Kawasaki GPX600R 1991, ZX600 C4 1991 Service Manual

5 (2)

Kawasaki GPX600R ’91 ZX600C-4

Part Diagrams

Kawasaki GPX600R

1991 ZX600C-4

Kawasaki GPX600R Fiche

Page 1 of 121

Kawasaki GPX600R ’91 ZX600C-4

Kawasaki GPX600R Fiche

Page 2 of 121

Kawasaki GPX600R ’91 ZX600C-4

Kawasaki GPX600R Fiche

Page 3 of 121

Kawasaki GPX600R ’91 ZX600C-4

AIR CLEANER

Ref #

Part #

Description

Qty

Spec Code

11011

11011-1252

CASE-AIR FILTER

1

[US]

11011A

11011-1256

CASE-AIR FILTER

1

[CA]

11012

11012-1619

CAP,AIR FILTER

1

 

11013

11013-1154

ELEMENT-AIR FILTER

1

 

13091

13091-1467

HOLDER,ELEMENT

1

 

13091A

13091-1468

HOLDER,ELEMENT

1

 

14073

14073-1211

DUCT,CARBURETOR

4

 

16126

16126-1005

VALVE,AIR SWITCH

1

 

92005

92005-1017

FITTING,TUBE,T-TYPE

1

 

92037

92037-072

CLAMP,TUBE

2

 

92037A

92037-1076

CLAMP,TUBE

1

 

92037B

92037-1730

CLAMP

1

 

92037C

92037-213

CLAMP,TUBE

4

 

92059

92059-1031

TUBE,19X25X260

1

 

92059A

92059-1040

TUBE,4X9X220

1

 

92059B

92059-1365

TUBE,4X9X80

1

 

92059C

92059-1674

TUBE,AIR SWITCH VALVE,LH

1

 

92059D

92059-1675

TUBE,AIR SWITCH VALVE,RH

1

 

92059E

92059-1712

TUBE,4X9X260

1

 

92059F

92059-1798

TUBE,BREATHER

1

 

92071

92071-1013

GROMMET,AIR FILTER

1

 

92071A

92071-1114

GROMMET,AIR FILTER

1

[CA]

92071B

92071-1123

GROMMET,AIR FILTER

1

 

92093

92093-1212

SEAL,AIR FILTERCAP

1

 

92144

92144-1771

SPRING,AIR FILTER DUCT

4

 

235

235B0616

SCREW-PAN-WP-CROS

2

 

702

702A05100

TUBE-RUBBER

1

 

Kawasaki GPX600R Fiche

Page 4 of 121

Kawasaki GPX600R ’91 ZX600C-4

AIR CLEANER

Kawasaki GPX600R Fiche

Page 5 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER HEAD

Ref #

Part #

Description

Qty

Spec Code

11004

11004-1152

GASKET-HEAD

1

 

11008

11008-1195

HEAD-COMP-CYLINDER

1

 

11012

11012-1491

CAP

4

 

16065

16065-1129

HOLDER-CARBURETOR

4

 

32033

32033-1942

PIPE

1

 

32033A

32033-1943

PIPE

1

 

49002

49002-1081

GUIDE-VALVE

16

 

92001

92001-1105

BOLT,FLANGED,6X38

20

 

92004

92004-066

STUD,6X27

8

 

92015

92015-1151

NUT,CAP,8MM

12

 

92043

92043-1263

PIN,6.2X8X14

20

 

92170

92170-1438

CLAMP

8

 

410

410B0800

WASHER-PLAIN-SMALL,8MM

12

 

670

670D1505

O RING

4

 

Kawasaki GPX600R Fiche

Page 6 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER HEAD

Kawasaki GPX600R Fiche

Page 7 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER HEAD COVER

Ref #

Part #

Description

Qty

Spec Code

11009

11009-1497

GASKET,CYLINDER HEAD COVER

1

 

11009A

11009-1905

GASKET,REED VALVE

2

 

11012

11012-1481

CAP,REED VALVE

2

 

11060

11060-1509

GASKET

2

 

12021

12021-1053

VALVE-ASSY-REED

2

 

14024

14024-1144

COVER,CYLINDER HEAD

1

 

92001

92001-1352

BOLT,FLANGED,6X22

4

 

92005

92005-1006

FITTING,REED VALVE

2

 

92022

92022-1637

WASHER,HEAD COVER BOLT

6

 

92043

92043-1263

PIN,6.2X8X14

4

 

92055

92055-1225

RING-O,HEADCOVER BOLT

6

 

92150

92150-1447

BOLT,HEAD COVER

6

 

Kawasaki GPX600R Fiche

Page 8 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER HEAD COVER

Kawasaki GPX600R Fiche

Page 9 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER/PISTON(S)

Ref #

Part #

Description

Qty

Spec Code

11005

11005-1493

CYLINDER-ENGINE

1

 

11007

11007-1086

LINER-CYLINDER

4

 

11009

11009-1578

GASKET,CYLINDER BASE

1

 

13001

13001-1254

PISTON-ENGINE,STD

4

 

13002

13002-1003

PIN-PISTON

4

 

13008

13008-1088

RING-SET-PISTON,STD

4

 

13025

13025-1086

RING-SET-PISTON L,O/S 0.50

4

 

13029

13029-1164

PISTON-ENGINE L,O/S 0.50

4

 

92002

92002-1104

BOLT,6X28

4

 

92015

92015-1170

NUT,CAP,6MM,BLACK

2

 

92033

92033-1161

RING-SNAP,PISTON PIN

8

 

92043

92043-1264

PIN,8.2X10X14

4

 

92055

92055-1287

RING-O,66.5MM

8

 

Kawasaki GPX600R Fiche

Page 10 of 121

Kawasaki GPX600R ’91 ZX600C-4

CYLINDER/PISTON(S)

Kawasaki GPX600R Fiche

Page 11 of 121

Kawasaki GPX600R ’91 ZX600C-4

VALVE(S)

Ref #

Part #

Description

Qty

Spec Code

12004

12004-1075

VALVE-INTAKE

8

 

12005

12005-1062

VALVE-EXHAUST

8

 

12009

12009-1060

RETAINER-VALVE SPRING

16

 

12011

12011-1051

COLLET

32

 

12016

12016-1062

ARM-ROCKER

8

 

12020

12020-1058

SHAFT-ROCKER

4

 

16007

16007-1143

SEAT-SPRING,12.1X16.2X0.5

16

 

16007A

16007-1144

SEAT-SPRING,17.5X23.8X0.5

16

 

49078

49078-1060

SPRING-ENGINE VALVE,OUTER

16

 

49078A

49078-1061

SPRING-ENGINE VALVE,INNER

16

 

92009

92009-1109

SCREW,VALVE ADJUST

16

 

92015

92015-1529

NUT,5MM

16

 

92049

92049-1218

SEAL-OIL,VSB58.558

16

 

92066

92066-1192

PLUG,14X11.5

4

 

92081

92081-1636

SPRING,ROCKER ARM

8

 

551

551A0540

PIN-DOWEL

4

 

670

670B2015

O RING,15MM

4

 

Kawasaki GPX600R Fiche

Page 12 of 121

Kawasaki GPX600R ’91 ZX600C-4

VALVE(S)

Kawasaki GPX600R Fiche

Page 13 of 121

Kawasaki GPX600R ’91 ZX600C-4

CAMSHAFT(S)/TENSIONER

Ref #

Part #

Description

Qty

Spec Code

11044

11044-1079

BRACKET,CHAIN GUIDE

1

 

12044

12044-1203

CAMSHAFT-VALVE,INTAKE

1

 

12044A

12044-1204

CAMSHAFT-VALVE,EXHAUST

1

 

12046

12046-1078

SPROCKET,CAMSHAFT,42 T

2

 

12049

12049-1009

TENSIONER,CAM CHAIN

1

 

12053

12053-1158

GUIDE-CHAIN,RR

1

 

12053A

12053-1159

GUIDE-CHAIN,FR

1

 

12053B

12053-1160

GUIDE-CHAIN,HEAD

1

 

13107

13107-1142

SHAFT,8X25

1

 

13116

13116-1012

ROD-PUSH,TENSIONER

1

 

13116A

13116-1020

ROD-PUSH,CAM CHAIN

1

 

92003

92003-208

BOLT,FLANGED,6X11

4

 

92015

92015-1100

NUT,CAP,18MM

1

 

92022

92022-1175

WASHER,18.3X24X1.4

1

 

92057

92057-1190

CHAIN,CAM,82RH2010-136L

1

 

92081

92081-1075

SPRING,TENSIONER

1

 

92081A

92081-1302

SPRING,TENSIONER

1

 

120

120P0618

BOLT-SOCKET,6X18

2

 

130

130Y0625

BOLT-FLANGED

2

 

610

610A0408

ROLLER,4X8

1

 

670

670B2021

O RING,21MM

1

 

Kawasaki GPX600R Fiche

Page 14 of 121

Kawasaki GPX600R ’91 ZX600C-4

CAMSHAFT(S)/TENSIONER

Kawasaki GPX600R Fiche

Page 15 of 121

Kawasaki GPX600R ’91 ZX600C-4

CRANKSHAFT

Ref #

Part #

Description

Qty

Spec Code

11044

11044-1075

BRACKET,CHAIN GUIDE

1

 

12053

12053-1156

GUIDE-CHAIN,UPP

1

 

12053A

12053-1157

GUIDE-CHAIN,LWR

1

 

13031

13031-1245

CRANKSHAFT-COMP

1

 

13034

13034-1016

METAL,CRANKSHAFT,BROWN

4

 

13034A

13034-1017

METAL,CRANKSHAFT,BLACK

AR

 

13034B

13034-1018

METAL,CRANKSHAFT,BLUE

AR

 

13034C

13034-1064

BUSHING,CRANKSHAFT,BLUE

6

 

13034D

13034-1065

BUSHING,CRANKSHAFT,BLACK

AR

 

13034E

13034-1066

BUSHING,CRANKSHAFT,BROWN

AR

 

13034F

13034-1067

BUSHING,CONNECTING ROD,BLUE

8

 

13034G

13034-1068

BUSHING,CONNECTING ROD,BLACK

AR

 

13034H

13034-1069

BUSHING,CONNECTING ROD,BROWN

AR

 

13107

13107-1142

SHAFT,8X25

1

 

13251

13251-1081-HH

ROD-ASSY-CONNECTING,H

4

 

13251A

13251-1081-II

ROD-ASSY-CONNECTING,I

4

 

13251B

13251-1081-JJ

ROD-ASSY-CONNECTING,J

4

 

13251C

13251-1081-KK

ROD-ASSY-CONNECTING,K

4

 

92001

92001-1887

BOLT,CONNECTING ROD,8MM

8

 

92002

92002-1479

BOLT

1

 

92002A

92002-1592

BOLT,SOCKET,6X14

4

 

92015

92015-1311

NUT,FLANGED,8MM

8

 

92043

92043-076

PIN

1

 

92049

92049-1013

SEAL-OIL,HSCY25367

1

 

92050

92050-081

SEAL-OIL,HSCY25397

1

 

92057

92057-1011

CHAIN,PRIMARY,MA0364X50L

1

 

92081

92081-112

SPRING

1

 

555

555A0408

PIN-SPRING,4X8

1

 

670

670B2016

O RING,16MM

1

 

Kawasaki GPX600R Fiche

Page 16 of 121

Kawasaki GPX600R ’91 ZX600C-4

CRANKSHAFT

Kawasaki GPX600R Fiche

Page 17 of 121

Kawasaki GPX600R ’91 ZX600C-4

SECONDARY SHAFT

Ref #

Part #

Description

Qty

Spec Code

13097

13097-1141

GEAR-PRIMARY SPUR,28 T

1

 

13127

13127-1123

SHAFT,SECONDARY

1

 

42034

42034-1004

COUPLING,OUTER,SECONDARY SHAFT

1

 

42034A

42034-1005

COUPLING,INNER,SECONDARY SHAFT

1

 

59051

59051-1137

GEAR-SPUR,10T,SECONDARY

1

 

92016

92016-028

NUT,20MM

1

 

92027

92027-1438

COLLAR,22X34X7.3

1

 

92028

92028-1037

BUSHING,20X25X16.6

1

 

92045

92045-1017

BEARING-BALL,#63/22X

1

 

92075

92075-1070

DAMPER,COUPLING

8

 

480

480J2200

CIRCLIP-TYPE-C,22MM

1

 

480A

480J2800

CIRCLIP-TYPE-C,28MM

1

 

601

601B6205

BEARING-BALL,#6205C3

1

 

Kawasaki GPX600R Fiche

Page 18 of 121

Kawasaki GPX600R ’91 ZX600C-4

SECONDARY SHAFT

Kawasaki GPX600R Fiche

Page 19 of 121

Kawasaki GPX600R ’91 ZX600C-4

CLUTCH

Ref #

Part #

Description

Qty

Spec Code

13087

13087-1052

HUB-CLUTCH

1

 

13088

13088-040

PLATE-FRICTION

7

 

13089

13089-026

PLATE-CLUTCH,T=2.0

5

 

13089A

13089-1067

PLATE-CLUTCH,T=2.6

1

 

13095

13095-1128

HOUSING-COMP-CLUTCH

1

 

13102

13102-1089

RELEASE-COMP-CLUTCH

1

 

13187

13187-1012

PLATE-CLUTCH OPERATING

1

 

46102

46102-1030

ROD,CLUTCH

1

 

92001

92001-1066

BOLT,FLANGED,6X18

5

 

92015

92015-1555

NUT,20MM

1

 

92022

92022-1116

WASHER,20.3X36X2.3

1

 

92026

92026-022

SPACER,25.5X47X2.5

1

 

92026A

92026-116

SPACER,THRUST,T=5.5

1

 

92028

92028-178

BUSHING,25X32X23.6

1

 

92045

92045-1235

BEARING-BALL,6001C3ML01

1

 

92046

92046-028

BEARING-NEEDLE,KTV323723

1

 

92081

92081-139

SPRING,CLUTCH

5

 

Kawasaki GPX600R Fiche

Page 20 of 121

Kawasaki GPX600R ’91 ZX600C-4

CLUTCH

Kawasaki GPX600R Fiche

Page 21 of 121

Kawasaki GPX600R ’91 ZX600C-4

TRANSMISSION

Ref #

Part #

Description

Qty

Spec Code

13127

13127-1151

SHAFT-TRANSMISSION INPUT,14T

1

 

13128

13128-1119

SHAFT-TRANSMISSION OUTPU T

1

 

13129

13129-1077

GEAR,INPUT 2ND,18 T

1

 

13129A

13129-1078

GEAR,OUTPUT 2ND,32T

1

 

13129B

13129-1083

GEAR,OUTPUT 5TH,25T

1

 

13129C

13129-1564

GEAR,OUTPUT LOW,36 T

1

 

13129D

13129-1657

GEAR,INPUT 5TH,26 T

1

( - ZX600AE094804)

13129E

13129-1658

GEAR,INPUT TOP,27 T

1

 

13129F

13129-1659

GEAR,OUTPUT 3RD,29 T

1

 

13129G

13129-1660

GEAR,OUTPUT 4TH,27T

1

 

13129H

13129-1662

GEAR,OUTPUT TOP,23 T

1

 

13144

13144-1117

SPROCKET-OUTPUT,15T(# 530)

1

 

13260

13260-1195

GEAR,INPUT 3RD&4TH,21T&24 T

1

 

13260B

13260-1203

GEAR,INPUT 5TH,26 T

1

( ZX600AE094805 -

 

 

 

 

)

13270

13270-1060

PLATE,SPROCKET

1

 

92022

92022-112

WASHER,20.5X30X1,STEEL

1

 

92022A

92022-1139

WASHER,TOOTHED,28.3X33.5X1

3

 

92022B

92022-1861

WASHER,TOOTHED,25.3X31.8X1.6

1

 

92024

92024-033

WASHER,TOOTHED,25.5X32X1

2

 

92026

92026-1022

SPACER,20.3X30X2.0

1

 

92027

92027-1106

COLLAR,25X32X23.5

1

 

92028

92028-1199

BUSHING,INPUT SHAFT

1

 

92028A

92028-1364

BUSHING,OUTPUT 3RD&4THGEAR

1

 

92028B

92028-1552

BUSHING,INPUT TOP GEAR

1

 

92028D

92028-1639

BUSHING

1

( ZX600AE094805 -

 

 

 

 

)

92028E

92028-180

BUSHING,26X34X16.6

1

 

92033

92033-015

RING-SNAP,20MM

2

 

92033A

92033-026

RING-SNAP,24MM

3

 

92033B

92033-1037

RING-SNAP,25.9MM

3

 

92045

92045-035

BEARING-BALL,83993SH2-CS

2

 

92046

92046-1030

BEARING-NEEDLE,VS20/14A

1

 

92046A

92046-1045

BEARING-NEEDLE,20V2715

1

 

132

132G0608

BOLT-FLANGED-SMALL

2

 

600

600A0500

BALL-STEEL,5/32\"

3

 

Kawasaki GPX600R Fiche

Page 22 of 121

Kawasaki GPX600R 1991, ZX600 C4 1991 Service Manual

Kawasaki GPX600R ’91 ZX600C-4

TRANSMISSION

Kawasaki GPX600R Fiche

Page 23 of 121

Kawasaki GPX600R ’91 ZX600C-4

GEAR CHANGE DRUM/SHIFT FORK(S)

Ref #

Part #

Description

Qty

Spec Code

13091

13091-1104

HOLDER,CHANGE DRUM PIN

1

 

13140

13140-1016

FORK-SHIFT,DRIVE

1

 

13140A

13140-1062

FORK-SHIFT,OUTPUT

2

 

13145

13145-1058

CAM-CHANGE DRUM

1

 

13151

13151-1007

SWITCH-COMP,NEUTRAL

1

 

13239

13239-1119

DRUM-ASSY-CHANGE

1

 

49047

49047-1069

ROD-SHIFT

1

 

92033

92033-035

RING-SNAP,37MM

1

 

92042

92042-014

PIN,DOWEL,4X15.8

1

 

92042A

92042-021

PIN,DOWEL,8X18

1

 

92042B

92042-030

PIN,DOWEL,4X13.8

5

 

92065

92065-058

GASKET,10.5X16X1,DRAIN PLUG

1

 

221

221B0620

SCREW-CSK-CROS,6X20

1

 

480

480J3000

CIRCLIP-TYPE-C,30MM

1

 

482

482J0100

CIRCLIP-TYPE-E,10MM

1

 

550

550D3020

PIN-COTTER,3.0X20

1

 

610

610A0406

ROLLER,4X6

1

 

Kawasaki GPX600R Fiche

Page 24 of 121

Kawasaki GPX600R ’91 ZX600C-4

GEAR CHANGE DRUM/SHIFT FORK(S)

Kawasaki GPX600R Fiche

Page 25 of 121

Kawasaki GPX600R ’91 ZX600C-4

GEAR CHANGE MECHANISM

Ref #

Part #

Description

Qty

Spec Code

13161

13161-042

LEVER-COMP-CHANGE SHAFT

1

 

13242

13242-1190

LEVER-ASSY-CHANGE,BOSS

1

 

13242A

13242-1191

LEVER-ASSY-CHANGE,PEDAL

1

 

39110

39110-1010

ROD-ASSY-TIE,CHANGE LEVER

1

 

92001

92001-1037

BOLT,NEUTRAL POSITION

1

 

92001A

92001-1455

BOLT,RETURN SPRING

1

 

92001B

92001-174

BOLT,10X26

1

 

92002

92002-1926

BOLT,CHANGE PEDAL

1

 

92022

92022-072

WASHER,12.5X21X1.2

1

 

92022A

92022-1561

WASHER,8.5X20X1.6

1

 

92024

92024-074

WASHER,LOCK,10MM

1

 

92043

92043-076

PIN

1

 

92081

92081-112

SPRING

1

 

92083

92083-018

SPRING

1

 

92144

92144-1074

SPRING,CHANGE PEDAL RETURN

1

 

92160

92160-1036

DAMPER,CHANGE PEDAL

1

 

130

130S0620

BOLT-FLANGED,6X20,BLACK

1

 

Kawasaki GPX600R Fiche

Page 26 of 121

Kawasaki GPX600R ’91 ZX600C-4

GEAR CHANGE MECHANISM

Kawasaki GPX600R Fiche

Page 27 of 121

Kawasaki GPX600R ’91 ZX600C-4

CRANKCASE

Ref #

Part #

Description

Qty

Spec Code

11009

11009-1344

GASKET,OIL PIPE,8.2X14X1.0

4

 

11009A

11009-1376

GASKET,12.4X17X1.5

2

 

13169

13169-1966

PLATE,BREATHER

1

 

14001

14001-5217

SET-CRANKCASE

1

 

14013

14013-004

RING-POSITION

2

 

14014

14014-1006

PLATE-POSITION

1

 

14055

14055-1078

CASE-GEAR

1

 

32033

32033-1858

PIPE,OIL

1

 

51044

51044-1071

TUBE-ASSY

1

 

92001

92001-1871

BOLT,BANJO,12X23

1

 

92002

92002-1449

BOLT,6X10

4

 

92002A

92002-1858

BOLT,BANJO,8X24

2

 

92004

92004-059

STUD,6X22

2

 

92004A

92004-1161

STUD,8X128.5

12

 

92005

92005-1129

FITTING,BREATHER

1

 

92037

92037-1181

CLAMP

1

 

92042

92042-016

PIN,DOWEL,6X16

2

 

92043

92043-1263

PIN,6.2X8X14

6

 

92043A

92043-1264

PIN,8.2X10X14

2

 

92046

92046-051

BEARING-NEEDLE,37BTM4312

1

 

92055

92055-1146

RING-O

1

 

92059

92059-1544

TUBE

1

 

92062

92062-011

NOZZLE,BLACK

1

 

92062A

92062-014

NOZZLE

1

 

92062B

92062-015

NOZZLE,SILVER

1

 

92066

92066-1096

PLUG,MAIN GALLERY,18X9,BLACK

1

 

132

132J0625

BOLT-FLANGED-SMALL

2

 

671

671B2555

O RING,55MM

1

 

Kawasaki GPX600R Fiche

Page 28 of 121

Kawasaki GPX600R ’91 ZX600C-4

CRANKCASE

Kawasaki GPX600R Fiche

Page 29 of 121

Kawasaki GPX600R ’91 ZX600C-4

CRANKCASE BOLT PATTERN

Ref #

Part #

Description

Qty

Spec Code

92002

92002-1077

BOLT,8X95

10

 

92002A

92002-1078

BOLT,6X95

4

 

92002B

92002-1080

BOLT,6X40

13

 

92002C

92002-1483

BOLT,6X75

2

 

Kawasaki GPX600R Fiche

Page 30 of 121

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