Engine start and battery charging system of motorcycle Kawasaki ZX600-J1 3 (ZX-6R, 2000-2002)
See this section in russian language
Battery — removal
Remove: Seats (see Frame Chapter ) Front Seat Bracket [A] (Battery Holder) Disconnect the negative terminal lead [B] and then positive terminal lead [С]. Caution! Be sure to disconnect the negative terminal lead first. Remove the battery.
Remove: Seats (see Frame Chapter ) Front Seat Bracket [A] (Battery Holder) Disconnect the negative terminal lead [B] and then positive terminal lead [С]. Caution! Be sure to disconnect the negative terminal lead first. Remove the battery.
Battery — electrolyte filling
Caution! Do not remove the aluminum seal sheet sealing the filler ports until just before use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Check to see that there is no peeling, tears or holes in the sealing...
Caution! Do not remove the aluminum seal sheet sealing the filler ports until just before use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Check to see that there is no peeling, tears or holes in the sealing...
Battery — initial charge
While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge Is required before use...
While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge Is required before use...
Battery — charging condition inspection
Battery charging condition can be checked by measuring battery terminal voltage. Remove the seats (see Frame chapter ). Disconnect the battery terminal leads. Caution! Be sure to disconnect the negative terminal lead first. Measure the battery...
Battery charging condition can be checked by measuring battery terminal voltage. Remove the seats (see Frame chapter ). Disconnect the battery terminal leads. Caution! Be sure to disconnect the negative terminal lead first. Measure the battery...
Battery — refreshing charge
Disconnect the battery terminal leads (see Charging Condition Inspection ). Remove the battery [А]. Refresh-charge by following method according to the battery terminal voltage. Warning! This battery is sealed type. Never remove sealing caps [B]...
Disconnect the battery terminal leads (see Charging Condition Inspection ). Remove the battery [А]. Refresh-charge by following method according to the battery terminal voltage. Warning! This battery is sealed type. Never remove sealing caps [B]...
Alternator cover — removal and installation
Removal Remove: Left Lower Fairing (see Frame chapter ) Coolant Reserve Tank [A] Fuel Tank (see Fuel System chapter ) Alternator Lead Connector [B] Place a suitable container under the alternator cover [C], and remove the cover. Installation Apply...
Removal Remove: Left Lower Fairing (see Frame chapter ) Coolant Reserve Tank [A] Fuel Tank (see Fuel System chapter ) Alternator Lead Connector [B] Place a suitable container under the alternator cover [C], and remove the cover. Installation Apply...
Stator coil — removal and installation
Removal Remove: Alternator Cover (see Alternator Cover Removal ) Holding Plate Bolts [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] Remove the stator coil [D] from the alternator cover. Installation Apply a non-permanent locking...
Removal Remove: Alternator Cover (see Alternator Cover Removal ) Holding Plate Bolts [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] Remove the stator coil [D] from the alternator cover. Installation Apply a non-permanent locking...
Alternator rotor — removal and installation
Removal Remove: Alternator Cover (see Alternator Cover Removal ) Starter Idle Gear and Shaft Wipe oil off the outer circumference of the rotor. Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [В]. Special...
Removal Remove: Alternator Cover (see Alternator Cover Removal ) Starter Idle Gear and Shaft Wipe oil off the outer circumference of the rotor. Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [В]. Special...
Alternator — inspection
There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused...
There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused...
Regulator/rectifier — inspection
Remove: Seat Cover (see Frame chapter ) Fuel Tank (see Fuel System chapter ) Connectors [A] (disconnect) Clamp [B] Bolts [A] Regulator/Rectifier [B] Rectifier circuit check: Check conductivity of the following pair of terminals. Rectifier circuit...
Remove: Seat Cover (see Frame chapter ) Fuel Tank (see Fuel System chapter ) Connectors [A] (disconnect) Clamp [B] Bolts [A] Regulator/Rectifier [B] Rectifier circuit check: Check conductivity of the following pair of terminals. Rectifier circuit...
Flegulator/flectifier output voltage — inspection
Check the battery condition (see Battery section ). Warm up the engine to obtain actual alternator operating conditions. Remove the seats (see Frame chapter ). Check that the ignition switch is turned off, and connect the hand tester [A] to the...
Check the battery condition (see Battery section ). Warm up the engine to obtain actual alternator operating conditions. Remove the seats (see Frame chapter ). Check that the ignition switch is turned off, and connect the hand tester [A] to the...
Starter motor — removal and installation
Removal Remove the fuel tank (see Fuel System chapter ). Slide back the rubber cap. Remove the starter motor terminal nut [A] and the mounting bolts [В]. Pull out the starter motor [С]. Installation Caution! Do not tap the starter motor shaft or...
Removal Remove the fuel tank (see Fuel System chapter ). Slide back the rubber cap. Remove the starter motor terminal nut [A] and the mounting bolts [В]. Pull out the starter motor [С]. Installation Caution! Do not tap the starter motor shaft or...
Starter motor — disassembly
Take off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [С]. Remove: Brush Springs Brush Holder Plate Screw [A] Negative Brushes [B] Brush Holder Plate [C] Unsolder the terminal [A] on the...
Take off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [С]. Remove: Brush Springs Brush Holder Plate Screw [A] Negative Brushes [B] Brush Holder Plate [C] Unsolder the terminal [A] on the...
Starter motor — assembly
Apply a thin coat of grease to the oil seal [А]. Fit the toothed washer [B] into the left-hand end cover. Install the positive brush plate [A] in the right-hand end cover [B] and solder the terminals [С]. Press the springs and holding the brush...
Apply a thin coat of grease to the oil seal [А]. Fit the toothed washer [B] into the left-hand end cover. Install the positive brush plate [A] in the right-hand end cover [B] and solder the terminals [С]. Press the springs and holding the brush...
Starter motor brush — inspection
Measure the length [A] of each brush. ★ If any is worn down to the service limit, replace the carbon brushes. Starter motor brush length: Standard: 7 mm Service Limit: 3.5 mm
Measure the length [A] of each brush. ★ If any is worn down to the service limit, replace the carbon brushes. Starter motor brush length: Standard: 7 mm Service Limit: 3.5 mm
Commutator — cleaning and inspection
Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. Measure the diameter [A] of the commutator [В]. ★ If the commutator diameter is less than the service limit, replace the starter motor with a new...
Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. Measure the diameter [A] of the commutator [В]. ★ If the commutator diameter is less than the service limit, replace the starter motor with a new...
Starter motor armature — inspection
Using the x 1 Ω hand tester range, measure the resistance between any two commutator segments [А]. ★ If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. Using the...
Using the x 1 Ω hand tester range, measure the resistance between any two commutator segments [А]. ★ If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. Using the...
Starter brush lead — inspection
Using the x 1 Ω hand tester range, measure the resistance as shown. [A] Terminal Bolt and Positive Brush [B] Right-hand End Cover and Negative Brush ★ If there is not close to zero ohms, the brush lead has an open. Replace the positive brush...
Using the x 1 Ω hand tester range, measure the resistance as shown. [A] Terminal Bolt and Positive Brush [B] Right-hand End Cover and Negative Brush ★ If there is not close to zero ohms, the brush lead has an open. Replace the positive brush...
Starter right-hand end cover assembly — inspection
Using the highest hand tester range, measure the resistance as shown. [A] Terminal and Right-hand End Cover ★ If there is any reading, the right-hand end cover assembly have a short. Replace the right-hand end cover assembly.
Using the highest hand tester range, measure the resistance as shown. [A] Terminal and Right-hand End Cover ★ If there is any reading, the right-hand end cover assembly have a short. Replace the right-hand end cover assembly.
Starter relay — inspection
Remove the seats. Remove the starter relay. Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. ★ If the relay does not work as specified, the relay is defective. Replace the relay. Testing relay Tester Range: x 1 Ω...
Remove the seats. Remove the starter relay. Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. ★ If the relay does not work as specified, the relay is defective. Replace the relay. Testing relay Tester Range: x 1 Ω...
Starter motor clutch — removal and installation
Removal Remove: Alternator Rotor (see Alternator Rotor Removal ) Starter Motor Clutch Bolts [A] and starter Motor Clutch [B] Installation Apply a non-permanent locking agent to the threads of the starter motor clutch bolts and tighten them. Torque -...
Removal Remove: Alternator Rotor (see Alternator Rotor Removal ) Starter Motor Clutch Bolts [A] and starter Motor Clutch [B] Installation Apply a non-permanent locking agent to the threads of the starter motor clutch bolts and tighten them. Torque -...
Starter motor clutch — inspection
Remove: Alternator Cover (see Electrical System chapter ) Starter Idle Gear Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [С]. ★ If the clutch...
Remove: Alternator Cover (see Electrical System chapter ) Starter Idle Gear Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [С]. ★ If the clutch...
- Information for owner
- Introduction to manual
- Troubleshooting
- Engine and systems
- Engine repair
- Fuel system
- Carburetor repair
- Cooling system
- Lube system
- Transmission
- Running gear and frame
- Frame and hinged elements
- Wheels and tires
- Brake system
- Front suspension and handlebar
- Rear suspension
- Electric equipment
- Equipment and devices
- Starting and charging system
- Ignition system
- Electrical circuits
Aprilia: RS-series Shiver (map) BMW: F-series R-series K-series (map) Ducati: ST series Monster (map) Harley: Street Sportster V-Rod (map) Honda: Africa Twin CB series VTX series (map) Kawasaki: ZX-6R Versys Vulcan (map) Suzuki: DR-Z V-Strom Boulevard (map) Triumph: Rocket Street Triple Tiger (map) Yamaha: Fazer DragStar R1 (map)