Kawasaki ZX-6R User Manual

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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.

Clutch Adjustment (Back-Torque Limiter Setting)

The Ninja ZX-6R 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 in the illastration,

becomes about 40.7 mm. 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 39.5 and 40.7 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.

* Steel plates of former model’s are available.

Thickness (mm) Part Number

2.0 13089-1073

 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.

Recommended Clutch

[A] Spacers [B] Needle Bearing [C] Bushing [D] Clutch Outer Casing [E] Clutch Hub [F] Sub Clutch Hub [G] Friction Plates: total 8 pcs. [H] Steel Plates [I] Spring Plate [J] Steel Plate with Spring

• 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 in the

figure on page 21 and 22. 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] (Total thickness of all clutch plates) 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.

 When decreasing the length [A], total thickness of clutch plates, use the optional spring

retainers (provided as optional production parts) to keep the preload of clutch springs according to the table below. If you have clutch slip during acceleration use shorter spring retainers by 1 mm to increase preload of clutch springs.

 When decreasing the length [A], total thickness of clutch plates, use the optional shim

(provided as optional production part) to keep the position of clutch release lever according to the table below.

 The standard setting of the number of leaf springs is four. By decreasing the number of

the leaf springs the sub clutch hub operates easily and pushes the clutch operating plate causing more slip. Two types of nuts are available for the number of leaf springs, two and three. They are provided as optional production parts. The number of leaf springs affects all over the operation of the back-torque limiter but especially the beginning of the operation.

Standard Selection of Spring Retainers

Total Thickness of Clutch Plates Size of Spring Retainers Remarks

40.2 ~ 40.7 mm 6 mm

P/No. 13091-1041

Original Setting

39.5 ~ 40.2 mm 5 mm P/No. 39108-0004

* If clutch slip is occurred with a retainer of 6 mm, try with a retainer of 5 mm.

Standard Selection of Shim

Total Thickness of Clutch Plates Size of Shim Remarks

Approx. 40.7 mm 2.0 mm

P/No. 92180-0149

Original Setting

40.2 mm 1.5 mm P/No. 92026-1590

39.5 ~ 40 mm 1.2 mm 92025-1137

Transmission

 Remove the three steel balls (600A0500) from the output shaft assembly.  Take kit and optional transmission gears are available to be closer to each gear ratio.

Transmission Shimming

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

0.5 mm, to prevent the seizure of gears and to keep smooth gear-shifting. Thickness Part No.

1.6 mm 92200-0050 Original

Spline washer (input)

Plane washer

(input, output)

1.8mm 92200-0231 Kit

1.4 mm 92200-0230 Kit

1.4 mm 92200-0138 Original

1.6 mm 92022-212 Production part

1.8 mm 92202-1722 Production part

1. Spline washer (input)

2. Plane washer

Generator (Option)

To quicken response by reducing the flywheel mass and to reduce the weight, use the

optional inner rotor generator.

 Select using the optional generator or original generator according to the situation.  Use the optional regulator and optional generator cover set when using the optional

generator.

 The output power of the optional generator is 10A/8000 rpm (Original: 30A/5000rpm).

The consume current of the racing model in running condition is 7 ~ 8A.

 Installing Option Generator

Generator Cover (Option)

Use the option generator with the optional generator cover.

NOTE

 When using the optional generator cover, use the optional generator.

Cover Gaskets

The optional cover gaskets are available. They are made from “meta-form” and made easy to exfoliation.

Ducts (Air Funnels)

Select suitable combination for target characteristic of engine.

Length （mm）

15 14073-0124 Option 20 14073-0125 Option 30 14073-0174 Option 40 14073-0151 STD 50 14073-0152 STD

Part Number

Muffler

With recommended muffler engine performance can be improved. Recommended muffler: Beet NASSERT-R 1002-E02-00 Web Site : http://www.beet.co.jp/(beetjapan) * For further information contact the manufacturer of muffler directly.

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. The optional tachometer is equipped with a water temperature display. Install the optional water temperature sensor to the optional water pipe and connect the sensor and the optional meter unit with the optional harness.

Radiator (Kit)

’05 model ZX-6RR and ’08 ZX-6R Racing Kit provides the capacity increased main radiator (39060-0020) to improve cooling performance.

Radiator Installation

 Use the radiator stay (35063-0439) and bracket (11054-1818) belong to kit, and fasten

the radiator to the Crankcase by bolts as shown in the figure.

 Stay has several installation holes. Install position is adjustable for proper position of

radiator.

 Some muffler may interfere with stay. In such case, make appropriate stay yourself.

 Machine the original cowl to meet the outline of radiator.  Standard Resave tank is not available. Use some appropriate tank.  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, or fender, tire and the front fork full bottomed.

 If you don’t use water temperature meter, use standard pipe, not oil cooler hose

(39062-0220). Nipple of radiator is plugged by CAP (11065-1056).

Water Hose Installation

Radiator inlet

 Divide the original water hose (39062-0156) at suitable position, and insert the hose

between cylinder head and radiator.

1. Water Hose 39062-0156  Insert the water hose (39062-0220) between oil cooler outlet and radiator.

Radiator outlet

 Apply a non-permanent locking agent to the thread of the water temperature sensor (Kit:

for Meter Lamp). Mount the sensor on the pipe (39192-0011).

 Insert the ground terminal of the water temperature sensor lead between the hose and

the pipe, and clamp the hose as shown in the figure. Fasten the another terminal to the

cover (generator) by the bolt. * If you don’t use water temperature meter, use standard pipe and hose at oilcooler outlet side and cover it radiator side with cap (11065-1056).

1. Water Hose 39062-0219 4. Sensor 21176-1099

2. Ground Wire 26011-0071 5. Lead Wire 26011-1779

3. Water Hose 39062-0166 (Standard) 6. Clamp 92171-0179

Reserve Tank Installation

When using the radiator (Kit), the original reserve tank cannot be used. Prepare a

suitable substitue.

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 liquid.

* End of the hose to atmosphere should be always

beyond the liquid surface.

Oil Catch Tank Installation

 Fasten the Bracket (E) to the Engine Hanger by using bolt (D).  Fasten Oil Catch Tank (A) to the Bracket (E) by using bolt (F) and nut (I).  Connect Air Cleaner, Crankcase and Oil Catch Tank by using hose1 (B) and hose2 (C).

A) Oil Catch Tank (52001-0004) B) Hose1 (Air Cleaner – Oil Catch Tank) C) Hose2 (Crankcase – Oil Catch Tank) D) Bolt (130BA0835 standard) E) Bracket (11054-1799) F) Bolt (120P0620) G) Dumper (92075-277) H) Collar (92027-194) I) Nut (92015-1193) J) Washer (92022-304) K) Drain Bolt (130Y0610)

Hose1 (B) and Hose2 (C) assembling

 Divide Hose (92059-1587, KIT) and Hose (92059-1629, KIT) as shown below.

 Divide installed tube (92192-0429, standard) as shown below.

 Assemble hoses as shown below

5. Fitting (92005-0080)

Frame Parts Installation

Throttle Parts (Kit)

The following throttle cases, grip and reels are available as optional parts. These optional

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°

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

Twist Grip Turn Angle

to Full Throttle

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, Open Side: 54012-0232

6. Throttle Cable, Close Side: 54012-0233

7. Bolt: 120S0625

8. Gap

1) Drive Chain

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

2) Chain Guard

1. Guard: 55020-0028

2. Bolt: 130J1020

3. Swingarm (Left Side)

Brake Pads (Kit)

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 lower braking force.

Front Brake Pads

P/No. Mark Braking Force

43082-0074 2508 High

Original TT2172HH Low

↨

Rear Brake Pads

P/No. Mark Braking Force

Original FO GG High

43082-1220 C93G

43082-1192 G196 Low

↨

Steering Damper (Kit)

The steering damper is useful at high speeds to prevent handlebar vibration. The steering damper should be installed to do not the steering handle movement stop by

the steering damper itself at the fully locket position both left and right side.

(Steering angle should be controlled by the regulation)

1) Recommended Steering Damper

OHLINS SD121

 Set the steering damper to the holder as shown.

2) Stroke(s)

SD121: 68 mm

1. Steering Damper: OHLINS SD121

2. Bracket: 11054-1816

3. Bracket: 11054-1817

4. Collar: 92152-0589

5. Ring: 670 B 2012

6. Washer: 410 B 0800

7. Bolt, Socket: 120 CA0630

8. Bolt, Socket: 120 CA0825

9. Bolt, Socket: 120 CA0865

10. Nut: 92105-1397

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

Rear Suspension Condition of Seat Height Adjustment

 When the seat height adjusts spacer applied, the rear suspension should be softened.

Seat Height Adjustment

Spacer Set: 92026-1586

P/No. Quantity Thickness

92026-1582 1 1.0 mm

92026-1583 1 2.0 mm

92026-1584 1 3.2 mm

92026-1585 2 4.5 mm

1. Nut 3. Collar

2. Spacer 4. Bracket

Front Fork Springs (Kit)

The optional front fork springs are available for racing.

1) Front Fork Specifications

Items Original

Rebounded damping setting (Upper) 1 1/2 turns out from the fully clockwise position

Compression damping setting (Lower) 1 1/2 turns out from the fully clockwise position

Fork oil SHOWA SS47 Fork oil level 97 mm

Oil lock Oil lock piece

Oil seal – – – Spring length 257.0 mm (Free Length)

Spring constant 9.0 N/mm

Sub spring stroke 28 mm

2) Front Fork Spring

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

Original 4.7 × 31.5 × 257.0 17.5 K = 9.0 N/mm

92145-0507 4.6 × 31.6 × 257.0 16.9 K = 8.25 N/mm

92145-0508 4.7 × 31.5 × 257.0 16.6 K = 9.25 N/mm

92145-0509 4.8 × 31.4 × 257.0 17.3 K = 9.75 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 spring constant value is stamped on the one side surface of the spring.

Fork Spring Installation

Electric Parts Installation

Battery

 Use the original battery or a battery with 12 V 7 Ah or more capacity.

Main Harness and Sub Harness (Kit)

Main harness and sub harness are available for racing use as optional parts. Select one

of them in accordance with your race regulation.

Main Harness (with Optional Meter): 26031-0559 Main Harness (with Original Meter): 26031-0558 Sub Harness (with Original Meter and Original Main Harness): 26031-0327

(Immobilizer non-installed model only) This set can not apply to the immobilizer installed model. For immobilizer installed model, apply the main harness of part number 26031-0058 or 26031-0559.

Meter (Kit) Installation

1. Tachometer with Water Temperature Gauge (Optional): 25031-1142

2. Collar (Optional): 92152-0058

3. Pad (Optional): 39156-0098

4. Bracket (Optional): 11053-1749

5. Rivet (Optional): 92039-1106

6. Nut (Optional): 92015-1233

7. Collar (Optional): 92152-1074

8. Bolt (Optional): 130J0625

9. Damper (Original): 92160-1167

10. Lamp Assembly (Optional): 23016-0006

 Insert the three collars [2] into the damper [3].  Insert the rivet [5] from the backside of the bracket [4] and fix them.  Install the bracket [4] to the original bracket [10].

Main Harness Combination Parts Table

Main Harness and Kit Part Combination Table

Harness

Part

Meter Assembly (Kit)

Harness for

Kit Meter

26031-0559

× ○ ○

Tachometer with Water

Temperature Gauge (Kit)

○ × ×

25031-1142 Water Temperature Gauge

Lead (Kit)

○ × ×

26011-1779 Water Temperature Sensor

Ground Lead (Kit)

○ × ×

26011-0071 Water Temperature Sensor

○ × ×

21176-1099 Relay Box (Original)

× × ○

27002-0007 Relay Assembly (Original)

○ ○ ×

27002-3703

Main Harness and Original Part Combination Table

Harness

Part

Main Harness (Original) Meter Assembly (Original) Left Handlebar Switches License Light Rear Brake Light Switch Turn Signal Light (Front, Rear, Left, Right) Headlight Tail/Brake Light Ignition Switch Fan Motor Horn Side Stand Switch Turn Signal Relay Fuse Box Neutral Switch Oil Pressure Switch

Harness for

Original Meter

26031-0558

Harness for Kit

Meter

26031-0559

× × × ○ × ○ × × × × × × × × × × × × × × × × × × × × × × × × × ×

○: need ×: no need.

Sub Harness

26031-0327

○

: need ×: no need.

Harness for

Original Meter

26031-0558

Wiring Routing

1. Vehicle-down Sensor 12. Main Throttle Sensor

2. Meter Assembly 13. Injector, Secondary

3. Shift Up Indicator Light 14. Injector, Primary

4. Right Handlebar Switch 15. Coolant Temperature Sensor

5. Left Handlebar Bar Switch 16. Speed Sensor

6. Intake Air Temperature Sensor 17. Crank Shaft Position Sensor

7. Boost Sensor 18. Gear Position Sensor

8. Cam Shaft Position Sensor 19. Battery (-)

9. Ignition Coil 20. Auto Shifter

10. Subthrottle Valve Actuator 21. Frame Ground

11. Cylinder Head Ground 22. Regulator

 The headlight beam (Hi/Lo) change switch on the left handlebar switch works as a speed

limit switch of the pit-road and passing switch works as same also.

 In case of using optional meter, the connector of coolant temperature sensor “15” must

used.

 The auto shifter “20” should be used according to local regulation.

1. Fuel Pump

2. Magnetic Switch

3. ECU

4. Relay Assembly (27002-3703)

5. Atmospheric Pressure Sensor

6. Power Source for Measuring Instruments

7. Setting Tool

 The relay assembly “4” should make sure to avoid the interference with other parts.  When apply the measuring instruments, the power source “6” available as a 12 V power

source.

 The setting tool should be used according to the manual of “Kawasaki FI Calibration

Tool”.

Wiring Diagram (with Kit Meter)

44 45

Wiring Diagram (with Original Meter Assembly)

Dummy Page

Racing Kit Parts List

’08

P8FR

Quantity-ZX600

Cylinder

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

92055 92055-011 RING-O,5MM 1

(OPTION)

1 DEC.27,2007

132 132BA0620 BOLT-FLANGED-SMALL,6X20 2

92055A 92055-086 RING-O,18.8X1.9 1

(OPTION)

No.

11004 11004-0067 GASKET-HEAD,T=0.70 1

11004A 11004-0068 GASKET-HEAD,T=0.60 1

11004B 11004-0069 GASKET-HEAD,T=0.55 1

11004C 11004-0070 GASKET-HEAD,T=0.50 1

11004D 11004-0071 GASKET-HEAD,T=0.45 1

12048 12048-1175 TENSIONER-ASSY 1

49118 49118-0110 CAMSHAFT-COMP,INTAKE 1

49118A 49118-0111 CAMSHAFT-COMP,EXHAUST 1

49118B 49118-0120 CAMSHAFT-COMP,EXHAUST 1

92015 92015-1078 NUT,FLANGED,6MM 1

(OPTION)

92043 92043-1506 PIN,10X14 4

This catalog covers:

’08 ZX600P8FR Engine B-3

’08

P8FR

Quantity-ZX600

(OPTION)

Crankshaft

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

2 DEC.27,2007

No.

92139 92139-0194 BUSHING,CONROD,BLUE AR

92139A 92139-0195 BUSHING,CONROD,BLACK 8

92139B 92139-0196 BUSHING,CONROD,BROWN AR

92139C 92139-0197 BUSHING,CRANK #5,BLUE AR

92139D 92139-0198 BUSHING,CRANK #5,BLACK 2

92139E 92139-0199 BUSHING,CRANK #5,BROWN AR

92139F 92139-0200 BUSHING,CRANK #1,BLUE AR

92139G 92139-0201 BUSHING,CRANK #1,BLK 8

92139H 92139-0202 BUSHING,CRANK #1,BRN AR

This catalog covers:

’08 ZX600P8FR Engine B-4

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Clutch

Part No. Description Spec Code

Ref.

3 DEC.27,2007

No.

39108 39108-0004 RETAINER-SPRING,T=5.0(STD-1.0) 6

92025 92025-1137 SHIM,15.3X27.5X1.20 1

92026 92026-1590 SPACER,T=1.5 1

This catalog covers:

’08 ZX600P8FR Engine B-5

’08

P8FR

Quantity-ZX600

(OPTION)

Part No. Description Spec Code

Transmission(TYPE-B)

This grid covers:

No.

Ref.

13127 13127-0055 SHAFT-TRANSMISSION INPUT,14T 1

13144 13144-0047 SPROCKET-OUTPUT,16T 1

GRID NO.

4 DEC.27,2007

13144A 13144-0048 SPROCKET-OUTPUT,15T 1

13262 13262-0526 GEAR,OUTPUT LOW,37T 1

13262A 13262-0527 GEAR,INPUT 2ND,18T 1

13262B 13262-0528 GEAR,OUTPUT 2ND,39T 1

13262C 13262-0529 GEAR,INPUT 3RD&4TH,20T&20T 1

13262D 13262-0530 GEAR,OUTPUT 4TH,33T 1

13262E 13262-0531 GEAR,INPUT 5TH,20T 1

13262F 13262-0532 GEAR,OUTPUT 5TH,30T 1

13262G 13262-0533 GEAR,INPUT 6TH,23T 1

13262H 13262-0534 GEAR,OUTPUT 6TH,32T 1

13262I 13262-0679 GEAR,INPUT 3RD&4TH,20T&19T 1

13262J 13262-0680 GEAR,INPUT 3RD&4TH,17T&20T 1

13262K 13262-0681 GEAR,INPUT 3RD&4TH,17T&20T 1

13262L 13262-0682 GEAR,INPUT 3RD&4TH,17T&23T 1

13262M 13262-0683 GEAR,OUTPUT 3RD,32T 1

92022 92022-1722 WASHER,22.3X35X1.8 AR

92022A 92022-212 WASHER,22.3X35X1.6 AR

92200 92200-0230 WASHER,28.3X34.0X1.4 AR

92200A 92200-0231 WASHER,28.3X34.0X1.8 AR

This catalog covers:

’08 ZX600P8FR Engine B-6

’08

P8FR

Quantity-ZX600

(OPTION)

Part No. Description Spec Code

Transmission(TYPE-C)

This grid covers:

No.

Ref.

13144 13144-0047 SPROCKET-OUTPUT,16T 1

13144A 13144-0048 SPROCKET-OUTPUT,15T 1

GRID NO.

5 DEC.27,2007

13262 13262-0535 GEAR,OUTPUT LOW,36T 1

13262A 13262-0536 GEAR,INPUT 2ND,16T 1

13262B 13262-0537 GEAR,OUTPUT 2ND,34T 1

13262C 13262-0538 GEAR,INPUT 5TH,24T 1

13262D 13262-0539 GEAR,OUTPUT 5TH.32T 1

13262E 13262-0540 GEAR,INPUT 6TH,26T 1

13262F 13262-0541 GEAR,OUTPUT 6TH,35T 1

13262G 13262-0684 GEAR,OUTPUT 4TH,39T 1

92022 92022-1722 WASHER,22.3X35X1.8 AR

92022A 92022-212 WASHER,22.3X35X1.6 AR

92200 92200-0230 WASHER,28.3X34.0X1.4 AR

92200A 92200-0231 WASHER,28.3X34.0X1.8 AR

This catalog covers:

’08 ZX600P8FR Engine B-7

’08

P8FR

Quantity-ZX600

(OPTION)

Part No. Description Spec Code

Transmission(TYPE-D)

This grid covers:

No.

Ref.

13144 13144-0047 SPROCKET-OUTPUT,16T 1

13144A 13144-0048 SPROCKET-OUTPUT,15T 1

GRID NO.

6 DEC.27,2007

13262 13262-0677 GEAR,INPUT 2ND,16T 1

13262A 13262-0678 GEAR,OUTPUT 2ND,36T 1

13262B 13262-0685 GEAR,OUTPUT 4TH,30T 1

13262C 13262-0686 GEAR,INPUT 5TH,23T 1

13262D 13262-0687 GEAR,OUTPUT 5TH,32T 1

13262E 13262-0688 GEAR,INPUT 6TH,23T 1

13262F 13262-0689 GEAR,OUTPUT 6TH,29T 1

92022 92022-1722 WASHER,22.3X35X1.8 AR

92022A 92022-212 WASHER,22.3X35X1.6 AR

92200 92200-0230 WASHER,28.3X34.0X1.4 AR

92200A 92200-0231 WASHER,28.3X34.0X1.8 AR

This catalog covers:

’08 ZX600P8FR Engine B-8

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Engine Cover(s)

Ref.

Part No. Description Spec Code

No.

7 DEC.27,2007

11061 11061-0303 GASKET,CLUTCH COVER 1

11061A 11061-0304 GASKET,GENERATOR COVER 1

11061B 11061-0305 GASKET,OIL PAN 1

11061C 11061-0306 GASKET,LARGE COVER 1

11061D 11061-0307 GASKET,SMALL COVER 1

14031 14031-0084 COVER-GENERATOR 1

This catalog covers:

’08 ZX600P8FR Engine B-9

’08

P8FR

Quantity-ZX600

(OPTION)

Fuel Injection

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

8 DEC.27,2007

No.

21175 21175-0145 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 26031-0327 HARNESS,SUB,STD METER&HARNESS 1

26031B 26031-0558 HARNESS,MAIN,STD METER 1

26031C 26031-0559 HARNESS,MAIN,KIT METER 1

27002 27002-3703 RELAY-ASSY 1

This catalog covers:

’08 ZX600P8FR Engine B-10

’08

P8FR

Quantity-ZX600

(OPTION)

Generator

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

9 DEC.27,2007

120 120CA0620 BOLT-SOCKET,6X20 2

No.

11054 11054-1799 BRACKET,OIL TANK 2

11054A 11054-1810 BRACKET,REGULATOR 1

14073 14073-0124 DUCT,FUNNEL,L=15 2

14073A 14073-0125 DUCT,FUNNEL,L=20 2

14073B 14073-0174 DUCT,FUNNNEL,L=30 2

21003 21003-0068 STATOR 1

21007 21007-0083 ROTOR 1

21066 21066-0010 REGULATOR-VOLTAGE 1

26031 26031-0635 HARNESS,ACG-REGULATOR 1

52001 52001-0004 TANK-OIL 1

92002 92002-1696 BOLT,SOCKET,6X25 4

92005 92005-0080 FITTING 2

92015 92015-1193 NUT,FLANGED,6MM 2

92022 92022-304 WASHER,6.2X11X1 1

92027 92027-194 COLLAR,L=11.1 2

92059 92059-1587 TUBE 1

92059A 92059-1629 TUBE,L=100MM 1

92075 92075-277 DAMPER 2

92150 92150-1717 BOLT,12X40 1

92200 92200-0306 WASHER,12X36X3.2 1

130 130BD0610 BOLT-FLANGED,6X10 1

This catalog covers:

’08 ZX600P8FR Engine B-11

’08

P8FR

Quantity-ZX600

(OPTION)

Radiator

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

10 DEC.27,2007

130 130BA0612 BOLT-FLANGED,6X12 1

No.

11054 11054-1818 BRACKET,RADIATOR 1

11065 11065-1056 CAP 1

35063 35063-0439 STAY,RADIATOR 1

39060 39060-0020 RADIATOR,BIG 1

39062 39062-0219 HOSE-COOLING,KIT RAD.-PIPE 1

39062A 39062-0220 HOSE-COOLING,O.COOLER-KIT RAD 1

39192 39192-0011 PIPE-WATER 1

49085 49085-1066 CAP-ASSY-PRESSURE 1

92043 92043-1436 PIN 1

92075 92075-1123 DAMPER,RUBBER 3

92170 92170-1287 CLAMP,COOLING HOSE 1

92171 92171-0179 CLAMP 3

554 554DA1000 PIN-SNAP,10MM 1

This catalog covers:

’08 ZX600P8FR Engine B-12

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

11 DEC.27,2007

No.

11054 11054-1816 BRACKET 1

11054A 11054-1817 BRACKET 1

13061 13061-1628 BOSS 1

13280 13280-0011 HOLDER,STEERING DAMPER 1

13280A 13280-0012 HOLDER,STEERING DAMPER 1

31064 31064-1151 PIPE-COMP,GRIP 1

32099 32099-0004 CASE,UPP 1

32099A 32099-0005 CASE,LWR 1

46003 46003-1351 HANDLE 2

46012 46012-1238 HOLDER-HANDLE,LH 1

46012A 46012-1239 HOLDER-HANDLE,RH 1

46075 46075-1143 GRIP,THROTTLE 1

54012 54012-0232 CABLE-THROTTLE,OPENING 1

54012A 54012-0233 CABLE-THROTTLE,CLOSING 1

59101 59101-0001 REEL,R21.5,60DEG 1

59101A 59101-0002 REEL,R20.0,65DEG 1

92015 92015-1316 NUT,FLANGED,16MM 1

92015A 92015-1397 NUT,LOCK,FLANGED,8MM 1

92026 92026-1586 SPACER,SET 1

92150 92150-1090 BOLT,6MM 2

92150A 92150-1494 BOLT,SOCKET,10X50 2

92151 92151-1593 BOLT,SOCKET,8X25 2

120 120CA0630 BOLT-SOCKET,6X30 3

92152 92152-0589 COLLAR 1

This catalog covers:

’08 ZX600P8FR Chassis C-3 Frame Fittings(1/2)

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

12 DEC.27,2007

120A 120CA0635 BOLT-SOCKET,6X35 2

120B 120CA0825 BOLT-SOCKET,8X25 1

120C 120CA0830 BOLT-SOCKET,8X30 2

120D 120CA0865 BOLT-SOCKET,8X65 1

120E 120CB0625 BOLT-SOCKET,6X25 2

410 410AA0800 WASHER-PLAIN-SMALL,8MM 2

No.

670 670B2012 O RING,12MM 1

This catalog covers:

’08 ZX600P8FR Chassis C-4 Frame Fittings(2/2)

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

13 DEC.27,2007

No.

92145 92145-0507 SPRING,FRONT FORK,K=8.25N/MM 2

92145A 92145-0508 SPRING,FRONT FORK,K=9.25N/MM 2

92145B 92145-0509 SPRING,FRONT FORK,K=9.75N/MM 2

This catalog covers:

’08 ZX600P8FR Chassis C-5 Front Fork

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

14 DEC.27,2007

No.

11053 11053-1749 BRACKET,KIT METER 1

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 92039-1231 RIVET 3

92152 92152-0058 COLLAR 3

130 130BB0625 BOLT-FLANGED,6X25 2

92152A 92152-1074 COLLAR 2

This catalog covers:

’08 ZX600P8FR Chassis C-6 Meter(s)

’08

P8FR

Quantity-ZX600

(OPTION)

This grid covers:

GRID NO.

Part No. Description Spec Code

Ref.

15 DEC.27,2007

No.

43082 43082-0074 PAD-ASSY-BRAKE,FR 1

43082A 43082-1192 PAD-ASSY-BRAKE,RR,C93 1

43082B 43082-1220 PAD-ASSY-BRAKE,RR,C93G 1

55020 55020-0028 GUARD,CHAIN 1

92057 92057-1529 CHAIN,DRIVE,120L(#520) 1

92058 92058-1090 JOINT-CHAIN,DRIVE(#520) 1

92145 92145-0504 SPRING,SHOCKABSORBER,K=95N/MM 1

92145A 92145-0505 SPRING,SHOCKABSORBER,K=100N/MM 1

92145B 92145-0506 SPRING,SHOCKABSORBER,K=105N/MM 1

130 130BB1020 BOLT-FLANGED,10X20 1

92153 92153-1777 BOLT,FLANGED,10X60 4

This catalog covers:

’08 ZX600P8FR Chassis C-7 Other

Doc No. 99929-0231-01

Kawasaki ZX-6R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Specifications

Racing Kit Service Data

Periodic Maintenance Chart

Preparation

Before Installing

Racing Kit Parts

Engine Parts Installation

Air Intake Parts

Cylinder Head

Camshaft Chain Tensioner

Camshafts, Sprockets

Valve Springs

Cylinder Compression

Crankshaft Main Journal and Connecting Rod Big End Bushings

Connecting Rod Bolts

Clutch Adjustment (Back-Torque Limiter Setting)

Transmission

Transmission Shimming

Generator (Option)

Generator Cover (Option)

Cover Gaskets

Ducts (Air Funnels)

Muffler

Water Temperature Sensor

Radiator (Kit)

Oil Catch Tank Installation

Frame Parts Installation

Throttle Parts (Kit)

Brake Pads (Kit)

Steering Damper (Kit)

Seat Height Adjustment

Front Fork Springs (Kit)

Electric Parts Installation

Battery

Main Harness and Sub Harness (Kit)

Meter (Kit) Installation

Main Harness Combination Parts Table

Wiring Routing

Wiring Diagram (with Kit Meter)

Wiring Diagram (with Original Meter Assembly)