1 - Factory Pro
Contents
1. gt lt EE 9 48 S i Se mE A d _ E or 1016 D e cm 68 Sy 016 Rd 016 E SS C Ge SSS 1 Sa un o LN _ gpm 8 1 16 mm Hole The locations of fender and its related parts are as follows Use the specified nuts or similar cap nuts to prevent the harness being damaged Nut Bracket or Relay Assembly Bracket 1068718W2 C 38 At the same time as processing the hole opening cut off one mounting boss of the exhaust butterfly valve actuator 106839BW3 C 1 Boss SI06841B G j 51068408 G 1 Nut 92210 0322 1 Bracket for Regulator Rectifier 2 Bracket for Vehicle down 11055 1671 Sensor 11055 1655 2 Bolt 132BA0620 3 Regulator Rectifier Original 21066 0028 39 Run both wirings wiring from main harness to regulator rectifier and wiring from generator to regulator rectifier in the left side of the starter relay and run them behind the frame 1 Wiring from Main Harness to Regulator Rectifier 2 Wiring form Generator to Regulator Rectifier 3 Starter Relay Run the main harness forwards along the inside of the main frame and run it between the throttle body and the mai2. 33 Fork Spring Installation Kit Spring Original Spring with Stamp without Stamp L 235 Omm L 235 amp 0 O00 amp 0 damat 000 am Go o w 1068568W5 C 34 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 Original Meter and Original Generator Regulator 26031 0789 Main Harness with Original Meter and Kit Generator Regulator 26031 0790 Sub Harness with Original Meter and Original Main Harness 26031 0327 35 Main Harness Combination Parts Table O need x need Harness for Harness for Kit Harness Original Generator Generator Sub Harness Part Regulator Regulator 26031 0327 26031 0789 26031 0790 Meter Assembly Original O O O Relay Box Original x 2 O 27002 0007 Relay Assembly Kit O O y 27002 3703 Notes Concerning Sub Harness 26031 0327 Use The sub harness 26031 0327 is designed to use Kit ECU with original main harness However such application is possible only with the models WITHOUT the immobilizer system To install Kit ECU onto the models WITH immobilizer system the Kit main harness 26031
3. 7 fe Cy e Ue AE decis SQ c p OE KTA ROY WSR oF OUR d Oo 92002 579 D KE aa 2 2 TA UM C ZA L YR Katz ee 92192A e GRID NO This grid covers Generator Ref Part No No art No 11055 11055 1671 OPTION 21003 0068 OPTION 21007 0083 OPTION 21066 0010 OPTION 52001 0007 OPTION 21003 21007 21066 52001 92002 92002 1696 OPTION 92022 304 OPTION 92075 1912 OPTION 92075A 92075 209 OPTION 92150 1717 OPTION 92022 92075 92150 92152 92152 0091 OPTION 92152A 92152 0237 OPTION 92153 1567 OPTION 92170 1060 OPTION 92192 0819 OPTION 92153 92170 92192 92192A 92192 0820 OPTION 92200 0306 OPTION 92200A 92200 3712 OPTION 92210 0322 OPTION 130 130800610 OPTION 92200 92210 132 132 0620 OPTION Description Spec Code BRACKET REGULATOR STATOR ROTOR REGULATOR VOLTAGE TANK OIL BOLT SOCKET 6X25 WASHER 6 2X11X1 DAMPER DAMPER BOLT 12X40 COLLAR COLLAR BOLT FLANGED 6X65 CLAMP TUBE OIL TANK AIR BOX TUBE CRANKCASE OIL TANK WASHER 12X36X3 2 WASHER 6 5X16X1 0 NUT CAP 6MM BOLT FLANGED 6X10 BOLT FLANGED SMALL 6X20 NOV 12 2008 Quantity ZX600 This catalog covers 09 ZX600R9FR Chassis F2130 59101 A d 120 32099A 32099 31064 92026 OPENING 54012 22 2 22 4 gt 54012 CLOSING Ref No 310
4. 2 6 13089 0009 Selection 7 Original 2 3 13089 0008 Selection 0 Original Thickness of Shim 2 0mm 92180 0149 Original 1 5mm 92026 1590 KIT Len 1 2mm 92025 1137 KIT Size of Spring retainer 6mm 13091 1041 Original 5mm 39108 0004 KIT Production Part gth Total thickness of all clutch plates Production Part 106436BW3 C 20 Race Recommended clutch Thickness of plate mm Part Number Used Number With Spring 13089 0003 first inside Use 2 3 13089 0008 Selection 5 Original 2 0 13089 0007 Selection 1 Original Thickness of Shim 2 0mm 92180 0149 Original 1 5mm 92026 1590 KIT 1 2mm 92025 1137 KIT Size of Spring retainer 6mm 13091 1041 Original Production Part 5mm 39108 0004 KIT Production Part Length A Total thickness of all clutch plates 106437BW3 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
5. Cut off Dampers and Collar to prevent them running on Chain Cover arrow part Cut off Damper and Collar to X Detail prevent them running on Chain Cover arrow part 2 2 2 Unit mm S106859BW2 C 28 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 Parts Name P No Throttle Case Upper 32099 0046 Throttle Case Lower 32099 0047 Bolts 2 120CA0518 Pipe Grip 31064 0187 2 Throttle Reels Tow types are available Throttle reel travel angle is marked on each part to identify Throttle Reel Travel Ange Effective angle excluding throttle cable free play Twist Grip Turn Angle id adds to Full Throttle 59101 0006 R19 3 65 deg 65 59101 0007 R21 0 60 deg 65 106889BN2 C 1 Identification Mark 2 Throttle Cable Tow types accelerator and decelerator cables are available Parts Name P No LD Mark Throttle Cable Accelerator Side 54012 0270 12 0270 xxxx Throttle Cable Decelerator Side 54012 0271 12 0271 xxxx Run the throttle cable A to the left side of the frame below 106827B G 29 106829BM9 C Upper Case 32099 0046 Lower Case 32099 0047 Bolts 120CA0518 Reel 65
6. 59101 0006 Reel 60 59101 0007 Throttle Pipe 31064 0187 Oar WN Groove for Identification on Mating Surface 106854BN2 C Assemble the throttle cases so that the groove for identification faces upwards see above It is correct to assemble the throttle cases so that the groove side have no clearance and the opposite lower side have clearance 30 Drive Chain Kit 1 Chain Guard 106831BM9 C 1 Guard 55020 0028 2 Bolt 130BA1020 3 Swingarm Left 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 Because of higher braking force replace the front caliper bolts with the kit parts to make the installation of the caliper stronger Front Brake Pads P No Stamp Braking Force 43082 0074 2508 High Original TT2911HH Low Rear Brake Pads P No LD Stamp Braking Force Original FO GG High 43082 1220 with Yellow Paint f 43082 1192 without Yellow Paint Low Steering Damper Kit For race usage it is recommended to use racing type steering damper see next page since the original damper is mainly designed for street riding or at most sport riding When install the racing type steering damper please make sure that the damper shall not limit the steering angle as normally stipulated by the race regulations 31 1
7. Kawasaki ninja zx 6R 2009 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 Base Manual Part Number Ninja ZX 6R Motorcycle Service Manual 2008 Kawasaki Heavy Industries Ltd First Edition 1 Nov 25 2008 Congratulation on your purchase of racing kit parts for the 2009 Ninja ZX 6R IMPORTANT This manual provides how to install racing kit parts for the 2009 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 1417 01 When you participate in a race it is necessary to modify the machine for the regulation So we want you to ask for the tuning up shop AAWARNING 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 r
8. e bd a b ee 24 Generator ODIO eoe ea prete deae asad dede gap a 25 Generator Cover Option ben esi eB lee He re cr pb a rene hae bun e Bie 25 Cover Gaskets iab dO We RW vere ea de sevo gn de d RR ERROR pav v aioe 25 EE 25 Water Temperature Sensor eerte oe RO EO atu een ee ies 26 Cooling System dte o e d daa EATE T e Ed 26 Oil Catch Tank Installation aede exe 27 Frame Parts INStanlation mem 29 Ihtottle Parts iul ei eee e 29 Drive Chain Kit 5 b php nans eden b der ae lessees ada 31 Brake Pads Kit isis api b eed o de e b ba ER da Pea de es eats ae ae 31 steering Damper Kil E 31 Height Adjustment itt fe n bte ES 32 Front Fork Springs tipi IUE rg e o odd oe 33 ee 35 52 ly KE 35 Main Harness and Sub Harness kul 35 speed Limit of Pit Road jis Bo p oce b E iaeaea 36 Installation of Brackets Regulator Rectifier and Vehicle down 36 Wiring Diagram with Original Meter Original Regulator 42 Wiring Diagram with Original Meter Kit Regulator Aussen 44 General Specifications Item 2009 Ninja ZX 6R Racing Engine Ignition timing Fuel Recommended Engine oil Recommended Level 12 5 BTDC 1
9. 0248 92139 0272 34 008 mm 34 016 mm 30 984 mm 30 992 mm purple 3 92139 0252 92139 0275 2 Crankpin Crankpin Diameter 106416BW1 C 1 Crankpin Diameter Marks mark over 29 992 mm 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 5106174851 C Size Color Thickness mm eo iso blue 1 485 1 490 92139 0165 92139 0194 black 1 480 1 485 92139 0166 92139 0195 brown 1 475 1 480 92139 0167 92139 0196 O Selection Table Connecting Rod Big End A oes Size Part Number Part Number Crankpin Diameter Mark Inside Diameter Color STD KIT None brown 92139 0167 92139 0196 33 000 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 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 origina
10. 39 0525 431593 Fax 39 0525 431792 P I e C F IT02424740344 E mail mbo mbmotorsport it Web site www mbmotorsport it For further information contact the manufacturer of radiator directly Reserve Tank Installation When not using the original reserve tank 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 26 Radiator Side Resever Tank Sub stitute Atmosphere Side Hoses Inside Diameter 5 5 5106200851 C Oil Catch Tank Installation O Fasten Oil Catch Tank A with Chain Cover to Crankcase by using bolt E In that case cut off part marked of Damper and Collar see next detail O Connect Air Cleaner Crankcase and Oil Catch Tank by using hose1 B and hose2 C S106826BW3 C A Oil Catch Tank 52001 0007 B Hose1 Air Cleaner Oil Catch Tank 92192 0819 Hose2 Crankcase Oil Catch Tank 92192 0820 C D Clamp 92170 1060 E Bolt 92153 1567 F Washer 92200 3712 G Dumper 92075 1912 H Collar 92152 0237 I Washer 92022 304 J Drain Bolt 130BD610 gt a 27 Detail Marked
11. Alternator Regulator Rectifier BK BK Fuse Battery eserve 12V8Ah Switch Fuel Pump BK LG BK Y W R BR Y 228 555 gs 222222 KE aonaa rox a ox Joint Connector 1 Vehicle down Sensor Relay Relay Box Joint Connector 2 BL WY TE K Y 18 6 Kawasaki Diagnostic System Connector ptt Color Code BK Black Interface BL Blue Bex BR Brown G Green GY Gray LB Light Blue LG Light Green 0 Orange P Pink PU Purple R Red V Violet wW White Y Yellow 1068858W5 C 45 Dummy Page 46 Racing Kit Parts List This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Cylinder E1121 Quantity ZX600 Ref N ve Part No Description Spec Code 09 E ore III 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 55 1 OPTION 11004C 11004 0070 GASKET HEAD T 0 50 1 OPTION 11004D 11004 0071 GASKET HEAD T 0 45 1 OPTION 12048 12048 1175 TENSIONER ASSY 1 OPTION 49118 49118 0149 CAMSHAFT COMPI
12. O Crankcase Main Journal inside Diameter 106415BW1 C 1 Main Journal Diameter Marks SIZE O mark over 34 000 mm within 34 008 mm None 34 008 mm and over within 34 016 mm O Main Journal Bush 1 0 5106173851 C Size Color O Main Journal Bush Part Number Part Number Size Color Thickness mm Journal Number STD KIT bl 1 5 92139 0245 92139 0269 e 4 499 1 503 2 4 92139 0248 92139 0272 purple 3 92139 0252 92139 0275 Black 1 5 92139 0246 92139 0270 1 495 1 499 2 4 92139 0249 92139 0273 green 3 92139 0252 92139 0276 Brawn 1 5 92139 0247 92139 0271 1 491 1 495 2 4 92139 0250 92139 0274 yellow 3 92139 0253 92139 0277 O Bush Selection Table Part Part d Size Journal Crankcase Inner Diameter Crankshaft Diameter Number Number Color Number STD KIT 1 5 92139 0247 92139 0271 1 brown 2 4 92139 0250 92139 0274 34 000 mm 34 008 mm 30 992 mm 31 000 mm yellow 3 92139 0253 92139 0277 1 5 92139 0246 92139 0270 5 NONE black 2 4 92139 0249 92139 0273 34 000 mm 34 008 mm 30 984 mm 30 992 mm green 3 92139 0252 92139 0276 1 5 92139 0246 92139 0270 NONE 1 black 2 4 92139 0249 92139 0273 34 008 mm 34 016 mm 30 992 mm 31 000 mm green 3 92139 0252 92139 0276 1 5 92139 0245 92139 0269 NONE NONE blue 2 4 92139
13. Recommended Steering Damper OHLINS SD121 Stroke 68 mm 106832BM9 C E M E die Steering Damper OHLINS SD121 Bolts 132BA0830 O rings 670B2012 Washer 410AA0800 Collar 92152 0798 Height Adjustment Loosen the nut 1 and insert the spacer 2 as required Tighten the nut 1 to 59 N m 6 0 kgf m 43 10 of torque 106833BM9 C Boc Nut 92015 1316 Spacer Set 92026 1586 T 1 0 mm 2 0 mm 3 2 mm 4 5 mm Spacer 92026 0140 Standard T 4 0 mm Bracket 32037 1887 Standard 32 Front Fork Springs Kit The optional front fork springs are available for racing 1 Front Fork Specifications Items Original Rebounded damping setting 4 turns out from the fully clockwise position Compression damping setting 5 1 2 turns out from the fully clockwise position Fork Spring Preload Setting 4 turns in from the fully counterclockwise position Fork oil SHOWA SS05 Fork oil level 80 mm Spring length 235 mm Free Length Spring constant 9 25 N mm Sub spring stroke 28 mm 2 Front Fork Spring P No Spring Constant Original K 9 25 N mm 44026 0141 K 8 75 N mm 44026 0142 K 9 75 N mm 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 SCH BN fi 108212BM1 C
14. are used 105 110 Recommended timing for race when long bolt holes are used OWhen grinding the cylinder head bottom surface grinding the cylinder top surface or using thinner gaskets be sure the valve to piston clearance especially OWhen using the sprocket long 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 107 5 110 Valve to Piston Clearance Min Intake 0 8mm Exhaust 1 4mm 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 cylinde
15. steel plates Replace one steel plate with a thinner one and try the setting If the operation of the back torque limiter is not enough replace other steel plates one by one Steel plates of ZX600K model s are available Thickness mm Part Number 2 0 13089 1073 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 21 Recommended Clutch S1O6091BW3 C A Spacers B Needle Bearing C Bushing D Clutch Outer Casing E Clutch Hub F Sub Clutch Hub G Friction Plates total 8 pcs H Steel Plates I Spring Plate J Steel Plate with Spring 22 e 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 GF060318 5 After installing the clutch to the engine measure and record the depth B shown in the figure on page 21 and 22 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
16. 0789 0790 is essential Normally the models with immobilizer system carry IMMOBILIZER logo on the key cylinder Speed Limit of Pit Road The turn signal switch A on the left handlebar switch works as a speed limit switch of the pit road when the turn signal switch is turned to the left or right To stop the speed limit push the switch in 51068368 G Installation of Brackets for Regulator Rectifier and Vehicle down Sensor Move the regulator rectifier behind the battery box when the kit main harnesses 26031 0679 0680 are used Install the original regulator rectifier on the two front hole of the bracket when the original regulator rectifier is used Install the kit regulator rectifier on the two rear holes of the bracket when the kit regulator rectifier is used The next figure indicates the case where the original regulator rectifier is used Install the vehicle down sensor using the kit bracket 36 1068378W4 C Jo Om Bracket for Regulator Rectifier 11055 1671 Dampers 92075 209 Collars 92152 0091 Nuts 92210 0322 Bracket for Vehicle down Sensor 11055 1665 Bolts 132BA0620 Relay Assembly 27002 3703 Regulator Rectifier Original 21066 0028 Regulator Rectifier Kit 21066 0010 37 When the original fender is used drill out the three holes of 16 mm as shown and insert the dampers 92075 209
17. 300 r min rpm Racing gasoline Racing oil Between upper and lower levels of oil level gauge Drive Train Primary drive reduction ratio 1 900 76 40 Transmission Gear Table Tu A Type B Type C Type D In 13127 0068 13127 0055 13127 0055 ist Out 13262 0712 13262 0526 13262 0535 Teeth Out In 38 14 37 14 36 14 Gear Ratio 2 714 2 643 2 571 In 13262 0744 13262 0527 13262 0536 13262 0677 And Out 13262 0508 13262 0528 13262 0537 13262 0678 Teeth Out In 33 15 39 18 34 16 36 16 Gear Ratio 2 200 2 167 2 125 2 25 In See Gear See Gear Selection Selection 3rd Out 13262 0509 13262 0683 Teeth Out In 37 20 32 17 Gear Ratio 1 850 1 882 In See Gear See Gear See Gear See Gear Selection Selection Selection Selection 4th Out 13262 0510 13262 0530 13262 0684 13262 0685 Teeth Out In 32 20 33 20 39 23 30 19 Gear Ratio 1 600 1 650 1 696 1 579 In 13262 0710 13262 0531 13262 0538 13262 0686 Sth Out 13262 0380 13262 0532 13262 0539 13262 0687 Teeth Out In 27 19 30 20 32 22 32 23 Gear Ratio 1 421 1 500 1 455 1 391 In 13262 0711 13262 0533 13262 0540 13262 0688 Gth Out 13262 0582 13262 0534 13262 0541 13262 0689 Teeth Out In 26 20 32 23 35 26 29 23 Gear Ratio 1 300 1 391 1 346 1 261 Input 3rd 4th Gear Selection Table 4th Gear A B C D A 13262 0709 13262 0529 13262 0679 3rd Gear B 13262 0680 13262 0681 13262 0682 The transmission gears
18. 5X1 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 4 NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Transmission TYPE C ETIGA Ref Quantity ZX600 13262E BR ke Part No Description Spec Code oo a AN yo j 13262 13262 0535 GEAR OUTPUT LOW 36T 1 13262A e Su OPTION N A 13262A 13262 0536 GEAR INPUT 2ND 16T 1 J OPTION g 13262B 13262 0537 GEAR OUTPUT 2ND 34T 1 OPTION 13262C 13262 0538 GEAR INPUT 5TH 24T 1 OPTION 13262D 13262 0539 GEAR OUTPUT 5TH 32T 1 OPTION 13262E 13262 0540 GEAR INPUT 6TH 26T 1 OPTION 13262F 13262 0541 GEAR OUTPUT 6TH 35T 1 OPTION 13262G 13262 0684 GEAR OUTPUT 4TH 39T 1 OPTION NN es EAN 3 Keke 7 SI AD 132626 5 NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Transmission TYPE D ETIGI Ref Quantity ZX600 13262E e ke Part No Description Spec Code oo tows NR Di 13262 13262 0677 GEAR INPUT 2ND 16T 1 e NS OPTION ON 2 13262A 13262 0678 GEAR OUTPUT 2ND 36T 1 J OPTION g 13262B 13262 0685 GEAR OUTPUT 4TH 30T 1 OPTION 13262C 13262 0686 GEAR INPUT 5TH 23T 1 OPTION 13262D 13262 0687 GEAR OUTPUT 5TH 32T 1 OPTION 13262E 13262 0688 GEAR INPUT 6TH 23T 1 OPTION 13262F 13262 0689 GEAR OUTPUT 6TH 29T 1 OPTION V nu
19. 64 32099 32099A 54012 54012A 59101 59101A 92015 92026 92152 120 132 410 670 10 GRID NO This grid covers Frame Fittings Part No 31064 0187 OPTION 32099 0046 OPTION 32099 0047 OPTION 54012 0270 OPTION 54012 0271 OPTION 59101 0006 OPTION 59101 0007 OPTION 92015 1316 OPTION 92026 1586 OPTION 92152 0798 OPTION 120CA0518 OPTION 132BA0830 OPTION 410AA0800 OPTION 670B2012 OPTION Description PIPE COMP GRIP CASE UPP CASE LWR CABLE THROTTLE OPENING CABLE THROTTLE CLOSING REEL R19 3 65DEG REEL R21 0 60DEG NUT FLANGED 16MM SPACER SET COLLAR 8X16X3 5 BOLT SOCKET 5X18 Spec Code BOLT FLANGED SMALL 8X30 WASHER PLAIN SMALL 8MM O RING 12MM NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Chassis Front Fork F2349 Ref Quantity ZX600 Gi N Part No Description Spec Code 09 eel a Il 44026 44026 0141 SPRING FRONT FORK K 8 75N MM 1 ll OPTION ll I 44026A 44026 0142 SPRING FRONT FORK K 9 75N MM 1 i E 3 e e eal Ld 9 9 Fog Sei rd pg kd L4 u TE 1 H 1 I H ND Li Fog 2 Fog gt i i 2 SS amp e ra i4036 8 B 44026A Lg e tt bd DA iE d B B ef ow a N 0 1 Li Hd Wi Si v ela e e e amp EA Pb d amp 4 amp H 6 aa 11 NOV 12 2008 This catalog cover
20. 9 Water Tempereture Meter i 10 Tachometer 11 Speedometer 12 llumination Light LED Lu 13 Shift Up Indicator Light LED Meter Unit BL W O Lj L BK Y Ct i O ar R BKk LG Lei BR R TT LH IW LH LB Q Indicator Light II 5 Left Switch Housing Horn Button Passing Button Turn Signal Dimmer Switch ANSON Lap Time Button Switch Starter Lockout Switch E m BK Y L 6 6 BK Y Laza R BK BL are EdxutEe 55 E AL 1 di Hiprr on 1 Pro H H I Hi o ft Switch Housing 71 H H BR EJ x 4144 Fuse Box Fuse Box 1 EGU Fuse 10 2 Ignition Fuse 10A pees r zzzz Fl FETTA SS Starter Ground ek Motor Starter Relay Main Fuse 30A 1068848W5 C 44 Sub throttle Sensor Subthrottle Valv Actuator s BR BK BL NZR Y R R W R Y Main Throttle Sensor a BR BK BL Inlet Air Pressure BR BK G W BL Sensor 2 Gear Position Sidestand Switch l ER Inlet Air Pressure Sensor 1 sx 55 Shift Sensor s w BL Y BL BR BK BL R BK Shift Sensor A D E w t R BK BR BK BL R BK BK Y BK L Y BK Pressure Switch Crankshaft NS Sensor
21. ETAINER SPRING T 5 0 STD 1 0 6 OPTION 92025 92025 1137 SHIM 15 3X27 5X1 20 1 OPTION 92026 92026 1590 SPACER T 1 5 1 OPTION 39108 os a zu amp IPS Wa dis SW N D n P3 zs 2 92025 P d 92026 VA M ew ow 3 NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Transmission TYPE B pi Ref Quantity ZX600 N 132626 ve Part No Description Spec Code 09 ore d 13127 13127 0055 SHAFT TRANSMISSION INPUT 14T 1 OPTION 13144 13144 0047 SPROCKET OUTPUT 16T 1 OPTION 13144A 13144 0048 SPROCKET OUTPUT 15T 1 OPTION 13262 13262 0526 GEAR OUTPUT LOW 37T 1 OPTION E 13262A 13262 0527 GEAR INPUT 2ND 18T 1 et OPTION A 92022 Gei 13262B 13262 0528 GEAR OUTPUT 2ND 39T 1 13262C l L OPTION 13262C 13262 0529 GEAR INPUT 3RD amp 4TH 20T amp 20T 1 OPTION 13262D 13262 0530 GEAR OUTPUT 4TH 33T 1 OPTION 13262E 13262 0531 GEAR INPUT 5TH 20T 1 OPTION 13262F 13262 0532 GEAR OUTPUT 5TH 30T 1 OPTION 13262G 13262 0533 GEAR INPUT 6TH 23T 1 OPTION 13262H 13262 0534 GEAR OUTPUT 6TH 32T 1 OPTION 132621 13262 0679 GEAR INPUT 3RD amp 4TH 20T amp 19T 1 OPTION 13262 13262 0680 GEAR INPUT 3RD amp 4TH 17T amp 20T 1 OPTION 13262K 13262 0681 GEAR INPUT 3RD amp 4TH 17T amp 20T 1 OPTION 13262L 13262 0682 GEAR INPUT 3RD amp 4TH 17T amp 23T 1 OPTION 13262M 13262 0683 GEAR OUTPUT 3RD 32T 1 OPTION 92022 92022 1722 WASHER 22 3X3
22. NTAKE 1 OPTION 92015 92015 1078 NUT FLANGED 6MM 1 OPTION 92043 92043 1506 PIN 10X14 4 OPTION 92055 92055 011 RING O 5MM 1 12048 OPTION 92055A 92055 086 RING O 18 8X1 9 1 OPTION 132 1328 0620 BOLT FLANGED SMALL 6X20 2 132 OPTION 1 NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Crankshaft E1321 Quantity ZX600 Ref N ve Part No Description Spec Code 09 E ore d 92139 92139 0194 BUSHING CONROD BLUE AR OPTION 92139A 92139 0195 BUSHING CONROD BLACK 8 OPTION 92139B 92139 0196 BUSHING CONROD BROWN AR OPTION 92139C 92139 0269 BUSHING CRANK 1 amp 5 BLUE AR OPTION 92139 A B 92139D 92139 0270 BUSHING CRANK 1 amp 5 BLACK 4 OPTION 92139E 92139 0271 BUSHING CRANK 1 amp 5 BROWN AR OPTION 92139F 92139 0272 BUSHING CRANK 28 4 BLUE AR OPTION NS 92139G 92139 0273 BUSHING CRANK 28 4 BLACK 4 OPTION 92139 A B 92139H 92139 0274 BUSHING CRANK 42844 BROWN AR 921 PP OPTION 921391 92139 0275 BUSHING CRANK 3 BLUE AR OPTION Te pa A 92139 92139 0276 BUSHING CRANK 3 BLACK 2 OPTION mm E 92139K 92139 0277 BUSHING CRANK 3 BROWN AR A OPTION 921390 E NC NN X x z St xw KA E yp VN PA 921390 E NP Qm Us 2 NOV 12 2008 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Clutch as EE Ge Part No Description Spec Code oo is e I L2 39108 39108 0004 R
23. RATION 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 grease Swingarm pivot uni track linkage grease Swingarm pivot uni track linkage check Replace add adjust clean or torque if necessary Preparation Before Installing Modify the parts based on your race regulation To 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 1068238W2 C A Wire Net 14037 0089 Remove the secondary valves of cylinder head and relational parts then plug the four holes Remove the oil receiver and plug the hole Remove the air cleaner element or cut the cleaner element off remaining
24. Required Engine Clutch plate check Throttle grip play check Spark plug clean gap Engine oil change Oil filter replace Valve lapping Cylinder head valve decarbonization Cylinder check Piston cylinder clearance check Piston Piston ring Piston pin replace Crankshaft main bearing check Connecting rod big end bearing check Transmission gear bearing check Engine sprocket check Coolant change Radiator hoses connections check Frame Brake operation check Brake pad wear check Brake fluid level check Brake fluid change year Brake master cylinder cup and dust seal replace year Brake caliper piston seal and dust seal replace year Brake hose replace 2 years Drive chain adjust Drive chain lubricate Drive chain wear check Drive chain guide replace If damaged Front fork clean check Front fork oil change First change after 2 races then every 5 races Nut bolt and fastener tightness check Fuel system clean Fuel hose fuel filter replace Steering play check Steering stem bearing grease Rear sprocket replace General lubrication of chassis perform FREQENCY OPE
25. e CN 22 p Q S eX 13262D SS Y ba D h ANG WGK N Ku 6 NOV 12 2008 This catalog covers 09 ZX600R9FR Engine AN d NG j 11061D GRID NO This grid covers Engine Cover s E1431 Ref No 11061 11061A 11061B 110610 11061D 14031 Part No 11061 0303 OPTION 11061 0304 OPTION 11061 0305 OPTION 11061 0306 OPTION 11061 0307 OPTION 14031 0084 OPTION Description Spec Code GASKET CLUTCH COVER GASKET GENERATOR COVER GASKET OIL PAN GASKET LARGE COVER GASKET SMALL COVER COVER GENERATOR NOV 12 2008 Quantity ZX600 This catalog covers GRID NO This grid covers 09 ZX600R9FR Engine Fuel Injection pius Ref Quantity ZX600 ME yen wo Part No Description Spec Code oo fe 1 1 1 11055 11055 1665 BRACKET VDS 1 gt OPTION 21175 21175 0248 CONTROL UNIT ELECTRONIC 1 OPTION 23016 23016 0006 LAMP ASSY INDICATOR 1 OPTION 26031 26031 0240 HARNESS INTERFACE BOX 1 OPTION 26031A 26031 0327 HARNESS SUB STD METER amp HARNESS 1 OPTION 26031B 26031 0789 HARNESS MAIN STD GENERATOR 1 OPTION 26031C 26031 0790 HARNESS MAIN KIT GENERATOR 1 OPTION 27002 27002 3703 RELAY ASSY 1 OPTION OPTION GENERATOR 8 NOV 12 2008 This catalog covers 09 ZX600R9FR Engine 92210 E1810 92210 92210 de 21007 o w i d i 92152 5 92182 de 22074 92150 92152 2 92075A 92075A 42 92200 92002 di
26. ider himself should do the basic works 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 Dummy page Table of Contents General SPCC d iio o oido i qusc copiae d opio ue pa posi 4 Racing Kit Service eed e restet ec 6 Periodic Maintenance sse een annuae ahhh aa naa annu nura hahaha sans nnn 7 EE HRS 9 Before Installing i Ur E YR aia iiai 9 IIE PINS 9 Engine Parts Installation enit eaae asta Gea ete hee ae 9 Air Intake TEE 9 Cylinder E E 11 Camshaft Chain TENSIONE 12 Camshafts Sprockets i a tM o e eaa e M edt da ee 13 Valve Springs Oe das DE DE aa 14 uere e duda ed o re dle ord cade deco Se dedu uva de nes 14 Crankshaft Main Journal and Connecting Rod Big End 5 sss 16 Connecting Rod Bolts nodi prep a aee Bg Da ai BEI ation 19 Clutch Adjustment Back Torque Limiter Settmgl esses esee nnne 20 TRANSMISSION iue RE gite irt iud E ei ee cce ett ores 24 Transmission Shimming
27. ing force to take up any gap and tighten the locknut 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 106414BW3 C A Tensioner B 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 adjusted from middle value to upper limit between adjustable range Original Timing Cam Lift Valve Clearance Intake 288 8 60 mm 0 13 0 19 mm Exhaust 258 7 20 mm 0 24 0 31 mm Kit Timing Cam Lift Valve Clearance Intake 8 60 mm 13 0 1 49118 0149 288 conformed to FIM regulation e a d 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 If 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 N m 1 5 kgf m 11 0 ft lb of torque Valve Timing Valve Timing is the same when the standard camshaft and the kit camshaft are used Timing cam lift center Intake Exhaust When round bolt holes
28. l connecting rod bolt has recesses at both ends to measure its length and determine the bolt stretch 106423BW1 C 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 O Replace the original bolts with new ones if they have already been tightened up to usable range 2 times 19 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 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 TUR Clutch Thickness of plate Part Number Used Number
29. l generator is 10A 8000 rpm Original 30A 5000rpm The consume current of the racing model in running condition is 7 8A Installing Option Generator Main Harness Parts List 1 Cover 14031 0084 Kit 2 Rotor 21007 0083 Kit 3 S tartor 21003 0068 Kit 4 Washer 92200 0308 Kit 5 Bolt 92150 1717 Production part 6 Bolt 92002 1696 Protuction part 7 Bolt 92153 1574 Original 1068808W2 C Generator Cover Option Use the 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 Muffler With recommended muffler engine performance can be improved Recommended muffler Beet NASSERT R 1002 B15 00 Web Site http www beet co jp beetjapan For further information contact the manufacturer of muffler directly 25 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 Cooling System With recommended radiator engine performance can be improved MB MOTORSPORT di Bagatti Marco e Silvio amp C s a s Via Ugo La Malfa 3 43014 Felegara di Medesano PR ITALY Tel
30. lay Relay Box 228 gs 222222 rz aonaa Joint Connector 1 Vehicle down Sensor 345434 555555 zzzzzr aonaam Joint Connector 2 BL WY TE K Y 18 6 Kawasaki Diagnostic System Connector BK Y WY BK Y R W BL Interface Box Color Code BK Black BL Blue BR Brown G Green GY Gray LB Light Blue LG Light Green 0 Orange P Pink PU Purple R Red V Violet W White Y Yellow 1068838W5 C 43 Wiring Diagram with Original Meter Kit Regulator Water Temperature Right Switch Housing Sensor 1 Front Brake Light Switch Primary Fuel 2 Engine Stop Switch Injectors 22 3 Starter Button 1 2 3 4 Inlet 4 Stop Watch Button Air Right Temperature Switch Housing Spark Plugs Secondary Fuel Sensor OOOO Injectors Speed x x Meter Unit api we Se OSS SET ERIS GR Wn Lage RA e DERE SE 1 Turn Signal Indicator Light LED PFE UI Stick T m 2 High Beam Indicator Light LED S eH Coils 3 Neutral Indicator Light LED 1 4 Fuel Level Warning WENN SE EE x Indicator Light LED Wiki 25 25 sz se ES 5 011 Pressure Warning Fl H Kb ME Immobilizer Indicator Light LED 55 55 255 6 Odometer Trip Meter Stop Watch gt KE 7 Gear Position Indicator dh 8 Glock
31. marked of 09 model have interchangeability with those of 08 model Gear Identification Slit Number Table STD Type B Type C Type D Type A In 0 1 1 1st Out 0 1 2 0 1 2 3 Out 0 1 2 3 1 3rd n Out 0 1 Ath In 0 1 2 3 Out 0 1 2 3 In 0 1 2 3 5th Out 0 1 2 3 Gth In 0 1 2 3 Out 0 1 2 3 Racing Kit Service Data Item Standard Cylinder Head Valves Spark plug tightening torque Duration Intake 288 Exhaust 258 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 11 BTDC Ignition System Spark plugs R0045Q 10 RO373A 10 13 N m 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 is 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 OPERATION Each Race 300 km Every 3 races 1 000 km Every 5 races 1 500 km Every 10 races 3 000 km As
32. n frame 1 Main Harness 40 Dummy Page 41 Wiring Diagram with Original Meter Original Regulator 1 2 3 4 om 000000009 Water Temperature Right Switch Housing Sensor 1 Front Brake Light Switch faery 2 Engine Stop Switch 22 3 Starter Button 1 2 3 4 Inlet 4 Stop Watch Button Air Right Temperature Switch Housing oe o Secondary Fuel Sensor Injectors Speed o 66 X FI PE as EE Sensor Meter Unit T Fri So A S i 2 3 4 Ne d sed ed ei Sa ae Turn Signal Indicator Light LED prp L di Stick p High Beam Indicator Light LED S eH Coils Neutral Indicator Light LED H Fuel Level Warning WENN nC eee SE SE x Indicator Light LED wavzczwr 25 sz FS KH 55 Oil Pressure Warning Fl Immobilizer Indicator Light LED 55 55 AE Odometer Trip Meter Stop Watch gt 5 S Gear Position Indicator dh Glock Water Tempereture Meter i Tachometer Beas Speedometer Illumination Light LED Lu Shift Up Indicator Light LED Meter Unit BL W L Li BK Y P im H BR R BKk LG BR R TT Li LH LB Indicator Light a H 27 er
33. n surfaces Details in Section A Details in Section B S106430BW3 C 1 Stepped Portions of throttle body holder and cylinder head 2 Stepped Portions of valve seat and cylinder head The combustion chambers are modified by cutting 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 combustion chamber with the valves installed Excessive smoothing may reduce the cylinder compression 106413BW1 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 8 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 Install the tensioner on the cylinder head with the tensioner rod is fully pushed back Turn the tensioner rod in with a screwdriver until it becomes hard to turn Turn the crankshaft clockwise forcing lightly to the tensioner rod with twist
34. o 39108 0004 If clutch slip is occurred with a retainer of 6 mm try with a retainer of 5 mm 40 2 40 7 mm 6 mm 23 Standard Selection of Shim Total Thickness of Clutch Plates Size of Shim Remarks P No 92180 0149 Approx 40 7 mm 2 0 mm Original Setting 40 2 mm 1 5mm P No 92026 1590 39 5 40 mm 1 2mm 92025 1137 Transmission Remove the three steel balls 600A0500 from the output shaft assembly Take 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 Thickness Part No 1 6 mm 92200 0050 Original Spline washer input 1 8mm 92200 0231 Kit 1 4mm 92200 0230 Kit BIS WES 1 4 mm 92200 0138 Original 1 6 mm 92022 212 Production part input output 1 8 mm 92202 1722 KIt 1064268W2 C 1 Spline washer input 2 Plane washer 24 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 optiona
35. punched plate to reduce the air flow resistance e te ap pn EE 7 106824BW4 C 1 Remove the parts N Remove the parts or cut the cleaner element off remaining the punching plate 3 Secondary Air Passages on Cylinder Head Plug the holes or insert the pins 92043 1506 instead of the original pins Output of Secondary Air on Air Cleaner Plug the hole 4 Plug the hole 10 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 throttle body 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 throttle body 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 O 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 intake 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 uneve
36. r 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 base gasket O 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 Part No Thickness Note LD Color 11004 0071 0 45 mm KIT Yellow 11004 0070 0 50 mm KIT White 11004 0069 0 55 mm KIT Red 11004 0068 0 60 mm KIT Blue 11004 0085 0 65 mm Original None 11004 0067 0 70 mm KIT Green 106037BW3 C 1 Squish Front Rear 2 Squish Left Right Crankshaft Main 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 Crankshaft Main Journal Diameter 106428BW1 C 1 Crankshaft Main Journal Diameter Marks SIZE 1 mark over 30 992 mm within 31 000 mm None over 30 984 mm within 30 992 mm
37. s GRID NO This grid covers 09 ZX600R9FR Chassis Other B N oe No Part No Description Spec Code 09 e i Y 43082 43082 0074 PAD ASSY BRAKE FR 1 es OPTION Y 43082A 43082 1192 PAD ASSY BRAKE RR C93 1 OPTION 43082B 43082 1220 PAD ASSY BRAKE RR C93G 1 OPTION 55020 55020 0028 GUARD CHAIN 1 OPTION 92145 A 92145 92145 0504 SPRING SHOCKABSORBER K 95N MM 1 OPTION el f Sa 92145A 92145 0506 SPRING SHOCKABSORBER K 105N MM 1 S WOES e WRG Boden OPTION ga POR 92153 92153 1777 BOLT FLANGED 10X60 4 OPTION 130 130 1020 BOLT FLANGED 10X20 1 OPTION 43082A B 12 NOV 12 2008 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Doc No 99929 0304 01
38. 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 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 Standard Selection of Spring Retainers Total Thickness of Clutch Plates Size of Spring Retainers Remarks P No 13091 1041 Original Setting 39 5 40 2 mm 5mm P N
39. vey see 3 57 BR x S E EWELL Fuse Box Fuse Box 1 EGU Fuse 10A 2 Ignition Fuse 10A Th 1 d 1 1 pi Lei iprrow r og 55 6 5555 55 Left Switch Housing Left Switch Housing Horn Button Passing Button Turn Signal Switch Dimmer Switch Lap Time Button Starter Lockout Switch Starter Ground gi Motor Starter Relay Main Fuse 30A 1068828W5 C 42 Gear Position Sub Main Zei throttle Throttle j Sensor Sensor Stgestane 3RD Switch l ER Subthrottle Valv x wk Actuator ER 5 5 Inlet Inlet Air Air Pressure Pressure Sensor 2 Sensor 1 szt 55 Bree Shift Sensor s w S23 BR BK D BL BL Y BL BR BK BL R BK Shift Sensor A D E w t R BK BR BK Qil Pressure Switch Crankshaft NS Sensor BL R BK BK Y Regulator Rectifier Alternator BK L Y BK 4 CAT IQ Ue L J Fuse Box BK LG BK Y W R BR Y R wy UN BK Y R W BK wy em f 5 I 5 25 I 1 Fuel u BA Batt Reserve Fuel Ecu Switch Fuel Pump Main Pump Relay Re
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