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	99924-1382-02
	Motorcycle Service Manual

© 2008 Kawasaki Heavy Industries, Ltd.

First Edition (1): Jan. 25, 2008

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.

1

Dummy page

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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

3

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

			STD	Type B	Type C	Type D
			(Type A)
		In	13127-0044	13127-0055	13127-0055
	1st	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
	2nd	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
		In	See Gear	See Gear
			Selection	Selection
	3rd	Out	13262-0509	13262-0683
		Teeth (Out/In)	37/20	32/17
		Gear Ratio	1.850	1.882
		In	See Gear	See Gear	See Gear	See Gear
			Selection	Selection	Selection	Selection
	4th	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
	5th	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
	6th	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

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Input 3rd/4th Gear Selection Table

4th Gear

		A	B	C	D
3rd Gear	A	13262-0506	13262-0529		13262-0679
	B	13262-0680	13262-0681	13262-0682

Gear Identification Slit Number Table

			STD	Type B	Type C	Type D
			(Type A)
	1st	In	0	1	1
		Out	0	1	2
	2nd	In	0	1	2	3
		Out	0	1	2	3
	3rd	In	0	1
		Out	0	1
	4th	In	0	1	2	3
		Out	0	1	2	3
	5th	In	0	1	2	3
		Out	0	1	2	3
	6th	In	0	1	2	3
		Out	0	1	2	3

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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	NGK R0045Q-10, R0373A-10
Spark plug tightening torque	13 N·m (1.3 kgf·m, 113 in·lb)

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.

6

Periodic Maintenance Chart

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

FREQENCY	Each	Every	Every	Every	As
	Race	3 races	5 races	10 races
OPERATION					Required
	(300 km)	(1 000 km)	(1 500 km)	(3 000 km)
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	●

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FREQENCY	Each	Every	Every	Every	As
	Race	3 races	5 races	10 races
OPERATION					Required
	(300 km)	(1 000 km)	(1 500 km)	(3 000 km)
Wheel bearing (rear) - - grease				●
Swingarm pivot, uni-track linkage - - grease			●
Swingarm pivot, uni-track linkage - - check*			●

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

8

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)

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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.

10

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.

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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.

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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	308°				8.30 mm			0.13 0.19 mm
49118-0110				(conformed to FIM regulation)
Exhaust	274°				7.30 mm			0.24 0.31 mm
49118-0111				(not conformed to FIM regulation)
Exhaust	274°				7.50 mm			0.24 0.31 mm
49118-0120				(conformed to FIM regulation)
					13

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.

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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

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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

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

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Main Journal Bush

A. Size Color

	Size Color		Thickness mm		Journal Number					Part Number			Part Number
										(STD)				(KIT)
	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
								Size		Journal		Part			Part
	Crankcase inner Diameter			Crankshaft Diameter								Number			Number
								Color		Number
												(STD)			(KIT)
	○			1				brown		1-4	92139-0191				92139-0202
	(34.000 mm ~ 34.008 mm)			(30.992 mm ~ 31.000 mm)						5	92139-0173				92139-0199
	○			NONE				black		1-4	92139-0190				92139-0201
	(34.000 mm ~ 34.008 mm)			(30.984 mm ~ 30.992 mm)						5	92139-0172				92139-0198
	NONE			1				black		1-4	92139-0190				92139-0201
	(34.008 mm ~ 34.016 mm)			(30.992 mm ~ 31.000 mm)						5	92139-0172				92139-0198
	NONE			NONE				blue		1-4	92139-0189				92139-0200
	(34.008 mm ~ 34.016 mm)			(30.984 mm ~ 30.992 mm)						5	92139-0171				92139-0197

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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	Part Number
			(STD)	(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

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Selection Table

	Connecting Rod Big End	Crankpin Diameter Mark	Size	Part Number	Part Number
	Inside Diameter		Color	(STD)	(KIT)
	None	○	brown	92139-0167	92139-0196
	(33.000 mm ~ 33.008 mm)	(29.992 mm ~ 30.000 mm)
	None	None	black	92139-0166	92139-0195
	(33.000 mm ~ 33.008 mm)	(29.984 mm ~ 29.992 mm)
	○	○	black	92139-0166	92139-0195
	(33.008 mm ~ 33.016 mm)	(29.992 mm ~ 30.000 mm)
	○	None	blue	92139-0165	92139-0194
	(33.008 mm ~ 33.016 mm)	(29.984 mm ~ 29.992 mm)

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.

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