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

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Transmission Case Bolts (M8)

2.0

Wheels/Tires

Front Axle Clamp Bolts

2.0

Front Axle

127

13.0

93.7

Rear Axle Nut

127

13.0

93.7

Final Drive

Chain Guide Bolts

1.2

106 in·lb

Engine Sprocket Cover Bolts (L = 45 mm)

9.8

1.0

87 in·lb

Engine Sprocket Cover Bolts (L = 55 mm)

9.8

1.0

87 in·lb

Engine Sprocket Cover Damper Screws

3.0

0.31

27 in·lb

Engine Sprocket Nut

147

15.0

108

Rear Axle Nut

127

13.0

93.7

Rear Sprocket Nuts

6.0

Brakes

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Lever Pivot Bolt

1.0

0.10

8.9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Brake Pedal Mounting Bolt

3.5

Front Brake Disc Mounting Bolts

2.8

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Brake Pad Pins

1.7

Front Brake Reservoir Cap Stopper Screw

1.2

0.12

11 in·lb

Front Caliper Mounting Bolts

3.5

Brake Pipe Banjo Bolts (L = 20.8 mm) (KIBS Equipped
Models)

2.3

Brake Pipe Banjo Bolt (L = 32.3 mm) (KIBS Equipped
Models)

2.3

Brake Pipe Joint Nuts (KIBS Equipped Models)

1.8

Front Master Cylinder Bleed Valve

5.4

0.55

48 in·lb

Front Master Cylinder Clamp Bolts

1.1

97 in·lb

Rear Brake Disc Mounting Bolts

2.8

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.7

Rear Brake Pad Pin

1.7

Rear Brake Pad Pin Plug

2.45

0.25

22 in·lb

Rear Caliper Pin Bolt

2.8

Suspension

Front Axle Clamp Bolts

2.0

Front Fork Top Plugs

3.6

Lower Front Fork Clamp Bolts

2.3

Lower Rear Shock Absorber Nut

3.5

Piston Rod Guide Case

9.2

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Rear Shock Absorber Bracket Nut

6.0

Swingarm Pivot Adjusting Collar Locknut

10.0

Swingarm Pivot Shaft

2.0

Swingarm Pivot Shaft Nut

108

11.0

79.7

Tie-Rod Nuts

6.0

Rocker Arm Bolt

3.5

Upper Front Fork Clamp Bolts

2.0

Upper Rear Shock Absorber Nut

3.5

Steering

Handlebar Clamp Bolts

2.5

Handlebar Positioning Bolts

9.8

1.0

87 in·lb

Left Switch Housing Screws

3.5

0.36

31 in·lb

Lower Front Fork Clamp Bolts

2.3

Right Switch Housing Screws

3.5

0.36

31 in·lb

Steering Stem Head Bolt

8.0

Steering Stem Nut

2.8

Throttle Case Screws

3.5

0.36

31 in·lb

Upper Front Fork Clamp Bolts

2.0

Frame

Front Fender Mounting Bolts

3.9

0.40

35 in·lb

Front Footpeg Bracket Bolts

2.5

Rear Footpeg Bracket Bolts

2.5

Rear Frame Bolts (M10)

4.5

Rear Frame Bolts (M8)

2.5

Sidestand Bolt

3.0

Sidestand Bracket Bolts

5.0

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Sidestand Nut

4.5

R, S

Windshield Mounting Bolts

0.42

0.043

3.7 in·lb

Electrical System

Alternator Cover Bolts

9.8

1.0

87 in·lb

Alternator Lead Holding Plate Bolt

9.8

1.0

87 in·lb

Alternator Rotor Bolt

155

15.8

114

Crankshaft Sensor Bolts

5.9

0.60

52 in·lb

Engine Ground Cable Terminal Bolt

9.8

1.0

87 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Turn Signal Light Mounting Screw

1.2

0.12

11 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

Left Switch Housing Screws

3.5

0.36

31 in·lb

License Plate Light Cover Screws

1.0

0.10

8.9 in·lb

License Plate Light Mounting Nuts

3.5

0.36

31 in·lb

Meter Unit Mounting Screws

1.2

0.12

11 in·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Oxygen Sensor (Equipped Models)

2.5

Regulator/Rectifier Bracket Screws

1.2

0.12

11 in·lb

Right Switch Housing Screws

3.5

0.36

31 in·lb

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Spark Plugs

1.3

115 in·lb

Starter Clutch Bolt Cap

2.9

0.30

26 in·lb

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

Starter Motor Cable Terminal Bolt

2.9

0.30

26 in·lb

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

Stator Coil Bolts

1.2

106 in·lb

Water Temperature Sensor

1.2

106 in·lb

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and

nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Torque

Threads Diameter

(mm)

N·m

kgf·m

ft·lb

3.4

∼

4.9

0.35

∼

0.50

∼

43 in·lb

5.9

∼

7.8

0.60

∼

0.80

∼

69 in·lb

∼

1.4

∼

1.9

∼

13.5

∼

2.6

∼

3.5

∼

4.5

∼

6.2

∼

7.4

∼

10.0

∼

115

∼

155

11.5

∼

16.0

∼

115

165

∼

225

17.0

∼

23.0

125

∼

165

225

∼

325

23.0

∼

33.0

165

∼

240

PERIODIC MAINTENANCE 2-11

Specifications

Item

Standard

Service Limit

Fuel System (DFI)

Throttle Grip Free Play

∼

3 mm (0.08

∼

0.12 in.)

– – –

Idle Speed

1 300 ±50 r/min (rpm)

– – –

Throttle Body Vacuum

33.4 ±1.33 kPa (251 ±10 mmHg) at idle speed

– – –

Bypass Screws (Turn Out)

∼

2 1/2 (for reference)

– – –

Air Cleaner Element

Viscous paper element

– – –

Cooling System

Coolant:

Type (Recommended)

Permanent type of antifreeze

– – –

Color

Green

– – –

Mixed Ratio

Soft water 50%, coolant 50%

– – –

Freezing Point

–35°C (–31°F)

– – –

Total Amount

2.5 L (2.6 US qt)

– – –

Engine Top End

Valve Clearance:

Exhaust

0.24

∼

0.31 mm (0.0094

∼

0.0122 in.)

– – –

Intake

0.13

∼

0.19 mm (0.0051

∼

0.0075 in.)

– – –

Clutch

Clutch Lever Free Play

∼

3 mm (0.08

∼

0.12 in.)

– – –

Engine Lubrication System

Engine Oil:

Type

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

– – –

Viscosity

SAE 10W-40

– – –

Capacity

2.8 L (3.0 US qt) (when filter is not removed)

– – –

3.1 L (3.3 US qt) (when filter is removed)

– – –

3.6 L (3.8 US qt) (when engine is completely dry)

– – –

Level

Between upper and lower level lines (Wait 2

∼

minutes after idling or running)

– – –

Wheels/Tires

Tread Depth:

Front

3.6 mm (0.14 in.)

1 mm (0.04 in.)

(AT, CH, DE) 1.6

mm (0.06 in.)

Rear

5.1 mm (0.20 in.)

Up to 130 km/h

(80 mph): 2 mm

(0.08 in.)

Over 130 km/h

(80 mph): 3 mm

(0.12 in.)

Air Pressure (when Cold):

Front

Up to 180 kg (397 lb) load:

250 kPa (2.50 kgf/cm², 36 psi)

– – –

Rear

Up to 180 kg (397 lb) load:

290 kPa (2.90 kgf/cm², 42 psi)

– – –

2-12 PERIODIC MAINTENANCE

Specifications

Item

Standard

Service Limit

Final Drive

Drive Chain Slack

∼

40 mm (1.2

∼

1.6 in.)

– – –

Drive Chain Wear (20-link
Length)

317.5

∼

318.2 mm (12.50

∼

12.53 in.)

319 mm (12.6 in.)

Standard Chain:

Make

ENUMA

– – –

Type

EK520RMX/3D

– – –

Link

112 links

– – –

Brakes

Brake Fluid:

Grade

DOT4

– – –

Brake Pad Lining
Thickness:

Front

4.0 mm (0.16 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Light Timing:

Front

Pulled ON

– – –

Rear

On after about 10 mm (0.39 in.) of pedal travel

– – –

Electrical System

Spark Plug:

Type

NGK CR9E

– – –

Gap

0.7

∼

0.8 mm (0.028

∼

0.031 in.)

– – –

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Air Cleaner Element Replacement

NOTE

○

In dusty areas, the element should be replaced more
frequently than the recommended interval.

WARNING

If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

Disconnect the intake air temperature sensor lead con-
nector [A].

•

Remove:

Screws [B]
Upper Air Cleaner Housing [C]

•

Discard the air cleaner element [A].

•

Install a new element [A] so that the screen side [B] faces
upward.

NOTICE

Use only the recommended air cleaner element
(Kawasaki part number 11013-0036). Using another
air cleaner element will wear the engine prema-
turely or lower the engine performance.

•

Install the upper air cleaner housing (see Air Cleaner
Housing Assembly in the Fuel System (DFI) chapter).

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

Idle Speed Inspection

•

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.

•

Check the idle speed.
If the idle speed is out of specified range, adjust it.

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until the idle speed is correct.

○

Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

Throttle Control System Inspection

•

Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cables.

Throttle Grip Free Play

Standard:

∼

3 mm (0.08

∼

0.12 in.)

•

Check that the throttle grip [B] moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt-
tle cables routing, grip free play, and cable damage. Then
lubricate the throttle cable.

•

Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable free
play and the cable routing.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If necessary, adjust the throttle cable as follows.

•

Loosen the locknuts [A] [B].

•

Screw both throttle cable adjusters [C] [D] to give the
throttle grip plenty of play.

•

Turn the decelerator cable adjuster [C] until it has no play
when the throttle grip is completely closed.

•

Tighten the locknut [A].

•

Turn the accelerator cable adjuster [D] until 2

∼

3 mm

(0.08

∼

0.12 in.) of throttle grip play is obtained.

•

Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.

Engine Vacuum Synchronization Inspection

NOTE

○

These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.

•

Situate the motorcycle so that it is vertical.

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Fuel Hose (see Fuel Hose Replacement)

•

Pull off the rubber caps [A] and vacuum hose [B] from the
fittings of each throttle body.

•

For the CAL Model, pull off the vacuum hoses.

•

Connect a vacuum gauge and hoses [A] (Special Tool:
57001-1369) to the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

•

Connect a highly accurate tachometer lead [B] to one of
the stick coil primary leads.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If any vacuum is not within specifications, adjust the by-
pass screws [A].

View from Rear [B]

Special Tool - Pilot Screw Adjuster, C [C]: 57001-1292

•

Adjust the each vacuum (#1

∼

#4) to the standard value.

•

Open and close the throttle valves after each measure-
ment.

NOTE

○

Do not turn the center adjusting screw [D].

•

Check the vacuums as before.
If all vacuums are within the specification range, finish the
engine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
replace the bypass screws #1

∼

#4 with new ones, refer

to the following procedure.

•

Remove the throttle body assy (see Throttle Body Assy
Removal in the Fuel System (DFI) chapter).

•

Turn in the bypass screw [A] with counting the number of
turns until it seals fully but not tightly. Record the number
of turns.

•

Remove:

Bypass Screw
Spring [B]
Washer [C]
O-ring [D]

•

Check the bypass screw hole in the throttle body for car-
bon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high flash-point
solvent.

•

Replace the bypass screw, spring, washer and O-ring as
a set.

•

Turn in the bypass screw until it seats fully but not tightly.

NOTICE

Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

•

Back out the same number of turns counted when first
turned in. This is to set the screw to its original position.

NOTE

○

A throttle body has different “turns out” of the bypass
screw for each individual unit. On setting the bypass
screw, use the “turns out” determined during disassem-
bly.

•

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Self-Diagnosis System chapter).

Special Tool - Throttle Sensor Setting Adapter:

57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Degital Meter (+)

→

R (sensor Y/W) lead

Degital Meter (–)

→

BK (sensor G) lead

Standard:

DC 1.02

∼

1.06 V at idle throttle opening

If the output voltage is out of the standard, check the input
voltage of the main throttle sensor (see Main Throttle Sen-
sor Input Voltage Inspection in the Self-Diagnosis System
chapter).

•

Remove the vacuum gauge hoses and install the rubber
caps and vacuum hose on the original position.

•

For CAL Model, install the vacuum hoses.

○

Run the vacuum hose according to Cable, Wire, and Hose
Routing section in the Appendix chapter.

•

Install the removed parts (see appropriate chapters).

Fuel System

Fuel Hose Inspection (fuel leak, damage, installation
condition)

○

If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hoses.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Check that the fuel hose is routed according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.

Hose Joints [A]
Fuel Hose [B]

•

Check that the fuel hose joints are securely connected.

○

Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked.

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.

If it does not locked, reinstall the hose joint.

Fuel Hose Replacement

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).

•

Be sure to place a piece of cloth around the fuel hose joint.

•

Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into slit on the joint
lock [B].

•

Turn the driver to disconnect the joint lock.

When removing with fingers

•

Open and push up [C] the joint lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

•

Pull the fuel hose joint [A] out of the delivery pipe [B].

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.

•

Clean the delivery pipe.

•

Cover the delivery pipe with the vinyl bag to keep it clean.

•

Remove the vinyl bag on the pipe.

•

Check that there are no flaws, burrs, and adhesion of
foreign materials on the delivery pipe [A].

•

Replace the fuel hose [A] with a new one.

•

Run the fuel hose correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

•

Insert [B] the fuel hose joint [C] straight onto the delivery
pipe until the hose joint clicks.

•

Push [D] the joint lock [E].

•

Push and pull [A] the fuel hose joint [B] back and forth
more than two times and make sure it is locked and does
not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.

If it comes off, reinstall the hose joint.

•

Install the fuel tank (see Fuel Tank Installation in the Fuel
System (DFI) chapter).

•

Start the engine and check the fuel hose for leaks.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Evaporative Emission Control System Inspection
(CAL Model)

•

Inspect the canister as follows.

○

Remove the purge valve from the canister bracket (see
Purge Valve Removal/Installation in the Self-Diagnosis
System chapter).

○

Disconnect the hoses [A].

○

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Screws [A]

○

Visually inspect the canister [B] for cracks or other dam-
age.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○

The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.

•

Inspect the purge valve (see Purge Valve Inspection in
the Self-Diagnosis System chapter).

○

Check that the hoses are securely connected and clips
are in position.

○

Replace any kinked, deteriorated or damaged hoses.

○

Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.

○

When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

Cooling System

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambi-
ent temperature).

•

Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re-
move the upper fairing assembly (see Upper Fairing As-
sembly Removal in the Frame chapter), and then unscrew
the reserve tank cap and add coolant to the “F” level line
[C].

“L”: Low
“F”: Full

NOTICE

For refilling, add the specified mixture of coolant
and soft water.

Adding water alone dilutes the

coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

Cooling System

Water Hose and Pipe Inspection (coolant leak, damage,
installation condition)

○

The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.

•

Visually inspect the hoses for signs of deterioration.
Squeeze the hoses.

A hose should not be hard and

brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.

•

Check that the hoses are securely connected and clamps
are tightened correctly.

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

Coolant Change

WARNING

Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Radiator Cap [A]

○

Remove the radiator cap in two steps. First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.

•

Place a container under the drain bolt [A] of the water
pump cover.

•

Drain the coolant from the radiator by removing the drain
bolt.

•

Remove:

Bolt [A]
Cap [B]

•

Pour the coolant into a container.

•

Install the coolant reserve tank [C] and tighten the bolt.

•

Tighten the drain bolt with new gasket.

Torque - Coolant Drain Bolt (Water Pump): 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Fill the radiator up to the radiator filler neck [A] with
coolant, and install the radiator cap.

NOTE

○

Pour in the coolant slowly so that it can expel the air
from the engine and radiator.

•

Fill the reserve tank up to the “F” level line with coolant,
and install the cap (see Coolant Level Inspection).

NOTICE

Soft or distilled water must be used with the an-
tifreeze (see below for antifreeze) in the cooling sys-
tem.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

Water and Coolant Mixture Ratio (Recommended)

Soft Water:

50%

Coolant:

50%

Freezing Point:

–35°C (–31°F)

Total Amount:

2.5 L (2.6 US qt)

NOTE

○

Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.

•

Bleed the air from the cooling system as follows.

○

Start the engine with the radiator cap removed and run it
until no more air bubbles [A] can be seen in the coolant.

○

Tap the radiator hoses to force any air bubbles caught
inside.

○

Stop the engine and add coolant up to the radiator filler
neck.

•

Install the radiator cap.

•

Start the engine, warm it up thoroughly until the radiator
fan turns on and then stop the engine.

•

Check the coolant level in the reserve tank after the en-
gine cools down.
If the coolant level is lower than the “L” level line, add
coolant to the “F” level line (see Coolant Level Inspection).

NOTICE

Do not add more coolant above the “F” level line.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Engine Top End

Valve Clearance Inspection

NOTE

○

Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).

•

Remove the cylinder head cover (see Cylinder Head
Cover Removal in the Engine Top End chapter).

•

Remove the timing inspection cap [A] and starter clutch
bolt cap [B] on the starter clutch cover [C].

•

Using a wrench on the starter clutch bolt [A], turn the
crankshaft clockwise until the line [B] (TDC mark for #1,4
pistons) on the starter clutch is aligned with the notches
[C] in the edge of the timing inspection hole [D] in the
starter clutch cover.

•

Using a thickness gauge [A], measure the valve clearance
between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust 0.24

∼

0.31 mm (0.0094

∼

0.0122 in.)

Intake

0.13

∼

0.19 mm (0.0051

∼

0.0075 in.)

NOTE

○

Thickness gauge is horizontally inserted on the valve
lifter.

Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

○

When positioning #1 piston TDC at the end of the
compression stroke:

Intake Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]

○

When positioning #4 piston TDC at the end of the
compression stroke:

Intake Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

Valve Clearance Adjustment

•

To change the valve clearance, remove the camshafts
(see Camshaft Removal in the Engine Top End chapter)
and valve lifters.

•

Replace the shim with one of a different thickness.

NOTE

○

Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.

•

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

Select a new shim thickness calculation as follows.

a + b – c = d

[a] Present Shim Thickness

[b] Measured Valve Clearance

[c] Specified Valve Clearance [Mean Value = 0.275 mm

(Exhaust), 0.160 mm (Intake)]

[d] Replace Shim Thickness

Example (Exhaust):

1.600 + 0.33 – 0.275 = 1.655 mm

○

Exchange the shim for the 1.675 size shim.

Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 2