KAWASAKI ZZR600 MANUAL PDF

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Additionally, Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

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No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously.

See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Additionally, Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system.

Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere.

Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. Tampering could include: a. Maladjustment of vehicle components such that the emission standards are exceeded.

Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.

Addition of components or accessories that result in the vehicle exceeding the standards. Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler s or any internal portion of the muffler s. Removal of the air box or air box cover.

Modifications to the muffler s or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual.

Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts.

Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual.

Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Remember to keep complete records of maintenance and repair with dates and any new parts installed.

Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the ignition coil section.

Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. It also precedes the text of a NOTE.

Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. Model Identification General Specifications Torque and Locking Agent Special Tools and Sealant Cable, Wire, and Hose Routing To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: 1 Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the leads from electrical parts, as well as damage to the electrical parts themselves.

However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location.

Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern.

Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem.

Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws particularly for the removing screws held by non-permanent locking agent in order to avoid damaging the screw heads.

Use a clean piece of thick cloth when lifting the engine or turning it over. A commercial solvent commonly available in North America is standard solvent generic name. Always follow manufacturer and container directions regarding the use of any solvent. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.

Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver.

Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise.

Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned.

Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended.

Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well.

Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts.

A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to leads of the same color. If there is any doubt as to the condition of them, replace them with new ones.

If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

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