Kawasaki ZX 6R 2009 Owners

8/13/2019 Kawasaki ZX 6R 2009 Owners

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Quick Reference GuideGENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide willassist you in finding the informationyoure looking for.

A Table of Contents is included afterthe Foreword.


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Whenever you see the symbolsshown below, heed their instructions!

Always follow safe operating and main-tenance practices.

WARNING

This warning symbol identifiesspecial instructions or proce-dures which, if not correctly fol-lowed, could result in personalinjury, or loss of life.

CAUTION

This caution symbol identifiesspecial instructions or proce-dures which, if not strictly ob-

served, could result in damageto or destruction of equipment.

NOTE

This note symbol indicates points ofparticular interest for more efficient

and convenient operation.


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FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-torcycle is the product of Kawasakis advanced engineering, exhaustive testing,and continuous striving for superior reliability, safety and performance.

Please read this Owners Manual carefully before riding so that you will bethoroughly familiar with the proper operation of your motorcycles controls, its fea-tures, capabilities, and limitations. This manual offers many safe riding tips, but itspurpose is not to provide instruction in all the techniques and skills required to ridea motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-

cle enroll in a motorcycle rider training program to attain awareness of the mentaland physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care andmaintenance described in this manual. For those who would like more detailed in-formation on their Kawasaki Motorcycle, a Service Manual is available for purchasefrom any authorized Kawasaki motorcycle dealer. The Service Manual contains de-

tailed disassembly and maintenance information. Those who plan to do their ownwork should, of course, be competent mechanics and possess the special toolsdescribed in the Service Manual.

Keep this Owners Manual aboard your motorcycle at all times so that you canrefer to it whenever you need information.


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TABLE OF CONTENTS

SPECIFICATIONS............................... 8

SERIAL NUMBER LOCATIONS......... 12

LOCATION OF PARTS ....................... 13

LOCATION OF LABELS..................... 16

LOADING AND ACCESSORIES

INFORMATION ................................ 19

GENERAL INFORMATION ................. 22

Meter Instruments ............................ 22

Tachometer:.................................. 23Digital Meter: ................................ 24

Warning/Indicator Lights: .............. 35

Key................................................... 41

Ignition Switch/Steering Lock........... 41

Right Handlebar Switches................ 43

Engine Stop Switch: ..................... 43

Starter Button: .............................. 44START/STOP Switch (Stop

Watch): ...................................... 44

Left Handlebar Switches .................. 44

Dimmer Switch: ............................ 44

Turn Signal Switch:....................... 45

Horn Button: ................................. 45

LAP Button: .................................. 45

Brake Lever Adjuster........................ 46

Fuel Tank Cap .................................. 47

Fuel Tank ......................................... 48

Fuel Requirement: ........................ 49

Side Stand ....................................... 52

Seats................................................ 53Seat Cover ....................................... 58

Helmet Hooks................................... 60

Tool Kit ............................................. 61

Air Cleaner Intake ............................ 61

BREAK-IN ........................................... 62

HOW TO RIDE THE MOTORCYCLE. 64

Starting the Engine .......................... 64Jump Starting................................... 67

Moving Off........................................ 69

Shifting Gears .................................. 70

Braking ............................................. 71


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Stopping the Engine......................... 73

Stopping the Motorcycle in an

Emergency ................................... 74

Parking ............................................. 75

Catalytic Converter........................... 76

SAFE OPERATION............................. 78

Safe Riding Technique ..................... 78

Daily Safety Checks ......................... 80

Additional Considerations for High

Speed Operation .......................... 82

MAINTENANCE AND ADJUSTMENT 84Periodic Maintenance Chart............. 89

Engine Oil ........................................ 100

Cooling System................................ 105

Spark Plugs...................................... 110

Evaporative Emission Control

System (California model only)..... 111

Valve Clearance ............................... 112Kawasaki Clean Air System............. 112

Exhaust Device ................................ 113

Air Cleaner ....................................... 114

Throttle Control System ................... 120

Engine Vacuum Synchronization ..... 122

Idle Speed........................................ 123

Clutch............................................... 124

Drive Chain ...................................... 126

Brakes.............................................. 136

Brake Light Switches........................ 140

Steering Damper.............................. 142

Front Fork......................................... 143

Rear Shock Absorber....................... 147

Wheels ............................................. 151

Battery.............................................. 157

Headlight Beam................................ 162Fuses ............................................... 164

General Lubrication.......................... 165

Cleaning Your Motorcycle ................ 167

Bolt and Nut Tightening.................... 173

STORAGE........................................... 176

TROUBLESHOOTING GUIDE............ 179

OWNER SATISFACTION.................... 180REPORTING SAFETY DEFECTS ...... 182

ENVIRONMENTAL PROTECTION..... 183

MAINTENANCE RECORD ................. 184

LABEL INFORMATION ...................... 191


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8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall Length 2 090 mm (82.3 in.)

Overall Width 710 mm (28.0 in.)

Overall Height 1 115 mm (43.9 in.)

Wheelbase 1 400 mm (55.1 in.)

Road Clearance 120 mm (4.7 in.)

Curb Mass 191 kg (421 lb)

ENGINE

Type DOHC, 4-cylinder, 4-stroke, liquid-cooled

Displacement 599 cm (36.6 cu in.)

Bore Stroke 67.0 42.5 mm (2.64 1.67 in.)

Compression Ratio 13.3 : 1

Starting System Electric starter

Cylinder Numbering Method Left to right, 1-2-3-4


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SPECIFICATIONS 9

Firing Order 1-2-4-3

Carburetion System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing (Electronicallyadvanced)

12.5 BTDC @1 300 r/min (rpm)

Spark Plugs NGK CR9E

Lubrication System Forced lubrication (wet sump)

Engine Oil Type: API SE, SF or SG

API SH, SJ, SL or SM with JASO MA, MA1 or MA2SAE 10W-40

Capacity: 3.6 L (3.8 US qt)

Coolant Capacity 2.5 L (2.6 US qt)

TRANSMISSION

Transmission Type 6-speed, return shift

Clutch Type Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio 1.900 (76/40)


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10 SPECIFICATIONS

Final Reduction Ratio 2.688 (43/16)

Overall Drive Ratio 6.638 (Top gear)

Gear Ratio 1st 2.714 (38/14)

2nd 2.200 (33/15)

3rd 1.850 (37/20)

4th 1.600 (32/20)

5th 1.421 (27/19)

6th 1.300 (26/20)

FRAME

Castor 24

Trail 103 mm (4.1 in.)

Tire Size: Front 120/70ZR17 M/C (58 W)

Rear 180/55ZR17 M/C (73 W)

Rim Size: Front 17 3.50

Rear 17 5.50

Fuel Tank Capacity 17 L (4.5 US gal)


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SPECIFICATIONS 11

ELECTRICAL EQUIPMENT

Battery 12 V 8 Ah

Headlight High beam 12 V 55 W + 65 W

Low beam 12 V 55 W

LED Tail/Brake Light 0.5/4.1 W

Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consultwith an authorized Kawasaki dealer.Specifications subject to change without notice.


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12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. Theyare the only means of identifying your particular machine from others of the samemodel type. These serial numbers may be needed by your dealer when orderingparts. In the event of theft, the investigating authorities will require both numbersas well as the model type and any peculiar features of your machine that can helpthem identify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number


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LOCATION OF PARTS 13

LOCATION OF PARTS

1. Clutch Lever2. Left Handlebar Switches3. Compression Damping Force

Adjuster (Front Fork)4. Rebound Damping Force Adjuster

(Front Fork)5. Meter Instruments

6. Brake Fluid Reservoir (Front)7. Right Handlebar Switches8. Front Brake Lever9. Throttle Grip

10. Ignition Switch/Steering Lock11. Steering Damper


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14 LOCATION OF PARTS

12. Headlight13. Air Cleaner Intake

14. Turn Signal Light15. Spark Plugs16. Fuel Tank17. Air Cleaner18. Riders Seat19. Seat Lock20. Passengers Seat

21. Tail/Brake Light22. License Plate Light

23. Brake Disc24. Spring PreloadAdjuster

25. Front Fork26. Brake Caliper27. Idle Adjusting Screw28. Side Stand

29. Rebound DampingForce Adjuster

30. Shift Pedal31. CompressionDamping ForceAdjuster

32. Drive Chain33. Chain Adjuster


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LOCATION OF PARTS 15

34. Fuse Box35. Battery

36. Fuel Tank Cap37. Muffler38. Swingarm39. Rear Shock Absorber

40. Rear Brake Pedal41. Rear Brake Light Switch

42. Oil Level Gauge43. Brake Fluid Reservoir (Rear)44. Coolant Reserve Tank


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16 LOCATION OF LABELS

LOCATION OF LABELS

1. Brake Fluid (Front)

2. Important Drive Chain Information

3. Tire and Load Data

4. Brake Fluid (Rear)

(For further information of label,refer to the LABEL INFORMATION

chapter.


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LOCATION OF LABELS 17

5. Noise Emission Control Information

6. Weight and Manufacture

7. Vehicle Emission Control

Information

8. Battery Poison/Danger

(For further information of label,

refer to the LABEL INFORMATIONchapter.)


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18 LOCATION OF LABELS

9. Daily Safety Checks

*10. Vacuum Hose Routing Diagram

11. Fuel Caution

*12. Fuel Level

(For further information of label,

refer to the LABEL INFORMATION

chapter.)*: Only on California model


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20 LOADING AND ACCESSORIES INFORMATION

following general guidelines have beenprepared to assist you in making yourdeterminations.1. Any passenger should be thor-

oughly familiar with motorcycle op-eration. The passenger can affectcontrol of the motorcycle by im-proper positioning during corneringand sudden movements. It is im-portant that the passenger sits still

while the motorcycle is in motionand not interfere with the operationof the motorcycle. Do not carry ani-mals on your motorcycle.

2. You should instruct any passengerbefore riding to keep his or her feeton the passenger footpegs and hold

on to the operator or seat strap. Donot carry a passenger unless he orshe is tall enough to reach the foot-pegs and footpegs are provided.

3. All baggage should be carried aslow as possible to reduce the effect

on the motorcycle center of gravity.Baggage weight should also be dis-tributed equally on both sides of themotorcycle. Avoid carrying baggage

that extends beyond the rear of themotorcycle.

4. Baggage should be securely at-tached. Make sure that the baggagewill not move around while you areriding. Recheck baggage security

as often as possible (not while themotorcycle is in motion) and adjustas necessary.

5. Do not carry heavy or bulky items ona luggage rack. They are designedfor light items, and overloading canaffect handling due to changes in

weight distribution and aerodynamicforces.

6. Do not install accessories or carrybaggage that impairs the perfor-mance of the motorcycle. Makesure that you have not adversely

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LOADING AND ACCESSORIES INFORMATION 21

affected any lighting components,road clearance, banking capability(i.e., lean angle), control operation,wheel travel, front fork movement,

or any other aspects of the motor-cycles operation.

7. Weight attached to the handlebar orfront fork will increase the mass ofthe steering assembly and can re-sult in an unsafe riding condition.

8. Fairings, windshields, backrests,and other large items have the ca-pability of adversely affecting stabil-ity and handling of the motorcycle,not only due to their weight, butalso due to the aerodynamic forcesacting on these surfaces while the

motorcycle is in operation. Poorlydesigned or installed items can re-sult in an unsafe riding condition.

9. This motorcycle is not intended tobe equipped with a sidecar or to be

used to tow any trailers or other ve-hicles. Kawasaki does not manu-facture sidecars or trailers for mo-torcycles and cannot predict the ef-

fects of such accessories on han-dling or stability, but can only warnthat the effects can be adverse andthat Kawasaki cannot assume re-sponsibility for the results of suchunintended use of the motorcycle.

Furthermore, any adverse effects onmotorcycle components caused bythe use of such accessories will notbe remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,and accessories must not exceed 180 kg

(397 lb).

22 GENERAL INFORMATION


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GENERAL INFORMATION

Meter Instruments

A. MODE ButtonB. RESET ButtonC. Shift-Up Indicator LightD. TachometerE. Red ZoneF. Fuel Level Indicator LightG. High Beam Indicator LightH. Neutral Indicator Light

I. Turn Signal Indicator LightJ. Warning LightK. Digital Meter

GENERAL INFORMATION 23


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Tachometer:The tachometer shows the engine

speed in revolutions per minute (r/min,rpm). On the top side of the tachometer

face is a portion called the red zone.Engine r/min (rpm) in the red zone isabove maximum recommended enginespeed and is also above the range forgood performance.

When the ignition key is turned toON, the tachometer momentarilygoes from the minimum to the maxi-mum, then goes back from the maxi-mum to the minimum reading to checkits operation. If the tachometer doesnot operate correctly, have it checkedby an authorized Kawasaki dealer.

CAUTION

Engine r/min (rpm) should notbe allowed to enter the red zone;

operation in the red zone willoverstress the engine and maycause serious engine damage.



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Digital Meter:The digital meter displays the follow-

ing functions: the speedometer, clock,trip meter, odometer, coolant tempera-

ture meter, stop watch, gear position,oil pressure warning symbol, and fuelinjection warning symbol. Pushingthe MODE button shifts the display inthe digital meter through the followingthree modes: odometer, trip meter andstop watch. When the ignition key isturned to ON, all the LCD segmentsare displayed for three seconds, then,depending on the mode selected, theclock or meters operate normally.

A. OdometerB. Trip meterC. Stop WatchD. Push MODE Button



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Digital Meter

A. Gear PositionB. SpeedometerC. Fuel Injection (FI)/Oil Pressure Warning

Symbol ( )D. Trip Meter/Odometer/Stop WatchE. Clock

F. Lap Counter/Coolant Temperature Meter

NOTE

Do not shift the digital meter displaywhile riding for safe operation.

Mphkm/h Display -Mphkm/h Display can alternate be-

tween English and metric modes (mphand km/h) in the digital meter. Make

sure that km/h or mph is correctly dis-played according to local regulationsbefore riding.

NOTE

Do not operate the vehicle with thedigital meter displaying in the wrong

unit (km/h or mph) of the digital me-ter. Shift the mphkm/h display in thedigital meter as follows.


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Push the RESET button. The hourdisplay stops flashing and the minutedisplay starts flashing. Push theMODE button to advance the min-

utes.

Push the RESET button. Both thehour and minute displays start flash-ing again.

Push the MODE button. The dis-plays stop flashing and the clockstarts working.

NOTE

Pushing the MODE button momen-tarily advances the hour or minutestep by step. Pushing and hold-ing the button advances the hour orminute continuously.

The clock works normally from theback-up power while the ignitionswitch is turned off.

When the battery is disconnected,

the clock resets to 1:00 and startsworking again when the battery isconnected.



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G O O 29

Odometer -The odometer shows the total dis-

tance in kilometers or miles that the ve-hicle has been ridden. This meter can-

not be reset.

NOTE

The data is maintained even if thebattery is disconnected.

When the figures come to 999999,they are stopped and locked.

Trip Meters -The trip meter shows the distance in

kilometers or miles traveled since it waslast reset to zero.

To reset the trip meter:

Push the MODE button to display thetrip meter.

Push the RESET button and hold it

in.

After two second, the figure displayturns to 0.0, and then starts countingwhen the vehicle is operated. Themeter counts until it is reset.



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NOTE

The data is maintained by the back-up power if the ignition key is turnedoff.

When the trip meter reaches 999.9while riding, the meter is reset to 0.0and continues counting.

When the battery is disconnected,the meter display is reset to 0.0.

Lap Counter/Coolant TemperatureMeter -

The Lap counter/coolant temperaturemeter shows either the lap number or

the coolant temperature. The lap num-ber is displayed when in the stop watchmode.

The coolant temperature is displayedas follows.

Start the engine. If the coolant tem-perature is below 40 C (104 F), notemperature is displayed.


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If the coolant temperature rises toabove 120 C (248 F), HI is dis-played and starts flashing. Thiswarns the operator that the coolant

temperature is too high. Stop theengine and check the coolant levelin the reserve tank after the enginecools down.

CAUTION

Do not let the engine continue

running when the coolant tem-perature shows HI. Prolongedengine operation will result insevere engine damage fromoverheating.

Stop Watch -The stop watch can be used in closed

course competition.The stop watch is operated as fol-

lows: Turn the ignition Key to ON. Push the MODE button to display the

stop watch.

Push the START/STOP switch on theright handlebar switch to the left.

A. Start/Stop Switch



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The stop watch starts timing laps.

A. Lap Time

After each lap, push the LAP buttonon the left handlebar switch.

A. Lap Button



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The stop watch starts timing the nextlap and the previous lap time is dis-played for ten seconds.

A. Lap TimeB. Lap Number

To stop the stop watch, push theSTART/STOP switch on the righthandlebar switch to the left.

To display each measured lap time,

push the RESET button momentarily.When no lap number is displayed,the time displayed is the total time ofall timed laps.

A. Total Lap Time



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To reset the stop watch and erase alllap numbers and times, push the RE-SET button for more than two sec-onds.

NOTE

If the coolant temperature risesabove 115 C (239 F) with the Lapnumber displayed, the Lap numberdisplay in the Lap/Coolant Tempera-ture Meter automatically shifts to thecoolant temperature meter.

When the battery is disconnected, alllap numbers and times are reset.

The lap time can be stored for a max-imum of 99 times.

Warning/Indicator Lights:N: When the transmission is in neutral,the neutral indicator light goes on.

: When the headlight is on highbeam, the high beam indicator lightgoes on.

: When the turn signal switch ispushed to the left or right, the turn sig-nal indicator light flashes.

Warning Light: This warning light inthe meter instrument has the two warn-ing light function: oil pressure warninglight and fuel injection system warninglight. This warning light flash on with

the each warning symbols: engine oilpressure warning symbol ( )/fuelinjection warning symbol (FI). If thewarning light flashs on with the enginerunning, have its cause checked by anauthorized Kawasaki dealer. Refer to



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the following each symbol instructions

( ) or (FI) for more detailed infor-mation.

: The warning light in the meterinstrument and the oil pressure warn-

ing symbol ( ) in the digital meterflash on whenever the oil pressure isdangerously low or the ignition switchis in the ON position with the engine

not running, and go off when the en-gine oil pressure is high enough. Re-fer to the Maintenance and Adjustmentchapter for more detailed engine oil in-formation.

FI: The warning light in the meter in-strument and the fuel injection warningsymbol (FI) in the digital meter flash onwhenever the ignition key is turned to

ON or trouble occurs in the fuel injec-tion system. After turning the ignitionkey to ON, the fuel injection warningsymbol (FI) goes off soon after it is en-sured that its circuit functions properly.If the warning light and warning symbolflashs on, have the FI system checked

by an authorized Kawasaki dealer.



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: The fuel level indicator light goeson and FUEL flashes in the digital me-ter, when only 3.5 L (3.7 US qt) of fuelremains. Refuel at the earliest oppor-

tunity when the fuel level indicator lightgoes on and FUEL flash.

When vehicle stands with SideStand, Fuel Level Indicator Light can-not show the amount of fuel in the fueltank exactly. Stand upright the vehicleto check the fuel level.

A. Fuel Level Indicator LightB. FUEL Flashes

NOTE

When pushing the MODE buttonwhile FUEL is displayed, the dis-

play can be shifted to odometer, trip

meter, or clock mode.


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To adjust the shift-up engine speed,press the RESET button and the shift-up engine speed timing advances in50 r/min (rpm) increments up to 16

500 r/min (rpm). Once the readingreaches at 16 500 r/min (rpm) whileadvancing, it returns to 14 000 r/min(rpm) and begins advancing.

A. Shift Up Indicator LightB. Adjustable Range

To complete the adjustment, pushthe MODE button and RESET but-ton simultaneously for more than twoseconds. The tachometer now oper-

ates normally.



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WARNING

Failing to properly observe theroad ahead increases the chanceof an accident. Do not concen-trate on the shift-up indicatorlight by taking your eyes off theroad, observe using peripheralvision.When shifting down to a lowergear, do not shift at such a high

speed that the engine r/min(rpm) jumps excessively. Notonly can this cause engine dam-age, but the rear wheel may skidand cause an accident. Down-shifting should be done below5 000 r/min (rpm) for each gear.

NOTE

Pushing and holding the RESET but-ton advances the shiftup enginespeed continuously.

The data is maintained even if thebattery is disconnected.

CAUTION

Engine r/min (rpm) should notbe allowed to enter the red zone;

operation in the red zone willoverstress the engine and maycause serious engine damage.



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KeyThis motorcycle has a combination

key, which is used for the ignitionswitch/steering lock, seat lock, and fuel

tank cap.Blank keys are available at a

Kawasaki dealers. Ask a dealer tomake any additional spare keys youmay need, using your original key as amaster.

Write your key number here.

Ignition Switch/Steering LockThis is a four-position, key-operated

switch. The key can be removed fromthe switch when it is in the OFF, LOCK,

or P (Park) position.

A. Ignition Switch/Steering LockB. ON position

C. OFF positionD. LOCK positionE. P (Park) position



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OFF Engine off. All electrical

circuits off.

ON Engine on. All electrical

equipment can be used.

LOCK Steering locked. Engine off.

All electrical circuits off.

P (Park)

Steering locked. Engine off.Tail and license plate lights on.All other electrical circuits cutoff.

NOTE

The tail, city and license plate lightsare on whenever the ignition key isin the ON position. One headlightgoes on when the starter button is

released after starting the engine. Toavoid battery discharge, always start

the engine immediately after turningthe ignition key to ON.

If you leave the P (Park) position onfor a long time (one hour), the battery

may become totally discharged.



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Right Handlebar SwitchesEngine Stop Switch:

In addition to the ignition switch,the engine stop switch must be in

the position for the motorcycle tooperate.

The engine stop switch is for emer-gency use. If some emergency re-quires stopping the engine, move the

engine stop switch to the position.

NOTEAlthough the engine stop switch

stops the engine, it does not turn offall the electrical circuits. Ordinarily,the ignition switch should be used tostop the engine.

A. Engine Stop SwitchB. Start/Stop Switch (Stop Watch)C. Starter Button


L ft H dl b S it h


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Starter Button:The starter button operates the elec-

tric starter when the transmission is inneutral.

Refer to the Starting the Engine sec-tion of the How to Ride the Motorcyclechapter for starting instructions.

START/STOP Switch (Stop Watch):Refer to the Digital Meter section of

this chapter for stop watch instructions.

Left Handlebar SwitchesDimmer Switch:

High or low beam can be selectedwith the dimmer switch. When the

headlight is on high beam ( ), thehigh beam indicator light goes on.

High beam.......( )

Low beam.......( )

NOTE

When the headlight is on high beam,both headlights go on. When theheadlight is on low beam, only oneheadlight goes on.


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B k L Adj t


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Brake Lever AdjusterThere is an adjuster on the brake

lever. The adjuster has 6 positions sothat the released lever position can be

adjusted to suit the operators hands.Push the lever forward and turn the ad-

juster to align the number with the markon the lever holder. The distance fromthe grip to the released lever is min-imum at Number 6 and maximum atNumber 1. A. Adjuster

B. Mark


Fuel Tank Cap


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Fuel Tank CapTo open the fuel tank cap, pull up the

key hole cover. Insert the ignition keyinto the fuel tank cap and turn the key

to the right.To close the cap, push it down into

place with the key inserted. The keycan be removed by turning it to the leftto the original position.

NOTE

The fuel tank cap cannot be closedwithout the key inserted, and the keycannot be removed unless the cap islocked properly.

Do not push on the key to close thecap, or the cap cannot be locked.

A. Key Hole CoverB. Ignition KeyC. Fuel Tank Cap


Fuel Tank WARNING


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Fuel TankThe following octane rating gasoline

is recommended in the fuel tank. Avoidfilling the tank for the rain or where

heavy dust is blowing so that the fueldoes not get contaminated.

A. Tank Cap

B. Fuel TankC. Top LevelD. Filler Neck

WARNING

Gasoline is extremely flammableand can be explosive under cer-tain conditions. Turn the igni-

tion key to OFF. Do not smoke.Make sure the area is well ven-tilated and free from any sourceof flame or sparks; this includesany appliance with a pilot light.Never fill the tank so the fuel

level rises into the filler neck. Ifthe tank is overfilled, heat maycause the fuel to expand andoverflow through the vents inthe tank cap.After refueling, make sure thefuel tank cap is closed securely.

If gasoline is spilled on the fueltank, wipe it off immediately.


CAUTION of a gasoline is a measure of its resis


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CAUTION

California models only: Neverfill the tank so the fuel level risesinto the filler neck. If the tank is

overfilled, heat may cause thefuel to expand and flow into theEvaporative Emission ControlSystem resulting in hard start-ing and engine hesitation andin compliance with the emission

regulation.

Fuel Requirement:

Fuel TypeUse clean, fresh unleaded gasoline

with a minimum Antiknock Index of 90.The Antiknock Index is posted on ser-vice station pumps. The octane rating

of a gasoline is a measure of its resis-tance to detonation or knocking. The

Antiknock Index is an average of theResearch Octane Number (RON) and

the Motor Octane Number (MON) asshown in the table.

MinimumOctane Rating Method

Rating

(RON + MON)Antiknock

Index 2

90

CAUTION

Use minimum of 90 octane gaso-line only to prevent severe en-gine damage.


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CAUTION Side Stand


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CAUTION

Never store this product withgasohol in the fuel system.Before storage it is recom-

mended that you drain all fuelfrom the fuel system. See theStorage section in this manual.

Side StandThe motorcycle is equipped with a

side stand.

A. Side Stand

NOTE

When using the side stand, turn thehandlebar to the left.

Whenever the side stand is used,make it a practice to kick the stand fullyup before sitting on the motorcycle.


NOTE Seats


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NOTE

The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does not

start if the transmission is in gear andthe side stand is down.

Seats

Riders Seat Removal

Remove the screw.

Remove the side cover by pulling out

it to detach the hook and projection,and hook-and-loop fastener.

A. ScrewB. ProjectionC. Hook-and-Loop FastenerD. HookE. Side Cover


Remove the bolts and pull off the seat Riders Seat Installation


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e o e t e bo ts a d pu o t e seatto the up and front.

A. Bolts (Both Side)B. Riders SeatC. Pull Up and Front

de s Seat sta at o

Place the tab on the rear of the ridersseat into the slot in the frame andtighten the bolt.

A. Riders SeatB. TabC. Slot


When installing the side cover, insert Passengers Seat Removal


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g ,the lower side of the cover into theframe first, and then insert the upperside of the cover into the under of the

riders seat to prevent damage of thehook.

A. Side Cover

B. Lower Part of CoverC. Upper Part of CoverD. Hook

gRemove the passengers seat by in-

serting the ignition key into the seatlock, and turning it clockwise.

A. Seat LockB. Ignition Key


NOTE


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When removing the passengersseat, pull it up while turning the key.

A. Passengers SeatB. Pull upC. Turn the Key


Passengers Seat Installation Pull up the front and rear ends of the


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Insert the tab on the rear of the pas-sengers seat into the slot in theframe.

Insert the left and right projections atthe front of the passengers seat intothe left and right holes on the frame.

Push down the front part of the pas-sengers seat until the lock clicks.

A. ProjectionsB. HolesC. TabD. Slot

passengers seat to make sure theyare securely locked.


Seat Cover NOTE


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(Only on Ninja ZX-6R MONSTERENERGY Model)

Seat Cover RemovalRemove the seat cover by insertingthe ignition key into the seat lock, andturning it clockwise.

A. Seat LockB. Ignition Key

When removing the seat cover, pull itup while turning the key.

A. Seat CoverB. Pull upC. Turn the Key

Seat Cover Installation

Insert the tab on the rear of the seatcover into the slot in the frame.


Insert the left and right projections atf f f

Replace the seat cover with the pas-


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the front of the seat cover into the leftand right holes on the frame.

Push down the front part of the seatcover until the lock clicks.

A. ProjectionsB. Holes

C. TabD. Slot

Pull up the front and rear ends ofthe seat cover to make sure they aresecurely locked.

sengers seat when carrying passengeror baggage on this motorcycle.

CAUTION

Do not carry the passenger orbaggage on the seat cover, or thecover could be damaged.

A. Riders SeatB. Seat Cover


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Tool KitTh t l kit i l t d d th

Air Cleaner IntakeTh i l i t k ll i t


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The tool kit is located under the pas-sengers seat.

The kit contains tools that are help-

ful in making roadside repairs, adjust-ments, and some maintenance proce-dures explained in this manual. Keepthe tool kit in the original place.

A. Tool KitB. Band

The air cleaner intake allows air toenter the fuel system. Never allow any-thing to restrict the flow of air into the

air cleaner. A restricted air cleaner willreduce performance and increase ex-haust emissions.

A. Air Cleaner Intake

62 BREAK-IN

BREAK-IN


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The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as thebreak-in period. If the motorcycle is not used carefully during this period, you mayvery well end up with a broken down instead of a broken in motorcycle after afew thousand kilometers.

The following rules should be observed during the break-in period.

The table shows maximum recommended engine speed during the break-in pe-riod.

Distance traveled Maximum engine speed

0 800 km (0 500 mi) 4 000 r/min (rpm)

800 1 600 km (500 1 000 mi) 6 000 r/min (rpm)

Do not start moving or race the engine immediately after starting it, even if theengine is already warm. Run the engine for two or three minutes at idle speed togive the oil a chance to work up into all the engine parts.

Do not race the engine while the transmission is in neutral.

BREAK-IN 63

WARNING


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New tires are slippery and may cause loss of control and injury.A break-in period of 160 km (100 miles) is necessary to establish normaltire traction. During break-in, avoid sudden and maximum braking and

acceleration, and hard cornering.

In addition to the above, at 1 000 km (600 mi) it is extremely important that theowner have the initial maintenance service performed by a competent mechanicfollowing the instructions in the Service Manual.

64 HOW TO RIDE THE MOTORCYCLE

HOW TO RIDE THE MOTORCYCLE


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Starting the Engine

Check that the engine stop switch isin the position.

A. Engine Stop SwitchB. Starter Button

Turn the ignition key to ON.NOTE

If the ignition key is turned to OFFposition, wait a short while (approx.5 seconds) before turning the key toON position again. When turningthe ignition key from OFF positionto ON position immediately, the im-

mobilizer system in this motorcyclemay not correctly recognize the igni-tion key.

HOW TO RIDE THE MOTORCYCLE 65

Make sure the transmission is in neu-tral

flash when the motorcycle falls downand the starter button pushed in Af-


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tral.

A. Neutral Indicator LightB. Ignition SwitchC. ON position

NOTE

The motorcycle is equipped with avehicle-down sensor, which causesthe engine to stop automatically andthe fuel injection warning symbol to

and the starter button pushed in. Af-ter righting the motorcycle, first turnthe ignition key to OFF and thenback to ON for a few seconds be-fore starting the engine.

After the meter operation check,leaving the throttle completelyclosed, push the starter button.

CAUTION

Do not operate the starter con-tinuously for more than 5 sec-onds, or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of the

starter to let it cool and the bat-tery power recover.


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Jump StartingIf your motorcycle battery is run

WARNING

B tt id t h d


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If your motorcycle battery is rundown, it should be removed andcharged. If this is not practical, a 12volt booster battery and jumper cablesmay be used to start the engine.

Battery acid generates hydro-gen gas which is flammable andexplosive under certain con-

ditions. It is present within abattery at all times, even in adischarged condition. Keep allflames and sparks (cigarettes)away from the battery. Wear eyeprotection when working with abattery. In the event of battery

acid contact with skin, eyes, orclothing, wash the affected ar-eas immediately with water for atleast five minutes. Seek medicalattention.

Connecting Jumper Cables Remove the riders seat. Make sure the ignition key is turned

to OFF.


Connect a jumper cable from thepositive (+) terminal of the booster

Connect another jumper cable fromthe negative () terminal of the


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positive ( ) terminal of the boosterbattery to the positive (+) terminal ofthe motorcycle battery.

A. Motorcycle Battery Positive (+) TerminalB. From Booster Battery Positive (+) TerminalC. Footpeg

D. From Booster Battery Negative ()Terminal

the negative ( ) terminal of thebooster battery to your motorcy-cle footpeg or other unpainted metalsurface. Do not use the negative ()terminal of the battery.

WARNING

Do not make this last connec-tion at the fuel system or battery.Take care that you do not touchthe positive and negative cablestogether, and do not lean overthe battery when making this lastconnection. Do not jump start afrozen battery. It could explode.Do not reverse polarity by con-

necting positive (+) to negative(), or a battery explosion andserious damage to the electricalsystem may occur.


Follow the standard engine startingprocedure.

Moving Off

Check that the side stand is up.


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p

CAUTION

Do not operate the starter con-tinuously for more than 5 sec-onds or the starter will overheatand the battery power will droptemporarily. Wait 15 secondsbetween each operation of thestarter to let it cool and the bat-tery power recover.

After the engine has started, discon-nect the jumper cables. Disconnectthe negative () cable from the mo-torcycle first.

Reinstall the removed parts.

C ec a e s de s a d s up

Pull in the clutch lever. Shift into 1st gear.

Open the throttle a little, and start tolet out the clutch lever very slowly.

As the clutch starts to engage, openthe throttle a little more, giving the en-gine just enough fuel to keep it fromstalling.

A. Shift Pedal


NOTE

The motorcycle is equipped with aShifting Gears

Close the throttle while pulling in the


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The motorcycle is equipped with aside stand switch. This switch is de-signed so that the engine does not

start if the transmission is in gear andthe side stand is down.

When the headlight is on high beam,two headlight beams go on, and onlow beam, the one side of the head-light goes on.

p gclutch lever.

Shift into the next higher or lowergear.

Open the throttle half way, while re-leasing the clutch lever.

For smooth riding, each gear positionshould cover the proper rate of speedshown in the table.

WARNINGWhen shifting down to a lowergear, do not shift at such a highspeed that the engine r/min(rpm) jumps excessively. Notonly can this cause engine dam-

age, but the rear wheel may skidand cause an accident. Down-shifting should be done below 5000 r/min (rpm) for each gear.


Vehicle speed when shifting

Shifting up km/h (mph) Shifting down km/h (mph)


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Shifting up km/h (mph) Shifting down km/h (mph)

1st 2nd 15 ( 9) 6th 5th 30 (19)

2nd 3rd 25 (15) 5th 4th 25 (15)

3rd 4th 35 (21) 4th 3rd 20 (12)

4th 5th 45 (27) 3rd 2nd 15 ( 9)

5th 6th 55 (34) 2nd 1st 15 ( 9)

NOTE

The transmission is equipped with apositive neutral finder. When the mo-torcycle is standing still, the transmis-sion cannot be shifted past neutralfrom 1st gear. To use the positiveneutral finder, shift down to 1st gear,then lift up on the shift pedal whilestanding still. The transmission willshift only into neutral.

Braking

Close the throttle completely, leav-ing the clutch engaged (except whenshifting gears) so that the engine willhelp slow down the motorcycle.

Shift down one gear at a time so thatyou are in 1st gear when you cometo a complete stop.

When stopping, always apply bothbrakes at the same time. Normally


the front brake should be applied a lit-tle more than the rear. Shift down or


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fully disengage the clutch as neces-sary to keep the engine from stalling.

Never lock the brakes, or it will causethe tires to skid. When turning a cor-ner, it is better not to brake at all. Re-duce your speed before you get intothe corner.

For emergency braking, disregarddownshifting, and concentrate on

applying the brakes as hard as pos-sible without skidding.

CAUTION

In order to protect the emissioncontrol parts, do not turn off the

ignition switch when the motor-cycle is in motion.

A. Front Brake Lever


Stopping the Engine

Close the throttle completely.


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A. Rear Brake Pedal

Shift the transmission into neutral. Turn the ignition key to OFF.

Support the motorcycle on a firm,level surface with the side stand.

Lock the steering.NOTE

The motorcycle is equipped with avehicle-down sensor, which causes

the engine to stop automatically andthe fuel injection warning symbol toflash when the motorcycle falls downand the starter button pushed in. Af-ter righting the motorcycle, first turnthe ignition key to OFF and thenback to ON for a few seconds be-

fore starting the engine.


Stopping the Motorcycle in anEmergency

Y K ki M t l h b

2. During removal of the air cleaner,dirt is allowed to enter and jam thef l i j ti t


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Your Kawasaki Motorcycle has beendesigned and manufactured to pro-vide you optimum safety and conve-nience. However, in order to fully ben-efit from Kawasakis safety engineeringand craftsmanship, it is essential thatyou, the owner and operator, properlymaintain your motorcycle and becomethoroughly familiar with its operation.

Improper maintenance can create adangerous situation known as throt-tle failure. Two of the most commoncauses of throttle failure are:1. An improperly serviced or clogged

air cleaner may allow dirt and dustto enter the throttle body and stick

to the throttle open.

fuel injection system.

In an emergency situation such as

throttle failure, your vehicle may bestopped by applying the brakes anddisengaging the clutch. Once thisstopping procedure is initiated, the en-gine stop switch may be used to stopthe engine. If the engine stop switch isused, turn off the ignition switch after

stopping the motorcycle.


Parking

Shift the transmission into neutrald t th i iti k t OFF

WARNING

The muffler and exhaust pipe


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and turn the ignition key to OFF.

Support the motorcycle on a firm,level surface with the side stand.

CAUTION

Do not park on a soft or steeplyinclined surface, or the motorcy-cle may fall over.

If parking inside a garage or otherstructure, be sure it is well ventilatedand the motorcycle is not close toany source of flame or sparks; thisincludes any appliance with a pilotlight.

The muffler and exhaust pipeare very hot while the engine isrunning and just after the engine

stops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffler

or exhaust pipe.

WARNING

Gasoline is extremely flammableand can be explosive under cer-

tain conditions.

Lock the steering to prevent theft.


NOTE

When stopping near traffic at night,Catalytic Converter

This motorcycle is equipped with at l ti t i th h t


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you can leave the taillight on forgreater visibility by turning the igni-

tion key to the P (park) position.Do not leave the ignition switch at Pposition too long, or the battery willdischarge.

catalytic converter in the exhaust sys-tem. Palladium, platinum and rhodiumin the converter react with carbon

monoxide and hydrocarbons to convertthem into carbon dioxide and water re-sulting in much cleaner exhaust gasesto be discharged into the atmosphere.

For proper operation of the catalyticconverter, the following cautions must

be observed.


WARNING

The muffler and exhaust pipe

Use only unleaded gasoline. Neveruse leaded gasoline. Leaded gaso-line significantly reduces the capabil


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p pare very hot while the engine isrunning and just after the engine

stops. This can ignite a fire, re-sulting in property damage orsevere personal injury.Do not idle or park your vehi-cle in an area where flammablematerials such as grasses or dryleaves may contact with muffler

or exhaust pipe.

line significantly reduces the capabil-ity of the catalytic converter.

Do not coast the vehicle with the igni-

tion switch and/or engine stop switchoff. Do not attempt to start the en-gine by rolling the vehicle if the bat-tery is discharged. Do not operatethe vehicle with the engine or anyone cylinder misfiring. Under these

conditions unburned air/fuel mixtureflowing out of engine excessively ac-celerates reaction in the converter al-lowing the converter to overheat andbecome damaged when the engineis hot, or reduces converter perfor-mance when the engine is cold.


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SAFE OPERATION 79

braking may cause the motorcycleto skid and lose control.

When riding in wet conditions oron loose roadway surfaces, the abil-ity to maneuver will be reduced All


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When going down long slopes,control vehicle speed by closing

the throttle. Use the front and rearbrakes for auxiliary braking.

In wet conditions, rely more on thethrottle to control vehicle speed andless on the front and rear brakes.

The throttle should also be used ju-diciously to avoid skidding the rearwheel from too rapid acceleration ordeceleration.

Riding at the proper rate of speedand avoiding unnecessarily fast ac-

celeration are important not only forsafety and low fuel consumption butalso for long vehicle life and quieteroperation.

ity to maneuver will be reduced. Allof your actions should be smoothunder these conditions. Sudden ac-

celeration, braking or turning maycause loss of control.

On rough roads, exercise caution,slow down, and grip the fuel tankwith the knees for better stability.

When quick acceleration is neces-sary as in passing, shift to a lowergear to obtain the necessary power.

Do not downshift at too high anr/min (rpm) to avoid damage from

overrevving to the engine.

Avoiding unnecessary weaving isimportant to the safety of both therider and other motorists.

80 SAFE OPERATION

Daily Safety ChecksCheck the following items each day before you ride. The time required is minimal,

and habitual performance of these checks will help ensure you a safe reliable ride


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and habitual performance of these checks will help ensure you a safe, reliable ride.If any irregularities are found during these checks, refer to the Maintenance and

Adjustment chapter or see your dealer for the action required to return the motor-

cycle to a safe operating condition.

WARNING

Failure to perform these checks every day before you ride may result inserious damage or a severe accident.

Fuel ............................. Adequate supply in tank, no leaks.Engine oil .................... Oil level between level lines.Tires ............................ Air pressure (when cold):

Front 250 kPa (2.50 kgf/cm, 36 psi)

Rear 290 kPa (2.90 kgf/cm, 42 psi)

Install the air valve cap.Drive chain .................. Slack 30

40 mm (1.2

1.6 in.).

Lubricate when chain is dry.Nuts, bolts, fasteners .. Check that steering and suspension components, axles,

and all controls are properly tightened or fastened.

SAFE OPERATION 81

Steering ...................... Action smooth but not loose from lock to lock.No binding of control cables.Steering Damper Unit: No oil leakage


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Steering Damper Unit: No oil leakage.Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04

in.) left.

No brake fluid leakage.Throttle ....................... Throttle grip play 2 3 mm (0.08 0.12 in.).Clutch ......................... Clutch lever play 23 mm (0.08 0.12 in.).

Clutch lever operates smoothly.Coolant ....................... No coolant leakage.

Coolant level between level lines (when engine is cold).Electrical equipment ... All lights (Headlight, Tail/Brake Lights, Turn Signal Lights,

Warning/Indicator Lights) and horn work.Engine stop switch ...... Stops engine.Side stand ................... Return to its fully up position by spring tension.

Return spring not weak or not damaged.

Refer to the Daily Safety Checks caution label attached to the back of left side

cover.

82 SAFE OPERATION

Additional Considerations for High Speed OperationBrakes: The importance of the brakes, especially during high speed operation,

cannot be overemphasized. Check to see that they are correctly adjusted and func-


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cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly.

Steering:Looseness in the steering can cause loss of control. Check to see that

the handlebar turns freely but has no play.Tires: High speed operation is hard on tires, and good tires are crucial for riding

safety. Examine their overall condition, inflate them to the proper pressure, andcheck the wheel balance.

Fuel: Have sufficient fuel for the high fuel consumption during high speed oper-ation.

Engine Oil: To avoid engine seizure and resulting loss of control, make sure thatthe oil level is at the upper level line.

Coolant: To avoid overheating, check that the coolant level is at the upper levelline.

Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals,horn, etc., all work properly.

Miscellaneous: Make sure that all nuts and bolts are tight and that all safety

related parts are in good condition.

SAFE OPERATION 83

WARNING

Handling characteristics of a motorcycle at high speeds may vary fromth f ili ith t l l hi h d D t tt t hi h


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those you are familiar with at legal highway speeds. Do not attempt highspeed operation unless you have received sufficient training and have the

required skills.

84 MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter must be carried out in


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j paccordance with the Periodic Maintenance Chart to keep the motorcycle in goodrunning condition. The initial maintenance is vitally important and must not be

neglected.With a basic knowledge of mechanics and the proper use of tools, you should be

able to carry out many of the maintenance items described in this chapter. If youlack proper experience or doubt your ability, all adjustments, maintenance, andrepair work should be completed by a qualified technician.

Please note that Kawasaki cannot assume any responsibility for damage result-ing from incorrect or improper adjustment done by the owner.

MAINTENANCE AND ADJUSTMENT 85

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporatedcrankcase emission (1) and exhaust emission (2) control systems in compliance


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crankcase emission (1) and exhaust emission (2) control systems in compliancewith applicable regulations of the United States Environmental Protection Agency

and California Air Resources Board. Additionally, Kawasaki has incorporated anevaporative emission control system (3) in compliance with applicable regulationsof the United States Envitonmental Protection Agency and California Air ResourcesBoard.

1. Crankcase Emission Control SystemThis system eliminates the release of crankcase vapors into the atmosphere.

Instead, the vapors are routed through an oil separator to the intake side of theengine. While the engine is operating, the vapors are drawn into the combustionchamber, where they are burned along with the fuel and air supplied by the fuelinjection system.

2. Exhaust Emission Control SystemThis system reduces the amount of pollutants discharged into the atmosphere

by the exhaust of this motorcycle. The fuel, ignition and exhaust systems of thismotorcycle have been carefully designed and constructed to ensure an efficientengine with low exhaust pollutant levels. The exhaust system of this model mo-torcycle includes a catalytic converter system.


3. Evaporative Emission Control SystemVapors caused by fuel evaporation in the fuel system are not vented into the

atmosphere. Instead, fuel vapors are routed into the running engine to be burned,


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or stored in a canister when the engine is stopped. Liquid fuel is caught by a vaporseparator and returned to the fuel tank.

High Altitude Performance Adjustment InformationHigh Altitude adjustment is not required.

MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue to

have low emission levels. This Owners Manual contains those maintenance rec-ommendations for your motorcycle. Those items identified by the Periodic Mainte-nance Chart are necessary to ensure compliance with the applicable standards.

As the owner of this motorcycle, you have the responsibility to make sure thatthe recommended maintenance is carried out according to the instructions in thisOwners Manual at your own expense.

The Kawasaki Limited Emission Control System Warranty requires that you re-

turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty.Please read the warranty carefully, and keep it valid by complying with the ownersobligations it contains.


You should keep a maintenance record for your motorcycle. To assist you inkeeping this record, we have provided space on pages 184 through 190 of thismanual where an authorized Kawasaki dealer, or someone equally competent, can


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record the maintenance. You should also retain copies of maintenance work orders,bills, etc., as verification of this maintenance.


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Frequency Whichevercomes

first*Odometer Reading

km 1 000 (mile 1 000) See


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Operation (EngineItems) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

KFuel hoses damage -inspect

year

KFuel hoses installationcondition - inspect

year

Coolant level - inspect 107Coolant leak - inspect year 105Radiator hosesdamage - inspect

year 105Radiator hosesinstallation condition -inspect

year

105




km 1 000 (mile 1 000) See


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Operation (EngineItems) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

Evaporative emissioncontrol system -function (Californiamodel only)(e)

111

Air suction system

damage - inspect (e) 113


2. Periodic Inspection (Chassis Related Items)




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first km 1 000 (mile 1 000)

Operation (ChassisItems)

Every 1(0.6)

6(3.75)

12(7.5)

18(11.25)

24(15)

30(18.75)

36(22.5)

SeePage

Clutch and drive train:

Clutch operation(play, engagement,

disengagement) -inspect 124

Drive chainlubrication condition -inspect #

every 600 km (400 mile) 135

Drive chain slack -inspect #

every 1 000 km (600 mile) 126

Drive chain wear -inspect # 131

KDrive chain guidewear - inspect


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km 1 000 (mile 1 000) SeeP


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Operation (ChassisItems) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

Brake hoses damage- inspect

year 137Brake pad wear -inspect # 136

Brake hosesinstallation condition- inspect

year 137

Brake fluid level -inspect

6month 137

Brake operation(effectiveness, play,drag) - inspect

year

139

Brake light switchoperation - inspect 140




km 1 000 (mile 1 000) SeeP


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Operation (ChassisItems) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

Suspensions:

Front forks/rearshock absorberoperation (dampingand smooth stroke) -

inspect

143/147

Front forks/rearshock absorber oilleak - inspect

year 143/147

KUni-trak rocker armoperation - inspect

KUni-trak tie rodsoperation - inspect




km 1 000 (mile 1 000) SeePage


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Operation(Chassis Items) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

Steering system:

KSteering play -inspect

year

KSteering stem

bearings - lubricate

2

years

Steering damper oilleak - inspect 142

Electrical system:

Lights and switchesoperation - inspect

year Headlight aiming -inspect

year 162Side stand switchoperation - inspect

year






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Operation(Chassis Items) Every 1(0.6) 6(3.75) 12(7.5) 18(11.25) 24(15) 30(18.75) 36(22.5)

Page

Engine stop switchoperation - inspect

year Chassis:

Chassis parts -

lubricate

year

165

Bolts and nutstightness - inspect 173


3. Periodic Replacement



km 1 000 (mile 1 000) S


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first km 1 000 (mile 1 000)

Change/Replace-ment Items

Every 1 (0.6) 12 (7.5) 24

(15)36

(22.5)48

(30)

SeePage

Air cleaner element #(e) - replace

every 18 000 km (11 250 mile) 114

K Engine oil # - change year 102K Oil filter - replace year 102K Fuel hoses - replace 4 years K Coolant - change 3 years 109K

Radiator hoses andO-rings - replace

3 years K Brake hoses - replace 4 years K

Brake fluid (front andrear) - change

2 years 139






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Change/Replace-ment Items Every 1 (0.6) 12 (7.5) 24(15) 36(22.5) 48(30)

Page

KRubber parts of mastercylinder and caliper -replace

4 years

Spark plug (e) -replace 110

K : Should be serviced by an authorized Kawasaki dealer.

* : For higher odometer readings, repeat at the frequency interval established here.

# : Service more frequently when operating in severe conditions: dusty, wet, muddy,

high speed, or frequent starting/stopping.

(e): Emission Related Item


Engine OilIn order for the engine, transmission,

and clutch to function properly, main-tain the engine oil at the proper level,

Oil Level Inspection

If the oil has just been changed, startthe engine and run it for several min-utes at idle speed. This fills the oil


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g p pand change the oil and replace the oil

filter in accordance with the PeriodicMaintenance Chart. Not only do dirtand metal particles collect in the oil, butthe oil itself loses its lubricative qualityif used too long.

WARNING

Motorcycle operation with insuf-ficient, deteriorated, or contami-nated engine oil will cause accel-erated wear and may result in en-gine or transmission seizure, ac-cident, and injury.

pfilter with oil. Stop the engine, then

wait several minutes until the oil set-tles.

CAUTION

Racing the engine before the oilreaches every part can cause en-

gine seizure.

If the motorcycle has just been used,wait several minutes for all the oil todrain down.


Check the engine oil level throughthe oil level gauge. With the motor-cycle held level, the oil level shouldcome up between the upper and

If the oil level is too high, remove theexcess oil through the oil filler open-ing using a syringe or some othersuitable device.


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lower level lines next to the gauge.

A. Oil Level Inspection WindowB. Oil Filler CapC. Upper Level Line

D. Lower Level Line

If the oil level is too low, add the oilto reach the correct level. Use thesame type and brand of oil that isalready in the engine.

CAUTION

If the engine oil gets extremely

low or if the oil pump does notfunction properly or oil pas-sages are clogged, the warninglight in the meter instrument andoil pressure warning symbol inthe digital meter will flash. Ifthey remain flashing while the

engine running above the idlespeed, stop the engine immedi-ately and find the cause.


Oil and/or Oil Filter Change

To change the engine oil and replaceoil filter, the engine oil drain plugand oil filter must be removed. The


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A. Oil Pressure Warning SymbolB. Warning Light

oil change and oil filter replacement

should be done by an authorizedKawasaki dealer.

A. Engine Oil Drain Plug


Tightening Torque

Engine Oil Drain Plug:29 Nm (3.0 kgfm, 21 ftlb)

Cartridge:( f f )


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A. Oil Filter Cartridge

WARNING

Motor oil is a toxic substance.Dispose of used oil properly.Contact your local authoritiesfor approved disposal methods

or possible recycling.

17 Nm (1.7 kgfm, 13 ftlb)

Recommended Engine Oil

Type:API SE, SF or SGAPI SH, SJ, SL or SM with JASO MA,MA1 or MA2

Viscosity:

SAE10W-40

NOTE

Do not add any chemical additive tothe oil. Oils fulfilling the above re-quirements are fully formulated and

provide adequate lubrication for boththe engine and the clutch.


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Coolant -Coolant absorbs excessive heat from

the engine and transfers it to the airat the radiator. If the coolant level be-comes low the engine overheats and

inhibitor chemicals are not used, overa period of time, the cooling systemaccumulates rust and scale in the wa-ter jacket and radiator. This will clogup the coolant passages and con


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comes low, the engine overheats and

may suffer severe damage. Check thecoolant level each day before riding themotorcycle, also carry out the mainte-nance and adjustments in accordancewith the periodic maintenance chart.Replenish coolant if the level is low.Change the coolant in accordance with

the Periodic Maintenance Chart.

Information for CoolantTo protect the cooling system (con-

sisting of the aluminum engine andradiator) from rust and corrosion, theuse of corrosion and rust inhibitor

chemicals in the coolant is essential. Ifcoolant containing corrosion and rust

up the coolant passages, and con-

siderably reduce the efficiency of thecooling system.

WARNING

Use coolant containing corro-sion inhibitors made specificallyfor aluminum engines and ra-diators in accordance with theinstructions of the manufacturer.Chemicals are harmful to the hu-man body.

Soft or distilled water must be used

with the antifreeze (see below for an-tifreeze) in the cooling system.


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Check the coolant level through thecoolant level gauge on the reservetank located to the right of the engine.The coolant level should be betweenthe F (Full) and L (Low) level lines

NOTE

Check the level when the engine iscold (room or atmospheric tempera-ture).


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the F (Full) and L (Low) level lines.

A. Reserve TankB. F (Full) Level LineC. L (Low) Level Line

If the amount of coolant is insuffi-cient, add coolant into the reservetank.


Coolant Filing

Remove the cap from the reservetank and add coolant through thefiller opening to the F (Full) level line.

NOTE

In an emergency you can add wa-ter alone to the coolant reserve tank,however it must be returned to the

t i t ti b th dditi


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A. Reserve Tank Cap

correct mixture ratio by the addition

of antifreeze concentrate as soon aspossible.

CAUTION

If coolant must be added of-ten, or the reserve tank com-

pletely runs dry, there is proba-bly leakage in the system. Havethe cooling system inspectedby your authorized Kawasakidealer.

Coolant ChangeHave the coolant changed by an au-thorized Kawasaki dealer.


Spark PlugsThe standard spark plug is shown in

the table. The spark plugs should bereplaced in accordance with the Peri-odic Maintenance Chart


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odic Maintenance Chart.

Spark plug removal should be doneonly by a competent mechanic follow-ing the instructions in the Service Man-ual.

Spark Plug

Standard

Plug: NGK CR9E

Plug Gap: 0.7 0.8 mm

(0.0280.032 in.)

TighteningTorque:

13 Nm (1.3 kgfm, 115 inlb)

A. 0.7 0.8 mm (0.028 0.032 in.)


Evaporative Emission ControlSystem (California modelonly)

This system routes fuel vapors fromthe fuel system into the running engine


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the fuel system into the running engine

or stores the vapors in a canister whenthe engine is stopped. Although no ad-justments are required, a thorough vi-sual inspection must be made at the in-tervals specified by the Periodic Main-tenance Chart.

Inspection Check that the hoses are securelyconnected.

Replace any kinked, deteriorated, ordamaged hoses.


Valve ClearanceValve and valve seat wear decreases

valve clearance, upsetting valve timing.

CAUTION

Kawasaki Clean Air SystemThe Kawasaki Clean Air System

(KCA) is a secondary air suction sys-tem that helps the exhaust gases toburn more completely. When the spent


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If valve clearance is left un-adjusted, wear will eventuallycause the valves to remainpartly open; which lowers per-formance, burns the valves andvalve seats, and may cause seri-ous engine damage.

Valve clearance for each valveshould be checked and adjusted inaccordance with the Periodic Mainte-nance Chart.

Inspection and adjustment should bedone only by a competent mechanicfollowing the instructions in the ServiceManual.

burn more completely. When the spent

fuel charge is released into the ex-haust system, it is still hot enough toburn. The KCA System allows extraair into the exhaust system so that thespent fuel charge can continue to burn.This continued burning action tends toburn up a great deal of the normally

unburned gases, as well as chang-ing a significant portion of the carbonmonoxide into carbon dioxide.


Air Suction Valves -The air suction valve is essentially a

check valve which allows fresh air toflow only from the air cleaner into theexhaust port. Any air that has passed

Exhaust DeviceThis motorcycle is equipped with a

exhaust device system. This systemcontrols the valve in the exhaust pipeand produces stable engine power at


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p y p

the air suction valve is prevented fromreturning. Inspect the air suction valvesin accordance with the Periodic Main-tenance Chart. Also, inspect the airsuction valves whenever stable idlingcannot be obtained, engine power isgreatly reduced, or there are abnormal

engine noises.Air suction valve removal and inspec-

tion should be done only by a compe-tent mechanic following the instructionsin the Service Manual.

p g p

low and middle engine speed. This ex-haust device is controlled by the ECU,and adjustment or maintenance shouldbe done only by a competent mechanicfollowing the instructions in the ServiceManual.

A. Exhaust Device Cables


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CAUTION

Use only the recommended aircleaner element (Kawasaki partnumber 11013-0036 or equiv-alent type) Using other air

Remove the Riders seat (refer toRiders Seat Removal in General In-formation chapter).

Remove the bracket bolt.


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alent type). Using other air

cleaner elements will wear theengine prematurely or lower theengine performance.

A. Bracket BoltsB. BracketC. Steering Damper Unit


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Put a clean, lint-free towel over theair cleaner element duct to keep dirtor other foreign material from enter-ing.

Element and fuel tank installation isperformed in the reverse order of re-moval.

Fix the harness with the clamps ofthe air cleaner housing.


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WARNINGIf dirt or dust is allowed to passthrough into the fuel injectionsystem, the throttle may becomestuck, possibly causing an acci-dent.

CAUTION

If dirt gets through into the en-gine, excessive engine wear andpossibly engine damage will oc-cur.

A. ClampsB. Harness


Run the throttle cables and clutch ca-ble as shown in the figure.

WARNING

Do not pinch the cables betweenthe bracket and the frame. Op-eration with incorrectly route, ordamaged cables could result in


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A. CablesB. Brackets

damaged cables could result in

an unsafe riding condition.


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Throttle Control SystemCheck the throttle grip play each day

before riding the motorcycle, and carryout the maintenance and adjustmentsin accordance with the Periodic Main-

Inspection

Check that the throttle grip play iscorrect by lightly turning the throttlegrip back and forth.


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tenance Chart. Adjust it if necessary.Throttle Grip -

The throttle grip controls the butterflyvalves in the throttle body. If the throt-tle grip has excessive play due to ei-ther cable stretch or maladjustment, itwill cause a delay in throttle response,especially at low engine speed. Also,the throttle valve may not open fully atfull throttle. On the other hand, if thethrottle grip has no play, the throttle willbe hard to control, and the idle speedwill be erratic.

A. Throttle GripB. Throttle Grip Play


Throttle Grip Play

2 3 mm (0.080.12 in.)

If there is improper play, adjust it.


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Adjustment Loosen the locknuts at the upperof the throttle cables, and turn boththrottle cable adjusters completelyso as to give the throttle grip plentyof play.

Turn out the decelerator cable ad-juster until it has no play when thethrottle grip is completely closed.Tighten the locknut.

Turn out the accelerator cable ad-juster until the throttle grip has theproper play. Tighten the locknut.

A. Decelerator CableB. Accelerator Cable

C. AdjustersD. Locknuts


If the throttle cables cannot be ad-justed with the adjuster at the upperof the throttle cable, further adjust-ment of the throttle cables should bedone only by a competent mechanic

Engine Vacuum SynchronizationEngine vacuum synchronization

must be checked and adjusted period-ically in accordance with the PeriodicMaintenance Chart only by a compe-


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following the instructions in the Ser-vice Manual.

With the engine idling, turn the han-dlebar to each side. If handlebarmovement changes the idle speed,the throttle cables may be improperlyadjusted or incorrectly routed, or they

may be damaged. Be sure to correctany of these conditions before idling.

WARNING

Operation with improperly ad-justed, incorrectly routed, or

damaged cables could result inan unsafe riding condition.

tent mechanic following the instructionsin the Service Manual.

NOTE

Poor engine vacuum synchronizationwill cause unstable idling, sluggishthrottle response, and reduce engine

power and performance.


Idle SpeedThe idle speed adjustment should be

performed in accordance with the Pe-riodic Maintenance Chart or wheneverthe idle speed is disturbed.

Idle Speed

1 250 1 350 r/min (rpm)


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Adjustment Start the engine, and warm it up thor-

oughly.

Adjust the idle speed by turning theidle adjusting screw.

A. Idle Adjusting Screw


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If it cannot be done, use the nuts atthe lower end of the clutch cable.

Drive ChainThe drive chain slack and lubrication

must be checked each day before rid-ing the motorcycle and must be main-tained in accordance with the PeriodicMaintenance Chart for safety and to


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A. NutsB. Clutch Cable

NOTE

After the adjustment is made, startthe engine and check that the clutch

does not slip and releases properly.For minor corrections, use the ad-

juster at the clutch lever.

Maintenance Chart for safety and toprevent excessive wear. If the chainbecomes badly worn or maladjusted -either too loose or too tight - the chaincould jump off the sprockets or break.

WARNING

A chain that breaks or jumps offthe sprockets could snag on theengine sprocket or lock the rearwheel, severely damaging themotorcycle and causing it to goout of control.

Chain Slack Inspection

Set the motorcycle up on its sidestand.


Rotate the rear wheel to find the po-sition where the chain is tightest, andmeasure the maximum chain slackby pulling up and pushing down thechain midway between the enginesprocket and rear wheel sprocket.

Drive Chain Slack

Standard: 30 40 mm (1.2 1.6 in.)

Chain Slack AdjustmentLoosen the left and right chain ad-


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sp oc et a d ea ee sp oc et

A. Chain Slack

If the drive chain is too tight or tooloose, adjust it so that the chain slackwill be within the standard value.

juster locknuts. Remove the cotter pin, and loosenthe axle nut.

A. Axle NutB. Cotter PinC. AdjusterD. Locknut


If the chain is too loose, turn out theleft and right chain adjusters evenly.

If the chain is too tight, turn in the leftand right chain adjusters evenly.

Turn out both chain adjusters evenlyuntil the drive chain has the cor-


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rect amount of slack. To keep thechain and wheel properly aligned,the notch on the left wheel alignmentindicator should align with the sameswingarm mark that the right indica-tor notch aligns with.

A. MarksB. Notch

C. IndicatorD. AdjusterE. Locknut


NOTE

Wheel alignment can also bechecked using the straightedge orstring method.

Rotate the wheel, measure the chainslack again at the tightest position,and readjust if necessary.

Install a new cotter pin through theaxle nut and axle, and spread its


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WARNINGMisalignment of the wheel willresult in abnormal wear, and mayresult in an unsafe riding condi-tion.

Tighten both chain adjuster locknuts. Tighten the axle nut to the specifiedtorque.

Tightening Torque

Axle Nut: 127 Nm (13.0 kgfm, 94 ftlb)

NOTEIf a torque wrench is not available,

this item should be serviced by aKawasaki dealer.

ends.

A. Cotter Pin


NOTE

When inserting the cotter pin, if theslots in the nut do not align withthe cotter pin hole in the axle shaft,tighten the nut clockwise up to the

WARNING

If the axle nut is not securelytightened or the cotter pin is notinstalled, an unsafe riding condi-tion may result.


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next alignment.It should be within 30 degree.Loosen once and tighten again when

the slot goes past the nearest hole.

A. Turn Clockwise

Check the rear brake (see the Brakessection).


Wear Inspection

Remove the front footpeg bracketbolts.

Remove the bolts and quick rivet. Remove the chain cover.


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A. Front FootpegB. Bolts

A. BoltsB. Quick RivetC. Chain Cover


NOTE

The chain cover uses the quick rivet.The quick rivet can be removed by

pushing the center pin into the quickrivets, and when installing it, pull the

f f

Quick Rivet Installation


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center pin fully up first, and then pushinto the center pin after inserting it.

Quick Rivet Removal

A. Quick RivetB. Center PinC. Push in.

A. Quick Rivet

B. Center PinC. Pull up fully.D. Push in.


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Drive Chain 20-Link Length

Service Limit: 323 mm (12.7 in.)

NOTE

I t ll th h i d f t f t

WARNING

For safety, use only the standardchain. It is an endless type andshould not be cut for installa-tion; have it installe

Kawasaki ZX 6R 2009 Owners

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Transcript of Kawasaki ZX 6R 2009 Owners