Kawasaki Ninja ZX-6R,RR (1995-2007) - Service Manual - Manuale di Officina - Reparaturanleitung

KAWASAKI ZX-6R,RR - REPAIR MANUAL - MANUALE RIPARAZIONI - REPARATURANLEITUNG

- English Service Manual, to vehicles Kawasaki ZX-6R,RR.
- Manuale di officina in italiano, ai veicoli Kawasaki ZX-6R,RR.
- Deutsches reparaturhandbuch, an fahrzeuge Kawasaki ZX-6R,RR.
 


CONTENTS, SOMMARIO, INHALT:


Kawasaki ZX-6R (1995) - Reparaturanleitung.pdf
Kawasaki ZX-6R (1997) - Motorcycle Service Manual - Parts Catalog.pdf
Kawasaki ZX-6R (2000) - Motorcycle Service Manual.pdf
Kawasaki ZX-6R (2001) - Werkstatthandbuch.pdf
Kawasaki ZX-6R (2003) - Motorcycle Service Manual.pdf
Kawasaki ZX-6R (2004) - Manuale di Assistenza della Motocicletta.pdf
Kawasaki ZX-6R (2004) - Motorcycle Assembly & Preparation Manual.pdf
Kawasaki ZX-6R (2004) - Motorcycle Service Manual.pdf
Kawasaki ZX-6R (2005) - Parts Catalog.pdf
Kawasaki ZX-6R (2007) - Manuale di Assistenza della Motocicletta.pdf
Kawasaki ZX-6R (2007) - Motorcycle Service Manual.pdf
Kawasaki ZX-6R,RR (2003) - Manuale di Assistenza della Motocicletta.pdf
Kawasaki ZX-6R,RR (2003) - Motorrad Werkstatt-Handbuch.pdf
Kawasaki ZX-6RR (2004) - Motorcycle Service Manual.pdf
Kawasaki ZX-6RR (2004) - Motorrad Werkstatt-Handbuch.pdf
Kawasaki ZX-6RR (2005) - Racing Kit Manual.pdf




MOTORCYCLE SERVICE MANUAL


- EMISSION CONTROL INFORMATION
- 1.
- 2.
- 3.
- TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
- Foreword
- General Information
- Before starting to perform an inspection service or carry out a
- Battery Ground
- Edges of Parts
- Solvent
- Cleaning vehicle before disassembly
- Arrangement and Cleaning of Removed Parts
- Storage of Removed Parts
- Inspection
- Replacement Parts
- Assembly Order
- Tightening Sequence
- Tightening Torque
- Force
- Gasket, O-ring
- Liquid Gasket, Non-permanent Locking Agent
- Press
- Ball Bearing and Needle Bearing
- Oil Seal, Grease Seal
- Circlips, Cotter Pins
- Lubrication
- Direction of Engine Rotation
- Electrical Wires
- Instrument
- ZX600P7F (Europe) Left Side View
- ZX600P7F (Europe) Right Side View
- ZX600P7F (US and Canada) Left Side View
- ZX600P7F (US and Canada) Right Side View
- Prefixes for Units
- Units of Temperature
- Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Inside Circlip Pliers:
- Fuel System (DFI)
- Throttle Control System Inspection
- Engine Vacuum Synchronization Inspection
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Idle Speed Inspection
- Idle Speed Adjustment
- Fuel Hose Inspection (fuel leak, damage, installation condition)
- Evaporative Emission Control System (California Model)
- Evaporative Emission Control System Inspection
- Engine Top End
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Air Suction System
- Air Suction System Damage Inspection
- Cooling System
- Coolant Level Inspection
- Radiator Hose Damage and Installation Condition Inspection
- Torque -
- Clutch
- Clutch Operation Inspection
- Wheels/Tires
- Air Pressure Inspection
- Wheel/Tire Damage Inspection
- Tire Tread Wear Inspection
- Wheel Bearing Damage Inspection
- Drive Train
- Drive Chain Lubrication Condition Inspection
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Torque -
- Wheel Alignment Inspection
- Drive Chain Wear Inspection
- Chain Guide Wear Inspection
- Brake System
- Brake Fluid Leak (Brake Hose and Pipe) Inspection
- Brake Hose Damage and Installation Condition Inspection
- Torque -
- Brake Operation Inspection
- Brake Fluid Level Inspection
- Brake Pad Wear Inspection
- Brake Light Switch Operation Inspection

- Suspensions
- Front Forks/Rear Shock Absorber Operation Inspection
- Front Fork Oil Leak Inspection
- Rear Shock Absorber Oil Leak Inspection
- Rocker Arm Operation Inspection
- Tie-Rod Operation Inspection
- Steering System
- Steering Play Inspection
- Special Tools -
- Steering Play Adjustment
- Special Tool -
- Torque -
- Steering Stem Bearing Lubrication
- Lights and Switches Operation Inspection
- Headlight Aiming Inspection
- Side Stand Switch Operation Inspection

- Engine Stop Switch Operation Inspection
- Others
- Chassis Parts Lubrication
- Pivots: Lubricate with Grease.
- Points: Lubricate with Grease.
- Cables: Lubricate with Rust Inhibitor
- Bolts, Nuts and Fasteners Tightness Inspection
- Bolt, Nut and Fastener to be checked
- Replacement Parts
- Air Cleaner Element Replacement
- Torque -
- Fuel Hose Replacement
- Torque -
- Coolant Change
- Torque -
- Radiator Hose and O-ring Replacement
- Torque -
- Engine Oil Change

- Torque -
- Oil Filter Replacement
- Special Tool -
- Torque -
- Brake Hose and Pipe Replacement
- Torque -
- Brake Fluid Change
- Torque -
- Torque -
- Master Cylinder Rubber Parts Replacement
- Special Tool -
- Special Tool -

- Silicone Grease -
- Torque -
- Caliper Rubber Parts Replacement
- Torque -
- Torque -
- Torque -
- Spark Plug Replacement
- Owner's Tool -
- Torque -
- Fuel System (DFI)
- Oil Pressure Gauge, 5 kgf/cm :
- Inlet Air Pressure Sensor [A]
- DFI System
- DFI System Wiring Diagram
- Terminal Numbers of ECU Connectors
- There are a number of important precautions that should be follo
- Torque -
- The warning indicator light (LED) [A] is used for the FI indicat
- Outline
- Special Tool -
- Sealant -
- DFI Diagnosis Flow Chart
- Inquiries to Rider
- NOTE
- The warning indicator light (LED) [A] is used for the FI indicat
- Self-diagnosis Outline
- Self-diagnosis Procedures
- Self-Diagnosis Flow Chart
- Service Code Reading
- Service Code Erasing
- Backups
- The main throttle sensor is a rotating variable resistor that ch
- Main Throttle Sensor Removal/Adjustment
- Main Throttle Sensor Input Voltage Inspection
- Special Tool -
- Special Tool -
- Main Throttle Sensor Output Voltage Inspection
- Special Tool -
- Special Tool -
- Main Throttle Sensor Resistance Inspection
- Main Throttle Sensor Circuit
- CAUTION
- Inlet Air Pressure Sensor Removal
- Inlet Air Pressure Sensor Installation
- Inlet Air Pressure Sensor Input Voltage Inspection
- Special Tool -
- Special Tool -
- Inlet Air Pressure Sensor Output Voltage Inspection
- Special Tool -
- Inlet Air Pressure Sensor Circuit
- Special Tools -
- Inlet Air Temperature Sensor Removal/Installation
- Inlet Air Temperature Sensor Output Voltage Inspection
- Special Tool -
- Sealant -
- Inlet Air Temperature Sensor Resistance Inspection
- Inlet Air Temperature Sensor Circuit
- Water Temperature Sensor Removal/Installation
- Sealant -
- Torque -
- Water Temperature Sensor Output Voltage Inspection
- Special Tool -
- Sealant -
- Water Temperature Sensor Circuit
- Water Temperature Sensor Resistance Inspection
- CAUTION
- Atmospheric Pressure Sensor Removal
- Atmospheric Pressure Sensor Installation
- Atmospheric Pressure Sensor Input Voltage Inspection
- Special Tool -
- Special Tool -
- Atmospheric Pressure Sensor Output Voltage Inspection
- Special Tool -
- Atmospheric Pressure Sensor Circuit
- Atmospheric Pressure/Altitude Relationship
- Crankshaft Sensor Removal/Installation
- Crankshaft Sensor Inspection
- Crankshaft Sensor Circuit
- Camshaft Position Sensor Removal/Installation
- Camshaft Position Sensor Inspection
- Camshaft Position Sensor Circuit
- Speed Sensor Removal/Installation
- Speed Sensor Inspection
- Speed Sensor Input Voltage Inspection
- Special Tool -
- Speed Sensor Output Voltage Inspection
- Special Tool -
- Speed Sensor Circuit
- Gear Position Switch Removal/Installation
- Gear Position Switch Inspection
- Gear Position Switch Input Voltage Inspection
- Special Tool -
- Gear Position Switch Circuit
- This sensor has a weight [A] with two magnets inside, and sends
- Vehicle-down Sensor Removal
- Vehicle-down Sensor Installation
- Torque -
- Vehicle-down Sensor Inspection
- Special Tool -
- Special Tool -
- Sealant -
- Vehicle-down Sensor Circuit
- Subthrottle Sensor Removal/Adjustment
- Subthrottle Sensor Input Voltage Inspection
- Special Tool -
- Special Tool -
- Subthrottle Sensor Output Voltage Inspection
- Special Tool -
- Special Tool -
- Resistance Inspection
- Subthrottle Sensor Circuit
- Oxygen Sensor ##1: Service Code 33
- Oxygen Sensor Removal/Installation
- Oxygen Sensor Inspection
- Special Tool -
- Sealant -
- Oxygen Sensor Circuit
- Exhaust Butterfly Valve Actuator Sensor Removal/Installation
- Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
- Special Tool -
- Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio
- Special Tool -
- Exhaust Butterfly Valve Actuator Sensor Inspection
- Exhaust Butterfly Valve Actuator Sensor Circuit
- Antenna Resistance Inspection
- Amplifier Input Voltage Inspection
- Special Tool -
- This code appears in the following conditions.
- User Key Inspection
- Immobilizer System Circuit
- ECU Communication Line Inspection
- ECU Communication Line Circuit

- Stick Coil ##1: Service Code 51
- Stick Coil Removal/Installation
- Stick Coil Input Voltage Inspection
- Special Tool -
- Stick Coil Circuit
- Radiator Fan Relay Removal/Installation
- Radiator Fan Relay Inspection
- Radiator Fan Relay Circuit
- Subthrottle Valve Actuator Removal
- Subthrottle Valve Actuator Inspection
- Subthrottle Valve Actuator Resistance Inspection
- Subthrottle Valve Actuator Input Voltage Inspection
- Special Tools -
- Subthrottle Valve Actuator Circuit
- Exhaust Butterfly Valve Actuator Removal
- Exhaust Butterfly Valve Actuator Installation
- Torque -
- Torque -
- Exhaust Butterfly Valve Actuator Inspection
- Exhaust Butterfly Valve Actuator Output Voltage Inspection
- Special Tool -
- Exhaust Butterfly Valve Actuator Circuit
- Air Switching Valve Removal/Installation
- Air Switching Valve Inspection
- Air Switching Valve Circuit (Other than Europe Models)
- Oxygen Sensor Heater Removal/Installation
- Oxygen Sensor Heater Inspection
- Special Tool -
- Special Tool -
- Sealant -
- Oxygen Sensor Circuit
- Oxygen Sensor ##1: Service Code 94
- Oxygen Sensor Removal/Installation
- Oxygen Sensor Inspection
- Special Tool -
- Sealant -
- Oxygen Sensor Circuit
- CAUTION
- ECU Identification
- ECU Removal
- ECU Installation
- ECU Power Supply Inspection
- Special Tool -
- ECU Power Source Circuit
- ECU Fuse Removal
- ECU Fuse Installation
- ECU Fuse Inspection
- Warning Indicator Light (LED) Inspection
- Warning Indicator Light (LED) (FI/Immobilizer) Circuit
- Fuel Pressure Inspection
- Special Tools -
- Fuel Flow Rate Inspection
- Special Tool -
- Fuel Pump Removal
- Fuel Pump Installation
- Torque -
- Fuel Pump Operation Inspection
- Fuel Pump Operating Voltage Inspection
- Special Tools -
- Fuel Pump Circuit
- Fuel Pump Relay Removal
- Fuel Pump Relay Inspection
- Special Tool -
- CAUTION
- Audible Inspection
- Injector Signal Test
- Special Tool -
- Injector Resistance Inspection
- Special Tool -
- Injector Unit Test
- Injector Voltage Inspection
- Special Tool -
- Special Tool -
- Injector Fuel Line Inspection
- Fuel Injector Circuit
- Free Play Inspection
- Free Play Adjustment
- Cable Installation
- Cable Lubrication
- Idle Speed Inspection
- Synchronization Inspection
- Synchronization Adjustment
- Throttle Body Assy Removal
- Special Tool -
- Throttle Body Assy Installation
- Torque -
- Torque -

- Throttle Body Assy Disassembly
- Throttle Body Assy Assembly
- Torque -
- Nozzle Assy Removal
- Nozzle Assy Installation
- Torque -
- Nozzle Assy Disassembly
- Nozzle Assy Assembly
- Torque -
- Torque -
- Air Cleaner Element Removal
- Air Cleaner Element Installation
- Air Cleaner Element Inspection
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Torque -
- Air Cleaner Housing Disassembly
- Air Cleaner Housing Assembly
- Torque -
- Oil Draining
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank and Cap Inspection
- Fuel Tank Cleaning
- The Evaporative Emission Control System routes fuel vapors from
- Parts Removal/Installation
- Hose Inspection
- Separator Inspection

- Separator Operation Test
- Canister Inspection
- Cooling System
- Bearing Driver, 32:
- Coolant Deterioration Inspection
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Cooling System Flushing
- Coolant Reserve Tank Removal
- Coolant Reserve Tank Installation
- Torque -
- Water Pump Removal
- Water Pump Installation
- Water Pump Impeller Disassembly/Assembly
- Torque -
- Water Pump Impeller Inspection
- Water Pump Housing Disassembly
- Water Pump Housing Assembly
- Special Tool -
- Special Tool -
- Mechanical Seal Inspection
- Radiator and Radiator Fan Removal
- Radiator and Radiator Fan Installation
- Torque -
- Torque -
- Torque -
- Torque -
- Radiator Inspection
- Radiator Cap Inspection
- Radiator Filler Neck Inspection
- Thermostat Removal
- Thermostat Installation
- Torque -
- Torque -
- Thermostat Inspection
- Hose Installation
- Torque -
- Hose Inspection
- Water Temperature Sensor Removal
- Water Temperature Sensor Inspection
- Engine Top End
- Compression Gauge, 20 kgf/cm :
- Air Suction Valve Removal
- Air Suction Valve Installation
- Torque -
- Air Suction Valve Inspection
- Air Switching Valve Removal

- Air Switching Valve Installation
- Air Switching Valve Operation Test
- Air Switching Valve Unit Test
- Clean Air System Hose Inspection
- Cylinder Head Cover Removal
- Cylinder Head Cover Installation
- Sealant -
- Torque -
- Torque -
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Torque -
- Torque -
- Camshaft Removal
- Camshaft Installation
- Torque -
- Torque -
- Camshaft, Camshaft Cap Wear
- Torque -
- Camshaft Runout
- Cam Wear
- Camshaft Chain Removal
- Cylinder Compression Measurement
- Special Tools -
- Torque -
- Cylinder Head Removal
- Cylinder Head Installation
- Torque -
- Torque -
- Torque -
- Cylinder Head Warp
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Valve Removal
- Special Tools -
- Valve Installation
- Valve Guide Removal
- Special Tool -
- Valve Guide Installation
- Special Tools -
- Special Tool -
- Valve-to-Guide Clearance Measurement (Wobble Method)

- Valve Seat Inspection
- Valve Seat Repair
- Special Tools -
- Throttle Body Assy Holder Removal
- Throttle Body Assy Holder Installation
- Torque -
- WARNING
- Muffler Body Removal
- Muffler Body Installation
- Torque -
- Torque -
- Rear Exhaust Pipe Removal
- Rear Exhaust Pipe Installation
- Torque -
- Front Exhaust Pipe Removal
- Front Exhaust Pipe Installation
- Torque -
- Exhaust Butterfly Valve Cable Removal
- Exhaust Butterfly Valve Cable Installation
- Torque -
- Torque -
- Torque -
- Torque -
- Clutch
- Clutch Holder:
- Clutch Lever Free Play Inspection
- Clutch Lever Free Play Adjustment
- Cable Removal
- Cable Installation
- Cable Lubrication
- Clutch Lever Installation
- Torque -
- Clutch Cover Removal
- Clutch Cover Installation
- Sealant -
- Torque -
- Release Shaft Removal
- Release Shaft Installation
- Clutch Cover Disassembly
- Clutch Cover Assembly
- Torque -
- Clutch Removal
- Special Tool -

- Clutch Installation
- Special Tool -
- Torque -
- Torque -
- Spring Plate Free Play Measurement
- Spring Plate Free Play Adjustment
- Torque -
- Clutch Plate, Wear, Damage Inspection
- Clutch Plate Warp Inspection
- Clutch Spring Free Length Measurement
- Damper Cam Inspection
- Engine Lubrication System
- Outside Circlip Pliers:
- WARNING
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Replacement
- Oil Pan Removal
- Oil Pan Installation
- Torque -
- Oil Pressure Relief Valve Removal
- Oil Pressure Relief Valve Installation
- Torque -
- Oil Pressure Relief Valve Inspection
- Oil Pump Removal
- Oil Pump Installation
- Torque -
- Torque -
- Torque -
- Torque -
- Oil Pump Gear Removal
- Oil Pump Gear Installation
- Torque -
- Oil Pump Gear Shaft Removal
- Special Tool -
- Oil Pump Gear Shaft Installation
- Special Tool -
- Oil Cooler Removal
- Oil Cooler Installation
- Torque -
- Torque -
- Oil Cooler/Oil Filter Case Removal
- Oil Cooler/Oil Filter Case Installation
- Torque -
- Torque -
- Torque -
- Oil Pressure Measurement
- Special Tools -
- Torque -
- Oil Pressure Switch Removal
- Oil Pressure Switch Installation
- Sealant -
- Torque -
- Torque -
- Engine Removal/Installation
- Engine Mount Nut Wrench:
- Engine Removal
- Special Tool -
- Engine Installation
- Torque -
- Torque -
- Torque -
- Torque -
- Special Tool -
- Torque -
- Torque -
- Crankshaft/Transmission
- Outside Circlip Pliers:
- Crankcase Splitting
- Crankcase Assembly
- Torque -
- Special Tool -
- Torque -
- Torque -
- Torque -
- Torque -
- Sealant -
- Torque -
- Torque -
- Torque -
- Crankshaft Removal
- Crankshaft Installation
- Connecting Rod Removal
- Connecting Rod Installation
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend
- Connecting Rod Twist
- Connecting Rod Big End Side Clearance
- Connecting Rod Big End Bearing Insert/Crankpin Wear
- Crankshaft Side Clearance
- Crankshaft Runout
- Crankshaft Main Bearing Insert/Journal Wear
- Piston Removal
- Special Tool -
- Piston Installation
- Special Tools -
- Cylinder Wear (Upper Crankcase)
- Piston Wear
- Piston Ring, Piston Ring Groove Wear
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap
- Starter Idle Gear Removal
- Starter Idle Gear Installation
- Sealant -
- Torque -
- Torque -
- Starter Clutch Removal
- Special Tools -
- Starter Clutch Installation
- Special Tools -
- Torque -
- Starter Clutch Disassembly
- Starter Clutch Assembly
- Starter Clutch Inspection
- Shift Pedal Removal
- Shift Pedal Installation
- Torque -
- Torque -
- Torque -

- External Shift Mechanism Removal
- Special Tool -
- External Shift Mechanism Installation
- Torque -
- Special Tool -
- External Shift Mechanism Inspection
- Torque -
- Transmission Assy Removal
- Transmission Assy Disassembly
- Transmission Assy Assembly
- Special Tool -
- Torque -
- Torque -
- Torque -
- Transmission Assy Installation
- Torque -
- Transmission Shaft Removal
- Transmission Shaft Installation
- Transmission Shaft Disassembly
- Special Tool -
- Transmission Shaft Assembly
- Shift Drum and Fork Removal
- Shift Drum and Fork Installation
- Shift Drum Disassembly
- Shift Drum Assembly
- Torque -
- Shift Fork Bending
- Shift Fork/Gear Groove Wear
- Shift Fork Guide Pin/Drum Groove Wear

- Gear Dog and Gear Dog Hole Damage
- Wheels/Tires
- Bearing Driver Set:
- Front Wheel Removal
- Special Tools -
- Front Wheel Installation
- Torque -
- Torque -
- Rear Wheel Removal
- Rear Wheel Installation
- Torque -
- Wheel Inspection
- Special Tools -
- Axle Inspection
- Balance Inspection
- Balance Adjustment
- Balance Weight Removal
- Balance Weight Installation
- Air Pressure Inspection/Adjustment
- Tire Inspection
- Tire Removal
- Tire Installation
- Tire Repair
- Hub Bearing Removal
- Special Tools -
- Hub Bearing Installation
- Special Tool -
- Special Tool -
- Hub Bearing Inspection
- Hub Bearing Lubrication
- Final Drive
- Inside Circlip Pliers:
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Wheel Alignment Inspection/Adjustment
- Drive Chain Wear Inspection
- Drive Chain Lubrication
- Drive Chain Removal
- Drive Chain Installation
- Engine Sprocket Removal
- Engine Sprocket Installation
- Torque -
- Torque -
- Rear Sprocket Removal
- Rear Sprocket Installation
- Torque -
- Coupling Installation
- Coupling Bearing Removal
- Special Tool -
- Special Tool -
- Coupling Bearing Installation
- Special Tool -
- Special Tool -
- Special Tool -
- Coupling Bearing Inspection
- Coupling Bearing Lubrication
- Coupling Damper Inspection
- Sprocket Wear Inspection
- Rear Sprocket Warp Inspection
- Brakes
- Inside Circlip Pliers:
- Brake Lever Position Adjustment
- Brake Pedal Position Inspection
- Brake Pedal Position Adjustment
- Torque -
- Brake Pedal Removal
- Brake Pedal Installation
- Torque -
- Torque -
- Torque -
- Front Caliper Removal
- Rear Caliper Removal
- Caliper Installation
- Torque -
- Front Caliper Disassembly
- Front Caliper Assembly
- Rear Caliper Disassembly
- Rear Caliper Assembly
- Caliper Fluid Seal Damage
- Rear Caliper Dust Boot and Friction Boot Damage
- Caliper Piston and Cylinder Damage

- Rear Caliper Holder Shaft Wear
- Front Brake Pad Removal
- Front Brake Pad Installation
- Torque -
- Rear Brake Pad Removal
- Rear Brake Pad Installation
- Brake Pad Wear Inspection
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Torque -
- Torque -
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Torque -
- Front Master Cylinder Disassembly
- Rear Master Cylinder Disassembly
- Master Cylinder Inspection (Visual Inspection)

- Master Cylinder Assembly
- Brake Disc Removal
- Brake Disc Installation
- Torque -
- Brake Disc Wear
- Brake Disc Warp
- Special Tools -
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Bleeding
- Torque -
- Torque -
- Torque -
- Brake Hose Removal/Installation
- Brake Hose Inspection
- Suspension
- Inside Circlip Pliers:
- Rebound Damping Force Adjustment
- Spring Preload Adjustment
- Compression Damping Force Adjustment
- Front Fork Removal (Each Fork Leg)
- Front Fork Installation
- Torque -
- Torque -
- Front Fork Oil Change
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Special Tool -
- Torque -
- Front Fork Disassembly
- Front Fork Assembly
- Special Tool -
- Special Tool -
- Torque -
- Inner Tube Inspection
- Dust Seal Inspection
- Spring Tension
- Rebound Damping Force Adjustment
- Compression Damping Force Adjustment
- Spring Preload Adjustment
- Special Tool -
- Special Tools -
- Rear Shock Absorber Removal
- Special Tools -
- Rear Shock Absorber Installation
- Torque -
- Rear Shock Absorber Inspection
- Rear Shock Absorber Scrapping
- Swingarm Removal
- Special Tool -
- Swingarm Installation
- Torque -
- Special Tool -
- Torque -
- Torque -
- Swingarm Bearing Removal
- Special Tool -
- Special Tool -
- Swingarm Bearing Installation
- Special Tools -
- Swingarm Bearing, Sleeve Inspection
- Chain Guide Inspection
- Tie-Rod Removal
- Special Tools -
- Tie-Rod Installation
- Torque -
- Rocker Arm Removal
- Special Tools -
- Rocker Arm Installation
- Torque -
- Tie-Rod and Rocker Arm Bearing Removal
- Special Tool -
- Tie-Rod and Rocker Arm Bearing Installation
- Special Tools -
- Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
- Rocker Arm/Tie-Rod Bearing Lubrication
- Steering
- Bearing Puller:
- Steering Inspection
- Steering Adjustment
- Stem, Stem Bearing Removal
- Special Tool -
- Special Tool -
- Special Tools -
- Stem, Stem Bearing Installation
- Special Tools -
- Special Tools -
- Special Tool -
- Torque -
- Torque -
- Steering Stem Bearing Lubrication
- Steering Stem Warp
- Stem Cap Deterioration, Damage
- Handlebar Removal
- Handlebar Installation
- Torque -
- Torque -
- Frame
- Rear Seat Removal
- Rear Seat Installation
- Front Seat Removal
- Front Seat Installation
- Lower Fairing Removal
- Lower Fairing Installation
- Middle Fairing Removal
- Windshield Removal
- Windshield Installation
- Torque -
- Upper Fairing Disassembly
- Upper Fairing Assembly
- Upper Fairing Installation
- Inner Cover Removal
- Inner Cover Installation
- Center Inner Fairing Removal
- Center Inner Fairing Installation
- Lower Inner Fairing Removal
- Lower Inner Fairing Installation
- Left Side Cover Removal
- Left Side Cover Installation
- Right Side Cover Removal
- Right Side Cover Installation
- Seat Cover Removal
- Seat Cover Installation
- Heat Insulation Plate Removal
- Heat Insulation Plate Installation
- Heat Insulation Rubber Plate Pemoval
- Heat Insulation Rubber Plate Installation
- Front Fender Removal
- Front Fender Installation
- Torque -
- Flap and Rear Fender Removal
- Flap and Rear Fender Installation
- Rear Frame Removal
- Rear Frame Installation
- Torque -
- Frame Inspection
- Sidestand Removal
- Sidestand Installation
- Torque -
- Torque -
- Electrical System
- Hand Tester:
- There are a number of important precautions that are musts when
- Wiring Inspection
- Special Tool -
- Battery Removal
- Battery Installation
- Battery Activation
- Precautions
- 1)
- 2)
- 3)
- 4)
- Interchange
- Charging Condition Inspection
- Refreshing Charge
- Alternator Cover Removal
- Alternator Cover Installation
- Sealant -
- Torque -
- Stator Coil Removal
- Stator Coil Installation
- Torque -
- Sealant -
- Torque -
- Alternator Rotor Removal
- Special Tools -
- Special Tool -
- Alternator Rotor Installation
- Special Tools -
- Special Tool -
- Special Tools -
- Torque -
- Alternator Inspection
- Special Tool -
- Regulator/Rectifier Removal
- Regulator/Rectifier Inspection
- Special Tool -
- Torque -
- Charging Voltage Inspection
- Special Tool -
- Charging System Circuit
- Crankshaft Sensor Removal
- Crankshaft Sensor Installation
- Torque -
- Sealant -
- Crankshaft Sensor Inspection
- Special Tool -
- Crankshaft Sensor Peak Voltage
- Special Tools -
- Stick Coil Removal
- Stick Coil Installation
- Stick Coil Inspection
- Stick Coil Primary Peak Voltage
- Special Tools -
- Spark Plug Removal
- Spark Plug Installation
- Spark Plug Clean and Inspection
- Camshaft Position Sensor Removal
- Camshaft Position Sensor Installation
- Torque -
- Camshaft Position Sensor Inspection
- Special Tool -
- Camshaft Position Sensor Peak Voltage Inspection
- Special Tools -
- Interlock Operation Inspection
- IC Igniter Inspection
- Ignition System Circuit
- Starter Motor Removal
- Starter Motor Installation
- Torque -
- Starter Motor Disassembly
- Starter Motor Assembly
- Brush Inspection
- Commutator Cleaning and Inspection
- Armature Inspection
- Special Tool -
- Brush Lead Inspection
- Special Tool -
- Right-hand End Cover Assembly Inspection
- Special Tool -
- Starter Relay Inspection
- Special Tool -
- Electric Starter Circuit
- This motorcycle adopt the daylight system and have a headlight r
- Headlight Beam Horizontal Adjustment
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- City Light Bulb Replacement
- Headlight Removal/Installation
- Tail/Brake Light (LED) Removal
- Tail/Brake Light (LED) Installation
- License Plate Light Bulb Replacement
- Headlight/Tail Light Circuit
- Turn Signal Light Bulb Replacement
- Turn Signal Light Removal
- Turn Signal Relay Inspection
- Turn Signal Light Circuit
- Air Switching Valve Operation Test
- Air Switching Valve Unit Test
- Special Tool -
- Fan Motor Inspection
- Radiator Fan Circuit
- Meter Unit Removal
- Meter Unit Disassembly
- Electronic Combination Meter Unit Inspection
- Fuel Level Sensor Line Self-Diagnosis Mode Inspection
- Meter Circuit
- This motorcycle is equipped with an immobilizer system to protec
- Operational Cautions
- Key Registration
- Special Tool -
- Spare User Key Registration Flow Chart
- Special Tool -
- All Keys Initial Registration Flow Chart
- Immobilizer System Parts Replacement
- Immobilizer System Inspection
- Immobilizer System Circuit
- Brake Light Timing Inspection
- Brake Light Timing Adjustment
- Gear Position Switch Removal
- Gear Position Switch Installation
- Torque -
- Gear Position Switch Inspection
- Special Tool -
- Switch Inspection
- Special Tool -
- Rear Brake Light Switch Connections
- Side Stand Switch Connections
- Oil Pressure Switch Connections *
- Water Temperature Sensor Inspection
- Speed Sensor Removal
- Speed Sensor Installation
- Torque -
- Speed Sensor Inspection
- Special Tool -
- Fuel Reserve Switch Inspection
- Oxygen Sensor Removal (Equipped Models)
- Oxygen Sensor Installation (Equipped Models)
- Torque -
- Oxygen Sensor Inspection (Equipped Models)
- The relay box [A] has relays and diodes. The relays and diodes c
- Relay Box Removal
- Relay Circuit Inspection
- Diode Circuit Inspection
- Relay Box Internal Circuit
- 30 A Main Fuse Removal
- Fuse Box Fuse Removal
- 10 A ECU Fuse Removal
- Fuse Installation
- Fuse Inspection
- Appendix
- California Model
- California Model
- NOTE
- Engine Doesn't Start, Starting Difficulty:
- Starter motor not rotating:
- Starter motor rotating but engine doesn't turn over:
- Engine won't turn over:
- No fuel flow:
- No spark; spark weak:
- Fuel/air mixture incorrect:
- Compression Low:
- Poor Running at Low Speed:
- Spark weak:
- Fuel/air mixture incorrect:
- Compression low:
- Run-on (dieseling):
- Other:
- Poor Running or No Power at High Speed:
- Firing incorrect:
- Fuel/air mixture incorrect:
- Compression low:
- Knocking:
- Miscellaneous:
- Overheating:
- Firing incorrect:
- Muffler overheating:
- Fuel/air mixture incorrect:
- Compression high:
- Engine load faulty:
- Lubrication inadequate:
- Oil cooler incorrect:
- Water temperature meter incorrect:
- Coolant incorrect:
- Cooling system component incorrect:
- Over Cooling:
- Water temperature meter incorrect:
- Cooling system component incorrect:
- Clutch Operation Faulty:
- Clutch slipping:
- Clutch not disengaging properly:
- Gear Shifting Faulty:
- Doesn't go into gear; shift pedal doesn't return:
- Jumps out of gear:
- Overshifts:
- Abnormal Engine Noise:
- Knocking:
- Piston slap:
- Valve noise:
- Other noise:

- Abnormal Drive Train Noise:
- Clutch noise:
- Transmission noise:
- Drive line noise:
- Abnormal Frame Noise:
- Front fork noise:
- Rear shock absorber noise:
- Disc brake noise:
- Other noise:
- Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:
- Exhaust Smokes Excessively:
- White smoke:
- Black smoke:
- Brown smoke:
- Handling and/or Stability Unsatisfactory:
- Handlebar hard to turn:
- Handlebar shakes or excessively vibrates:
- Handlebar pulls to one side:
- Shock absorption unsatisfactory:
- Brake Doesn't Hold:
- Battery Trouble:
- Battery discharged:
- Battery overcharged:




MANUALE DI ASSISTENZA DELLA MOTOCICLETTA



- INFORMAZIONI SUL CONTROLLO DELLE EMISSIONI
- 1.
- 2.
- 3.
- VIETATA LA MANOMISSIONE DEL SISTEMA DI CONTROLLO DELLE EMISSIO
- Premessa
- Informazioni generali
- Prima di eseguire un controllo, una manutenzione o di realizzare
- Massa batteria
- Bordi dei componenti
- Solventi
- Pulizia della motocicletta prima del disassemblaggio
- Disposizione e pulizia dei componenti rimossi
- Rimessaggio dei componenti rimossi
- Controllare
- Pezzi di ricambio
- Ordine di montaggio
- Sequenza di serraggio
- Coppia di serraggio
- Forza
- Guarnizione, O-ring
- Pasta sigillante , prodotto frenafiletti non permanente
- Pressa
- Cuscinetto a sfere e cuscinetto ad aghi
- Guarnizione, guarnizione di ingrassaggio
- Anelli di sicurezza, copiglie
- Lubrificazione
- Direzione della rotazione del motore
- Cavi elettrici
- Strumentazione
- Veduta lato sinistro del modello ZX600P7F (per l’Europa)
- Veduta lato destro del modello ZX600P7F (per l’Europa)
- Veduta lato sinistro del modello ZX600P7F (per USA e Canada)
- Veduta lato destro del modello ZX600P7F (per USA e Canada)
- Prefissi per le unit di misura
- Unit di misura della temperatura
- Manutenzione periodica
- La manutenzione programmata deve essere eseguita in conformit a
- Le seguenti tabelle elencano la coppia di serraggio per la maggi
- Pinze per anelli elastici di sicurezza interni:
- Impianto di alimentazione (DFI)
- Controllo del sistema di comando acceleratore
- Controllo sincronizzazione depressione motore
- Attrezzo speciale -

- Attrezzo speciale -
- Attrezzo speciale -
- Attrezzo speciale -
- Controllo del regime minimo
- Regolazione del regime del minimo
- Controllo del flessibile del carburante (perdita di carburante,
- Sistema di controllo emissione vapori (modello per la California
- Controllo del sistema di controllo emissione vapori
- Parte superiore del motore
- Controllo del gioco delle valvole
- Regolazione del gioco valvola
- Sistema di aspirazione aria
- Controllo danni al sistema di aspirazione aria
- Impianto di raffreddamento
- Controllo livello liquido refrigerante
- Controllo dei danni al tubo flessibile del radiatore e delle con
- Coppia -
- Frizione
- Controllo funzionamento frizione
- Ruote/pneumatici
- Controllo pressione
- Controllo danni a ruote/pneumatici
- Controllo usura battistrada pneumatici
- Controllo danni al cuscinetto della ruota
- Trasmissione
- Controllo condizioni di lubrificazione catena di trasmissione
- Controllo del gioco della catena di trasmissione
- Regolazione del gioco della catena di trasmissione
- Coppia -
- Controllo allineamento ruota
- Controllo usura della catena di trasmissione
- Controllo usura del guidacatena
- Impianto freni
- Controllo perdite liquido freni (tubi flessibile e rigido dei fr
- Controllo dei danni ai flessibili dei freni e delle condizioni d
- Coppia -
- Controllo funzionamento freni
- Controllo livello liquido freni
- Controllo usura pastiglie del freno
- Controllo funzionamento interruttore luce freno
- Sospensioni
- Controllo funzionamento forcella anteriore/ammortizzatore poster
- Controllo perdite di olio dalla forcella anteriore
- Controllo perdite d’olio dall’ammortizzatore posteriore
- Controllo funzionamento bilanciere
- Controllo funzionamento tiranti
- Sistema sterzo
- Controllo gioco sterzo
- Attrezzi speciali -
- Regolazione gioco sterzo
- Attrezzo speciale -
- Coppia -
- Lubrificazione cuscinetto cannotto sterzo
- Controllo funzionamento luci e interruttori
- Controllo puntamento del faro
- Controllo funzionamento interruttore cavalletto laterale
- Controllo funzionamento interruttore di arresto motore
- Altri
- Lubrificazione componenti telaio
- Perni: Lubrificare con grasso.
- Punti: Lubrificare con grasso.
- Cavi: Lubrificare con prodotto antiruggine
- Controllo serraggio bulloni, dadi e elementi di fissaggio
- Dado, bullone ed elemento di fissaggio da controllare
- Pezzi di ricambio
- Sostituzione cartuccia filtro aria
- Coppia -
- Sostituzione tubo flessibile carburante
- Coppia -
- Cambio del liquido refrigerante
- Coppia -
- Sostituzione tubo flessibile radiatore e O-ring
- Coppia -
- Cambio olio motore
- Coppia -
- Sostituzione filtro olio
- Attrezzo speciale -
- Coppia -
- Sostituzione tubi flessibili e tubi rigidi
- Coppia -
- Cambio liquido freni
- Coppia -
- Coppia -
- Sostituzione componenti in gomma della pompa freni
- Attrezzo speciale -
- Attrezzo speciale -
- Grasso al silicone -
- Coppia -
- Sostituzione componenti in gomma della pinza
- Coppia -
- Coppia -
- Coppia -
- Sostituzione candele
- Attrezzo in dotazione -
- Coppia -
- Impianto di alimentazione (DFI)

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