Kawasaki GPX600R 1991, ZX600 C4 1991 Service Manual
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]
11011 A 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,T UBE 1
92037B 92037-1730 CLAMP 1
92037C 92037-213 C LAMP,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 FILTER CAP 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,CYLIND ER 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,HEAD COVER 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 92033-116 1 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 Q ty Spec Code
12004 12004-1075 VALVE-INTAKE 8
12005 12005-1062 VALVE-EXHAUST 8
12009 12009-1060 RETAINER-VALVE SPRING 16
12011 120 11 - 10 51 COLLET 3 2
12016 12016-1062 ARM-ROCKER 8
12020 12020-105 8 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
92 009 92009-1109 SCREW,VALVE ADJUST 16
92015 92015-1529 NUT,5MM 16
92049 92049-1218 SEAL-OIL,VSB58.558 16
920 6 6 92 0 6 6-1 1 9 2 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
12053 A 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
13116 A 13116-1020 ROD-PUSH,CAM CHAIN 1
92003 92003-208 BOLT,FLANGED,6X11 4
92015 92015-1100 NUT,CAP,18MM1
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
12053 A 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 A R
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-CONNECT I NG,I 4
13251B 13251-1081-JJ ROD-ASSY-CONNECTING,J 4
13251C 13251-1081-KK ROD-ASSY-CONNECTI NG,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,28T 1
13127 13127-1123 SHAFT,SECONDARY 1
42034 42034-1004 COUPLING,OUTER,SECONDARY SHAFT 1
42034 A 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,22MM1
480A 480J2800 CIRCLIP-TYPE-C,28MM1
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 OPERATING1
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,6001 C3ML01 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 OUTPUT 1
13129 13129-1077 GEAR,INPUT 2ND,18T 1
131 29A 13129-1078 GEAR,OUTPUT 2ND,32T 1
131 29B 13 129-1 083 GEAR,OUTPUT 5TH,25T 1
13129C 13129-1564 GEAR,OUTPUT LOW,36T 1
13129D 13129-1657 GEAR,INPUT 5TH,26T 1 ( - ZX600AE094804)
13129E 13129-1658 GEAR,INPUT TOP,27T 1
131 29F 13129-16 59 GEAR,OUTPUT 3RD,29T 1
131 29G 131 29-1660 GEAR,OUTPUT 4TH,27T 1
131 29H 13129-1662 GEAR,OUTPUT TOP,23T 1
13144 13144-1117 SPROCKET-OUTPUT,15T(#530) 1
132 6 0 1326 0 -1195 GEAR,INPUT 3RD&4TH,21T&24T 1
132 6 0 B 132 6 0 -1203 GEAR,INPUT 5TH,26T 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&4TH GEAR 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,20MM2
92033A 92033-026 RING-SNAP,24MM3
92033B 92033-1037 RING-SNAP,25.9 MM 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 1 32G06 0 8 BOLT-FLANGED-SMALL 2
600 600A0500 BALL-STEEL,5/32\" 3
)
)
Kawasaki GPX600R Fiche Page 22 of 121
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
131 45 13145-1058 CAM-CHANGE DRUM 1
1315 1 1 3151 -10 07 SWITCH-COMP,NEUTRAL 1
132 39 132 39 - 111 9 DRUM-ASSY-CHANGE 1
49047 49047-1069 ROD-SHIFT 1
92 03 3 92 0 33 - 03 5 R IN G-SNAP,3 7 MM1
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,30MM1
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 MEC HANISM
Ref # Part # Description Qty Spec Code
13161 13161-042 LEVER-COMP-CHAN GE 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 LE VER 1
92001 92001-10 37 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,10MM1
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 MEC HANISM
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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