Engine fuel supply system of motorcycle Kawasaki ZX-6R/ZX-600-J (2000-2002)

Fuel system exploded view
1. Air Cleaner Housing; 2. Air Cleaner Element; 3. Air Vent Filter; 4. Vacuum Switch Valve; 5. Silencer Ass’y (CA Model); 6. Vacuum Hose Ass’y (CA Model); 7. Carburetor Vent Hose (CA Model); AO: Apply high-quality-form-air-filter oil; CA: California...

Fuel system specifications
Throttle Grip and Cables: Throttle grip free play — 2-3 mm Choke Cable: Free Play — 2-3 mm Carburetors: Make, type — MIKUNI, BDSR-36 x 4 Main jet — #1, 4: #155, #2, 3: #157.5 Main air jet — #45 Jet needle — 5E110-54-1, (Other than US, CN) #1,4;...

Throttle grip and cables
Free play inspection Check the throttle grip free play [А]. ★ If the free play is incorrect, adjust the throttle cable. Throttle grip free play standard — 2-3 mm Check that the throttle grip moves smoothly from full open to close, and the throttle...

Choke cable — inspection, adjustment and installation
Free play inspection Push the choke lever [A] all the way to the front. Check choke cable free play [В]. О Determine the amount of choke cable play at the choke lever. Pull the choke lever until the starter plunger lever [C] at the carburetor...

Air cleaner element — removal and installation
Removal Remove: Seats (see Frame chapter ) Fuel Tank (see Fuel Tank Removal ) Upper Housing Mounting Bolts [A] Upper Housing [B] Remove the following parts as a unit. Upper Plastic Holder [A] Element [B] Lower Plastic Holder [C] Put a clean,...

Air cleaner element — cleaning and inspection
Warning! Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the...

Air cleaner housing — removal
Remove: Seats (see Frame chapter ) Fuel Tank (see Fuel Tank Removal ) Engine Breather Hose [A] Rubber Plugs [B] Fuel Cut Valve Connectors [C] (California and H Models) Remove: Air Cleaner Housing Mounting Bolts [A] Free the main harness from the...

Air cleaner housing — installation
Insert the housing into the air ducts [A] securely, and fit the projection [B] of the housing in the recess of the air ducts. Tighten: Housing Mounting Bolts Be sure to fit the engine breather hose. Install the rubber plugs in place.

Air vent filter — cleaning
Slide the clamps of air vent filter and remove the filter. Clean the filter by directing a stream of compressed air from clean side [A] to dirty side [В].

Fuel tank — removal and installation
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 well-ventilated and free from any source of flame or sparks: this includes any...

Fuel tank — inspection
Remove the hose(s) from the fuel tank, and open the tank cap. Check to see if the water drain pipe [B] (also the breather pipe [C] for the California model) in the tank is not clogged. Check the tank cap breather also. ★ If they are clogged, remove...

Fuel tank — cleaning
Warning! Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash- point solvents to clean the tank....

Fuel tap — removal and installation
Removal Remove the Fuel Tap Position Lever (see Fuel Tank Removal ). Remove the fuel tank and drain it. Remove: Bolts [A] Nylon Flat Washers [B] Fuel Tap [C] Installation Be sure the О-rings [A] is in good condition to prevent leaks. Be sure the...

Fuel tap — inspection
Remove the fuel tap. Check the fuel tap filter screens [A] for any breaks or deterioration. If the fuel tap screens have any breaks or are deteriorated, they may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap. ★ If...

Fuel pump and fuel filter — 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 well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

Fuel pump and fuel filter — installation
Install the fuel filter so that the arrow [A] on it shows the fuel flow from the fuel tank to the fuel pump. Connect the fuel hose [C] from the fuel filter to the pump fitting marked «INLET’ [В]. Be sure to route the hoses so that they will not be...

Fuel pump and fuel filter — inspection
Fuel pump inspection Refer to Electrical System chapter. Fuel filter inspection Remove: Seats (see Frame chapter ) Fuel Tank (see Fuel Tank Removal ) Band Visually inspect the fuel filter. ★ If the filter is clear with no signs of dirt or other...

Evaporative emission control system (California model only)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at...