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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.
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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.
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T able of Content s General Specifications ...................................................................................................... 4 Racing Kit Service Data ...............................................................................
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.
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.
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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.
• 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].
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 .
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 .
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.
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 .
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 .
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.
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).
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 .
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) 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.
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.
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 clockw.
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.
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.
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 Harn.
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.
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.
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.
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 (OP.
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.
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-TRANSMISSI.
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 .
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 .
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 .
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-ELECTRONI.
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 (OPTIO.
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 (OPTIO.
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.
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 .
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.
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.
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) 4.
Doc No. 99929-0231-01.
Ein wichtiger Punkt beim Kauf des Geräts Kawasaki ZX-6R (oder sogar vor seinem Kauf) ist das durchlesen seiner Bedienungsanleitung. Dies sollten wir wegen ein paar einfacher Gründe machen:
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Wenn Sie aber schon Kawasaki ZX-6R besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Kawasaki ZX-6R verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Kawasaki ZX-6R. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Kawasaki ZX-6R gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
