Front suspension and handlebars of motorcycle Kawasaki ZX-6R/ZX-600-J (2000-2002)

Front suspension exploded view
L: Apply a non-permanent locking agent. R: Replacement Parts. T1:20 N·m (2.0 kg·m, 14 5 ft·lb) T2: 23 N·m (2.3 kg·m, 16.5 ft·lb) T3: 28 N·m (2.9 kg·m, 21 ft·lb) T4: 39 N·m (4.0 kg·m, 29 ft·lb)

Suspension specifications
ItemStandard Front Fork (per one unit): Fork inner tube diameter∅46 mm Air PressureAtmospheric pressure (Non-adjustable) Rebound damper setting7th click from the first click of the fully clockwise position (Usable Range: 1→12 clicks) Compression...

Rebound damping force — adjustment
To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 7th click from the 1st click...

Compression damping force — adjustment
To adjust the compression damping force, turn the compression damping adjuster [A] until you feel a click. The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 9th click from the 1st...

Spring preload — adjustment
Turn the spring preload adjuster [A] to change spring preload setting. The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 14 mm [B] from top as shown. Adjuster protrusion (from...

Front fork (each fork leg) — removal and installation
Removal Remove: Lower and Upper Fairings (see Frame chapter) Front Wheel (see Wheels/Tires chapter) Front Fender (see Frame chapter) ★ Loosen the handlebar holder bolt [A], upper fork clamp bolt [B] and fork top plug [C] before hand if the fork leg...

Fork oil change
Remove the front fork (see Front Fork Removal). Turn the spring preload adjuster [A] counterclockwise until the fully position. Unscrew the top plug [B] out of the inner tube. Holding the piston rod nut [A] with a wrench [B], remove the fork top...

Front fork — disassembly
γRemove the front fork (see Front Fork Removal). Drain the fork oil (see Fork Oil Change). Hold the front fork in a vise [A]. Stop the cylinder [B] from turning by using the fork cylinder holder [C]. Special Tool - Fork Cylinder Holder:...

Front fork — assembly
Replace the following parts with new one. Oil Seal Guide Bushings Install the following parts onto the inner tube. Outer Tube Guide Bushing Inner Tube Guide Bushing Insert the cylinder unit [A] into the inner tube [B]. Install the cylinder base [C]...

Front fork inner tube — inspection
Visually inspect the inner tube, and repair any damage. Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. ★ If the damage is not repairable, replace the inner tube....

Front fork dust seal — inspection
Inspect the dust seals [A] for any signs of deterioration or damage. ★ Replace it if necessary.

Front fork spring tension
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. ★ If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the...

Steering exploded view
AD: Apply adhesive. G: Apply grease. L: Apply a non-permanent locking agent. T1: 3.4 N·m (0.35 kg·m, 30 in·lb) T2: 15 N·m (1.5 kg·m, 11 ft·lb) T3: 9.8 N·m (1.0 kg·m, 87 in·lb) T4: 20 N·m (2.0 kg·m, 14.5 ft·lb) T5: 23 N·m (2.3 kg·m, 16.5 ft·lb) T6:...

Steering system — inspection
Check the steering. Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from...

Steering system — adjustment
Remove: Upper fairing (see Frame chapter) Fuel Tank (see Fuel System chapter) Rear View Mirror Bracket Loosen: Lower Fork Clamp Bolts (both sides) Stem Head Nut [A] Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001-1100 [B] ★ If...

Steering stem, stem bearing — removal
Remove: Fairings (see Frame chapter) Fuel Tank (see Fuel System chapter) Rear View Mirror Bracket Brake Hose Joint Bolt [A] and Bracket Bolt [A] Front Wheel (see Wheels/Tires chapter) Front Fork (see Suspension chapter) Steering Stem Head Nut and...

Steering stem, stem bearing — installation
Apply grease to the outer races, and drive them into the head pipe at the same time. Special tools: Head Pipe Outer Race Press Shaft: 57001-1075 [A] Head Pipe Outer Race Drivers: 57001-1446 [B] Head Pipe Outer Race Driver: 57001-1447 [C] Install the...

Stem bearing — lubrication
Remove the steering stem. Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. Visually check the...

Handlebar — removal and installation
Removal Remove: Screws [A] and Wind Sealed [B] Remove: Clutch Lever Assembly Left Handlebar Switch Housing Front Brake Master Cylinder Right Handlebar Switch Housing Throttle Case and Grip Remove the handlebar bolts [A], and then pull out the...

Handlebar holder — removal and installation
Removal Raise the front wheel off the ground. Loosen the handlebar holder bolts [A] and upper fork clamp bolts [B]. Remove stem head nut [C] and steering stem head [D]. Remove handlebar holder position bolts [A] and handlebar holders [B]....