Kawasaki ZX-6R manuel d'utilisation

Ninja ZX-6R 2008 Ninja ZX-6R Racing Kit Manual This manual contains only the information of the racing kit part s. Refer to the base manual listed below for information of the original model. Base Manual Part Number Ninja ZX-6R Motorcycle Service Manual 99924-1382-02 © 2008 Kawasaki Heavy Industries, Ltd. First Edition (1): Jan. 25, 2008[...]

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Congratulation on your purchase of raci ng kit part s for the 2008 Ninja ZX-6R. IMPORT ANT This manual provides how to install racing kit p arts for the 2008 Ninja ZX-6R and how to tune up basically . As for the basic knowledge, refer to the bas e Service Manual for the Ninja ZX-6R (P/No. 99924-1382-02). When you particip ate in a race, it is neces[...]

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T able of Content s General Specifications ...................................................................................................... 4 Racing Kit Service Data .................................................................................................... 6 Periodic Maintenance Chart ................................................[...]

General S pecifications Item 2008 Ninja ZX-6R Racing Engine: Ignition timing 12.5°BTDC @1 300 r/min (rpm) Fuel (Recommended) Racing gasoline Engine oil (Recommended): Racing oil Level Between upper and lower levels of oil level gauge. Drive T rain: Primary drive reduction ratio 1.900 (76/40) T ransmission Gear T able STD (T ype A) T ype B T ype C [...]

Input 3rd/4th Gear Selection T able 4th Gear A B C D A 13262-0506 13262-0529 13262-0679 3rd Gear B 13262-0680 13262-0681 13262-0682 Gear Identification Slit Number T able STD (T ype A) T ype B T ype C T ype D In 0 1 1 1st Out 0 1 2 In 0 1 2 3 2nd Out 0 1 2 3 In 0 1 3rd Out 0 1 In 0 1 2 3 4th Out 0 1 2 3 In 0 1 2 3 5th Out 0 1 2 3 In 0 1 2 3 6th Out[...]

Racing Kit Service Dat a Item St andard Cylinder Head, V alves: Duration: Intake 288° Exhaust 266° Camshaft timing (cam lif t center): Intake 105° (A TDC) Exhaust 1 10° (BTDC) V alve clearance: Intake 0.16 mm Exhaust 0.28 mm V alve to piston clearance: Intake 0.80 mm (Minimum) @12°A TDC Exhaust 1.40 mm (Minimum) @1 1°BTDC Ignition System: S p[...]

Periodic Maintenance Chart The scheduled maintenance must be done in a ccordance with this chart to keep the motorcycle in good running condition. FREQENCY OPERA TION Each Race (300 km) Every 3 races (1 000 km) Every 5 races (1 500 km) (3 000 km) Every 10 races As Required Engine Clutch plate - - check* ● Throttle grip play - - check* ● S park [...]

FREQENCY OPERA TION Each Race (300 km) Every 3 races (1 000 km) Every 5 races (1 500 km) Every 10 races (3 000 km) As Required Wheel beari ng (rear) - - grease ● Swingarm pivot, uni-track linkage - - grease ● Swingarm pivot, uni-track linkage - - check* ● *: Replace, add, adjust, clean, or torque if necessary . 8[...]

Prep aration Before Inst alling  Modify the part s based on your race regulation.  T o avoid misuse keep the part s repl aced with the kit p art s sep arate.  When reusing part s, clean them and check them for damage or deterioration.  Main Removal Parts: Lights Rear V iew Mirrors Side S tand S tarter Lockout Switch  Remove the side [...]

 Remove the secondary valves of cylinder head and relational parts, then plug the each holes.  Remove the oil receiver and plug the hole.  Remove the air cleaner elem ent or cut the cleaner element off remaining punched plate to reduce the air flow resistance. 1. Remove the p arts. 2. Plug the holes. 3. Replace with plugs (92043-1506), and[...]

Cylinder Head  Grind off the stepped portions of the port s and smooth the inside of ports to make intake/exhaust gas flow more smooth.  Grind off the stepped portion only at the mating surface betwe en the carburetor holder and the intake port. Do not port it. T o ext end the intake port, air flow speed will be reduced and the engine perform[...]

 The combustion chambers are modified by cu tting work but the edges shown must be hand finished for smooth corners (Round them to about R1).  Chamfer the machining edge of the cylinder head where the valve seat is installed, also smooth the dome of the com bustion chamber with the valves installed. Excessive smoothing may reduce the cylinder[...]

A. T ensioner B. T ensioner Rod C. O-ring D. O-ring E. Lock nut Camshaf t s, S procket s Camshaf t s , Sprocket s:  Adjust the valve clearance within the specified value, but more performance is expected when adjusted from middle value to upper limit between adjustable range. Original T iming Cam Lift V alve Clearance Intake 288 ° 8.30 mm 0.13 [...]

 If you don’t adjust the valve timing for racing, install the camshaft sprocket to the kit camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-6R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjust able range of the long bolt holes.  T ighten the c[...]

Cylinder Head Gasket Part No. Thickness Note 1 1004-0071 0.45 mm KIT 1 1004-0070 0.50 mm KIT 1 1004-0069 0.55 mm KIT 1 1004-0068 0.60 mm KIT 1 1004-0057 0.65 mm Original 1 1004-0067 0.70 mm KIT 1. Squish, Front/Rear 2. Squish, Left/Right 15[...]

Crankshaf t Main Journal and Co nnecting Rod Bi g End Bushings  T o adjust clearance of crankshaft main journal you can select proper bush in accordance with the marks.  The kit bushings are improved in anti-seiz uring characteristics as well as in wear-resistance as comp ared with the standard bushings. 1) Crankshaft Main Journal  Cranksh[...]

 Main Journal Bush A. Size Color Size Color Thickness mm Journal Number Part Number (STD) Part Number (KIT) 1-4 92139-0189 92139-0200 blue 1.499-1.503 5 92139-0171 92139-0197 1-4 92139-0190 92139-0201 black 1.495-1.499 5 92139-0172 92139-0198 1-4 92139-0191 92139-0202 brown 1.491-1.495 5 92139-0173 92139-0199  Selection T able Crankcase inner[...]

2) Crankpin  Crankpin Diameter 1. Crankpin Diameter Marks “ { ” mark : over 29.992 mm within 30.000 mm None : 29.984 mm and over within 29.992 mm  Connecting Rod Big End Inside Diameter Connecting Rod Big End Inside Diameter Marks “ { ” mark : over 33.008 mm within 33.016 mm None : 33.000 mm and over within 33.008 mm A. Inside Diamete[...]

 Selection T able Connecting Rod Big End Inside Diameter Crankpin Diameter Ma rk Size Color Part Number (STD) Part Number (KIT) None ○ (33.000 mm ~ 33.008 mm) (29.992 mm ~ 30.000 mm) brown 92139-0 167 92139-0196 None None (33.000 mm ~ 33.008 mm) (29.984 mm ~ 29.992 mm) black 92139-0166 92139-0195 ○ ○ (33.008 mm ~ 33.016 mm) (29.992 mm ~ 30[...]

Clutch Adjustment (Back-T orque Limiter Setting) The Ninja ZX-6R engine is equipped with the Kawa saki back-torque limiter mechanism in the clutch. The back-torque limit er works to reduce the chance of rear wheel hop caused by engine braking during hard braking and down shifting. The back-torque limiter operating condition can be changed by changi[...]

 The standard setting of length [A], total thickness of clutch plates shown in the illastration, becomes about 40.7 mm. For this setting the effect ive stroke of clutch spring plate during the back-torque limiter operat ion is adjusted between 0.45 and 0.75 mm. By increasing the effective stroke the back- torque limiter causes more slip. The ef [...]

Recommended Clutch [A] S pacers [B] Needle Bearing [C] Bushing [D] Clutch Outer Casing [E] Clutch Hub [F] Sub Clutch Hub [G] Friction Plates: tot al 8 pcs. [H] S teel Plates [I] S pring Plate [J] S t eel Plate with S pring 22[...]

• Engage the cam followers (Clutch Hub) wit h the cams (Sub Clutch Hub). • T o measure the effective stroke of clutch spring plat e, set a dial gaug e [A] against the raised center [B] of the clut ch spring plate. • Move t he clutch housing gear bac k and forth [C]. The differ ence between the highest and lowest gauge readings is the amount o[...]

St andard Selection of Shim T otal Thick ness of Clutch Plates Size of Shim Remarks Approx. 40.7 mm 2.0 mm P/No. 92180-0149 Original Setting 40.2 mm 1.5 mm P/No. 92026-1590 39.5 ~ 40 mm 1.2 mm 92025-1 137 T ransmission  Remove the three steel balls (600A050 0) from the output shaft assembly .  T ake kit and optional transmission gears are ava[...]

Generator (Option) T o quicken response by reducing the flywheel mass and to reduce the weight, use the optional inner rotor generator .  Select using the optional generat or or original generator a ccording to the situation.  Use the optional regulator and optional generat or cover set when using the optional generator .  The output power[...]

Muffler With recommended muffler engine performance can be improved. Recommended muffler: Beet NASSER T -R 10 02-E02-00 Web Site : http://www .beet.co.jp/(beetjapan) * For further information contact t he manufacturer of muffler directly . W ater T emperature Sensor The original water temperature sensor instal led in the cylinder head must be remai[...]

Radiator Inst allation  Use the radiator stay ( 35063-0439) and bracket (1 1054-1818) belong to kit, and fasten the radiator to the Crankcase by bolts as shown in the figure.  S tay has several installation holes. Inst all position is adjustable for proper position of radiator .  Some muffler may inte rfere with stay . In such case, make a[...]

W ater Hose Installation Radiator inlet  Divide the original water hose (39062-0156) at suitable position, and insert the hose between cylinder head and radiator . 1. W ater Hose 39062-0156  Insert the water hose ( 39062-0220) between oil cooler outlet and radiator . Radiator outlet  Apply a non-permanent locking agent to the thread of the[...]

1. W ater Hose 39062-02 19 4. Sensor 21 176-1099 2. Ground Wire 2601 1-0071 5. Lead Wire 2601 1-1779 3. W ater Hose 39062-0166 (S t andard) 6. Clamp 92171-0179 Reserve T ank Inst allation When using the radiator (Kit), the original reserve tank cannot be used. Prepare a suitable substitue. Reserve T ank should be equipped with a band so as not to a[...]

Oil Catch T ank Inst allation  Fasten the Bracket (E) to the E ngine Hanger by using bolt (D).  Fasten Oil Catch T ank (A) to the Bra cket (E) by using bolt (F) and nut (I).  Connect Air Cleaner , Crankcase and Oil Catch T ank by using hose1 (B) and hose2 (C). A) Oil Catch T ank (52001-0004) B) Hose1 (Air Cleaner – Oil Catch T ank) C) Ho[...]

Hose1 (B) and Hose2 (C) assembling  Divide Hose (92059-1587, KIT) and Hose (92059-1629, KIT) as shown below .  Divide installed t ube (92192-0429, standard) as shown below . 31[...]

 Assemble hoses as shown below 5. Fitting (92005-0080) 32[...]

Frame Part s Inst allation Throttle Part s (Kit) The following throttle cases, gr ip and reels are available as opt ional part s. These optional part s quicken throttle response to the twist grip. 1) Throttle Case Parts P/No. Throttle Case, Upper 32099-0004 Throttle Case, Lower 32099-0005 Bolts (2) 120S0625 Grip, Right 46075-1 143 2) Throttle Reels[...]

1) Drive Chain #520 Joint endless drive chain is available as an optional part s. 2) Chain Guard 1. Guard: 55020-0028 2. Bolt: 130J1020 3. Swingarm (Lef t Side) Brake Pads (Kit) The front and rear brake pads for racing use are available. The front pads are for higher braking force, and the rear pads are for lower braking force. Front Brake Pads P/N[...]

1) Recommended Steering Damper OHLINS SD121  Set the steering damper to the holder as shown. 2) Stroke(s) SD121: 68 mm 1. S teering Damper: OHLINS SD121 2. Bracket: 1 1054-1816 3. Bracket: 1 1054-1817 4. Collar: 92152-0589 5. Ring: 670 B 2012 6. Washer: 410 B 0800 7. Bolt, Socket: 120 CA0630 8. Bolt, Socket: 120 CA0825 9. Bolt, Socket: 120 CA086[...]

1. Nut 3. Collar 2. S pacer 4. Bracket 36[...]

Front Fork Springs (Kit) The optional front fork springs are available for racing. 1) Front Fork Specifications Items Original Rebounded damping setting (Upper) 1 1/2 turns o u t from the fully clockwise position Compression damping setting (Lower) 1 1/2 turns out from the fully clockwise position Fork oil SHOW A SS47 Fork oil level 97 mm Oil lock [...]

Fork Spring Inst allation 38[...]

Electric Part s Inst allation Battery  Use the original battery or a battery with 12 V 7 Ah or more capacity . Main Harness and Sub Harness (Kit) Main harness and sub harness are available for racing use as optional part s. Select one of them in accordance wit h your race regulation. Main Harness (with Optional Meter): 26031-0559 Main Harness (w[...]

Meter (Kit) Inst allation 1. T achometer with W ater T em perature Gauge (Optional): 25031-1 142 2. Collar (Opti onal): 92152-0058 3. Pad (Optional): 39156-0098 4. Bracket (Optional): 1 1053-1749 5. Rivet (Optional): 92039-1 106 6. Nut (Optional): 92015-1233 7. Collar (Opti onal): 92152-1074 8. Bolt (Optional): 130J0625 9. Damper (Original): 92160-[...]

Main Harness Combination Parts T able Main Harness and Kit Part Combination T able ○ : need × : no need. Harness Part Harness for Kit Meter 26031-0559 Harness for Original Meter 26031-0558 Sub Harness 26031-0327 Meter Assembly (Kit) × ○ ○ T achometer with W ater T emperature Gauge (Kit) 25031-1 142 ○ × × W ater T emperature Gauge Lead ([...]

Wiring Routing 1. V ehicle-down Sensor 12. Main Throttle Sensor 2. Meter Assembly 13. Injector , Secondary 3. Shif t Up Indicator Light 14. Injector , Primary 4. Right Handlebar Switch 15. Coolant T e mperature Sensor 5. Lef t Handlebar Bar Switch 16. S peed Sensor 6. Intake Air T emperature Sensor 17. Crank Shaft Position Sensor 7. Boost Sensor 18[...]

1. Fuel Pump 2. Magnetic Switch 3. ECU 4. Relay Assembly (27002-3703) 5. Atmospheric Pressure Sensor 6. Power Source for Measuring Instrument s 7. Setting T ool  The relay assembly “4” should make sure to avoid the interferenc e with other p arts.  When apply the measuring instrum ents, the power source “6” available as a 12 V power s[...]

Wiring Diagram (with Kit Meter) 44[...]

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Wiring Diagram (with Original Meter Assembly) 46[...]

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Racing Kit P ar ts List[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-3 Cylinder Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11004 11004-0067 GASKET-HEAD ,T=0.70 1 (OPTION) 11004A 11004-0068 GASKET-HEAD ,T=0.60 1 (OPTION) 11004B 11004-0069 GASKET-HEAD ,T=0.55 1 (OPTION) 11004C 11004-0070 GASKET-HEAD ,T=0.50 1 (OPTION) 1[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-4 Crankshaft Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 92139 92139-0194 BUSHING,CONROD ,BLUE AR (OPTION) 92139A 92139-0195 BUSHING,CONROD ,BLACK 8 (OPTION) 92139B 92139-0196 BUSHING,CONROD ,BRO WN AR (OPTION) 92139C 92139-0197 BUSHING,CRANK #5,BLUE [...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-5 Clutch Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 39108 39108-0004 RET AINER-SPRING,T=5.0(STD-1.0) 6 (OPTION) 92025 92025-1137 SHIM,15.3X27.5X1.20 1 (OPTION) 92026 92026-1590 SP A CER,T=1.5 1 (OPTION) 3 DEC.27,2007[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-6 T ransmission(TYPE-B) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 13127 13127-0055 SHAFT-TRANSMISSION INPUT ,14T 1 (OPTION) 13144 13144-0047 SPROCKET-OUTPUT ,16T 1 (OPTION) 13144A 13144-0048 SPROCKET-OUTPUT ,15T 1 (OPTION) 13262 13262-0526 GEAR,OUTP[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-7 T ransmission(TYPE-C) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 13144 13144-0047 SPROCKET-OUTPUT ,16T 1 (OPTION) 13144A 13144-0048 SPROCKET-OUTPUT ,15T 1 (OPTION) 13262 13262-0535 GEAR,OUTPUT LOW ,36T 1 (OPTION) 13262A 13262-0536 GEAR,INPUT 2ND ,1[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-8 T ransmission(TYPE-D) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 13144 13144-0047 SPROCKET-OUTPUT ,16T 1 (OPTION) 13144A 13144-0048 SPROCKET-OUTPUT ,15T 1 (OPTION) 13262 13262-0677 GEAR,INPUT 2ND ,16T 1 (OPTION) 13262A 13262-0678 GEAR,OUTPUT 2ND ,3[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-9 Engine Co ver(s) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11061 11061-0303 GASKET ,CLUTCH COVER 1 (OPTION) 11061A 11061-0304 GASKET ,GENERA T OR COVER 1 (OPTION) 11061B 11061-0305 GASKET ,OIL P AN 1 (OPTION) 11061C 11061-0306 GASKET ,LARGE COVER [...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-10 Fuel Injection Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 21175 21175-0145 CONTROL UNIT-ELECTRONIC 1 (OPTION) 21176 21176-1099 SENSOR,TEMP 1 (OPTION) 26011 26011-0071 WIRE-LEAD ,TEMP SENSOR EAR TH 1 (OPTION) 26011A 26011-1779 WIRE-LEAD ,METER-TEMP[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-11 Generator Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11054 11054-1799 BRACKET ,OIL T ANK 2 (OPTION) 11054A 11054-1810 BRACKET ,REGULA T OR 1 (OPTION) 14073 14073-0124 DUCT ,FUNNEL,L=15 2 (OPTION) 14073A 14073-0125 DUCT ,FUNNEL,L=20 2 (OPTION) 1407[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Engine B-12 Radiator Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11054 11054-1818 BRACKET ,RADIA T OR 1 (OPTION) 11065 11065-1056 CAP 1 (OPTION) 35063 35063-0439 ST A Y ,RADIA TOR 1 (OPTION) 39060 39060-0020 RADIA TOR,BIG 1 (OPTION) 39062 39062-0219 HOSE-COOLI[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Chassis C-3 Frame Fittings(1/2) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11054 11054-1816 BRACKET 1 (OPTION) 11054A 11054-1817 BRACKET 1 (OPTION) 13061 13061-1628 BOSS 1 (OPTION) 13280 13280-0011 HOLDER,STEERING DAMPER 1 (OPTION) 13280A 13280-0012 HOLDER,ST[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Chassis C-4 Frame Fittings(2/2) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 120A 120CA0635 BOL T-SOCKET ,6X35 2 (OPTION) 120B 120CA0825 BOL T-SOCKET ,8X25 1 (OPTION) 120C 120CA0830 BOL T-SOCKET ,8X30 2 120D 120CA0865 BOL T-SOCKET ,8X65 1 (OPTION) 120E 120CB062[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Chassis C-5 Front Fork Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 92145 92145-0507 SPRING,FRONT FORK,K=8.25N/MM 2 (OPTION) 92145A 92145-0508 SPRING,FRONT FORK,K=9.25N/MM 2 (OPTION) 92145B 92145-0509 SPRING,FRONT FORK,K=9.75N/MM 2 (OPTION) 13 DEC.27,2007[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Chassis C-6 Meter(s) Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 11053 11053-1749 BRACKET ,KIT METER 1 (OPTION) 23016 23016-0006 LAMP-ASSY ,INDICA TOR 1 (OPTION) 25031 25031-1142 METER-ASSY 1 (OPTION) 39156 39156-0098 P AD ,KIT METER 1 (OPTION) 92015 92015-123[...]

This catalog covers: GRID NO . This grid covers: ’08 ZX600P8FR Chassis C-7 Other Quantity-ZX600 ’08 Ref. No . P ar t No. Description Spec Code P8FR 43082 43082-0074 P AD-ASSY-BRAKE,FR 1 (OPTION) 43082A 43082-1192 P AD-ASSY-BRAKE,RR,C93 1 (OPTION) 43082B 43082-1220 P AD-ASSY-BRAKE,RR,C93G 1 (OPTION) 55020 55020-0028 GU ARD ,CHAIN 1 (OPTION) 9205[...]

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