2005 Kawasaki ZX6R Assembly and Preparation Manual -(1).pdf

Ninja ZX-6R

Assembly & Preparation

Manual

Motorcycle

Foreword

In order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-

bled before crating. Since some of the most

commonly removed parts have a direct bear-

ing on a vehicle’s reliability and safety, consci-

entious pre-sale assembly and preparation be-

comes extremely important. Good setup pro-

cedures can prevent needless warranty claims

and give customers a greater sense of confi-

dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex-

plains step by step procedures of the following

items for all Kawasaki motorcycles.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or less of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

correctly followed, could result in dam-

age to, or destruction of equipment.

1. Uncrating

2. Assembly

3. Preparation

NOTE

○ This note symbol indicates points of particular

interest for more efficient and convenient op-

eration.

The selling dealer assumes sole responsibil-

ity for any unauthorized modifications prior to

sale. Refer to your Service Binder for any Ser-

vice Bulletins specifying Factory Directed Mod-

ifications (Special Claims) which must be per-

formed before the vehicle is ready for sale.

Whenever you see the following symbols

heed their instructions! Always follow safe

operating and maintenance practices.

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 ac-

curate as possible. All procedures and specifi-

cations subject to change without notice.

Sep. 2004 (K)

Table of Contents

Un crating ...................................................................................... 3

Opening Crate ............................................................................. 3

Parts Check................................................................................. 4

As sembly ...................................................................................... 4

Steering Stem Head Nut ............................................................. 4

Clutch Cable................................................................................ 5

W indshield................................................................................... 5

Rider’s Seat Bolt.......................................................................... 5

Brake Disc Cleaning.................................................................... 5

P reparation ................................................................................... 6

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

UNCRATING 3

Uncrating

Opening Crate

• Clear a space about 6 m (20 ft) square to give

yourself plenty of space to work.

• Place the crate upright on its base.

• Remove the parts box.

CAUTION

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 dis-

card them.

A. Lower Support Bracket

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.

• Remove the cardboard cover.

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