Kawasaki Ninja ZX6, ZX600 & ZZ-R 600 1990 - 2004

Clymer Owners Service & Repair Manual

1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

by Clymer Staff

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Kawasaki Ninja ZX6, ZX600 & ZZ-R 600 1990 - 2004 - Front Cover

Front Cover

Front Cover

description

Kawasaki Ninja ZX6, ZX600 & ZZ-R 600 1990 - 2004 Service & Repair Manual Covers the following models:
● ZX600 D (U.S. and Canada) (1990-1993)
● ZX600 E (U.S. and Canada) (1993-2004)
● ZZ-R600 D (U.K) (1990-1993)
● ZZ-R600 E (U.K.) (1993-2003)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Torque specifications / Special tips / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic's tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Cylinder leakage test / Clutch / Transmission / Drive train noise / Handling / Frame noise / Brakes

LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list / Maintenance schedule / Oil and filter change / Engine oil pressure test / Air filter cleaning and oiling / Periodic lubrication / Periodic maintenance / Unscheduled maintenance / Tune-up / Valve clearance adjustment / Compression test / Spark plugs / Ignition timing / Carburetor idle mixture / Carb synchronization / Specifications

ENGINE TOP END
Engine principles / Cylinder head cover / Camshaft / Camshaft chain tensioner / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Specifications

ENGINE LOWER END
Servicing the engine in the frame / Engine removal and installation / Oil pump / Oil pan, oil pipe and strainer / Oil pressure relief valve / Oil cooler and upper hose / Stator coil and left-hand crankcase cover / Alternator rotor, starter clutch and gears / Crankcase / Shift lever needle bearing replacement / Crankshaft / Connecting rods / Camshaft chain / Engine break-in / Specifications

CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch cable / Clutch release mechanism / External gearshift mechanism / Specifications

TRANSMISSION AND INTERNAL SHIFT MECHANISM
Engine drive sprocket cover / Engine drive sprocket / Transmission / Internal gearshift mechanism / Specifications

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor separation / Fuel level / Float height / Throttle cables / Choke cable / Air filter air box / Fuel tank / Fuel shutoff valve / Fuel pump / Clean air system / Crankcase breather system / Evaporative emission control system / Exhaust system / Specifications

ELECTRICAL SYSTEM
Basic information / Charging system / Stator coil / Regulator/rectifier / Ignition system / IC igniter unit / Ignition coil / Timing rotor and pickup coil / Starting system / Starter system / Lighting system / Switches / Components / Fuel pump and relay / Thermostatic fan switch / Low fuel level warning system / Fuel level system / Junction box and fuses / Wiring and connectors / Wiring diagrams / Specifications

COOLING SYSTEM
Hoses and hose clamps / Cooling system inspection / Coolant reservoir tank / Radiator and fan / Cooling fan / Thermostat / Water pump / Thermostatic fan switch and water temperature sensor / Specifications

FRONT SUSPENSION AND STEERING
Front wheel and hub / Wheels / Handlebar / Handlebar left-hand grip / Steering stem and head / Steering head bearing race / Steering stem bearing / Front forks / Fork service / Specifications

REAR SUSPENSION
Rear wheel and hub / Rear coupling and driven sprocket / Drive chain / Shock absorber / Swing arm and shock linkage / Suspension linkage / Specifications

BRAKES
Disc brakes / Brake pad / Caliper / Master cylinder / Brake hose / Brake disc / Bleeding the system / Rear brake pedal and arm / Specifications

BODY AND FRAME
Seat / Front fender / Frame side covers and grab rail / Front fairing / Centerstand / Sidestand / Footpegs / Specifications

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 0892879319 (0-892-87931-9)
  • ISBN-13: 9780892879311 (978-0-892-87931-1)
  • Format: Softcover, 624 pages
  • Date Published: 11-2004

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