Kawasaki ZX6R 636 Service Manual Assembly_05
Ninja ZX-6R
Motorcycle
Assembly & Prepa
Manual
ration
Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki motorcycles.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or less of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
correctly followed, could result in damage to, or destruction of equipment.
NOTE
○This note symbol indicates points of particular
interest for more efficient and convenient operation.
Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.
© 2004 Kawasaki Heavy Industries, Ltd. Sep. 2004 (K)
Table of Contents
crating ......................................................................................
Un
Opening Crate ............................................................................. 3
Parts Check ................................................................................. 4
sembly ......................................................................................
As
Steering Stem Head Nut ............................................................. 4
Clutch Cable ................................................................................ 5
indshield...................................................................................
W
Rider’s Seat Bolt.......................................................................... 5
Brake Disc Cleaning .................................................................... 5
reparation ...................................................................................
P
Battery Service ............................................................................ 6
Front Brake Fluid ......................................................................... 13
Rear Brake Fluid ......................................................................... 15
Clutch Lever and Cable............................................................... 17
Drive Chain.................................................................................. 17
Front Fork .................................................................................... 19
Rear Shock Absorber .................................................................. 20
Tire Air Pressures........................................................................ 21
Fuel ............................................................................................. 21
Coolant ........................................................................................ 21
Engine Oil (4-stroke) ................................................................... 23
Throttle Grip and Cable ............................................................... 24
Rear Brake Light Switch.............................................................. 24
Idle Speed Adjustment ................................................................ 25
Headlight Aim .............................................................................. 25
Digital Meter ................................................................................ 25
Fastener Check ........................................................................... 28
Standard Torque Table ................................................................ 30
Test Ride the Motorcycle ............................................................. 30
A & P Check List ......................................................................... 30
3
4
5
6
Uncrating
Opening Crate
Clear a space about 6 m (20 ft) square to give
•
yourse
Place the crate upright on its base.
•
Remove the cardboard cover.
•
Remov
•
When you remove the crate bracket
from the motorcycle, be careful not to
drop any parts and bracket onto the
fuel tank and other components, and
not to scratch the fuel tank by the crate
bracket. This could damage the fuel
tank or components.
First, remove the lower crate bolt (D = 22) at
•
the steering stem and discard it.
Remove the upper crate bolts (D = 8) to take
•
off the crate bracket and foam pad and discard them.
lf plenty of space to work.
e the parts box.
CAUTION
A. Lower Support Bracket
UNCRATI
NG 3
A. Lower Crate Bolt (D = 22)
B. Upper Crate Bolts (D = 8)
C. Crate Bracket
D. Foam Pad
Take out all the bolts and screws and remove
•
the top and sides of the crate.
Lift the vehicle upward about 10 cm (4 in.) and
•
remove the two lower support brackets. Roll
the vehicle off the crate base.
4 ASSEMB
LY
Parts Check
Open the parts box, and check the parts
•
against the illustrations. There may be minor differences between these illustrations
and the actual vehicle parts. In the following
charts under Remarks, D = diameter in millimeters, and L = length in millimeters.
No. Part Name Qty Remarks
1 Steering S tem Head Nut 1 D=28
2 Plastic Washer 6 D=5.3×11.5
Socket Bolt 6 D = 5, L = 16
ellnut
W
Windshield 1
3 Socket Bolt, Rider’s Seat 2 D = 6, L = 16.3
attery Electrolyte, YTX9-BS
4
B
5
Owner’s Manual
Assembly
SteeringStemHeadNut
Remove the steering stem head dummy nut
•
and discard it. Do not remove the steering
stem flat washer under the dummy nut.
Remove the non-permanent locking agent
•
and clean the steering stem shaft threads.
Install the steering stem head nut (D = 28) on
•
the flat washer with the chamfered side facing
upwards and tighten it to the specified torque.
Torque: 78 N·m (8.0 kgf·m, 58 ft·lb)
6 D
1 12 V 8 Ah
1
=5
A. Dummy Nut
B. Flat Washer
A. Chamfered Side of Stem Head Nut
B. Flat Washer
Clutch Cable
Apply a light coat of grease on the clutch inner
•
cable.
Line up the slots on the clutch lever and ad-
•
juster.
Fit the tip of the clutch inner cable into the
•
lever socket, slide the inner c able through the
slots, and release the outer cable into the adjuster.
ASSEMBLY 5
A. Front Tab
B. Slot
C. Upper Fairing
Install the six plastic washers and the socket
•
bolts (D = 5, L = 16) on the upper fairing.
A. Clutch Cable
B. Adjuster
C. Cable Tip
D. Clutch Lever
Windshield
Fit the six wellnuts (D = 5) into the holes in the
•
edge of the windshield from the outside with
their flanges out.
A. Plastic Washers and Socket Bolts
B. Windshield
Tighten the windshield bolts. Do not over
•
tighten the windshield bolts.
Rider’s Seat Bolt
Install the rider’s seat bolts. See “Battery Ser-
•
vice” section.
Brake Disc Cleaning
Clean the front and rear brake discs using
•
oilless solvent.
A. Windshield
B. Wellnuts
Put the front tab into the slot of the upper
•
fairing.
WARNING
If not removed, the anticorrosive treatment applied to the brake disc surface
will interfere with brake action, and an
unsafe riding condition could result.
6 PREPARATION
A. Rider’s Seat
Preparation
Battery Service
Rider’s Seat Removal
Unscrew the left and right side cover bolts
•
(D = 6) (3) and remove the covers by pulling
them outward to clear the projections.
A. Left Side Cover
B. Bolts (D = 6)
C. Projections
The battery used in this motorcycle is a sealed
type and never ne
procedure for activating a new battery to ensure
the best possible battery performance.
Activating
ing the battery with electrolyte, and charging.
Read the electrolyte safety label and the following proc
tion.
edures carefully before battery activa-
eds to be refilled. Follow the
the battery requires two steps, fill-
CAUTION
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
Make sure to use the electrolyte packed in the
•
crate with the unit.
Make sure that the model name of the elec-
•
trolyte container matches the model name of
the battery. These names must be the same.
Battery Model Name for
ZX636-C1: YTX9-BS
A. Right Side Cover
B. Bolt (D = 6)
C. Projection
Remove the rider’s seat by pulling the front of
•
it up and forward.
A.
Model Name of the Electrolyte
B. Model Name of the Battery
CAUTION
Sealed battery electrolyte has a higher
concentration of sulfuric acid. Each
container contains the proper amount
of electrolyte for its specific battery.
Insufficient or incorrect electrolyte will
reduce battery performance and service
life. Electrolyte over capacity can lead
to battery cracking or leaking and result
in corrosion damage to the vehicle.
Battery Removal
Check for fuel in the fuel tank.
•
If fuel remains in the fuel tank, do the following
•
procedures.
Draw the fuel out from the fuel tank with a
•
commercially available pump.
Use a soft plastic hose as a pump inlet hose
•
in order to insert the hose smoothly.
Put the hose through the filler opening into the
•
tank and draw the fuel out.
PREPARATION 7
A. Fuel Tank
B. Fuel Tank Bolt (D = 6)
C. Fuel Tank Bolts (D = 8)
Remove the fuel tank pivot bolt (D = 6).
•
Disconnect the fuel pump connector (4P).
•
WARNING
The fuel could not be removed completely from the fuel tank. Be careful for
remained fuel spillage.
A. Commercially Available Pump
B. Soft Plastic Hose
C. Filler Opening
D. Front
Remove the fuel tank bolts (D = 6, D = 8) (3).
•
A. Fuel Tank Pivot Bolt (D = 6)
B. Fuel Pump Connector (4P)
Open the fuel tank cap to lower the pressure
•
in the tank.
NOTE
○During tank removal, keep the tank cap open
to release pressure in the tank. This reduces
fuel spillage.
Be sure to place a piece of cloth around the
•
fuel hose joint.
Push the joint lock claws.
•
8PREPAR
ATION
A. Fuel Hose Joint
B. Joint Lock Claws
Pull the joint lock.
•
Pull the fuel hose joint out of the delivery pipe.
•
WARNING
Be prepared for fuel spillage; any spilled
fuel must be completely wiped up immediately.
When the fuel hose is disconnected, fuel
spills out from the hose and the pipe because of residual pressure. Cover the
hose connection with a piece of clean
cloth to prevent fuel spillage.
A. Fuel Tank
B. Drain Hose
Close the fuel tank cap.
•
Remove the fuel tank, and place it on a flat
•
surface.
For California Model, note the following.
•
CAUTION
For California model, if gasoline, solvent, water or any other liquid enters the
canister, the canister’s vapor absorbing
capacity is greatly reduced. If the canister does become contaminated, replace
it with a new one.
Remove the fuel return hose (red) and
•
breather hose (blue) from the fuel tank.
A. Joint Lock
B. Fuel Hose Joint
Remove the drain hose from the fuel tank.
•
A. Fuel Tank
B. Fuel Return Hose (Red)
C. Breather Hose (Blue)
Be sure to plug the evaporative fuel return
•
hose to prevent fuel spilling before fuel tank
removal.
WARNING
For California model, be careful not to
spill the gasoline through the return
hose. Spilled fuel is hazardous.
PREPARA
TION 9
If liquid or gasoline flows into the breather
•
hose, remove the hose and blow it clean with
compressed air.
Be careful of fuel spillage from the fuel tank
•
since fuel still remains in the fuel tank and fuel
pump.
WARNING
Store the fuel tank in an area which is
well-ventilated and free from any source
me or sparks. Do not smoke in this
of fla
area. Place the fuel tank on a flat surface
and plug the fuel pipes to prevent fuel
age.
leak
Remove the fuel tank bracket bolts.
•
Remove the left seat cover bolt (D = 6) (1) and
•
right seat cover bolts (D = 6) (2).
Place the battery on a level surface.
•
Check to see that the sealing sheet has no
•
peeling, tears, or holes in it.
Remove the sealing sheet.
•
NOTE
○The battery is vacuum sealed. If the sealing
sheet
require a longer initial charge.
Remove the electrolyte container from the
•
vinyl bag.
De
•
and set aside, these will be used later to seal
the battery.
has leaked air into the battery, it may
tach the strip of caps [A] from the container
A. Fuel Tank Bracket Bolts (D = 6)
B. Seat Cover Bolts (D = 6)
C. Battery
Take the battery out of the battery case.
•
Battery Specifications
Make Yuasa
Battery Type
Battery Capacity 12 V 8 Ah
Electrolyte Capacity 0.40 L
Battery/Electrolyte Set P/No. 26012-1326
YTX9-BS
Battery Activation
Filling the Battery with Electrolyte
CAUTION
Do not remove the aluminum sealing
sheet [A] from the filler ports [B] until
just prior to use. Be sure to use the dedicated electrolyte container for correct
electrolyte volume.
NOTE
○Do not pierce or otherwise open the sealed
cells [B] of the electrolyte container. Do not
attempt to separate individual cells.
Place the electrolyte container upside down
•
with the six sealed cells into the filler ports
of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
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