Kawasaki ZX-6R User Manual

Ninja ZX-6R

2008 Ninja ZX-6R

Racing Kit Manual

This manual contains only the information of the racing kit parts. Refer to the base

manual listed below for information of the original model.

Base Manual Part Number

Ninja ZX-6R

Motorcycle Service Manual

99924-1382-02

Congratulation on your purchase of racing kit parts for the 2008 Ninja ZX-6R.

IMPORTANT

This manual provides how to install racing kit parts for the 2008 Ninja ZX-6R and how to

tune up basically.

As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-6R (P/No.

99924-1382-02).

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.

WARNING

AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE.

CAUTION

When operating the engine, be careful not to trouble persons with noise. Do not turn the engine with loud engine and exhaust noise.

DISCLAIMER OF WARRANTY

ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED

OR IMPLIED.

BASIC WORKS IN INSTALLING KIT PARTS

We are going to make up the original Ninja ZX-6R for the racing machine. We recommend that the 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 as tuning shop.

Dummy page

Table of Contents

General Specifications ......................................................................................................4

Racing Kit Service Data ....................................................................................................6

Periodic Maintenance Chart .............................................................................................7

Preparation......................................................................................................................... 9

Before Installing ....................................................................................................................................9

Racing Kit Parts................................................................................................................. 9

Engine Parts Installation...................................................................................................9

Air Intake Parts .....................................................................................................................................9

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

Camshaft Chain Tensioner..................................................................................................................12

Camshafts, Sprockets.........................................................................................................................13

Valve Springs......................................................................................................................................14

Cylinder Compression.........................................................................................................................14

Crankshaft Main Journal and Connecting Rod Big End Bushings ......................................................16

Connecting Rod Bolts .........................................................................................................................19

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

Transmission.......................................................................................................................................24

Transmission Shimming ......................................................................................................................24

Generator (Option)..............................................................................................................................25

Generator Cover (Option) ...................................................................................................................25

Cover Gaskets ....................................................................................................................................25

Ducts (Air Funnels) .............................................................................................................................25

Muffler.................................................................................................................................................26

Water Temperature Sensor.................................................................................................................26

Radiator (Kit).......................................................................................................................................26

Oil Catch Tank Installation ..................................................................................................................30

Frame Parts Installation ..................................................................................................33

Throttle Parts (Kit)...............................................................................................................................33

Brake Pads (Kit)..................................................................................................................................34

Steering Damper (Kit) .........................................................................................................................34

Seat Height Adjustment ......................................................................................................................35

Front Fork Springs (Kit).......................................................................................................................37

Electric Parts Installation................................................................................................39

Battery ................................................................................................................................................39

Main Harness and Sub Harness (Kit) .................................................................................................39

Meter (Kit) Installation.........................................................................................................................40

Wiring Routing ....................................................................................................................................42

Wiring Diagram (with Kit Meter) .....................................................................................44

Wiring Diagram (with Original Meter Assembly)...........................................................46

General Specifications

Item 2008 Ninja ZX-6R Racing

Engine:

Ignition timing 12.5°BTDC @1 300 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 1.900 (76/40)

Transmission Gear Table

In 13127-0044 13127-0055

1st

2nd

3rd

4th

5th

6th

Out 13262-0507 13262-0526 13262-0535

Teeth (Out/In) 38/14 37/14 36/14

Gear Ratio 2.714 2.643 2.571

In 13262-0372 13262-0527 13262-0536 13262-0677

Out 13262-0508 13262-0528 13262-0537 13262-0678

Teeth (Out/In) 33/15 39/18 34/16 36/16

Gear Ratio 2.200 2.167 2.125 2.25

Out 13262-0509 13262-0683

Teeth (Out/In) 37/20 32/17

Gear Ratio 1.850 1.882

Out 13262-0510 13262-0530 13262-0684 13262-0685

Teeth (Out/In) 32/20 33/20 39/23 30/19

Gear Ratio 1.600 1.650 1.696 1.579

In 13262-0374 13262-0531 13262-0538 13262-0686

Out 13262-0380 13262-0532 13262-0539 13262-0687

Teeth (Out/In) 27/19 30/20 32/22 32/23

Gear Ratio 1.421 1.500 1.455 1.391

In 13262-0375 13262-0533 13262-0540 13262-0688

Out 13262-0582 13262-0534 13262-0541 13262-0689

Teeth (Out/In) 26/20 32/23 35/26 29/23

Gear Ratio 1.300 1.391 1.346 1.261

STD

(Type A)

See Gear

Selection

See Gear

Selection

Type B Type C Type D

（13127-0055）

See Gear

Selection

See Gear

Selection

See Gear

Selection

See Gear

Selection

Input 3rd/4th Gear Selection Table

3rd Gear

A 13262-0506 13262-0529 13262-0679

B 13262-0680 13262-0681 13262-0682

A B C D

Gear Identification Slit Number Table

1st

2nd

3rd

4th

5th

6th

In 0 1 1

Out 0 1 2

In 0 1 2 3

Out 0 1 2 3

In 0 1

Out 0 1

In 0 1 2 3

Out 0 1 2 3

In 0 1 2 3

Out 0 1 2 3

In 0 1 2 3

Out 0 1 2 3

STD

(Type A)

4th Gear

Type B Type C Type D

Racing Kit Service Data

Item Standard

Cylinder Head, Valves:

Duration:

Intake 288°

Exhaust 266° Camshaft timing (cam lift center):

Intake 105° (ATDC)

Exhaust 110° (BTDC) Valve clearance:

Intake 0.16 mm

Exhaust 0.28 mm Valve to piston clearance:

Intake 0.80 mm (Minimum) @12°ATDC

Exhaust 1.40 mm (Minimum) @11°BTDC

Ignition System:

Spark plugs

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

NGK R0045Q-10, R0373A-10

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

When the clearance between the valve and the piston head is smaller than the minimum specific values, turn the installed position of the camshaft sprocket on the camshaft and change the camshaft timing.

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

FREQENCY

OPERATION

Engine

Clutch plate - - check* ●

Throttle grip play - - check* ●

Spark plug - - clean/gap* ●

Engine oil - - change ●

Oil filter - - replace ●

Valve lapping ●

Cylinder head/valve - - decarbonization ●

Cylinder - - check* ●

Piston/cylinder clearance - - check* ●

Piston, Piston ring, Piston pin - - replace ●

Crankshaft main bearing - - check* ●

Connecting rod big end bearing - - check* ●

Transmission gear, bearing - - check* ●

Engine sprocket - - check* ●

Coolant - - change ●

Radiator hoses, connections - - check* ●

Frame

Brake operation - - check* ●

Brake pad wear - - check* ●

Brake fluid level - - check* ●

Brake fluid - - change* year

Brake master cylinder cup and dust seal - - replace year

Brake caliper piston seal and dust seal - - replace year

Brake hose - - replace 2 years

Drive chain - - adjust ●

Drive chain - - lubricate ●

Drive chain wear - - check* ●

Drive chain guide - - replace If damaged

Front fork - - clean/check* ●

Front fork oil - - change First change after 2 races, then every 5 races

Nut, bolt, and fastener tightness - - check* ●

Fuel system - - clean ●

Fuel hose, fuel filter - - replace ●

Steering play - - check* ●

Steering stem bearing - - grease ●

Rear sprocket - - replace ●

General lubrication of chassis - - perform ●

Each

Race

(300 km)

Every

3 races

(1 000 km)

Every

5 races

(1 500 km) (3 000 km)

Every

10 races

Required

FREQENCY

OPERATION

Wheel bearing (rear) - - grease ●

Swingarm pivot, uni-track linkage - - grease ●

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

Each

Race

(300 km)

Every

3 races

(1 000 km)

Every

5 races

(1 500 km)

Every

10 races

(3 000 km)

Required

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

Preparation

Before Installing

 Modify the parts based on your race regulation.  To avoid misuse keep the parts replaced with the kit parts separate.  When reusing parts, clean them and check them for damage or deterioration.  Main Removal Parts:

Lights Rear View Mirrors Side Stand Starter Lockout Switch

 Remove the side stand switch. When the optional main harness is not used, connect

removing Black/Yellow and Green/White Leads directly.

Racing Kit Parts

Also, we have provided the spare parts, and other optional parts (engine, frame, and electric parts) for racing. So please order each parts referring to the “Racing Kit Parts List” in the back of this manual.

Engine Parts Installation

Air Intake Parts

 Remove the wire net of Ram – Air duct intake to reduce the air flow resistance.  Remove the tank (16181-0011) to reduce the weight. Plug the holes firmly with a tape.

The air pressure in the duct rises during high speed operation because the Ram Air System is used.

A. Wire Net (14037-0057)

B. Tank (16181-0011)

 Remove the secondary valves of cylinder head and relational parts, then plug the each

holes.

 Remove the oil receiver and plug the hole.  Remove the air cleaner element or cut the cleaner element off remaining punched plate

to reduce the air flow resistance.

1. Remove the parts.

2. Plug the holes.

3. Replace with plugs (92043-1506), and plug the holes.

Cylinder Head

 Grind off the stepped portions of the ports and smooth the inside of ports to make

intake/exhaust gas flow more smooth.

 Grind off the stepped portion only at the mating surface between the carburetor holder

and the intake port. Do not port it. To extend the intake port, air flow speed will be reduced and the engine performance at the high speed range may be down.

 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 valve seat and

the port.

 Smooth the inside of the intake port and exhaust port.  Use the hand grinder.  Use #200 oil stone for eliminating any stepped portions.  Use #200 oil stone for smoothing and #300 oil stone for finishing.

NOTE

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

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

1. Stepped Portions of carburetor holder and cylinder head.

2. Stepped Portions of valve seat and cylinder head.

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

hand finished for smooth corners (Round them to about R1).

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

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

XXX. Edges

NOTE

 When grinding the cylinder head bottom surface or using thinner gaskets, adjust the

valve timing to keep that the valve to piston clearance is not less than the minimum value (IN: 0.8 mm, EX: 1.4 mm).

Camshaft Chain Tensioner

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

tensioner body.

 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.

 Tighten the rock nut after adjustment.

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.

A. Tensioner B. Tensioner Rod C. O-ring D. O-ring E. Lock nut

Camshafts, Sprockets

Camshafts, Sprockets:

 Adjust the valve clearance within the specified value, but more performance is expected

when adjusted from middle value to upper limit between adjustable range.

Original Timing Cam Lift Valve Clearance Intake 288° 8.30 mm 0.13 ∼ 0.19 mm Exhaust 266° 7.50 mm 0.24 ∼ 0.31 mm

Kit Timing Cam Lift Valve Clearance Intake 49118-0110 Exhaust 49118-0111 Exhaust 49118-0120

308°

274°

(conformed to FIM regulation)

(not conformed to FIM regulation)

(conformed to FIM regulation)

8.30 mm

7.30 mm

7.50 mm

0.13 ∼ 0.19 mm

0.24 ∼ 0.31 mm

 If you don’t adjust the valve timing for racing, install the camshaft sprocket to the kit

camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-6R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range of the long bolt holes.

 Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11.0 ft·lb) of torque.

Valve Timing (when the round bolt holes are used)

Timing (cam lift center) Intake Exhaust

Original 105° 110°

Race use 105° 110°

 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 0.8 mm

Exhaust 1.4 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.  Measure the valve to piston clearance at about 12° ATDC (Intake) and 11° BTDC

(Exhaust) of crankshaft timing. At this point, the valve to piston clearance will be minimum.

Valve Springs

The original machine’s valve springs should be used

Cylinder Compression

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

the cylinder base gasket or smooth the cylinder top surface to make the piston squish

0.65 ~ 0.8 mm. Keep the piston squish more than 0.65 mm.

 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.

Squish Measurement

[1] Front and Rear 0.65 ~ 0.80 mm [2] Left and Right 0.67 ~ 0.85 mm

 The most preferable squish measurement is [1] 0.65 mm/[2] 0.67 mm.  Select proper cylinder head gasket and cylinder base gasket.  Note that by grinding the cylinder head surface only left and right squishes become

narrower, while by grinding the cylinder top surface or decreasing the gasket-thickness all the squishes become narrower.

Cylinder Head Gasket

Part No. Thickness Note 11004-0071 0.45 mm KIT 11004-0070 0.50 mm KIT 11004-0069 0.55 mm KIT 11004-0068 0.60 mm KIT 11004-0057 0.65 mm Original 11004-0067 0.70 mm KIT

1. Squish, Front/Rear

2. Squish, Left/Right

Crankshaft Main Journal and Connecting Rod Big End Bushings

 To adjust clearance of crankshaft main journal you can select proper bush in accordance

with the marks.

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

wear-resistance as compared with the standard bushings.

1) Crankshaft Main Journal  Crankshaft Main Journal Diameter

1. Crankshaft Main Journal Diameter Marks

SIZE “1” mark : over 30.992 mm within 31.000 mm None : over 30.984 mm within 30.992 mm

 Crankcase Main Journal inside Diameter

1. Main Journal Diameter Marks

“{” mark : over 34.000 mm within 34.008 mm None : 34.008 mm and over within 34.016 mm

SIZE

 Main Journal Bush

A. Size Color

Size Color Thickness mm Journal Number

blue 1.499-1.503

1-4 92139-0189 92139-0200

5 92139-0171 92139-0197

black 1.495-1.499

1-4 92139-0190 92139-0201

5 92139-0172 92139-0198

brown 1.491-1.495

1-4 92139-0191 92139-0202

5 92139-0173 92139-0199

 Selection Table

Crankcase inner Diameter Crankshaft Diameter

○

(34.000 mm ~ 34.008 mm) (30.992 mm ~ 31.000 mm)

○

(34.000 mm ~ 34.008 mm) (30.984 mm ~ 30.992 mm)

NONE 1 1-4 92139-0190 92139-0201

(34.008 mm ~ 34.016 mm) (30.992 mm ~ 31.000 mm)

NONE NONE 1-4 92139-0189 92139-0200

(34.008 mm ~ 34.016 mm) (30.984 mm ~ 30.992 mm)

1 1-4 92139-0191 92139-0202

NONE 1-4 92139-0190 92139-0201

Size

Color

brown

black

blue

Part Number

(STD)

Journal

Number

5 92139-0173 92139-0199

5 92139-0172 92139-0198

5 92139-0171 92139-0197

Part Number

(KIT)

Part

Number

(STD)

Part

Number

(KIT)

2) Crankpin  Crankpin Diameter

1. Crankpin Diameter Marks

“{” mark : over 29.992 mm within 30.000 mm None : 29.984 mm and over within 29.992 mm

 Connecting Rod Big End Inside Diameter

Connecting Rod Big End Inside Diameter Marks

“{” mark : over 33.008 mm within 33.016 mm None : 33.000 mm and over within 33.008 mm

A. Inside Diameter Mark ({ or None) B. Weight Mark, Alphabet (G.H etc)

 Connecting Rod Big End Bushings

Size Color Thickness mm

Part Number

(STD)

Part Number

(KIT)

blue 1.485-1.490 92139-0165 92139-0194

black 1.480-1.485 92139-0166 92139-0195

brown 1.475-1.480 92139-0167 92139-0196

 Selection Table

Connecting Rod Big End

Inside Diameter

None

(33.000 mm ~ 33.008 mm) (29.992 mm ~ 30.000 mm)

None None

(33.000 mm ~ 33.008 mm) (29.984 mm ~ 29.992 mm)

○ ○

(33.008 mm ~ 33.016 mm) (29.992 mm ~ 30.000 mm)

○

(33.008 mm ~ 33.016 mm) (29.984 mm ~ 29.992 mm)

Crankpin Diameter Mark

○

None

Size

Color

brown 92139-0167 92139-0196

black 92139-0166 92139-0195

blue 92139-0165 92139-0194

Part Number

(STD)

Part Number

(KIT)

Connecting Rod Bolts

Use the original connecting bolts and nuts. The original connecting rod bolt has recesses at both ends to measure its length and

determine the bolt stretch.

 Install the original bolts into the connecting rod.  Before every tightening, use a point micrometer to measure the length of the bolts and

record the values to find the bolt stretch.

 Apply a small amount of molybdenum disulfide grease to the threads of bolts.  Tighten the big end nuts at the torque of 11.8 ±2 N·m (1.2 ±0.2 kgf·m): reference  Check the length of the bolts and find the bolt stretch.

Bolt Length after tightening – Bolt Length before tightening = Stretch

Bolt Stretch

Usable Range: 0.33 ~ 0.38 mm (0.013 ~ 0.015 in.)

 Turn the big end nuts more until the bolt stretch reaches the usable range.

NOTE

 Replace the original bolts with new ones if they have already been tightened up to usable

range 2 times.

+ 46 hidden pages