Kawasaki ZX-6R Manuel d'utilisateur

Ninja ZX-6R 2008 Ninja ZX-6R Racing Kit Manual This manual contains only the information of the racing kit parts. Refer to the base manua

FREQENCY OPERATION 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 bearing (rear) - - gre

Preparation Before Installing  Modify the parts based on your race regulation.  To avoid misuse keep the parts replaced with the kit parts separate.

 Remove the secondary valves of cylinder head and relational parts, then plug the each holes.  Remove the oil receiver and plug the hole.  Remove

Cylinder Head  Grind off the stepped portions of the ports and smooth the inside of ports to make intake/exhaust gas flow more smooth.  Grind off th

 The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners (Round them to about R1).  Chamfe

A. Tensioner B. Tensioner Rod C. O-ring D. O-ring E. Lock nut Camshafts, Sprockets Camshafts, Sprockets:  Adjust the valve clearance within th

 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 cha

Cylinder Head Gasket Part No. Thickness Note 11004-0071 0.45 mm KIT 11004-0070 0.50 mm KIT 11004-0069 0.55 mm KIT 11004-0068 0.60 mm KIT 11004-0

Crankshaft Main Journal and Connecting Rod Big End Bushings  To adjust clearance of crankshaft main journal you can select proper bush in accordance

 Main Journal Bush A. Size Color Size Color Thickness mm Journal NumberPart Number (STD) Part Number (KIT) 1-4 92139-0189 92139-0200 blue 1.499-

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

 Selection Table Connecting Rod Big End Inside Diameter Crankpin Diameter Mark Size Color Part Number (STD) Part Number (KIT) None ○ (33.000 mm ~ 33.

Clutch Adjustment (Back-Torque Limiter Setting) The Ninja ZX-6R engine is equipped with the Kawasaki back-torque limiter mechanism in the clutch. The

 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

Recommended Clutch [A] Spacers [B] Needle Bearing [C] Bushing [D] Clutch Outer Casing [E] Clutch Hub [F] Sub Clutch Hub [G] Friction Pla

• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub). • To measure the effective stroke of clutch spring plate, set a dial gauge [

Standard Selection of Shim Total Thickness of Clutch Plates Size of Shim Remarks Approx. 40.7 mm 2.0 mm P/No. 92180-0149 Original Setting 40.2 mm

Generator (Option) To quicken response by reducing the flywheel mass and to reduce the weight, use the optional inner rotor generator.  Select using

Muffler With recommended muffler engine performance can be improved. Recommended muffler: Beet NASSERT-R 1002-E02-00 Web Site : http://www.beet.

Radiator Installation  Use the radiator stay (35063-0439) and bracket (11054-1818) belong to kit, and fasten the radiator to the Crankcase by bolts a

Congratulation on your purchase of racing kit parts for the 2008 Ninja ZX-6R. IMPORTANT This manual provides how to install racing kit parts for the

Water Hose Installation Radiator inlet  Divide the original water hose (39062-0156) at suitable position, and insert the hose between cylinder head a

1. Water Hose 39062-0219 4. Sensor 21176-1099 2. Ground Wire 26011-0071 5. Lead Wire 26011-1779 3. Water Hose 39062-0166 (Standard) 6.

Oil Catch Tank Installation  Fasten the Bracket (E) to the Engine Hanger by using bolt (D).  Fasten Oil Catch Tank (A) to the Bracket (E) by using

Hose1 (B) and Hose2 (C) assembling  Divide Hose (92059-1587, KIT) and Hose (92059-1629, KIT) as shown below.  Divide installed tube (92192-0429, s

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

Frame Parts Installation Throttle Parts (Kit) The following throttle cases, grip and reels are available as optional parts. These optional parts quick

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. Swinga

1) Recommended Steering Damper OHLINS SD121  Set the steering damper to the holder as shown. 2) Stroke(s) SD121: 68 mm 1. Steering Damper: OHLINS SD

1. Nut 3. Collar 2. Spacer 4. Bracket 36

Front Fork Springs (Kit) The optional front fork springs are available for racing. 1) Front Fork Specifications Items Original Rebounded damping setti

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Fork Spring Installation 38

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

Meter (Kit) Installation 1. Tachometer with Water Temperature Gauge (Optional): 25031-1142 2. Collar (Optional): 92152-0058 3. Pad (Optional

Main Harness Combination Parts Table Main Harness and Kit Part Combination Table ○: need ×: no need. Harness Part Harness for Kit Meter 26031-0559 Ha

Wiring Routing 1. Vehicle-down Sensor 12. Main Throttle Sensor 2. Meter Assembly 13. Injector, Secondary 3. Shift Up Indicator Light 14.

1. Fuel Pump 2. Magnetic Switch 3. ECU 4. Relay Assembly (27002-3703) 5. Atmospheric Pressure Sensor 6. Power Source for Measuring Instrumen

Wiring Diagram (with Kit Meter) 44

45

Wiring Diagram (with Original Meter Assembly) 46

47

Table of Contents General Specifications ...4 Rac

Dummy Page 48

Racing Kit Parts List

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-3CylinderQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11004 11004-006

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-4CrankshaftQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR92139 92139-0

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-5ClutchQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR39108 39108-0004

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-6Transmission(TYPE-B)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR131

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-7Transmission(TYPE-C)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR131

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-8Transmission(TYPE-D)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR131

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-9Engine Cover(s)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11061 11

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-10Fuel InjectionQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR21175 21

General Specifications Item 2008 Ninja ZX-6R Racing Engine: Ignition timing 12.5°BTDC @1 300 r/min (rpm) Fuel (Recommended) Racing gasoline

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-11GeneratorQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11054 11054-1

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Engine B-12RadiatorQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11054 11054-18

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Chassis C-3 Frame Fittings(1/2)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Chassis C-4 Frame Fittings(2/2)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR12

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Chassis C-5 Front ForkQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR92145 92145

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Chassis C-6 Meter(s)Quantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR11053 11053-1

This catalog covers:GRID NO.This grid covers:’08 ZX600P8FR Chassis C-7 OtherQuantity-ZX600’08Ref.No.Part No. Description Spec CodeP8FR43082 43082-0074

Doc No. 99929-0231-01

Input 3rd/4th Gear Selection Table 4th Gear A B C D A 13262-0506 13262-0529 13262-0679 3rd Gear B 13262-0680 13262-0681 13262-0682 Gear Id

Racing Kit Service Data Item Standard Cylinder Head, Valves: Duration: Intake 288° Exhaust 266° Camshaft timing (cam lift center):

Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQ