kawasaki ninja zx6r 2002 manual
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kawasaki ninja zx6r 2002 manualSpecial tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done. Periodic Maintenance Chart (Other than United States and Canada Models). 1-11 Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION).1-13 Technical Information - Non-Contact Hall IC-Type Speed Sensor. 1-22 Technical Information - Alternator Made from Rare Magnet. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent. The initial maintenance is vitally important and must not be neglected.The initial maintenance is vitally important and must not be neglected.This system draws air into the exhaust ports, dilutes and burns harmful ingredients in the exhaust gas in order to reduce them. To cope with, the IC igniter test-operates the fuel cut valves when starting the engine and prevents lock of the valves. Conventional system applies fuel-on method.) Catalysts are supposed to act in some way to loosen the bonds of the reacting substances. In other words, they lower the energy of activation, thus allowing the reaction to proceed more rapidly. This makes the square wave equal to the pulse of the rotor nut output. Main Characters Rare magnet used and assembled in the alternator for the ZX600-J model has six (6) times higher performance than that of the traditional use ferrite magnet. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. LG: Apply grease to the threads. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Fuel Pump Relay 19. Engine (Battery) Ground Light Lead 13. Rear Brake Light Switch 20. Clamp 3. Horn 15. Starter Relay 21. Face the white mark forward. 3. Coolant Reserve Tank 13.http://bakirotomotiv.com/upload/kral-flow-meter-manual.xml
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Align the marks. 4. Reserve Tank Overflow Hose 14. Drain Hose (California model only) 5. Install the clamps with the baffle plate.Breather Hose (To Canis- 2. To Air Vent Filter Carburetor Holder) ter, Blue) 3. Carburetor Vent Hose 13. Fitting (4 Way) 21. Breather Hose (To Fuel 4. To Right Turn Signal Light 3. Breather Hose (To Fuel Tank, Blue) 12. Canister 4. Through the cut portion of Rear Fender 13. Carburetor Vent Hose (Yellow) 3. Purge Hose (green) 12. Breather Hose (Blue) (To Fuel Tank) 4. Element Removal. CAL: California. Throttle Sensor 2. Throttle Cable (decelerator) 12. Fuel Cut Valve (CAL, H Models) 3. Choke Cable 13. Cooling Hose Assy (other than US, CA 4. Pilot Screw Models) 5. Pilot (Slow) Jet 14. If the free play is incorrect, adjust the throttle cable.If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level. WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetors. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Check the tank cap breather also. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart. Turn the ignition switch OFF. Do not smoke.http://arkaimavto.ru/store/file/kr2000-manual.xml Make sure the area is well-ventilated and free from any source of flame or sparks;. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system. The radiator fan may start even if the ignition switch is off.If there are obstructions to air flow, remove them. If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one. Valve Removal.4-23 Air Suction Valve Removal. Valve Installation.4-23 Air Suction Valve Installation.Valve Guide Removal. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Replace the shim with one of a different thickness.This shim will give the proper clearance. This shim will give the proper clearance. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. Wait until the mufflers cool down.Clutch Cable Removal. Clutch Cable Installation.Clutch Cable Lubrication.Clutch Lever Installation.Clutch Cover. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.https://labroclub.ru/blog/boss-me-50b-manual-espa-ol If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 82.1 mm (3.23 in.) Service Limit: 78.0 mm (3.07 in.) Cylinder Head 5. Oil Filter 16. Camshaft Cap 6. It could cause an accident and injury. Transmission.8-18 Crankcase Assembly.Shift Pedal Removal.8-18 Crankshaft and Connecting Rods. L: Apply a non-permanent locking agent. R: Replacement Parts. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. If the clearance exceeds the service limit, replace the crankcase halves as a set. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. If the shaft is bent, straighten or replace it. If the serration are damaged, replace the shaft.Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place. Front Wheel Installation.Rear Wheel Removal.Rear Wheel Installation. Wheel Inspection.Axle Inspection.Balance Inspection.Balance Adjustment.Balance Weight Removal.Balance Weight Installation. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant. CAUTION Do not lay the wheel on the ground with the disc facing down. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make. CAUTION Do not lay the wheel on the ground with the disc facing down. If any bear- ings are removed, they will need to be replaced with new ones.http://mebiphar.com/images/colt-black-powder-revolver-manual.pdf HO: Apply heavy oil. L: Apply a non-permanent locking agent. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection). Take out only the caliper mounting bolts for caliper re- moval. The brakes will not function on the first appli- cation of the lever or pedal if this is not done. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. R: Replacement Parts. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Compression Damping Force Adjustment Adjuster Damping. Fork Oil Viscosity: KHL34 (KAYABA G10) or equivalent Amount (per side) When changing oil:. Replace it if necessary. If the spring of either fork leg is shorter than the service limit, it must be replaced. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. Neutral Switch 21. Oil Pressure Switch 2. Water Temperature Sen- 12. Side Stand Switch 22. Throttle Sensor 13. Speed Sensor 23. Fuel Cut Valves (CAL, H 3. Stick Coils 14. Starter Relay and Main Models) 4. If the connector is corroded or dirty, clean it carefully. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced no- ticeably if charged under conditions other than given above. If the reading is below the specified, refreshing charge is required.A much lower reading than that given in the table indicates that the alternator is defective. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. CAUTION Use only Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. An ohmmeter other the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the headlight relay unit will be damaged. Dimmer Switch 3. Headlight 12. Alternator 13. Headlight Fuse 20 A 4. City Light 5. Headlight Relay (Hi) 14. Main Fuse 30 A 6. Battery Light 9. Headlight Circuit Relay 16. Headlight Switch 3. Headlight 10. Headlight Fuse 10 A 17. An ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the pump relay will be damaged. Fuel Cut Valve Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. The fan may start even if the ignition switch is off.CAUTION Place the meter unit so that the face is up. CAUTION Do not drop the meter unit. Place the meter unit so that it faces upward. If the meter unit is left upside down or sideways for a long time or dropped, it will malfunction. If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 10 mm (3.94 in.) of pedal. The relays and diodes can not be removed.It Spark plug incorrect is meant simply as a rough guide to assist IC igniter trouble the troubleshooting for some of the more Cam sensor trouble. Also, check to see that each cotter pin is in place and in good condition. Service Repair ManualThis is the most complete Service.Service Repair ManualThis is the most complete Service Repair Manual for the 2000-2002 Kawasaki ZX600J Ninja ZX-6RThis DOWNLOAD contains of high quality diagrams and instructions onThis is a must for the Do-It-Yourselfer. You will not be dissatisfied. Models Covers:Service Repair Manual Covers. General Information. Fuel System. Cooling System. Engine Top End. Clutch. Engine Lubrication System. Final Drive. Brakes. Suspension. Steering. Frame. Electrical System. Appendix. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. All pages are is great to have2002 KAWASAKI ZX600-J3 NINJA ZX-6R Service Repair Workshop Manual. I got an A on my final paper which really helped my grade. Knowing that I can count on them in the future has really helped relieve the stress, anxiety and workload. I recommend everyone to give them a try. You'll be glad you did.Ever since my years of high school, I really have no idea what professors are looking for to give good grades. After some google searching, I found this service ? www.HelpWriting.net ? who helped me write my research paper. The final result was amazing, and I highly recommend ? www.HelpWriting.net ? to anyone in the same mindset as me.Part No.99924-1254-07 Printed in JapanMotorcycle. Service ManualQuick Reference Guide. General Information 1 j. Fuel System 2 j. Cooling System 3 j. Engine Top End 4 j. Clutch 5 j. Engine Lubrication System 6 j. Final Drive 10 j. Brakes 11 j. Suspension 12 j. Steering 13 j. Frame 14 j. Electrical System 15 j. Appendix 16 jMotorcycle. Service Manual. All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, orNo liability can be accepted for any inaccuracies or omissions in this publication, although every possibleThe right is reserved to make changes at any time without prior notice and without incurring an obligationSee your Motorcycle dealer for the latestAll information contained in this publication is based on the latest product information available at the timeABDC after bottom dead center m meter(s). AC alternating current min minute(s). ATDC after top dead center N newton(s). BBDC before bottom dead center Pa pascal(s). BDC bottom dead center PS horsepower. BTDC before top dead center psi pound(s) per square inch. DC direct current rpm revolution(s) per minute. F farad(s) TDC top dead centerL liter(s). Read OWNER’S MANUAL before operating.This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vaporsWhile the engine is operating,This system reduces the amount of pollutants discharged into the atmosphere by the exhaustVapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what isAmong those acts presumed to constitute tampering are the acts listed below:This manual is designed primarily for use byHowever, it contains enough detail and basic in-In order to perform the work efficiently andWhenever special tools orFor the duration of the warranty period,To get the longest life out of your vehicle. Service Manual.Kawasaki motorcycles are introduced by the. Service Manual. Genuine parts provided asHow to Use This Manual. In this manual, the product is divided into itsThe Quick Reference Guide shows you allFor example, if you want ignition coil informa-Then, use the. Table of Contents on the first page of the chap-Whenever you see these WARNING and. CAUTION symbols, heed their instructions! Always follow safe operating and maintenanceThis manual contains four more symbols (inIndicates a conditional step or what action toIn most chapters an exploded view illustrationContents. In these illustrations you will find theTable of Contents. Before Servicing. 1-2. Model Identification. 1-5. General Specifications. 1-6. Periodic Maintenance Chart (United States and Canada Models). 1-9. Periodic Maintenance Chart (Other than United States and Canada Models). 1-11. Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION). 1-13. Technical Information - Non-Contact Hall IC-Type Speed Sensor. 1-22. Technical Information - Alternator Made from Rare Magnet. 1-24. Torque and Locking Agent. 1-25. Special Tools and Sealant. 1-31. Cable, Wire, and Hose Routing. 1-37. Cable, Wire and Hose Routing (ZX600-J4). 1-47Before starting to perform an inspection service or carry out a disassembly and reassembly opera-To facilitate actual operations, notes, illustra-Especially note the following:Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shortenFor the same reason, before installing a new part, clean off any dust orFor reinstallation, first connect the positiveGenerally, installation or assembly is the reverse of removal or disassembly. However, if instal-Note parts locations andIt is preferable to mark and record the locations and routing wheneverWhen installing bolts, nuts, or screws for which a tightening sequence is given in this Service. Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, orThen, tighten them to the specified torque in the tighteningIf tightening sequence instructions are not given, tighten themConversely, to remove a part, first loosen all the bolts, nuts, or screwsWhen torque values are given in this Service Manual, use them. Either too little or too muchUse a good quality, reliable torque wrench.Common sense should dictate how much force is necessary in assembly and disassembly. IfWatch for sharp edges, as they could cause injury through careless handling, especially duringUse a clean piece of thick cloth when lifting the engineA high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-Always follow manufacturerReplace a gasket or an O-ring with a new part when disassembling. Remove any foreign matterClean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam-When using a press or driver to install a part such as a wheel bearing, apply a small amount ofDo not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace anyInstall bearings with the manufacturerApply force only to theReplace any oil or grease seals that were removed with new ones, as removal generally dam-When pressing in an oil or grease seal which has manufacturer’s marks,When installing circlips and retaining rings, take care to compress or expand them only enoughInstall the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re-If old ones are reused, they could become detached whileEngine wear is generally at its maximum while the engine is warming up and before all the slidingDuring assembly, make sure to apply oil to any slidingOld grease or dirty oil could have lost its lubricativeSome oils and greases in particular should be used only in certainTo rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos-To carry out properWhen there is a replacement instruction, replace these parts with new ones every time they areReplacement parts will be damaged or lose their original function once they are removed. There-Although the pre-All the electrical leads are either one-color or two-color. A two-color lead is identified first byFor example, a yellow lead with thin red stripes is. Unless instructed otherwise, electrical leads must be connected to leads of the same color. Two-Color ElectricalWhen parts have been disassembled, visually inspect these parts for the following conditionsAbrasion Crack Hardening Warp. Bent Dent Scratch Wear. Color change Deterioration SeizureSpecification terms are defined as follows:If the measurement shows excessive wear or deteri-ZX600-J1 Left Side View. ZX600-J1 Right Side ViewItems ZX600-J1, J2 ZX600-J3. Dimensions. Overall Length 2 030 mm (79.9 in.), (PN) 2 060 mm (81.1 in.) Items ZX600-J1, J2 ZX600-J3. Exhaust:Items ZX600-J1, J2 ZX600-J3. Front Suspension. Type Telescopic fork The scheduled maintenance must be done in accordance with this chart to keep the motorcycle inThe initial maintenance is vitally important and must not be neglected. FREQUENCY WhicheverOPERATION EveryAir cleaner element and air vent filter -. Evaporative emission control system. Swingarm pivot, Unit-trak linkage -. Nut, bolts, and fasteners tightness -. Brake master cylinder cup and dustCaliper fluid seal and dust seal - replace 4 yearsFREQUENCY WhicheverOPERATION EveryCoolant filter - clean year. CAL: CaliforniaThe scheduled maintenance must be done in accordance with this chart to keep the motorcycle inThe initial maintenance is vitally important and must not be neglected. Brake master cylinder cup and dustCaliper fluid seal and dust seal - replace 4 years. Coolant filter - clean yearThe ZX600J have catalytic converters.This system draws air into the exhaust ports, dilutes and burnsThis allows the carburetor to be setBut, under the trend that the emission regulation becomes more severe, Kawasaki has adopted. Moreover, a BDSR 36The harmful ingredients in the exhaust gasAs actual examples, carbon monoxide (CO) is reduced about 70, hydrocarbons (HC) about 60,Exhaust Gas after Purification. Kawasaki Low Exhaust Emission SystemThe burned gas, which goes out from the combustion chamber, is injected with secondary air (addingSecondary Air Injection SystemSince the carburetorExhaust Gas before Purification. A small-size three-way catalytic converter (precatalytic converter) is installed in the pipe ahead atAccordingly, the precatalytic converter will be acti-Activation of the precatalytic converter raises the exhaustThe converter is a three-way catalytic converter upon which platinum and rhodium are applied,The main catalytic converter isWhen the exhaust gas passes through theThe honeycomb structure is convenient for the catalytic converter because it has a large surfaceIn addition, its inherentCatalytic ConvertersWhen excessive unburned gasoline flows more than the allowable amount into the exhaust gas dur-In an excessive case, the problemMoreover, there is a possibility that the purification performance be-It runs by the IC Igniter and opens. A catalyst protection system works in the followingThe limiter has fuel cut-off and ignition cut-off operations.When the engine stop switch is turned off while coasting the motorcycle, fuel is cut off. For ex-Fuel is cut off when an electric current of a primary coil becomes abnormal because of a cutoff ofIf a driver always runs the engine under the red zone in the tachometer, the IC igniter doesn’tTo cope with, the ICLeaded gasoline harms the purification efficiency of the catalysts. The performance of the catalyst protection system is summed up as follows. Fuel Cut Valve. Performance of Catalyst Protection System. No Running Condition. Ignition. Switch. Engine. Stop. Protection. System. Fuel. Cutvalve. Remedy (Action)No Running Condition. Remedy (Action)ON, and run.Special maintenance is not necessary except for the inspection of the air suction valve (which hasIt is impossible to replace only catalytic converters because they are welded in the muffler. So, inPurification efficiency decreases in a very short period because lead poisons the catalytic con-Especially in the case that a lot of unburned gasoline flows into the catalytic converters underIf they melt down, it causes poor engineSo, the muffler assyIt has the same durability as a conventional muffler.As any harmful toxic substance is not used especially, it can be disposed as usual industrial wastes. The body of the muffler is made of aluminum steel. The catalytic converter is also made of stain-Catalyst protection system against mishandling is applied to a vehicle with catalysts. But, we prohibitUsage of leaded gasoline is prohibited completely. Only fuel and additives which are specified inIn case of some ingredients which give bad effects to the catalysts (such as phosphorus “P”, leadThe engine running without igniting causes a great flow of unburned gasoline and the decreasingSo, avoid coastingUnder the condition that the engine stopIncomplete connection or cut-off of the pri-In this case, from the standpoint to protect theKawasaki Low Exhaust Emission SystemConventionalIn this case,If you have no choice but running by yourself, keepConnect another full-charged battery with jumper ca-The mechanism is simple and power loss is minimum because the system uses the vacuum pres-As the exhaust valve opens, and the burned fuel passes theThis fresh air burnsThe secondary air injection system consists of a vacuum switch valve, and two air suction valves. Without using an air pump, the air suction valve can draw fresh air into the exhaust passage near theAir Suction Valves. The air suction valves is a check valve which allows fresh air to flow only from the air cleaner viaRemove and inspect the air suction valvesAlso, remove and inspect the airVacuum Switch Valve. Although the vacuum switch valve usually permits secondary air flow, it closes when a high vacuumThis is to shut off secondary airThese explosions, or backfiring in the exhaust system could damageRegular inspection of the vacuum switch valve is not needed. If backfiring occurs frequently in theSecondary Air Injection SystemThe three-way catalysts are used for the catalytic converters and the main catalytic converter. TheseCO and HC are oxidized (O is added) by platinum (Pt) and converted to harmless carbon dioxideNOx is reduced (O is removed) by rhodium (Rh) and converted to harmless nitrogen (N2) and oxygenMain Catalytic ConverterMost catalysts are powders of metal or of metallic compounds, and they increase the rate of aCatalysts are supposed to act in some way to loosen the bonds of the reacting substances. In otherThe catalyst itself undergoes no permanent chemical change, or can be recovered when the chem-So, the muffler with built-in catalyst has the same durability as the conven-The mechanism of catalytic action is supposed to be a surface phenomenon in which reactantsThe catalytic converter is made ofThe alumina adheresThe alumina surface isCatalyst is applied onThe rougher the surface is, the more activelyIf various impurities like lead are absorbed, they block the small portion of the catalyst surface,This is the reason why leaded fuel poisons the catalystCatalysts are generally efficient in small quantities. A catalyst can catalyze the reaction of severalThe three-way catalyst is a blend of platinum (Pt)But a converter uses only about 0.05 gram of Pt and 0.01Details. The electronic combination meter unit, superior to theConstruction and Operation. Hall Element. The semi-conductors (e.g. CaAs, InAs, InSb) are calledDifferential Amplifier. This can output the difference between output powers ofHigh Pass Filter. Sensitivity of the two (2) Hall elements. Surface magnetic induction of a magnet.