Kawasaki ZX6R 636 Service Manual Parts_05

KAWASAKI ZX-6R

2005

PARTS CATALOG

AIR CLEANER

Ref # Part # Description Qty Spec Code

130 130L0630 BOLT-FLANGED,M6X30 1
11010 11010-0061 FILTER-ASSY-AIR 1
11013 11013-0010 ELEMENT-AIR FILTER 1
11061 11061-0127 GASKET 2
11065 11065-0082 CAP,AIR FILTER CASE 1
13045 13045-1057 RECEIVER-OIL 1
14073 14073-0077 DUCT,#1,#4 2
14073A 14073-0081 DUCT,#2,#3 2
16126 16126-1433 VALVE,AIR SWITCH 1
92005 92005-1402 FITTING 1 [CA]
92027 92027-251 COLLAR,L=13.1 1
92037 92037-010 CLAMP,TUBE 1
92037A 92037-1593 CLAMP 1
92037B 92037-1712 CLAMP 1
92059 92059-103 TUBE,6X9X360 1
92160 92160-1162 DAMPER 1
92170 92170-1017 CLAMP 1
92170A 92170-1060 CLAMP 2
92171 92171-0436 CLAMP,FUNNEL TIGHTEN 4
92172 92172-0177 SCREW,5X16 6
92191 92191-1813 TUBE,FITTING-AIR SWITC H 1 [CA]
92192 92192-0009 TUBE,10X16X29 2
92192A 92192-0153 TUBE,BLOW-BY 1
92192B 92192-0154 TUBE,A/C-ASV 1 [CN,US]
92192C 92192-0168 TUBE,FITTING-A/C 1 [CA]

AIR DUCT

Ref # Part # Description Qty Spec Code

14037 14037-0026 SCREEN,INTAKE 1
16181 16181-0002 TANK-RESONATOR 1
39045 39045-0011 DUCT-ASSY,RAM 1
92071 92071-3704 GROMMET 1
92093 92093-0030 SEAL,RAMDUCT 1
92153 92153-0875 BOLT,6X18 4
92172 92172-0009 SCREW,TAPPING,5X20 2
92210 92210-0130 NUT 4

BRAKE PEDAL/TORQUE LINK

Ref # Part # Description Qty Spec Code

180 180L0614 BOLT-UPSET-WS 1
13236 13236-0069 LEVER-COMP,BRAKE PEDAL 1
92022 92022-1282 WASHER,7X28X1.6 1
92022A 92022-326 WASHER,15.3X24X1 1
92145 92145-0230 SPRING,BRAKE PEDAL RETURN 1
92190 92190-1185 TUBE,16X19X30 1

CABLES

Ref # Part # Description Qty Spec Code

54010 54010-0030 CABLE,SEAT LOCK 1
54011 54011-0042 CABLE-CLUTCH 1
54012 54012-0132 CABLE-THROTTLE 1
92171 92171-0447 CLAMP,CABLE 1

CAMSHAFT(S)/TENSIONER

Ref # Part # Description Qty Spec Code

120 120P0625 BOLT-SOCKET,6X25 1
670 670D1509 O RING,9MM 1
670A 670D2014 O RING,14MM 1
12046 12046-0038 SPROCKET,CAM,32T 2
12048 12048-1181 TENSIONER-ASSY 1
12053 12053-1475 GUIDE-CHAIN,FR 1
12053A 12053-1476 GUIDE-CHAIN,RR 1
12053B 12053-1477 GUIDE-CHAIN,UPP 1
13107 13107-0089 SHAFT 1
13107A 13107-1416 SHAFT,CHAIN GUIDE,FR 1
49118 49118-0006 CAMSHAFT-COMP,INTAKE 1
49118A 49118-0024 CAMSHAFT-COMP,EXHAUST 1
92022 92022-2373 WASHER,6.2X15.0X1.2 1
92027 92027-1143 COLLAR,6.3X10X12 1
92055 92055-086 RING-O,18.8X1.9 1
92057 92057-1531 CHAIN,CAM 1
92151 92151-1829 BOLT,SOCKET,6X10 4
92151A 92151-1930 BOLT,FLANGED-SMALL,M6X25 2

CHAIN COVER

Ref # Part # Description Qty Spec Code

36014 36014-0020 CASE-CHAIN 1
92071 92071-0020 GROMMET 1
92151 92151-1654 BOLT,SOCKET,6X14 3

CHASSIS ELECTRICAL EQUIPMENT

Ref # Part # Description Qty Spec Code

130 130V0610 BOLT-FLANGED,M6X10 3
11053 11053-1228 BRACKET,RADIATOR 1
21061 21061-0001 RECTIFIER 1
26006 26006-0001 FUSE,15A 3
26006A 26006-1078 FUSE,10A 6
26011 26011-0037 WIRE-LEAD 1
26011A 26011-0056 WIRE-LEAD,BATTERY(-) 1
26011B 26011-0069 WIRE-LEAD,BATTERY(+) 1
26012 26012-1326 BATTERY,YTX9-BS,12V 8AH 1
26031 26031-0248 HARNESS,MAIN 1
27002 27002-0001 RELAY-ASSY 1
27002A 27002-0006 RELAY-ASSY,SIGNAL LAMP 1
27003 27003-0030 HORN 1
56030 56030-0091 LABEL,FUSE BOX 1
56030A 56030-0092 LABEL,FUSE BOX 1
92037 92037-1069 CLAMP,L=60 5
92037A 92037-1827 CLAMP,HOSE 1
92072 92072-1195 BAND,L=202 2
92072A 92072-1414 BAND 1
92153 92153-0410 BOLT,SOCKET,6X10 1
92161 92161-0203 DAMPER,RELAY BOX 1
92161A 92161-0283 DAMPER,SIGNAL RELAY 1
92171 92171-0462 CLAMP 1
92171A 92171-0465 CLAMP,HARNESS 2
92171B 92171-0478 CLAMP 1

CLUTCH

Ref # Part # Description Qty Spec Code

120 120Q0620 BOLT-SOCKET,6X20 6
13087 13087-0019 HUB-CLUTCH 1
13087A 13087-0020 HUB-CLUTCH 1
13088 13088-1124 PLATE-FRICTION 8
13089 13089-0007 PLATE-CLUTCH,T=2.0 AR
13089A 13089-0008 PLATE-CLUTCH,T=2.3 5
13089B 13089-0009 PLATE-CLUTCH,T=2.6 2
13091 13091-1041 HOLDER,CLUTCH SPRING 6
13095 13095-0042 HOUSING-COMP-CLUTCH,NO MARK 1
13095A 13095-0044 HOUSING-COMP-CLUTCH,"A" MARK 1
13095B 13095-0045 HOUSING-COMP-CLUTCH,"B" MARK 1
13095C 13095-0046 HOUSING-COMP-CLUTCH,"C" MARK 1
13102 13102-0015 RELEASE-COMP-CLUTCH 1
13187 13187-0008 PLATE-CLUTCH OPERATING 1
39130 39130-1078 SPRING-LEAF 2
39130A 39130-1079 SPRING-LEAF 2
46102 46102-0051 ROD 1
92026 92026-0022 SPACER 1
92026A 92026-1356 SPACER 1
92046 92046-1052 BEARING-NEEDLE,AXK1102 1
92046A 92046-1263 BEARING-NEEDLE,K38X43X28.8X 1
92139 92139-0067 BUSHING,25X38X29.05 1
92144 92144-1854 SPRING,FRICTION PLATE 1
92145 92145-0293 SPRING 6
92145A 92145-1159 SPRING,ROD 1
92145B 92145-1339 SPRING 1
92153 92153-0797 BOLT 6
92180 92180-0149 SHIM,15.3X27.5X2.0 1
92200 92200-1260 WASHER,FRICTION PLATE 1
92200A 92200-1423 WASHER,11.2X18X0.5 1
92200B 92200-1487 WASHER,12X18.5X0.5 1
92210 92210-0152 NUT 1

COWLING

Ref # Part # Description Qty Spec Code

130 130L0616 BOLT-FLANGED,M6X16 3
411 411F0600 WASHER-PLAIN,6MM,BLACK 4
11053 11053-1289 BRACKET,MIRROR&METER 1
14091 14091-0435 COVER,UPP COWLING 2
14091A 14091-0456 COVER 2
39154 39154-0008 WINDSHIELD 1
39156 39156-0077 PAD,INNER COWLING,LH 1
39156A 39156-0078 PAD,INNER COWLING,RH 1
55028 55028-0027-723 COWLING,UPP,C.P.BLUE 1
55028A 55028-0027-724 COWLING,UPP,P.M.RED 1
55028B 55028-0027-725 COWLING,UPP,M.F.R.TITANIUM 1
55028C 55028-0027-777 COWLING,UPP,L.GREEN 1
55028D 55028-0032 COWLING,FR,CNT 1
55028E 55028-0035 COWLING,INNER,LH 1
55028F 55028-0036 COWLING,INNER,RH 1
56001 56001-0005 MIRROR-ASSY,LH 1
56001A 56001-0006 MIRROR-ASSY,RH 1
92015 92015-1757 NUT,WELL,5MM 6
92075 92075-1067 DAMPER 4
92153 92153-1244 BOLT,SOCKET,5X16 6
92172 92172-0175 SCREW,TAPPING,5X16 2
92200 92200-0006 WASHER,NYLONE,5.3X11.5X0.5 6
92210 92210-0003 NUT,CAP,6MM 4
92210A 92210-0130 NUT 3

COWLING LOWERS

Ref # Part # Description Qty Spec Code

130 130L0520 BOLT-FLANGED,M5X20 4
130A 130L0616 BOLT-FLANGED,M6X16 1
11053 11053-0402 BRACKET,LWR COWLING 1
11053A 11053-1393 BRACKET,COWLING,LH 1
14091 14091-0353-723 COVER,SIGNAL LAMP,LH,C.P.BLUE 1
14091A 14091-0353-724 COVER,SIGNAL LAMP,LH,P.M.RED 1
14091B 14091-0353-725 COVER,SIGNAL LAMP,LH,TITANIUM 1
14091C 14091-0353-777 COVER,SIGNAL LAMP,LH,L.GREEN 1
14091D 14091-0354-723 COVER,SIGNAL LAMP,RH,C.P.BLUE 1
14091E 14091-0354-724 COVER,SIGNAL LAMP,RH,P.M.RED 1
14091F 14091-0354-725 COVER,SIGNAL LAMP,RH,TITANIUM 1
14091G 14091-0354-777 COVER,SIGNAL LAMP,RH,L.GREEN 1
14091H 14091-0418 COVER,HEAT GUARD,LH 1
14091I 14091-0419 COVER,HEA T GUARD ,R H 1
55028 55028-0028-723 COWLING,CNT,LH,C.P.BLUE 1
55028A 55028-0028-724 COWLING,CNT,LH,P.M.RED 1
55028B 55028-0028-725 COWLING,CNT,LH,M.F.R.TITANIUM 1
55028C 55028-0028-777 COWLING,CNT,LH,L.GREEN 1
55028D 55028-0029-723 COWLING,CNT,RH,C.P.BLUE 1
55028E 55028-0029-724 COWLING,CNT,RH,P.M.RED 1
55028F 55028-0029-725 COWLING,CNT,RH,M.F.R.TITANIUM 1
55028G 55028-0029-777 COWLING,CNT,RH,L.GREEN 1
55028H 55028-0030-8J COWLING,LWR,LH,F.S.BLACK 1
55028I 55028-0031-8J COWLING,LWR,RH,F.S.BLACK 1
55028J 55028-0033 COWLING,FR,LH 1
55028K 55028-0034 COWLING,FR,RH 1
92015 92015-1757 NUT,WELL,5MM 16
92039 92039-0014 RIVET 5
92153 92153-0489 BOLT,SOCKET,6MM 7
92153A 92153-0873 BOLT,SOCKET,5X20 8
92153B 92153-1244 BOLT,SOCKET,5X16 4
92171 92171-1280 CLAMP 1
92172 92172-0175 SCREW,TAPPING,5X16 4
92200 92200-0006 WASHER,NYLONE,5.3X11.5X0.5 12
92200A 92200-0157 WASHER,10.4X15.9X0.5 7

CRANKCASE

Ref # Part # Description Qty Spec Code

670 670D1505 O RING 3
13271 13271-0380 PLATE,BREATHER 1
13271A 13271-0381 PLATE,SIDE BREATHER 1
14001 14001-0053 SET-CRANKCASE 1
14013 14013-004 RING-POSITION 2
14014 14014-0017 PLATE-POSITION 1
21176 21176-0028 SENSOR,SPEED 1
27010 27010-1313 SWITCH,OIL PRESSURE 1
39193 39193-0025 PIPE-OIL 1
39193A 39193-0026 PIPE-OIL 1
92002 92002-1449 BOLT,6X10 2
92002A 92002-1778 BOLT,SOCKET,6X16 2
92002B 92002-1796 BOLT,SOCKET,6X12 2
92005 92005-1238 FITTING,BREATHER 1
92026 92026-0058 SPACER 1
92026A 92026-0069 SPACER,14.3X16.6X3.2 2
92042 92042-007 PIN,DOWEL,6.3X8X14 2
92043 92043-1506 PIN 3
92043A 92043-1690 PIN,6X16 2
92046 92046-037 BEARING-NEEDLE,7E-HK1412 1
92049 92049-1307 SEAL-OIL,TC32528 1
92049A 92049-1520 SEAL-OIL,TC14245 1
92055 92055-0065 RING-O,13.8X1.9 2
92055A 92055-1146 RING-O,20X2 1
92055B 92055-1343 RING-O,5.5X1.5 2
92062 92062-0006 NOZZLE,OIL JET 2
92066 92066-1012 PLUG,OIL LINE,7.2X8 1
92066A 92066-1110 PLUG 2
92066B 92066-1252 PLUG,PT3/8X12 1
92066C 92066-1394 PLUG,MAIN GALLERY,18X9 1
92150 92150-1019 BOLT,SOCKET,5X20 2
92150A 92150-1841 BOLT,6X12 1
92151 92151-1774 BOLT,FLANGED,M6X16 1
92153 92153-0753 BOLT,8X15 2
92170 92170-1167 CLAMP 1
92170A 92170-1925 CLAMP 1
92171 92171-0473 CLAMP,WATER HOSE 1
92192 92192-0155 TUBE,BREATHER 1

CRANKCASE BOLT PATTERN

Ref # Part # Description Qty Spec Code

130 130P0675 BOLT-FLANGED,M6X75 2
92150 92150-1250 BOLT,7X70 2
92150A 92150-1547 BOLT,6X35 3
92153 92153-0329 BOLT,6X95 2
92153A 92153-0692 BOLT,8X94 4
92153B 92153-0693 BOLT,8X71 6
92153C 92153-0925 BOLT,M6X50,WHITE 1
92153D 92153-0926 BOLT,M6X65,WHITE 2
92153E 92153-0927 BOLT,M6X85,WHITE 1
92153F 92153-1109 BOLT,7X38 6
92200 92200-0153 WASHER,8.5X18X3.0 10
92200A 92200-1461 WASHER,6.8X11.5X1.0 2

CRANKSHAFT

Ref # Part # Description Qty Spec Code

13031 13031-0041 CRANKSHAFT-COMP,"A" MARK 1
13031A 13031-0042 CRANKSHAFT-COMP,NO MARK 1
13031B 13031-0043 CRANKSHAFT-COMP,"B" MARK 1
13031C 13031-0044 CRANKSHAFT-COMP,"C" MARK 1
13251 13251-0008-KK ROD-ASSY-CONNECTING,K 4
92015 92015-1527 NUT,CONNECTING ROD,7MM 8
92139 92139-0071 BUSHING,CRANK #3,BLUE 4
92139A 92139-0072 BUSHING,CRANK #3,BLACK AR
92139B 92139-0073 BUSHING,CRANK #3,BROWN AR
92139C 92139-0074 BUSHING,CRANK #1,BLUE 6
92139D 92139-0075 BUSHING,CRANK #1,BLACK AR
92139E 92139-0076 BUSHING,CRANK #1,BROWN AR
92139F 92139-0087 BUSHING,CONNECTING ROD,YELLOW AR
92139G 92139-0088 BUSHING,CONNECTING ROD,GREEN 8
92139H 92139-0089 BUSHING,CONNECTING ROD,PURPLE AR
92153 92153-1172 BOLT,7MM 8

CYLINDER HEAD

Ref # Part # Description Qty Spec Code

551 551A0612 PIN-DOWEL,6X12 2
11004 11004-0027 GASKET-HEAD 1
11008 11008-0039 HEAD-COMP-CYLINDER 1
11061 11061-0042 GASKET,BEARING CAP 4
16065 16065-1386 HOLDER-CARBURETOR 4
39156 39156-0072 PAD,SOUND ABSORPTION 1
49002 49002-1152 GUIDE-VALVE AR
92004 92004-1249 STUD,8X22 8
92005 92005-1273 FITTING 1
92043 92043-1263 PIN,6.2X8X14 4
92043A 92043-1264 PIN,8.2X10X14 4
92055 92055-0073 RING-O,11.7X1.4 4
92055A 92055-0074 RING-O,25.5X2 4
92055B 92055-1536 RING-O,42X1.9 4
92066 92066-0002 PLUG,PT1/2X12.5 4
92066A 92066-1420 PLUG,PT3/8X10 1
92150 92150-1928 BOLT,SOCKET,6X92 1
92153 92153-0406 BOLT,TORX,M6X14 8
92153A 92153-1250 BOLT,9X146 8
92153B 92153-1251 BOLT,9X138 2
92153C 92153-1258 BOLT,6X40 20
92171 92171-0173 CLAMP,CARBURETOR HOLDER 2
92200 92200-0193 WASHER,9.2X19X2.3 10

CYLINDER HEAD COVER

Ref # Part # Description Qty Spec Code

11061 11061-0156 GASKET,HEAD COVER 1
11065 11065-1247 CAP 2
12021 12021-1130 VALVE-ASSY-REED 2
14091 14091-0372 COVER,HEAD 1
92002 92002-1327 BOLT,FLANGED,M6X10.5X12 6
92055 92055-1352 RING-O,HEAD COVER BOLT 6
92153 92153-1284 BOLT,SOCKET,6X18 4
92170 92170-1514 CLAMP 1
92171 92171-0459 CLAMP 2

CYLINDER/PISTON(S)

Ref # Part # Description Qty Spec Code

130 130Y0610 BOLT-FLANGED,M6X10 1
11005 11005-0036 CYLINDER-ENGINE 1
11061 11061-0041 GASKET,CYLINDER BASE 1
13001 13001-0051 PISTON-ENGINE 4
13002 13002-0005 PIN-PISTON 4
13008 13008-0015 RING-SET-PISTON 4
92022 92022-304 WASHER,6.2X11X1 1
92033 92033-1161 RING-SNAP,PISTON PIN 8
92043 92043-4009 PIN,10.1X12X14 2

DECALS (BLUE)

Ref # Part # Description Qty Spec Code

56052 56052-0154 MARK,WINDSHIELD,KAWASAKI 1
56052A 56052-0506 MARK,FUEL TANK COVER,KAWASAKI 2
56052B 56052-0507 MARK,SEAT COVER,ZX-6R 2
56052C 56052-0508 MARK,CNT COWLING,NINJA 2
56052D 56052-0509 MARK,CNT COWLING,636 2

DECALS (GREEN)

Ref # Part # Description Qty Spec Code

56052 56052-0154 MARK,WINDSHIELD,KAWASAKI 1
56052A 56052-0497 MARK,FUEL TANK COVER,KAWASAKI 2
56052B 56052-0498 MARK,SEAT COVER,ZX-6R 2
56052C 56052-0499 MARK,CNT COWLING,NINJA 2
56052D 56052-0500 MARK,CNT COWLING,636 2

DECALS (RED)

Ref # Part # Description Qty Spec Code

56052 56052-0154 MARK,WINDSHIELD,KAWASAKI 1
56052A 56052-0510 MARK,FUEL TANK COVER,KAWASAKI 2
56052B 56052-0511 MARK,SEAT COVER,ZX-6R 2
56052C 56052-0512 MARK,CNT COWLING,NINJA 2
56052D 56052-0513 MARK,CNT COWLING,636 2

DECALS (TITANIUM)

Ref # Part # Description Qty Spec Code

56052 56052-0154 MARK,WINDSHIELD,KAWASAKI 1
56052A 56052-0502 MARK,FUEL TANK COVER,KAWASAKI 2
56052B 56052-0503 MARK,SEAT COVER,ZX-6R 2
56052C 56052-0504 MARK,CNT COWLING,NINJA 2
56052D 56052-0505 MARK,CNT COWLING,636 2

ENGINE COVER(S)

Ref # Part # Description Qty Spec Code

132 132J0630 BOLT-FLANGED-SMALL,M6X30 1
132A 132J0635 BOLT-FLANGED-SMALL,M6X35 4
551 551A0814 PIN-DOWEL,8X14 2
11053 11053-1353 BRACKET,CLUTCH WIRE 1
11053A 11053-1456 BRACKET,GENERATOR COVER,RR 1
11053B 11053-1677 BRACKET,GENERATOR COVER,FR 1
11053C 11053-1699 BRACKET,PULSER COVER 1
11053D 11053-1700 BRACKET,CLUTCH COVER 1
11060 11060-1853 GASKET,CLUTCH COVER 1
11060A 11060-1867 GASKET,PULSING COVER 1
11061 11061-0113 GASKET,GENERATOR COVER 1
13271 13271-0561 PLATE 1
14026 14026-0018 COVER-CHAIN 1
14031 14031-0032 COVER-GENERATOR 1
14032 14032-0037 COVER-CLUTCH 1
14091 14091-0319 COVER,PULSER 1
16115 16115-1009 CAP-OIL FILLER 1
52005 52005-1057 GAUGE,OIL LEVEL 1
56031 56031-1895 LABEL-MANUAL,OIL CAPACITY 1
92042 92042-007 PIN,DOWEL,6.3X8X14 2
92046 92046-1010 BEARING-NEEDLE,HK1210 2
92049 92049-1271 SEAL-OIL,TB12205.5 1
92055 92055-049 RING-O,31.7X2.4 1
92151 92151-1134 BOLT,6X30 5
92151A 92151-1201 BOLT,6X30 1
92151B 92151-1365 BOLT,SOCKET,5X12 2
92153 92153-0608 BOLT,6X30 6
92153A 92153-0634 BOLT,6X35 8
92153B 92153-0635 BOLT,6X40 1
92153C 92153-0786 BOLT,6X30 1
92153D 92153-0830 BOLT,6X50 1
92153E 92153-0929 BOLT,M6X40,YEL 1
92153F 92153-0992 BOLT,SOCKET 1
92170 92170-1577 CLAMP 1
92171 92171-0411 CLAMP 1
92171A 92171-0477 CLAMP 2
92171B 92171-1238 CLAMP 1