2005 Ninja ZX-6RR Racing Kit Manual
Contents
1. 15 ISOd BONS di ut dd edat a adatta uud duds 15 Clutch Adjustment Back Torque Limiter 16 Uia TERT III 20 EE ASAN SS OES lA 5 Tm 20 EE DE E a E a 22 Generator COVER ORISSA OEE E OEE E OE E 22 COVE ASI areia 22 SD E ne 22 22 Water Temperature 5 0 0 0 22 Radiator KIU 22 Radiator INSANI ION 23 RN 24 Reserve 25 Frame STAN AON 2 EE 26 ede ToS 26 Final DRIVE Parts aucune an ida ien Mu R ht 27 5 28 Damperi o 28 Sesbhelgp FAG US scd ouo atate atio dues d vd ue cod edet 29 TOR EOLK SDFIDQgS Pied Feed dod esed eod esed Passadas 31 ito2. 44026 44026 0066 SPRING FRONT FORK K 8 50N MM 2 44026A 44026 0067 SPRING FRONT FORK K 9 50N MM 2 OPTION 44026 44026 0068 SPRING FRONT FORK K 10 0N MM 2 OPTION I 44026C 44026 0070 SPRING FRONT FORK K 10 5N MM 2 1 44026D 44026 0071 SPRING FRONT FORK K 11 0N MM 2 T 21 ps V p kd amp d NE C e _2 44026 A D z A I A e e T P F T d 4 T 4 T 1 T d ub no 1 Pd e I j N E E A amp U U do S N 1 AS N ENA gt SN ES 6 12 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Chassis Meter s F2530 Ref Description Spec Code Quantity ZX600 11053 11053 1749 METER 1 OPTION dnt 25031 25031 1142 METER ASSY 1 OPTION 92015 92015 1233 NUT FLANGED 6MM BLACK 2 92152 130 92039 92039 1106 RIVET 3 92152 92152 0058 COLLAR 3 92152 92152 1074 COLLAR 2 OPTION 92161 92161 0053 DAMPER 1 OPTION La 130 13010625 BOLT FLANGED M6X25 2 guo M LM M LEE O Or 2 M 13 DEC 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Chassis Other F27
3. EEE DEE 33 cce 33 Main Harness and SUD Harness ocu adi adt aod e a od secta aad 33 Meter InsStallatlOri DES bS 33 VVIBIBIS I ERRA CE DM MM LR M M 36 Wiring Diagram With er eo aoa 42 Wiring Diagram with Original Meter Assembly 44 Wiring Diagram SUD Mamess se casa dasa cada dama SRS 46 General Specifications Engine Ignition timing Fuel Recommended Engine oil Recommended L evel Transmission Gear Table mes mec 13127 0033 13127 0033 13127 0034 13127 00135 13262 0297 13260 1619 13260 1543 13262 0034 Teeth Out In 39 16 39 16 35 14 40 17 Gear Ratio 2 437 2 437 2 500 2 352 In 13260 1987 23262 0091 13260 1987 13262 0035 2nd Out 13260 1992 13262 0092 13260 1992 13262 0036 Teeth Out In 37 18 37 19 Original 32 17 Gear Ratio 2 055 1 947 2 055 1 822 In 13262 0143 see note see note see note 3rd Out 13260 1993 13262 0038 13260 1993 13262 0038 Teeth Out In 31 18 35 21 Original 35 22 Gear Ratio 1 722 1 666 1 722 1 590 In 13262 0143 see note see note see note Ath Out 13262 0044 13260 1994 13262 0044 13262 0090 Teeth Out In 33 22 29 20 Original 29 21 Gear Ratio 1 500 1 450 1 500 1 380 In 13262 0144 1326
4. e o add adjust clean or torque if necessary Preparation Before Installing e Modify the parts based on your race regulation o avoid misuse keep the parts replaced with the kit parts separate When reusing parts clean them and check them for damage or deterioration e Main Removal Parts Lights Rear View Mirrors Side Stand Starter Lockout Switch Remove the side stand switch When the optional main harness is not used connect removing Black Yellow and Green White Leads directly Racing Kit Parts Also we have provided the spare parts and other optional parts engine frame and electric parts for racing So please order each parts referring to the Racing Kit Parts List in the back of this manual Engine Parts Installation Air Intake Parts e Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance O When removing the air cleaner element remove the element and relational parts as shown in next page e Remove the tank 16181 0002 to reduce the weight Plug the holes firmly with a tape The air pressure in the duct rises during high speed operation because the Ram Air oystem is used A Remove Wire Net B Remove this part and plug the hole Q7X6NRO2W4 1 Remove parts 2 Remove the parts 3 Plug the holes Cylinder Head e Grind off the stepped portions of the ports and smooth the inside of
5. Kawasaki ninja ZX 6RR 2005 Ninja ZX 6RR Racing Kit Manual This manual contains only the information of the racing kit parts Refer to the base manual listed below for information of the original model Ninja ZX 6RR 99924 1346 01 Motorcycle Service Manual O 2005 Kawasaki Heavy Industries Ltd First Edition 1 Jan 14 2005 Congratulation on your purchase of racing kit parts for the 2005 Ninja ZX 6RR IMPORTANT This manual provides how to install racing kit parts for the 2005 Ninja ZX 6RR and how to tune up basically As for the basic knowledge refer to the base Service Manual for the Ninja ZX 6RR P No 99924 1346 01 When you participate in a race it is necessary to modify the machine for the regulation So we want you to ask for the tuning up shop WARNING AFTER MODIFICATION TO TUNE THE VEHICLE TO COMPETITION MACHINE IT SHOULD NOT BE USED ON PUBLIC STREETS ROADS OR HIGHWAYS THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE CAUTION When operating the engine be careful not to trouble persons with noise Do not turn the engine with loud engine and exhaust noise DISCLAIMER OF WARRANTY ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED BASIC WORKS IN INSTALLING KIT PARTS We are going to make up the original Ninja ZX 6RR for the racing machine We recommend that the rider himself should do the basic w
6. 13262 13262F 13262G 13262H 132621 13262 13262 92200 92200 92200 Part No 13127 0033 OPTION 13144 0014 OPTION 13144 1297 OPTION 13144 1298 OPTION 13260 1619 OPTION 13260 1994 OPTION 13262 0038 OPTION 13262 0091 OPTION 13262 0092 OPTION 13262 0109 OPTION 13262 0144 OPTION 13262 0145 OPTION 13262 0147 OPTION 13262 0148 OPTION 13262 0149 OPTION 13262 0150 OPTION 13262 0187 OPTION 13262 0188 OPTION 92200 1534 OPTION 92200 1535 OPTION 92200 1536 OPTION Description opec Code SHAFT TRANSMISSION INPUT 16T SPROCKET OUTPUT 14T SPROCKET OUTPUT 15T SPROCKET OUTPUT 16T GEAR OUTPUT LOW 39T 4TH 29T GEAR OUTPUT 3RD 35T GEAR INPUT 2ND 19T GEAR OUTPUT 2ND 37T GEAR INPUT SRD amp 4TH 18T amp 20T GEAR INPUT 5TH 21T GEAR INPUT SRD amp 4TH 21T amp 20T GEAR INPUT SRD amp 4TH 21T amp 21T GEAR INPUT SRD amp 4TH 22T amp 20T GEAR INPUT SRD amp 4TH 21T amp 22T GEAR OUTPUT 5TH 28T GEAR OUTPUT 6TH 27T GEAR INPUT 6TH 22T WASHER INPUT T 1 7 WASHER OUTPUT T 1 7 WASHER T 1 2 DEC 9 2004 Quantity ZX600 AR AR AR GRID This covers Transmission TYPE B This catalog covers 05 ZX600 NR1 Engine 13260 Quantity ZX600 Ref Part No Description opec Code 13127 13127 0034 SHAFT TRANSMISSION INPUT 14T OPTION 13144 13144 0014 SPROCKET OUTPUT 14T OPTION 1314
7. BR BL BR BK Y BL BK BK Y ECU Electronic Control Unit Axe FEL Y BK BK GY R BK BR BK BL Regulator ER Y Rectifier Alternator EN E Y W G W P HH BR W Y R EN Y E Hee T m EN da P BK TTT W BL gt LB xxl W G W BK m 222 1kOt2 1 2W Equivalent R W ULT q G BK BEE D LLL DL W BkK lho Lo laio 0 1 j 0 BK 0 6 lll O R E ER Ell DL BL Y E E opo S S 444444 4 BL BK E Fa E BR BL G ES Pl Su BL R aaa A BK BL pum i BK 0 li 5 BK W LE FEL o 4 BK G lll j BK TEL 4 BR Y BK R E EB ESET j 2 3 R REN E A E Ss E ES EE dl dE BR R a O HIN 1000 2 lll G BK 4 28 Equivalent 1 1 G BK AA LL j pd 4 4 GY BK Y 5 2 gt gt VoYE S anl 2 a E Xs ES mu rien Interface gt gt Re Kawasaki Self Fuel diagnositic S Motor gt Reserve Vehicle System Esame Switch down Connector Self ue Pum Sensor diagnosis P Indicator Terminal S106244BW5 C 45 Wiring Diagram Sub Harness ECU ECU Mai
8. Diode h en E witc A15 J Pod E A PED BK Y ES Tachometer with Water Tempereture Gauge Bis 1 Ml dl llc Ala ll 1440000 H4 n 44 Relay Box 1 Relay 2 Headlight Relay Fuse Cace 3 Main Relay 10 W 4 Fuel ump Relay ee gt gt T33 5 Starter Circuit Relay gt lt zg ECU Warning Light Relay Box S106241BW5 C 42 Inlet Air Main Temperature Throttle Sensor Atmospheric Subthrottle Sensor Inlet Air Pressure Sensor Pressure x E Sensor Sensor Exhaust Butterfly Valve ue Actuator SM aoe th m ow m e E x m 25 d d a EE 4265 az 5 m ten m FE 25x en gt E gt S Electronic m Control Unit en 5 e nt GY G R R BK E BL Regulator Y G Rectifier Alternator HH Y BL Bi Y W P G N HH BR W NEL Y R 0 siege eee ma Y 2225 BK BL EE co ca Po EH W BL gt LB x x 1kQ 2 1 29 Equivalent R ENG E G BK Tdi p fp W BK Ii PLE p fo 0 0 s W Y ell 0 Y 1 dd bf l 0 BK Il dd 0 6 Ii dd 0 R dl ld TH BL Y 1 BL BK Co __ l BL G Il 491
9. 0100 92139 as OPTION 92139G 92139 0101 OPTION 92139F H 92139H 92139 0102 QR te EN OPTION 22 92139F H 1 I N Y 4 ec ON 5 Gon FON NS NN y zl 7 xz ts N p il See BEA RA Jum a NO Que x WA gt 3 a V e m L EN m has n gt DE WA E 92139F H gt 2 Nu Y 92139 39F H 39F H Description opec Code BUSHING BLACK BUSHING BROWN BUSHING PINK BUSHING CRANK 38 amp 5 BLUE BUSHING CRANK 38 5 BUSHING CRANK 38 5 BUSHING CRANK 18 28 4 BUSHING CRANK 18 28 4 BUSHING CRANK 18 28 4 9 2004 Quantity ZX600 AR AR AR AR This catalog covers GRID NO This grid covers 05 ZX600 NR1 Engine Clutch E1350 Ref m Part No Description Spec Code Quantity ZX600 39108 39108 0004 RETAINER SPRING L 5MM 6 OPTION 92015 92015 1929 NUT 1 OPTION 92025 92025 1756 SHIM T 0 4 1 OPTION 92210 92210 0088 NUT 1 OPTION BN IPSS AN 92025 556 N 92015 92210 N QNM QUON CS 9 AAA AL 9 3 DEC 9 2004 This catalog covers 05 ZX600 NR1 Engine 13262 13262 92200A GRID NO This grid covers Transmission TYPE A Ref No 19127 13144 13144 13144 13260 13260 13262 13262 13262 13262 132620
10. 92171 92171 0179 OPTION 130 130W0630 OPTION 554 55441000 OPTION 92171 fer Generator 92171 39192 10 Description STAY RADIATOR RADIATOR BIG PIPE WATER CAP ASSY PRESSURE PIN DAMPER RUBBER COLLAR CLAMP BOLT FLANGED M6X30 PIN SNAP 10MM DEC 9 2004 Spec Code Quantity ZX600 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Chassis Frame Fittings lll No Part No Description Spec Code 13280A 13280 13280 0011 HOLDER STEERING DAMPER 1 13280 OPTION 120 13280A 13280 0012 HOLDER STEERING DAMPER 1 52 q 31064 31064 1151 PIPE COMP GRIP 1 OPTION 32099 32099 0004 CASE UPP 1 OPTION 20 Woe 32099A 32099 0005 CASE LWR 1 OPTION ow em NG 46075 46075 1143 GRIPTHROTTLE 1 OPTION 59101 59101 0001 REEL R21 5 60DEG 1 OPTION Aw 59101A 59101 0002 REEL R20 0 65DEG 1 d DEN OPTION 54012 54012 0160 CABLE THROTTLE OPENING 1 gt EN Neg A 161 CABLE THROTTLE CLOSING i 54012A 54012 0161 1 A RAN 54012A OPTION Sa 3 q CLOSING s 92015 92015 1316 NUT FLANGED 16MM 1 o W amp 92015 OPTION S N 92026 92026 1586 SPACER SET 1 120 120 0635 BOLT SOCKET 6X35 2 V NN OPTION 120A 12050625 BOLT SOCKET 6X25 BLACK 2 OPTION 11 DEC 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Chassis Front Fork 9 Ref Quantity ZX600 No Description Spec Code
11. NR1 Engine Fuel Injection E1530 Ret Quantity ZX600 N A Part No Description Spec Code 05 21175 21175 0074 CONTROL UNIT ELECTRONIC OPTION 26081 26031 0240 HARNESS INTERFACE BOX OPTION 21175 8 DEC 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Engine Generator i Y NEAN Ne SACS Ke Part No Description Spec Code 05 m iom E NR1 26011A EM lez 2 Nu wu AN 21001 21001 0031 GENERATOR SMALL 1 X Mn b A OPTION 21066 21066 0010 REGULATOR VOLTAGE 1 v OPTION 21176 21176 1099 SENSOR TEMP 1 OPTION 26011 26011 0071 WIRE LEAD TEMP SENSOR EARTH 1 OPTION 26011A 26011 1779 WIRE LEAD 1 Ref Radiator OPTION 26031 26031 0325 HARNESS MAIN OP METER 1 OPTION 26031A 26031 0326 HARNESS MAIN STD METER 1 OPTION 26031B 26031 0327 HARNESS SUB STD METER amp HARNESS 1 OPTION 92153 92153 0386 BOLT TORX M6X28 4 OPTION 26031A METER 9 DEC 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Engine Radiator E3032 Ref N Part No Ref Frame di mk 35063 35063 0230 19 Wo NE 39060 39060 0020 9 P OPTION 2 ey C 39192 39192 0011 J f S M OPTION a 49085 49085 1066 WO 130 SET Ru OPTION 4202 d s 92043 92043 1436 sy p JEN OPTION x 9 49085 92075 92075 1123 S pe 39060 OPTION 92152 92152 1074 OPTION
12. OPTION 13262 0035 OPTION 13262 0036 OPTION 13262 0038 OPTION 13262 0090 OPTION 13262 0109 OPTION 13262 0110 OPTION 13262 0146 OPTION 13262 0147 OPTION 13262 0148 OPTION 13262 0149 OPTION 13262 0254 OPTION 92200 1534 OPTION 92200 1535 OPTION 92200 1536 OPTION Transmission TYPE C Description opec Code SHAFT TRANSMISSION INPUT 17T SPROCKET OUTPUT 14T SPROCKET OUTPUT 15T SPROCKET OUTPUT 16T GEAR INPUT 26 GEAR OUTPUT 5TH 28T GEAR OUTPUT LOW 40T GEAR INPUT 2ND 17T GEAR OUTPUT 2ND 32T GEAR OUTPUT 3RD 35T GEAR OUTPUT 4TH 35T GEAR INPUT 3RD amp 4TH 18T amp 20T GEAR INPUT 5TH 22T GEAR INPUT SRD amp 4TH 20T amp 20T GEAR INPUT SRD amp 4TH 21T amp 21T GEAR INPUT SRD amp 4TH 22T amp 20T GEAR INPUT SRD amp 4TH 21T amp 22T GEAR OUTPUT WASHER INPUT T 1 7 WASHER OUTPUT T 1 7 WASHER T 1 2 DEC 9 2004 Quantity ZX600 AR AR AR This catalog covers 05 ZX600 NR1 Engine GRID NO This grid covers Engine Cover s E1431 Ref Part No 11060 11060 1989 OPTION 11060A 11060 1991 OPTION 11061 11061 0162 OPTION 11061A 11061 0173 OPTION 14031 14031 0046 OPTION Description Spec Code GASKET CLUTCH COVER GASKET PLUSING COIL COVER GASKET GENERATOR COVER GASKET OIL PAN COVER GENERATOR FOR SMALL ACG DEC 9 2004 Quantity ZX600 This catalog covers GRID NO This grid covers 05 ZX600
13. 106227BW5 C 32 Electric Parts Installation 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 parts Select one of them in accordance with your race regulation Main Harness with Optional Meter 26031 0325 oub Harness with Original Meter and Original Main Harness 26031 0327 Main Harness with Original Meter 26031 0326 Meter Kit Installation 5106171842 C Tachometer with Water Temperature Gauge Optional 25031 1142 Collar Optional 92152 0058 Damper Optional 92161 0053 Bracket Optional 11053 0220 Rivet Optional 92039 1106 Nut Optional 92015 1233 Washer Optional 92022 1690 Bolt Optional 130J0616 Damper Original 92160 1167 10 Bracket Original 11053 1289 Insert the three collars 2 into the damper 3 Insert the rivet 5 from the backside of the bracket 4 and fix them e Install the bracket 4 to the original bracket 10 CON O OBR N gt 33 Main Harness Combination Parts Table Main Harness and Kit Part Combination Table O need x no need Harness for Harness for Kit Meter Original Meter 26031 0325 26031 0326 Sub Harness 26031 0327 Tachometer with Temperature Gauge Kit 25031 1142 Water Temperature Gauge Lead Kit 26011 1779 Water Temperature Sensor Ground Lead Kit x x 26011 0071 Wa
14. 1111 BL R 4 gt BK BL Il EE RS Lj BK 0 cd o O BK W E ER __ O l BK 6 Il Ne dd f pL BK Il Ne dd NH BR Y Ill Il 111 BK R 0 R EE EL __ j pf l LB il ooo ooo oo o op pL pf DLL BR R 0 ll dll G BK o dl 14 G BK 557 lo Ml dl _____ 114 dd BK Y 1000225 HM 1 28 Equivalent 111 LG G gt gt E m AR 3 see a a7 x m 5 x 11 E Interface Kawasaki Box Self diagnositic SS Reserve Vehicle System Main Switch d Connector SERE MEN Fuel own Ground 30A Bun ensor Self diagnosis Indicator Terminal 8106242BW5 C 43 Wiring Diagram with Original Meter Assembly 1 10 11 12 Water Camshaft Primary Fuel Injectors Subthrottle Temperature Position Right Switch Housing Valve Sensor Sensor 1 Engine Stop Switch zl 2 e E Actuator 2 Starter Button Speed Meter Unit 3 Stop Watch Switch Sensor Turn Signal T 5 E m m 2 Indicator Light LED ES o High Beam T d Indicator Light LED 0 O O Secondary 24 dia Fuel gt ex Neutral OFF 1 1 Injectors Indicator Light LED ON 1 2 3 4 m 011 Pressure Warning m cm Indicato
15. 2 0144 13262 0110 Out 13262 0150 Original 13262 0047 13260 1995 Teeth Out In 28 21 29 21 28 22 Gear Ratio 1 333 1 380 1 272 In 13262 0188 13262 0188 13260 1990 Out 13262 0187 Original 13262 0050 13262 0254 Teeth Out In 27 22 28 22 30 26 Gear Ratio 1 227 1 272 1 153 12 5 BTDC 91 300 r min rpm Racing gasoline Racing oil Between upper and lower levels of oil level gauge Drive Train Primary drive reduction ratio 1 891 87 46 4th gear type 13262 0149 A B 13262 0147 A C 13262 0143 B B NA B C NA C B 13262 0146 C C e 0145 A A 13262 0109 B A 13262 0148 C A 3rd gear type STD 13 Type A k B X Reduction Ratio Number of Grooves 1st gear out STD is interchangeable with type A Racing Kit Service Data Cylinder Head Valves Duration Intake 320 Exhaust 272 Camshaft timing cam lift center Intake 105 ATDC Exhaust 105 BTDC Valve clearance Intake 0 18 mm Exhaust 0 28 mm Valve to piston clearance Intake 0 7 mm Minimum 12 ATDC Exhaust 1 4 mm Minimum 12 BTDC Ignition System opark plugs 016 10 7 10 opark plug tightening torque 13 N m 1 3 kgf m 113 in Ib These values show the specifications when standard cylinder head and gasket are used When the clearance between the valve and the piston head is smaller than
16. 4A 13144 1297 SPROCKET OUTPUT 15T OPTION 13144B 13144 1298 SPROCKET OUTPUT 16T OPTION 13260 13260 1543 GEAR OUTPUT LOW 35T OPTION 13260A 13260 1987 GEAR INPUT 2ND 18T OPTION 13260B 13260 1992 GEAR OUTPUT 2ND 37T OPTION 13260C 13260 1993 GEAR OUTPUT 3RD 31T OPTION 13262 13262 0044 GEAR OUTPUT 4TH 33T OPTION 13262A 13262 0047 GEAR OUTPUT 5TH 29T OPTION 13262B 13262 0050 GEAR OUTPUT 6TH 28T OPTION 13262C 13262 0109 GEAR INPUT3RD amp 4TH 18T amp 20T OPTION 13262D 13262 0143 GEAR INPUT 3RD84TH 18T amp 22T OPTION 13262E 13262 0144 GEAR INPUT 5TH 21T OPTION 13262F 13262 0147 GEAR INPUT 3RD amp 4TH 21T amp 21T OPTION 13262G 13262 0148 GEAR INPUT 3RD amp 4TH 22T amp 20T OPTION 13262H 13262 0149 GEAR INPUT 3RD amp 4TH 21T amp 22T OPTION 132621 13262 0188 GEAR INPUT 6TH 22T OPTION 92200 92200 1534 WASHER INPUT T 1 7 OPTION 92200A 92200 1535 WASHER OUTPUT T 1 7 OPTION 92200B 92200 1536 WASHER T 1 2 OPTION 5 DEC 9 2004 This catalog covers 05 ZX600 NR1 Engine 13262 132620 92200A GRID NO This grid covers Hef 13127 13144 13144 13144 13260 13260 13262 13262 13262 13262 132620 13262 13262F 13262G 13262H 132621 13262 13262 92200 92200 92200 Part No 13127 0035 OPTION 13144 0014 OPTION 13144 1297 OPTION 13144 1298 OPTION 13260 1990 OPTION 13260 1995 OPTION 13262 0034
17. 50 Ref Description opec Code Quantity ZX600 2505 43082 43082 0005 PAD ASSY BRAKE FR F9633 2 OPTION 43082A 43082 1192 PAD ASSY BRAKE RR C93 1 OPTION 43082B 43082 1220 PAD ASSY BRAKE RR C93G 1 AH 3 55020 55020 0028 GUARD CHAIN 1 S OPTION gt Sod 92057 92057 1529 CHAIN DRIVE 120L 520 1 Y 247 Yat NN a PCS 92058 92058 1090 JOINT CHAIN DRIVE 520 1 92145 92145 0318 SPRING SHOCKABSORBER K 100N MM 1 OPTION 92145A 92145 0319 SPRING SHOCKABSORBER K 110N MM 1 OPTION 130 130J1020 BOLT FLANGED 10X20 1 43082A B OPTION 14 DEC 9 2004 lt Kawasaki KAWASAKI INDUSTRIES LTD Consumer Products amp Machinery Company Doc No 99929 1868 01
18. Device Cable ECU Electronic Control Unit Diagnosis Connector Interface Box Connector Vehicle Down Sensor Fuel Pump Lead Relay Box Exhaust Device Motor Battery Lead Magnetic Switch Battery Lead 39 5 m eu si ez Ds E LA pA oy2 Ue i lt L z lt 0 JD SSS 0 040 DO Ach fe Removal Parts 1 2 3 Rear Brake Switch Side Stand Switch Neutral Switch Other Parts Regulator Main Harness Sub throttle Valve Actuator Engine Harness Lead Clamp Clamp Speed Sensor Battery Lead Starter Motor Lead Clamp 41 Wiring Diagram with Kit Meter Water Camshaft Primary Fuel e Subthrottle Temperature Position Valve Sensor LE Sensor 1 2 Actuator Right Switch Housing gt Engine Stop E ere Sto Starter Watch ES dem Speed p Button Butt om m A n Switch Hon F Sensor Secondary d T l 1 Fuel bre NE 2 im 1 2 gt Xu 1 es xx gt MO MO Mo 0 zo o zo a LEN LI L Ignition Coil Vue iz ick iia uet nei arf i DOCG Engine Head N Cover Ground Z n n 53 PA Water Tempereture
19. Low Rear Brake Pads Original FO GG High 43082 1220 C93G 1 43082 1192 C93 Low Steering Damper Kit The steering damper is useful at high speeds to prevent handlebar vibration The steering damper should be installed to do not the steering handle movement stop by the steering damper itself at the fully locket position both left and right side Steering angle should be controlled by the regulation 1 Recommended Steering Damper OHLINS SD1005 Set the steering damper to the holder as shown 2 Stroke s SD1005 120 mm 3 Installation Install the steering damper carefully to avoid the steering damper as a stopper 1 Steering Damper OHLINS SD1005 2 Holder 13280 0011 3 Holder 13280 0012 4 Bolt Socket 120P0635 28 The holder s one side mating surface are shifted from center about 1 5 mm to ensure tightening force O Install the holder properly shown below to avoid steering damper operation stick 5106049851 C 1 No Gap 2 Gap 3 mm or less 4 Damper Adjuster otandard Position 8th click 1st click harder is fully clockwise click Usable Range 1st to 12 17th click Seat Height Adjustment Loosen the nut 1 and insert the spacer 2 as required Tighten the nut 1 to 59 N m 6 0 kgf m 43 ft lb of torque O One turn of the spring adjusting nut changes the spring length by 1 5 mm Rear Suspension Condition of Seat Height Adjustment When the seat height adjusts spacer ap
20. and determine the bolt stretch 080853BW1 C Install the original bolts into the connecting rod Before every tightening use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch Apply a small amount of molybdenum disulfide grease to the threads of bolts Tighten the big end nuts at the torque of 20 N m 2 0 kgf m reference Check the length of the bolts and find the bolt stretch Bolt Length after tightening Bolt Length before tightening Stretch Bolt Stretch Usable Range 0 33 0 38 mm 0 013 0 015 in Turn the big end nuts more until the bolt stretch reaches the usable range NOTE O Replace the original bolts with new ones if they have already been tightened up to usable range 2 times Clutch Adjustment Back Torque Limiter Setting The Ninja ZX 6RR engine is equipped with the Kawasaki back torque limiter mechanism in the clutch The back torque limiter 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 changing the total thickness of clutch plates and changing the number of leaf springs Try different settings and select the best Size of spring retainer 91 1041 GINAL PRODUCTION PART Total thickness of Length A all clutch plates SIZX63R1W3 The standard setting of length A total thickness of clutch plates shown below
21. becomes about 38 8 mm Supposed combination of steel plates is t1 6 with spring x 1 pcs 1 6 x 1 pcs t2 0 x 5 pcs For this setting the effective stroke of clutch spring plate during the back torque limiter operation is adjusted between 0 45 and 0 75 mm By increasing the effective stroke the back torque limiter causes more slip The effective stroke increases by decreasing the length A The length A between 37 6 and 38 8 mm is available by changing the combination of the steel plates Replace one steel plate with a thinner one and try the setting If the operation of the back torque limiter is not enough replace other steel plates one by one Thickness mm Part Number Used Number LUMINE 20 13089 0007 Selection 5 Original Steel plates of 2004 model s are available Thickness mm Part Number For precise setting the measurement of the effective stroke of clutch spring plate is recommended e Remove oil from clutch plates e Hold an extra drive shaft in a vise and install the following clutch parts on the shaft A Spacers B Needle Bearing C Bushing D Clutch Outer Casing E Clutch Hub F Sub Clutch Hub G Friction Plates 8 pcs H Steel Plates Spring Plate J Steel Plate with Spring S108091BW3 C e Engage cam followers Clutch Hub with cams Sub Clutch Hub e o measure the effective stroke of clutch spring plate set a dial gauge A against the raise
22. ction part 92200 1375 Production part 92200 1238 Original output Plane washer 20 Plane Washer combination example 1 0 1 0 2 1 0 7 1 4 28 14 14 pl og TE cee Sr TCT 5 57 12 T a E EIS TT Ser p Fo TT i EP TERN 1 Spline washer input 2 Spline washer output 3 Plane washer 21 Generator Kit To quicken response by reducing the flywheel mass and to reduce the weight use the optional inner rotor generator Select using the optional generator or original generator according to the situation Use the optional regulator and optional generator cover set when using the optional generator The output power of the optional generator is 10A 8000 rpm Original 22 5 5000 The consume current of the racing model in running condition is 7 8A Generator Cover Kit To increase the lean angle of the machine use the optional generator cover NOTE O When using the optional generator cover use the optional generator Cover Gaskets The optional cover gaskets are available They are made from meta form and made easy to exfoliation Ducts Air Funnels The original machine s air funnel should be used The suitable funnel is originally equipped for racing in 05 model Muffler With recommended muff
23. d center B of the clutch spring plate e Move the clutch housing gear back and forth C The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate D Drive Shaft 0 060 18 5 After installing the clutch to the engine measure and record the depth B shown in the figure on page 18 The length from the clutch spring plate to the top surface of the sub clutch hub using a caliper or a depth gauge Manage the depth B to adjust the effective stroke after that because the friction disks would be worn and the length A Total thickness of all clutch plates would change The decrease of the depth B from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured e When decreasing the length A total thickness of clutch plates use the optional spring retainers provided as optional production parts to keep the preload of clutch springs according to the table below If you have clutch slip during acceleration use shorter spring retainers by 1 mm to increase preload of clutch springs e When decreasing the length A total thickness of clutch plates use the optional shim provided as optional production part to keep the position of clutch release lever according to the table below The standard setting of the number of leaf springs is four By decreasing the number of the leaf springs the sub clutch hub ope
24. djustable range f you can not 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 6RR Service Manual If you adjust the valve timing install the sprocket to the camshaft between the adjustable range of the long bolt holes Tighten the camshaft sprocket bolts to 15 N m 1 5 kgf m 11 0 ft lb of torque Valve Timing when the round bolt holes are used Original 105 105 Race use 103 107 103 107 O When grinding the cylinder head bottom surface grinding the cylinder top surface or using thinner gaskets be sure the valve to piston clearance especially O When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly Valve to Piston Clearance Min Intake Exhaust If the valve to piston clearance is less than the minimum value do not start the engine because the valves will touch the piston and the engine may be damaged Measure the valve to piston clearance at about 12 ATDC Intake and 12 BTDC Exhaust of crankshaft timing At this point the valve to piston clearance will be minimum Valve Springs The original machine s valve springs should be used Cylinder Compression To adjust the cylinder compression adjust the thickness of t
25. he cylinder head gasket and the cylinder base gasket or smooth the cylinder top surface to make the piston squish 0 65 0 8 mm Keep the piston squish more than 0 65 mm O Position the piston at Top Dead Center and put a small piece of modeling clay on the shoulder of the piston Install the cylinder head gasket and cylinder head and tighten the head bolts to the specified torque O Remove the cylinder head and measure the thickness of the clay The thickness of the collapsed clay is the size of the squish Squish Measurement 1 Front and Rear 0 65 0 80 mm 2 Left and Right 0 67 0 85 mm O The most preferable squish measurement is 1 0 65 mm 2 0 67 mm O Select proper cylinder head gasket and cylinder base gasket O Note that by grinding the cylinder head surface only left and right squishes become narrower while by grinding the cylinder top surface or decreasing the gasket thickness all the squishes become narrower Cylinder Head Gasket 11004 0020 KIT Cylinder Base Gasket NE 8 11061 0037 KIT 8108037 3 1 Squish Front Rear 2 Squish Left Right Crankshaft Main Journal and Con rod Big End Bushings e Crankshaft Main Journal Bushings Use original bushings Con rod Big End Bushings Use kit bushings Size colors are same as original Connecting Rod Bolts Use the original connecting bolts and nuts The original connecting rod bolt has recesses at both ends to measure its length
26. ler engine performance can be improved Recommended muffler Beet NASSERT R 1002 E01 00 Home Page http www beet co j beet japan For further information contact the manufacture of muffler directly Water Temperature Sensor The original water temperature sensor installed in the cylinder head must be remain and connected to the main harness because the electronic control unit E C U needs the output signal from the original water temperature sensor The optional tachometer is equipped with a water temperature display Install the optional water temperature sensor to the optional water pipe and connect the sensor and the optional meter unit with the optional harness Radiator Kit 05 model ZX 6RR Racing Kit provides the capacity increased main radiator 39060 0020 to improve cooling performance 22 Radiator Installation Use the radiator stay 35063 0230 belong to kit and fasten the radiator to the oil pan by bolts as shown in the figure Q2X6NROAW3 C The stay is specialized for a recommended Beet muffler and is not available for a standard muffler Make your stay for a standard muffler or any other ones e Machine the original cowl to meet the outline of radiator e Fill the space between the cowl and the sides of radiator by fixing a sponge or the like NOTE O After radiator s installation be sure to check that there is no interference between the radiator and the manifold or fender tire and the front fork full b
27. liquid surface Radiator SIZX83R4W1 C 25 Frame Parts Installation Throttle Parts Kit The following throttle cases grip and reels are available as optional parts These optional parts quicken throttle response to the twist grip 1 Throttle Case Throttle Case Upper 32099 0004 Throttle Case Lower 32099 0005 Bolts 2 12080625 Grip Right 46075 1143 2 Throttle Reels Tow types are available Twist Grip Turn Angle 59101 0001 59101 0002 Throttle Reel Travel Angle S 106007BN2 1 Identification Mark 26 32099 0005 Upper Case 32099 0004 Reel 60 59101 0001 Reel 65 59101 0002 Throttle Cable Open Side 54012 0160 Throttle Cable Close Side 54012 0161 Bolt 12050625 Gap 3 Throttle Cables The throttle cables are also available as optional parts use these parts when the above optional throttle reel is used Throttle Cable Acceleration 54012 0160 Throttle Cable Deceleration 54012 0161 Final Drive Parts Kit 1 Drive Chain 520 Joint endless drive chain is available as an optional parts 2 Chain Guard 1 Guard 55020 0028 2 Bolt 130J1020 3 Swingarm Left Side 27 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 higher braking force Front Brake Pads 43082 0005 F9633 High Original C93YT
28. n Terminal Terminal Harness Interface Kawasaki self Diagnositic oystem Connector 46 Color Code Black BL Blue Brown Green GY LB Light Blue LG Light Green Orange P Pink PU Purple Red OW White OY Yellow 5106245BW3 G Racing Parts List This catalog covers GRID NO This grid covers 05 ZX600 NR1 Engine Cylinder Head c No Part No Description opec Code 11004 11004 0018 GASKET HEAD T 0 55 1 OPTION 11004A 11004 0019 GASKET HEAD T 0 65 1 OPTION 11004B 11004 0020 GASKET HEAD T 0 40 1 OPTION 11061 11061 0033 GASKET CYLINDER BASE T 0 20 1 OPTION 11061A 11061 0036 GASKET CYLINDER BASE T 0 15 1 OPTION 11061B 11061 0037 GASKET CYLINDER BASE T 0 30 1 OPTION 12048 12048 1175 TENSIONER ASSY 1 OPTION 49118 49118 0036 CAMSHAFT COMP INTAKE 1 OPTION 49118A 49118 0037 CAMSHAFT COMPEXHAUST 1 OPTION 132 132J0620 BOLT FLANGED SMALL M6X20 2 OPTION 1 DEC 9 2004 This catalog covers GRID NO This grid covers 05 ZX600 NR1 Engine Crankshaft E1321 Hef ANS Part No Wi 92139 92139 0068 a OPTION aN 92139A 92139 0069 OPTION 92139 A B 92139 92139 0070 5A WA OPTION MEN A 92139C 92139 0097 To A OPTION AS 92139D 92139 0098 v 92139F H 92139E 92139 0099 OPTION 92139 A B 92139F 92139
29. ng thinner gaskets adjust the valve timing to keep that the valve to piston clearance is not less than the minimum value IN 0 7 mm EX 1 4 Camshaft Chain Tensioner e Replace the cam chain tensioner with the kit to decrease the flutter of tensioner e Apply the engine oil to the tensioner rod O ring and tensioner body insert them into the tensioner body O Check to see that the tensioner rod turns freely in the body if not polish the tensioner rod or fine the female threads in the body with a tap Diameter x Pitch 6 mm x 1 0 mm Install the tensioner on the cylinder block with the tensioner rod is fully pushed back urn the tensioner rod in with a screwdriver until it becomes hard to turn Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to take up any gap and tighten the locknut NOTE O Never forward the tensioner rod forcibly this will increase mechanical loss of the tensioner and may damage to the chain guide O The cam chain tensioner must be adjusted at every race 5106036803 C Tensioner Tensioner Rod O ring O ring O A W N gt Lock nut 11 Camshafts Sprockets Camshafts Sprockets Original Camshaft Intake Original Camshaft Exhaust Adjust the valve clearance within the specified value Intake 0 11 0 19 mm Exhaust 0 25 0 31 mm More performance is expected when adjusted from middle value to upper limit between a
30. orks removing parts or installing parts etc given advices by the tuning shop In a race although trouble will be apt to happen if you participate in basic works you can discriminate cause of trouble so you can return the race soon But concerning difficult technical works you should as tuning shop Table of Contents General SDeOIICatlollS vesti CS aaa Eu bna etl a Eel Rex Sa 3 RACING IE SerIVICe eee EGE ni um tan 5 sore ot RN RI ERE NEL MEM 5 REPRISE DR PRE RR PRE RE Ee 7 Xie INS UNIO O TS 7 qt Ue ell 7 Engine Parts 5 7 UM OM 7 CINCO em 9 Camshalbt Chaim TENSIONET nc iba ss dass part esti eo arid Suc aed 11 Camshans SDIOCKOlS essi erede a eet vete aate etr td ted v Gu PRA 12 SONOS aeree OO 12 Cylinder COMPRESS ON cd aS 13 Crankshaft Main Journal and Con rod Big End
31. ottomed 23 Radiator Installation Radiator inlet Apply non permanent locking agent to the thread of the water temperature sensor Kit for Meter Lamp Mount the sensor on the pipe 39192 0011 Divide the original water hose at suitable position and insert the water pipe 39192 0011 Insert the ground terminal of the water temperature sensor lead between the hose and the pipe and clamp the hose as shown in the figure Fasten the another terminal to the cover crankshaft sensor by the bolt P Meter Radiator Um Head S1ZX63R2W2 C Sensor 21176 1099 Water Pipe 39192 0011 Clamp 92171 0179 Lead Wire 26011 1779 Original Water Hose 39062 0022 Ground Wire 26011 0071 E WN 24 Radiator outlet e When using the radiator stay Kit drill a hole of 4 mm dia in the stay and fasten the hose with the band because of no use of the original water hose clamp 92171 0421 7 reference View from reference 7 SIZX83R3W2 Reserve Tank Installation When using the radiator Kit the original reserve tank cannot be used Prepare a suitable substitue Reserve Tank should be equipped with a band so as not to affect the running and the handling NOTE O Capacity of a reserve tank should be more than 200 cc O Position of the hose to a reserve tank End of the hose to the radiator should be always in the liquid End of the hose to atmosphere should be always beyond the
32. plied the rear suspension should be softened 29 Seat Height Adjustment opacer Set 92026 1586 Used nut and seat height adjustable range Std 11 mm Quantity Thickness Range from standard position Spacer for seat height adjust insert between collar and bracket 8106210BW4 1 Nut 3 Collar 2 Spacer 4 Bracket 30 Front Fork Springs Kit The optional front fork springs are available for racing 1 Front Fork Specifications Rebounded damping setting Upper 2 1 4 turns out from the fully clockwise position Compression damping setting Lower 2 3 4 turns out from the fully clockwise position Fork oil SHOWA 558 Fork oil level 115 mm Oil lock Oil lock piece Cil seal Spring length 297 1 mm Free Length Spring constant 9 0 N mm opacer length 50 mm Sub spring stroke 20 mm 2 Front Fork Spring Original 4 7 26 8 297 1 K 9 0 N mm A Coil Diameter B Spring Inside Diameter C Spring Free Length 3 Front Fork Spring Replacement Replace the main spring referring to the Fork Oil Change section of the base Service Manual NOTE O Install the optional springs facing the smaller spring end diameter side upward Identification Mark The spring constant value is stamped on the one side surface of the spring 31 Fork Spring Installation Original with Stamp 297 1mm Kit Spring L Spring without Stamp Original 297 1mm 0000 8
33. ports to make intake exhaust gas flow more smooth O Grind off the stepped portion only at the mating surface between the carburetor holder and the intake port Do not port it To extend the intake port air flow speed will be reduced and the engine performance at the high speed range may be down O Mark the carburetor holders so that they can be installed in their original positions O Grind off and smooth stepped portions at the mating surface between valve seat and the port O Smooth the inside of the intake port and exhaust port e Chamfer the machining edge of the cylinder head where the valve seat is installed also smooth the dome of the combustion chamber with the valves installed Excessive smoothing may reduce the cylinder compression Use the hand grinder O Use 200 oil stone for eliminating any stepped portions Use 200 oil stone for smoothing and 300 oil stone for finishing NOTE O These procedures make air resistance less and intake exhaust gas flow more smooth However much more effect can not be expected by excessive grinding and smoothing It may be done to the extent of getting rid of uneven surfaces S106034BW1 C A Stepped Portions Combustion Chamber Dome The combustion chambers are modified by cutting work but the edges shown must hand finished for smooth corners Round them to about R1 106035BW1 C 1 Edges 4 NOTE O When grinding the cylinder head bottom surface or usi
34. r Light LED EE de X M X En occ Fuel Level Warning Indicator Light LED s ET ES Indicator Light LED n Odometer Trip Meter E ox Glock Stop Watch Fi Do Water Temperature Gauge Tachometer Speedometer Meter Light LED lL s Shift Up Indicator Light LED DOS Engine Head NS Cover Ground SS Meter Unit gt a O d A 9 3 15 4 1 I HE 7 8 L 9 BR R VR RE 69 D EE BRR lll IL m ptt lll 2 SS sapo sans XLED Light Emitting Diode m Fuse ps Cace gt x n e Iz Color Code Blue Brown I qr Chocolate i RIL RI RE Ip SE on BERN 2 o LB Light Blue Left Switch Housing m Light Green MM elay Box P Pink 1 Relay PU Purple 3 Turn Signal Switch 2 Headlight Relay OR Red 4 Dimmer Switch 3 Main Relay OW White 5 Starter Lockout Switch 4 Fuel Pump Relay 6 5 Time Button 44 Starter Circuit Relay S106243BW5 C Inlet Air Main Temperature Throttle Inlet Sensor Atmospheric Subthrottle Sensor Air Grankshaft Pressure Pressure Sensor Sensor Sensor Sensor Exhaust Butterfly Valve Mi Actuator xx FE en BR BK G W BR BK BL BL BR BK
35. rates easily and pushes the clutch operating plate causing more slip Two types of nuts are available for the number of leaf springs two and three They are provided as optional production parts The number of leaf springs affects all over the operation of the back torque limiter but especially the beginning of the operation Standard Selection of Spring Retainers Total Thickness of Clutch oize of opring Remarks Plates Retainers P No 13091 1041 Original Setting 37 6 38 2 mm P No 39108 0004 If clutch slip is occurred with a retainer of 6 mm try with a retainer of 5 mm 38 2 38 8 mm Standard Selection of Shim Total Thickness of Clutch Plates Size of Shim Remarks P No 92025 1755 Original Setting 38 0 38 6 mm P No 92025 1756 37 6 38 0 mm Without Shim Approx 38 8 mm Transmission e Remove the three steel balls 600A0500 from the output shaft assembly This is done to start easily the engine with the second gear Take kit and optional transmission gears are available to be closer to each gear ratio Transmission Shimming By using washers with various thickness keep the axial clearance between 0 3 mm and 0 4 mm to prevent the seizure of gears and to keep smooth gear shifting Ties opline washer 92200 1239 Original input 92200 1534 Kit opline washer 92200 1240 Original output 92200 1535 kit 92022 1026 Production part 92022 112 Original input 92200 1536 Kit 92022 223 Produ
36. ter Temperature Sensor T 21176 1099 Main Harness and Original Part Combination Table O need x no need Harness for Kit Harness for Meter Original Meter 26031 0325 26031 0326 x Oil Pressure Switch 0X E X 34 Dummy 35 Wiring Routing Right Side View Removal Parts 1 Side Stand Switch Front Harness Headlight Turn Signal Light Front Left Turn Signal Light Front Right Left Handlebar Bar Switch Meter Assembly Original Part Ignition Switch CON O Rear Brake Light Switch Horn 9 Fan Motor Do not remove the following parts when Original Meter Harness 26031 0326 used 5 Left Handlebar Bar Switch 6 Meter Assembly Original Part Other Parts 10 Frame ground 11 Engine Harness 12 Subthrottle Valve Actuator 13 Main Throttle Sensor 14 Intake Air Temperature Sensor 15 Sub throttle Sensor 16 Right Handle Bar Switch 17 Cam Shaft Position Sensor 18 Ignition Coil 19 Manifold Pressure Sensor 20 Atmospheric Pressure Sensor 21 Injector 22 Injector 23 Water Temperature Sensor 24 Regulator 25 Speed Sensor 37 2 47 49 9 8 0 38 Removal Parts 1 Turn Signal Light Left Tail And Stop Light Turn Signal Relay O A W N Turn Signal Light Right Fuse Box 6 License Light Other Parts 7 8 9 10 11 12 13 14 15 16 17 Exhaust
37. the minimum specific values turn the installed position of the camshaft sprocket on the camshaft and change the camshaft timing Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQENCY Every Every Every 5 5 10 races Required OPERATION 300 km 1 000 km 1 500 km 3 000 km Clutch plate check Throttle grip play check LION OL d d 2 Spark plug clean gap Engine oil change HI ls pe j _ dai 4 Lo de 1 ee Cil filter replace Valve lapping Cylinder head valve decarbonization FREQENCY Each Every Every Every x S Race 3races 5 10 races Required OPERATION 300 km 1 000 km 1 500 km 3 000 km _ Piston Piston ring Piston pn repae _ Crankshaft main bearing check e Cowedmgmdbgenieanng cwwde _ lT Brake caliper piston seal and dust 0 Brake hose repiace ll 1l TO rense name e EE _ General wbicatonofenassis perorm e o Weslbeaina tenore 2 Sumampwrwmerag seme 2 Swingarm pict
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