Kawasaki ZX6 Ninja 1990-2004 Clymer Motorcycle Repair Manual

Description

This ZX-6 Ninja repair manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1990-1993 ZX6 Kawasaki Ninja ZX600 D1-D4 and 1993-2004 ZX6 Kawasaki Ninja ZX600 E1-E5 US, Canada and UK motorcycles.

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

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 620 illustrated pages.

QUICK REFERENCE DATA

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

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, Tires and wheels, Battery, Periodic lubrication/ Periodic maintenance, Unscheduled maintenance, Engine tune-up, Engine top end, Engine principles, Cylinder head cover, Camshaft, Camshaft chain tensioner, Cylinder head, Valves and valve components, Cylinder block, Piston and piston rings

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

CHAPTER FIVE, ENGINE LOWER END
Servicing engine in frame, Engine, Oil pump, Oil pan, oil pipe and strainer, Oil pressure relief valves, 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

CHAPTER SIX, CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover, Clutch cable replacement, Clutch, Clutch release mechanism, External gearshift mechanism

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

CHAPTER EIGHT, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor operation, Carburetor assembly, Carburetor separation, Fuel level, Float height, Throttle cables replacement, Choke cable replacement, Air filter air box, Fuel tank, Fuel shutoff valve, Fuel pump (1993-on E models), Clean air system (U.S. and Swiss models), Crankcase breather system (U.S. only), Evaporative emission control system (California only), Exhaust system

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, Horn, Fuel pump and relay (1993-on E models), Thermostatic fan switch, Low fuel level warning system (1990-1993 D models), Fuel level system (1993-on E models), Junction box and fuses, Wiring and connectors, Wiring diagrams

CHAPTER TEN, COOLING SYSTEM
Hoses and hose clamps, Cooling system inspection, Coolant reservoir tank, Radiator and radiator fan, Cooling fan, Thermostat, Water pump, Thermostatic fan switch and water temperature sensor

CHAPTER ELEVEN, FRONT SUSPENSION AND STEERING
Front wheel, Front hub, Wheels, Tubeless tire changing, Tire repairs, Handlebar, Handlebar left-hand grip replacement, Steering stem and head, Steering head bearing race replacement, Steering stem bearing replacement, Front forks, Fork service

CHAPTER TWELVE, REAR SUSPENSION
Rear wheel, Rear hub, Rear coupling and driven sprocket, Drive chain, Tire changing and tire repairs, Shock absorber, Swing arm and shock linkage, Suspension linkage

CHAPTER THIRTEEN, BRAKES
Disc brakes, Front brake pad replacement, Front caliper, Front master cylinder, Rear brake pad replacement, Rear caliper (1990-1993 D models), Rear caliper (1993-on E models), Rear master cylinder, Brake hose replacement, Brake disc, Bleeding the system, Rear brake pedal and arm

CHAPTER FOURTEEN, BODY AND FRAME
Seat, Front fender, Frame side covers and grabrail, Front fairing (1990-1993 D models), Front fairing (1993-on E models), Centerstand, Sidestand, Footpegs

INDEX

WIRING DIAGRAMS