded View 1. Air Cleaner Housing 2. Air Cleaner Element 3. Air Vent Filter 4. Vacuum Switch Valve 5. Silencer Assy (CAL Model) 6. Vacuum Hose Assy (CAL Model) 7. Carburetor Vent Hose (CAL Model) AO: Apply high quality form air filter oil. CAL: California...
  • Page 61 FUEL SYSTEM 2-3 Exploded View 1. Throttle Cable (accelerator) 11. Throttle Sensor 2. Throttle Cable (decelerator) 12. Fuel Cut Valve (CAL, H Models) 3. Choke Cable 13. Cooling Hose Assy (other than US, CA 4. Pilot Screw Models) 5. Pilot (Slow) Jet 14.
  • Page 62 2-4 FUEL SYSTEM Exploded View 1. Fuel Pump 2. Fuel Filter 3. Seal (CAL Model) 4. Evaporative Emission Control System (CAL Model) 5. Vacuum Valve 6. Separator 7. Canister T1: 2.5 N·m (0.25 kg·m, 22 in·lb) (with white washer) 4.9 N·m (0.50 kg·m, 43 in·lb) (with black washer) CAL: California...
  • Page 63: Specifications

    FUEL SYSTEM 2-5 Specifications Item Standard Throttle Grip And Cables 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play Choke Cable 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Free Play Carburetors Make, Type MIKUNI, BDSR-36 × 4 Main Jet #1, 4: #155, #2, 3: #157.5 Main Air Jet...
  • Page 64: Throttle Grip And Cables

    2-6 FUEL SYSTEM Throttle Grip and Cables Throttle Grip Play Inspection Throttle Grip Free Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 65: Choke Cable

    FUEL SYSTEM 2-7 Choke Cable Choke Cable Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free play [B]. ○ Determine the amount of choke cable play at the choke lever.
  • Page 66: Carburetors

    2-8 FUEL SYSTEM Carburetors Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 67: Synchronization Adjustment

    FUEL SYSTEM 2-9 Carburetors Synchronization Adjustment • Turn the adjusting screw to synchronize the carburetors. ○ Apply grease to the tip of the adjusting screw threads. ○ First synchronize the left two and then the right two car- buretors by means of the left and right adjusting screws [A, C].
  • Page 68: Service Fuel Level Adjustment

    2-10 FUEL SYSTEM Carburetors • Wait until the fuel level in the gauge settles. • Keeping the gauge vertical, align the "middle" line with the mark. NOTE ○ Do not lower the "middle" line below the mark of the carburetor body. If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level.
  • Page 69: Fuel System Cleanliness Inspection

    FUEL SYSTEM 2-11 Carburetors NOTE ○ Do not push the needle rod [A] in during the float height measurement [B]. • Assemble the carburetor, and recheck the fuel level. If the fuel level cannot be adjusted by this method, the float or the float valve [C] is damaged.
  • Page 70: Carburetor Installation

    2-12 FUEL SYSTEM Carburetors • Loosen the carburetor clamp screws [A], and remove the carburetors. • Remove the throttle cable ends and choke cable. • Stuff pieces of lint-free, clean cloth into the carburetor holders to keep dirt out of the engine. WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly...
  • Page 71: Carburetor Disassembly

    FUEL SYSTEM 2-13 Carburetors Carburetor Disassembly • Remove the carburetors. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 72: Carburetor Assembly

    2-14 FUEL SYSTEM Carburetors Carburetor Assembly • Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of turns counted during dis- assembly. • For the US model, install the pilot screw plug as follows: install a new plug [B] in the pilot screw hole of the car- buretor body [C], and apply a small amount of a bonding agent [D] to the circumference of the plug to fix the plug.
  • Page 73: Carburetor Cleaning

    FUEL SYSTEM 2-15 Carburetors Carburetor Cleaning WARNING Clean the carburetors in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetors.
  • Page 74 2-16 FUEL SYSTEM Carburetors • Slide the starter plunger lever to the left and release it to check that the starter plungers move smoothly and return by spring tension. If the starter plungers do not work properly, replace the carburetors. •...
  • Page 75: Coolant Filter Cleaning (Other Than United States And Canada Models)

    FUEL SYSTEM 2-17 Carburetors Coolant Filter Cleaning (Other than United States and Canada Models) Before winter season starts, clean the filter of carburetor system. • Remove the fuel tank (see Fuel Tank Removal). • Drain the coolant (see Cooling System chapter). •...
  • Page 76: Air Cleaner

    2-18 FUEL SYSTEM Air Cleaner Element Removal • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel Tank Removal) Upper Housing Mounting Bolts [A] Upper Housing [B] • Remove the following parts as a unit. Upper Plastic Holder [A] Element [B] Lower Plastic Holder [C] •...
  • Page 77: Air Cleaner Housing Removal

    FUEL SYSTEM 2-19 Air Cleaner Air Cleaner Housing Removal • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel Tank Removal) Engine Breather Hose [A] Rubber Plugs [B] Fuel Cut Valve Connectors [C] (California and H Models) • Remove: Air Cleaner Housing Mounting Bolts [A] •...
  • Page 78: Fuel Tank

    2-20 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 79: Fuel Tank Inspection

    FUEL SYSTEM 2-21 Fuel Tank Fuel Tank Inspection • Remove the hose(s) from the fuel tank, and open the tank cap. • Check to see if the water drain pipe [B] (also the breather pipe [C] for the California model) in the tank is not clogged. Check the tank cap breather also.
  • Page 80: Fuel Tap Installation

    2-22 FUEL SYSTEM Fuel Tank Fuel Tap Installation • Be sure the O-rings [A] is in good condition to prevent leaks. • Be sure the flat washers [B] are in good condition to pre- vent leaks. ○ Do not use steel washers in place of the flat washers, because they will not seal the bolts properly and fuel will leak.
  • Page 81: Fuel Pump, Fuel Filter

    FUEL SYSTEM 2-23 Fuel Pump, Fuel Filter Fuel Pump, Fuel Filter Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 82: Evaporative Emission Control System (California Model Only)

    2-24 FUEL SYSTEM Evaporative Emission Control System (California Model Only) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 83: Separator Operation Test

    FUEL SYSTEM 2-25 Evaporative Emission Control System (California Model Only) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 84: Vacuum Valve Inspection

    2-26 FUEL SYSTEM Evaporative Emission Control System (California Model Only) Vacuum Valve Inspection • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Bracket [A] and Vacuum Valve [B] Vacuum Valve Hoses [C] • Remove the drain screw [A] from the bottom of the cham- ber.
  • Page 85 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Filter Cleaning ..................... Water Pump..........................
  • Page 86: Exploded View

    3-2 COOLING SYSTEM Exploded View 1. Radiator Fan Switch T3: 12 N·m (1.2 kgf·m, 104 in·lb) 2. Water Temperature Sensor T4: 7.8 N·m (0.80 kgf·m, 69 in·lb) 3. Coolant By-pass Fitting T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) 4. Drain Plug T6: 11 N·m (1.1 kgf·m, 95 in·lb) 5.
  • Page 87: Specifications

    93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18 psi) Relief pressure: Thermostat 58 ∼ 62°C (136 ∼ 144°F) Valve opening temperature Valve full opening lift 8 mm (0.32 in.) or more @75°C (167°F) Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 88: Coolant Flow Chart

    3-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 89 COOLING SYSTEM 3-5 Coolant Flow Chart 1. Radiator 5. Drain Plug 2. Radiator Cap 6. Water Pump 3. Radiator Fan 7. Water Temperature Sensor 4. Fan Switch 8. Oil Cooler 9. Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
  • Page 90: Coolant

    3-6 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 91: Coolant Filling

    COOLING SYSTEM 3-7 Coolant • Remove: Lower Fairing (see Frame chapter) Radiator Cap [A] • Place a container under the drain plug [A] at the bottom of the water pump cover [B]. • Drain the coolant from the radiator and engine by remov- ing the drain plug.
  • Page 92: Pressure Testing

    3-8 COOLING SYSTEM Coolant Water and Coolant Mixture Ratio (Recommended) Soft Water Coolant Freezing Point –35°C (–31°F) Total Amount 2.3 L (2.43 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. • Bleed the air from the cooling system as follows. ○...
  • Page 93: Cooling System Flushing

    COOLING SYSTEM 3-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 94: Water Pump

    3-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubrication Sys- tem chapter. Water Pump Installation • Refer to Oil Pump Installation in the Engine Lubrication System chapter. Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump body for coolant leaks.
  • Page 95: Radiator, Radiator Fan

    COOLING SYSTEM 3-11 Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 96: Radiator Inspection

    3-12 COOLING SYSTEM Radiator, Radiator Fan Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 97: Thermostat

    COOLING SYSTEM 3-13 Thermostat Thermostat Removal • Remove: Coolant (see Coolant Draining) Seats (see Frame chapter) Fuel Tank (see Fuel System chapter) Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation • Be sure to install the O-ring [A] on the housing cover. •...
  • Page 98: Hose And Pipes

    3-14 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 99: Radiator Fan Switch, Water Temperature Sensor

    • Apply silicone sealant to the threads of the water temper- ature sensor. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the fan switch and water temperature sensor. Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb) Water Temperature Sensor: 7.8 N·m (0.80 kgf·m,...
  • Page 101: Valve Guide

    ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..4-19 Specifications ........Valve Clearance Adjustment..4-20 Clean Air System....... Valve Removal ......4-23 Air Suction Valve Removal... Valve Installation ......4-23 Air Suction Valve Installation..Valve Guide Removal ....
  • Page 102: Engine Top End

    4-2 ENGINE TOP END Exploded View 1. Closed coil end faces downward. T8: 7.8 N·m (0.80 kgf·m, 69 in·lb) T1: 9.8 N·m (1.0 kgf·m, 87 in·lb) EO: Apply engine oil. T2: 12 N·m (1.2 kgf·m, 104 in·lb) L: Apply a non-permanent locking agent. T3: 13 N·m (1.3 kgf·m, 113 in·lb) M: Apply molybdenum disulfide grease.
  • Page 103 ENGINE TOP END 4-3 Exploded View 1. R marked side face up. T2: 12 N·m (1.2 kgf·m, 104 in·lb) 2. RN marked side face up. T3: 34 N·m (3.5 kgf·m, 25 ft·lb) 3. A marking hollow facing forward. T4: 45 N·m (4.5 kgf·m, 33 ft·lb) 4.
  • Page 104: Specifications

    4-4 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Open → Close Pressure 57 ∼ 65 kPa (430 ∼ 490 mmHg) – – – Camshafts Cam Height: 34.345 ∼ 34.453 mm Exhaust 34.24 mm (1.348 in.) (1.352 ∼...
  • Page 105 ENGINE TOP END 4-5 Specifications Item Standard Service Limit 0.03 ∼ 0.12 mm Inlet 0.29 mm (0.011 in.) (0.0012 ∼ 0.0047 in.) Valve Seat Cutting Angle 45°, 32°, 60° – – – Valve Seat Surface: Width: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) Exhaust –...
  • Page 106: Valve Seat Cutter

    Valve Guide Arbor, 4: 57001-1273 Valve Guide Reamer, 4: 57001-1274 Valve Seat Cutter Holder, 4: 57001-1275 Fork Oil Level Gauge: 57001-1290 Compression Gauge Adapter, M10 × 1.0: 57001-1317 Valve Seat Cutter, 60° - 33: 57001-1334 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 107: Clean Air System

    ENGINE TOP END 4-7 Clean Air System Air Suction Valve Removal • Remove: Seats (see Frame chapter) Fuel Tank, Air Cleaner Housing (see Fuel System chap- ter) • Separate the intake silencer [A] from the vacuum switch valve [B]. • Remove: Vacuum Switch Valve with the Hoses Air Suction Valve Cover Bolts [C]...
  • Page 108: Vacuum Switch Valve Installation

    4-8 ENGINE TOP END Clean Air System Vacuum Switch Valve Installation • Install the vacuum switch valve so that the air hole [A] faces downwards. • Route the hoses correctly (see General Information chap- ter). Vacuum Switch Valve Test • Remove: Fuel Tank, Air Cleaner Housing (see Fuel System chap- ter)
  • Page 109: Cylinder Head Cover

    ENGINE TOP END 4-9 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Lower Fairing (see Frame chapter) Coolant (drain, see Cooling System chapter) Other than US, CAL Models Seats (see Frame chapter) Fuel Tank, Air Cleaner Housing and Carburetor (see Fuel System chapter) Vacuum Valve (California Model only) Vacuum Switch Valve and Hoses...
  • Page 110: Cylinder Head Cover Installation

    Replace the head cover gasket with a new one if dam- aged. • Apply silicone sealant to the cylinder head as shown [A]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Be sure to install the pins [A] and rubber gaskets [B]. •...
  • Page 111: Camshaft Chain Tensioner

    ENGINE TOP END 4-11 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 112: Camshaft, Camshaft Chain

    4-12 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 Pistons [B] Timing Mark (crankcase halves mating surface) •...
  • Page 113 ENGINE TOP END 4-13 Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown.
  • Page 114: Camshaft, Camshaft Cap Wear Inspection

    4-14 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A].
  • Page 115: Camshaft Chain Removal

    ENGINE TOP END 4-15 Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the camshaft chain [A] from the crankshaft sprocket.
  • Page 116: Cylinder Head

    4-16 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Stick Coils Spark Plugs...
  • Page 117: Cylinder Head Removal

    ENGINE TOP END 4-17 Cylinder Head Cylinder Head Removal • Drain the coolant (see Cooling System chapter). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Chain Tensioner (see Camshaft Chain Ten- sioner Removal) Camshafts (see Camshaft Removal) Water Temperature Sensor Lead Connector [A] Oil Hose Banjo Bolt [B] •...
  • Page 118: Cylinder Head Warp Inspection

    4-18 ENGINE TOP END Cylinder Head Cylinder Head Warp Inspection • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp –...
  • Page 119: Valves

    ENGINE TOP END 4-19 Valves Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Crankshaft Sensor Cover Cylinder Head Cover (see Cylinder Head Cover Re- moval) •...
  • Page 120: Valve Clearance Adjustment

    4-20 ENGINE TOP END Valves Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions.
  • Page 121 ENGINE TOP END 4-21 Valves VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 122 4-22 ENGINE TOP END Valves VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 123: Valve Removal

    ENGINE TOP END 4-23 Valves Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions. •...
  • Page 124: Valve Guide Installation

    4-24 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 125: Valve Seat Inspection

    ENGINE TOP END 4-25 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 126 4-26 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 127 ENGINE TOP END 4-27 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 128 4-28 ENGINE TOP END Valves • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 129 ENGINE TOP END 4-29 Valves...
  • Page 130: Cylinder, Pistons

    4-30 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Head (see Cylinder Head Removal) Water Hoses [A] Rear Camshaft Chain Guide and Bolt • Remove the cylinder. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. •...
  • Page 131: Piston Installation

    ENGINE TOP END 4-31 Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001-910 [A] • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 132: Cylinder Wear Inspection

    4-32 ENGINE TOP END Cylinder, Pistons • Do not mix up the top and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. ○ Install the second ring [C] so that the "RN" mark [D] faces Cylinder Wear Inspection •...
  • Page 133: Piston Ring Groove Width Inspection

    ENGINE TOP END 4-33 Cylinder, Pistons Piston Ring Groove Width Inspection • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring/Groove Width Standard: 0.84 ∼ 0.86 mm (0.0331 ∼ 0.0339 in.) 0.82 ∼...
  • Page 134: Carburetor Holder

    4-34 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Be sure to install the O-rings [A]. • Tighten the carburetor holder bolts [B]. • Tighten the #1,3 right carburetor holder bolts with clamp [C] (use of clamps for California Model only). Torque - Carburetor Holder Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
  • Page 135: Muffler

    ENGINE TOP END 4-35 Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Muffler and Exhaust Pipe Removal • Remove: Lower Fairings (see Frame chapter) Exhaust Pipe Mounting Bolt [A] •...
  • Page 136: Muffler Body Removal

    4-36 ENGINE TOP END Muffler Muffler Body Removal • Remove: Exhaust Pipe Connecting Nuts [A] Muffler Mounting Bolt, Nut [B] and Washer Pull the muffler body [C] backward. Muffler Body Installation • Replacing the muffler body gasket with new one. •...
  • Page 137 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................Clutch Lever Installation....................Clutch Cover...........................
  • Page 138: Exploded View

    5-2 CLUTCH Exploded View 1. Clutch Lever Pivot Nut T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) T3: 12 N·m (1.2 kgf·m, 104 in·lb) T4: 137 N·m (14 kgf·m, 101 ft·lb) T5: 1.5 N·m (0.15 kgf·m, 13 in·lb) or Hand-Tight CL: Apply cable lubricant.
  • Page 139: Specifications

    Clutch Spring Free Length 82.1 mm (3.23 in.) 78.0 mm (3.07 in.) 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) Clutch Plate Assembly Length – – – Special Tool - Clutch Holder: 57001-1243 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 140: Clutch Lever And Cable

    5-4 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 141: Clutch Cable Removal

    CLUTCH 5-5 Clutch Lever and Cable Clutch Cable Removal • Remove the right lower fairing (see frame chapter). • Slide the dust cover at the clutch cable lower end out of place. • Loosen the nuts, and slide the lower end of the clutch cable to give the cable plenty of play.
  • Page 142: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Replace the cover gasket with a new one. •...
  • Page 143: Clutch Removal

    CLUTCH 5-7 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Lubrication System chap- ter) Right Lower Fairing (see Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C], spring and washer) Friction Plates, Steel Plates Spring, Spring Seat...
  • Page 144 5-8 CLUTCH Clutch ○ Install the spacer [A] so that the stepped side [B] faces inward. ○ Install the washer [A] so that the OUT SIDE mark faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut.
  • Page 145: Clutch Plate Assembly Inspection

    CLUTCH 5-9 Clutch • Apply molybdenum disulfide grease to the pusher end [A] and install the bearing [B], pusher [C] spring [D] and washer [E] in the clutch spring plate [F]. • Install the clutch spring plate and spring, and tighten the clutch spring bolts.
  • Page 146: Clutch Plate Assembly Adjustment

    5-10 CLUTCH Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. ○ Remove: Spring Bolts Spring Holders Springs Spring Plate • Replace the following steel plate(s). Part No.
  • Page 147: Clutch Spring Free Length Measurement

    CLUTCH 5-11 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 82.1 mm (3.23 in.) Service Limit: 78.0 mm (3.07 in.)
  • Page 149 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Pan............................ Oil Pan Removal ....................... Oil Pan Installation ......................Oil Pressure Relief Valve......................
  • Page 150: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) or Hand T8: 25 N·m (2.5 kgf·m, 18 ft·lb) -Tight T9: 31 N·m (3.2 kgf·m, 23 ft·lb) T2: 2.0 N·m (0.20 kgf·m, 17 in·lb) EO: Apply engine oil. T3: 9.8 N·m (1.0 kgf·m, 87 in·lb) G: Apply grease.
  • Page 151: Engine Oil Flow Chart

    ENGINE LUBRICATION SYSTEM 6-3 Engine Oil Flow Chart 1. Oil Pan 12. Drive Shaft 2. Oil Screen 13. Output Shaft 3. Oil Pump 14. Oil Pressure Switch 4. Oil Pressure Relief Valve 15. Cylinder Head 5. Oil Filter 16. Camshaft Cap 6.
  • Page 152: Specifications

    Oil pressure @4 000 r/min (rpm), oil temperature 90°C (194°F) Special Tools - Outside Circlip Pliers: 57001-144 Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Filter Wrench: 57001-1249 Oil Pressure Gauge Adapter, M18 × 1.5: 57001-1278 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 153: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 6-5 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 154: Oil Filter Change

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter NOTE ○ Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil Filter Change •...
  • Page 155: Oil Pan

    ENGINE LUBRICATION SYSTEM 6-7 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Oil Change) Muffler (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] Oil Pan Installation • Clean the oil screen [A]. •...
  • Page 156: Oil Pressure Relief Valve

    6-8 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See the Oil Pan Removal. Oil Pressure Relief Valve Installation • See the Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 157: Oil Pump

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Oil Pump Removal • Drain: Coolant (see Cooling System chapter) Engine Oil (see Engine Oil Change) • Remove: Water Hoses [A] Bolts [B] and Water Pump Cover [C] Impeller Bolt [A] Impeller [B] Water Pump Body [A] Oil Pump Cover [B] Oil (Water) Pump Shaft [C] Outer Rotor [D] and Inner Rotor...
  • Page 158: Oil Pump Drive Gear Removal

    6-10 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Pins [A] Water Pump Body [B] Impeller [A] and Bolt [B] • Tighten: Torque - Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C] Water Pump Cover [D] • Apply a non-permanent locking agent to the threads of the water pump cover bolts, and tighten them.
  • Page 159: Oil Cooler

    ENGINE LUBRICATION SYSTEM 6-11 Oil Cooler Oil Cooler Removal • Remove: Lower Fairing (see Frame chapter) • Drain: Engine Oil (see Engine Oil Change) Coolant (see Cooling System chapter) • Remove the oil filter. • Remove the oil cooler hoses [A] from the oil cooler. •...
  • Page 160: Oil Pressure Measurement

    6-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairing (see Frame chapter). • Remove the oil passage plug, and attach the gauge [A] and adapter [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, M18 ×...
  • Page 161: Oil Pressure Switch

    Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Tighten: Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 163 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Specifications ......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 164: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb) T3: 49 N·m (5.0 kgf·m, 36 ft·lb)
  • Page 165: Specifications

    ENGINE REMOVAL/INSTALLATION 7-3 Specifications Special Tool - Jack: 57001-1238 Engine Mount Nut Wrench: 57001-1450...
  • Page 166: Engine Removal/Installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
  • Page 167: Engine Installation

    ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Pull off the connectors from the engine and free the wiring from the clamps. Crankshaft Sensor Lead Connector [A] Battery Ground Cable [B] Starter Motor Cable [C] Alternator Lead Connector [D] Side Stand Switch Lead Connector [E] Speed Sensor Connector [F] Stick Coil Harness Connector [A] •...
  • Page 168 7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Turn the adjusting bolt [H] until the clearance [X] between the crankcase and frame come to zero mm. • Tighten the bracket bolts [A]. Torque - Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 169 CRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Inspection ... 8-17 Specifications ........Starter Motor Clutch Disassembly 8-17 Crankcase Splitting......Starter Motor Clutch Assembly ..8-17 Crankcase Splitting ...... Transmission ........8-18 Crankcase Assembly ....Shift Pedal Removal ....8-18 Crankshaft and Connecting Rods..
  • Page 170: Exploded View

    8-2 CRANKSHAFT/TRANSMISSION Exploded View T1: 4.9 N·m (0.5 kgf·m, 43 in·lb) T11: See the text. T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) D: Do not apply any grease or oil. T3: 12 N·m (1.2 kgf·m, 104 in·lb) EO: Apply engine oil. T4: 15 N·m (1.5 kgf·m, 11 ft·lb) G: Apply grease.
  • Page 171 CRANKSHAFT/TRANSMISSION 8-3 Exploded View T1: 12 N·m (1.2 kgf·m, 104 in·lb) T2: 15 N·m (1.5 kgf·m, 11 ft·lb) T3: 28 N·m (2.9 kgf·m, 21 ft·lb) EO: Apply engine oil. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 172: Specifications

    8-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods 0.13 ∼ 0.33 mm (0.0051 ∼ 0.0130 in.) Connecting Rod Big End Side Clearance 0.5 mm (0.020 in.) 0.031 ∼ 0.059 mm Connecting Rod Big End Bearing 0.10 mm (0.0012 ∼ 0.0023 in.) Insert/Crankpin Clearance (0.004 in.) 29.984 ∼...
  • Page 173 6.05 ∼ 6.20 mm (0.2382 ∼ 0.2441 in.) Shift Drum Groove Width 6.3 mm (0.248 in.) Special Tool - Bearing Puller: 57001-135 Outside Circlip Pliers: 57001-144 Bearing Puller Adapter: 57001-317 Flywheel & Pulley Holder: 57001-1605 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Sealant): 92104-1063...
  • Page 174: Crankcase Splitting

    8-6 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Oil Hose (Cylinder Head ∼...
  • Page 175: Crankcase Splitting

    Apply silicone sealant to the breather plate mating surface [A] 1 to 1.5 mm (0.04 ∼ 0.06 in.) thick, wait until sealant dries, and then install the breather plate [B]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-1063 • Apply a non-permanent locking agent to the threads and tighten the bolts [C].
  • Page 176 8-8 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts, using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the 8 mm bolts [1 ∼ 10]. Torque - Crankcase 8 mm Bolts: 30 N·m (3.0 kgf·m, 22 ft·lb) ○...
  • Page 177: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 8-9 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 178 8-10 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plasti- gage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 179 CRANKSHAFT/TRANSMISSION 8-11 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
  • Page 180: Crankshaft/Connecting Rod Cleaning

    8-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply a small amount of engine oil to the threads [A] and seating surface [B] of the connecting rod nuts. • First, tighten the nuts to the specified torque. • Next, tighten the nuts 160° more. ○...
  • Page 181: Connecting Rod Twist Inspection

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft and Connecting Rods Connecting Rod Twist Inspection • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 182 8-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 183: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 8-15 Crankshaft and Connecting Rods Crankshaft Side Clearance Inspection • Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No. 2 journal [B] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set.
  • Page 184 8-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 29.984 ∼ 30.000 mm (1.1805 ∼ 1.1811 in.) Standard: Service Limit: 29.96 mm (1.1795 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 185: Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 8-17 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter) Starter Idle Gear • Turn the starter motor clutch gear [a] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
  • Page 186: Transmission

    8-18 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. • Remove the shift lever and shift pedal. Shift Pedal Installation •...
  • Page 187: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 8-19 Transmission External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration are damaged, replace the shaft. If the springs [B] [C] are damaged in any way, replace them.
  • Page 188: Transmission Shaft Disassembly

    8-20 CRANKSHAFT/TRANSMISSION Transmission • Install the drive shaft and output shaft into the upper crankcase half. • Apply engine oil to the sliding surfaces of the gears and bearings. ○ The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races.
  • Page 189: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 8-21 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 190: Shift Drum And Fork Installation

    8-22 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Installation • Set the transmission gears in the neutral position. • Install the shift drum so that the punch mark [A] on it faces oil pan side. • Install the forks as shown. •...
  • Page 191: Shift Fork/Gear Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 8-23 Transmission Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 192 8-24 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 11. Toothed Washer 2. 2nd Gear 12. Thrust Washer 3. 3rd Gear 13. Circlip 4. 4th Gear 14. Needle Bearing 15. Bearing Outer Race 5. 5th Gear 6. 6th (Top) Gear 16. Bushing 17. Ball Bearing 7.
  • Page 193 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... 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....................
  • Page 194: Exploded View

    9-2 WHEELS/TIRES Exploded View T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 127 N·m (13 kgf·m, 94 ft·lb) G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 195: Specifications

    WHEELS/TIRES 9-3 Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front J17M/C × MT3.50 – – – Rear J17 × MT5.50 – – – Rim runout: Axial TIR 0.5 mm (0.020 in.) or less TIR 1 mm (0.040 in.) Radial TIR 0.8 mm (0.031 in.) or less TIR 1 mm (0.040 in.)
  • Page 196: Front Wheel Removal

    9-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Lower Fairing (see Frame chapter) Brake Caliper Mounting Bolts [A] • Loosen: Right Side Axle Clamp Bolts [A] Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 197: Rear Wheel Removal

    WHEELS/TIRES 9-5 Wheels (Rims) • Tighten the axle clamp bolts [A] on the right fork leg first. Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kg·m, 14.5 ft·lb) • Check the clearance [B] between the right fork leg [D] and collar [C] with the thickness gauge.
  • Page 198: Rear Wheel Installation

    9-6 WHEELS/TIRES Wheels (Rims) • Remove the rear caliper. • Remove the chain cover. • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 199: Wheel Inspection

    WHEELS/TIRES 9-7 Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...
  • Page 200: Balance Adjustment

    9-8 WHEELS/TIRES Wheels (Rims) Balance Adjustment • If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the marking using adhesive tape. • Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position.
  • Page 201 41075-1016 30 (1.05 oz) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram sizes. An imbalance of less than 10 grams will not usually affect running stability. ○ Do not use four or more balance weight (more than 90 gram).
  • Page 202 9-10 WHEELS/TIRES Wheels (Rims) ○ Check that the blade [A] and weight [B] seat fully on the rim flange [C], and that the clip [D] is hooked over the rim ridge [E] and reaches rim flat portion.
  • Page 203: Tires

    WHEELS/TIRES 9-11 Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 204: Tire Removal

    9-12 WHEELS/TIRES Tires NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○ Check and balance the wheel when a tire is replaced with a new one. Tire Removal •...
  • Page 205 WHEELS/TIRES 9-13 Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the air valve [A] through the rim from the inside out until it snaps into place.
  • Page 206: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 207: Hub Bearing

    WHEELS/TIRES 9-15 Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals Circlips [A] Special Tool - Inside Circlip Pliers: 57001-143 [B] • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 208: Hub Bearing Inspection

    9-16 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 209 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View ........................10-2 Specifications ........................10-3 Drive Chain..........................10-4 Drive Chain Slack Inspection .................... 10-4 Drive Chain Slack Adjustment ..................10-4 Wheel Alignment Inspection/Adjustment ................10-4 Drive Chain Wear Inspection .................... 10-5 Drive Chain Lubrication.....................
  • Page 210: Exploded View

    10-2 FINAL DRIVE Exploded View T1: 6.9 N·m (0.7 kgf·m, 61 in·lb) T2: 12 N·m (1.2 kgf·m, 104 in·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 127 N·m (13.0 kgf·m, 94 ft·lb) G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent.
  • Page 211: Specifications

    FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain 30 ∼ 35 mm (1.18 ∼ 1.38 in.) Chain Slack 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-Link Length 323 mm (12.72 in.) Standard Chain: Make ENUMA – – – EK525MVXL, Endless (ZX600-J1 ∼...
  • Page 212: Drive Chain Slack Inspection

    10-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspec- tion).
  • Page 213: Drive Chain Wear Inspection

    FINAL DRIVE 10-5 Drive Chain Drive Chain Wear Inspection • Remove: Chain Cover • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.
  • Page 214: Drive Chain Removal

    10-6 FINAL DRIVE Drive Chain • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. • Wipe off any excess oil.
  • Page 215 FINAL DRIVE 10-7 Drive Chain ∼ Drive Chain Replacement (ZX600-J4 (US), ∼ ZX600J6F (CA)) CAUTION For safety, if the drive chain shall be replaced, re- place it using a recommended tool. Recommended Tool - Type: EK JOINT Tool #50 Brand: ENUMA CHAIN Body [A] Handlebar [B] Cutting and Rivetting Pin [C]...
  • Page 216 10-8 FINAL DRIVE Drive Chain • Screw the handlebar [A] into the body. • Turn the pin holder with the wrench [B] clockwise to ex- tract the link pin. • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease the seals [B] [C].
  • Page 217 FINAL DRIVE 10-9 Drive Chain • Set the plate holder (B) [A] and the cutting and rivetting pin [B] as shown. • Turn the pin holder until the rivetting pin touches the link pin. • Turn the wrench clockwise until the tip of rivetting pin con- tact with the link pin.
  • Page 218: Sprocket, Coupling

    10-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Bolt [A] Speed Sensor [B] Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 219: Rear Sprocket Removal

    FINAL DRIVE 10-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 220: Coupling Bearing Installation

    10-12 FINAL DRIVE Sprocket, Coupling Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 [B] • Pack the bearing with high temperature grease. •...
  • Page 221: Sprocket Wear Inspection

    FINAL DRIVE 10-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection).
  • Page 223 BRAKES 11-1 Brakes Table of Contents Exploded View ........11-2 Rear Brake Pad Installation ..11-12 Specifications ........11-4 Brake Pad Wear Inspection ..11-12 Brake Pedal ........11-5 Master Cylinder ......... 11-13 Brake Lever Position Adjustment. 11-5 Front Master Cylinder Removal ... 11-13 Brake Pedal Position Inspection .
  • Page 224: Exploded View

    11-2 BRAKES Exploded View 1. Brake Rod Joint Cotter Pin T8: 18 N·m (1.8 kgf·m, 13 ft·lb) 2. Brake Pedal Bolt T9: 21 N·m (2.1 kgf·m, 15 ft·lb) T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T10: 27 N·m (2.8 kgf·m, 20 ft·lb) T2: 1.5 N·m (0.15 kgf·m, 13 in·lb) T11: 25 N·m (2.5 kgf·m, 18 ft·lb) T3: 2.9 N·m (0.30 kgf·m, 26 in·lb)
  • Page 225 BRAKES 11-3 Exploded View...
  • Page 226: Specifications

    11-4 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 57 mm (2.24 in.) below footpeg top –...
  • Page 227: Brake Pedal

    BRAKES 11-5 Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 228: Calipers

    11-6 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 229: Front Caliper Disassembly

    BRAKES 11-7 Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.
  • Page 230: Front Caliper Assembly

    11-8 BRAKES Calipers Front Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. • Tighten: Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 231: Rear Caliper Assembly

    BRAKES 11-9 Calipers NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○ Remove the pads and spring (see Rear Brake Pad Re- moval).
  • Page 232: Caliper Fluid Seal Damage Inspection

    11-10 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. •...
  • Page 233: Brake Pads

    BRAKES 11-11 Brake Pads Front Brake Pad Removal • Remove: Pad Spring Bolts [A] Pad Spring [B] Clip [A] Pad Pin [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 234: Rear Brake Pad Installation

    11-12 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the anti-rattle spring in place. • Install the brake pads. • Install the pad pin and clip. The clip must be "outside" of the pads.
  • Page 235: Master Cylinder

    BRAKES 11-13 Master Cylinder Front Master Cylinder Removal • Loosen the reservoir bracket bolts [A]. • Disconnect the front brake light switch connectors. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation).
  • Page 236: Rear Master Cylinder Installation

    11-14 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 237: Master Cylinder Assembly

    BRAKES 11-15 Master Cylinder Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 238 11-16 BRAKES Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 239: Brake Disc

    BRAKES 11-17 Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 240: Brake Fluid

    11-18 BRAKES Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 241: Bleeding The Brake Line

    BRAKES 11-19 Brake Fluid • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 242 11-20 BRAKES Brake Fluid NOTE ○ The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. • Remove the reservoir cap, and fill the reservoir with fresh brake fluid to the upper level line in the reservoir.
  • Page 243 BRAKES 11-21 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 244: Brake Hose

    11-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 245 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-4 Front Fork ..........................12-6 Rebound Damping Force Adjustment................12-6 Compression Damping Force Adjustment ................ 12-6 Spring Preload Adjustment ....................12-7 Front Fork Removal (each fork leg) .................. 12-8 Front Fork Installation .......................
  • Page 246: Exploded View

    12-2 SUSPENSION Exploded View T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 23 N·m (2.3 kgf·m, 16.5 ft·lb) T3: 28 N·m (2.9 kgf·m, 21 ft·lb) T4: 39 N·m (4.0 kgf·m, 29 ft·lb) L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 247 SUSPENSION 12-3 Exploded View T1: 59 N·m (6.0 kgf·m, 43 ft·lb) T2: 108 N·m (11 kgf·m, 80 ft·lb) T3: 34 N·m (3.5 kgf·m, 25 ft·lb) G: Apply or add grease. 1. Nut (ZX600-J1 Model) Washer (ZX600-J2 ∼ Model) 2. Grease Nipple (ZX600-J1 ∼ J3 Models)
  • Page 248: Specifications

    12-4 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 46 mm (1.81 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 7th click from the first click of the fully clockwise position (ZX600-J1 ∼ J3) (Usable Range: 1 ←→...
  • Page 249: Fork Piston Rod Puller, M12 ×

    SUSPENSION 12-5 Specifications Item Standard Spring Preload Setting Position Standard Spring length 180 mm (7.09 in.) Usable Range Spring length 182 mm (7.17 in.) to 170 mm (6.69 in.) (weaker to stronger) Gas Pressure 980 kPa (10 kg/cm², 142 psi, Non-adjustable) CA: Canada Model US: United States Model Special Tools - Fork Piston Rod Puller, M12 ×...
  • Page 250: Front Fork

    12-6 SUSPENSION Front Fork Rebound Damping Force Adjustment ZX600-J1 ∼ J3 • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 7th click from the 1st click of the fully clockwise position.
  • Page 251: Spring Preload Adjustment

    SUSPENSION 12-7 Front Fork ○ The damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Compression Damping Force Adjustment Adjuster Damping...
  • Page 252: Front Fork Removal (Each Fork Leg)

    12-8 SUSPENSION Front Fork Front Fork Removal (each fork leg) • Remove: Lower and Upper Fairings (see Frame chapter) Front Wheel (see Wheels/Tires chapter) Front Fender (see Frame chapter) Loosen the handlebar holder bolt [A], upper fork clamp bolt [B] and fork top plug [C] beforehand if the fork leg is to be disassembled.
  • Page 253 SUSPENSION 12-9 Front Fork • Holding the piston rod nut [A] with a wrench [B], remove the fork top plug from the piston rod. • Remove: Rebound Damping Adjuster Rod [A] Washer [B] Spacer [C] Washer [A] Fork Spring [B] •...
  • Page 254 12-10 SUSPENSION Front Fork • Hold the fork tube upright, press the inner tube and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Viscosity: KHL34 (KAYABA G10) or equivalent Amount (per side) When changing oil:...
  • Page 255: Front Fork Disassembly

    SUSPENSION 12-11 Front Fork • Pull the piston rod [A] up above the inner tube top. • Screw the rod nut [B] on to the piston rod with the cham- fered side down. ○ Check that the visible thread length is at least 11 mm (0.43 in.) [D].
  • Page 256: Front Fork Assembly

    12-12 SUSPENSION Front Fork • Take the cylinder unit [A]. ○ Do not disassemble the cylinder unit. • Separate the inner tube from the outer tube as follows. ○ Slide up the dust seal [A]. ○ Remove the retaining ring [B] from the outer tube. ○...
  • Page 257: Inner Tube, Outer Tube Inspection

    SUSPENSION 12-13 Front Fork • Insert the cylinder unit [A] into the inner tube [B]. • Install the cylinder base [C] on the cylinder unit. • Insert the inner tube, cylinder unit, cylinder base as set into the outer tube [D]. •...
  • Page 258: Dust Seal Inspection

    12-14 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 259: Rear Shock Absorber

    SUSPENSION 12-15 Rear Shock Absorber Rebound Damping Force Adjustment ZX600-J1 ∼ J3 • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position.
  • Page 260: Spring Preload Adjustment

    12-16 SUSPENSION Rear Shock Absorber Compression Damping Force Adjustment Adjuster Damping Setting Load Road Speed Position Force Weak Light Soft Good ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ ↓ Strong Hard Heavy High A: 20 clicks (ZX600-J1 ∼ J3) 5 turns out (ZX600-J4 ∼...
  • Page 261: Rear Shock Absorber Installation

    SUSPENSION 12-17 Rear Shock Absorber • Remove: Lower Shock Absorber Bolt [A] Upper Tie-Rod Bolt [B] • Remove: Upper Shock Absorber Nut [A] Upper Shock Absorber Bolt [B] • Remove the shock absorber forward the ground. Rear Shock Absorber Installation •...
  • Page 262: Swingarm

    12-18 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Wheel (see Wheels/Tires chapter) Chain Cover (see Final Drive chapter) Brake Hose Clamp [A] Lower Shock Absorber Nut and Bolt [B] Upper Tie-Rod Nut and Bolt [C] Swingarm Pivot Nut [D] • Pull off the pivot shaft and remove the swingarm.
  • Page 263: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 12-19 Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. • Check the ball bearing. ○ Since the ball bearing is made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
  • Page 264: Tie-Rod, Rocker Arm

    12-20 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Upper and Lower Fairings (see Frame chapter) Radiator (see Cooling System chapter) Muffler (see Engine Top End chapter) • Squeeze the brake lever slowly and hold it with a band [A]. •...
  • Page 265: Rocker Arm/Tie-Rod Bearing, Sleeve Inspection

    SUSPENSION 12-21 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. • Visually inspect the swingarm sleeves and needle bear- ings. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 267 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Specifications ......................... 13-3 Steering ..........................13-4 Steering Inspection ......................13-4 Steering Adjustment......................13-4 Steering Stem......................... 13-5 Steering Stem, Stem Bearing Removal ................13-5 Steering Stem, Stem Bearing Installation ................. 13-5 Steering Stem Bearing Lubrication ................... 13-7 Steering Stem Warp Inspection ..................
  • Page 268: Exploded View

    13-2 STEERING Exploded View T1: 3.5 N·m (0.35 kgf·m, 30 in·lb) T2: 4.9 N·m (0.5 kgf·m, 36 in·lb) T3: 9.8 N·m (1.0 kgf·m, 87 in·lb) T4: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T5: 25 N·m (2.5 kgf·m, 18 ft·lb) T6: 34 N·m (3.5 kgf·m, 25 ft·lb) T7: 49 N·m (5.0 kgf·m, 36 ft·lb) T8: 15 N·m (1.5 kgf·m, 11 ft·lb) AD: Apply adhesive.
  • Page 269: Specifications

    STEERING 13-3 Specifications Special Tools - Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver, 55: 57001-1446 Head Pipe Outer Race Driver, 47: 57001-1447 Steering Stem Bearing Driver, 42.5: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 Jack: 57001-1238...
  • Page 270: Steering Inspection

    13-4 STEERING Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 271: Steering Stem

    STEERING 13-5 Steering Stem Steering Stem, Stem Bearing Removal • Remove: Fairings (see Frame chapter) Fuel Tank (see Fuel System chapter) Rear View Mirror Bracket Brake Hose Joint Bolt [A] and Bracket Bolt [A] Front Wheel (see Wheels/Tires chapter) Front Fork (see Suspension chapter) Steering Stem Head Nut and Washer Steering Stem Head and Handlebars •...
  • Page 272 13-6 STEERING Steering Stem • Replace the bearing inner races with new ones. • Install the oil seal [D] on the steering stem, and drive the lower ball bearing inner race [A] applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver, 42.5: 57001 -1344 [B] Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 [C]...
  • Page 273: Steering Stem Bearing Lubrication

    STEERING 13-7 Steering Stem NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. Torque - Steering Stem Head Nut: 49 N·m (5.0 kgf·m, 36 ft·lb) Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 14.5 ft·lb) Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 14.5 ft·lb)
  • Page 274: Handlebar

    13-8 STEERING Handlebar Handlebar Removal • Remove: Screws [A] and Windshield [B] • Remove: Clutch Lever Assembly Left Handlebar Switch Housing Front Brake Master Cylinder Right Handlebar Switch Housing Throttle Case and Grip • Remove the handlebar bolts [A], and then pull out the handlebars [B].
  • Page 275: Handlebar Holder Installation

    STEERING 13-9 Handlebar Handlebar Holder Installation • Apply a non-permanent locking agent to the thread of handlebar position bolts and tighten them. Torque - Handlebar Holder Position Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the remove parts (see appropriate chapters). •...
  • Page 277 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Seats ............................14-5 Rear Seat Removal......................14-5 Rear Seat Installation......................14-5 Front Seat Removal ......................14-5 Front Seat Installation ....................... 14-5 Fairings........................... 14-6 Lower Fairing Removal ..................... 14-6 Inner (Upper) Fairing Removal ..................14-6 Inner (Lower) Fairing Removal ..................
  • Page 278: Exploded View

    14-2 FRAME Exploded View 1. California Model 2. Front Fender Mounting Bolts 3. Footpeg Mounting Bolts 4. Footpeg Bracket Mounting Bolts 5. Sidestand Mounting Bolt T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 34 N·m (3.5 kgf·m, 25 ft·lb) T3: 49 N·m (5.0 kgf·m, 36 ft·lb) T4: 44 N·m (4.5 kgf·m, 33 ft·lb) T5: 59 N·m (6.0 kgf·m, 43 ft·lb) G: Apply grease.
  • Page 279 FRAME 14-3 Exploded View...
  • Page 280 14-4 FRAME Exploded View 1. PN Model 2. Unitted States , Canada Models PN: WVTA Approval Model with Pipe Catalytic Converter (Norway)
  • Page 281: Seats

    FRAME 14-5 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turning the key counterclockwise, pulling up the rear of the seat [B], and pulling the seat backward. Rear Seat Installation • Slip the rear seat hooks [A] into the hollow-cubic bracket [B] on the frame.
  • Page 282: Fairings

    14-6 FRAME Fairings Lower Fairing Removal • Remove: Screws [A] [B] Allen Bolts [C] • Pull the lower front part of the lower fairing outward to clear the stoppers [D]. • Remove the lower fairing. • Remove the other side lower fairing in the same manner. NOTE ○...
  • Page 283 FRAME 14-7 Fairings • Remove: Rear View Mirrors [A] Bolts [B] • Remove: Air Vent Filter Hose [A] Headlight/Turn Signal Light Lead Connector [B] Upper Fairing...
  • Page 284: Seat Covers

    14-8 FRAME Seat Covers Seat Cover Removal • Remove: Seats Bolts and Grab Rails [A] Screws and Seat Lock [B] Screws [C] (Left and Right) • Pull the seat cover backward. Seat Cover Installation • Set the seat cover [A], and insert the rivet [B] into the holes in the seat cover and rear fender.
  • Page 285: Fenders

    FRAME 14-9 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Left and Right) Bolts [B] and Screws [C] (Left and Right) • Remove the front fender [D]. Rear Fender Removal • Remove: Seats Fuel Tank Seat Cover Junction Box Starter Relay Assy Turn Signal Relay Battery...
  • Page 286: Rear Frame Removal

    14-10 FRAME Frame Rear Frame Removal • Remove: Rear Fender (see Rear Fender Removal) Bolts [A] and IC Igniter Bracket [B] Clamps for Main Harness Frame Bolts and Nuts [C] Rear Frame Installation • Tighten: Torque - Rear Frame Bolts and Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb) Frame Inspection •...
  • Page 287 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Exploded View........................15-3 Wiring Diagram (United States and Canada) (ZX600-J1 ∼ J2) ..........15-6 Wiring Diagram (United States and Canada) (ZX600-J3 ∼) ........... 15-8 Wiring Diagram (Australia) ..................... 15-10 Wiring Diagram (Other than United States, Canada, Australia, and Malaysia) ...... 15-12 Wiring Diagram (Malaysia) .....................
  • Page 288 15-2 ELECTRICAL SYSTEM Starter Motor Disassembly....................15-46 Starter Motor Assembly ....................15-47 Brush Inspection ....................... 15-48 Commutator Cleaning and Inspection................15-48 Armature Inspection......................15-49 Brush Lead Inspection ...................... 15-49 Right-hand End Cover Assembly Inspection ..............15-49 Starter Relay Inspection....................15-49 Lighting System ........................
  • Page 289: Exploded View

    ELECTRICAL SYSTEM 15-3 Exploded View 1. Crankshaft Sensor 2. IC Igniter 3. Stick Coils T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 12 N·m (1.2 kgf·m, 104 in·lb) T3: 13 N·m (1.3 kgf·m, 113 in·lb) T4: 44 N·m (4.5 kgf·m, 33 ft·lb) L: Apply a non-permanent locking agent.
  • Page 290 15-4 ELECTRICAL SYSTEM Exploded View 1. Starter Lockout Switch T5: 120 N·m (12 kgf·m, 87 ft·lb) 2. Oil Pressure Switch T6: 1.0 N·m (0.1 kgf·m, 9 in·lb) 3. Front Brake Light Switch T7: 1.5 N·m (0.15 kgf·m, 13 in·lb) 4. Neutral Switch T8: 34 N·m (3.5 kgf·m, 25 ft·lb) T1: 3.4 N·m (0.35 kgf·m, 30 in·lb) G: Apply grease or engine oil.
  • Page 291 ELECTRICAL SYSTEM 15-5 Exploded View 1. Turn Signal Relay 2. Water Temperature Sensor 3. Fan Switch 4. Side Stand Switch 5. Headlight Relays 6. Rear Brake Light Switch T1: 7.8 N·m (0.80 kgf·m, 69 in·lb) T2: 18 N·m (1.8 kgf·m, 13 ft·lb) T3: 9.8 N·m (1.0 kgf·m, 87 in·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb) L: Apply a non-permanent locking agent.
  • Page 292: Wiring Diagram (United States And Canada) (Zx600-J1 ~ J2)

    15-6 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) (ZX600-J1 ∼ J2)
  • Page 293 ELECTRICAL SYSTEM 15-7 Wiring Diagram (United States and Canada) (ZX600-J1 ∼ J2)
  • Page 294: Wiring Diagram (United States And Canada) (Zx600-J3 ~)

    15-8 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) (ZX600-J3 ∼)
  • Page 295 ELECTRICAL SYSTEM 15-9 Wiring Diagram (United States and Canada) (ZX600-J3 ∼)
  • Page 296: Wiring Diagram (Australia)

    15-10 ELECTRICAL SYSTEM Wiring Diagram (Australia)
  • Page 297 ELECTRICAL SYSTEM 15-11 Wiring Diagram (Australia)
  • Page 298: Wiring Diagram (Other Than United States, Canada, Australia, And Malaysia)

    15-12 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, Australia, and Malaysia)
  • Page 299 ELECTRICAL SYSTEM 15-13 Wiring Diagram (Other than United States, Canada, Australia, and Malaysia)
  • Page 300: Wiring Diagram (Malaysia)

    15-14 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
  • Page 301 ELECTRICAL SYSTEM 15-15 Wiring Diagram (Malaysia)
  • Page 302: Specifications

    15-16 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC 53.5 ∼ 72.5 V Alternator Output Voltage 0.3 ∼ 0.4 Ω Stator Coil Resistance Charging Voltage (Regulator/Rectifier 14.7 ±0.5 V Output Voltage) Ignition System...
  • Page 303: Flywheel Puller Assembly, M38 × 1.5/M35 ×

    Flywheel Holder: 57001-1313 Hand Tester: 57001-1394 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405 Peak Voltage Adapter: 57001-1415 Lead Wire-Peak Voltage Adapter: 57001-1449 Needle Adapter Set: 57001-1457 Throttle Sensor Setting Adapter: 57001-1521 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 304: Parts Location

    15-18 ELECTRICAL SYSTEM Parts Location 1. Starter Lockout Switch 11. Neutral Switch 21. Oil Pressure Switch 2. Water Temperature Sen- 12. Side Stand Switch 22. Throttle Sensor 13. Speed Sensor 23. Fuel Cut Valves (CAL, H 3. Stick Coils 14. Starter Relay and Main Models) 4.
  • Page 305: Precautions

    ELECTRICAL SYSTEM 15-19 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 306 15-20 ELECTRICAL SYSTEM Precautions Connectors [B]...
  • Page 307: Electrical Wiring

    ELECTRICAL SYSTEM 15-21 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 308: Battery

    15-22 ELECTRICAL SYSTEM Battery Battery Removal • Remove: Seats (see Frame Chapter) Front Seat Bracket [A] (Battery Holder) • Disconnect the negative (–) cable [B] and then positive (+) cable [C]. CAUTION Be sure to disconnect the negative (–) cable first. •...
  • Page 309: Initial Charge

    ELECTRICAL SYSTEM 15-23 Battery • Make sure air bubbles [A] are coming up from all six filler ports. ○ Leave the container this way for 5 minutes or longer. NOTE ○ If no air bubbles are coming up from a filler port, tap [B] the bottom of the container two or three times.
  • Page 310: Interchange

    15-24 ELECTRICAL SYSTEM Battery When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced no- ticeably if charged under conditions other than given above.
  • Page 311: Refreshing Charge

    ELECTRICAL SYSTEM 15-25 Battery NOTE ○ Measure with a digital voltmeter [A] which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard: 12.8 V or more Refreshing Charge •...
  • Page 312 15-26 ELECTRICAL SYSTEM Battery • Determine battery condition after refreshing charge. ○ Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt- age according to the table below. Criteria Judgement 12.8 V or higher Good 12.0 ∼...
  • Page 313: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Check that knock pins [B] are in place on the crankcase.
  • Page 314: Alternator Rotor Removal

    15-28 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Shaft • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [B].
  • Page 315: Alternator Inspection

    ELECTRICAL SYSTEM 15-29 Charging System • Install the washer [A] so that the chamfer side [B] faces outward. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. ○ Install the rotor and tighten it with 70 N·m (7 kgf·m, 52 ft·lb) of torque.
  • Page 316: Regulator/Rectifier Inspection

    15-30 ELECTRICAL SYSTEM Charging System If the output voltage shows the value in the table, the al- ternator operates properly. If the output voltage shows a much higher than the value in the table, the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective.
  • Page 317 ELECTRICAL SYSTEM 15-31 Charging System Rectifier Circuit Check • Check the rectifier resistance as follows. • Disconnect the regulator/rectifier connector. • Connect the hand tester (special tool) to the regulator/rec- tifier as shown in the table, and check the resistance in both directions of each diode in the rectifier following the table.
  • Page 318: Charging Voltage Inspection

    15-32 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 319 ELECTRICAL SYSTEM 15-33 Charging System • Start the engine, and note the voltage readings at vari- ous engine speeds with the headlight turned on and then turned off. (To turn off the headlight of US , Canada, Aus- tralia and Malaysia models, disconnect the headlight con- nector in the upper fairing.) The readings should show nearly battery voltage when the engine speed is low, and, as the engine speed rises, the readings should also rise.
  • Page 320 15-34 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load...
  • Page 321: Ignition System

    ELECTRICAL SYSTEM 15-35 Ignition System...
  • Page 322: Crankshaft Sensor Removal

    15-36 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 323: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply a non-permanent locking agent to the threads of the crankshaft sensor cover bolt [A].
  • Page 324: Crankshaft Sensor Peak Voltage Measurement

    15-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Measurement • Remove: Fuel Tank (see Fuel System chapter) Crankshaft Sensor Lead Connector • Set the Hand Tester [B] to the × 25 V DC range, and connect it to the peak voltage adapter [E] as shown in the diagram.
  • Page 325: Stick Coil (Ignition Coil Together With Spark Plug Cap) Inspection

    ELECTRICAL SYSTEM 15-39 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○...
  • Page 326: Spark Plug Removal

    15-40 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 327: Spark Plug Gap Inspection

    ELECTRICAL SYSTEM 15-41 Ignition System Spark Plug Gap Inspection • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) CAUTION Use only the recommended spark plugs (special marks...
  • Page 328 15-42 ELECTRICAL SYSTEM Ignition System Throttle Sensor Operation Check • Remove the fuel tank (see fuel System chapter). • Disconnect the throttle sensor lead connector. • Connect the adapter [A] between the connectors [B]. Special Tool - Throttle Sensor Setting Adapter: 57001 -1521 •...
  • Page 329 IC igniter with a new one. CAUTION Use only Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery...
  • Page 330 15-44 ELECTRICAL SYSTEM Ignition System...
  • Page 331 ELECTRICAL SYSTEM 15-45 Ignition System Ignition System Circuit 1. Junction Box 9. Main Fuse 30 A 2. Ignition Switch 10. Starter Lockout Switch 3. Engine Stop Switch 11. Battery 4. Starter Button 12. Neutral Switch 5. Throttle Sensor 13. Side Stand Switch 6.
  • Page 332: Electric Starter System

    15-46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove the fuel tank (see Fuel System chapter). • Slide back the rubber cap. • Remove the starter motor terminal nut [A] and the mount- ing bolts [B]. • Pull out the starter motor [C]. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body.
  • Page 333: Starter Motor Assembly

    ELECTRICAL SYSTEM 15-47 Electric Starter System • Unsolder the terminal [A] on the positive brush plate and remove it. Starter Motor Assembly • Apply a thin coat of grease to the oil seal [A]. • Fit the toothed washer [B] into the left-hand end cover. •...
  • Page 334: Brush Inspection

    15-48 ELECTRICAL SYSTEM Electric Starter System • Align the groove [A] in the right-hand end cover and the mark [B] on the yoke. • Align the tongue [A] on the left-hand end cover and the terminal [B] on the right-hand end cover. Brush Inspection •...
  • Page 335: Armature Inspection

    ELECTRICAL SYSTEM 15-49 Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 336 15-50 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Junction Box 5. Starter Circuit Relay 6. Ignition Fuse 10 A 7. Starter Lockout Switch 8. Neutral Switch 9. Starter Motor 10.
  • Page 337: Lighting System

    ELECTRICAL SYSTEM 15-51 Lighting System The US, Canada, Australia, and Malaysia models adopt the daylight system and have a headlight relay in the junc- tion box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on.
  • Page 338: Headlight Relay Unit Inspection

    CAUTION Use only Hand Tester 57001-1394 for this test. An ohmmeter other the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the headlight relay unit will be damaged.
  • Page 339 ELECTRICAL SYSTEM 15-53 Lighting System 1. Ignition Switch 10. Headlight Fuse 10 A 2. High Beam Indicator Light 11. Dimmer Switch 3. Headlight 12. Alternator 13. Headlight Fuse 20 A 4. City Light 5. Headlight Relay (Hi) 14. Main Fuse 30 A 6.
  • Page 340: Turn Signal Relay Inspection

    15-54 ELECTRICAL SYSTEM Lighting System 1. Ignition Switch 7. Junction Box 14. Main Fuse 30 A 2. High Beam Indicator 8. Tail Light Fuse 10 A 15. Battery Light 9. Headlight Circuit Relay 16. Headlight Switch 3. Headlight 10. Headlight Fuse 10 A 17.
  • Page 341 ELECTRICAL SYSTEM 15-55 Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Lights (Right & Left) 2. Front Right Turn Signal Light 3. Front Left Turn Signal Light 4. Hazard Button 5. Turn Signal Switch 6. Turn Signal Relay 7.
  • Page 342: Fuel Pump

    CAUTION Use only Hand Tester 57001-1394 for this test. An ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the pump relay will be damaged.
  • Page 343: Fuel Pump Operational Inspection

    ELECTRICAL SYSTEM 15-57 Fuel Pump Fuel Pump Operational Inspection • Remove the fuel pump with the fuel filter (see Fuel System chapter). • Prepare a container filled with kerosene. • Prepare the rubber hoses, and connect them to the pump fittings.
  • Page 344 15-58 ELECTRICAL SYSTEM Fuel Pump Fuel Pump Circuit 1. Junction Box 2. Ignition Fuse 10 A 3. Engine Stop Switch 4. Starter Button 5. Fuel Pump Relay 6. Fuel Pump 7. Stick Coil 8. Ignition Switch 9. Main Fuse 30 A 10.
  • Page 345: Fuel Cut Valve

    ELECTRICAL SYSTEM 15-59 Fuel Cut Valve The fuel cut valves [A] are adopted for protection of the catalytic converter. Fuel Cut Valve Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 346 15-60 ELECTRICAL SYSTEM Fuel Cut Valve Fuel Cut Valve Circuit 1. Ignition Switch 2. Junction Box 3. Horn Fuse 10 A 4. Starter Relay 5. Main Fuse 30 A 6. Battery 7. Gray Connector 8. Brown Connector 9. Fuel Cut Valve 10.
  • Page 347: Radiator Fan System

    ELECTRICAL SYSTEM 15-61 Radiator Fan System WARNING The radiator fan is connected directly to the battery. The fan may start even if the ignition switch is off. NEVER TOUGH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
  • Page 348 15-62 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 2. Radiator Fan Switch 3. Junction Box 4. Fan Fuse 10 A 5. Main Fuse 30 A 6. Battery...
  • Page 349: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 15-63 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Windshield (see Handlebar Removal in the Steering chapter) • Remove the meter unit by taking off the mounting nuts [A] with the washers. • Slide the dust cover [B] and remove the wiring connector. CAUTION Place the meter unit so that the face is up.
  • Page 350: Electronic Combination Meter Unit Inspection

    15-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit. CAUTION Do not drop the meter unit. Place the meter unit so that it faces upward. If the meter unit is left upside down or sideways for a long time or dropped, it will malfunction.
  • Page 351 ELECTRICAL SYSTEM 15-65 Meter, Gauge, Indicator Unit ODO/TRIP or CLOCK/TEMP BUTTON Operate Confir- mation • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Check that when the button [A] or [B] is pushed and held continuously, the display [C] or [D] turns an other mode within two seconds.
  • Page 352 15-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Speed Sensor Electric Source Check • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Set the hand tester to the DC25 V range and connect it to the terminals [2] and [4].
  • Page 353 ELECTRICAL SYSTEM 15-67 Meter, Gauge, Indicator Unit Tachometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [6].
  • Page 354: Switches And Sensors

    15-68 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Turn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brake pedal. If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 10 mm (3.94 in.) of pedal...
  • Page 355: Radiator Fan Switch Inspection

    ELECTRICAL SYSTEM 15-69 Switches and Sensors Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant so that the sensitive portions [C] are located in almost the same depth.
  • Page 356: Water Temperature Sensor Inspection

    15-70 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Cooling Sys- tem chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. •...
  • Page 357: Throttle Sensor Position Adjustment

    ELECTRICAL SYSTEM 15-71 Switches and Sensors • Connect the adapter [B] between the connectors [A]. Special Tool - Throttle Sensor Setting Adapter: 57001 -1521 • Connect the hand tester to the adapter. Hand Tester (+) → Y/W Lead [C] Hand Tester (–) → BK/BL Lead [D] •...
  • Page 358: Speed Sensor Inspection

    15-72 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Final Drive chapter) • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394 •...
  • Page 359: Junction Box

    ELECTRICAL SYSTEM 15-73 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box. •...
  • Page 360: Diode Circuit Inspection

    15-74 ELECTRICAL SYSTEM Junction Box *7 - 13 ∞ 12 - 13 ∞ Starter Circuit (+) (–) (+) (–) Headlight Relay Relay *13 - 9 Not ∞ ** 13 - 11 ∞ (+) (–) 12 - 11 Not ∞ ** (*): United States, Canada, Australia , and Malaysia Models only (**): The actual reading varies with the hand tester used.
  • Page 361 ELECTRICAL SYSTEM 15-75 Junction Box Junction Box Internal Circuit (United States, Canada, Australia, and Malaysia) Junction Box Internal Circuit (Other than United States, Canada, Australia, and Malaysia) A. Accessory Fuse 10 A G. Headlight Relay B. Fan Fuse 10 A H.
  • Page 362: Fuse

    15-76 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Seats (see Frame chapter) Starter Relay and 30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal •...
  • Page 363 APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide ......................16-2 General Lubrication ........................ 16-7 Lubrication ........................16-7 Nut, Bolt, and Fastener Tightness ..................16-8 Tightness Inspection ......................16-8 Unit Conversion Table ......................16-9...
  • Page 364: Troubleshooting Guide

    16-2 APPENDIX Troubleshooting Guide NOTE Spark plug cap shorted or not in good con- ○ This is not an exhaustive list, giving every tact possible cause for each problem listed. It Spark plug incorrect is meant simply as a rough guide to assist IC igniter trouble the troubleshooting for some of the more Cam sensor trouble...
  • Page 365 APPENDIX 16-3 Troubleshooting Guide Fuel cut valve won’t fully open (check fuel Air cleaner clogged, poorly sealed, or miss- cut valve and IC igniter) Carburetor holder loose Air cleaner duct loose Air cleaner duct loose Air cleaner O-ring damaged Air cleaner O-ring damaged Water or foreign matter in fuel Fuel pump trouble Carburetor holder loose...
  • Page 366: Over Cooling

    16-4 APPENDIX Troubleshooting Guide Over Cooling: Muffler overheating: For KLEEN, do not run the engine even if Gauge incorrect: with only one cylinder misfiring or poor Water temperature meter broken running (Request the nearest service fa- Water temperature sensor broken cility to correct it) Cooling system component incorrect: For KLEEN, do not push-start with a dead...
  • Page 367: Abnormal Engine Noise

    APPENDIX 16-5 Troubleshooting Guide Abnormal Engine Noise: Rear wheel misaligned Knocking: Abnormal Frame Noise: IC igniter trouble Carbon built up in combustion chamber Front fork noise: Fuel poor quality or incorrect Oil insufficient or too thin Spark plug incorrect Spring weak or broken Overheating Rear shock absorber noise: Piston slap:...
  • Page 368: Battery Trouble

    16-6 APPENDIX Troubleshooting Guide Steering stem bearing damaged Front fork, rear shock absorber spring weak Steering stem bearing lubrication inade- Rear shock absorber oil leaking quate Brake Doesn’t Hold: Steering stem bent Tire air pressure too low Air in the brake line Handlebar shakes or excessively vibrates: Pad or disc worn Tire worn...
  • Page 369: General Lubrication

    APPENDIX 16-7 General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri- cation...
  • Page 370: Nut, Bolt, And Fastener Tightness

    16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 371: Unit Conversion Table

    APPENDIX 16-9 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 372 MODEL APPLICATION Year Model Beginning Frame No. □ JKAZX4J1 YA000001 or 2000 ZX600-J1 JKAZX600JJA000001 □ JKAZX4J1 IA003001 or 2001 ZX600-J2 JKAZX600JJA030001 □ 2002 ZX600-J3 JKAZX4J1 2A048001 □ 2005 ZX600-J4 JKAZX4J1 5A055001 □ 2006 ZX600J6F JKAZX4J1 6A059001 □ 2007 ZX600J7F JKAZX4J1 7A065001 □...

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Ninja zx-6r 2001Zx6r