Kawasaki Ninja ZX-6R 2015 Owner's manual

Quick Reference Guide
A Table of Contents is included after the Foreword.
SAFETY INFORMATION j
GENERAL INFORMATION j
HOW TO RIDE THE MOTORCYCLE j
MAINTENANCE AND ADJUSTMENT j
APPENDIX j
MAINTENANCE RECORD j
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and main­tenance practices.
DANGER
DANGER indicates a hazardous
situation which, if not avoided,
will result in death or serious in-
jury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
NOTICE is used to address prac-
tices not related to personal in-
jury.
NOTE
NOTE indicates information that may
help or guide you in the operation or service of the vehicle.
NOTICE
THIS PRODUCT HAS BEEN MANUFACTURED FOR US E IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP­ERATOR AND AS A VEHICLE ONLY.
Foreword
Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo­torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and p e rfo rmance.
Please read this Owner ’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea­tures, capabilities, and limitations. This manual offers many safe riding tips, but its purpose is n ot to provide instruction in all the techniques and skills required to ride a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi­cle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and maintenance described in this manual. For those who would like more detailed in­formation on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains de­tailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual.
Keep this Owner’s Manual aboard your motorcycle at all times so that you can refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when it is sold.
All rights reserved. No part of this publication may be reproduced without our
prior written permission.
This publication includes the latest information available at the time of printing. However, there may be minor differences be twee n the actual product and illustra­tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2014 Kawasaki H eavy Industries, Ltd. Feb. 21, 2014. (1)
(Australian model only)
TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and
(b) The use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.
TABLE OF CONTENTS
SAFETY INFORMATION .................... 10
Read Owner’s Manual ..................... 10
Training ............................................ 10
Daily Checks and Periodic
Maintenance ................................. 10
Loading and Accessories
Information.................................... 11
Passenger .................................... 12
Baggage and Luggage ................. 13
Accessories .................................. 13
Other Load.................................... 14
If You are Involved in an A ccident.... 14
Safe Operation ................................. 15
Carbon Monoxide Hazard............. 15
Fueling.......................................... 16
Never Ride with Drugs or Alcohol. 16
Protective Gear and Clothing ....... 16
Safe Riding Techniques................ 17
Additional Con siderations for High
Speed Operation ....................... 19
GENERAL INFORMATION................. 21
Specifications................................... 21
Serial Number Locations.................. 26
Location of Labels ............................ 27
Location of Parts .............................. 34
Meter Instruments ............................ 37
Tachometer................................... 39
Multifunction Meter ....................... 40
Indicator Lights ............................. 51
Warning Indicator Lights ............... 57
Keys ................................................. 62
Ignition Switch/Steering Lock ........... 65
Right Handlebar Switches................ 67
Left Handlebar Switches .................. 68
Brake Lever Adjuster........................ 69
Fuel Tank Cap .................................. 69
Fuel .................................................. 70
Fuel Requirements ....................... 70
Filling the Tank.............................. 73
Side Stand ....................................... 74
Seat.................................................. 75
Helmet Hooks................................... 79
Tool Kit ............................................. 80
Air Cleaner Intake ............................ 80
Event Data Recorder........................ 81
HOW TO RIDE THE MOTORCYCLE .82
Break-In ........................................... 82
Starting the Engine .......................... 83
Jump Starting ................................... 86
Moving Off........................................ 88
Shifting Gears .................................. 89
Braking............................................. 90
Kawasaki Intelligent anti-lock
Brake System (KIBS, For models
equipped with KIBS) ..................... 91
Stopping the Engine......................... 94
Stopping the Motorcycle in an
Emergency ................................... 94
Parking............................................. 95
Kawasaki TRaction Control (KTRC). 97
Power Mode ..................................... 100
KTRC and Power Mod e
Combination ................................. 102
MAINTENANCE AND ADJUSTMENT 103
Daily Checks .................................... 105
Periodic Maintenance....................... 108
Engine Oil ........................................ 113
Coolant............................................. 116
Air Cleaner ....................................... 118
Throttle Control System ................... 122
Idle Speed ........................................ 125
Clutch............................................... 126
Drive Chain ...................................... 127
Brakes.............................................. 132
Brake Light Switches........................ 134
Suspension System ......................... 136
Front Fork ..................................... 136
Rear Shock Absorber ................... 139
Setting Tables............................... 141
Wheels ............................................. 144
Battery.............................................. 148
Headlight.......................................... 151
Fuses ............................................... 152
General Lubrication.......................... 154
Cleaning Your Motorcycle ................ 155
General Precautions ..................... 155
Washing Your Motorcycle ............. 157
APPENDIX .......................................... 161
Storage ............................................ 161
Troubleshooting Guide..................... 164
OWNER SATISFACTION................. 165
Environmental Protection ................. 167
MAINTENANCE RECORD ................. 168
10 SAFETY INFORMATION

SAFETY INFORMATION

Read Owner’s Manual
Read this Owner’s Manual care­fully before riding so that you will be thoroughly familiar with the proper op­eration of your motorcycle’s controls, its fe ature s, capabilities, and limita­tions. This manual offers many safe riding tips, but its purpose is not to pro­vide instruction in all of the techniques and skills required to ride a motorcycle safely.

Training

Kawasaki strongly recommends that all operators of this vehicle complete a suitable motorcycle rider training pro­gram to learn the proper skills and tech­niques necessary for safe motorcycle operation.

DailyChecksandPeriodic Maintenance

It is important to keep your motorcy­cle properly maintained and in safe rid­ing condition. Inspect your motorcy­cle before every ride and carry out all periodic maintenance. See the Daily Checks section and the Periodic Main­tenance section in the MAINTENANCE AND ADJUSTMENT chapter for more information.
WARNING
Failure to perform these checks
or to correct a problem before
operation may result in serious
damage or an accident. Always
perform daily checks before op-
eration.
SAFETY INFORMATION 11
To ensure your motorcycle is ser­viced using the latest servicing infor­mation, it is recommended that an authorized Kawasaki Dealer performs the periodic maintenance as directed in the Owner’s Manual.
If you notice any irregular operat­ing condition, have your motorcycle thoroughly checked at an authorized Kawasaki dealer as soon as possible.

Loading and Accessories Information

WARNING
Incorrect loading, improper in­stallation or use of accessories or modification of your motorcy­cle may result in an unsafe riding condition. Before you ride the motorcycle,makesureitisnot overloaded and that you have followed these in structions.
Maximum L oad
Weight of rider, passenger, baggage, and accessories must not exceed 180 kg (397 lb).
With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation
12 SAFETY INFORMATION
or use of accessories, or motorcycle modification, will void the motorcycle warranty; can negatively affect perfor­mance, stability and safety; and can even be illegal.
In selecting and using accessories, and in loading the motorcycle, you are personally responsible for your own safety and the safety of other persons involved.
NOTE
Kawasaki Parts and Accessories
have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components.
Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in
fitting additional accessories. The fol­lowing general guidelines have been prepared to assist you in m aking your determinations.
Passenger
1. Never carry more than one passen­ger.
2. The passenger should only sit on the pillion.
3. Any passenger should be thor­oughly familiar with motorcycle op­eration. The passenger can affect control of the motorcycle by im­proper positioning during cornering and sudden movements. It is im­portant that the passenger sits still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry ani­mals on your motorcycle.
SAFETY INFORM ATION 13
4. Do not carry passengers unless passenger footpegs are installed. Instruct any passenger before riding to keep his or her feet on the pas­senger footpegs and hold on to the operator or seat strap. Do not carry a passenger unless he or she is tall enough to reach the footpegs with their feet.
Baggage and Luggage
1. All baggage should be carried as low as possible to reduce the effect on the motorcycle’s center of grav­ity. Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying bag­gage that extends beyond the rear of the motorcycle.
2. Baggage should be securely at­tached. Make sure that the baggage
will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary.
3. Do not carry heavy or bulky items on a luggage rack. It is designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces.
Accessories
1. Do not install accessories or carry baggage that impairs the perfor­mance of the motorcycle. Make sure that you have not adversely affected any lighting components, road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement,
14 SAFETY INFORMATION
or any other aspects of the motor­cycle’s operation.
2. Weight attached to the handlebar or front fork will increase the mas s of thesteeringassemblyandcanre­sult in an unsafe riding condition.
3. Fairings, windshields, backrests, and other large items have the ca­pability of adversely affecting stabil­ity and handling of the motorcycle, not only due to their weight, but also due to the aerodynamic force acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can re­sult in an unsafe riding condition.
Other Load
1. This motorcycle is not intended to be equipped with a sidecar or to be
used to tow any trailers or other ve­hicles. Kawasaki does not manu­facture sidecars or trailers for mo­torcycles and cannot predict the ef­fects of such accessories on han­dling or stability, but can only warn thattheeffectscanbeadverseand that Kawasaki cannot assume re­sponsibility for the results of such unintended use of the motorcycle.
2. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.

If You are Involved in an Accident

Make sure of your own safety first. Determine the severity of any injuries and call for emergency assistance if needed. Always follow applicable laws
and regulations if any other person, ve­hicle or property is involved.
Do not attempt to continue riding without first evaluating your motorcy­cle’s condition. Inspect for fluid leaks, check critical nuts and bolts, and check the handlebars, control levers, brakes, and wheels for damage and proper function. Ride slowly and cautiously
- your motorcycle may have suffered damage that is not immediately appar­ent. Have your motorcycle thoroughly checked at a Kawasaki dealer as soon as possible.

Safe Operation

The following should be carefully ob­served for safe and effective vehicle operation.
SAFETY INFORM ATION 15
Carbon Monoxide Hazard
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in en­closed areas. Operate only in a well-ventilated area.
16 SAFETY INFORMATION
Fueling
WARNING
Gasoline is extremely flammable and can be explosive under cer­tain conditions. To avoid a possible fire or explo­sion, turn the ignition switch to “OFF.” Do not smoke. Make sure theareaiswellventilatedand free from any source of flame or sparks; this includes any appli­ance with a pilot light.
Never Ride with Drugs or Alcohol
Alcohol and drugs impair your judg­ment and reaction time. Never con­sume alcohol or drugs before or while riding motorcycles.
Protective Gear and Clothing
Helmet
Kawasaki strongly recommends both the operator and passenger wear a hel­met even if this is not a legal require­ment.
- Make sure that your helmet fits cor-
rectly and is properly fastened.
- Choose a mot orcycle helm et that
meets the safety standards appli­cable to your country. Ask your motorcycle dealer to advise you if necessary.
SAFETY INFORM ATION 17
Eye Protection
Always use eye protection. If your helmet does not have a v isor installed, wear goggles.
Gloves
Wear gloves which have suitable protection for your hands, especially against abrasion.
Clothing
Wear protective clothing.
- Wear bright, highly visible cloth ing
that allows freedom of movement to suit your riding style.
- Always wear a long- s lee ve d jacket
and long t ro users w hich a re abra­sion resistant and keep you warm.
- Avoid wearing clothes which have
loose cuffs or other fastenings which could interfere with the con­trols of your motorcycle.
Boots
Wear proper protective boots that fit properly and do not interfere with gear shifting or braking.
Safe Riding Techniques
Keep Hands on Handlebars
When riding always keep both hands on the handlebars and both feet on the footpegs. Removing your hands from the handlebars or feet from the foot­pegs while riding can be hazardous. If you remove even one hand or foot, you reduce your ability to control the motor­cycle.
Look Over Your Shoulder
Before changing lanes, look over your shoulder to make sure the way is clear. Do not rely solely on the rear
18 SAFETY INFORMATION
view mirror; you may misjudge a vehi­cle’s distance and speed, or you may not see it at all.
Accelerate and Brake Smoothly
In general your actions should be smooth as sudden acceleration, brak­ing or turning may caus e loss of control, especially when riding in wet conditions or on loose road surfaces, when the ability to maneuver will be reduced.
Select Correct Gear Speeds
When going up steep slopes, shift to a lower gear so that there is power to spare rather than overloading the en­gine.
Use Both Front and Rear Brakes
When applying the brakes, use both the front and rear brakes. Applying only one brake for sudden braking may cause the motorcycle to skid and lose control.
Use Engine Brake
When going down long slopes, help control vehicle speed by closing the throttle so that the engine can act as an auxiliary brake. Use the front and rear brakes for primary braking.
Riding in Wet Conditions
Rely more on the throttle to control vehicle speed and less on the front and rear brakes. The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceleration.
Braking performance is also reduced in wet conditions. Carefully ride at a slow speed and apply the brakes sev­eral times to help dry and restores them to normal operating performance.
Lubricate the drive chain after wet
-weather riding to prevent rust and cor­rosion.
SAFETY INFORM ATION 19
Ride Prudently
Riding at the proper speed and avoid­ing unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long ve­hicle life and quieter operation.
Riding on Rough Roads
Exercise caution, slow down, and grip the fuel tank with the knees for better stability.
Acceleration
When quick acceleration is neces­sary to pass another vehicle, shift to a lower gear to obtain the necessary power.
Downshifting
To avoid engine damage and rear
-wheel lock-up do not downshift at high rpm.
Avoid Unnecessary Weaving
Unnecessary weaving jeopardizes the safety of both the rider and other motorists.
Additional Considerations for High Speed Operation
WARNING
Handling characteristics of a
motorcycle at high speeds m ay
vary from those you are familiar
with at legal highway speeds.
Do not attempt high speed oper-
ation unless you have received
sufficient training and have the
required skills.
Do not operate at high speeds on
public roads.
20 SAFETY INFORMATION
Brakes
The importance of the brakes, es­pecially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly.
Steering
Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
Tires
High speed operation is hard on tires, and good tires are crucial for safe rid­ing. Examine their overall condition, in­flate them to the proper pressure, and check the wheel balance.
Fuel
Have sufficient fuel for the high fuel consumption during high speed opera­tion.
Engine Oil
To avoid engine s eizure and resulting loss of control, make sure that the oil level is at the upper level line.
Coolant
To avoid overheating, check that the coolant level is at the upper level line.
Electrical Equipment
Make sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly.
Miscellaneous
Make sure that all nuts and bolts are tight and that all safety related parts are in good condition.

Specifications

GENERAL INFORMATION 21

GENERAL INFORMATION

PERFORMAN
Maximum Horsepower
Maximum Torque
Minimum Turning Radius
DIMENSI
Overall
Overall
Overal
Wheelbase
Road Cl
Curb Mass
CE
ONS
Length
Width
lHeight
earance
96.4 kW (131 PS) @13 500 r/min (rpm)
(SEA) 95.0 kW (129 PS) @13 000 r/min (rpm)
71 N·m (7.2 kgf·m, 52 ft·lb) @11 500 r/min (rpm)
4in.)
82.09 in.)
7.8 in.)
(43.90 in.)
(54.92 in.)
5.12 in.)
423 lb)
(428 lb)
(ZX636
(ZX63
E)
6F)
3.4 m (13
2 085 mm (
705 mm (2
1115mm
1 395 mm
130 mm (
192 kg (
194 kg
22 GENERAL INFORMATION
ENGINE
Type DOHC, 4-cylinder, 4-stroke, liquid-cooled
Displacement 636cm³(38.8cuin.)
Bore × Stroke 67.0 × 45.1 mm (2.64 × 1.78 in.)
Compression Ratio 12.9 : 1
Starting System Electric starter
Cylinder Numbering Me thod Left to right, 1-2-3-4
Firing Order 1-2-4-3
Fuel System FI (Fuel Injection)
Ignition System Battery and coil (transistorized ignition)
on Timing
Igniti (Electronically advanced)
Spark Plug
Lubrication System Forced lubrication (wet sump)
Type
Gap 0.7 0.8 mm (0.028 0.031 in.)
12.5° BTDC @1 300 r/min (rpm) 36.4° BTDC @4 800 r/min (rpm)
NGK CR9E
GENERAL INFORMATION 23
Engine Oil: Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 3.6 L (3.8 US qt)
Coolant Capacity 2.5 L (2.6 US qt)
TRANSMISSION
Transmission Type 6-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
Primary Reduction Ratio 1.900 (76/40)
Final Reduction Ratio 2.688 (43/16)
Overall Drive Ratio 6.638 (Top gear)
Gear Ratio: 1st 2.846 (37/13)
2nd 2.200 (33/15)
3rd 1.850 (37/20)
4th 1.600 (32/20)
5th 1.421 (27/19)
6th 1.300 (26/20)
24 GENERAL INFORMATION
FRAME
Caster 23.5°
Trail 101 mm (3.98 in.)
Tire Size: Front 120/70ZR 17 M/C (58W)
Rear 180/55ZR17 M/C (73W)
Rim Size: Front J17M/C × MT3.50
Rear J17M/C × MT5.50
Fuel Tank Capacity 17 L (4.5 US gal)
Brake Fluid: Front DOT4
Rear DOT4
ELECTRICAL EQUIPMENT
Battery 12V8Ah(10HR)
Headlight: High Beam 12 V 55 W
Low Beam 12 V 55 W
Tail/Brake Li gh t LED
SEA: Southeast Asia model
GENERAL INFORMATION 25
Even if one of LED (Light Emitting Diode) tail/brake light does not go on, consult with an authorized Kawasaki dealer.
Specifications are subject to change without notice, and may not apply to every country.
26 GENERAL INFORMATION

Serial Number Locations

The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These s erial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it.
Engine No.
A. Engine Number
Frame No.
A. Frame Number

Location of Labels

All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may op­erate your vehicle. Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the co rrect posi­tion.
NOTE
The sample warning labels in this
section have part numbers to help
GENERAL INFORMATION 27
you and your dealer obtain the cor­rect replacement. Refer to the actual vehicle label for
model specific d ata grayed out in the illustration.
1. Brake Fluid (Front)
28 GENERAL INFORMATION
2. Brake Fluid (Rear)
3. Battery Poison/Danger
4. Rear Shock Ab sorb er Warning
GENERAL INFORMATION 29
5. Radiator Cap Danger
6. Fuel Notice
7. Important Drive Chain Information
8. Tire and Load Data
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