Kawasaki 2006 NINJA ZX-10R User Manual

Ninja ZX-10R

2006 Ninja ZX-10R

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-10R

Motorcycle Service Manual

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Feb. 2, 2006

99924-1365-01

Congratulation on your purchase of racing kit parts for the 2006 Ninja ZX-10R.

IMPORTANT

This manual provides how to install racing kit parts for the 2006 Ninja ZX-10R and how to

tune up basically.

As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-10R (P/No.

99924-1365-01).

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.

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.

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-10R for the racing machine. We
recommend that the rider 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 ask to tuning shop.

WARNING

CAUTION

1

Table of Contents

General Specifications .........................................................................................................3

Racing Kit Service Data.......................................................................................................5

Periodic Maintenance Chart.................................................................................................5

Engine Parts Installation ......................................................................................................7

Air Intake Parts .................................................................................................................7

Camshaft Chain Tensioner................................................................................................8

Camshafts, Sprockets.......................................................................................................9

Cylinder Head.................................................................................................................11

Cylinder Compression ....................................................................................................12

Pistons............................................................................................................................13

Crankshaft Main Journal Bushings .................................................................................15

Connecting Rod Bolts .....................................................................................................17

Connecting Rod Big End Bushings.................................................................................19

Clutch Adjustment (Back-Torque Limiter Setting) ...........................................................20

Transmission ..................................................................................................................26

Alternator ........................................................................................................................28

Water Temperature Sensor.............................................................................................32

Radiator (Kit) ..................................................................................................................32

Oil Catch Tank (Kit).........................................................................................................36

Cover Gaskets (Kit) ........................................................................................................38

ECU (Kit) ........................................................................................................................38

Frame Parts Installation.....................................................................................................39

Throttle Parts (Kit Parts) .................................................................................................39

Final Drive Parts (Kit Parts) ............................................................................................40

Brake Pads (Kit Parts) ....................................................................................................40

Seat Height Adjustment ..................................................................................................41

Front Fork Springs (Kit Parts) .........................................................................................43

Electrical System ...............................................................................................................45

Battery ............................................................................................................................45

Main Harness and Sub Harness (Kit Part)......................................................................45

Wiring Diagram (with Original Meter)..............................................................................54

Wiring Diagram (with Kit Meter)......................................................................................56

2

General Specifications

Item 2006 Ninja ZX-10R Racing

Engine:

Ignition timing 10°BTDC @1 100 r/min (rpm)
Fuel (Recommended) Racing gasoline
Engine oil (Recommended): Racing oil
Level Between upper and lower levels of oil level gauge.

Drive Train:

Primary drive reduction ratio 1.611 (87/54)

Transmission Gear Table

STD（Type A） Type B Type C Type D

1st

2nd

3rd

4th

5th

6th

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

In
Out
Teeth (Out/In)
Gear Ratio

13127-0020
13262-0170

38/15

2.533
13262-0185
13262-0152

39/19

2.053

See Gear

Selection

13262-0182

33/19

1.737

See Gear

Selection

13262-0166

32/21

1.525

13262-0135
13262-0183

29/21

1.381

13262-0136
13262-0171

30/23

1.304

13127-0030
13262-0267

31/13

2.385

-

-

-

-

See Gear

Selection

13262-0268

34/19

1.789

See Gear

Selection

13262-0269

31/20

1.550

13262-0265
13262-0270

29/20

1.450

13262-0266
13262-0271

29/21

1.381

13127-0031
13262-0275

34/14

2.429

-

-

-

-

See Gear

Selection

13262-0276

28/16

1.750

-

-

-

-

13262-0273
13262-0277

28/20

1.400

13262-0274
13262-0278

28/21

1.333

13127-0032
13262-0281

37/16

2.313
13262-0279
13262-0282

36/18

2.000

-

-

-

-

-

-

-

-

13262-0135

(STD)

13262-0351

30/21

1.429
13262-0280
13262-0283

28/22

1.273

3

Input 3rd/4th Gear Selection Table

4th Gear

A (=C) B

3rd Gear

A 13262-0134 (19/21) 13262-0286 (19/20)
B 13262-0284 (19/21) 13262-0264 (19/20)
C 13262-0272 (16/21) 13262-0285 (16/20)

Gear Identification Slit Number Table

Standard (Type A) Type B Type C Type D

1st

Input 0 2 3 4

Output 1 2 3 4

2nd

Input 1 - - 2

Output 1 - - 2

3rd

Input 1 2 0 -

Output 0 2 3 -

4th

Input 0 1 - -

Output 2 1 - -

5th

Input 2 0 3 -

Output 1 0 3 2

6th

Input 1 2 3 4

Output 0 2 3 4

Engine Sprocket

13144-0021 #520-16T
13144-0022 #520-17T

4

Racing Kit Service Data

Item Standard

Cylinder Head, Valves:

Valve timing:
Duration:
Intake 300°
Exhaust 292°
Camshaft timing (cam lift center):
Intake 104° (ATDC)
Exhaust 102° (BTDC)
Valve clearance:
Intake 0.22 mm
Exhaust 0.20 mm
Squish 0.85 mm
Valve to piston clearance:
Intake 1.45 mm @10°ATDC
Exhaust 1.80 mm @10°BTDC

Ignition System:

Spark plugs

Spark plug tightening torque 13 N·m (1.3 kgf·m, 113 in·lb)

These values show the specifications when standard cylinder head and gasket are used.

NGK CR9EIA-9 (STD), R0045Q-10 or
R0373A-10

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the

motorcycle in good running condition.

FREQENCY
OPERA TION
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 ring, piston, and piston pin - - replace

(When pistons 13001-0077 are used)

Piston ring, piston, and piston pin - - replace

(When pistons 13001-0078 are used)

Crankshaft main bearing - - check* ●

Each
Race

Every

2 races

●

Every

3 races

●

Every

5 races

Every

10 races

As

Required

5

FREQENCY

OPERATION

Each
Race

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

Brake caliper piston seal and dust seal - -

replace

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 ●

Wheel bearing (rear) - - grease ●

Swingarm pivot, uni-track linkage - - grease ●

Swingarm pivot, uni-track linkage - - check* ●

Every

2 races

Every

3 races

Every

5 races

Every

10 races

As

Required

year

year

*: Replace, add, adjust, clean, or torque if necessary.

6

Engine Parts Installation

Air Intake Parts

 Remove the air cleaner element or cut the cleaner element off remaining the wire net to

reduce the air flow resistance.

○When removing the air cleaner element, remove the element and relational parts as

shown below.

1. Relational Parts of Secondary Air: Remove the Parts.

2. Remove the parts or cut the cleaner element off remaining the wire net.

3. Secondary Air Passages on Cylinder Head: Plug the holes, or press-fit the plugs
(92066-1005) instead of the original pins.
Output of Secondary Air on Air Cleaner: Plug the hole

4. Air Cleaner Drain Tube: Use it cutting it in suitable length.

7

Camshaft Chain Tensioner

 Replace the cam chain tensioner with the kit to decrease the flutter of tensioner.
 Apply the engine oil to the tensioner rod, O-ring and tensioner body, insert them into the

tensioner body.

○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 × Pitch = 6 mm × 1.0
mm).

 Install the tensioner on the cylinder block 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 twisting force to

take up any gap and tighten the locknut.

 After adjusting the tensioner rod、if the tensioner rod does not stick out from the tensioner

body, use the kit long tensioner rod (13116-1166).

NOTE

○Never forward the tensioner rod forcibly, this will increase mechanical loss of the

tensioner and may damage to the chain guide.

○The cam chain tensioner must be adjusted at every race.

1. Tensioner Body 4. O-ring

2. Tensioner Rod: 13116-1166 (Kit) 5. Locknut

3. O-ring

8

Camshafts, Sprockets

Camshafts, Sprockets:

Camshaft Duration Lift
49118-0008 (STD) (Intake) 300° 9.1 mm
49118-0045 (STD) (Exhaust) 292° 8.5 mm
49118-0034 (Kit) (Intake) 310° 9.7 mm
49118-0077 (Kit) (Exhaust) 280° 8.0 mm

 Use the kit valve springs (49078-0049) when the kit exhaust camshaft (49118-0077) is

used.

○Install the kit valve springs facing the rough coiled side (pink paint end) to the retainer.

 Adjust the valve clearance within the specified value. Intake: 0.15 ~ 0.24 mm, Exhaust:

0.17 ~ 0.22 mm

 More performance is expected when adjusted from middle value to upper limit between

adjustable range.

 If you can not adjust the valve timing for racing, install the camshaft sprocket to the

camshaft using the round bolt holes and adjust the cam chain timing according to the
Ninja ZX-10R 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 ft·lb) of torque.

Valve Timing

Timing (cam lift center) Intake Exhaust
When the round bolt holes are used
(Original)

(Original camshaft)

When the long bolt holes are used

○When grinding the cylinder head bottom surface, grinding the cylinder top surface or

using thinner gaskets, be sure the valve to piston clearance especially.

○When 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.

Valve to Piston Clearance (Min.)

Intake 0.7 mm

Exhaust 1.2 mm

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.

Adjust the valve timing again to keep the valve to piston clearance more than the
minimum value.
 Method of measuring clearance of valve and piston –1.

○Holding the crankshaft at 10° ATDC (intake) and 10° BTDC (exhaust) of crankshaft

timing, measure the amount of the tappet movement until the valve comes in contact
with the piston pushing the tappet.

104°

108°

(Kit camshaft)

102°

(Original or Kit camshaft)

102°

(Original or Kit camshaft)

9

 Method of measuring clearance of valve and piston –2.

○Adjust the valve clearance and valve timing.
○Remove the cylinder head, and put a small piece of modeling clay on the hollow of piston

to prevent valve from coming in contact.

○Install the cylinder head and adjust the camshaft chain timing.
○Turn the crankshaft by two rotations or more.
○Remove the cylinder head and measure the thickness of the clay. The thickness of the

collapsed clay is a clearance of the valve and the piston.

10

Cylinder Head

 Before reassemble the cylinder head grind off the stepped portions of the port and

smooth the inside of ports to make intake/exhaust gas flow smooth.

○Grind off the stepped portions only at the mating surface between the carburetor holder

and the intake port.

○When using the kit camshaft (49118-0034), grind off the inside of the intake port to extent

1mm from the original port diameter for improve the performance.

○Mark the carburetor holders so that they can be installed in their original positions.
○Grind off and smooth the stepped portions at the mating surface between the valve seat

and the port.

○Smooth the inside of the intake port and exhaust port.

 Chamfer the machining edge of the cylinder head where the valve seat installed, also

smooth the dome of the combustion chamber with the valves installed. Excessive
smoothing may reduce the cylinder compression.

 Use the hand grinder.

○Use #200 oil stone for eliminating any stepped portion and #300 oil stone for finishing.

NOTE

○These procedures make air resistance less and intake/exhaust gas flow more smooth.

However, much more ef fect can not be expected by excessive grinding and smoothing. It
may be done to the extent of getting rid of uneven surfaces.

A: Stepped Portions B: Grind off the rib to 5 mm
╳: Grind Area ( All around port )

11

 The combustion chambers are modified by cutting work but the edges shown must be

hand finished for smooth corners.

NOTE

○When grinding the cylinder head surface or using thinner gasket, adjust the valve timing

to keep that the valve to piston clearance is not less than the minimum value (IN: 0.7 mm,
EX: 1.2 mm).

Cylinder Compression

 To adjust the cylinder compression, adjust the thickness of the cylinder head gasket or

smooth the cylinder head under surface or cylinder top surface to make the piston squish

0.65 mm. Keep the piston squish more than 0.65 mm.

○Grind off the cylinder head under surface to 0.4 mm. Do not grind the cylinder upper

surface. This can raise the compression ratio while keeping the clearance of the piston
and valve, and one of the squish. Although, as the engine machining is uneven,
determine the cutting dimension after keeping the recess and the squish before
machining.

○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.

○Remove the cylinder head and measure the thickness of the clay. The thickness of the

collapsed clay is the size of the squish.

○The most preferable squish measurement is 0.65 mm.
○Select proper cylinder head gasket.

Cylinder Head Gasket

Part No. Tightening thickness Remarks
11004-0026
11004-0052 0.60 mm KIT
11004-0022 0.55 mm KIT
11004-0034 0.50 mm KIT
11004-0023 0.45 mm KIT

0.65 mm（STD）

KIT

12

Pistons

Kit Piston: SB
(1) 13001-0077
 Kit pistons are exclusive the two piston rings for reduce the compression height

(between the center of piston pin hole and the shoulder of the piston) and the
mechanical friction loss.

 Kit piston has more reduced the weight compared the original piston.
 To adjust the cylinder compression to 14.3, use the kit pistons and grind off the cylinder

head under surface to 0.4 mm.

○Always use the higher octane rating gasoline for prevent the knocking.

 Use the kit piston rings and kit piston pins.
 When replacing the kit pistons with the original pistons, inspect the squish (refer to the

Cylinder Compression section).

13

(2) 13001-0078
 Kit pistons are exclusive the two piston rings for reduce the compression height

(dimension between the center of piston pin hole to shoulder of the piston) and the
mechanical friction loss.

 Kit piston has more reduced the weight compared the original piston.
 To adjust the cylinder compression to 14.5, use the kit pistons and remodel the original

cylinder head.

 Use the kit piston rings and kit piston pins.
 When replacing the kit pistons with the original pistons, inspect the squish (refer to the

Cylinder Compression section).

 Remodel the cylinder head according to the following figure.
 The specified squish is 0.60 to 0.65 mm: front and rear, and 0.60 to 0.67 mm: left and

right side.

 Replace the cylinder head gasket with the thinner or thicker one or grind the side squish

portions of the combustion chamber and the piston head with the emery cloth if the
squish is without the specified range.

Note: Remodel the cylinder head following below.

○Grind the around the valve seats in the combustion camber until taking up the edges and

smoothing, and then polish the combustion chamber lightly. Do not polish too much
because the cylinder compression decreases.

○At this time, do so as not to damage the valve seat with the valve installed.
○Do not damage the 90°valve seating surface during the cylinder head modification.

14

Note: Use the kit pistons (13001-0077, -0078) following below.

○Use the kit connecting rod assemblies (13251-0015).
○Use the kit piston rings (13008-0019).
○There are the machining edges for the valve relief portions of the piston heads. Must be

hand finished for smooth corners. (Round the corner to R1)

Crankshaft Main Journal Bushings

The kit bushings are improved in anti-seizuring characteristics as well as in

wear-resistance as compared with the standard bushings.

Crankshaft Main Journal Clearance

※ When adjust the clearance by measurement in case aiming the clearance 0.035 mm.

15

Crankshaft Main Journal Diameter Marks

None: 34.984~34.992 mm
“1” Mark: 34.993~35.000 mm

None [C]
1: [D]

Crankcase Main Bearing Inside Diameter Marks

○: 38.000~38.008 mm

None: 38.009~38.016 mm

Mark portion: # 1~5

Crankshaft Main Journal Bushings

Color

Kit Bushing

#1.5

Kit Bushing

#2,3,4

Standard Bushing

#1.5

Standard Bushing

#2,3,4

Blue 92139-0146 92139-0149 92139-0029 92139-0032

Black 92139-0147 92139-0150 92139-0030 92139-0033

Brown 92139-0148 92139-0151 92139-0031 92139-0034

[A]: Color Mark

Thickness

1.503〜1.499
mm

1.499〜1.495
mm

1.495〜1.483
mm

16

Crankshaft Main Journal Bushing Selection

Crankshaft 1 1 None None
Crankcase

○

None

○

None
Crankshaft Main Journal Bushing Brown Black Blue
Clearance (recommend) 10 ~ 34 µm 10 ~ 34 µm 10 ~ 34 µm

NOTE

○Make the clearances between the crankshaft main journals within the prescribed

allowances. Excessive clearances will cause the oil pressure at the crankshaft main
journals to drop and lead to the damage of the bearing.

Connecting Rod Bolts

1. Original Connecting Rod
Use the original connecting bolts and nuts.
Make recesses at both ends of the original connecting rod bolt to measure its length and

determine the bolt stretch.

Connecting Rod : 13251 – 0019
Bolt : 92153 – 0491
92153 – 0809 (Spare Part : Attached Recess)
Nut : 92015 - 1311

 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 and seating

surfaces of nuts and bolts.

 Tighten the big end nuts at the torque (reference torque) of 20 N·m (2.0 kgf·m, 14.5 ft·lb).
 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. 32 mm (0.0126 in.) target

 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.

○Replace the bolts with new ones if they are used for the engine with a not clear feature.

17

2. Kit Connecting Rod
Connecting Rod Bolt
Use the kit connecting rod bolts (with the original connecting rod bolts) and nuts.
The kit connecting rod can use the original connecting rod bolt (92153-0491).
When using the original connecting rod bolts, make recesses at both ends of the original
connecting rod bolt to measure its length and determine the bolt stretch.
Connecting rod : 13251 – 0015
Bolt : 92153 – 0809 (Attached Recess)
Nut: 92015 - 1311

※Installation of the kit connecting rod bolt is same as installation of the original connecting

rod bolt in the 1. original connecting rod section. Refer to the 1. original connecting rod
section.

18

Connecting Rod Big End Bushings

The connecting rod bushing in the kit has improved its anti-seizure feature than standard

one.
Connecting Rod Big End Bushing/Crankpin Clearance
※When adjust the clearance by measurement in case aiming the clearance 0.050 mm.

Crankpin Diameter Marks

○: 34.493~34.500 mm
None: 34.484~34.492 mm

Connecting Rod Big End Bore Diameter Marks

○: 37.509~37.516 mm
None: 37.500~37.508 mm

[A]. Diameter Mark (○ or no mark)
[B]. Weight Mark (Alphabet, E, F et)

Connecting Rod Big End Bushings

Color

Kit Bushing Part

Thickness

Number
Blue 92139-0109 1.488 ~ 1.493 mm
Black 92139-0110 1.483 ~ 1.488 mm
Brown 92139-0111 1.478 ~ 1.483 mm
Pink 92139-0156 1.473 ~ 1.478 mm

[A]. Color Mark

Big End Bushing Selection

Crankshaft
Connecting Rod None

○ ○

○

None None
None

○

Bushing Brown Black Blue
Clearance (recommend) 34 ~ 60 µm 32 ~ 58 µm 30 ~ 56µm

※Use the pink bushings when the clearances cannot adjusted within the prescribed

allowances even if the brown bushings are used.

NOTE

○Make the clearances between the connecting rod big ends within the prescribed

allowances. Excessive clearances will cause the oil pressure at the connecting rod big
end to drop and lead to the damage of the bearing.

19

Clutch Adjustment (Back-Torque Limiter Setting)

The Ninja ZX-10R 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.

 The standard setting of length [A], total thickness of clutch plates shown below, becomes

about 53.5 mm (t 2.9 × 7 pcs. + t 2.6 × 2 pcs.). 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 51.9 and

53.5 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 is not
enough replace other steel plates one by one.

Thickness (mm) Part Number

1.6 13089-0005

2.3 13089-0008 (STD)

2.6 13089-0009 (STD)

2.9 13089-1093 (STD)

※ The steel plate (t 1.6 13089-0005) is the standard part for ZX-6RR.

20

When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers
(provided as optional production parts) to keep the preload of clutch springs according to
the table below.

Length [A] Part Number Height [H]

53.0 ~ 53.5 mm 13091-1840 8 mm

52.5 ~ 52.9 mm 13091-1041

＋Washer (92022-304)

51.9 ~ 52.4 mm 13091-1041 6 mm

※ Washer (92022-304) = Outside Dia. 11 mm

Inside Dia. 6.2 mm
Thickness 1.0 mm

※ If you have clutch slip during acceleration use shorter spring retainers by one size to

increase preload of clutch springs.

 The original springs and retainers can be used if the length [A] is between 51.9 ~ 53.5

mm.

 For precise setting the measurement of the effective stroke of clutch spring plate is

recommended.

• Remove oil from clutch plates.

• Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.

7 mm

(6 mm＋1 mm)

21

[A] Spacers [G] Friction Plates (48 Slots)
[B] Needle Bearing [H] Steel Plates (t 2.6 mm)
[C] Bushing [I] Washer
[D] Clutch Housing [J] Spring
[E] Clutch Hub [K] Friction Plates (36 Slots)
[F] Sub Clutch Hub [L] Steel Plates (t 2.9 mm)
[M] Spring Plate
[N] Spring Retainer

22

• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub).

• To measure the effective stroke of clutch spring plate, set a dial gauge [A] against the

raised center [B] of the clutch spring plate.

• 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

 After installing the clutch to the engine, measure and record the depth [B] shown below,

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] 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.

23

Spring Plate Assembly

The spring plate assembly are available for increase the spring constant. When outbreak
the starting judder, use the spring plate assembly of the kit parts. Whenever the plate
thickness is difference for adjusting the clutch plate, take care the length [A].

Part Number Spring Constant ID Color

13089-0003 2004 ~ 2005 ZX-10R (Standard) None

13089-0011 40 % up comparison standard White
13089-0012 60 % up comparison standard Blue

※Identification Color: The ID marks are on the springs between the steel plates.

24

[A] Spacers [G] Friction Plates
[B] Needle Bearing [H] Spring Plate Assembly
[C] Bushing [I] Steel Plates
[D] Clutch Housing [J] Spring Plate
[E] Clutch Hub [K] Spring Retainer
[F] Sub Clutch Hub

25

Transmission

 Type B ~ D of the kit gears are available of the 2006 model ZX-10R. To change the gear

ratios with combination the gears.

 Remove the three steel balls (600A0500) from the output shaft assembly. This is done to

start easily the engine with the second gear.

 Replace the circlips with new ones if they were removed.

Transmission Shimming

By using washers with various thickness, keep the axial clearance between 0.3 mm and

0.4 mm, to prevent the inclination of gears and to keep smooth gear-shifting.

Thickness (mm) Part No. Remarks
① Spline washer

1.2 92200-0229 Kit

1.4 92200-0230 Kit

1.6 92200-0050 Original

1.8 92200-0231 Kit

2.0 92200-0232 Kit

② Plane washer A

0.8 92200-0225 Kit

1.0 92200-0226 Kit

1.2 92200-0051 Original

1.4 92200-0227 Kit

1.6 92200-0228 Kit

③ Plane washer B

1.4 92200-0138 Original

26

Use the type B ~ D input shafts with the shim adjustment since their sizes are, different from
the standard shaft, designed taking the shim adjustment into account in order to make the

rd

dog lengths of the 3

– 5th & 2nd – 6th gear dogs equal. Adjust the dog length of each gears

to smooth gear-shifting.

Standard Adjusting

①-2 Use the standard spline washer t1.6 mm (92200-0050)
②-2 Use the standard spline washer t1.2 mm (92200-0051)

When thin the washer of ①-1 (②-1) from the standard washer and thickly the washer of ①

-2 (②-2) from the standard washer to increase the dog length of gears also reverse the
combination to reduced the dog length of gear.

27

Alternator

Racing kit of the 2006 model ZX-10R are available the alternator. To quicken response by
reducing the flywheel mass and to reduce the weight, use the kit alternator. Also use the kit
alternator improve the engine ability

Kit Alternator Rated Output
10 A @ 8 000 rpm (original: 30 A @ 5 000 rpm)

※Effective current 7~8 A for running the race method vehicle.

 Select and use the kit alternator or original alternator for racing conditions.

1. Kit Alternator Installation

When using the kit alternator, remove the related parts of the original alternator, and
changing the around parts of the starter from original parts to kit parts. Install the kit
alternator as shown in the illustration.

Used Parts Table

Part Name Part No. Remark
1 Cover 14031-0063 Kit
2 Rotor 21007-0083 Kit
3 Stator 21003-0044
4 Washer 92200-0306 Kit
5 Bolt 92153-0386 Kit
6 Bolt 92151-1546 Kit
7 Bolt 92150-1717 Original

21001-0042

Kit

28

Stator Installation

The stator is fixed to the cover (14031-0063) by the bolts.
Run the alternator lead from the inside of the cover as shown in the illustration.

A. Fix the stator to the cover by the bolts.

Regulator Installation
Use the kit alternator and the kit regulator (21066-0010) as a set. Install the kit regulator
same position of the original regulator. Connect the kit sub harness (26031-0323) between
the kit regulator and the kit alternator.

29

2. In case of without Starter Motor

※ Refer to the illustration of 1. Kit Alternator Installation.

Remove the related parts of the starter motor and insert the plugs to the hole of the
starter motor inserted as shown in the illustration.

1. Remove the parts.

30

r

Part Name Part No. Remark

1 Plug 92066-1332 Kit
2 Plug 92066-1333 Kit
3 O-ring 92055-1262 Kit
4 Bolt 130G0625 Kit
5 Nut 312B0600 Kit

 Calk the bolt for unplug the plug.
 Insert the plug into the hole of the starter moto

and tighten the nut.

 Apply liquid gasket.

 Replace the pulsing rotor with the kit rotor

(21007-0085).

1. Rotor: 21007-0085 (Kit)

2. Collar: 92143-1291 (Kit)

3. Washer: 92200-0238 (Original)

4. Bolt: 92153-1521 (Original)

31

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.

Radiator (Kit)

2006 model ZX-10R racing kit provides the sub radiator (39060-0030) to improved the
cooling function.

Radiator Installation

Sub Radiator
 Cut the brackets at the bottom of the main radiator.

A. Cut the brackets.

 Install the sub radiator stays as shown in the illustration.

○ Fix the center kit stay (35063-0316) on the crankcase by the bolt.
○ Fix the right side kit stay (35063-0317) on the starter cover [A] by the bolt.
○ Fix the left side kit stay (35063-0318) on the alternator cover [B] by the bolts.

※ If the stay contacts to the around parts, grind the stay to privent the contact.
※ As some stays may not be able to install according to the applied muffler, remodel the

stay or make suitable one by your owe.

32

 Connect the main radiator and sub radiator with the brackets (11054-0459).

○ Fix the brackets (11054-0459) on the sub radiator by the bolts (130L0612).

 Fix a wire netting in front of sub radiator for prevent the fin damages due to the stepping

stone.

 Machine the original cowl to meet the outline of radiator.
 Fill the space between the cowl and the sides of radiator by fixing a sponge or the like.

NOTE

○After radiator ’s installation, be sure to check that there is no interference between the

radiator and the manifold, tire and the front fork full bottomed.

33

Water Pipe Installation
Use the main radiator only.
 Divide the original water hose (39062-0109) between the cylinder head and the radiator

and insert the water pipe (39192-0011).

 Install the kit water temperature sensor (for water temperature gauge of kit meter,

21176-1099) to the kit water pipe.

 Pinch the terminal of the kit water temperature sensor ground lead (26011-0071)

between the water hose and the kit water pipe and clamp it on the hose as shown in the
illustration. Install the other side terminal of the ground lead with the crankshaft sensor
cover by the bolt.

Water Outlet of Radiator Body

Same situation of the original radiator.

34

Use the kit sub radiator with the main radiator.
Water Inlet of Radiator Body
 Divide the original water hose (39062-0109) between the cylinder head and the radiator

and insert the water pipe (39192-0039).

 Install the kit water temperature sensor (for water temperature gauge of kit meter,

21176-1099) to the kit water pipe.

 Pinch the terminal of the kit water temperature sensor ground lead (26011-0071)

between the water hose and the kit water pipe and clamp it on the hose as shown in the
illusturation. Install the other side terminal of the ground lead with the crankshaft sensor
cover.

Water Outlet of Main Radiator

Remove the original water pipe (39192-0029) and install the kit water pipe (39192-0038).

Install the kit water hose (39062-1072) between the water pipe and the kit sub radiator.

Reserve tank Installation

When using the radiator (Kit), the original reserve
tank cannot be used. Prepare a suitable substitute
reserve tank.
Reserve Tank should be equipped with a band so
as not to affect the running and the handling.

NOTE

○Capacity of a reserve tank should be more than 200 cc.
○Position of the hose to a reserve tank.

* End of the hose to the radiator should be always in the coolant.

* End of the hose to atmosphere should be always beyond the coolant surface.

35

Oil Catch Tank (Kit)

Use the oil catch tank for the engine blowby gas.
Oil Catch Tank: 52001-0002
Tank Capacity: Approximately 570 cc

Oil Catch Tank Installation

 Install the mounting bracket (11054-0455) with regulator under the cross pipe of the

frame by the bolts (use the original regulator mounting bolts).

 Install the oil catch tank to the bracket as shown in the illustration.

Used Bolts: 132L0608 (x2)

 After installing the oil catch tank, make sure not to interface with the drive chain,

swingarm (suspension at fully bottomed).

 Close the boss of oil drain of the oil catch tank with M6 bolt and washer (92022-304), add

the wiring not to be missing.

Oil Catch Tank Hose Installation

1 92192-0226 Crankcase to oil catch tank
2 92192-0227 Oil catch tank to air cleaner

 Remove the original breather hose (92192-0237).
 Install the hose clamps so that the kit clamps (92171-0338) are catch tank side and the

original clamps (92171-0391) are other side on the hoses.

 Run the hoses as shown in the illustration.

NOTE

○Protect the hose and check the no blockade at the its curved part when the hose is afraid

of interfering with edge part on the way of the hose routing. Specially, about the hose
toward the crankcase, check the no blockage by the fuel pump.

36

37

Cover Gaskets (Kit)

The kit cover gasket are available of the 2006 model ZX-10R.
They are made from “metal-foam” and made easy to separate.
Starter Clutch Cover: 11061-0230
Idle Gear Cover: 11061-0229
Clutch Cover: 11061-0232
Oil Pan: 11061-0233
Alternator Cover: 11061-0231

ECU (Kit)

The 2006 model ZX-10R kit ECU has following functions. Refer to the Kawasaki FI
Calibration Tool Instruction manual for the ECU function set up method.

1. Auto Shift Functions

Be sure use the point type sensor.
Recommended: Dynojet mode or Battle Factory mode

Part installation is refer to the Electrical Part Installation section in this Manual.

2. Pit Road Engine Revolution Limit Functions
ON/Off Changing Switch Part Number: 27010-0040 (use the kit meter)

Part installation is refer to the Electrical Part Installation section in this Manual.

3. Shift Indicator Functions

Part installation is refer to the Electrical Part Installation section in this Manual.

NOTE

○When using the original meter, lit the shift up indicator light so that the shift up indicator

lamp of the kit does not used.

○Use the shift up indicator lamp of the kit together with the kit meter but do not function as

the FI indicator light.

38

Frame Parts Installation

Throttle Parts (Kit Parts)

The following throttle cases, grip and reels are available as kit parts. These kit parts
quicken throttle response to the twist grip.

1) Throttle Case

Parts P/No.
Throttle Case, Upper 32099-0004

Throttle Case, Lower 32099-0005

Bolts (2) 120S0625

Grip, Right 46075-1143

2) Throttle Reels

Tow types are available.

P/No. I.D. Mark

59101-0001 R21.5 60°

59101-0002 R20.0 65°

Twist Grip Turn Angle

to Full Throttle

Throttle Reel Travel Angle················Effective angle excluding throttle cable free play.

1. Identification Mark

1. Upper Case: 32099-0004

2. Lower Case: 32099-0005

3. Reel, 60°: 59101-0001

4. Reel, 65°: 59101-0002

5. Throttle Cable, Acceleration: 54012-0185

6. Throttle Cable, Deceleration: 54012-0186

7. Bolt: 120S0625

8. Install the upper case and lower case which mating clearance backward.

39

Final Drive Parts (Kit Parts)

1) Drive Chain

#520 Joint endless drive chain is available as an kit parts.

2) Chain Guard

1. Guard: 55020-0236

2. Bolt: 130J1020

3. Swingarm (Left Side)

Brake Pads (Kit Parts)

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 higher braking force.

Front Brake Pads

P/No. Mark Braking Force

43082-0005 F9633 High

Original C93YT ↨

43082-1293 C93ZM Low

(ZX-6RR Original)

NOTE

○ Removing the plate (13271-0365) from original front brake pads of ZX-10R is

permissible.

Rear Brake Pads

P/No. Mark Braking Force

Original FO GG High
43082-1220 C93G ↨
43082-1192 C93 Low

40

Seat 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 ft·lb) of torque.
 When changing the seat height, adjust the spring preload of the rear shock absorber.

○ As the rear suspension tends to be softer when raising the seat height with the adjusting

spacer of the seat height applied, adjust the spring preload of the rear shock absorber as
required.

○ One turn of the spring adjusting nut changes the spring length by 1.5 mm.

41

Seat Height Adjustment

42

Front Fork Springs (Kit Parts)

The kit front fork springs are available for racing.

1) Front Fork Specifications

Items Original

Rebounded damping setting (Upper) 9th (0 ~ -11)
Compression damping setting (Lower) 7th (0 ~ -13)
Fork oil KAYABA KHL 15-10
Fork oil level 111 mm
Oil lock Oil lock piece
Oil seal – – –
Spring length 230.1 mm (mount), 232.1 mm (free)
Spring constant 8.8 N/mm
Spacer length 101 mm
Sub spring stroke 20.5 mm

2) Front Fork Spring

P/No. A × B × C (mm) Number of Wiring Spring Constant

Original 4.7 × 28.7 ×232.1 14.6 K = 9.25 N/mm
44026-0091 4.8 × 28.5 ×232.1 14.8 K = 9.5 N/mm

44026-0092 4.8 × 28.5 ×232.1 14.1 K = 10.0 N/mm

44026-0093 4.9 × 28.3 × 232.1 14.7 K = 10.5 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 following ID marks are on the springs.

Spring

ID Mark (Smaller

diameter end side)

44026-0091 (K = 9.5) One slit
44026-0092 (K = 10.0) Two slit

44026-0093 (K = 10.5) Three slit

43

Fork Spring Installation

44

Electrical System

Battery

Use the original battery with 12 V 10 Ah or more capacity.

Main Harness and Sub Harness (Kit Part)

Main harness and sub harness are available for racing use as kit parts. Select one of them
in accordance with your race regulation.

Main Harness (with Original Meter and Kit Meter): 26031-0328
Sub Harness (with Original Meter): 26031-0425
Sub Harness (with Kit Meter): 26031-0426

Meter (Kit Parts) Installation

1. Shift Up Indicator Lamp (Kit): 23016-0006

2. Tachometer with Water Temperature Gauge (Kit): 25031-1142

3. Damper (Kit): 39156-0098

4. Meter Bracket (Kit): 11053-1673

5. Collar (Kit): 92152-0058

6. Rivet (Kit): 92039-1106

7. Bracket (Kit): 11053-0423

8. Bracket (Kit): 11053-0424

9. Bolt (Kit): 130J0618

10. Nut (Kit): 92015-1233

11. Ram Air Duct (Original): 39045-0015

 Insert the three collars [5] into the damper [3].
 Insert the rivet [6] from the backside of the meter bracket [4] and fix them.
 Install the bracket [4] to the original air duct [11].

45

Main Harness Combination Parts Table

Use the kit main harness or sub harness with the following parts as a set.

Parts

Main Harness

(26031-0426)

Main Harness

(26031-0425)

Sub Harness

(26031-0427)

Meter Assembly (Original)

Tachometer with Water temperature Gauge (Kit)

Water Temperature Gauge Lead (Kit)

Water temperature sensor (Kit)

Relay Box (Kit)

NOTE

○ When using the main harness (26031-0425, 0426), relay box (27002-1062) required.
○ When using the sub harness (26031-0427) no kit parts required.

○ ╳ ○

╳ ○ ╳
╳ ○ ╳
╳ ○ ╳

○ ○ ╳

Removal Parts

When using the kit main harness (kit meter: 26031-0425), the following original parts are

not required.

Original Main Harness
Meter Assembly
Bracket (Rear View Mirror & Meter Assembly)
Ignition Switch
Left Switch Housing
Rear Brake Light Switch
Side Stand Switch
Relay Box
Turn Signal Relay
Head Light, Tail/ Brake Light
License Plate Light
Front Right Turn Signal Light
Front Left Turn Signal Light
Rear Right Turn Signal Light
Rear Left Turn Signal Light
Horn

46

When using the kit main harness (Original meter: 26031-0426), the following original

parts are not required.

Original Main Harness
Ignition Switch
Rear Brake Light Switch
Side Stand Switch
Relay Box
Turn Signal Relay
Head Light, Tail/ Brake Light
License Plate Light
Front Right Turn Signal Light
Front Left Turn Signal Light
Rear Right Turn Signal Light
Rear Left Turn Signal Light
Horn

Kit Meter

When using the kit tachometer with water temperature gauge, the following kit parts, kit

main harness (26031-0425) are required.

Tachometer with Water Temperature Gauge (Kit): 25031-1142
Water Temperature Gauge Lead (Kit): 26011-1779
Water Temperature Gauge Ground Lead (Kit): 26011-0071
Water Temperature Sensor (Kit): 21176-1099

47

Kit Main Harness Installation

48

1. To throttle bodies connector (Brown).

2. Intake Air Temperature Sensor (Black)

3. Frame Ground

4. Regulator

5. Starter Relay

6. To front sub harness connector (26031-0307 or 26031-0308).

7. Camshaft Position Sensor (Gray)

8. Ignition Coils (Gray)

9. Camshaft Position Sensor

10. Connect to the ignition coil (with tape from #1 to #4)

11. Auto Shifter (Blue)

12. White Connector (do not use)

13. Fuel Pump (Black)

 Remove the original main harness from the frame.
 Install the kit main harness (26031-0425, 0426) as shown in the illustration.
 Use the original part for the [8] battery ground cable.
 Connect the [9] camshaft position sensor connector to the camshaft position sensor at

the cylinder head front side.

 When using the recommended auto shifter to connect the [11] auto shifter connector.

NOTE

○ When using the kit tachometer, always connect the water temperature sensor connector

at the cylinder head rear side.

○ For recommended auto shifter, refer to the Kawasaki FI Calibration Tool Instruction

Manual of another sheet.

49

1. To connect the Fuel Pump.

2. To connect the E.C.U (Black).

3. To connect the atmospheric pressure sensor (Black).

4. To connect the inter face box (Black).

5. To connect the vehicle down sensor (Gray).

6. Relay Box (27002-1062)

7. To connect the relay box (Black).

 Remove the original relay box and original turn signal relay.
 Install the [6] relay (27002-1062) to the position removed the turn signal relay (Original).

Be careful to the interference with surrounding parts when install to the other position.

50

Sub Harness (Original Meter) Installation

1. To connect the original meter (Black).

2. To connect the right switch housing (Black).

3. To connect the left switch housing (Black).

4. Semitransparent connector (not use)

5. To connect the shift up indicator (Green).

 Install the harness (26031-0426) for the original meter as shown in the illustration.
 When using the original meter, use the left and right original switch housings.

NOTE

○ When using the original meter, function the head light dimmer switch or/and passing

button for the speed control switch function.

○ Hold the stop watch function of the stop watch switch.
○ In case of difficulty confirming the shif t up indicator lamp in the original meter, connect to

the [5] optional shift up indicator lamp.

51

Sub Harness (Kit Meter) Installation

1. Shift up Indicator Lamp (23016-0006)

2. To connect the shift up indicator lamp (Green).

3. Tachometer with Water Temperature Gauge (25031-1142)

4. To connect the tachometer with water temperature gauge (Black).

5. To connect the right switch housing (Black).

6. To connect the speed control switch (27010-0040) (Black).

7. Semitransparent connector (not use)

 Install the harness for the kit meter (26031-0425) as shown in the illustration.

NOTE

○ The right switch housing is usable both the original (46094-0040) and the kit

(46091-1809) one.

52

Kit Sub Harness (26031-0427) Installation

 Install the kit sub harness (26031-0244) as shown in the illustration.

1. E.C.U.

2. Sub Harness (26031-0427)

3. To connect the auto-shifter (Blue).

4. To connect the speed limit switch (Black).

5. To connect the inter face box (Black).

 Connect the [3] auto shifter and the [4] speed limit switch, extending the lead as

required.

53

Wiring Diagram (with Original Meter)

54

55

Wiring Diagram (with Kit Meter)

56

57

Racing Kit Parts List

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-3

This grid covers:

Valve(s)

Ref.

Part No. Description Spec Code

No.

49078 49078-0049 SPRING-ENGINE VALVE,EXHAUST 8

(OPTION)

Quantity-ZX1000

’06

DR6F

1 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-4

This grid covers:

Camshaft(s)/Tensioner

Ref.

Part No. Description Spec Code

No.

12048 12048-0028 TENSIONER-ASSY 1
13116 13116-1166 ROD-PUSH AR
49118 49118-0034 CAMSHAFT-COMP,INTAKE 1
49118A 49118-0077 CAMSHAFT-COMP,EXHAUST 1
49118B 49118-0078 CAMSHAFT-COMP,INTAKE 1

92015 92015-1078 NUT,FLANGED,6MM 1
92055 92055-0053 RING-O,20.8X1.9 1
92055A 92055-011 RING-O,5MM 1

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Quantity-ZX1000

’06

DR6F

2 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-5

This grid covers:

Crankshaft/Piston(s)

Ref.

Part No. Description Spec Code

No.

13001 13001-0077 PISTON-ENGINE,SB 4
13001A 13001-0078 PISTON-ENGINE 4
13002 13002-0013 PIN-PISTON 4
13008 13008-0019 RING-SET-PISTON 4
13251 13251-0015 ROD-ASSY-CONNECTING,L=110.45 4

92015 92015-1311 NUT,FLANGED,8MM 8
92033 92033-1161 RING-SNAP,PISTON PIN 8
92139 92139-0109 BUSHING,SB CONROD,BLUE AR
92139A 92139-0110 BUSHING,SB CONROD,BLACK 8
92139B 92139-0111 BUSHING,SB CONROD,BROWN AR

92139C 92139-0146 BUSHING,CRANK #1,BLUE AR
92139D 92139-0147 BUSHING,CRANK #1,BLACK 4
92139E 92139-0148 BUSHING,CRANK #1,BROWN AR
92139F 92139-0149 BUSHING,CRANK #2,BLUE AR
92139G 92139-0150 BUSHING,CRANK #2,BLACK 6

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Quantity-ZX1000

’06

DR6F

92139H 92139-0151 BUSHING,CRANK #2,BROWN AR
92139I 92139-0156 BUSHING,CON-ROD,PINK AR
92153 92153-0809 BOLT,CON-ROD,M8X45.5 8

3 DEC.21,2005

(OPTION)
(OPTION)
(OPTION)

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-6

This grid covers:

Clutch

Ref.

Part No. Description Spec Code

No.

13089 13089-0011 PLATE-CLUTCH,STD +40% 1
13089A 13089-0012 PLATE-CLUTCH,STD +60% 1

(OPTION)
(OPTION)

Quantity-ZX1000

’06

DR6F

4 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-7

This grid covers:

Transmission(1/2)(TYPE-B)

Ref.

Part No. Description Spec Code

No.

13127 13127-0041 SHAFT-TRANSMISSION INPUT,13T 1
13144 13144-0021 SPROCKET-OUTPUT,16T,#520 1
13144A 13144-0022 SPROCKET-OUTPUT,17T,#520 1
13262 13262-0152 GEAR,OUTPUT 2ND,39T 1
13262A 13262-0185 GEAR,INPUT 2ND,19T 1

13262B 13262-0264 GEAR,INPUT 3RD&4TH,19T&20T 1
13262C 13262-0265 GEAR,INPUT 5TH,20T 1
13262D 13262-0266 GEAR,INPUT 6TH,21T 1
13262E 13262-0267 GEAR,OUTPUT LOW,31T 1
13262F 13262-0268 GEAR,OUTPUT 3RD,34T 1

13262G 13262-0269 GEAR,OUTPUT 4TH,31T 1
13262H 13262-0270 GEAR,OUTPUT 5TH,29T 1
13262I 13262-0271 GEAR,OUTPUT 6TH,29T 1
13262J 13262-0284 GEAR,INPUT 3RD&4TH,19T&21T 1
13262K 13262-0285 GEAR,INPUT 3RD&4TH,16T&20T 1

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Quantity-ZX1000

’06

DR6F

13262L 13262-0286 GEAR,INPUT 3RD&4TH,19T&20T 1
92200 92200-0225 WASHER,28.1X34.0X0.8 AR
92200A 92200-0226 WASHER,28.1X34.0X1.0 AR
92200B 92200-0227 WASHER,28.1X34.0X1.4 AR
92200C 92200-0228 WASHER,28.1X34.0X1.6 AR

92200D 92200-0229 WASHER,28.3X34.0X1.2 AR

5 DEC.21,2005

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This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-8

This grid covers:

Transmission(2/2)(TYPE-B)

Ref.

Part No. Description Spec Code

No.

92200E 92200-0230 WASHER,28.3X34.0X1.4 AR
92200F 92200-0231 WASHER,28.3X34.0X1.8 AR
92200G 92200-0232 WASHER,28.3X34.0X2.0 AR

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’06

DR6F

6 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-9

This grid covers:

Transmission(1/2)(TYPE-C)

Ref.

Part No. Description Spec Code

No.

13127 13127-0042 SHAFT-TRANSMISSION INPUT,14T 1
13144 13144-0021 SPROCKET-OUTPUT,16T,#520 1
13144A 13144-0022 SPROCKET-OUTPUT,17T,#520 1
13262 13262-0152 GEAR,OUTPUT 2ND,39T 1
13262A 13262-0166 GEAR,OUTPUT 4TH,32T 1

13262B 13262-0185 GEAR,INPUT 2ND,19T 1
13262C 13262-0272 GEAR,INPUT 3RD&4TH,16T&21T 1
13262D 13262-0273 GEAR,INPUT 5TH,20T 1
13262E 13262-0274 GEAR,INPUT 6TH,21T 1
13262F 13262-0275 GEAR,OUTPUT LOW,34T 1

13262G 13262-0276 GEAR,OUTPUT 3RD,28T 1
13262H 13262-0277 GEAR,OUTPUT 5TH,28T 1
13262I 13262-0278 GEAR,OUTPUT 6TH,28T 1
92200 92200-0225 WASHER,28.1X34.0X0.8 AR
92200A 92200-0226 WASHER,28.1X34.0X1.0 AR

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’06

DR6F

92200B 92200-0227 WASHER,28.1X34.0X1.4 AR
92200C 92200-0228 WASHER,28.1X34.0X1.6 AR
92200D 92200-0229 WASHER,28.3X34.0X1.2 AR

7 DEC.21,2005

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This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-10

This grid covers:

Transmission(2/2)(TYPE-C)

Ref.

Part No. Description Spec Code

No.

92200E 92200-0230 WASHER,28.3X34.0X1.4 AR
92200F 92200-0231 WASHER,28.3X34.0X1.8 AR
92200G 92200-0232 WASHER,28.3X34.0X2.0 AR

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’06

DR6F

8 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-11

This grid covers:

Transmission(1/2)(TYPE-D)

Ref.

Part No. Description Spec Code

No.

13127 13127-0043 SHAFT-TRANSMISSION INPUT,16T 1
13144 13144-0021 SPROCKET-OUTPUT,16T,#520 1
13144A 13144-0022 SPROCKET-OUTPUT,17T,#520 1
13262 13262-0279 GEAR,INPUT 2ND,18T 1
13262A 13262-0280 GEAR,INPUT 6TH,22T 1

13262B 13262-0281 GEAR,OUTPUT LOW,37T 1
13262C 13262-0282 GEAR,OUTPUT 2ND,36T 1
13262D 13262-0283 GEAR,OUTPUT 6TH,28T 1
13262E 13262-0351 GEAR,OUTPUT 5TH,30T 1
92200 92200-0225 WASHER,28.1X34.0X0.8 AR

92200A 92200-0226 WASHER,28.1X34.0X1.0 AR
92200B 92200-0227 WASHER,28.1X34.0X1.4 AR
92200C 92200-0228 WASHER,28.1X34.0X1.6 AR
92200D 92200-0229 WASHER,28.3X34.0X1.2 AR

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’06

DR6F

9 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-12

This grid covers:

Transmission(2/2)(TYPE-D)

Ref.

Part No. Description Spec Code

No.

92200E 92200-0230 WASHER,28.3X34.0X1.4 AR
92200F 92200-0231 WASHER,28.3X34.0X1.8 AR
92200G 92200-0232 WASHER,28.3X34.0X2.0 AR

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’06

DR6F

10 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-13

This grid covers:

Gear Change Drum/Shift Fork(s)

Ref.

Part No. Description Spec Code

No.

13145 13145-0021 CAM-CHANGE DRUM 1

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’06

DR6F

11 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine B-14

This grid covers:

Gear Change Mechanism

Ref.

Part No. Description Spec Code

No.

13161 13161-0042 LEVER-COMP-CHANGE SHAFT 1
92026 92026-1534 SPACER,14X20X1.0 1
92144 92144-1029 SPRING 1
92145 92145-0287 SPRING 1

480 480J1400 CIRCLIP-TYPE-C,14MM 1

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’06

DR6F

12 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine C-3

This grid covers:

Engine Cover(s)

Ref.

Part No. Description Spec Code

No.

11004 11004-0022 GASKET-HEAD,T=0.55 1
11004A 11004-0023 GASKET-HEAD,T=0.45 1
11004B 11004-0026 GASKET-HEAD,T=0.65 1
11004C 11004-0034 GASKET-HEAD,T=0.50 1
11004D 11004-0052 GASKET-HEAD,T=0.60 1

11061 11061-0229 GASKET,IDLE GEAR COVER 1
11061A 11061-0230 GASKET,STARTER COVER 1
11061B 11061-0231 GASKET,GENERATOR COVER 1
11061C 11061-0232 GASKET,CLUTCH COVER 1
11061D 11061-0233 GASKET,OIL PAN 1

14031 14031-0063 COVER-GENERATOR 1
16065 16065-0033 HOLDER-CARBURETOR 2
92055 92055-1262 RING-O,24.4X3.1 1
92066 92066-1005 PLUG 4
92066A 92066-1332 PLUG,STARTER HOLE 1

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’06

DR6F

92066B 92066-1333 PLUG,STARTER HOLE 1
92151 92151-1546 BOLT,FLANGED,6X25 7

130 130G0625 BOLT-FLANGED,6X25 1
312 312B0600 NUT-HEX,6MM 1

13 DEC.21,2005

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This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine C-4

This grid covers:

Fuel Injection

Ref.

Part No. Description Spec Code

No.

21175 21175-0096 CONTROL UNIT-ELECTRONIC 1
21176 21176-1099 SENSOR,TEMP 1
26011 26011-0071 WIRE-LEAD,TEMP SENSOR EARTH 1
26011A 26011-1779 WIRE-LEAD,METER-TEMP SENSOR 1
26031 26031-0240 HARNESS,INTERFACE BOX 1

26031A 26031-0425 HARNESS,KIT METER 1
26031B 26031-0426 HARNESS,STD METER 1
26031C 26031-0427 HARNESS,STD 1
27002 27002-1062 RELAY-ASSY 1

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’06

DR6F

14 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine C-5

This grid covers:

Oil Pump

Ref.

Part No. Description Spec Code

No.

13107 13107-0127 SHAFT 1
16142 16142-0036 COVER-PUMP 1
16154 16154-0060 ROTOR-PUMP 1

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Quantity-ZX1000

’06

DR6F

15 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine C-6

This grid covers:

Generator

Ref.

Part No. Description Spec Code

No.

11054 11054-0455 BRACKET,OIL TANK 1
21001 21001-0042 GENERATOR 1

21007 21007-0085 ROTOR 1
21066 21066-0010 REGULATOR-VOLTAGE 1
26031 26031-0323 HARNESS 1

52001 52001-0002 TANK-OIL 1
92022 92022-304 WASHER,6.2X11X1 1
92143 92143-1291 COLLAR,SPROCKET 1

92153 92153-0386 BOLT,TORX,M6X28 4
92171 92171-0338 CLAMP 2
92192 92192-0226 TUBE,CASE-TANK 1

92192A 92192-0227 TUBE,TANK-AIR CLEANER 1
92200 92200-0306 WASHER,12X36X3.2 1

130 130Y0610 BOLT-FLANGED,6X10 1
132 132L0608 BOLT-FLANGED-SMALL,6X8 2

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’06

DR6F

16 DEC.21,2005

This catalog covers:

GRID NO.

’06 ZX1000DR6F Engine C-7

This grid covers:

Radiator

Ref.

Part No. Description Spec Code

No.

11054 11054-0459 BRACKET 4
35063 35063-0316 STAY,MAIN 1
35063A 35063-0317 STAY,RH,SUB RAD 1
35063B 35063-0318 STAY,LH,SUB RAD 1
39060 39060-0030 RADIATOR,SUB 1

39062 39062-1072 HOSE-COOLING 2
39192 39192-0011 PIPE-WATER 1
39192A 39192-0038 PIPE-WATER,LH,SUB RAD 1
39192B 39192-0039 PIPE-WATER,RH,SUB RAD 1
49085 49085-1078 CAP-ASSY-PRESSURE 1

92043 92043-1436 PIN 3
92075 92075-1123 DAMPER,RUBBER 3
92171 92171-0179 CLAMP 7

130 130L0612 BOLT-FLANGED,6X12 2
554 554A1000 PIN-SNAP,10MM 3

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’06

DR6F

17 DEC.21,2005

This catalog covers:

GRID NO.

This grid covers:

’06 ZX1000DR6F Chassis D-3 Rear Hub

Ref.

Part No. Description Spec Code

No.

43082 43082-0005 PAD-ASSY-BRAKE,FR,F9633 2
43082A 43082-1192 PAD-ASSY-BRAKE,RR,C93 1
43082B 43082-1220 PAD-ASSY-BRAKE,RR,C93G 1
44026 44026-0091 SPRING-FRONT FORK,K=9.5N/MM 2
44026A 44026-0092 SPRING-FRONT FORK,K=10.0N/MM 2

44026B 44026-0093 SPRING-FRONT FORK,K=10.5N/MM 2
55020 55020-0236 GUARD,CHAIN 1
92057 92057-1529 CHAIN,DRIVE,120L(#520) 1
92058 92058-1090 JOINT-CHAIN,DRIVE(#520) 1

130 130J1020 BOLT-FLANGED,10X20 1

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Quantity-ZX1000

’06

DR6F

18 DEC.21,2005

This catalog covers:

GRID NO.

This grid covers:

’06 ZX1000DR6F Chassis D-4 Handlebar

Ref.

Part No. Description Spec Code

No.

27010 27010-0040 SWITCH,SPEED CONTROL 1
31064 31064-1151 PIPE-COMP,GRIP 1
32099 32099-0004 CASE,UPP 1
32099A 32099-0005 CASE,LWR 1
46075 46075-1143 GRIP,THROTTLE 1

46091 46091-1809 HOUSING-ASSY-CONTROL,RH 1
54012 54012-0185 CABLE-THROTTLE,OPENING 1
54012A 54012-0186 CABLE-THROTTLE,CLOSING 1
59101 59101-0001 REEL,R21.5,60DEG 1
59101A 59101-0002 REEL,R20.0,65DEG 1

92160 92160-1625 DAMPER,KILL SWITCH 1

120 120S0625 BOLT-SOCKET,6X25 2
220 220C0522 SCREW-PAN-CROS,5X22 2

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Quantity-ZX1000

’06

DR6F

19 DEC.21,2005

This catalog covers:

GRID NO.

This grid covers:

’06 ZX1000DR6F Chassis D-5 Meter(s)

Ref.

Part No. Description Spec Code

No.

11053 11053-1673 BRACKET,KIT METER 1
11054 11054-0423 BRACKET,COWLING STAY,LH 1
11054A 11054-0424 BRACKET,COWLING STAY,RH 1
13061 13061-0124 BOSS 2
23016 23016-0006 LAMP-ASSY,INDICATOR 1

25031 25031-1142 METER-ASSY 1
39156 39156-0098 PAD,KIT METER 1
92015 92015-1233 NUT,FLANGED,6MM,BLACK 2
92039 92039-1106 RIVET 3
92152 92152-0058 COLLAR 3

92153 92153-1275 BOLT,SOCKET,6X12 2

130 130J0618 BOLT-FLANGED,6X18 2
554 554A1200 PIN-SNAP 2
670 670E2014 O RING,14MM 2

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’06

DR6F

20 DEC.21,2005

Doc No. 99929-0011-01