Diagnosis and troubleshooting of motorcycle Kawasaki ZX-6R/ZX-600-J (2000-2002)
This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
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Engine does not start, starting difficulty
Starter motor not rotating: Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine...
Starter motor not rotating: Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine...
Poor running at low speed
Spark weak: Battery voltage low Spark plug dirty, broken, or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Stick coil trouble Fuel/air mixture incorrect: Pilot screw...
Spark weak: Battery voltage low Spark plug dirty, broken, or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Stick coil trouble Fuel/air mixture incorrect: Pilot screw...
Poor running or no power at high speed
Firing incorrect: Spark plug dirty, broken, or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Stick coil trouble Fuel/air mixture incorrect: Starter plunger stuck open...
Firing incorrect: Spark plug dirty, broken, or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Stick coil trouble Fuel/air mixture incorrect: Starter plunger stuck open...
Engine overheating and overcooling
Overheating Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect IC Igniter trouble Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest...
Overheating Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect IC Igniter trouble Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest...
Clutch operation faulty
Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging...
Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging...
Gear shifting faulty
Doesn't go into gear; shift pedal doesn't return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring...
Doesn't go into gear; shift pedal doesn't return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring...
Abnormal engine noise
Knocking: IC igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole...
Knocking: IC igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole...
Abnormal drive train noise
Clutch noise: Clutch rubber damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Transmission noise: Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil...
Clutch noise: Clutch rubber damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Transmission noise: Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil...
Abnormal frame noise
Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise: Bracket, nut, bolt, etc....
Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise: Bracket, nut, bolt, etc....
Oil pressure warning light goes on
Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearings worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the...
Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearings worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the...
Exhaust smokes excessively
White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too...
White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too...
Handling and/or stability unsatisfactory
Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem locknut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low...
Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem locknut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low...
Brake does not hold
Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside
Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside
Accumulator battery trouble
Battery discharged: Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte insufficient) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring...
Battery discharged: Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte insufficient) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring...
- 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