Introduction to repair manual motorcycle Kawasaki ZX600-J1 3 (ZX-6R, 2000-2002)

List of abbreviations
A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton (s) BBDC before bottom dead center Pa pascal (s) BDC bottom dead center PS horsepower BTDC before top dead...

Before servicing of motorcycle
Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary....

Model identification
ZX600-J1 Left Side View: ZX600-J1 Right Side View:

General specifications
Dimensions Overall length — 2030 mm, (PN) 2060 mm Overall width — 730 mm Overall height — 1175 mm Wheelbase — 1400 mm Road clearance — 145 mm Seat height — 820 mm Dry mass — 171 kg, (CA) 173 kg. (H) 172 kg Curb mass: Front — 100 kg Rear — 96 kg,...

Periodic maintenance chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Operation Every 1000 km (600 mile) 6000 km (4000 mile)...

KLEEN (Kawasaki low exhaust emission)
The ZX600J have catalytic converters. The secondary air injection system [A] helps Kawasaki keep motorcycle exhaust gases below the established emission regulation limits. This system draws air into the exhaust ports, dilutes and burns harmful...

Non-contact hall IC-Type speed sensor
Details The electronic combination meter unit, superior to the conventional type in weight and durability is installed on the ZX600-J. The hall IC-type speed sensor is installed on the ZX600-J together with it, which needs no cable and speedometer...

Alternator made from rare magnet
Rare magnet material Sintered metal made from mainly neodium (Nd), ferric magnet (Fe), and boron (B). Main characters Rare magnet used and assembled in the alternator for the ZX600-J model has six (6) times higher performance than that of the...

Torque and locking agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks» column mean: L: Apply a non-permanent locking agent to the threads. LG: Apply...

Special tools and sealant
Bearing Puller: 57001-135 Valve Spring Compressor Assembly: 57001-241 Inside Circlip Pliers: 57001-143 Bearing Puller Adapter: 57001-317 Outside Circlip Pliers: 57001-144 Piston Pin Puller Assembly: 57001-910 Oil Pressure Gauge, 10 kg/cm 2 :...

Cable, wire, and hose routing
1. Choke Cable; 2. Clutch Cable; 3. Throttle Cables; 4, Front Fork; 5. Coolant Reserve Tank Hose; 6. Coolant By-pass Hose; 7. To Main Harness; 8. Air Intake Duct; 9. Turn Signal Light Lead; 10. Run the clutch cable over the coolant hoses; 11. Clamp;...

Additional considerations for racing
This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be experienced under racing conditions. KAWASAKI STRONGLY...

General lubrication
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime Lubricate the points listed below with indicated lubricant. Note. Whenever the vehicle has been operated under wet or rainy...

Nut, bolt, and fastener tightness
Tightness inspection Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note. For the engine fasteners, check the tightness of them when the engine is cold (at room...