Foreword In order to ship Kawasaki vehicles as effi- ciently as possible, they are partially disassem- WARNING bled before crating. Since some of the most This warning symbol identifies special commonly removed parts have a direct bear- instructions or procedures which, if not ing on a vehicle’s reliability and safety, consci-...
UNCRATING 3 Uncrating Opening Crate • Clear a space about 6 m (20 ft) square to give yourself plenty of space to work. • Place the crate upright on its base. • Remove the cardboard cover. • Remove the parts box. CAUTION When you remove the crate bracket from the motorcycle, be careful not to...
4 ASSEMBLY Parts Check • Open the parts box, and check the parts against the illustrations. There may be mi- nor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in mil- limeters, and L = length in millimeters.
ASSEMBLY 5 Clutch Cable • Apply a light coat of grease on the clutch inner cable. • Line up the slots on the clutch lever and ad- juster. • Fit the tip of the clutch inner cable into the lever socket, slide the inner cable through the slots, and release the outer cable into the ad- juster.
6 PREPARATION A. Rider’s Seat Preparation The battery used in this motorcycle is a sealed type and never needs to be refilled. Follow the Battery Service procedure for activating a new battery to ensure the best possible battery performance. Rider’s Seat Removal Activating the battery requires two steps, fill- •...
PREPARATION 7 CAUTION Sealed battery electrolyte has a higher concentration of sulfuric acid. Each container contains the proper amount of electrolyte for its specific battery. Insufficient or incorrect electrolyte will reduce battery performance and service life. Electrolyte over capacity can lead to battery cracking or leaking and result in corrosion damage to the vehicle.
8 PREPARATION A. Fuel Tank A. Fuel Hose Joint B. Drain Hose B. Joint Lock Claws • • Close the fuel tank cap. Pull the joint lock. • • Remove the fuel tank, and place it on a flat Pull the fuel hose joint out of the delivery pipe. surface.
PREPARATION 9 • • If liquid or gasoline flows into the breather Place the battery on a level surface. • hose, remove the hose and blow it clean with Check to see that the sealing sheet has no compressed air. peeling, tears, or holes in it.
• If using a recommended battery charger, fol- low the charger’s instructions for newly acti- vated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150–9 • If the above chargers are not available, use equivalent one.
PREPARATION 11 CAUTION Once the strip of caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the bat- tery. NOTE ○ To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds.
12 PREPARATION A. Fuel Tank A. Fuel Hose Joint B. Fuel Return Hose (Red) • When installing the fuel tank, check that the C. Breather Hose (Blue) hose is securely connected to the tank, and be sure not to pinch this or any other hose or •...
PREPARATION 13 A. Fuel Tank A. Rider’s Seat B. Fuel Tank Bolt (D = 6) B. Rider’s Seat Bolt C. Fuel Tank Bolts (D = 8) C. Right Side Cover D. Projection Rider’s Seat Installation E. Grommet • Insert the tabs on the rear of the rider’s seat •...
14 PREPARATION A. Reservoir A. Front Brake Fluid Reservoir B. Cap B. Upper Level Line C. Clockwise C. Lower Level Line D. 1/6 turn D. Cap Stopper Screw • If the fluid level in the reservoir is lower than CAUTION the lower level line, check for fluid leaks in the Brake fluid quickly ruins painted sur- front brake lines and fill the reservoir.
PREPARATION 15 • Attach a clear plastic hose to the bleed valve on front master cylinder and run the other end of the hose into a container. • With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.
16 PREPARATION • Operate the brake pedal several times. • If it feels spongy, there might be air in the brake line. • If necessary, bleed the air in the rear brake line. • Also check for fluid leakage around the fit- tings.
PREPARATION 17 • Clutch Lever Free Play Adjustment When air bleeding is finished, check that the • fluid level is between the upper and lower Turn the adjuster so that the clutch lever will have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play. level lines.
18 PREPARATION • If the chain is too loose, turn out the left and right chain adjusters evenly. • If the chain is too tight, turn in the left and right chain adjusters evenly. • Turn both chain adjusters evenly until the drive chain has the correct amount of slack.
PREPARATION 19 A. Spring Preload Adjuster A. Cotter Pin B. Wrench B. Turning Clockwise C. 17 mm (0.7 in.) • Bend the cotter pin over the nut. D. Nut • Turn the spring preload adjusters into the nut to increase spring force and out to decrease spring force using a 22 mm wrench.
20 PREPARATION CAUTION Rear Shock Absorber Do not force to turn the rebound damp- ing force adjuster from the fully seated Rebound Damping Force Adjustment position or the adjusting mechanism • Check the position of the rebound damping may be damaged. force adjuster at the lower end of the rear •...
PREPARATION 21 Fuel WARNING Fill the tank in a well-ventilated area, and take ample care that there are no sparks or open flames anywhere near the work area. • Open the fuel tank cap, and check for debris in the fuel tank. •...
22 PREPARATION A. Fuel Tank A. Reserve Tank B. Suitable Object B. F (Full) Level Line C. Reserve Tank C. L (Low) Level Line • • Remove the cap from the reserve tank and If the amount of coolant is insufficient, do the add coolant through the filler opening to the F following procedures to add coolant.
PREPARATION 23 NOTE ○ A permanent type of antifreeze is installed in the cooling system when shipped. It is col- ored green and contains ethylene glycol. It is mixed at 50% and has the freezing point of –35 °C (–31 °F). Engine Oil (4-stroke) Engine Oil Level Inspection NOTE...
24 PREPARATION Throttle Grip and Cable Throttle Grip Free Play Inspection • Inspect the throttle grip free play. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) •...
PREPARATION 25 Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Adjust the idle speed to 1 250 ∼ 1 350 r/min (rpm) by turning the idle adjusting screw. Idle Speed: 1 250 ∼ 1 350 r/min (rpm) A.
26 PREPARATION A. Km/Mile Display A. Shift Up Indicator Light B. °C/°F Display • To complete the adjustment, push the MODE • button and RESET button simultaneously for The km/mile (and °C/°F temperature) display more than two seconds. shifts as follows. A.
28 PREPARATION Fastener Check • The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place.
PREPARATION 29 Torque Fastener Remarks N·m kgf·m ft·lb Frame/Steering Handlebar bolts Steering stem head nut Brake Front caliper bleed valves 0.80 69 in·lb Front caliper mounting bolts Front master cylinder clamp bolts 0.90 78 in·lb Front master cylinder bleed valve 0.60 52 in·lb Rear brake bleed valve...
30 PREPARATION Electrical System: Standard Torque Table Headlight - check high and low beams. This table relating tightening torque to thread Taillight - check operation. diameter, lists the basic torque for bolts and Brake Light - check operation. nuts. Use this table for only the bolts and nuts Turn Signal Lights - check operation.
MODEL APPLICATION Year Model Name 2005 ZX636-C1 Ninja ZX-6R Part No.99931-1447-01...