Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year)

1-10 GENERAL INFORMATION

General Specifications

Items

ZX636ED/FD

Dimensions

Overall Length

2 085 mm (82.09 in.)

Overall Width

705 mm (27.8 in.)

Overall Height

1 115 mm (43.90 in.)

Wheelbase

1 395 mm (54.92 in.)

Road Clearance

130 mm (5.12 in.)

Seat Height

830 mm (32.7 in.)

Curb Mass:

ZX636ED

192 kg (423 lb)

ZX636FD

194 kg (428 lb)

Front:

ZX636ED

98 kg (216 lb)

ZX636FD

99 kg (218 lb)

Rear:

ZX636ED

94 kg (207 lb)

ZX636FD

95 kg (209 lb)

Fuel Tank Capacity

17 L (4.5 US gal)

Performance

Minimum Turning Radius

3.4 m (11.2 ft)

Engine

Type

4-stroke, DOHC, 4-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

67.0 × 45.1 mm (2.64 × 1.78 in.)

Displacement

636 cm³ (38.8 cu in.)

Compression Ratio

12.9:1

Maximum Horsepower

96.4 kW (131 PS) at 13 500 r/min (rpm),
(WVTA (78.2 H)) 78.2 kW (106 PS) at 13 500 r/min (rpm),
(SEA) 95.0 kW (129 PS) at 13 000 r/min (rpm),
(CA), (CAL), (US) – – –

Maximum Torque

71 N·m (7.2 kgf·m, 52 ft·lb) at 11 500 r/min (rpm),
(WVTA (78.2 H)) 61 N·m (6.2 kgf·m, 45 ft·lb) at 10 800 r/min
(rpm),
(CA), (CAL), (US) – – –

Carburetion System

FI (Fuel Injection), KEIHIN TTK38 × 4

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced (IC igniter in ECU)

Ignition Timing

From 12.5° BTDC at 1 300 r/min (rpm) to 36.4° BTDC at 4 800
r/min (rpm)

Spark Plug

NGK CR9E

Cylinder Numbering Method

Left to right, 1-2-3-4

Firing Order

1-2-4-3

GENERAL INFORMATION 1-11

General Specifications

Items

ZX636ED/FD

Valve Timing:

Intake:

Open

44° (BTDC)

67° (ABDC)

Duration

291°

Exhaust:

Open

58° (BBDC)

20° (ATDC)

Duration

258°

Lubrication System

Forced lubrication (wet sump with oil cooler)

Engine Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE 10W-40

Capacity

3.6 L (3.8 US qt)

Drive Train

Primary Reduction System:

Type

Gear

Reduction Ratio

1.900 (76/40)

Clutch Type

Wet multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st

2.846 (37/13)

2nd

2.200 (33/15)

3rd

1.850 (37/20)

4th

1.600 (32/20)

5th

1.421 (27/19)

6th

1.300 (26/20)

Final Drive System:

Type

Chain drive

Reduction Ratio

2.688 (43/16)

Overall Drive Ratio

6.638 at Top gear

Frame

Type

Tubular, diamond

Caster (Rake Angle)

23.5°

Trail

101 mm (3.98 in.)

Front Tire:

Type

Tubeless

Size

120/70ZR17 M/C (58 W)

Rim Size

J17M/C × MT3.50

Rear Tire:

Type

Tubeless

Size

180/55ZR17 M/C (73 W)

Rim Size

J17M/C × MT5.50

1-12 GENERAL INFORMATION

General Specifications

Items

ZX636ED/FD

Front Suspension:

Type

Telescopic fork (upside-down)

Wheel Travel

120 mm (4.72 in.)

Rear Suspension:

Type

Swingarm (uni-trak)

Wheel Travel

134 mm (5.28 in.)

Brake Type:

Front

Dual discs

Rear

Single disc

Electrical Equipment

Battery

12 V 8 Ah

Headlight:

Type

Semi-sealed beam

Bulb:

High

12 V 55 W (quartz-halogen)

Low

12 V 55 W (quartz-halogen)

Tail/Brake Light

LED

Alternator:

Type

Three-phase AC

Rated Output

26 A/14 V at 5 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ...................................................................................................

2-3

Torque and Locking Agent......................................................................................................

2-5

Specifications .........................................................................................................................

2-11

Special Tools ..........................................................................................................................

2-13

Periodic Maintenance Procedures..........................................................................................

2-14

Fuel System (DFI)................................................................................................................

2-14

Air Cleaner Element Replacement....................................................................................

2-14

Idle Speed Inspection .......................................................................................................

2-15

Idle Speed Adjustment......................................................................................................

2-15

Throttle Control System Inspection...................................................................................

2-15

Engine Vacuum Synchronization Inspection.....................................................................

2-16

Fuel System ......................................................................................................................

2-19

Fuel Hose Replacement ...................................................................................................

2-20

Evaporative Emission Control System Inspection (CAL Model) .......................................

2-22

Cooling System....................................................................................................................

2-23

Coolant Level Inspection...................................................................................................

2-23

Cooling System.................................................................................................................

2-23

Coolant Change ................................................................................................................

2-23

Water Hose and O-ring Replacement ...............................................................................

2-26

Engine Top End ...................................................................................................................

2-27

Valve Clearance Inspection ..............................................................................................

2-27

Valve Clearance Adjustment.............................................................................................

2-28

Air Suction System Damage Inspection............................................................................

2-30

Clutch...................................................................................................................................

2-31

Clutch Operation Inspection .............................................................................................

2-31

Engine Lubrication System ..................................................................................................

2-32

Engine Oil Change............................................................................................................

2-32

Oil Filter Replacement ......................................................................................................

2-33

Wheels/Tires ........................................................................................................................

2-34

Air Pressure Inspection.....................................................................................................

2-34

Wheels and Tires ..............................................................................................................

2-34

Wheel Bearing Damage Inspection ..................................................................................

2-35

Final Drive............................................................................................................................

2-36

Drive Chain Lubrication Condition Inspection ...................................................................

2-36

Drive Chain Slack Inspection ............................................................................................

2-36

Drive Chain Slack Adjustment ..........................................................................................

2-37

Wheel Alignment Inspection .............................................................................................

2-38

Drive Chain Wear Inspection ............................................................................................

2-38

Chain Guide Wear Inspection ...........................................................................................

2-39

Brakes..................................................................................................................................

2-39

Brake System....................................................................................................................

2-39

Brake Fluid Level Inspection.............................................................................................

2-40

Brake Fluid Change ..........................................................................................................

2-41

Brake Hose and Pipe Replacement..................................................................................

2-43

Master Cylinder Rubber Parts Replacement ....................................................................

2-46

Caliper Rubber Parts Replacement ..................................................................................

2-47

Brake Pad Wear Inspection ..............................................................................................

2-51

Brake Light Switch Operation Inspection ..........................................................................

2-51

Suspension ..........................................................................................................................

2-52

Suspension System ..........................................................................................................

2-52

2-2 PERIODIC MAINTENANCE

Steering ...............................................................................................................................

2-53

Steering Play Inspection ...................................................................................................

2-53

Steering Play Adjustment..................................................................................................

2-54

Steering Stem Bearing Lubrication ...................................................................................

2-55

Electrical System .................................................................................................................

2-56

Lights and Switches Operation Inspection........................................................................

2-56

Headlight Aiming Inspection .............................................................................................

2-58

Sidestand Switch Operation Inspection ............................................................................

2-59

Engine Stop Switch Operation Inspection.........................................................................

2-60

Spark Plug Replacement ..................................................................................................

2-61

Others ..................................................................................................................................

2-61

Chassis Parts Lubrication ................................................................................................

2-61

Condition of Bolts, Nuts and Fasteners Tightness Inspection ..........................................

2-62

PERIODIC MAINTENANCE 2-3

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.

Periodic Inspection

*A: Service at number of years shown or indicated odometer reading intervals, whichever comes

first.

*B: For higher odometer readings, repeat at the frequency interval established here.

*C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed,

or frequent starting/stopping.

○

: Emission Related Item

: Inspection
: Change or Replace
: Lubrication

Odometer Reading (*B)

× 1 000 km (× 1 000 mile)

Items

year

(*A)

(0.6)

(3.8)

(7.6)

(11.4)

(15.2)

See
Page

Fuel System

○

Air cleaner element (*C)

2-14

○

Idle speed

2-15

○

Throttle control system (play, smooth return,
no drag)

2-15

○

Engine vacuum synchronization

2-16

Fuel system

2-19

Fuel hose

2-20

○

Evaporative emission control system (CAL
Model)

2-22

Cooling System

Coolant level

2-23

Cooling system

2-23

Coolant, water hoses and O-rings

: every 36 000 km

(22 500 mile)

2-23,

2-26

Engine Top End

○

Valve clearance (US and CA Models)

2-27

Valve clearance (Other than US and CA
Models)

: every 42 000 km

(26 250 mile)

2-27

○

Air suction system

2-30

Clutch

Clutch operation (play, engagement,
disengagement)

2-31

Engine Lubrication System

Engine oil and oil filter (*C)

2-32,

2-33

Wheels and Tires

Tire air pressure

2-34

Wheels and tires

2-34

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Odometer Reading (*B)

× 1 000 km (× 1 000 mile)

Items

year

(*A)

(0.6)

(3.8)

(7.6)

(11.4)

(15.2)

See
Page

Wheel bearing damage

2-35

Final Drive

Drive chain lubrication condition (*C)

: every 600 km (400 mile)

2-36

Drive chain slack (*C)

: every 1 000 km (600 mile)

2-36

Drive chain wear (*C)

2-38

Drive chain guide wear

2-39

Brakes

Brake system

2-39

Brake fluid level

:0.5

2-40

Brake fluid (front and rear)

2-41

Brake hose/rubber parts of brake master
cylinder and caliper

: every 48 000 km

(30 000 mile)

2-43,
2-46,

2-47

Brake pad wear (*C)

2-51

Brake light switch operation

2-51

Suspension

Suspension system

2-52

Steering

Steering play

2-53

Steering stem bearings

2-55

Electrical System

Electrical system

2-56

○

Spark plugs

2-61

Others

Chassis parts

2-61

Condition of bolts, nuts and fasteners

2-62

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease.

SS: Apply silicone sealant.

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Fuel System (DFI)

Air Cleaner Housing Assembly Screws

1.2

0.12

11 in·lb

Air Cleaner Housing Clamp Bolts

2.0

0.20

18 in·lb

Air Intake Duct Mounting Bolts

9.8

1.0

87 in·lb

Air Intake Duct Assembly Screws

1.5

0.15

13 in·lb

Crankshaft Sensor Bolts

5.9

0.60

52 in·lb

Delivery Pipe Assy Mounting Screws

3.43

0.35

30 in·lb

Exhaust Butterfly Valve Actuator Mounting Screws

4.3

0.44

38 in·lb

Exhaust Butterfly Valve Actuator Pulley Bolt

4.9

0.50

43 in·lb

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Gear Position Switch Screws

2.9

0.30

26 in·lb

Intake Air Temperature Sensor Screw

1.2

0.12

11 in·lb

Oxygen Sensor (Equipped Models)

2.5

Throttle Body Assy Holder Bolts

1.2

106 in·lb

Throttle Body Assy Holder Clamp Bolts

2.9

0.30

26 in·lb

Throttle Cable Holder Plate Bolt

3.9

0.40

35 in·lb

Throttle Case Screws

3.5

0.36

31 in·lb

Water Temperature Sensor

1.2

106 in·lb

Cooling System

Coolant By-pass Fitting Bolt

8.8

0.90

78 in·lb

Coolant Drain Bolt (Cylinder)

9.8

1.0

87 in·lb

Coolant Drain Bolt (Water Pump)

8.8

0.90

78 in·lb

Heat Insulation Plate Bolt

3.9

0.40

35 in·lb

Impeller Bolt

9.8

1.0

87 in·lb

Oil Cooler Mounting Bolts

2.0

Radiator Upper Bolts

9.8

1.0

87 in·lb

Thermostat Housing Cover Bolts

5.9

0.60

52 in·lb

Water Hose Clamp Screws

3.0

0.31

27 in·lb

Water Hose Fitting Bolts

9.8

1.0

87 in·lb

Water Pump Cover Bolts

1.2

106 in·lb

Water Temperature Sensor

1.2

106 in·lb

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Engine Top End

Air Suction Valve Cover Bolts

9.8

1.0

87 in·lb

Breather Hose Fitting

1.5

Camshaft Cap Bolts

1.2

106 in·lb

Camshaft Chain Tensioner Cap Bolt

2.0

Camshaft Chain Tensioner Mounting Bolts

1.1

97 in·lb

Camshaft Sprocket Bolts

1.5

Coolant Drain Bolt (Cylinder)

9.8

1.0

87 in·lb

Cylinder Head Bolts (M9)

see the

text

←

MO, S

Cylinder Head Bolts (M6)

1.2

106 in·lb

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

Exhaust Butterfly Valve Actuator Mounting Screws

4.3

0.44

38 in·lb

Exhaust Butterfly Valve Actuator Pulley Bolt

4.9

0.50

43 in·lb

Exhaust Butterfly Valve Cable Locknuts

5.0

0.51

44 in·lb

Front Camshaft Chain Guide Bolt (Lower)

1.2

106 in·lb

Front Camshaft Chain Guide Bolt (Upper)

2.5

Muffler Body Mounting Bolt

2.5

Premuffler Chamber Bracket Bolt

4.1

Premuffler Chamber Mounting Bolt

4.1

Muffler Body End Cover Bolts

7.0

0.71

62 in·lb

Spark Plugs

1.3

115 in·lb

Starter Clutch Bolt Cap

2.9

0.30

26 in·lb

Throttle Body Assy Holder Bolts

1.2

106 in·lb

Throttle Body Assy Holder Clamp Bolts

2.9

0.30

26 in·lb

Timing Inspection Cap

2.9

0.30

26 in·lb

Upper Camshaft Chain Guide Bolts

1.2

106 in·lb

Water Passage Plugs

19.6

2.00

14.5

Clutch

Clutch Cover Bolts (M6, L = 40 mm)

9.8

1.0

87 in·lb

Clutch Cover Bolts (M6, L = 25 mm)

9.8

1.0

87 in·lb

Clutch Hub Nut

135

13.8

100

Clutch Lever Clamp Bolts

7.8

0.80

69 in·lb

Clutch Stopper Bolts

8.8

0.90

78 in·lb

Oil Filler Plug

–

Hand-tighten

Engine Lubrication System

Air Bleed Bolt

9.8

1.0

87 in·lb

Engine Oil Drain Bolt

3.0

Impeller Bolt

9.8

1.0

87 in·lb

Oil Cooler Mounting Bolts

2.0

Oil Cooler/Oil Filter Case Mounting Bolts

2.0

Oil Filter

1.7

G, R

Oil Filter Guard Bolts

4.0

0.41

35 in·lb

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Oil Filter Holder Bolt

2.5

Oil Jet Nozzles

2.9

0.30

26 in·lb

Oil Pan Bolts

9.8

1.0

87 in·lb

Oil Passage Plug

1.7

Oil Passage Plugs (Taper)

2.0

Oil Pressure Relief Valve

1.5

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Oil Pump Drive Gear Bolt

9.8

1.0

87 in·lb

Water Pump Cover Bolts

1.2

106 in·lb

Engine Removal/Installation

Adjusting Collar Locknuts

5.0

Adjusting Collars

9.8

1.0

87 in·lb

S, (M)

Left Front Engine Mounting Bolt

4.5

Lower Engine Mounting Nut

4.5

R, S

Middle Engine Mounting Nut

4.5

R, S

Right Front Engine Mounting Bolt

4.5

Crankshaft/Transmission

Bearing Holder Screws

4.9

0.50

43 in·lb

Breather Hose Fitting

1.5

Breather Plate Bolts

9.8

1.0

87 in·lb

Connecting Rod Big End Nuts

see the

text

←

Crankcase Bolt (M8, L = 90 mm)

2.8

Crankcase Bolts (M8, L = 95 mm)

3.2

MO, S

Crankcase Bolts (M8, L = 75 mm)

2.8

Crankcase Bolts (M6, L = 68 mm)

1.2

106 in·lb

Crankcase Bolts (M6, L = 50 mm)

1.2

106 in·lb

Gear Position Switch Screws

2.9

0.30

26 in·lb

Gear Positioning Lever Bolt

1.2

106 in·lb

Idle Gear Cover Bolts

9.8

1.0

87 in·lb

Oil Jet Nozzles

2.9

0.30

26 in·lb

Oil Passage Nozzle

4.9

0.50

43 in·lb

Oil Passage Plug

1.7

Oil Passage Plugs (Taper)

2.0

Race Holder Screws

4.9

0.50

43 in·lb

Shift Drum Cam Holder Bolt

1.2

106 in·lb

Shift Pedal Mounting Bolt

2.5

Shift Shaft Return Spring Pin

2.9

Starter Clutch Bolt

5.0

Starter Clutch Cover Bolt (L = 20 mm)

9.8

1.0

87 in·lb

Starter Clutch Cover Bolts (L = 30 mm)

9.8

1.0

87 in·lb

Transmission Case Bolt (M6)

9.8

1.0

87 in·lb

Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 1