kawasakiNinjaZX6RZX600J1ServiceManual

KawasakiNinjaZX-6RMotorcycleServiceManualThisquickreferenceguidewillassistyouinlocatingadesiredtopicorprocedure.•Bendthepagesbacktomatchtheblacktabofthedesiredchapternumberwiththeblacktabontheedgeateachtableofcontentspage.•Refertothesectionaltableofcontentsfortheexactpagestolocatethespecifictopicrequired.QuickReferenceGuideGeneralInformationFuelSystemCoolingSystemEngineTopEndClutchEngineLubricationSystemEngineRemoval/InstallationCrankshaft/TransmissionWheels/TiresFinalDriveBrakesSuspensionSteeringFrameElectricalSystemAppendix112131415161718191101111121131141151161NinjaZX-6RMotorcycleServiceManualLISTOFABBREVIATIONSAampere(s)Ibpound(s)ABDCafterbottomdeadcentermmeler(s)ACalternatingcurrentminminute(s)ATDeaftertopdeadcenterNnewton(s)BBDCbeforebottomdeadcenterP,pascal(s)BDCbottomdeadcenterPShorsepowerBTOCbeforetopdeadcenterpsipound{s)persquareinch'cdegree(s)CelsiusrrevolutionDCdirectcurrentrpmrevolution(s)perminuteFfarad(s)TDCtopdeadcenter'Fdegree(s)FahrenheitTIRtotalindicatorreadingftfoot,feetVvolt(s)Qgram(s)Wwatt(s)hhour(s)nohm(s)Lliter(s)ReadOWNER'SMANUALbeforeoperating.EMISSIONCONTROLINFORMATIONToprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission(1)andexhaustemission(2)controlsystemsincompliancewithapplicableregulationsoftheUnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.Additionally,Kawasakihasincorporatedanevaporativeemissioncontrolsystem(3)incompliancewithapplicableregulationsoftheCaliforniaAirResourcesBoardonvehiclessoldinCaliforniaonly.1.CrankcaseEmissionControlSystemThissystemeliminatesthereleaseofcrankcasevaporsintotheatmosphere.Instead,thevaporsareroutedthroughanoilseparatortotheintakesideoftheengine.Whiletheengineisoperating,thevaporsaredrawnintocombustionchamber,wheretheyareburnedalongwiththefuelandairsuppliedbythecarburetionsystem.2.ExhaustEmissionControlSystemThissystemreducestheamountofpollutantsdischargedintotheatmospherebytheexhaustofthismotorcycle.Thefuel,ignition,andexhaustsystemsofthismotorcyclehavebeencarefullydesignedandconstructedtoensureanefficientenginewithlowexhaustpollutantlevels.3.EvaporativeEmissionControlSystemVaporscausedbyfuelevaporationinthefuelsystemarenotventedintotheatmosphere.Instead,fuelvaporsareroutedintotherunningenginetobeburned,orstoredinacanisterwhentheengineisstopped.Liquidfueliscaughtbyavaporseparatorandreturnedtothefueltank.TheCleanAirAct,whichistheFederallawcoveringmotorvehiclepollution,containswhatiscommonlyreferredtoastheAct'stamperingprOvisions.··Sec.203{a)Thefollowingactsandthecausingthereofareprohibited...(3)(A)foranypersontoremoveorrenderinoperativeanydeviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengineIncompliancewithregulationsunderthistitlepriortoitssaleanddeliverytotheultimatepurchaser,orforanymanufacturerordealerknowinglytoremoveorrenderinoperativeanysuchdeviceorelementofdesignaftersuchsaleanddeliverytotheultimatepurchaser.(3)(8)foranypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortradingmotorvehiclesormotorvehicleengines,orwhooperatesafleetofmotorvehiclesknowinglytoremoveorrenderinoperativeanydeviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengineincompliancewithregulationsunderthistitlefollOWingitssaleanddeliverytotheultimatepurchaser...•NOTEoThephraseremoveorrenderinoperativeanydeviceorelementofdesignhasbeengenerallyinterpretedasfollows:1.Tamperingdoesnotincludethetemporaryremovalorrenderinginoperativeofdevicesorelementsofdesigninordertoperformmaintenance.2.Tamperingcouldinclude:a.Maladjustmentofvehiclecomponentssuchthattheemissionstandardsareexceeded.b.Useofreplacementpartsoraccessorieswhichadverselyaffecttheperformanceordurabilityofthemotorcycle.c.Additionofcomponentsoraccessoriesthatresultinthevehicleexceedingthestandards.d.Permanentlyremoving,disconnecting,orrenderinginoperativeanycomponentorelementofdesignoftheemissioncontrolsystems.WERECOMMENDTHATALLDEALERSOBSERVETHESEPROVISIONSOFFEDERALLAW,THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING$10,000PERVIOLATION.TAMPERINGWITHNOISECONTROLSYSTEMPROHIBITEDFederallawprohibitsthefollowingactsorthecausingthereof:(1)Theremovalorrenderinginoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofanydeviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrolpriortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse,or(2)theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativebyanyperson.Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow:•ReplacementoftheoriginalexhaustsystemormufflerwithacomponentnotincompliancewithFederalregulations.•Removalofthemuffler(s)oranyinternalportionofthemuffler{s).•Removaloftheairboxorairboxcover.•Modificationstothemutfler(s)orairintakesystembycutting,drilling,orothermeansifsuchmodificationsresultinincreasednoiselevels.ForewordThismanualisdesignedprimarilyforusebytrainedmechanicsinaproperlyequippedshop.However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhode