Ninja ZX-6R
2008 Ninja ZX-6R
Racing Kit Manual
This manual contains only the information of the racing kit parts. Refer to the base
manual listed below for information of the original model.
Base Manual
Ninja ZX-6R
Motorcycle Service Manual
© 2008 Kawasaki Heavy Industries, Ltd.
Part Number
99924-1382-02
First Edition (1): Jan. 25, 2008
Congratulation on your purchase of racing kit parts for the 2008 Ninja ZX-6R.
IMPORTANT
This manual provides how to install racing kit parts for the 2008 Ninja ZX-6R and how to
tune up basically.
As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-6R (P/No.
99924-1382-02).
When you participate in a race, it is necessary to modify the machine for the regulation.
So we want you to ask for the tuning up shop.
WARNING
AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE,
IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE
OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED
COMPETITION EVENTS UPON A CLOSED COURSE.
CAUTION
When operating the engine, be careful not to trouble persons with noise. Do not turn the
engine with loud engine and exhaust noise.
DISCLAIMER OF WARRANTY
ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED
OR IMPLIED.
BASIC WORKS IN INSTALLING KIT PARTS
We are going to make up the original Ninja ZX-6R for the racing machine. We
recommend that the rider himself should do the basic works, removing parts or installing
parts etc., given advices by the tuning shop. In a race, although trouble will be apt to
happen, if you participate in basic works, you can discriminate cause of trouble, so you can
return the race soon.
But concerning difficult technical works, you should as tuning shop.
1
Dummy page
2
Table of Contents
General Specifications ......................................................................................................4
Racing Kit Service Data ....................................................................................................6
Periodic Maintenance Chart .............................................................................................7
Preparation.........................................................................................................................9
Before Installing ....................................................................................................................................9
Racing Kit Parts .................................................................................................................9
Engine Parts Installation...................................................................................................9
Air Intake Parts .....................................................................................................................................9
Cylinder Head .....................................................................................................................................11
Camshaft Chain Tensioner..................................................................................................................12
Camshafts, Sprockets .........................................................................................................................13
Valve Springs......................................................................................................................................14
Cylinder Compression.........................................................................................................................14
Crankshaft Main Journal and Connecting Rod Big End Bushings ......................................................16
Connecting Rod Bolts .........................................................................................................................19
Clutch Adjustment (Back-Torque Limiter Setting)................................................................................20
Transmission.......................................................................................................................................24
Transmission Shimming......................................................................................................................24
Generator (Option)..............................................................................................................................25
Generator Cover (Option) ...................................................................................................................25
Cover Gaskets ....................................................................................................................................25
Ducts (Air Funnels) .............................................................................................................................25
Muffler.................................................................................................................................................26
Water Temperature Sensor .................................................................................................................26
Radiator (Kit).......................................................................................................................................26
Oil Catch Tank Installation ..................................................................................................................30
Frame Parts Installation ..................................................................................................33
Throttle Parts (Kit)...............................................................................................................................33
Brake Pads (Kit)..................................................................................................................................34
Steering Damper (Kit) .........................................................................................................................34
Seat Height Adjustment ......................................................................................................................35
Front Fork Springs (Kit).......................................................................................................................37
Electric Parts Installation................................................................................................39
Battery ................................................................................................................................................39
Main Harness and Sub Harness (Kit) .................................................................................................39
Meter (Kit) Installation .........................................................................................................................40
Wiring Routing ....................................................................................................................................42
Wiring Diagram (with Kit Meter) .....................................................................................44
Wiring Diagram (with Original Meter Assembly) ...........................................................46
3
General Specifications
Item
2008 Ninja ZX-6R Racing
Engine:
Ignition timing
Fuel (Recommended)
Engine oil (Recommended):
Level
12.5°BTDC @1 300 r/min (rpm)
Racing gasoline
Racing oil
Between upper and lower levels of oil level gauge.
Drive Train:
Primary drive reduction ratio
1.900 (76/40)
Transmission Gear Table
1st
2nd
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
3rd
Out
Teeth (Out/In)
Gear Ratio
In
4th
5th
6th
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
STD
(Type A)
13127-0044
13262-0507
38/14
2.714
13262-0372
13262-0508
33/15
2.200
See Gear
Selection
13262-0509
37/20
1.850
See Gear
Selection
13262-0510
32/20
1.600
13262-0374
13262-0380
27/19
1.421
13262-0375
13262-0582
26/20
1.300
Type B
Type C
13127-0055
13262-0526
37/14
2.643
13262-0527
13262-0528
39/18
2.167
See Gear
Selection
13262-0683
32/17
1.882
See Gear
Selection
13262-0530
33/20
1.650
13262-0531
13262-0532
30/20
1.500
13262-0533
13262-0534
32/23
1.391
(13127-0055)
4
Type D
13262-0535
36/14
2.571
13262-0536
13262-0537
34/16
2.125
13262-0677
13262-0678
36/16
2.25
See Gear
Selection
13262-0684
39/23
1.696
13262-0538
13262-0539
32/22
1.455
13262-0540
13262-0541
35/26
1.346
See Gear
Selection
13262-0685
30/19
1.579
13262-0686
13262-0687
32/23
1.391
13262-0688
13262-0689
29/23
1.261
Input 3rd/4th Gear Selection Table
4th Gear
3rd Gear
A
B
C
A
13262-0506
13262-0529
B
13262-0680
13262-0681
D
13262-0679
13262-0682
Gear Identification Slit Number Table
1st
2nd
3rd
4th
5th
6th
STD
(Type A)
Type B
Type C
In
0
1
1
Out
0
1
2
In
0
1
2
3
Out
0
1
2
3
In
0
1
Out
0
1
In
0
1
2
3
Out
0
1
2
3
In
0
1
2
3
Out
0
1
2
3
In
0
1
2
3
Out
0
1
2
3
5
Type D
Racing Kit Service Data
Item
Standard
Cylinder Head, Valves:
Duration:
Intake
Exhaust
Camshaft timing (cam lift center):
Intake
Exhaust
Valve clearance:
Intake
Exhaust
Valve to piston clearance:
Intake
Exhaust
288°
266°
105° (ATDC)
110° (BTDC)
0.16 mm
0.28 mm
0.80 mm (Minimum) @12°ATDC
1.40 mm (Minimum) @11°BTDC
Ignition System:
Spark plugs
NGK R0045Q-10, R0373A-10
13 N·m (1.3 kgf·m, 113 in·lb)
Spark plug tightening torque
These values show the specifications when standard cylinder head and gasket are used.
When the clearance between the valve and the piston head is smaller than the minimum
specific values, turn the installed position of the camshaft sprocket on the camshaft and
change the camshaft timing.
6
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the
motorcycle in good running condition.
FREQENCY
OPERATION
Each
Every
Every
Every
Race
3 races
5 races
10 races
(300 km) (1 000 km) (1 500 km) (3 000 km)
As
Required
Engine
Clutch plate - - check*
●
Throttle grip play - - check*
●
Spark plug - - clean/gap*
●
Engine oil - - change
●
Oil filter - - replace
●
Valve lapping
●
Cylinder head/valve - - decarbonization
●
Cylinder - - check*
●
Piston/cylinder clearance - - check*
●
Piston, Piston ring, Piston pin - - replace
●
Crankshaft main bearing - - check*
●
Connecting rod big end bearing - - check*
●
Transmission gear, bearing - - check*
●
Engine sprocket - - check*
●
Coolant - - change
●
Radiator hoses, connections - - check*
●
Frame
Brake operation - - check*
●
Brake pad wear - - check*
●
Brake fluid level - - check*
●
Brake fluid - - change*
year
Brake master cylinder cup and dust seal - - replace
year
Brake caliper piston seal and dust seal - - replace
year
Brake hose - - replace
2 years
Drive chain - - adjust
●
Drive chain - - lubricate
●
Drive chain wear - - check*
●
Drive chain guide - - replace
If damaged
Front fork - - clean/check*
●
Front fork oil - - change
First change after 2 races, then every 5 races
Nut, bolt, and fastener tightness - - check*
●
Fuel system - - clean
●
Fuel hose, fuel filter - - replace
●
Steering play - - check*
●
Steering stem bearing - - grease
●
Rear sprocket - - replace
●
General lubrication of chassis - - perform
●
7
FREQENCY
OPERATION
Each
Every
Every
Every
Race
3 races
5 races
10 races
(300 km) (1 000 km) (1 500 km) (3 000 km)
Wheel bearing (rear) - - grease
●
Swingarm pivot, uni-track linkage - - grease
●
Swingarm pivot, uni-track linkage - - check*
●
*: Replace, add, adjust, clean, or torque if necessary.
8
As
Required
Preparation
Before Installing
Modify the parts based on your race regulation.
To avoid misuse keep the parts replaced with the kit parts separate.
When reusing parts, clean them and check them for damage or deterioration.
Main Removal Parts:
Lights
Rear View Mirrors
Side Stand
Starter Lockout Switch
Remove the side stand switch. When the optional main harness is not used, connect
removing Black/Yellow and Green/White Leads directly.
Racing Kit Parts
Also, we have provided the spare parts, and other optional parts (engine, frame, and
electric parts) for racing. So please order each parts referring to the “Racing Kit Parts List”
in the back of this manual.
Engine Parts Installation
Air Intake Parts
Remove the wire net of Ram – Air duct intake to reduce the air flow resistance.
Remove the tank (16181-0011) to reduce the weight. Plug the holes firmly with a tape.
The air pressure in the duct rises during high speed operation because the Ram Air
System is used.
A. Wire Net (14037-0057)
B. Tank (16181-0011)
9
Remove the secondary valves of cylinder head and relational parts, then plug the each
holes.
Remove the oil receiver and plug the hole.
Remove the air cleaner element or cut the cleaner element off remaining punched plate
to reduce the air flow resistance.
1. Remove the parts.
2. Plug the holes.
3. Replace with plugs (92043-1506), and plug the holes.
10
Cylinder Head
Grind off the stepped portions of the ports and smooth the inside of ports to make
intake/exhaust gas flow more smooth.
Grind off the stepped portion only at the mating surface between the carburetor holder
and the intake port. Do not port it. To extend the intake port, air flow speed will be
reduced and the engine performance at the high speed range may be down.
Mark the carburetor holders so that they can be installed in their original positions.
Grind off and smooth the stepped portions at the mating surface between valve seat and
the port.
Smooth the inside of the intake port and exhaust port.
Use the hand grinder.
Use #200 oil stone for eliminating any stepped portions.
Use #200 oil stone for smoothing and #300 oil stone for finishing.
NOTE
These procedures make air resistance less and intake/exhaust gas flow more smooth.
However, much more effect can not be expected by excessive grinding and smoothing.
It may be done to the extent of getting rid of uneven surfaces.
1. Stepped Portions of carburetor holder and cylinder head.
2. Stepped Portions of valve seat and cylinder head.
11
The combustion chambers are modified by cutting work but the edges shown must be
hand finished for smooth corners (Round them to about R1).
Chamfer the machining edge of the cylinder head where the valve seat is installed, also
smooth the dome of the combustion chamber with the valves installed. Excessive
smoothing may reduce the cylinder compression.
XXX. Edges
NOTE
When grinding the cylinder head bottom surface or using thinner gaskets, adjust the
valve timing to keep that the valve to piston clearance is not less than the minimum
value (IN: 0.8 mm, EX: 1.4 mm).
Camshaft Chain Tensioner
Replace the cam chain tensioner with the kit to gain the durability.
Apply the engine oil to the tensioner rod, O-ring and tensioner body, insert them into the
tensioner body.
Check to see that the tensioner rod turns freely in the body, if not, polish the tensioner rod
or fine the female threads in the body with a tap (Diameter × Pitch = 6 mm × 1.0 mm).
Install the tensioner on the cylinder block with the tensioner rod is fully pushed back.
Turn the tensioner rod in with a screwdriver until it becomes hard to turn.
Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to
take up any gap and tighten the locknut.
Tighten the rock nut after adjustment.
NOTE
Never forward the tensioner rod forcibly, this will increase mechanical loss of the
tensioner and may damage to the chain guide.
The cam chain tensioner must be adjusted at every race.
12
A.
B.
C.
D.
E.
Tensioner
Tensioner Rod
O-ring
O-ring
Lock nut
Camshafts, Sprockets
Camshafts, Sprockets:
Adjust the valve clearance within the specified value, but more performance is expected
when adjusted from middle value to upper limit between adjustable range.
Original
Timing
Cam Lift
Valve Clearance
Intake
288°
8.30 mm
0.13 ∼ 0.19 mm
Exhaust
266°
7.50 mm
0.24 ∼ 0.31 mm
Kit
Intake
49118-0110
Exhaust
49118-0111
Exhaust
49118-0120
Timing
308°
274°
274°
Cam Lift
8.30 mm
(conformed to FIM regulation)
7.30 mm
(not conformed to FIM regulation)
7.50 mm
(conformed to FIM regulation)
13
Valve Clearance
0.13 ∼ 0.19 mm
0.24 ∼ 0.31 mm
0.24 ∼ 0.31 mm
If you don’t adjust the valve timing for racing, install the camshaft sprocket to the kit
camshaft using the round bolt holes and adjust the cam chain timing according to the
Ninja ZX-6R Service Manual. If you adjust the valve timing, install the sprocket to the
camshaft between the adjustable range of the long bolt holes.
Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11.0 ft·lb) of torque.
Valve Timing (when the round bolt holes are used)
Timing (cam lift center)
Intake
Exhaust
Original
105°
110°
Race use
105°
110°
When grinding the cylinder head bottom surface, grinding the cylinder top surface or
using thinner gaskets, be sure the valve to piston clearance especially.
When using the sprocket long bolt holes and adjusting the valve timing to be different
from the standard timing, check the valve to piston clearance of all cylinders after
adjusting the valve clearance correctly.
Valve to Piston Clearance (Min.)
Intake
0.8 mm
Exhaust
1.4 mm
If the valve to piston clearance is less than the minimum value, do not start the engine
because the valves will touch the piston and the engine may be damaged.
Measure the valve to piston clearance at about 12° ATDC (Intake) and 11° BTDC
(Exhaust) of crankshaft timing. At this point, the valve to piston clearance will be
minimum.
Valve Springs
The original machine’s valve springs should be used
.
Cylinder Compression
To adjust the cylinder compression, adjust the thickness of the cylinder head gasket and
the cylinder base gasket or smooth the cylinder top surface to make the piston squish
0.65 ~ 0.8 mm. Keep the piston squish more than 0.65 mm.
Position the piston at Top Dead Center, and put a small piece of modeling clay on the
shoulder of the piston. Install the cylinder head gasket and cylinder head, and tighten
the head bolts to the specified torque.
Remove the cylinder head and measure the thickness of the clay. The thickness of the
collapsed clay is the size of the squish.
Squish Measurement
[1] Front and Rear
0.65 ~ 0.80 mm
[2] Left and Right
0.67 ~ 0.85 mm
The most preferable squish measurement is [1] 0.65 mm/[2] 0.67 mm.
Select proper cylinder head gasket and cylinder base gasket.
Note that by grinding the cylinder head surface only left and right squishes become
narrower, while by grinding the cylinder top surface or decreasing the gasket-thickness
all the squishes become narrower.
14
Cylinder Head Gasket
Part No.
11004-0071
11004-0070
11004-0069
11004-0068
11004-0057
11004-0067
Thickness
0.45 mm
0.50 mm
0.55 mm
0.60 mm
0.65 mm
0.70 mm
Note
KIT
KIT
KIT
KIT
Original
KIT
1. Squish, Front/Rear
2. Squish, Left/Right
15
Crankshaft Main Journal and Connecting Rod Big End Bushings
To adjust clearance of crankshaft main journal you can select proper bush in accordance
with the marks.
The kit bushings are improved in anti-seizuring characteristics as well as in
wear-resistance as compared with the standard bushings.
1) Crankshaft Main Journal
Crankshaft Main Journal Diameter
1. Crankshaft Main Journal Diameter Marks
“1” mark
None
SIZE
: over 30.992 mm
within 31.000 mm
: over 30.984 mm
within 30.992 mm
Crankcase Main Journal inside Diameter
1. Main Journal Diameter Marks
SIZE
“{” mark
None
: over 34.000 mm
within 34.008 mm
: 34.008 mm and over within 34.016 mm
16
Main Journal Bush
A.
Size Color
Size Color
Thickness mm
blue
1.499-1.503
black
1.495-1.499
brown
1.491-1.495
Journal Number
1-4
5
1-4
5
1-4
5
Part Number
(STD)
92139-0189
92139-0171
92139-0190
92139-0172
92139-0191
92139-0173
Part Number
(KIT)
92139-0200
92139-0197
92139-0201
92139-0198
92139-0202
92139-0199
Selection Table
Crankcase inner Diameter
○
Crankshaft Diameter
1
(34.000 mm ~ 34.008 mm) (30.992 mm ~ 31.000 mm)
○
NONE
(34.000 mm ~ 34.008 mm) (30.984 mm ~ 30.992 mm)
NONE
1
(34.008 mm ~ 34.016 mm) (30.992 mm ~ 31.000 mm)
NONE
NONE
(34.008 mm ~ 34.016 mm) (30.984 mm ~ 30.992 mm)
17
Part
Part
Number
Number
(STD)
(KIT)
1-4
92139-0191
92139-0202
5
92139-0173
92139-0199
1-4
92139-0190
92139-0201
5
92139-0172
92139-0198
1-4
92139-0190
92139-0201
5
92139-0172
92139-0198
1-4
92139-0189
92139-0200
5
92139-0171
92139-0197
Size
Journal
Color
Number
brown
black
black
blue
2) Crankpin
Crankpin Diameter
1. Crankpin Diameter Marks
“{” mark
None
: over 29.992 mm
within 30.000 mm
: 29.984 mm and over within 29.992 mm
Connecting Rod Big End Inside Diameter
Connecting Rod Big End Inside Diameter Marks
“{” mark : over 33.008 mm
within 33.016 mm
None
: 33.000 mm and over within 33.008 mm
A. Inside Diameter Mark
({ or None)
B. Weight Mark, Alphabet
(G.H etc)
Connecting Rod Big End Bushings
Size Color
Thickness mm
Part Number
(STD)
Part Number
(KIT)
blue
1.485-1.490
92139-0165
92139-0194
black
1.480-1.485
92139-0166
92139-0195
brown
1.475-1.480
92139-0167
92139-0196
18
Selection Table
Connecting Rod Big End
Inside Diameter
Crankpin Diameter Mark
None
○
(33.000 mm ~ 33.008 mm)
(29.992 mm ~ 30.000 mm)
None
None
(33.000 mm ~ 33.008 mm)
(29.984 mm ~ 29.992 mm)
○
○
(33.008 mm ~ 33.016 mm)
(29.992 mm ~ 30.000 mm)
○
None
(33.008 mm ~ 33.016 mm)
(29.984 mm ~ 29.992 mm)
Size
Part Number
Part Number
Color
(STD)
(KIT)
brown
92139-0167
92139-0196
black
92139-0166
92139-0195
black
92139-0166
92139-0195
blue
92139-0165
92139-0194
Connecting Rod Bolts
Use the original connecting bolts and nuts.
The original connecting rod bolt has recesses at both ends to measure its length and
determine the bolt stretch.
Install the original bolts into the connecting rod.
Before every tightening, use a point micrometer to measure the length of the bolts and
record the values to find the bolt stretch.
Apply a small amount of molybdenum disulfide grease to the threads of bolts.
Tighten the big end nuts at the torque of 11.8 ±2 N·m (1.2 ±0.2 kgf·m): reference
Check the length of the bolts and find the bolt stretch.
Bolt Length after tightening – Bolt Length before tightening = Stretch
Bolt Stretch
Usable Range: 0.33 ~ 0.38 mm (0.013 ~ 0.015 in.)
Turn the big end nuts more until the bolt stretch reaches the usable range.
NOTE
Replace the original bolts with new ones if they have already been tightened up to usable
range 2 times.
19
Clutch Adjustment (Back-Torque Limiter Setting)
The Ninja ZX-6R engine is equipped with the Kawasaki back-torque limiter mechanism in
the clutch. The back-torque limiter works to reduce the chance of rear wheel hop caused by
engine braking during hard braking and down shifting. The back-torque limiter operating
condition can be changed by changing the total thickness of clutch plates and changing the
number of leaf springs. Try different settings and select the best.
20
The standard setting of length [A], total thickness of clutch plates shown in the illastration,
becomes about 40.7 mm. For this setting the effective stroke of clutch spring plate during
the back-torque limiter operation is adjusted between 0.45 and 0.75 mm. By increasing
the effective stroke the back-torque limiter causes more slip. The effective stroke
increases by decreasing the length [A]. The length [A] between 39.5 and 40.7 mm is
available by changing the combination of the steel plates. Replace one steel plate with a
thinner one and try the setting. If the operation of the back-torque limiter is not enough
replace other steel plates one by one.
* Steel plates of former model’s are available.
Thickness (mm)
Part Number
2.0
13089-1073
For precise setting the measurement of the effective stroke of clutch spring plate is
recommended.
• Remove oil from clutch plates.
• Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.
21
Recommended Clutch
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[H]
[I]
[J]
Spacers
Needle Bearing
Bushing
Clutch Outer Casing
Clutch Hub
Sub Clutch Hub
Friction Plates: total 8 pcs.
Steel Plates
Spring Plate
Steel Plate with Spring
22
• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub).
• To measure the effective stroke of clutch spring plate, set a dial gauge [A] against the raised
center [B] of the clutch spring plate.
• Move the clutch housing gear back and forth [C]. The difference between the highest and
lowest gauge readings is the amount of the effective stroke of clutch spring plate.
[D] Drive Shaft
After installing the clutch to the engine, measure and record the depth [B] shown in the
figure on page 21 and 22. The length from the clutch spring plate to the top surface of the
sub clutch hub, using a caliper or a depth gauge. Manage the depth [B] to adjust the
effective stroke after that, because the friction disks would be worn and the length [A]
(Total thickness of all clutch plates) would change. The decrease of the depth [B] from
the initial setting shows the increase of the effective stroke of clutch spring plate from the
value initially measured.
When decreasing the length [A], total thickness of clutch plates, use the optional spring
retainers (provided as optional production parts) to keep the preload of clutch springs
according to the table below. If you have clutch slip during acceleration use shorter
spring retainers by 1 mm to increase preload of clutch springs.
When decreasing the length [A], total thickness of clutch plates, use the optional shim
(provided as optional production part) to keep the position of clutch release lever
according to the table below.
The standard setting of the number of leaf springs is four. By decreasing the number of
the leaf springs the sub clutch hub operates easily and pushes the clutch operating plate
causing more slip. Two types of nuts are available for the number of leaf springs, two and
three. They are provided as optional production parts. The number of leaf springs affects
all over the operation of the back-torque limiter but especially the beginning of the
operation.
Standard Selection of Spring Retainers
Total Thickness of Clutch Plates Size of Spring Retainers
Remarks
P/No. 13091-1041
40.2 ~ 40.7 mm
6 mm
Original Setting
39.5 ~ 40.2 mm
5 mm
P/No. 39108-0004
* If clutch slip is occurred with a retainer of 6 mm, try with a retainer of 5 mm.
23
Standard Selection of Shim
Total Thickness of Clutch Plates
Size of Shim
Approx. 40.7 mm
2.0 mm
40.2 mm
39.5 ~ 40 mm
1.5 mm
1.2 mm
Remarks
P/No. 92180-0149
Original Setting
P/No. 92026-1590
92025-1137
Transmission
Remove the three steel balls (600A0500) from the output shaft assembly.
Take kit and optional transmission gears are available to be closer to each gear ratio.
Transmission Shimming
By using washers with various thickness, keep the axial clearance between 0.3 mm and
0.5 mm, to prevent the seizure of gears and to keep smooth gear-shifting.
Thickness
Part No.
1.6 mm
92200-0050
Original
Spline washer (input)
1.8mm
92200-0231
Kit
1.4 mm
92200-0230
Kit
1.4 mm
92200-0138
Original
Plane washer
1.6 mm
92022-212
Production part
(input, output)
1.8 mm
92202-1722
Production part
1. Spline washer (input)
2. Plane washer
24
Generator (Option)
To quicken response by reducing the flywheel mass and to reduce the weight, use the
optional inner rotor generator.
Select using the optional generator or original generator according to the situation.
Use the optional regulator and optional generator cover set when using the optional
generator.
The output power of the optional generator is 10A/8000 rpm (Original: 30A/5000rpm).
The consume current of the racing model in running condition is 7 ~ 8A.
Installing Option Generator
Generator Cover (Option)
Use the option generator with the optional generator cover.
NOTE
When using the optional generator cover, use the optional generator.
Cover Gaskets
The optional cover gaskets are available.
They are made from “meta-form” and made easy to exfoliation.
Ducts (Air Funnels)
Select suitable combination for target characteristic of engine.
Length (mm)
Part Number
15
14073-0124
Option
20
14073-0125
Option
30
14073-0174
Option
40
14073-0151
STD
50
14073-0152
STD
25
Muffler
With recommended muffler engine performance can be improved.
Recommended muffler: Beet NASSERT-R 1002-E02-00
Web Site
: http://www.beet.co.jp/(beetjapan)
* For further information contact the manufacturer of muffler directly.
Water Temperature Sensor
The original water temperature sensor installed in the cylinder head must be remain and
connected to the main harness because the electronic control unit (E.C.U.) needs the
output signal from the original water temperature sensor. The optional tachometer is
equipped with a water temperature display. Install the optional water temperature sensor to
the optional water pipe and connect the sensor and the optional meter unit with the optional
harness.
Radiator (Kit)
’05 model ZX-6RR and ’08 ZX-6R Racing Kit provides the capacity increased main
radiator (39060-0020) to improve cooling performance.
26
Radiator Installation
Use the radiator stay (35063-0439) and bracket (11054-1818) belong to kit, and fasten
the radiator to the Crankcase by bolts as shown in the figure.
Stay has several installation holes. Install position is adjustable for proper position of
radiator.
Some muffler may interfere with stay. In such case, make appropriate stay yourself.
Machine the original cowl to meet the outline of radiator.
Standard Resave tank is not available. Use some appropriate tank.
Fill the space between the cowl and the sides of radiator by fixing a sponge or the like.
NOTE
After radiator’s installation, be sure to check that there is no interference between the
radiator and the manifold, or fender, tire and the front fork full bottomed.
If you don’t use water temperature meter, use standard pipe, not oil cooler hose
(39062-0220). Nipple of radiator is plugged by CAP (11065-1056).
27
Water Hose Installation
Radiator inlet
Divide the original water hose (39062-0156) at suitable position, and insert the hose
between cylinder head and radiator.
1. Water Hose 39062-0156
Insert the water hose (39062-0220) between oil cooler outlet and radiator.
Radiator outlet
Apply a non-permanent locking agent to the thread of the water temperature sensor (Kit:
for Meter Lamp). Mount the sensor on the pipe (39192-0011).
Insert the ground terminal of the water temperature sensor lead between the hose and
the pipe, and clamp the hose as shown in the figure. Fasten the another terminal to the
cover (generator) by the bolt.
* If you don’t use water temperature meter, use standard pipe and hose at oilcooler outlet
side and cover it radiator side with cap (11065-1056).
28
1. Water Hose 39062-0219
2. Ground Wire 26011-0071
3. Water Hose 39062-0166 (Standard)
4. Sensor 21176-1099
5. Lead Wire 26011-1779
6. Clamp 92171-0179
Reserve Tank Installation
When using the radiator (Kit), the original reserve tank cannot be used. Prepare a
suitable substitue.
Reserve Tank should be equipped with a band so as not to affect the running and the
handling.
NOTE
Capacity of a reserve tank should be more than
200 cc.
Position of the hose to a reserve tank.
* End of the hose to the radiator should be always
in the liquid.
* End of the hose to atmosphere should be always
beyond the liquid surface.
29
Oil Catch Tank Installation
Fasten the Bracket (E) to the Engine Hanger by using bolt (D).
Fasten Oil Catch Tank (A) to the Bracket (E) by using bolt (F) and nut (I).
Connect Air Cleaner, Crankcase and Oil Catch Tank by using hose1 (B) and hose2 (C).
A) Oil Catch Tank (52001-0004)
B) Hose1 (Air Cleaner – Oil Catch Tank)
C) Hose2 (Crankcase – Oil Catch Tank)
D) Bolt (130BA0835 standard)
E) Bracket (11054-1799)
F) Bolt (120P0620)
G) Dumper (92075-277)
H) Collar (92027-194)
I) Nut (92015-1193)
J) Washer (92022-304)
K) Drain Bolt (130Y0610)
30
Hose1 (B) and Hose2 (C) assembling
Divide Hose (92059-1587, KIT) and Hose (92059-1629, KIT) as shown below.
Divide installed tube (92192-0429, standard) as shown below.
31
Assemble hoses as shown below
5. Fitting (92005-0080)
32
Frame Parts Installation
Throttle Parts (Kit)
The following throttle cases, grip and reels are available as optional parts. These optional
parts quicken throttle response to the twist grip.
1) Throttle Case
Parts
Throttle Case, Upper
Throttle Case, Lower
Bolts (2)
Grip, Right
P/No.
32099-0004
32099-0005
120S0625
46075-1143
2) Throttle Reels
Tow types are available.
P/No.
I.D. Mark
59101-0001
59101-0002
R21.5
R20.0
Twist Grip Turn Angle
to Full Throttle
60°
65°
Throttle Reel Travel Angle················Effective angle excluding throttle cable free play.
1. Identification Mark
1.
2.
3.
4.
5.
6.
7.
8.
Upper Case: 32099-0004
Lower Case: 32099-0005
Reel, 60°: 59101-0001
Reel, 65°: 59101-0002
Throttle Cable, Open Side: 54012-0232
Throttle Cable, Close Side: 54012-0233
Bolt: 120S0625
Gap
33
1) Drive Chain
#520 Joint endless drive chain is available as an optional parts.
2) Chain Guard
1. Guard: 55020-0028
2. Bolt: 130J1020
3. Swingarm (Left Side)
Brake Pads (Kit)
The front and rear brake pads for racing use are available. The front pads are for higher
braking force, and the rear pads are for lower braking force.
Front Brake Pads
P/No.
Mark
Braking Force
43082-0074
2508
High
↨
Original
TT2172HH
Low
P/No.
Mark
Braking Force
Original
43082-1220
43082-1192
FO GG
C93G
G196
High
Rear Brake Pads
↨
Low
Steering Damper (Kit)
The steering damper is useful at high speeds to prevent handlebar vibration.
The steering damper should be installed to do not the steering handle movement stop by
the steering damper itself at the fully locket position both left and right side.
(Steering angle should be controlled by the regulation)
34
1) Recommended Steering Damper
OHLINS SD121
Set the steering damper to the holder as shown.
2) Stroke(s)
SD121: 68 mm
1. Steering Damper: OHLINS SD121
2. Bracket: 11054-1816
3. Bracket: 11054-1817
4. Collar: 92152-0589
5. Ring: 670 B 2012
6. Washer: 410 B 0800
7. Bolt, Socket: 120 CA0630
8. Bolt, Socket: 120 CA0825
9. Bolt, Socket: 120 CA0865
10. Nut: 92105-1397
Seat Height Adjustment
Loosen the nut (1) and insert the spacer (2) as required.
Tighten the nut (1) to 59 N·m (6.0 kgf·m, 43 ft·lb) of torque.
One turn of the spring adjusting nut changes the spring length by 1.5 mm.
Rear Suspension Condition of Seat Height Adjustment
When the seat height adjusts spacer applied, the rear suspension should be softened.
Seat Height Adjustment
Spacer Set: 92026-1586
P/No.
Quantity
Thickness
92026-1582
1
1.0 mm
92026-1583
1
2.0 mm
92026-1584
1
3.2 mm
92026-1585
2
4.5 mm
35
1. Nut
2. Spacer
3. Collar
4. Bracket
36
Front Fork Springs (Kit)
The optional front fork springs are available for racing.
1) Front Fork Specifications
Items
Original
Rebounded damping setting (Upper)
Compression damping setting (Lower)
Fork oil
Fork oil level
Oil lock
Oil seal
Spring length
Spring constant
Sub spring stroke
1 1/2 turns out from the fully clockwise position
1 1/2 turns out from the fully clockwise position
SHOWA SS47
97 mm
Oil lock piece
–––
257.0 mm (Free Length)
9.0 N/mm
28 mm
2) Front Fork Spring
P/No.
A × B × C (mm)
Number of Winding
Spring Constant
Original
4.7 × 31.5 × 257.0
17.5
K = 9.0 N/mm
92145-0507
4.6 × 31.6 × 257.0
16.9
K = 8.25 N/mm
92145-0508
4.7 × 31.5 × 257.0
16.6
K = 9.25 N/mm
92145-0509
4.8 × 31.4 × 257.0
17.3
K = 9.75 N/mm
A: Coil Diameter
B: Spring Inside Diameter
C: Spring Free Length
3) Front Fork Spring Replacement
Replace the main spring referring to the Fork Oil Change section of the base Service
Manual.
Identification Mark
The spring constant value is stamped on the one side surface of the spring.
37
Fork Spring Installation
38
Electric Parts Installation
Battery
Use the original battery or a battery with 12 V 7 Ah or more capacity.
Main Harness and Sub Harness (Kit)
Main harness and sub harness are available for racing use as optional parts. Select one
of them in accordance with your race regulation.
Main Harness (with Optional Meter): 26031-0559
Main Harness (with Original Meter): 26031-0558
Sub Harness (with Original Meter and Original Main Harness): 26031-0327
(Immobilizer non-installed model only)
This set can not apply to the immobilizer installed model. For immobilizer
installed model, apply the main harness of part number 26031-0058 or
26031-0559.
39
Meter (Kit) Installation
1. Tachometer with Water Temperature Gauge (Optional): 25031-1142
2. Collar (Optional): 92152-0058
3. Pad (Optional): 39156-0098
4. Bracket (Optional): 11053-1749
5. Rivet (Optional): 92039-1106
6. Nut (Optional): 92015-1233
7. Collar (Optional): 92152-1074
8. Bolt (Optional): 130J0625
9. Damper (Original): 92160-1167
10. Lamp Assembly (Optional): 23016-0006
Insert the three collars [2] into the damper [3].
Insert the rivet [5] from the backside of the bracket [4] and fix them.
Install the bracket [4] to the original bracket [10].
40
Main Harness Combination Parts Table
Main Harness and Kit Part Combination Table
○: need ×: no need.
Harness
Part
Meter Assembly (Kit)
Tachometer
with
Water
Temperature Gauge (Kit)
25031-1142
Water Temperature Gauge
Lead (Kit)
26011-1779
Water Temperature Sensor
Ground Lead (Kit)
26011-0071
Water Temperature Sensor
21176-1099
Relay Box (Original)
27002-0007
Relay Assembly (Original)
27002-3703
Harness for
Kit Meter
26031-0559
×
Harness for
Original Meter
26031-0558
○
Sub Harness
26031-0327
○
○
×
×
○
×
×
○
×
×
○
×
×
×
×
○
○
○
×
Main Harness and Original Part Combination Table
○: need ×: no need.
Harness
Part
Main Harness (Original)
Meter Assembly (Original)
Left Handlebar Switches
License Light
Rear Brake Light Switch
Turn Signal Light (Front, Rear, Left, Right)
Headlight
Tail/Brake Light
Ignition Switch
Fan Motor
Horn
Side Stand Switch
Turn Signal Relay
Fuse Box
Neutral Switch
Oil Pressure Switch
41
Harness for Kit
Meter
26031-0559
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
Harness for
Original Meter
26031-0558
×
○
○
×
×
×
×
×
×
×
×
×
×
×
×
×
Wiring Routing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Vehicle-down Sensor
Meter Assembly
Shift Up Indicator Light
Right Handlebar Switch
Left Handlebar Bar Switch
Intake Air Temperature Sensor
Boost Sensor
Cam Shaft Position Sensor
Ignition Coil
Subthrottle Valve Actuator
Cylinder Head Ground
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Main Throttle Sensor
Injector, Secondary
Injector, Primary
Coolant Temperature Sensor
Speed Sensor
Crank Shaft Position Sensor
Gear Position Sensor
Battery (-)
Auto Shifter
Frame Ground
Regulator
The headlight beam (Hi/Lo) change switch on the left handlebar switch works as a speed
limit switch of the pit-road and passing switch works as same also.
In case of using optional meter, the connector of coolant temperature sensor “15” must
used.
The auto shifter “20” should be used according to local regulation.
42
1.
2.
3.
4.
5.
6.
7.
Fuel Pump
Magnetic Switch
ECU
Relay Assembly (27002-3703)
Atmospheric Pressure Sensor
Power Source for Measuring Instruments
Setting Tool
The relay assembly “4” should make sure to avoid the interference with other parts.
When apply the measuring instruments, the power source “6” available as a 12 V power
source.
The setting tool should be used according to the manual of “Kawasaki FI Calibration
Tool”.
43
Wiring Diagram (with Kit Meter)
44
45
Wiring Diagram (with Original Meter Assembly)
46
47
Dummy Page
48
Racing Kit Parts List
’08 ZX600P8FR Engine
This catalog covers:
B-3
Ref.
No.
1
1
4
1
1
2
CAMSHAFT-COMP,EXHAUST
NUT,FLANGED,6MM
PIN,10X14
RING-O,5MM
RING-O,18.8X1.9
BOLT-FLANGED-SMALL,6X20
92043
1
DEC.27,2007
1
CAMSHAFT-COMP,EXHAUST
92043-1506
(OPTION)
92055 92055-011
92055A 92055-086
132 132BA0620
(OPTION)
1
CAMSHAFT-COMP,INTAKE
1
1
1
1
1
P8FR
’08
Quantity-ZX600
1
Spec Code
TENSIONER-ASSY
GASKET-HEAD,T=0.45
GASKET-HEAD,T=0.50
GASKET-HEAD,T=0.55
GASKET-HEAD,T=0.60
GASKET-HEAD,T=0.70
Description
12048-1175
(OPTION)
49118 49118-0110
(OPTION)
49118A 49118-0111
(OPTION)
49118B 49118-0120
(OPTION)
92015 92015-1078
12048
11004D
11004C
11004B
11004A
11004-0067
(OPTION)
11004-0068
(OPTION)
11004-0069
(OPTION)
11004-0070
(OPTION)
11004-0071
(OPTION)
Part No.
Cylinder
This grid covers:
11004
GRID NO.
’08 ZX600P8FR Engine
This catalog covers:
92139-0194
(OPTION)
92139-0195
(OPTION)
92139-0196
(OPTION)
92139-0197
(OPTION)
92139-0198
(OPTION)
2
92139E 92139-0199
(OPTION)
92139F 92139-0200
(OPTION)
92139G 92139-0201
(OPTION)
92139H 92139-0202
(OPTION)
92139D
92139C
92139B
92139A
92139
Part No.
Crankshaft
B-4
Ref.
No.
This grid covers:
GRID NO.
8
AR
BUSHING,CRANK #1&#2&#3&#4,BLK
BUSHING,CRANK #1&#2&#3&#4,BRN
DEC.27,2007
AR
BUSHING,CRANK #1&#2&#3&#4,BLUE
2
AR
AR
8
AR
P8FR
’08
Quantity-ZX600
AR
Spec Code
BUSHING,CRANK #5,BROWN
BUSHING,CRANK #5,BLACK
BUSHING,CRANK #5,BLUE
BUSHING,CONROD,BROWN
BUSHING,CONROD,BLACK
BUSHING,CONROD,BLUE
Description
’08 ZX600P8FR Engine
This catalog covers:
B-5
Ref.
No.
92026
92025
3
39108-0004
(OPTION)
92025-1137
(OPTION)
92026-1590
(OPTION)
Part No.
Clutch
This grid covers:
39108
GRID NO.
Spec Code
DEC.27,2007
SPACER,T=1.5
SHIM,15.3X27.5X1.20
RETAINER-SPRING,T=5.0(STD-1.0)
Description
1
1
6
P8FR
’08
Quantity-ZX600
’08 ZX600P8FR Engine
This catalog covers:
B-6
Part No.
4
92200A 92200-0231
(OPTION)
13262L 13262-0682
(OPTION)
13262M 13262-0683
(OPTION)
92022 92022-1722
(OPTION)
92022A 92022-212
(OPTION)
92200 92200-0230
(OPTION)
13262G 13262-0533
(OPTION)
13262H 13262-0534
(OPTION)
13262I 13262-0679
(OPTION)
13262J 13262-0680
(OPTION)
13262K 13262-0681
(OPTION)
13262B 13262-0528
(OPTION)
13262C 13262-0529
(OPTION)
13262D 13262-0530
(OPTION)
13262E 13262-0531
(OPTION)
13262F 13262-0532
(OPTION)
13127-0055
(OPTION)
13144 13144-0047
(OPTION)
13144A 13144-0048
(OPTION)
13262 13262-0526
(OPTION)
13262A 13262-0527
(OPTION)
Ref.
No.
AR
WASHER,28.3X34.0X1.4
DEC.27,2007
AR
AR
WASHER,22.3X35X1.6
WASHER,28.3X34.0X1.8
AR
WASHER,22.3X35X1.8
1
1
GEAR,INPUT 3RD&4TH,17T&20T
GEAR,OUTPUT 3RD,32T
1
GEAR,INPUT 3RD&4TH,17T&20T
1
1
GEAR,INPUT 3RD&4TH,20T&19T
GEAR,INPUT 3RD&4TH,17T&23T
1
1
GEAR,OUTPUT 5TH,30T
GEAR,OUTPUT 6TH,32T
1
GEAR,INPUT 5TH,20T
1
1
GEAR,OUTPUT 4TH,33T
GEAR,INPUT 6TH,23T
1
1
GEAR,INPUT 2ND,18T
GEAR,INPUT 3RD&4TH,20T&20T
1
GEAR,OUTPUT LOW,37T
1
1
SPROCKET-OUTPUT,15T
GEAR,OUTPUT 2ND,39T
1
SPROCKET-OUTPUT,16T
P8FR
’08
Quantity-ZX600
1
Spec Code
SHAFT-TRANSMISSION INPUT,14T
Description
Transmission(TYPE-B)
This grid covers:
13127
GRID NO.
’08 ZX600P8FR Engine
This catalog covers:
B-7
Part No.
5
92022-1722
(OPTION)
92022A 92022-212
(OPTION)
92200 92200-0230
(OPTION)
92200A 92200-0231
(OPTION)
92022
13262C 13262-0538
(OPTION)
13262D 13262-0539
(OPTION)
13262E 13262-0540
(OPTION)
13262F 13262-0541
(OPTION)
13262G 13262-0684
(OPTION)
13144-0047
(OPTION)
13144A 13144-0048
(OPTION)
13262 13262-0535
(OPTION)
13262A 13262-0536
(OPTION)
13262B 13262-0537
(OPTION)
Ref.
No.
AR
AR
WASHER,28.3X34.0X1.4
WASHER,28.3X34.0X1.8
DEC.27,2007
AR
1
GEAR,OUTPUT 4TH,39T
WASHER,22.3X35X1.6
1
GEAR,OUTPUT 6TH,35T
AR
1
GEAR,INPUT 6TH,26T
WASHER,22.3X35X1.8
1
1
GEAR,OUTPUT 2ND,34T
GEAR,OUTPUT 5TH.32T
1
GEAR,INPUT 2ND,16T
1
1
GEAR,OUTPUT LOW,36T
GEAR,INPUT 5TH,24T
1
SPROCKET-OUTPUT,15T
P8FR
’08
Quantity-ZX600
1
Spec Code
SPROCKET-OUTPUT,16T
Description
Transmission(TYPE-C)
This grid covers:
13144
GRID NO.
’08 ZX600P8FR Engine
This catalog covers:
B-8
Part No.
6
92022A 92022-212
(OPTION)
92200 92200-0230
(OPTION)
92200A 92200-0231
(OPTION)
13262C 13262-0686
(OPTION)
13262D 13262-0687
(OPTION)
13262E 13262-0688
(OPTION)
13262F 13262-0689
(OPTION)
92022 92022-1722
(OPTION)
13144-0047
(OPTION)
13144A 13144-0048
(OPTION)
13262 13262-0677
(OPTION)
13262A 13262-0678
(OPTION)
13262B 13262-0685
(OPTION)
Ref.
No.
1
GEAR,OUTPUT 6TH,29T
AR
AR
WASHER,28.3X34.0X1.4
WASHER,28.3X34.0X1.8
DEC.27,2007
AR
WASHER,22.3X35X1.6
AR
1
GEAR,INPUT 6TH,23T
WASHER,22.3X35X1.8
1
1
GEAR,OUTPUT 4TH,30T
GEAR,OUTPUT 5TH,32T
1
GEAR,OUTPUT 2ND,36T
1
1
GEAR,INPUT 2ND,16T
GEAR,INPUT 5TH,23T
1
SPROCKET-OUTPUT,15T
P8FR
’08
Quantity-ZX600
1
Spec Code
SPROCKET-OUTPUT,16T
Description
Transmission(TYPE-D)
This grid covers:
13144
GRID NO.
’08 ZX600P8FR Engine
This catalog covers:
B-9
Ref.
No.
14031
7
11061D
11061C
11061B
11061A
14031-0084
(OPTION)
11061-0303
(OPTION)
11061-0304
(OPTION)
11061-0305
(OPTION)
11061-0306
(OPTION)
11061-0307
(OPTION)
Part No.
Spec Code
DEC.27,2007
COVER-GENERATOR
GASKET,SMALL COVER
GASKET,LARGE COVER
GASKET,OIL PAN
GASKET,GENERATOR COVER
GASKET,CLUTCH COVER
Description
Engine Cover(s)
This grid covers:
11061
GRID NO.
1
1
1
1
1
1
P8FR
’08
Quantity-ZX600
’08 ZX600P8FR Engine
This catalog covers:
B-10
Part No.
8
26031A 26031-0327
(OPTION)
26031B 26031-0558
(OPTION)
26031C 26031-0559
(OPTION)
27002 27002-3703
(OPTION)
21175-0145
(OPTION)
21176 21176-1099
(OPTION)
26011 26011-0071
(OPTION)
26011A 26011-1779
(OPTION)
26031 26031-0240
(OPTION)
Ref.
No.
1
1
HARNESS,MAIN,KIT METER
RELAY-ASSY
DEC.27,2007
1
1
HARNESS,INTERFACE BOX
HARNESS,MAIN,STD METER
1
WIRE-LEAD,METER-TEMP SENSOR
1
1
WIRE-LEAD,TEMP SENSOR EARTH
HARNESS,SUB,STD METER&HARNESS
1
SENSOR,TEMP
P8FR
’08
Quantity-ZX600
1
Spec Code
CONTROL UNIT-ELECTRONIC
Description
Fuel Injection
This grid covers:
21175
GRID NO.
’08 ZX600P8FR Engine
This catalog covers:
92002-1696
(OPTION)
92005-0080
(OPTION)
92015-1193
(OPTION)
92022-304
(OPTION)
92027-194
(OPTION)
92002
130
120
9
120CA0620
(OPTION)
130BD0610
(OPTION)
92059-1587
(OPTION)
92059A 92059-1629
(OPTION)
92075 92075-277
(OPTION)
92150 92150-1717
(OPTION)
92200 92200-0306
(OPTION)
92059
92027
92022
92015
92005
26031
52001
21066
21007
21003-0068
(OPTION)
21007-0083
(OPTION)
21066-0010
(OPTION)
26031-0635
52001-0004
(OPTION)
21003
11054-1799
(OPTION)
11054A 11054-1810
(OPTION)
14073 14073-0124
(OPTION)
14073A 14073-0125
(OPTION)
14073B 14073-0174
(OPTION)
11054
Part No.
Generator
B-11
Ref.
No.
This grid covers:
GRID NO.
2
2
DUCT,FUNNEL,L=20
DUCT,FUNNNEL,L=30
2
1
1
DAMPER
BOLT,12X40
WASHER,12X36X3.2
DEC.27,2007
BOLT-FLANGED,6X10
1
2
1
TUBE,L=100MM
BOLT-SOCKET,6X20
1
2
1
2
2
4
1
1
1
1
TUBE
COLLAR,L=11.1
WASHER,6.2X11X1
NUT,FLANGED,6MM
FITTING
BOLT,SOCKET,6X25
HARNESS,ACG-REGULATOR
TANK-OIL
REGULATOR-VOLTAGE
ROTOR
1
2
DUCT,FUNNEL,L=15
STATOR
1
BRACKET,REGULATOR
P8FR
’08
Quantity-ZX600
2
Spec Code
BRACKET,OIL TANK
Description
’08 ZX600P8FR Engine
This catalog covers:
B-12
Ref.
No.
554
130
92171
92170
10
92170-1287
(OPTION)
92171-0179
(OPTION)
130BA0612
(OPTION)
554DA1000
(OPTION)
39062A 39062-0220
(OPTION)
39192 39192-0011
(OPTION)
49085 49085-1066
(OPTION)
92043 92043-1436
(OPTION)
92075 92075-1123
(OPTION)
39062
39060
35063
11065
11054-1818
(OPTION)
11065-1056
(OPTION)
35063-0439
(OPTION)
39060-0020
(OPTION)
39062-0219
(OPTION)
Part No.
Radiator
This grid covers:
11054
GRID NO.
Spec Code
1
1
3
CAP-ASSY-PRESSURE
PIN
DAMPER,RUBBER
DEC.27,2007
PIN-SNAP,10MM
BOLT-FLANGED,6X12
CLAMP
1
1
3
1
1
PIPE-WATER
CLAMP,COOLING HOSE
1
1
1
1
1
1
P8FR
’08
Quantity-ZX600
HOSE-COOLING,O.COOLER-KIT RAD
HOSE-COOLING,KIT RAD.-PIPE
RADIATOR,BIG
STAY,RADIATOR
CAP
BRACKET,RADIATOR
Description
’08 ZX600P8FR Chassis
This catalog covers:
C-3
Part No.
11
92150A 92150-1494
92151 92151-1593
(OPTION)
92152 92152-0589
(OPTION)
120 120CA0630
(OPTION)
59101A 59101-0002
(OPTION)
92015 92015-1316
(OPTION)
92015A 92015-1397
(OPTION)
92026 92026-1586
(OPTION)
92150 92150-1090
46012A 46012-1239
46075 46075-1143
(OPTION)
54012 54012-0232
(OPTION)
54012A 54012-0233
(OPTION)
59101 59101-0001
(OPTION)
31064-1151
(OPTION)
32099 32099-0004
(OPTION)
32099A 32099-0005
(OPTION)
46003 46003-1351
46012 46012-1238
31064
11054-1816
(OPTION)
11054A 11054-1817
(OPTION)
13061 13061-1628
(OPTION)
13280 13280-0011
(OPTION)
13280A 13280-0012
(OPTION)
Ref.
No.
3
BOLT-SOCKET,6X30
DEC.27,2007
1
2
BOLT,6MM
COLLAR
1
SPACER,SET
2
2
1
NUT,LOCK,FLANGED,8MM
BOLT,SOCKET,10X50
BOLT,SOCKET,8X25
1
NUT,FLANGED,16MM
1
REEL,R21.5,60DEG
1
1
CABLE-THROTTLE,CLOSING
REEL,R20.0,65DEG
1
CABLE-THROTTLE,OPENING
2
1
HANDLE
HOLDER-HANDLE,LH
1
1
1
CASE,LWR
HOLDER-HANDLE,RH
GRIP,THROTTLE
1
1
HOLDER,STEERING DAMPER
CASE,UPP
1
HOLDER,STEERING DAMPER
1
1
BOSS
PIPE-COMP,GRIP
1
BRACKET
P8FR
’08
Quantity-ZX600
1
Spec Code
BRACKET
Description
Frame Fittings(1/2)
This grid covers:
11054
GRID NO.
’08 ZX600P8FR Chassis
This catalog covers:
C-4
GRID NO.
Part No.
410
670
12
410AA0800
670B2012
(OPTION)
120A 120CA0635
(OPTION)
120B 120CA0825
(OPTION)
120C 120CA0830
120D 120CA0865
(OPTION)
120E 120CB0625
(OPTION)
Ref.
No.
2
BOLT-SOCKET,6X25
DEC.27,2007
2
1
2
1
BOLT-SOCKET,8X30
BOLT-SOCKET,8X65
WASHER-PLAIN-SMALL,8MM
O RING,12MM
1
BOLT-SOCKET,8X25
P8FR
’08
Quantity-ZX600
2
Spec Code
BOLT-SOCKET,6X35
Description
Frame Fittings(2/2)
This grid covers:
’08 ZX600P8FR Chassis
This catalog covers:
13
92145-0507
(OPTION)
92145A 92145-0508
(OPTION)
92145B 92145-0509
(OPTION)
92145
Part No.
Front Fork
C-5
Ref.
No.
This grid covers:
GRID NO.
2
SPRING,FRONT FORK,K=9.75N/MM
DEC.27,2007
2
SPRING,FRONT FORK,K=9.25N/MM
P8FR
’08
Quantity-ZX600
2
Spec Code
SPRING,FRONT FORK,K=8.25N/MM
Description
’08 ZX600P8FR Chassis
This catalog covers:
C-6
Ref.
No.
14
92039-1231
(OPTION)
92152 92152-0058
(OPTION)
92152A 92152-1074
(OPTION)
130 130BB0625
(OPTION)
92039
92015
39156
25031
23016
11053-1749
(OPTION)
23016-0006
(OPTION)
25031-1142
(OPTION)
39156-0098
(OPTION)
92015-1233
(OPTION)
Part No.
Meter(s)
This grid covers:
11053
GRID NO.
2
2
COLLAR
BOLT-FLANGED,6X25
DEC.27,2007
3
COLLAR
2
1
1
1
1
P8FR
’08
Quantity-ZX600
3
Spec Code
RIVET
NUT,FLANGED,6MM,BLACK
PAD,KIT METER
METER-ASSY
LAMP-ASSY,INDICATOR
BRACKET,KIT METER
Description
’08 ZX600P8FR Chassis
This catalog covers:
C-7
Part No.
130
15
130BB1020
(OPTION)
92058-1090
(OPTION)
92145 92145-0504
(OPTION)
92145A 92145-0505
(OPTION)
92145B 92145-0506
(OPTION)
92153 92153-1777
(OPTION)
92058
43082-0074
(OPTION)
43082A 43082-1192
(OPTION)
43082B 43082-1220
(OPTION)
55020 55020-0028
(OPTION)
92057 92057-1529
(OPTION)
Ref.
No.
Other
This grid covers:
43082
GRID NO.
1
4
SPRING,SHOCKABSORBER,K=105N/MM
BOLT,FLANGED,10X60
DEC.27,2007
1
1
SPRING,SHOCKABSORBER,K=100N/MM
BOLT-FLANGED,10X20
1
1
CHAIN,DRIVE,120L(#520)
SPRING,SHOCKABSORBER,K=95N/MM
1
GUARD,CHAIN
1
1
PAD-ASSY-BRAKE,RR,C93G
JOINT-CHAIN,DRIVE(#520)
1
PAD-ASSY-BRAKE,RR,C93
P8FR
’08
Quantity-ZX600
1
Spec Code
PAD-ASSY-BRAKE,FR
Description
Doc No. 99929-0231-01