2007 Ninja ZX-6R Racing Kit Manual
Contents
1. ed 27 IBI cec 28 Water Temperature SENSO reusi a se sn se sine sre a 28 Radiator e ES 20 Radiator ns 29 E T m 30 Reserve Tank InstallallOEi Ded 32 Oi Gaich Tank Msala uunc temen tu Ec 33 Frame Parts rovs IA 36 DATORIE TUE E T UU T 36 Final Drive PINS eit sues 37 BS FAS PAA red 38 estan 38 Seat Height AG Eae _ _ __ ______ __ 39 iie admo eee DET 41 FF alls 43 BANA E M 43 Haimess and Sub Harness IKID bae tee o 43 Meter KIO Installat ON mm 44 VMI ties OUI cars 46 Wiring Diagram WITH AIC Meter Ai 48 Wiring Diagram with Original Meter Assembly pp 50 General Specifications Engine Ignition timing 12 5 BTDC 21 300 r min rpm Racing gasoline Fuel Recommended Engine oil Recommended Racing oil Level Between upper and lower levels of oil level gauge Drive Train Primary drive reducti2. 4 YA SX p 11061B 11061 0305 119616 ARS OPTION 2 D 5 wie 11061C 11061 0306 EM OPTION 11061D 11061 0307 87 OPTION 14031 14031 0084 ag lt U JI ES NA SE p NA yn Xa gt ZEN 1467 TP 5 Pa DN 4 Xx M BC BSF ORS Au 2 2 T The lt 4 7 f sud Description Spec Code 07 GASKET CLUTCH COVER 1 GASKET GENERATOR COVER 1 GASKET OIL PAN 1 GASKET LARGE COVER 1 GASKET SMALL COVER 1 COVER GENERATOR 1 DEC 20 2006 This catalog covers GRID This grid covers 07 ZX600P7FR Engine Fuel Injection N 7 Description Spec Code 07 5 NS 26011 s ASN 21175 21175 0145 CONTROL UNIT ELECTRONIC 1 OPTION 26011A 6 55 o gt ua 21176 21176 1099 SENSOR TEMP 1 OPTION 6 21 176 26011 26011 0071 WIRE LEAD TEMP SENSOR EARTH 1 OPTION 26011A 26011 1779 WIRE LEAD METER TEMP SENSOR 1 wi Radiator OPTION 26031A 26031 26031 0240 HARNESS INTERFACE BOX 1 OPTION 26031A 26031 0327 HARNESS SUB STD METER amp HARNESS 1 OPTION 26031B 26031 0558 HARNESS MAIN STD METER 1 OPTION 26031C 26031 0559 HARNESS MAIN KIT METER 1 OPTION 27002 27002 3703 RELAY ASSY 1 OPTION FOR OPTION METER 7 DEC 20 2006 This catalog covers 07 ZX600P7FR Engine E1810 an fi 1
3. Stay has several installation holes Install position is adjustable for proper position of radiator Some muffler may interfere with stay In such case make appropriate stay yourself S106417BW3 C Machine the original cowl to meet the outline of radiator Standard Resave tank is not available Use some appropriate tank 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 bottomed 29 Water Hose Installation Radiator inlet Divide the original water hose 39062 0156 at suitable position and insert the hose between cylinder head and radiator Gylinder Head Radiator 4 108439BW1 C 1 Water Hose 39062 0156 Insert the water hose 39062 0220 between oil cooler outlet and radiator Radiator outlet Apply a non permanent locking agent to the thread of the water temperature sensor Kit for Meter Lamp Mount the sensor on the pipe 39192 0011 e 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 generator by the bolt If you don t use water temperature meter use standard pipe and hose at oilcooler outlet side and cover it radia
4. Insert between collar and bracket 5106393 4 1 Nut 3 Collar 2 Spacer 4 Bracket 40 Front Fork Springs The optional front fork springs are available for racing 1 Front Fork Specifications Rebounded damping setting Upper 1 1 2 turns out from the fully clockwise position Compression damping setting Lower 1 1 2 turns out from the fully clockwise position Fork oil SHOWA SS47 Fork oil level 97 mm Oil lock Oil lock piece Oil seal Spring length 257 0 mm Free Length Spring constant 9 0 N mm Sub spring stroke 28 mm 2 Front Fork Spring Original 4 7 x 31 5 x 257 0 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 Identification Mark The spring constant value is stamped on the one side surface of the spring 41 Fork Spring Installation Kit Spring with Stamp 257 Original Spring without Stamp 257 0mm QC 0 0C 7 20 lt gt 4 00000 42 5106394805 C 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
5. GRID NO This grid covers Radiator Ref Part 11054 11054 1818 11065 11065 1056 OPTION 35063 35063 0439 OPTION 39060 39060 0020 OPTION 39062 39062 0219 OPTION 39062A 39062 0220 OPTION 39192 39192 0011 OPTION 49085 49085 1066 OPTION 92043 92043 1436 OPTION 92075 92075 1123 OPTION 92170 92170 1287 OPTION 92171 92171 0179 OPTION 130 130 0612 OPTION 554 554 1000 OPTION Description Spec Code BRACKET RADIATOR CAP STAY RADIATOR RADIATOR BIG HOSE COOLING KIT RAD PIPE HOSE COOLING O COOLER KIT RAD PIPE WATER CAP ASSY PRESSURE PIN DAMPER RUBBER CLAMP COOLING HOSE CLAMP BOLT FLANGED 6X12 PIN SNAP 10MM DEC 20 2006 Quantity ZX600 p qs pep wq pq This catalog covers 07 ZX600P7FR Chassis 46003 OPENING 54012 54012A CLOSING TEE SS wo oo GRID This grid covers Frame Fittings 1 2 11054 11054A 13061 13280 13280A 31064 32099 32099A 46003 46012 46012A 46075 54012 54012 59101 59101 92015 92015 92026 92150 92150 92151 92152 120 10 Part 11054 1816 OPTION 11054 1817 OPTION 13061 1628 OPTION 13280 0011 OPTION 13280 0012 OPTION 31064 1151 OPTION 32099 0004 OPTION 32099 0005 OPTION 46003 1351 46012 1238 46012 1239 46075 1143 OPTION 54012 0186 OPTION 54012 0216 OPTION 59101 0001 OPTION
6. Kawasaki Ninja Zx 6R 2007 Ninja ZX 6R 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 6R 99924 1382 01 Motorcycle Service Manual 2007 Kawasaki Heavy Industries Ltd First Edition 1 Feb 23 2007 Congratulation on your purchase of racing kit parts for the 2007 Ninja ZX 6R IMPORTANT This manual provides how to install racing kit parts for the 2007 Ninja ZX 6R and how to tune up basically As for the basic knowledge refer to the base Service Manual for the Ninja ZX 6R P No 99924 1382 01 When you participate it is necessary to modify the machine for the regulation 50 we want you to ask for the tuning up shop WARNING AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE IT SHOULD NOT BE USED ON PUBLIC STREETS ROADS OR HIGHWAYS THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN 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 6R for the racing machine We recommend that the rider himself should do the basic work
7. amp ae i rR 92059A 92005 92059 Pat GRID NO This grid covers Generator Ref Part 11054 11054 1799 OPTION 11054A 11054 1810 OPTION 14073 14073 0124 OPTION 14073A 14073 0125 OPTION 14073B 14073 0174 OPTION 21003 21003 0068 OPTION 21007 21007 0083 OPTION 21066 21066 0010 OPTION 52001 52001 0004 OPTION 92002 92002 1696 OPTION 92005 92005 0080 OPTION 92015 92015 1193 OPTION 92022 92022 304 OPTION 92027 92027 194 OPTION 92059 92059 1587 OPTION 92059A 92059 1629 OPTION 92075 92075 277 OPTION 92150 92150 1717 OPTION 92200 92200 0306 OPTION 120 120 0620 OPTION 130 130Y0610 OPTION Description BRACKET OIL TANK BRACKET REGULATOR DUCT FUNNEL L 15 DUCT FUNNEL L 20 DUCT FUNNEL L 30 STATOR ROTOR REGULATOR VOLTAGE TANK OIL BOLT SOCKET 6X25 FITTING NUT FLANGED 6MM WASHER 6 2X11X1 COLLAR L 11 1 TUBE TUBE L 100MM DAMPER BOLT 12X40 WASHER 12X36X3 2 BOLT SOCKET 6X20 BOLT FLANGED 6X10 DEC 20 2006 Spec Code Quantity ZX600 p qs Ee This catalog covers 07 ZX600P7FR Engine gt E3032 49085 39060 55 amp 3 92171 Wea _ 12 Ref Fuel 5 Injection S M 4 gt b 130 AA 39062 92171 SE 39192 N J 7 92171 DA
8. Hose1 B and Hose2 C assembling Divide Hose 92059 1587 and Hose 92059 1629 as shown below Fitting 6mm Fitting AFitting Crankcase 108433BW3 C Divide installed tube 92192 0429 standard as shown below ir Cleaner Divide at the end of R JR Fitting 108434BW1 C 34 0 Assemble hoses as shown below 5 Fitting 92005 0080 oda case Oil Gatch Tank 15 Gleaner Gatch Tank 35 108435BW2 C 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 120S0625 Grip Right 46075 1143 2 Throttle Reels Tow types are available Twist Grip Turn Angle 59101 0001 59101 0002 Throttle Reel Travel Angle 5106007 2 1 Identification Mark 36 Upper Case 32099 0004 Lower Case 32099 0005 Reel 60 59101 0001 Reel 65 59101 0002 Throttle Cable Open Side 54012 0186 Throttle Cable Close Side 54012 0216 Bolt 12050625 Gap Final Drive Parts Kit 1 Drive Chain 520 Joint endless drive chain is available as an optional parts 2 Chain Guard 5106378 9 C 1 Guard 55020 0028 2 Bolt 130J1020 3 Swingarm Left Side 3 Brake
9. GEAR OUTPUT LOW 37T GEAR INPUT 2ND 18T GEAR OUTPUT 2ND 39T GEAR INPUT 3RD amp 4TH 20T amp 20T GEAR OUTPUT 4TH 33T GEAR INPUT 5TH 20T GEAR OUTPUT 5TH 30T GEAR INPUT 6TH 23T GEAR OUTPUT 6TH 32T WASHER 22 3X35X1 8 WASHER 22 3X35X1 6 WASHER 28 3X34 0X1 4 WASHER 28 3X34 0X1 8 DEC 20 2006 Quantity ZX600 ee pep pq AR AR AR AR This catalog covers GRID This grid covers 07 ZX600P7FR Engine Transmission TYPE C MW T e p d Part No Description Spec Code 07 N lt gt 0 __ 13144 13144 0047 SPROCKET OUTPUT 16T 1 OPTION 13144 13144 0048 SPROCKET OUTPUT 15T 1 OPTION 13262 13262 0535 GEAR OUTPUT LOW 36T 1 OPTION 13262 13262 0536 GEAR INPUT 2ND 16T 1 OPTION 132628 13262 0537 GEAR OUTPUT 2ND 34T 1 A 13262 13262 0538 GEAR INPUT 5TH 22T 1 OPTION 132620 13262 0539 GEAR OUTPUT 5TH 32T 1 OPTION 13262 13262 0540 GEAR INPUT 6TH 26T 1 OPTION 13262F 13262 0541 GEAR OUTPUT 6TH 35T 1 OPTION 92022 92022 1722 WASHER 22 3X35X1 8 AR OPTION 92022A 92022 212 WASHER 22 3X35X1 6 AR OPTION 92200 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200A 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION DEC 20 2006 This catalog covers GRID NO This grid covers 07 ZX600P7FR Engine Engine Cover s E1431 Part art No 11061 11061 0303 OPTION 11061A 11061 0304 e
10. 26031 0559 Sub Harness with Original Meter and Original Main Harness 26031 0327 Main Harness with Original Meter 26031 0558 43 Meter Kit Installation 51063828 3 C Tachometer with Water Temperature Gauge Optional 25031 1142 Collar Optional 92152 0058 Pad Optional 39156 0098 Bracket Optional 11053 1749 Rivet Optional 92039 1106 Nut Optional 92015 1233 Collar Optional 92152 1074 Bolt Optional 130J0625 Damper Original 92160 1167 10 Lamp Assembly Optional 23016 0006 e 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 CONDO gt 44 Harness Combination Parts Table Main Harness and Kit Part Combination Table need no need Harness for Harness for Kit Meter Original Meter 26031 0559 26031 0558 Sub Harness 26031 0327 Tachometer with Temperature Gauge Kit 25031 1142 Water Temperature Gauge Lead Kit 26011 1779 Water Temperature Sensor Ground Lead Kit 26011 0071 Water Temperature Sensor 21176 1099 Relay Box Original 2 002 0007 Relay Assembly Original 2 002 3703 Main Harness and Original Part Combination Table need x no need Harness for Kit Harness for Meter Original Meter 26031 0559 26031 0558 x Oil Pressure Switch x x ee 45 Wirin
11. 59101 0002 OPTION 92015 1316 OPTION 92015 1397 OPTION 92026 1586 OPTION 92150 1090 92150 1494 92151 1593 OPTION 92152 0589 OPTION 120CA0630 OPTION Description BRACKET BRACKET BOSS Spec Code HOLDER STEERING DAMPER HOLDER STEERING DAMPER PIPE COMP GRIP CASE UPP CASE LWR HANDLE HOLDER HANDLE LH HOLDER HANDLE RH GRIP THROTTLE CABLE THROTTLE CABLE THROTTLE CLOSING REEL R21 5 60DEG REEL R20 0 65DEG NUT FLANGED 16MM NUT LOCK FLANGED 8MM SPACER SET BOLT 6MM BOLT SOCKET 10X50 BOLT SOCKET 8X25 COLLAR BOLT SOCKET 6X30 DEC 20 2006 Quantity ZX600 This catalog covers GRID NO This grid covers 07 ZX600P7FR Chassis Frame Fittings 2 2 F2130 Ref 46012A ao Description Spec Code Quantity ZX600 46003 120A 120CA0825 BOLT SOCKET 8X25 1 OPTION 120B 120CA0830 BOLT SOCKET 8X30 2 120C 120CA0865 BOLT SOCKET 8X65 1 OPTION 120D 120P0635 BOLT SOCKET 6X35 2 59101 4 M OPTION 120E 12050625 BOLT SOCKET 6X25 2 20001 31064 OPTION 410 41080800 WASHER PLAIN SMALL 8MM 2 670 670 2012 O RING 12MM 1 OPTION OPENING 54012 54012A CLOSING 11 DEC 20 2006 This catalog covers GRID NO This grid covers 07 ZX600P7FR Chassis Front Fork rows Ref Quantity ZX600 ilo Part No Description Spec Code 92145 92145 0507 SPRING FRONT FORK K 8 25N MM 2 92145 92145 0508
12. 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 Front Brake Pads 43082 0074 2508 High Original TT2172HH Low Rear Brake Pads Original High 43082 1220 43082 1192 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 50121 Set the steering damper to the holder as shown 2 Stroke s 0121 68 mm Steering Damper OHLINS 50121 Bracket 11054 1816 Bracket 11054 1817 Collar 92152 0589 Ring 670 B 2012 Washer 410 B 0800 Bolt Socket 120 CA0630 Bolt Socket 120 CA0825 Bolt Socket 120 CA0865 0 Nut 92105 1397 ss WA 38 Seat Height Adjustment Loosen the nut 1 and insert the spacer 2 as required Tighten the nut 1 to 59 Nm 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 e When the seat height adjusts spacer applied the rear suspension should be softened 39 Seat Height Adjustment Spacer Set 92026 1586 Spacer for seat height adjust
13. Selection Table Crankcase inner Diameter Crankshaft Diameter 1 34 000 34 008 30 992 31 000 RU 34 000 mm 34 008 mm 30 984 mm 30 992 mm 1 34 008 34 016 30 992 31 000 Felis ae 34 008 mm 34 016 mm 30 984 mm 30 992 mm Journal Number Part Number STD 92139 0191 92139 0173 92139 0190 92139 0172 92139 0190 92139 0172 92139 0189 92139 0171 Part Number KIT 92139 0202 92139 0199 92139 0201 92139 0198 92139 0201 92139 0198 92139 0200 92139 0197 2 Crankpin Crankpin Diameter 1 Crankpin Diameter Marks O mark over 29 992 mm 108416BW1 C within 30 000 mm None 29 984 mm and over within 29 992 mm O Connecting Rod Big End Inside Diameter Connecting Rod Big End Inside Diameter Marks O mark over 33 008 mm within 33 016 mm None 33 000 mm and over within 33 008 mm A Inside Diameter Mark O or None B Weight Mark Alphabet G H etc O Connecting Rod Big End Bushings Part Number STD 92139 0165 92139 0166 92139 0167 Size Color Thickness mm blue 1 485 1 490 black 1 480 1 485 brown 1 475 1 480 5108174851 Part Number KIT 92139 0194 92139 0195 92139 0196 Selection Table Part Part Connecting Rod Big End Size Crankpin Diameter Mark Number Number Inside Diameter Color STD KIT None brown 92139 0167 92139 0196 3
14. UN BK Y BK Y BK Y BK Y SS Frame Ground Battery Engine 12V8Ah Ground Fuse Box Motor 1 ECU Fuse 15 Main 2 Measuring Instruments Fuse Fuse 104 3 Ignition Fuse 15 108385BW5 C Li EE c Position Sensor ain DNE Side Subthrottle throttle Stand Sensor Sensor Switch Regulator i P fRectifier Inlet Air Qil Temperature a Pressure Crank Sensor an 2 Switch shaft EE Az Sensor Speed ctuator E Sensor Inlet Air 2 Pressure Sensor Shift a gt ove Lx Sensor NES T 2 555 A D um ca m mE MM eg c Ld Sensor gt re S W 5 455 B 25 z e IL mai a m C TEC C a 2 Eam 055155 lites xm artt ar a sft E Immobilizer Dnderfazss Rum Joint Joint Kawasaki Box Connector 2 Connector 3 Atmespheric Self Pressure diagnositic Sensor System m Reserve Switch fyel Pump MeasurinE Instruments R Power Source elay Box 51 Alternator BK BK BK BK BK BK L i 2 3 4 5 6 7 8 9 51063868 5 C 52 Racing Kit Parts List This catalog covers
15. from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured 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 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 operates 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 24 Standard Selection of Spring Retainers Total Thickness of Clutch Plates Size of Spring Retainers P No 13091 1041 40 2 40 7 mm Original Setting 39 5 40 2 mm P No 39108 0004 If clutch slip is occurred with a retainer of 6 mm try with a retainer of 5 mm Standard Selection of Shim Total Thickness of Clutch Plates Size of
16. 07 ZX600P7FR Engine 49118A GRID This grid covers E1121 Cylinder Ref El Part No 11004 11004 0067 OPTION 11004A 11004 0068 OPTION 11004B 11004 0069 OPTION 11004C 11004 0070 OPTION 11004D 11004 0071 OPTION 12048 12048 1175 OPTION 49118 49118 0110 OPTION 49118A 49118 0111 OPTION 92015 92015 1078 92043 92043 1506 OPTION 92055 92055 011 92055A 92055 086 132 132BAO0620 OPTION Description GASKET HEAD T 0 70 GASKET HEAD T 0 60 GASKET HEAD T 0 55 GASKET HEAD T 0 50 GASKET HEAD T 0 45 TENSIONER ASSY CAMSHAFT COMBINTAKE CAMSHAFT COMP EXHAUST NUT FLANGED 6MM PIN 10X14 RING O 5MM RING O 18 8X1 9 BOLT FLANGED SMALL 6X20 DEC 20 2006 Spec Code Quantity ZX600 p qs pep wq pq This catalog covers 07 ZX600P7FR Engine 92139 A B S Y 92139 A B Ir n 27 AY NM l Wa 92139C E L LA e us a 92139F H 92139F H nera sera gt GRID NO This grid covers Crankshaft Ref No 92139 92139 921398 92139 921390 92139 92139 92139G 92139H Part No 92139 0194 OPTION 92139 0195 OPTION 92139 0196 OPTION 92139 0197 OPTION 92139 0198 OPTION 92139 0199 OPTION 92139 0200 OPTION 92139 0201 OPTION 92139 0202 OPTION Description Spec Code BUSHING CONROD BLUE BUSHING CONROD BLACK BUSHING CONROD BROWN BUSHING CRANK 5 BLUE BUSHING CRANK 5 BL
17. 1 0011 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 System is used 51064118 2 C A Wire Net 14037 0057 B Tank 16181 0011 e Remove the secondary valves of cylinder head and relational parts then plug the each holes e Remove the oil receiver and plug the hole e Remove the air cleaner element or cut the cleaner element off remaining punched plate to reduce the air flow resistance 51064428 4 C 1 Remove the parts 2 Plug the holes 3 Replace with plugs 92043 1506 and plug the holes 9 Cylinder Head Grind off the stepped portions of the ports and smooth the inside of 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 the stepped portions at the mating surface between valve seat and the port Smooth the inside of the intake port and exhaust port Use the hand grinder O Use 200 oil stone for eliminating any stepped portions O Use 200 oil stone for smoothing and 300 oil stone for finishing NOTE O These procedures make air resistance less and inta
18. 3 000 mm 33 008 mm 29 992 mm 30 000 mm None None black 92139 0166 92139 0195 33 000 mm 33 008 mm 29 984 mm 29 992 mm black 92139 0166 92139 0195 33 008 mm 33 016 mm 29 992 mm 30 000 mm O None blue 92139 0165 92139 0194 33 008 mm 33 016 mm 29 984 mm 29 992 mm Connecting Rod Bolts Use the original connecting bolts and nuts The original connecting rod bolt has recesses at both ends to measure its length and determine the bolt stretch 108423BW1 C e 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 11 8 2 N m 1 2 0 2 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 Replace the original bolts with new ones if they have already been tightened up to usable range 2 times 20 Clutch Adjustment Back Torque Limiter Setting The Ninja ZX 6R 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
19. 8 5 C Wiring Diagram with Original Meter Assembly 1 Signal Indicator Light LED 2 High Beam Indicator Light LEB 3 Neutral Indicator Light LED 4 Fuel Level Warning Indicator Light LED 5 011 Pressure Warning Fl immobilizer Indicator Light LEB 8 Odometer Trip Meter Stop Watch Indicator 7 Position Indicator 8 Clock 9 Water Temperature fauge 10 Tachometer 11 12 Meter Light LED 13 Shift Up Indicator Light LED Right Switch Housing Right Switch Housing 9 4 Engine 1 Brake deed Light Switch br m Cover 2 Engine Stop 11 Ground Switch SS 3 Starter Button 4 Stop Watch Button 5 55 mau Su Joint Connector 1 K Y BK Y BK Y K Y K Y Indicator Light 0 eft Switch Housing Horn Button Passing Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Lap Time Button Ch Ch 4 I LE Water ae Temperature ostion Ro Fuel Es d Switch 4 Sensor 4 Spark Plugs Ao niectors Q L X eS cT 1 2 3 4 58 Stick mac ue 25 Geils 12 en 2 Mw co 5 BL Y 6 BR BK Vehicle down Sensor 50 Ay 1 BR ae pce S Fuse Box 1
20. ACK BUSHING CRANK 5 BROWN BUSHING CRANK 18 28 38 4 BUSHING CRANK 18 28 38 4 BLK BUSHING CRANK 18 28 38 4 20 2006 Quantity ZX600 RENT pep op oq AR AR AR AR AR AR This catalog covers 07 ZX600P7FR Engine GRID NO This grid covers Clutch E1350 Hef Part No No art No 39108 0004 OPTION 92025 1137 OPTION 92026 1590 OPTION 39108 92025 92026 39108 ov ARN gt 4946 SES 6 SF a 92025 92026 J ry gt aN 0 Description Spec Code RE TAINER SPRING T 5 0 STD 1 0 SHIM 15 3X27 5X1 20 SPACER T21 5 DEC 20 2006 Quantity ZX600 p qs mer pq This catalog covers 07 ZX600P7FR Engine 132626 GRID This grid covers Transmission T YPE B E1361 Ref No 13127 13144 13144A 13262 13262A 13262B 13262 132620 13262 13262F 13262G 13262H 92022 92022A 92200 92200A Part No 13127 0055 OPTION 13144 0047 OPTION 13144 0048 OPTION 13262 0526 OPTION 13262 0527 OPTION 13262 0528 OPTION 13262 0529 OPTION 13262 0530 OPTION 13262 0531 OPTION 13262 0532 OPTION 13262 0533 OPTION 13262 0534 OPTION 92022 1722 OPTION 92022 212 OPTION 92200 0230 OPTION 92200 0231 OPTION Description Spec Code SHAFT TRANSMISSION INPUT 14T SPROCKET OUTPUT 16T SPROCKET OUTPUT 15T
21. OPTION 55020 55020 0028 GUARD CHAIN 1 OPTION 5 92057 92057 1529 CHAIN DRIVE 120L 520 1 OPTION SN NS 92153 cf 92058 92058 1090 JOINT CHAIN DRIVE 520 1 OPTION 92145 92145 0504 SPRING SHOCKABSORBER K 95N MM 1 OPTION 92145A 92145 0505 SPRING SHOCKABSORBER K 100N MM 1 OPTION 43082A B 92145B 92145 0506 SPRING SHOCKABSORBER K 105N MM 1 OPTION 92153 92153 1777 BOLT FLANGED 10X60 4 OPTION 130 13071020 BOLT FLANGED 10X20 1 OPTION 14 DEC 20 2006 E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Doc No 99929 0136 01
22. SPRING FRONT FORK K 9 25N MM 2 OPTION 92145B 92145 0509 SPRING FRONT FORK K 9 75N MM 2 h d Ld 99 2 62 L 2 i l 4 J J l 4 A P P A M WE I p 22 WA t 2 e e C2 92145 D x E E z B B d I I 8 8 N e WI 22 12 DEC 20 2006 This catalog covers GRID This grid covers 07 ZX600P7FR Chassis Meter s Ref Quantity ZX600 No Part No Description Spec Code 11053 11053 1749 METER 1 OPTION 2015 23016 23016 0006 LAMP ASSYINDICATOR 1 OPTION 25031 25031 1142 METER ASSY 1 92152 130 39156 39156 0098 METER 1 we OPTION 92015 92015 1233 NUT FLANGED 6MM BLACK 2 i OPTION 92039 92039 1106 RIVET 3 OPTION 92152 92152 0058 COLLAR 3 OPTION 92152A 92152 1074 COLLAR 2 see OPTION 130 13010625 BOLT FLANGED 6X25 2 WA Sh OPTION iz 23016 13 DEC 20 2006 This catalog covers GRID NO This grid covers 07 ZX600P7FR Chassis Other 43082 e Ref Part No Description Spec Code 43082 43082 0074 PAD ASSY BRAKE FR 1 OPTION 43082A 43082 1192 PAD ASSY BRAKE RR C93 1 OPTION 43082B 43082 1220 PAD ASSY BRAKE RR C93G 1
23. Shim P No 92180 0149 Approx 40 7 mm 2 0 mm dd Original Setting EE 402mm 1 15 P No 92026 1990 39 5 40 mm 1 2 mm 92025 1137 Transmission Remove the three steel balls 600A0500 from the output shaft assembly e 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 5 mm to prevent the seizure of gears and to keep smooth gear shifting 0000 92200 0050 Original Spline washer input 92200 0231 Kit 92200 0230 Kit 92200 0138 Original 92022 212 Production part 92202 1722 Production part Plane washer input output 25 PS EIN im 42 1 Spline washer input 2 Plane washer 26 Generator Option 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 30A 5000rpm The consume current of the racing model in running condition is 7 8A Installing Option Generator 6 Bolt 92002 1696 KIT 108438BW2 C Generator Cover Option Use the
24. To AAA Brake operation check e Waepdwew mex Brake fluid level check Brake fluid change MCN Koo o _ Dwecwn Mae ve chai 9 1 T Fuel hose fuel filter replace Steering play check uH NON m a General kibriaton otchassis pedum Weebewmo em geme Swingarm pvt unitrackinkage grease Swingarm pvt unstack Replace add adjust clean or torque if necessary Preparation Before Installing Modify the parts based on your race regulation avoid misuse keep the parts replaced with the kit parts separate When reusing parts clean them and check them for damage or deterioration 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 Remove the wire net of Ram Air duct intake to reduce the air flow resistance Remove the tank 1618
25. ase gasket 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 0071 KIT 11004 0068 11004 0067 KIT 8108037 3 1 Squish Front Rear 2 Squish Left Right Crankshaft Journal and Connecting Rod Big End Bushings To adjust clearance of crankshaft main journal you can select proper bush in accordance with the marks The kit bushings are improved in anti seizuring characteristics as well as in wear resistance as compared with the standard bushings 1 Crankshaft Main Journal O Crankshaft Main Journal Diameter 4 a H XN 9 1 Crankshaft Main Journal Diameter Marks SIZE 1 mark over 30 992 within 31 000 mm None over 30 984 mm within 30 992 mm 108428BW1 C O Crankcase Main Journal inside Diameter 108415BW1 C 1 Main Journal Diameter Marks mark over 34 000 mm within 34 008 mm None 34 008 mm and over within 34 016 mm Main Journal Bush A Size Color Size Color 1 499 1 503 1 495 1 499 1 491 1 495 Thickness mm Journal Number Part Number STD 92139 0189 92139 0171 92139 0190 92139 0172 92139 0191 92139 0173 Part Number KIT 92139 0200 92139 0197 92139 0201 92139 0198 92139 0202 92139 0199
26. g Routing 8 900 03 20909 09900 2 108383BW2 C 1 Vehicle down Sensor 12 Main Throttle Sensor 2 Meter Assembly 13 Injector Secondary 3 Shift Up Indicator Light 14 Injector Primary 4 Right Handlebar Switch 15 Coolant Temperature Sensor 5 Left Handlebar Bar Switch 16 Speed Sensor 6 Intake Air Temperature Sensor 17 Crank Shaft Position Sensor 7 Boost Sensor 18 Gear Position Sensor 8 Cam Shaft Position Sensor 19 Battery 9 Ignition Coil 20 Auto Shifter 10 Subthrottle Valve Actuator 21 Frame Ground 11 Cylinder Head Ground 22 Regulator The headlight beam Hi Lo change switch on the left handlebar switch works as a speed limit switch of the pit road and passing switch works as same also n case of using optional meter the connector of coolant temperature sensor 15 must used The auto shifter 20 should be used according to local regulation 46 108384BW2 C Fuel Pump Magnetic Switch ECU Relay Assembly 27002 3703 Atmospheric Pressure Sensor Power Source for Measuring Instruments Setting Tool The relay assembly 4 should make sure to avoid the interference with other parts e When apply the measuring instruments the power source 6 available as a 12 V power source The setting tool should be used according to the manual of Kawasaki Fl Calibration Tool 47 Wiring Diagram with Kit Meter Water Camshaft Temperature Post
27. 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 Original Glutch 13089 0009 TU 4 13089 0008 Thickness of Shim 2 0mm 92180 0149 Original 1 5mm 92026 1590 KIT 1 2mm 92025 1137 KIT retainer 6mm 13091 1041 Original Production Part 50mm 39108 0004 KIT Production Part Depth B sth Total thickness of all clutch plates 51064368 3 C 21 Race Recommended clutch Thickness of Shim 2 0mm 92180 0149 Original 1 5mm 92026 1590 KIT 1 2mm 92025 1137 KIT retainer 6mm 13091 1041 Original Production Part 5mm 39108 0004 KIT Production Part Depth B ength Total thickness of all clutch plates 108437BW3 C The standard setting of length A total thickness of clutch plates shown in the illastration becomes about 40 7 mm 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 39 5 and 40 7 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
28. ightening torque 13 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 15 smaller than 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 races 5 10 races Required OPERATION 300 km 1 000 1 500 3 000 km Clutch plate check Throttle grip play check LX WA Spark plug clean gap Le Engine oil change L 1 l1 Ll ee pe j j ____ e jd Oil filter replace Valve lapping Cylinder head valve decarbonization FREQENCY Each Every Every Every S Race 3races 5 10 races Required OPERATION 300 km 1 000 km 1 500 km 3 000 km Paw Piston ng Pee n ee _ crmstatmanosano ee _ Connecting rod big end bearing check e Transmission gear bearing check e Engine sprocket check ___ Coolant change e Radiator hoses connections check
29. ion Primaly Fuel Injectors Switch Sensor Right Switch Housing YA t Front Brake 2 oe Spark Plugs M Wu Secondary tap Fuel Injectors 3 8tarter Button N m ELI Ns gt 2 3 4 4 Watch TITE E SI Button Stick m m a Y R BR W m 1 Right Saitch HE Housing D 2 m __ W R WAR 0 6 0 BK W R W R Cover BK Y Ground Joint ol of xx 2 Gonnector i SE BK Y BK Y BK Y H BK Y Water Temperature Gauge Tachometer 11 BD R Indicator Light Warning Im HEC EE x ice j dg ol B Tr px W BL BL G BR BK Light I comm D 6 Left Switch Housing Vehicle S Frame 1 Button down Ground 2 Passing Button Sensor Starter 3 Turn Signal Switch 4 Dimmer Switch 5 Starter Lockout Switch 6 Lap Time Button Battery 12V8An Engine Ground Fuse Box 1 Fuse 15 Main 2 Measuring Instruments Fuse Fuse 10 30 3 lgnition Fuse 15 108387BW5 C Starter Motor 48 Speed Sensor Y BK Y Position Gear Sensor ui Alterna
30. is not enough replace other steel plates one by one Steel plates of former 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 22 Recommended Clutch 51080918 3 Spacers 8 Needle Bearing C Bushing D Clutch Outer Casing E Clutch Hub F Sub Clutch Hub Friction Plates total 8 pcs H Steel Plates I Spring Plate J Steel Plate with Spring 23 Engage the cam followers Clutch Hub with the cams Sub Clutch Hub e To measure the effective stroke of clutch spring plate set a dial gauge A against the raised 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 62060318 5 After installing the clutch to the engine measure and record the depth shown in the figure on page 21 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
31. ke 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 Details in Section A B 108430BW3 C 1 Stepped Portions of carburetor holder and cylinder head 2 Stepped Portions of valve seat and cylinder head e Ihe combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners Round them to about R1 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 11 108413BW1 XXX Edges NOTE O When grinding the cylinder head bottom surface or using 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 mm Camshaft Chain Tensioner Replace the cam chain tensioner with the kit to gain the durability 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 e Install the tensioner on the cylinder block with the tensioner rod is fully pushed back Turn the tensioner rod in with a screwdrive
32. on ratio 1 900 76 40 Transmission Gear Table In 13127 0044 13127 0055 13127 0055 ie Out 13262 0507 13262 0526 13262 0535 Teeth Out In 38 14 37 14 36 14 Gear Ratio 2 714 2 643 2 571 In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio 13262 0372 13262 0508 33 15 2 200 See note 13262 0509 37 20 1 850 See note 13262 0510 32 20 1 600 13262 0374 13262 0380 27 19 1 421 13262 0375 13262 0381 26 20 1 300 13262 0527 13262 0528 39 18 2 167 13262 0529 13262 0530 33 20 1 650 13262 0531 13262 0532 30 20 1 500 13262 0533 13262 0534 32 23 1 391 13262 0536 13262 0537 34 16 2 123 13262 0538 13262 0539 32 22 1 455 13262 0540 13262 0541 35 26 1 346 4th gear type _ 13262 0506 13262 0529 Input 3rd 4th gear 3rd 4th 3rd gear type 51064418 3 C Gear oi ey Number of Grooves Racing Kit Service Data Cylinder Head Valves Duration Intake 288 Exhaust 266 Camshaft timing cam lift center Intake 105 ATDC Exhaust 110 BTDC Valve clearance Intake 0 16 mm Exhaust 0 28 mm Valve to piston clearance Intake 0 80 mm Minimum 12 ATDC Exhaust 1 40 mm Minimum 12 BTDC Ignition System Spark plugs R0045Q 10 7 10 Spark plug t
33. ong 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 11 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 the 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 b
34. option generator with 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 Select suitable combination for target characteristic of engine Length mm Part Number 14073 0124 14073 0125 14073 0174 14073 0151 14073 0152 27 Muffler With recommended muffler engine performance can be improved Recommended muffler Beet NASSERT R 1002 E02 00 Web Site http www beet co jp beetjapan For further information contact the manufacturer 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 and 07 ZX 6R Racing Kit provides the capacity increased main radiator 39060 0020 to improve cooling performance 28 Radiator Installation Use the radiator stay 35063 0439 and bracket 11054 1818 belong to kit and fasten the radiator to the Crankcase by bolts as shown in the figure
35. r 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 e Tighten the rock nut after adjustment 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 108414BW3 C A lensioner Tensioner Rod C O ring D O ring E Lock nut Camshafts Sprockets Camshafts Sprockets Adjust the valve clearance within the specified value but more performance is expected when 208 from middle value to upper limit between adjustable range Exhaust 0 24 0 311 mm ee Valve Clearance Exhaust 20 24 0 311 mm f 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 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 1 5 11 0 ft lb of torque Valve Timing when the round bolt holes are used Original Race use 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 l
36. s 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 SPSCINCAHOMS 3 Racing ii SS Cl CO 5 Penodi Maintenance Ch aa v a ARRA eR 5 FAV UON T AA 7 212 eR E TU AA hi 7 PEE ES 7 ENGINE als NSS gt 7 Ar mtake 7 CVIder Ga 10 Tensionet RET m 12 8 a iom rU M EOD PM M EM CHEM CE iene 13 14 Cylinder COMPFESS OW 15 Crankshaft Main Journal and Connecting Rod Big End Bushings pp 17 Connecting a unt 20 Clutch Adjustment Back Torque Limiter 5 21 AUSTIN S SION ect rerum 25 TRANS MISSION SNIMMIN o pc ei ___ ___ 25 Generator OPUON 27 Generator Cover ODIO Ht 27 27 CAIN FUNNEIS
37. tor Main Side Subthrottle Throttle Stand Sensor Sensor Switch Regulator GFF Rectifier Inlet Air 011 Temperature Pressure Sensor y Switch shaft Valve Sensar Actuator En YA at Inlet Air 0 0 2 Pressure Sensor Shift Sensor Sut ZES 25 A D ang mum mr ones m Shift 0 e Sensor 305 Te S W ce EE 52 BK Y BL R BK DL DL 5 d TM D ERE umm __________ 5 1 OO O 7 gt gt gt 3 0 30 gt gt gt gt gt Sa ID x 552222 352 sz 2 s Immobilizer Interface Self Joint Joint Kawasaki Box Connector 2 Connector 3 Atmospheric Self Pressure diagnositic Sensor System ee Connector 5 gt Fuel Reserve Switch Pump Weasuring Instruments Power Source Relay Box 49 BK BL R BK YAA Y BL 1 2 3 4 5 5 7 8 BL Y Y R Y BK P BK R BK R BR Y BK Y 0 8 O R BL 8 BL R BK amp 8 BK G R BK Y LG R W BL R BL LB 07 0 BK BL Y BL BK BK Y BK Y BK 0 Diagnosis Tarminal 5106388
38. tor side with cap 11065 1056 30 A WN Radiator Water Hose 39062 0219 Ground Wire 26011 0071 Water Hose 39062 0166 Standard Sensor 21176 1099 Lead Wire 26011 1779 Clamp 92171 0179 31 5106431803 C 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 liquid surface Radiator Atmosphere Side Side Hoses Inside Diameter Resever Tank Sub stitute 5108200851 32 Oil Catch Tank Installation O Fasten the Bracket E to the Engine Hanger by using bolt D Fasten Oil Catch Tank A to the Bracket E by using bolt F and nut 1 O Connect Air Cleaner Crankcase and Oil Catch Tank by using hose1 B and hose2 C Capacity of a 011 Catch Tank 740cc A Oil Catch Tank 52001 0004 B 1 Air Cleaner Oil Catch Tank C Hose2 Crankcase Oil Catch Tank D Bolt 130BA08395 standard E Bracket 11054 1799 F Bolt 120P0620 G Dumper 92075 277 H Collar 92027 194 Nut 92015 1193 J Washer 92022 304 K Drain Bolt 130Y0610 33
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