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Ninja ZX-6R
2008 Ninja ZX-6R
Racing Kit Manual
This manual contains only the information of the racing kit parts. Refer to the base
manual listed below for information of the original model.
Base Manual Part Number
Ninja ZX-6R
99924-1382-02
Motorcycle Service Manual
© 2008 Kawasaki Heavy Industries, Ltd. First Edition (1): Jan. 25, 2008
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Congratulation on your purchase of racing kit parts for the 2008 Ninja ZX-6R. IMPORTANT This manual provides how to install racing kit parts for the 2008 Ninja ZX-6R and how to tune up basically. As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-6R (P/No. 99924-1382-02). When you participate in a race, it is necessary to modify the machine for the regulation. So we want you to ask for the tuning up shop. WARNING AFTER ANY MODIFICATION TO TUNE THE V
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Table of Contents General Specifications......................................................................................................4 Racing Kit Service Data ....................................................................................................6 Periodic Maintenance Chart .............................................................................................7 Preparation.........................................................................................
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General Specifications Item 2008 Ninja ZX-6R Racing Engine: Ignition timing 12.5°BTDC @1 300 r/min (rpm) Fuel (Recommended) Racing gasoline Engine oil (Recommended): Racing oil Level Between upper and lower levels of oil level gauge. Drive Train: Primary drive reduction ratio 1.900 (76/40) Transmission Gear Table STD Type B Type C Type D (Type A) In 13127-0044 13127-0055 （13127-0055 ） Out 13262-0507 13262-0526 13262-0535 1st Teeth (Out/In) 38/14 37/14 36/14 Gear R
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Input 3rd/4th Gear Selection Table 4th Gear A B C D A 13262-0506 13262-0529 13262-0679 3rd Gear B 13262-0680 13262-0681 13262-0682 Gear Identification Slit Number Table STD Type B Type C Type D (Type A) In 0 1 1 1st Out 0 1 2 In 0 1 2 3 2nd Out 0 1 2 3 In 0 1 3rd Out 0 1 In 0 1 2 3 4th Out 0 1 2 3 In 0 1 2 3 5th Out 0 1 2 3 In 0 1 2 3 6th Out 0 1 2 3 5
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Racing Kit Service Data Item Standard Cylinder Head, Valves: Duration: Intake 288° Exhaust 266° Camshaft timing (cam lift center): Intake 105° (ATDC) Exhaust 110° (BTDC) Valve clearance: Intake 0.16 mm Exhaust 0.28 mm Valve to piston clearance: Intake 0.80 mm (Minimum) @12°ATDC Exhaust 1.40 mm (Minimum) @11°BTDC Ignition System: Spark plugs NGK R0045Q-10, R0373A-10 Spark plug tightening torque 13 N·m (1.3 kgf·m, 113 in·lb) These values sh
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Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQENCY Each Every Every Every As Race 3 races 5 races 10 races Required OPERATION (300 km) (1 000 km)(1 500 km) (3 000 km) Engine Clutch plate - - check* ● Throttle grip play - - check* ● Spark plug - - clean/gap* ● Engine oil - - change ● Oil filter - - replace ● Valve lapping ● Cylinder head/valve -
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FREQENCY Each Every Every Every As Race 3 races 5 races 10 races Required OPERATION (300 km) (1 000 km)(1 500 km) (3 000 km) Wheel bearing (rear) - - grease ● Swingarm pivot, uni-track linkage - - grease ● Swingarm pivot, uni-track linkage - - check* ● *: Replace, add, adjust, clean, or torque if necessary. 8
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Preparation Before Installing Modify the parts based on your race regulation. To avoid misuse keep the parts replaced with the kit parts separate. When reusing parts, clean them and check them for damage or deterioration. Main Removal Parts: Lights Rear View Mirrors Side Stand Starter Lockout Switch Remove the side stand switch. When the optional main harness is not used, connect removing Black/Yellow and Green/White Leads directly. Racing Kit Parts Also, we have provided the
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Remove the secondary valves of cylinder head and relational parts, then plug the each holes. Remove the oil receiver and plug the hole. Remove the air cleaner element or cut the cleaner element off remaining punched plate to reduce the air flow resistance. 1. Remove the parts. 2. Plug the holes. 3. Replace with plugs (92043-1506), and plug the holes. 10
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Cylinder Head Grind off the stepped portions of the ports and smooth the inside of ports to make intake/exhaust gas flow more smooth. Grind off the stepped portion only at the mating surface between the carburetor holder and the intake port. Do not port it. To extend the intake port, air flow speed will be reduced and the engine performance at the high speed range may be down. Mark the carburetor holders so that they can be installed in their original positions. Grind off and smooth t
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The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners (Round them to about R1). Chamfer the machining edge of the cylinder head where the valve seat is installed, also smooth the dome of the combustion chamber with the valves installed. Excessive smoothing may reduce the cylinder compression. XXX. Edges NOTE When grinding the cylinder head bottom surface or using thinner gaskets, adjust the valve timing to keep that the
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A. Tensioner B. Tensioner Rod C. O-ring D. O-ring E. Lock nut Camshafts, Sprockets Camshafts, Sprockets: Adjust the valve clearance within the specified value, but more performance is expected when adjusted from middle value to upper limit between adjustable range. Original Timing Cam Lift Valve Clearance Intake 288° 8.30 mm 0.13 ∼ 0.19 mm Exhaust 266° 7.50 mm 0.24 ∼ 0.31 mm Kit Timing Cam Lift Valve Clearance Intake 8.30 mm 308° 0.13 ∼ 0.19 mm 49118-0110 (conformed to
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If you don’t adjust the valve timing for racing, install the camshaft sprocket to the kit camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-6R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range of the long bolt holes. Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11.0 ft·lb) of torque. Valve Timing (when the round bolt holes are used) Timing (cam lift center) Intake Exha
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Cylinder Head Gasket Part No. Thickness Note 11004-0071 0.45 mm KIT 11004-0070 0.50 mm KIT 11004-0069 0.55 mm KIT 11004-0068 0.60 mm KIT 11004-0057 0.65 mm Original 11004-0067 0.70 mm KIT 1. Squish, Front/Rear 2. Squish, Left/Right 15
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Crankshaft Main Journal and Connecting Rod Big End Bushings To adjust clearance of crankshaft main journal you can select proper bush in accordance with the marks. The kit bushings are improved in anti-seizuring characteristics as well as in wear-resistance as compared with the standard bushings. 1) Crankshaft Main Journal Crankshaft Main Journal Diameter 1. Crankshaft Main Journal Diameter Marks SIZE “1” mark : over 30.992 mm within 31.000 mm None : over 30.984 mm within 30
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Main Journal Bush A. Size Color Part Number Part Number Size Color Thickness mm Journal Number (STD) (KIT) 1-4 92139-0189 92139-0200 blue 1.499-1.503 5 92139-0171 92139-0197 1-4 92139-0190 92139-0201 black 1.495-1.499 5 92139-0172 92139-0198 1-4 92139-0191 92139-0202 brown 1.491-1.495 5 92139-0173 92139-0199 Selection Table Part Part Size Journal Crankcase inner Diameter Crankshaft Diameter Number Number Color Number (STD) (KIT) ○ 1 1-4 92139-0191 92139-0202 brown (
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2) Crankpin Crankpin Diameter 1. Crankpin Diameter Marks “ ” mark : over 29.992 mm within 30.000 mm None : 29.984 mm and over within 29.992 mm Connecting Rod Big End Inside Diameter Connecting Rod Big End Inside Diameter Marks “ ” mark : over 33.008 mm within 33.016 mm None : 33.000 mm and over within 33.008 mm A. Inside Diameter Mark ( or None) B. Weight Mark, Alphabet (G.H etc) Connecting Rod Big End Bushings Part Number Part Number Size Color
