Electrical equipment and instruments of motorcycle Kawasaki ZX-6R/ZX-600-J (2000-2002)

Electrical system exploded view
1. Pickup Coil. 2. IC Igniter. 3. Stick Coils. SS: Apply silicone sealant. L: Apply a non-permanent locking agent. T1: 5.9 N·m (0.60 kg·m, 52 in·lb) T2: 11 N·m (1.1 kg·m, 95 in·lb) T3: 13 N·m (1.3 kg·m, 113 ft·lb) T4: 40 N·m (4.0 kg·m, 29 ft·lb) 1....

Electrical system specifications
Battery: Type — MF (Maintenance Free) Battery Capacity — 12 V 8 Ah Voltage — 12.8 V or more Charging system: Type — Three-phase AC Alternator output voltage — 53.5-72.5 V Stator coil resistance — 0.3-0.4 Ω Charging voltage (regulator/rectifier...

Electrical parts location
1. Starter Lockout Switch; 2. Water Temperature Sensor; 3. Stick Coils; 4. Battery; 5. Junction Box; 6. IC Igniter; 7. Fuel Pump Relay; 8. Radiator Fan Switch; 9. Alternator; 10. Starter Motor; 11. Neutral Switch; 12. Side Stand Switch; 13. Speed...

Electrical system precautions
There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. Always check...

Wiring inspection
Visually inspect the wiring for signs of burning, fraying, etc. ★ If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. ★ If the connector is corroded or dirty, clean it...

Headlight beam — horizontal adjustment
The US, Canada, Australia, and Malaysia models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The...

Headlight beam — vertical adjustment
Turn the vertical adjusters [B] on the headlight in or out to adjust the headlight vertically. Note. On high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the...

Headlight bulb — replacement
Remove: Headlight Connector Headlight Bulb Dust Cover Hook [A] Headlight Bulb [B] Caution! When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can...

Turn signal relay — inspection
Remove: Seats (see Frame chapter ) Turn Signal Relay [A] Connect one 12 V battery and turn signal lights as indicated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery...

Fuel pump — removal and installation
The fuel pump [A] operates when the starter button is pushed on or the engine is running. When the fuel level in the float chamber is low, the fuel pump operates to supply the fuel into the float chamber. When the fuel reaches a certain level, the...

Fuel pump relay — inspection
Remove the seats (see Frame chapter ). Take off the fuel pump relay [А]. Set the hand tester to the x 1 kΩ range and make the measurements shown in the table. Special Tool - Hand Tester: 57001-1394 ★ If the tester readings are not as specified,...

Fuel pump — operational inspection
Remove the fuel pump with the fuel filter (see Fuel System chapter ). Prepare a container filled with kerosene. Prepare the rubber hoses, and connect them to the pump fittings. Connect a suitable pressure gauge to the outlet hose as shown. Fuel Pump...

Fuel cut valve — removal and installation
The fuel cut valves [A] are adopted for protection of the catalytic converter. Removal Warning! Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is...

Fuel cut valve — inspection
Remove the fuel cut valve [А]. Connect and disconnect one 12 V battery [B] to the fuel cut valve connector as shown. The valve rod moves. If the protrusion exceeds the standard (too long or too short), the valve is defective and must be replaced....

Radiator fan system circuit — inspection
Disconnect the leads from the radiator fan switch [А]. Using an auxiliary wire [B], connect the radiator fan switch leads. ★ If the fan rotates, inspect the fan switch. ★ If the fan does not rotate, inspect the following. Leads and Connectors Main...

Radiator fan motor — inspection
Remove the left lower fairing (see Frame chapter ). Disconnect the 2-pin connector [A] in the fan motor leads. Using two auxiliary wires, supply battery [B] power to the fan motor. If the fan does not rotate, the fan motor is defective and must be...

Meter unit — removal
Remove: Wind Sealed Remove the meter unit by taking off the mounting nuts [A] with the washers. Slide the dust cover [B] and remove the wiring connector. Caution! Place the meter or gauge so that the face is up. If a meter or gauge is left upside...

Meter unit — disassembly
Remove: Meter Unit (see Meters, Gauge Removal ) Screws [A] Lower Meter Cover [B] Separate the meter assembly [A] and upper meter cover [В].

Meter unit — bulb replacement
Remove: Meter Unit. Turn out the socket [A] counterclockwise. Pull the bulb out off the socket. Caution! Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified value.

Electronic combination meter unit — inspection
Remove the meter unit. Caution! Do not drop the meter unit. Place the meter unit so that it faces upward. If the meter unit is left upside down or sideways for a long time or dropped, it will malfunction. Using the auxiliary wires, connect the 12V...

Speed sensor — inspection
Remove: Speed Sensor. Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394 Trace [A] each side of the speed sensor...

Brake light timing — inspection
Turn on the ignition switch. Check the operation of the rear brake light switch by depressing the brake pedal. ★ If it does not as specified, adjust the brake light timing. Brake light timing. Standard: On after about 10 mm of pedal travel [A]

Brake light timing — adjustment
Brake light timing is adjusted by changing the position of the rear brake light switch. Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the adjusting nut [А]. Caution! To avoid damaging...

Fladiator fan switch — inspection
Remove the fan switch (see Cooling System chapter ). Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. Suspend an accurate thermometer [B] in the coolant. Note. The switch...

Water temperature sensor — inspection
Remove the water temperature sensor (see Cooling System chapter ). Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. Suspend an accurate thermometer [B] in the coolant....

Throttle sensor — removal and installation
Caution! Do not remove the throttle sensor [А]. When replacing the sensor, refer to Throttle Sensor Position Adjustment.

Throttle sensor — inspection
Remove the fuel tank (see Fuel System chapter ). Prepare an auxiliary fuel tank and connect the fuel hose to the carburetors. Start the engine and warm it up thoroughly. Check: Idle Speed (see Fuel System chapter ) Battery Charging Condition ( see...

Throttle sensor position — adjustment
Start the engine. Check idle speed (see Fuel System chapter ). Stop the engine and remove the carburetor. Caution! Do not turn the idle adjusting screw when removing the carburetor. Connect the throttle sensor setting adapter to the sensor lead...

Junction box fuse circuit — inspection
The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Remove the seats (see Frame chapter ). Remove the junction box. Pull off the connectors from the junction box. Make sure all connector terminals are...

Junction box starter circuit/headlight relay — inspection
Remove the junction box. Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown. ★ If the tester does not read as specified, replace the junction box. Relay circuit...

Junction box diode circuit — inspection
Remove the junction box. Check conductivity of the following pairs of terminals. Diode circuit inspection: Tester Connection *13-8, *13-9, 12-11, 12-14, 15-14, 16-14 *: U.S.A., Canada, Australia, and Malaysia Models only. ★ The resistance should be...

30A main fuse — removal
Remove: Seats (see Frame chapter ) Starter Relay and 30A Main Fuse Connector [A] Pull out the main fuse [B] from the starter relay with needle nose pliers. Installation If a fuse fails during operation, inspect the electrical system to determine the...

Junction box fuse — removal
Remove the seats (see Frame chapter ). Unlock the hook to lift up the lid [А]. Pull the fuses [B] straight out of the junction box with needle nose pliers. C: Headlight Fuse Installation If a fuse fails during operation, inspect the electrical...

Fuse inspection
Remove the fuse (see Fuse Removal ). Inspect the fuse element. ★ If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating,...