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[Page 1] Kawasaki NINJA ZX-6R -
Ninja ZX–6R Ninja ZX-6RR Motorcycle Service Manual ...
[Page 2] Kawasaki NINJA ZX-6R -
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[Page 3] Kawasaki NINJA ZX-6R -
This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectio...
[Page 4] Kawasaki NINJA ZX-6R -
[Page 5] Kawasaki NINJA ZX-6R -
Ninja ZX-6R Ninja ZX-6RR Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwi...
[Page 6] Kawasaki NINJA ZX-6R -
LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC b...
[Page 7] Kawasaki NINJA ZX-6R -
Foreword This m anual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and rep...
[Page 8] Kawasaki NINJA ZX-6R -
Whenever you see these WA RNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could re...
[Page 9] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification..............................
[Page 10] Kawasaki NINJA ZX-6R -
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions...
[Page 11] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of...
[Page 12] Kawasaki NINJA ZX-6R -
1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is no...
[Page 13] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ba...
[Page 14] Kawasaki NINJA ZX-6R -
1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect t he adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from o...
[Page 15] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-7 Model Identificat ion ZX636–B1 (Ninja ZX-6R) Left Side View: ZX636–B1 (Ninja ZX-6R) Right Side View: ...
[Page 16] Kawasaki NINJA ZX-6R -
1-8 GENERAL INFORMATION Model Identification ZX600–K1 (Ninja ZX-6RR) Left Side View: ZX600–K1 (Ninja ZX-6RR) Right Side View: ...
[Page 17] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-9 General Specifications Items ZX636-B1 ∼ (Ninja ZX-6R) Dimensions: Overall length 2 025 mm (79.7 in.) Overall width 720 m m (28.3 in.) Overall height 1 100 mm (43.3 in.) Wheelbase 1 400 mm (55.1 in.) Road clearance 130 mm (5....
[Page 18] Kawasaki NINJA ZX-6R -
1-10 GENERAL INFORMATION General Specifications Items ZX636-B1 ∼ (Ninja ZX-6R) Engine oil: Type API SE, SF or SG API SH or SJ with JASO M A Viscosi ty SAE10W-40 Capacity 4.0 L (4.2 U S qt) Drive Train: Primary reduction system: Type Gear Reduction ...
[Page 19] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-11 General Specifications Items ZX636-B1 ∼ (Ninja ZX-6R) Lo 12 V 55 W (quartz-halogen) Tail/brake light 12 V 0.5/3.8 W (LED) (US), (CAL), (CA) 12 V 0.5/5 W (LED) Alternator: Type Three-phase AC Rated output 22.5 A / 14 V @5 00...
[Page 20] Kawasaki NINJA ZX-6R -
1-12 GENERAL INFORMATION General Specifications Items ZX600-K1 (Ninja ZX-6RR) Dimensions: Overall length 2 025 mm (79.7 in.) Overall width 720 mm (28.3 i n.) Overall height 1 100 mm (43.3 in.) Wheelbase 1 400 mm (55.1 in.) Road clearance 130 mm (5.1 ...
[Page 21] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-13 General Specifications Items ZX600-K1 (Ninja ZX-6RR) Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 2.022 (89/44) Clutch type Wet multi disc Tr ansmission: Type...
[Page 22] Kawasaki NINJA ZX-6R -
1-14 GENERAL INFORMATION General Specifications Items ZX600-K1 (Ninja ZX-6RR) Alternator: Type Three-phase AC Rated output 22.5 A / 14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country. (US): Uni...
[Page 23] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-15 Technical Information – Air Inlet System Center Ram Air Inlet The ram air duct w as moved from both left and right side to center of the fairing so that incoming air has a straighter path to the airbox, increasing ram air e...
[Page 24] Kawasaki NINJA ZX-6R -
1-16 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZX636–B1 ∼ and ZX600–K1 utilize large bore throttle bodies to increase power output. How- ever, sudden changes in throttle opening can cause hesi...
[Page 25] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-17 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle...
[Page 26] Kawasaki NINJA ZX-6R -
1-18 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZX636–B1 ∼ and ZX600–K1 models that cannot function if gears are engaged and/or the sidestand is ...
[Page 27] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-19 Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a...
[Page 28] Kawasaki NINJA ZX-6R -
1-20 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials o f Semi-Conductor and Emitting Color Materials of Semi-Conductor Emitting Color Ga...
[Page 29] Kawasaki NINJA ZX-6R -
GENERAL INFORMATION 1-21 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, K awasaki has adopted a t ype of simplified KAWASAKI LOW EX HAUST EMISSION SYSTEM (KLEEN), which have no cataly...
[Page 30] Kawasaki NINJA ZX-6R -
1-22 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0.01 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of Volume: L × 0....
[Page 31] Kawasaki NINJA ZX-6R -
PERIODIC MAINTE NANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart .............. 2-2 Torque and Locking Agent................. 2-4 Specifications .................................... 2-9 Special Tools ........................
[Page 32] Kawasaki NINJA ZX-6R -
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUEN...
[Page 33] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever 1 000 km * ODOMETER READING comes (600 m ile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 m ile) 30 000 km (20 000 mile)...
[Page 34] Kawasaki NINJA ZX-6R -
2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: Ti ghten th...
[Page 35] Kawasaki NINJA ZX-6R -
PERIODIC MAINTE NANCE 2-5 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Coolant By-pass Fitting 8.8 0.90 78 in·lb L Water Hose Fitting Bolts 12 1.2 106 in·lb Radiator Mounting Bolts 6.9 0.70 61 in·lb Radiator Bracket M ountin...
[Page 36] Kawasaki NINJA ZX-6R -
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Oil Pipe Holder Bolts 12 1.2 104 in·lb Oil Pressure Relief Valve 15 1.5 11 L Oil Pressure Switch 15 1.5 11 SS Oil Pressure Switch Terminal Bolt 1.5 0.15 13 ...
[Page 37] Kawasaki NINJA ZX-6R -
PERIODIC MAINTE NANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Speed Sensor Mounting Bolt 3.9 0.40 35 in·lb L Rear Sprocket Nuts 59 6.0 43 Rear Sprocket Studs – – – L Brakes: Bleed Valves 7.8 0.80 69 in·lb Brake...
[Page 38] Kawasaki NINJA ZX-6R -
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Clutch Lever Holder Bolts 7.8 0.80 69 in·lb S Frame: Footpeg Holder Bolts 34 3.5 25 L Side Stand Bolt 44 4.5 32 G Footpeg Stay Bolts 25 2.5 18 Side Stand Br...
[Page 39] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-9 Specific ations Item Standard Service Limit Fuel System: Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle speed 1 300 ± 50 r/min (rpm) ––– Throttle body vacuum: ZX636B 24 ± 1.3 kPa (180 ± 10 mmHg...
[Page 40] Kawasaki NINJA ZX-6R -
2-10 PERIODIC MAINTENANCE Specificatio ns Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (397 lb) load: ––– 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) ––– Final...
[Page 41] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: 57001–1100 Jack: 57001–1238 Oil Filter Wrench: 57001–1249 Pilot Screw Adjuster, C: 57001–1292 Lead Wire-Peak Voltage Ada pter: 57001–1449 ...
[Page 42] Kawasaki NINJA ZX-6R -
2-12 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hose [A] is designed to be used throughout the motorcycle’s life without any maintenance. However, if the motorcycle i s not properly...
[Page 43] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-13 Maintenance Procedure Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove: Throttle Body (see Fuel System (DFI) chapter) ○ Check the main throttle valves and throttle bores [A] for car...
[Page 44] Kawasaki NINJA ZX-6R -
2-14 PERIODIC MAINTENANCE Maintenance Procedure Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • Situate the motorcycle so t...
[Page 45] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-15 Maintenance Procedure • Plug: Vacuum Switch Valve H ose [A] and its Air Cleaner Hous- ing Hole [B] Removed Vacuum Hoses • Install the air cleaner housing [A]. • Start the engine and warm i t up thoroughly. • Check th...
[Page 46] Kawasaki NINJA ZX-6R -
2-16 PERIODIC MAINTENANCE Maintenance Procedure If any one vacuum m easurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 • Adjust the lowest vacuum bet...
[Page 47] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Back out the same number of turns c ounted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for eac...
[Page 48] Kawasaki NINJA ZX-6R -
2-18 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Inlet Air Temperature Sensor Connector [A] Air Cleaner Cover Screws [B] Air Cleaner Cover [C] • Discard: Air Cleaner Ele...
[Page 49] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Check the liquid/vapor separator as follows: ○ Remove: Seats (see Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle r ight side. ○ Visu...
[Page 50] Kawasaki NINJA ZX-6R -
2-20 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Right Inner Cover (see Frame chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the s...
[Page 51] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-21 Maintenance Procedure Water and Coolant M ixture Ratio (Recommended) Soft Water: 50 % Coolant: 50 % Freezing Point: – 35°C (– 31°F) Total Amount: 2.4 L ( 2. 5 US qt) NOTE ○ Choose a suitable mixture ratio by referrin...
[Page 52] Kawasaki NINJA ZX-6R -
2-22 PERIODIC MAINTENANCE Maintenance Procedure Valve Clearance Check Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Picku...
[Page 53] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-23 Maintenance Procedure Valve Clearance Adjustment • To change the v alve clearance, remove the cam shaft chain tensioner, camshafts and valve l ifters. Replace the shim with one of a different thickness. NOTE ○ Mark and r...
[Page 54] Kawasaki NINJA ZX-6R -
2-24 PERIODIC MAINTENANCE Maintenance Procedure VALV E CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure t he clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal colu...
[Page 55] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-25 Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal colu...
[Page 56] Kawasaki NINJA ZX-6R -
2-26 PERIODIC MAINTENANCE Maintenance Procedure Clutch Clutch Adjustment Check Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the l ever holder. If the g...
[Page 57] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-27 Maintenance Procedure Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine drain plug [A] to drain the oil. ○ The oil in the oil f...
[Page 58] Kawasaki NINJA ZX-6R -
2-28 PERIODIC MAINTENANCE Maintenance Procedure • Install the oil filter clamp so that projection [B] fits the slot [A] of oil cooler. ○ Be sure to place the rubber tube on the projection. • Tighten: Torque - Oil Filter Clamp Bolt [C]: 5.9 N·m...
[Page 59] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-29 Maintenance Procedure NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○ Check and balance t he wheel when a tire is replaced with a new one. Air Pressure Inspect...
[Page 60] Kawasaki NINJA ZX-6R -
2-30 PERIODIC MAINTENANCE Maintenance Procedure WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. • Tighten both chain adjuster locknuts securely. • Tighten the axle nut. Torque - Rear Ax...
[Page 61] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-31 Maintenance Procedure Drive Chain Wear Inspection • Remove: Chain Cover • Rotate the rear w heel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive...
[Page 62] Kawasaki NINJA ZX-6R -
2-32 PERIODIC MAINTENANCE Maintenance Procedure Drive Chain Lubrication • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
[Page 63] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Light Timing A djustment Brake light timing is adjusted by changing the position of the rear brake light switch. • Adjust the position of the switch so that the brake light goes on after the spe...
[Page 64] Kawasaki NINJA ZX-6R -
2-34 PERIODIC MAINTENANCE Maintenance Procedure • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the ...
[Page 65] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-35 Maintenance Procedure Bleeding the Brake Line The brake fluid has a very l ow compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air...
[Page 66] Kawasaki NINJA ZX-6R -
2-36 PERIODIC MAINTENANCE Maintenance Procedure • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the front/rear brake fluid reservoir cap [B] clockwise [C] by hand until the resistance i...
[Page 67] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-37 Maintenance Procedure Brake Hoses and Connections Check • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ Thehighpressureinsidethebrakelinecancausefluidto leak [A] or the hose to bur...
[Page 68] Kawasaki NINJA ZX-6R -
2-38 PERIODIC MAINTENANCE Maintenance Procedure Steering Steering Check Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 • With the front wheel pointing straight ahead, alternately tap ea...
[Page 69] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-39 Maintenance Procedure NOTE ○ Turn the stem nut 1/8 turn at a time maximum. • Install the lock washer so that claw of washer fit the notch of steering stem nut. • First tighten the steering stem locknut by hand until th...
[Page 70] Kawasaki NINJA ZX-6R -
2-40 PERIODIC MAINTENANCE Maintenance Procedure Spark Plug Gap Inspection • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark P...
[Page 71] Kawasaki NINJA ZX-6R -
PERIODIC MAINTENANCE 2-41 Maintenance Procedure • With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cabl...
[Page 72] Kawasaki NINJA ZX-6R -
2-42 PERIODIC MAINTENANCE Maintenance Procedure Nut, Bolts, and Fasteners Tightness Check Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ...
[Page 73] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) Table of Contents Exploded View................................... 3-4 Specifications .................................... 3-10 Special Tools ..................................... 3-12 DFI System................
[Page 74] Kawasaki NINJA ZX-6R -
3-2 F UEL SYSTEM (DFI) Output Voltage Inspection............ 3-87 Vehicle-down Sensor (Service Code 31)................................................... 3-89 Removal....................................... 3-89 Installation.............................
[Page 75] Kawasaki NINJA ZX-6R -
[Page 76] Kawasaki NINJA ZX-6R -
3-4 F UEL SYSTEM (DFI) Exploded View ...
[Page 77] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 A ir cleaner housing mounting bolt 6.9 0.70 61 in·lb 2 Air inlet duct mounting bolts 6.9 0.70 61 in·lb 3 A ir cleaner housing clamp bolts 2.5 0.25 22 in·lb No. Pa...
[Page 78] Kawasaki NINJA ZX-6R -
3-6 F UEL SYSTEM (DFI) Exploded View ...
[Page 79] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-7 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Inlet air pressure sensor screw 4.9 0.50 43 in·lb 2 Atmospheric pressure sensor screw 4.9 0.50 43 in·lb 3 Fuel delivery pipe mounting screws 3.4 0.35 30 in·lb 4 T...
[Page 80] Kawasaki NINJA ZX-6R -
3-8 F UEL SYSTEM (DFI) Exploded View ...
[Page 81] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-9 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel pump bolts 9.8 1.0 87 in·lb 2. Fuel Pump 3. Canister 4. Separator 5. Red 6. Blue 7. Green 8. White L: Apply a non-permanent locking agent. R: Replacement Parts...
[Page 82] Kawasaki NINJA ZX-6R -
3-10 FU EL SYSTEM (DFI) Specificatio ns Item Standard Digital Fuel Injection System Idle Speed 1 300 ± 50 r/min (rpm) Throttle Assy: Type Four barrel type Bore φ38 mm (1.5 in) Throttle body vacuum: ZX636B 24 ± 1.3 kPa (180 ± 10 mmHg) ZX600K 22 ±...
[Page 83] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-11 Specific ations Item Standard Vehicle-down Sensor: Detection method Magnetic flux detection method Detection angle More than 60 ∼ 70° for each bank Detection time Within 0.5 ∼ 1.0 sec. Output voltage with the sensor tilted...
[Page 84] Kawasaki NINJA ZX-6R -
3-12 FU EL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Carburetor Drain P lug Wrench, Hex 3: 57001–1269 Fork Oil Level Gauge: 57001–1290 Pilot Screw Adjuster, C: 57001–1292 Hand Tester: 57001–1394 Throttle Sensor Setting Adapte...
[Page 85] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-13 Special Tools Kawasaki Bond (Silicone Sealant): 56019–120 ...
[Page 86] Kawasaki NINJA ZX-6R -
3-14 FU EL SYSTEM (DFI) DFI System DFI System ...
[Page 87] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-15 DFI System 1. ECU (Electric Control Unit) 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor ...
[Page 88] Kawasaki NINJA ZX-6R -
3-16 FU EL SYSTEM (DFI) DFI System DFI System Wiring Diagram ...
[Page 89] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Subthrottle Valve Actuator 2. Injector #1 3. Injector #2 4. Injector #3 5. Injector #4 6. Water Temperature Sensor 7. Speed Sensor 8. Inlet A ir Temperature Sensor 9. Atmospheric Pressure Sensor 10. Subt...
[Page 90] Kawasaki NINJA ZX-6R -
3-18 FU EL SYSTEM (DFI) DFI System Terminal Numbers of EC U Connectors ...
[Page 91] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-19 DFI System Terminal Names 1. Power Supply to Sensors 2. Main Throttle Sensor Output Signal 3. Subthrottle Sensor Output Signal 4. Atmospheric Pressure Sensor Output Signal 5. Water Tem perature Sensor Output Signal 6. Unused 7....
[Page 92] Kawasaki NINJA ZX-6R -
3-20 FU EL SYSTEM (DFI) DFI S ervicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any...
[Page 93] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ The fuel hose [A] is designed to be used through out the motorcycle’s life without any maintenance, however, i f the motorcycle is not properly handled, the high pressure in- side the fuel line c...
[Page 94] Kawasaki NINJA ZX-6R -
3-22 FU EL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is s...
[Page 95] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System ○ After m easurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [ B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) Seals of Conne...
[Page 96] Kawasaki NINJA ZX-6R -
3-24 FU EL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors s...
[Page 97] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○ Electrical Connectors: Female Connectors [A] Male Connectors [B] ...
[Page 98] Kawasaki NINJA ZX-6R -
3-26 FU EL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart ...
[Page 99] Kawasaki NINJA ZX-6R -
FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Notes: OK: No problem. NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. • Bring the motorcycle in...
[Page 100] Kawasaki NINJA ZX-6R -
3-28 FU EL SYSTEM (DFI) Troubleshooting the DFI System Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the r ider has encountered. ○ Try to find out exactly what problem oc...
Service manual supplement (141 pages)
Service manual (633 pages)
Quick reference manual (177 pages)
Service manual (681 pages)
Assembly & preparation manual (46 pages)
Brochure (4 pages)