Kawasaki Ninja ZX-6 1990-2004 Service & Repair Manual (Clymer M468-2)

Kawasaki Ninja ZX-6 1990-2004 Service & Repair Manual (Clymer M468-2)
Brand:Clymer
Product Code:Clymer M468-2
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Clymer Kawasaki Ninja ZX-6, 1990-2004
Copyright:2004
UPC Code:024185793199
ISBN: 9780892879311

Item ID:M468-2

This Kawasaki Ninja Manual is 624 pages.

QUICK REFERENCE DATA

CHAPTER ONE / 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

CHAPTER TWO / 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

CHAPTER THREE / 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

CHAPTER FOUR / 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

CHAPTER FIVE / 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

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

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

CHAPTER EIGHT / 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

CHAPTER NINE / 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

CHAPTER TEN / 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

CHAPTER ELEVEN / 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

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

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

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

INDEX

WIRING DIAGRAMS


Models covered:
1990 1991 1992 1993 Kawasaki ZX600 D (U.S. & Canada)
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Kawasaki ZX600 E (U.S. & Canada)
1990 1991 1992 1993 Kawasaki ZZ-R600 D (U.K.)
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Kawasaki ZZ-R600 E (U.K.)

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