Ninja ZX-6R

MotorcycleAssembly & Preparation

Manual

ForewordIn order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly removed parts have a direct bear-ing on a vehicle’s reliability and safety, consci-entious pre-sale assembly and preparation be-comes extremely important. Good setup pro-cedures can prevent needless warranty claimsand give customers a greater sense of confi-dence in Kawasaki and their Kawasaki Dealers.This Assembly and Preparation Manual ex-

plains step by step procedures of the followingitems for all Kawasaki motorcycles.

1. Uncrating2. Assembly3. Preparation

The selling dealer assumes sole responsibil-ity for any unauthorized modifications prior tosale. Refer to your Service Binder for any Ser-vice Bulletins specifying Factory Directed Mod-ifications (Special Claims) which must be per-formed before the vehicle is ready for sale.Whenever you see the following symbols

heed their instructions! Always follow safeoperating and maintenance practices.

WARNINGThis warning symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in per-sonal injury, or less of life.

CAUTIONThis caution symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in dam-age to, or destruction of equipment.

NOTE○This note symbol indicates points of particularinterest for more efficient and convenient op-eration.

Kawasaki Heavy Industries, Ltd. accepts noliability for any inaccuracies or omissions in thispublication, although every possible measurehas been taken to make it as complete and ac-curate as possible. All procedures and specifi-cations subject to change without notice.

© 2004 Kawasaki Heavy Industries, Ltd. Sep. 2004 (K)

Table of Contents

Uncrating ...................................................................................... 3Opening Crate ............................................................................. 3Parts Check................................................................................. 4

Assembly ...................................................................................... 4Steering Stem Head Nut ............................................................. 4Clutch Cable................................................................................ 5Windshield................................................................................... 5Rider’s Seat Bolt.......................................................................... 5Brake Disc Cleaning.................................................................... 5

Preparation ................................................................................... 6Battery Service ............................................................................ 6Front Brake Fluid......................................................................... 13Rear Brake Fluid ......................................................................... 15Clutch Lever and Cable............................................................... 17Drive Chain.................................................................................. 17Front Fork.................................................................................... 19Rear Shock Absorber .................................................................. 20Tire Air Pressures........................................................................ 21Fuel ............................................................................................. 21Coolant ........................................................................................ 21Engine Oil (4-stroke) ................................................................... 23Throttle Grip and Cable ............................................................... 24Rear Brake Light Switch.............................................................. 24Idle Speed Adjustment ................................................................ 25Headlight Aim .............................................................................. 25Digital Meter ................................................................................ 25Fastener Check ........................................................................... 28Standard Torque Table ................................................................ 30Test Ride the Motorcycle ............................................................. 30A & P Check List ......................................................................... 30

UNCRATING 3

UncratingOpening Crate•Clear a space about 6 m (20 ft) square to giveyourself plenty of space to work.• Place the crate upright on its base.•Remove the cardboard cover.•Remove the parts box.

CAUTIONWhen you remove the crate bracketfrom the motorcycle, be careful not todrop any parts and bracket onto thefuel tank and other components, andnot to scratch the fuel tank by the cratebracket. This could damage the fueltank or components.

•First, remove the lower crate bolt (D = 22) atthe steering stem and discard it.• Remove the upper crate bolts (D = 8) to takeoff the crate bracket and foam pad and dis-card them.

A. Lower Crate Bolt (D = 22)B. Upper Crate Bolts (D = 8)C. Crate BracketD. Foam Pad

•Take out all the bolts and screws and removethe top and sides of the crate.• Lift the vehicle upward about 10 cm (4 in.) andremove the two lower support brackets. Rollthe vehicle off the crate base.

A. Lower Support Bracket

4 ASSEMBLY

Parts Check•Open the parts box, and check the partsagainst the illustrations. There may be mi-nor differences between these illustrationsand the actual vehicle parts. In the followingcharts under Remarks, D = diameter in mil-limeters, and L = length in millimeters.

No. Part Name Qty Remarks1 Steering Stem Head Nut 1 D = 282 Plastic Washer 6 D = 5.3 × 11.5

Socket Bolt 6 D = 5, L = 16Wellnut 6 D = 5Windshield 1

3 Socket Bolt, Rider’s Seat 2 D = 6, L = 16.34 Battery Electrolyte, YTX9-BS 1 12 V 8 Ah5 Owner’s Manual 1

AssemblySteering Stem Head Nut•Remove the steering stem head dummy nutand discard it. Do not remove the steeringstem flat washer under the dummy nut.

A. Dummy NutB. Flat Washer

•Remove the non-permanent locking agentand clean the steering stem shaft threads.• Install the steering stem head nut (D = 28) onthe flat washer with the chamfered side facingupwards and tighten it to the specified torque.Torque: 78 N·m (8.0 kgf·m, 58 ft·lb)

A. Chamfered Side of Stem Head NutB. Flat Washer

ASSEMBLY 5

Clutch Cable•Apply a light coat of grease on the clutch innercable.• Line up the slots on the clutch lever and ad-juster.• Fit the tip of the clutch inner cable into thelever socket, slide the inner cable through theslots, and release the outer cable into the ad-juster.

A. Clutch CableB. AdjusterC. Cable TipD. Clutch Lever

Windshield•Fit the six wellnuts (D = 5) into the holes in theedge of the windshield from the outside withtheir flanges out.

A. WindshieldB. Wellnuts

•Put the front tab into the slot of the upperfairing.

A. Front TabB. SlotC. Upper Fairing

• Install the six plastic washers and the socketbolts (D = 5, L = 16) on the upper fairing.

A. Plastic Washers and Socket BoltsB. Windshield

•Tighten the windshield bolts. Do not overtighten the windshield bolts.

Rider’s Seat Bolt• Install the rider’s seat bolts. See “Battery Ser-vice” section.

Brake Disc Cleaning•Clean the front and rear brake discs usingoilless solvent.

WARNINGIf not removed, the anticorrosive treat-ment applied to the brake disc surfacewill interfere with brake action, and anunsafe riding condition could result.

6 PREPARATION

PreparationBattery ServiceRider’s Seat Removal•Unscrew the left and right side cover bolts(D = 6) (3) and remove the covers by pullingthem outward to clear the projections.

A. Left Side CoverB. Bolts (D = 6)C. Projections

A. Right Side CoverB. Bolt (D = 6)C. Projection

•Remove the rider’s seat by pulling the front ofit up and forward.

A. Rider’s Seat

The battery used in this motorcycle is a sealedtype and never needs to be refilled. Follow theprocedure for activating a new battery to ensurethe best possible battery performance.Activating the battery requires two steps, fill-

ing the battery with electrolyte, and charging.Read the electrolyte safety label and the follow-ing procedures carefully before battery activa-tion.

CAUTIONIncorrect Battery Activation will reducebattery performance and service life. Besure to strictly follow the Battery Serviceinstructions in this Manual.

•Make sure to use the electrolyte packed in thecrate with the unit.•Make sure that the model name of the elec-trolyte container matches the model name ofthe battery. These names must be the same.

Battery Model Name forZX636-C1: YTX9-BS

A. Model Name of the ElectrolyteB. Model Name of the Battery

PREPARATION 7

CAUTIONSealed battery electrolyte has a higherconcentration of sulfuric acid. Eachcontainer contains the proper amountof electrolyte for its specific battery.Insufficient or incorrect electrolyte willreduce battery performance and servicelife. Electrolyte over capacity can leadto battery cracking or leaking and resultin corrosion damage to the vehicle.

Battery Removal•Check for fuel in the fuel tank.• If fuel remains in the fuel tank, do the followingprocedures.•Draw the fuel out from the fuel tank with acommercially available pump.•Use a soft plastic hose as a pump inlet hosein order to insert the hose smoothly.• Put the hose through the filler opening into thetank and draw the fuel out.

WARNINGThe fuel could not be removed com-pletely from the fuel tank. Be careful forremained fuel spillage.

A. Commercially Available PumpB. Soft Plastic HoseC. Filler OpeningD. Front

•Remove the fuel tank bolts (D = 6, D = 8) (3).

A. Fuel TankB. Fuel Tank Bolt (D = 6)C. Fuel Tank Bolts (D = 8)

•Remove the fuel tank pivot bolt (D = 6).•Disconnect the fuel pump connector (4P).

A. Fuel Tank Pivot Bolt (D = 6)B. Fuel Pump Connector (4P)

•Open the fuel tank cap to lower the pressurein the tank.

NOTE○During tank removal, keep the tank cap opento release pressure in the tank. This reducesfuel spillage.

•Be sure to place a piece of cloth around thefuel hose joint.• Push the joint lock claws.

8 PREPARATION

A. Fuel Hose JointB. Joint Lock Claws

•Pull the joint lock.• Pull the fuel hose joint out of the delivery pipe.WARNING

Be prepared for fuel spillage; any spilledfuel must be completely wiped up imme-diately.When the fuel hose is disconnected, fuelspills out from the hose and the pipe be-cause of residual pressure. Cover thehose connection with a piece of cleancloth to prevent fuel spillage.

A. Joint LockB. Fuel Hose Joint

•Remove the drain hose from the fuel tank.

A. Fuel TankB. Drain Hose

•Close the fuel tank cap.• Remove the fuel tank, and place it on a flatsurface.• For California Model, note the following.

CAUTIONFor California model, if gasoline, sol-vent, water or any other liquid enters thecanister, the canister’s vapor absorbingcapacity is greatly reduced. If the canis-ter does become contaminated, replaceit with a new one.

•Remove the fuel return hose (red) andbreather hose (blue) from the fuel tank.

A. Fuel TankB. Fuel Return Hose (Red)C. Breather Hose (Blue)

•Be sure to plug the evaporative fuel returnhose to prevent fuel spilling before fuel tankremoval.

WARNINGFor California model, be careful not tospill the gasoline through the returnhose. Spilled fuel is hazardous.

PREPARATION 9

• If liquid or gasoline flows into the breatherhose, remove the hose and blow it clean withcompressed air.• Be careful of fuel spillage from the fuel tanksince fuel still remains in the fuel tank and fuelpump.

WARNINGStore the fuel tank in an area which iswell-ventilated and free from any sourceof flame or sparks. Do not smoke in thisarea. Place the fuel tank on a flat surfaceand plug the fuel pipes to prevent fuelleakage.

•Remove the fuel tank bracket bolts.• Remove the left seat cover bolt (D = 6) (1) andright seat cover bolts (D = 6) (2).

A. Fuel Tank Bracket Bolts (D = 6)B. Seat Cover Bolts (D = 6)C. Battery

•Take the battery out of the battery case.Battery SpecificationsMake YuasaBattery Type YTX9-BSBattery Capacity 12 V 8 AhElectrolyte Capacity 0.40 LBattery/Electrolyte Set P/No. 26012-1326

Battery ActivationFilling the Battery with Electrolyte

CAUTIONDo not remove the aluminum sealingsheet [A] from the filler ports [B] untiljust prior to use. Be sure to use the ded-icated electrolyte container for correctelectrolyte volume.

•Place the battery on a level surface.•Check to see that the sealing sheet has nopeeling, tears, or holes in it.• Remove the sealing sheet.

NOTE○The battery is vacuum sealed. If the sealingsheet has leaked air into the battery, it mayrequire a longer initial charge.

•Remove the electrolyte container from thevinyl bag.•Detach the strip of caps [A] from the containerand set aside, these will be used later to sealthe battery.

NOTE○Do not pierce or otherwise open the sealedcells [B] of the electrolyte container. Do notattempt to separate individual cells.

•Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pushdown to break the seals of all six cells. Youwill see air bubbles rising into each cell as theports fill.

NOTE○Do not tilt the electrolyte container.

10 PREPARATION

•Check the electrolyte flow.• If no air bubbles [A] are coming up from thefiller ports, or if the container cells have notemptied completely, tap the container [B] afew times.

• Keep the container in place for 20 minutes ormore. Don’t remove the container from thebattery until it’s empty, the battery requires allthe electrolyte from the container for properoperation.

CAUTIONRemoval of the container before it iscompletely empty can shorten the ser-vice life of the battery. Do not removethe electrolyte container until it is com-pletely empty and 20 minutes haveelapsed.

•Gently remove the container from the battery.• Let the battery sit for 30 minutes prior tocharging to allow the electrolyte to permeateinto the plates for optimum performance.

NOTE○Charging the battery immediately after fillingcan shorten service life. Let the battery sit forat least 30 minutes after filling.

Initial Charge•Place the strip of caps loosely over the fillerports.

A. Strip

•Newly activated sealed batteries require aninitial charge.Standard Charge 0.9 A × 5 ∼ 10 hours

• If using a recommended battery charger, fol-low the charger’s instructions for newly acti-vated sealed battery.

Kawasaki-recommended chargers:Optimate IIIYuasa 1.5 Amp Automatic ChargerBattery Mate 150–9

• If the above chargers are not available, useequivalent one.

NOTE○Charging rates will vary depending on howlong the battery has been stored, tempera-ture, and the type of charger used. Let batterysit 30 minutes after initial charge, then checkvoltage using a voltmeter. If it is not at least12.8 volts, repeat charging cycle.

•After charging is completed, press downfirmly with both hands to seat the strip ofcaps [A] into the battery (don’t pound or ham-mer). When properly installed, the strip ofcaps will be level with the top of the battery.

PREPARATION 11

CAUTIONOnce the strip of caps [A] is installedonto the battery, never remove the caps,nor add water or electrolyte to the bat-tery.

NOTE○To ensure maximum battery life and customersatisfaction, it is recommended the battery beload tested at three times its amp-hour ratingfor 15 seconds.Re-check voltage and if less than 12.8 voltsrepeat the charging cycle and load test. If stillbelow 12.8 volts the battery is defective.

Battery Installation•Turn the ignition switch OFF.•Route the battery cables as shown, and firstconnect the red capped positive cable (+) tothe positive terminal, and then negative cable(–) to the negative terminal.• Put a light coat of grease on the terminals toprevent corrosion.•Cover the terminals with their protective caps.

A. BatteryB. Positive Cable (+)C. Negative Cable (–)

A. BatteryB. Positive Cable (+)C. Negative Cable (–)D. Vehicle-down SensorE. Fuel Pump Connector (4P)F. Clamp

•Reinstall the fuel tank bracket and tighten thebolts (D = 6) (2).• Reinstall the left and right seat cover bolts (D= 6) (3) and tighten them.

A. Fuel Tank Bracket Bolts (D = 6)B. Seat Cover Bolts (D = 6)

•For California Model, note the following.○To prevent the gasoline from flowing into orout of the canister, hold the separator perpen-dicular to the ground.

○Route the hoses correctly. Make sure they donot get pinched or kinked.

○Route the hoses with a minimum of bendingso that the air or vapor will not be obstructed.

12 PREPARATION

A. Fuel TankB. Fuel Return Hose (Red)C. Breather Hose (Blue)

•Pull the joint lock.• Insert the fuel hose joint straight onto the de-livery pipe until the hose joint clicks.• Push the joint lock until the hose joint clicks.

A. Fuel Hose JointB. Joint Lock

•Push and pull the hose joint back and forthmore than two times and make sure it islocked and doesn’t come off, when the hosejoint is correctly installed, it should slide onthe delivery pipe about 5 mm (0.2 in.).

WARNINGMake sure the hose joint is installed cor-rectly on the delivery pipe by sliding thejoint, or the fuel could leak.

A. Fuel Hose Joint

•When installing the fuel tank, check that thehose is securely connected to the tank, andbe sure not to pinch this or any other hose orwire with the fuel tank.

A. Fuel TankB. Drain Hose

•Reinstall the fuel tank pivot bolt (D = 6) andtighten it.• Connect the fuel pump connector (4P).

A. Fuel Tank Pivot Bolt (D = 6)B. Fuel Pump Connector (4P)

•Reinstall the fuel tank bolts (D = 6, D =8) (3)and tighten them.

PREPARATION 13

A. Fuel TankB. Fuel Tank Bolt (D = 6)C. Fuel Tank Bolts (D = 8)

Rider’s Seat Installation• Insert the tabs on the rear of the rider’s seatunder the bracket.

A. Rider’s SeatB. TabsC. InsertD. Bracket

• Install the rider’s seat bolts (D = 6, L = 16.3)(2)and tighten them.• Insert the projections of both side covers intothe grommets.

A. Rider’s SeatB. Rider’s Seat BoltC. Right Side CoverD. ProjectionE. Grommet

• Install the side cover bolts (D = 6) and tightenthem.

A. Right Side CoverB. Bolt (D = 6)C. Projection

Front Brake FluidFront Brake Fluid Level Inspection•With the front brake fluid reservoir held hor-izontal, check that the fluid level is betweenthe upper and lower level lines.

14 PREPARATION

A. Front Brake Fluid ReservoirB. Upper Level LineC. Lower Level LineD. Cap Stopper Screw

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thefront brake lines and fill the reservoir.• Loosen the cap stopper screw to remove thefront brake fluid reservoir cap and diaphragm.• Fill the reservoir to the upper level line withDOT4 brake fluid.

WARNINGNever reuse old brake fluid.Do not use fluid from a container thathas been left unsealed or that has beenopen for a long time.Do not mix two types of fluid for use inthe brakes. This lowers the brake fluidboiling point and could reduce brake ef-fectiveness. It may also cause the rub-ber brake parts to deteriorate.Don’t leave the reservoir cap off for anylength of time to prevent moisture con-tamination of the fluid.Don’t add or change brake fluid in therain or during conditions of blowing dustor debris.

NOTE○First, tighten the front brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

A. ReservoirB. CapC. ClockwiseD. 1/6 turn

CAUTIONBrake fluid quickly ruins painted sur-faces. Wipe up any spilled fluid immedi-ately.

•Operate the brake lever several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the front brakeline.• Also check for fluid leakage around the fit-tings.Front Brake Line Air Bleeding•Remove the reservoir cap and diaphragm,and check that there is plenty of fluid in thereservoir.

NOTE○The fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

PREPARATION 15

•Attach a clear plastic hose to the bleed valveon front master cylinder and run the other endof the hose into a container.•With the reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the brake master cylinderend of the line.• Pump the brake lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve. Then releasethe lever. Repeat this operation until no moreair can be seen coming out into the plastichose.

A. Hold the brake lever applied.B. Quickly open and close the bleed valve.C. Release the brake lever.

•Tighten the bleed valve to the specifiedtorque.Torque: 5.9 N·m (0.60 kgf·m, 52 in·lb)

•Attach a clear plastic hose to the bleed valveon each front brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the brake master cylinderend of the line.• Pump the brake lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve. Then releasethe lever. Repeat this operation until no moreair can be seen coming out into the plastichose.

A. Hold the brake lever applied.B. Quickly open and close the bleed valve.C. Release the brake lever.

•Repeat the previous step one more time forthe other front disc brake.•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Tighten the bleed valve(s) to the specifiedtorque.Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Install the diaphragm and reservoir cap.NOTE

○First, tighten the front brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

•Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.

Rear Brake FluidRear Brake Fluid Level Inspection•With the rear brake fluid reservoir held hor-izontal, check that the fluid level is betweenthe upper and lower level lines.

16 PREPARATION

A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level Line

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thebrake line, and fill the reservoir.• Remove the reservoir cap and diaphragm,and fill the reservoir to the upper level line withDOT4 brake fluid.

CAUTIONBrake fluid quickly ruins painted sur-faces. Wipe up any spilled fluid immedi-ately.

NOTE○First, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

A. ReservoirB. CapC. ClockwiseD. 1/6 turn

•Operate the brake pedal several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the rear brakeline.• Also check for fluid leakage around the fit-tings.Rear Brake Line Air Bleeding•Remove the rear brake reservoir cap and di-aphragm, and check that there is plenty offluid in the reservoir.

NOTE○The fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

•Attach a clear plastic hose to the bleed valveon the rear brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake pedal several times until no air bub-bles can be seen rising up through the fluidfrom the holes at the bottom of the reservoir.This bleeds the air from the rear brake mastercylinder end of the line.• Pump the brake pedal a few times until itbecomes hard and then, holding the pedalpushed down, quickly open (turn counter-clockwise) and close the bleed valve. Thenrelease the pedal. Repeat this operation untilno more air can be seen coming out into theplastic hose.

A. Hold the brake pedal applied.B. Quickly open and close the bleed valve.C. Release the brake pedal.

PREPARATION 17

•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Tighten the bleed valve to the specifiedtorque.Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Install the diaphragm and reservoir cap.NOTE

○First, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

•Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.

Clutch Lever and CableClutch Lever Free Play Inspection•Check that the clutch lever has the specifiedamount of free play as shown in the figure.

Clutch Lever Free Play:2 ∼ 3 mm (0.08 ∼ 0.12 in.)

A. AdjusterB. Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)C. 4 ∼ 6 mm (0.16 ∼ 0.24 in.)

• If the free play is incorrect, adjust the freeplay.

NOTE○Before checking the clutch lever free play,make sure that the gap between clutch leverholder and adjuster is 4 ∼ 6 mm (0.16 ∼ 0.24in.).

Clutch Lever Free Play Adjustment•Turn the adjuster so that the clutch lever willhave 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play.• If it cannot be done, use the adjusting nuts atthe lower end of the clutch cable.

A. Adjusting NutsB. Clutch Cable

NOTE○After the adjustment is made, start the engineand check that the clutch does not slip andthat it releases properly.○For minor corrections, use the adjuster at theclutch lever.

Drive ChainDrive Chain Slack and Wheel AlignmentInspection•Set the motorcycle up on its side stand.•Make sure that the drive chain has the speci-fied amount of play, and that the left and rightnotches are on the same marks or points onthe left and right of the swingarm.

WARNINGMisalignment of the wheel will result inabnormal wear, and may result in an un-safe riding condition.

•Rotate the rear wheel to find the positionwhere the chain is tightest, and measurethe maximum chain slack by pulling up andpushing down the chain midway between theengine sprocket and rear sprocket.

Drive Chain Slack:30 ∼ 35 mm (1.2 ∼ 1.4 in.)

18 PREPARATION

A. 30 ∼ 35 mm (1.2 ∼ 1.4 in.)

• If the drive chain is too tight or too loose, ad-just it so that the chain slack will be within thestandard value.

WARNINGA chain that breaks or jumps off thesprockets could snag on the enginesprocket or lock the rear wheel, se-verely damaging the motorcycle andcausing it to go out of control.

Drive Chain Slack Adjustment•Remove the cotter pin, and loosen the rearaxle nut.• Loosen the left and right chain adjuster lock-nuts.

A. Rear Axle NutB. Cotter PinC. AdjusterD. Locknut

• If the chain is too loose, turn out the left andright chain adjusters evenly.• If the chain is too tight, turn in the left and rightchain adjusters evenly.• Turn both chain adjusters evenly until thedrive chain has the correct amount of slack.To keep the chain and wheel properly aligned,the wheel alignment indicator notches shouldalign with the same marks on each side ofthe swingarm.

A. MarksB. NotchC. IndicatorD. AdjusterE. Locknut

NOTE○Wheel alignment can also be checked usingthe straightedge or string method.

•Tighten both chain adjuster locknuts.• Tighten the rear axle nut to the specifiedtorque.Torque: 127 N·m (13.0 kgf·m, 94 ft·lb)

•Rotate the wheel, measure the chain slackagain at the tightest position, and readjust ifnecessary.• Install a new cotter pin.

NOTE○When inserting the cotter pin, if the slots in thenut do not align with the cotter pin hole in theaxle, tighten the nut clockwise up to the nextalignment.○It should be within 30 degrees.○Loosen once and tighten again when the slotgoes past the nearest hole.

PREPARATION 19

A. Cotter PinB. Turning Clockwise

•Bend the cotter pin over the nut.

A. Cotter PinB. Nut

WARNINGIf the rear axle nut is not securely tight-ened or the cotter pin is not installed, anunsafe riding condition may result.

•Check the rear brake effectiveness.Front ForkSpring Preload Adjustment•Check the position of the spring preload ad-justers on the left and right fork legs.

STD Spring Preload:17 mm (0.7 in.) from the top of adjuster

A. Spring Preload AdjusterB. WrenchC. 17 mm (0.7 in.)D. Nut

•Turn the spring preload adjusters into the nutto increase spring force and out to decreasespring force using a 22 mm wrench. The ad-justing range stretches 10 ∼ 25 mm (0.4 ∼ 1.0in.) from the top of each adjuster. Be sure toturn both adjusters to the same position.

WARNINGIf both spring preload adjusters andboth rebound and compression damp-ing force adjusters are not adjustedequally, handling may be impaired anda hazardous condition may result.

Rebound Damping Force Adjustment•Check the position of the rebound dampingforce adjusters on the left and right fork legs.

STD Rebound Damping Force:1 3/4 turns out (Counterclockwise fromthe fully seated position).

A. Rebound Damping Force AdjusterB. Screwdriver

20 PREPARATION

CAUTIONDo not force to turn the rebound damp-ing force adjuster from the fully seatedposition or the adjusting mechanismmay be damaged.

•Turn the rebound damping force adjuster allthe way into the spring preload adjuster witha screwdriver. This makes the damping forcegreatest.• Turn out the adjuster to decrease dampingforce. Be sure to turn both adjusters by thesame number of turns.Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjusters on the bottom of the leftand right fork legs.

STD Compression Damping Force:3/4 turn out (Counterclockwise from thefully seated position).

A. Compression Damping Force Adjuster

CAUTIONDo not force to turn the compressiondamping force adjuster from the fullyseated position or the adjusting mecha-nism may be damaged.

•Turn the compression damping force adjusterall the way clockwise with a screwdriver tomake the damping force greatest.• Turn the adjuster counterclockwise to de-crease damping force. Be sure to turn bothadjusters by the same number of turns.

Rear Shock AbsorberRebound Damping Force Adjustment•Check the position of the rebound dampingforce adjuster at the lower end of the rearshock absorber.

STD Rebound Damping Force:9 clicks (Counterclockwise from thefully seated position).

A. Rebound Damping Force Adjuster

CAUTIONDo not force to turn the rebound damp-ing force adjuster from the fully seatedposition or the adjusting mechanismmay be damaged.

•Turn the rebound damping force adjuster allthe way clockwise with a screwdriver to makethe damping force greatest.• Turn the adjuster counterclockwise to de-crease damping force.Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjuster on the gas reservoir at theupper end of the rear shock absorber.

STD Compression Damping Force:3/4 turn out (Counterclockwise from thefully seated position).

PREPARATION 21

A. Compression Damping Force Adjuster

CAUTIONDo not force to turn the compressiondamping force adjuster from the fullyseated position or the adjusting mecha-nism may be damaged.

•Turn the compression damping force adjusterall the way clockwise with a screwdriver tomake the damping force greatest.• Turn the adjuster counterclockwise to de-crease damping force.

Tire Air Pressures•To prevent flat-spotting during shipment, thetires are over-inflated before crating. Adjustthe pressures to the specified values in thefront and rear, and make sure to tighten thecaps securely.

Tire Air Pressure [when cold]:Front: 250 kPa (2.5 kgf/cm², 36 psi)Rear: 290 kPa (2.9 kgf/cm², 42 psi)

A. Tire Air Pressure Gauge

Fuel

WARNINGFill the tank in a well-ventilated area, andtake ample care that there are no sparksor open flames anywhere near the workarea.

•Open the fuel tank cap, and check for debrisin the fuel tank.• Fill the fuel tank with one gallon or four litersof unleaded gasoline. Use a gasoline with aminimum Antiknock Index rating according tothe recommendation of your country. Refer tothe following table.The antiknock index is an average of the Re-

search Octane Number (RON) and the MotorOctane Number (MON), as shown in the table.

Octane Rating Method MinimumRating

(RON + MON)Antiknock Index

290

Research Octane Number (RON) 95

•Close the fuel tank cap, and check for anyleaks.

CoolantCoolant Level Inspection•Situate the motorcycle so that it is perpendic-ular to the ground.•Check the coolant level through the coolantlevel gauge on the reserve tank located to theleft of the engine. The coolant level should bebetween the F (Full) and L (Low) level lines.

NOTE○Check the level when the engine is cold (roomor atmospheric temperature).

22 PREPARATION

A. Reserve TankB. F (Full) Level LineC. L (Low) Level Line

• If the amount of coolant is insufficient, do thefollowing procedures to add coolant.• Remove the rider’s seat.• Remove the fuel tank bolts.

A. Fuel TankB. Fuel Tank Bolt (D = 6)C. Fuel Tank Bolts (D = 8)

•Raise the front of the fuel tank.NOTE

○To keep the fuel tank raised, support it frombelow with a suitable object. Be careful not todrop or damage the fuel tank.

A. Fuel TankB. Suitable ObjectC. Reserve Tank

•Remove the cap from the reserve tank andadd coolant through the filler opening to the F(Full) level line.

A. Reserve Tank Cap

• Install the reserve tank cap.• Install the fuel tank in the reverse order ofremoval.•When installing the fuel tank, check that thedrain hose is securely connected to the tank,and be sure not to pinch this or any other hoseor wire with the fuel tank.

A. Fuel TankB. Drain Hose

• Install the parts removed.

PREPARATION 23

NOTE○A permanent type of antifreeze is installed inthe cooling system when shipped. It is col-ored green and contains ethylene glycol. It ismixed at 50% and has the freezing point of–35 °C (–31 °F).

Engine Oil (4-stroke)Engine Oil Level Inspection

NOTE○This vehicle’s engine is filled with 10W-40 oilfrom the factory. DO NOT DRAIN and refillthe crankcase before use. Check oil level anddrain plug tightness.

Engine Oil Drain Plug Torque:29 N·m (3.0 kgf·m, 22 ft·lb)

A. Engine Oil Drain Plug

•Park the vehicle on level ground.• Before starting the engine, check that the en-gine has oil.• Check that the engine has oil through theoil level sight gauge in the lower side of theclutch cover.

CAUTIONIf the engine is run without oil, it will beseverely damaged.

•Start the engine and run it for several minutesat idle speed. Stop the engine, then wait sev-eral minutes until the oil settles.•Check the engine oil level through the oil levelsight gauge. The oil level should come upbetween the upper and lower level lines nextto the gauge.

A. Oil Level Sight GaugeB. Oil Filler CapC. Upper Level LineD. Lower Level Line

• If the oil level is too high, remove the excessoil through the oil filler opening, using a sy-ringe or some other suitable device.• If the oil level is too low, add oil to reach thecorrect level. Use the same type of oil that isalready in the engine.•When replacing the cap, be sure the O-ring isin place, and tighten the cap in finger tight.

Recommended Engine Oil

Type: API SE, SF or SGAPI SH or SJ with JASO MA

Viscosity: SAE 10W-40Capacity: 3.4 L (3.6 US qt)

[when filter is not removed]3.6 L (3.8 US qt)[when filter is removed]

Although 10W-40 engine oil is the recom-mended oil for most conditions, the oil viscositymay need to be changed to accommodateatmospheric conditions in your riding area.

24 PREPARATION

Throttle Grip and CableThrottle Grip Free Play Inspection• Inspect the throttle grip free play. If the freeplay is incorrect, adjust the throttle cables.

Throttle Grip Free Play:2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•Check that the throttle grip moves smoothlyfrom full open to close, and the throttle closesquickly and completely in all steering posi-tions by the return spring. If the throttle gripdoes not return properly, check the throttle ca-ble routing, grip free play, and for possible ca-ble damage. Then lubricate the throttle ca-bles.

A. Throttle GripB. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•Run the engine at idle speed, and turn thehandlebar all the way to the right and left toensure that the idle speed does not change.If the idle speed increases, check the throttlegrip free play.

WARNINGOperation with an improperly adjusted,incorrectly routed, or damaged cablecould result in an unsafe riding condi-tion.

Throttle Grip Free Play Adjustment• Loosen both locknuts of the throttle cablesand turn both adjusters in completely to givethe throttle grip plenty of play.• Turn out the decelerator cable adjuster untilthere is no play when the throttle grip is com-pletely closed. Tighten the locknut.

A. Accelerator CableB. Decelerator CableC. AdjustersD. Locknuts

•Turn out the accelerator cable adjuster un-til the specified amount of play is obtained.Tighten the locknut.

Rear Brake Light SwitchRear Brake Light Switch Adjustment•Turn on the ignition switch. The brake lightshould illuminate when the brake pedal is de-pressed about 10 mm (0.4 in.)• If it does not, turn the adjusting nut at the rearbrake light switch as required.

A. Rear Brake Light SwitchB. Adjusting NutC. Lights sooner.D. Lights later.

CAUTIONTo avoid damaging the electrical con-nections inside the switch, be sure thatthe switch body does not turn during ad-justment.

PREPARATION 25

Idle Speed Adjustment•Start the engine and warm it up thoroughly.• Adjust the idle speed to 1 250 ∼ 1 350 r/min(rpm) by turning the idle adjusting screw.Idle Speed: 1 250 ∼ 1 350 r/min (rpm)

A. Idle Adjusting Screw

•Open and close the throttle grip a few timesto make sure that the idle speed does notchange.•With the engine idling, turn the handlebar toeach side. If handlebar movement changesthe idle speed, check the throttle cable routingand free play.

WARNINGOperation with improperly routed, ordamaged throttle cable could result inan unsafe riding condition.

•Check for any exhaust leaks and correct ifnecessary.

Headlight AimThe headlight beam is adjustable both hori-

zontally and vertically. Headlight aim must becorrectly adjusted for safe riding as well as on-coming drivers. In most areas it is illegal to ridewith an improperly adjusted headlights.Horizontal Adjustment•Turn the horizontal adjuster in or out until thebeam points straight ahead.

A. Horizontal AdjusterB. Vertical Adjuster

Vertical Adjustment•Turn the vertical adjuster in or out to adjustthe headlight vertically.

NOTE○On high beam, the brightest point should beslightly below horizontal with the motorcycleon its wheels and the rider seated. Adjustthe headlight to the proper angle according tolocal regulation.

Digital MeterCheck the Mile/Km Display in the Dig-ital Meter:Mile/Km Display can alternate between U.S.

and metric modes (mile and km) in the digitalmeter. Make sure that km or mile is correctlydisplayed according to local regulations beforesale.

NOTE○Do not operate the vehicle with the digital me-ter displaying in the wrong unit (km or mile) ofthe digital meter. Shift the km/mile display inthe digital meter as follows.

•Turn the ignition key to “ON”.• The km/mile (or °C/°F temperature) displayshifts by pushing the RESET button is whilethe MODE button is pushed in.

26 PREPARATION

A. Km/Mile DisplayB. °C/°F Display

•The km/mile (and °C/°F temperature) displayshifts as follows.

A. Km and °C DisplayB. Mile and °F DisplayC. Mile and °C DisplayD. Km and °F DisplayE. Push RESET Button with MODE Buttonin

NOTE○The data is maintained even if the battery isdisconnected.

Change the Shift Up Indicator LightMode to “OFF”:The Shift-up indicator light can be used in

closed course competition. Do not use theshift-up indicator during everyday riding.The shift-up indicator light has three modes,

light off, light on (dim) and light on (bright).• Change the light mode to “OFF” in thetachometer.• Turn the ignition key to “ON”.• Push the MODE and RESET button simulta-neously for more than 2 seconds.• To change the shift-up indicator light mode,push the MODE button and the shift-up indi-cator light will shift between light on (bright),light on (dim), and off.

A. Shift Up Indicator Light

•To complete the adjustment, push the MODEbutton and RESET button simultaneously formore than two seconds.

PREPARATION 27

Dummy Page

28 PREPARATION

Fastener Check•The torque values listed are for assembly and preparation items only, see the appropriate ServiceManual for a more comprehensive list. Check tightness of all fasteners that are in the table beforeretail delivery. Also check to see that each cotter pin or circlip is in place.

PREPARATION 29

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

Frame/Steering1 Handlebar bolts 25 2.5 182 Steering stem head nut 78 8.0 58Brake3 Front caliper bleed valves 7.8 0.80 69 in·lb4 Front caliper mounting bolts 34 3.5 255 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S6 Front master cylinder bleed valve 5.9 0.60 52 in·lb7 Rear brake bleed valve 7.8 0.80 69 in·lb8 Rear caliper mounting bolts 25 2.5 189 Rear master cylinder mounting bolts 25 2.5 18Wheel10 Front axle clamp bolts 20 2.0 15 AL11 Front axle nut 127 13.0 94Suspension12 Front fork clamp bolts (Upper) 20 2.0 1513 Rear shock absorber mounting nut (Upper) 34 3.5 2514 Swingarm pivot adjusting collar locknut 98 10 7215 Swingarm pivot shaft nut 108 11 81Others16 Front footpeg bracket bolts 25 2.5 1817 Rear footpeg bracket bolts 25 2.5 18Engine18 Engine oil drain plug 29 3.0 22Cotter pin or Circlip19 Front footpeg pin circlip – – –20 Rear axle nut cotter pin – – –21 Rear footpeg pin circlip – – –22 Rear master cylinder cotter pin – – –

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.S: Tighten the upper clamp bolt first, and then the lower clamp bolt.

30 PREPARATION

Standard Torque TableThis table relating tightening torque to thread

diameter, lists the basic torque for bolts andnuts. Use this table for only the bolts and nutswhich do not require a specific torque value.All of the values are for use with dry solvent-cleaned threads.General Fasteners

TorqueThreadsdia.(mm) N·m kgf·m ft·lb

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.510 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 2512 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 4514 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 7216 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 11518 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 16520 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

Test Ride the Motorcycle•Complete the test ride checklist.Control Cables:Throttle control cables must work withoutbinding in any steering position.

Steering:Action is free from lock-to-lock.

Suspension:Check operation front and rear.

Engine:Electric starter works properly and enginestarts promptly. Good throttle response andreturn.

Transmission and Clutch:Smooth operation.

Brakes:Adequate, smooth stopping power, No drag.

Digital Meter:Check operation

Electrical System:Headlight - check high and low beams.Taillight - check operation.Brake Light - check operation.Turn Signal Lights - check operation.Horn - check operation.Instrument Lights and Indicator Lights -Check operation.

Engine Stop Switch Works:Starter Interlock Switch Works:No Unusual Noises:No Fuel, Oil, Brake Fluid, or CoolantLeaks:PREPARATION COMPLETE.

WARNINGNew tires are slippery and may causeloss of control and injury. A break-in pe-riod of 160 km (100 miles) is necessaryto establish normal tire traction.During break-in, avoid sudden andmaxi-mum braking and acceleration, and hardcornering.

A & P Check List•Complete the A & P Check List.

MODEL APPLICATIONYear Model Name2005 ZX636-C1 Ninja ZX-6R

Part No.99931-1447-01