Elements of transmission motorcycle Kawasaki ZX-6R/ZX-600-J (2000-2002)

Clutch exploded view
CL: Apply cable lubricant. G: Apply grease. EO: Apply engine oil. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts W: Apply water. T1: 5.9 N·m (0.60 kg·m, 52 in·lb) T2: 8.8 N·m (0.90 kg·m, 78 in·lb)...

Clutch specifications
ItemStandardService Limit Clutch Lever Position5-way adjustable (to suit rider)— Clutch Lever Free Play2-3 mm— Clutch: Friction plate thickness2.72-2.88 mm2.2 mm Friction and steel plate warp0.2 mm or less0.3 mm Clutch spring free length82.1 mm78.0...

Clutch lever free play — inspection
Pull the clutch lever just enough to take up the free play [A]. Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either...

Clutch lever free play — adjustment
Warning! To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. Turn the adjuster [A] so that 5-6 mm [B] of threads are visible. Slide the dust cover [A] at the clutch cable lower end out of place. Loosen both...

Clutch cable — removal and installation
Removal Remove the right lower fairing (see Frame chapter). Slide the dust cover at the clutch cable lower end out of place. Loosen the nuts, and slide the lower end of the clutch cable to give the cable plenty of play. Screw in the adjuster. Line...

Clutch lever — installation
Install the clutch lever so that the mating surface [A] of the switch housing is aligned with the mating surface [B] of the clutch lever clamp.

Clutch cover — removal and installation
Removal Remove: Engine Oil (drain, see Engine Lubrication System chapter) Right Lower Fairing (see Frame chapter) Oil Hose Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B] Turn the release lever [A] toward the rear as shown, and remove the...

Clutch release shaft — removal and installation
Removal Caution! Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. Remove the clutch cover (see Clutch Cover Removal). Pull the lever and shaft assembly...

Clutch — removal
Remove: Engine Oil (drain, see Engine Lubrication System chapter) Right Lower Fairing (see Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C],...

Clutch — installation
Inspect the clutch plate assembly length (see Clutch Plate Assembly Inspection). Install the following parts on the drive shaft. [A] Spacer [B] Sleeve [C] Needle Bearing [D] Clutch Housing [E] Spacer [F] Clutch Hub [G] Washer [H] Nut Install the...

Clutch plate assembly — inspection
Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). Measure the length [A] of the clutch plate assembly as shown. Assemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plate [E] Steel Pile [F] Spring Plate [G]...

Clutch plate assembly — adjustment
Inspect the clutch plate assembly length, and then replace the steel plate(s) which brings the length within the specified range. Remove: Spring Bolts Spring Holders Springs Spring Plate Replace the following steel plate(s) Part No.Thickness...

Clutch plate, wear, damage — inspection
Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of the friction plate [A] at several points. ★ If any plates show signs of damage, or if they have worn past the...

Clutch plate warp — inspection
Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. ★ If any...

Clutch spring free length — measurement
Measure the free length of the clutch springs [A]. ★ If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 82.1 mm Service Limit: 78.0 mm

Shift pedal — removal and installation
Removal Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. Remove the shift lever and shift pedal. Installation Install the shift pedal [A] so that the distance between the center of the...

External shift mechanism — removal and installation
Removal Remove: Engine Oil (drain, see Engine Lubrication System chapter) Shift Pedal (see Shift Pedal Removal) Clutch (see Clutch chapter) Bolts [A], Oil Pipe Holders [B], Oil Pipe [C] and O-ring Remove: Shift Shaft [A] Bolt [B] Gear Positioning...

External shift mechanism — inspection
Examine the shift shaft [A] for any damage. ★ If the shaft is bent, straighten or replace it. ★ If the serration are damaged, replace the shaft. ★ If the springs [B] [C] are damaged in any way, replace them. ★ If the shift mechanism arm [D] is...

Transmission shaft — removal and installation
Removal Split the crankcase (see Crankcase Splitting). Remove the drive shaft [A] and output shaft [B]. Installation Check to see that the set pins [A] and set rings [B] are in place. Install the drive shaft and output shaft into the upper crankcase...

Transmission — disassembly and assembly
Disassembly Remove the transmission shafts (see Transmission Shaft Removal). Remove the circlips, disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 The 5th gear [A] on the output shaft has three steel balls...

Shift drum and fork — removal and installation
Removal Remove: Clutch (see Clutch chapter) Oil Pan (see Engine Lubrication System chapter) External Shift Mechanism (see External Shift Mechanism Removal) Gear Positioning Lever Bolt [A] and Screw [B] Shift Drum Bearing Holder [C] Pull out the...

Shift drum — disassembly and assembly
Disassembly Remove the shift drum (see Shift Drum and Fork Removal). While holding the shift drum with a vise, remove the shift drum cam holder bolt. [A] Shift Drum Cam Holder Bolt [B] Dowel Pin Assembly Be sure to install the dowel pin. Apply a...

Shift fork bending
Visually inspect the shift forks, and replace any fork, that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A]

Shift fork/gear groove wear
Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear grooves. ★ If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift fork ear thickness Standard: 5.9-6.0 mm...

Shift fork guide pin/drum groove wear
Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. ★ If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift fork guide pin diameter Standard:...

Gear dog and gear dog hole damage
Visually inspect the gear dogs [A] and gear dog holes [B]. ★ Replace any damaged gears or gears with excessively worn dogs or dog holes.

Transmission exploded view
1. 1st Gear; 2. 2nd Gear; 3. 3rd Gear; 4. 4th Gear; 5. 5th Gear; 6. 6th (Top) Gear; 7. Toothed Washer; 8. Thrust Washer (Thin); 9. Circlip; 10. Circlip; 11. Toothed Washer; 12. Thrust Washer; 13. Circlip; 14. Needle Bearing; 15. Bearing Outer Race;...

Final drive exploded view
G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. O: Apply oil. R: Replacement Parts T1: 6.9 N·m (0.7 kg·m, 61 in·lb) T2: 11 N·m (1.1 kg·m. 95 in·lb) T3: 59 N·m (6.0 kg·m, 43 ft·lb) T4: 125 N·m (13.0 kg·m, 92 ft·lb)

Final drive specifications
ItemStandardService Limit Drive Chain: Chain slack35-40 mm(Usable range)35-45 mm 20-link length317.5-318.2 mm323 mm Standard chain - MakeENUMA— - TypeEK525MVXL, Endless— - Link108 links— Sprockets: Rear sprocket warp0.4 mm or less0.5 mm Special...

Drive chain slack inspection
Note. Check the slack with the motorcycle setting on its side stand. Clean the chain if it is dirty, and lubricate it if it appears dry. Check the wheel alignment (see Wheel Alignment Inspection). Rotate the rear wheel to find the position where the...

Drive chain slack adjustment
Remove the cotter pin [A], and loosen the axle nut [B]. Loosen the both chain adjuster locknuts [C]. ★ If the chain is too loose, turn out the left and right chain adjuster [D] evenly. ★ If the chain is too tight, turn in the left and right chain...

Wheel alignment inspection adjustment
Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. ★ If they are not, adjust the chain slack and align the wheel alignment (see Slack...

Drive chain wear inspection
Remove. Chain cover Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. ★ If there is any irregularity, replace the drive chain. ★ Lubricate the drive chain if it appears dry. Stretch the chain taut by...

Drive chain wear lubrication
If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. Caution!...

Drive chain — removal and installation
Removal Remove: Chain Cover Screws [A] Chain Cover [B] Rear Wheel (see Wheels/Tires chapter) Swingarm (see Suspension chapter) Engine Sprocket Cover (see this chapter) Disengage the drive chain [A] from the engine sprocket [B], and take it off the...

Engine sprocket — removal and installation
Removal Remove: Speed Sensor Bolt [A] Speed Sensor [B] Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. Note. When loosening the engine sprocket nut, hold the...

Rear sprocket — removal and installation
Removal Remove the rear wheel (see Wheel/Tires chapter). Caution! Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Remove the...

Sprocket wear inspection
Visually inspect the engine and rear sprocket teeth for wear and damage. ★ If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection). [A] Worn Tooth (Engine Sprocket) [B] Worn...

Rear sprocket warp inspection
Raise the rear wheel off the ground (see Wheels/Tires chapter) so that it will turn freely. Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The...

Coupling bearing — removal and installation
Removal Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 [B] Remove the bearing by tapping from the wheel side. Special Tool - Bearing Driver Set: 57001-1129 [A] Installation Replace the bearing with a new...

Coupling bearing inspection and lubrication
Note. It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one. Wash the bearing with a high flash-point solvent, dry it (do not spin it while it is...