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1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual

1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 1
1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 1
1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 2
1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 3
1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 4
1990-2005 Kawasaki Ninja ZX-6, ZZ-R600, ZZ-R500, ZX500, ZX600 motorcycle service manual Preview image 5
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File Specifications

  • File Size: 35.67 MB
  • File Type: ZIP
  • Language: English
  • Printable: Yes
  • Estimated Download Time: 0.73 Minutes
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Models Covered in this Manual

  • 1990-2002 Kawasaki Ninja ZX6
  • 1993-2005 Kawasaki ZZR600
  • 1990-1993 Kawasaki Ninja ZX500
  • 1994-2005 Kawasaki Ninja ZX6R
  • 2003-2004 Kawasaki ZX6RR
  • 2002-2005 Kawasaki ZZR1200
  • 1990-1992 Kawasaki ZX600

Serial numbers:

  • Ninja ZX6: ZX600C, ZX600D, ZX600E, ZX600F, ZX600G, ZX600H, ZX600J, ZX600K, ZX600M, ZX600N, ZX600P, ZX600R
  • ZZR600: ZX600D, ZX600E, ZX600J, ZX600K, ZX600M, ZX600N, ZX600P, ZX600R
  • Ninja ZX500: EX500A, EX500B
  • Ninja ZX6R: ZX636A, ZX636B, ZX636C, ZX636D, ZX636E, ZX636F

Production/model years: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Product Information

Table of Contents

1. General Information

  • Model Identification
  • Specifications
  • Torque Specifications
  • Tools
  • Maintenance Chart

2. Fuel System

  • Carburetor Assembly and Disassembly
  • Fuel Injection System
  • Air Cleaner
  • Fuel Tank and Tap
  • Evaporative Emission Control System

3. Cooling System

  • Radiator and Fan
  • Coolant
  • Water Pump

4. Engine Top End

  • Cylinder Head
  • Valves
  • Camshaft
  • Cylinder and Piston

5. Clutch

  • Clutch Assembly
  • Master Cylinder
  • Slave Cylinder
  • Clutch Bleeding

6. Engine Lubrication System

  • Oil Path
  • Oil Pump
  • Oil Pan and Pressure Relief Valve

7. Engine Removal / Installation

  • Engine Removal
  • Engine Installation
  • Engine Adjustment

8. Crankshaft / Transmission

  • Crankshaft
  • Connecting Rods
  • Transmission
  • Gear Shifting

9. Wheels / Tires

  • Wheel Alignment
  • Tire Inspection
  • Axles

10. Final Drive

  • Chain
  • Sprockets
  • Rear Hub

11. Brakes

  • Brake Pads Replacement
  • Brake Fluid Service
  • Master Cylinder
  • Calipers

12. Suspension

  • Front Fork
  • Rear Shock Absorber
  • Swingarm

13. Steering

  • Steering Play Adjustment
  • Steering Head Bearings

14. Frame

  • Frame Inspection
  • Fairing

15. Electrical System

  • Battery and Charging System
  • Ignition System
  • Electric Starter
  • Lighting System
  • Switches

16. Appendix

  • Troubleshooting
  • Wiring Diagrams
  • Sealant and Bonding Agent
  • Supplement for Newer Models
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