2009ZX-6R Racing Kit Manual

Ninja ZX-6R2009 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 Ninja ZX-6R Motorcycle Service Manual Part Number 99924-1417-01 © 2008 Kawasaki Heavy Industries, Ltd. First Edition (1): Nov. 25, 2008 Congratulation on your purchase of racing kit parts for the 2009 Ninja ZX-6R. IMPORTANT This manual provides how to install racing kit parts for the 2009 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. 99924-1417-01). 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 VEHICLE TO A COMPETITION MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE. CAUTION When operating the engine, be careful not to trouble persons with noise. Do not turn the engine with loud engine and exhaust noise. DISCLAIMER OF WARRANTY ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED. BASIC WORKS IN INSTALLING KIT PARTS We are going to make up the original Ninja ZX-6R for the racing machine. We recommend that the rider himself should do the basic works, removing parts or installing parts etc., given advices by the tuning shop. In a race, although trouble will be apt to happen, if you participate in basic works, you can discriminate cause of trouble, so you can return the race soon. But concerning difficult technical works, you should as tuning shop. 1 Dummy page 2 . ................................................9 Before Installing ............................................14 Crankshaft Main Journal and Connecting Rod Big End Bushings .................33 Electric Parts Installation.........................................................................................................................................................................................................................................................................26 Cooling System..................26 Oil Catch Tank Installation .........................................19 Clutch Adjustment (Back-Torque Limiter Setting)..............................................................6 Periodic Maintenance Chart .......................................................25 Water Temperature Sensor..........................................................................................................................................................................................................32 Front Fork Springs (Kit)................16 Connecting Rod Bolts ....................................................... Sprockets ......................................................................................................................................................................................................................27 Frame Parts Installation ...................................................................................................................................................................................................20 Transmission....................................................31 Steering Damper (Kit) ......................................................24 Generator (Option)......................................................................31 Brake Pads (Kit)...............................................13 Valve Springs........................................................................................................................................................................35 Main Harness and Sub Harness (Kit) .......14 Cylinder Compression..............................................................................................7 Preparation...........................................................................................................................................................................................35 Battery ..................................................................................................................................................................................................................................25 Muffler...........................................................................................................................................31 Height Adjustment..................................................................................................................4 Racing Kit Service Data ...........................11 Camshaft Chain Tensioner...............................................................................................................................................................................................................25 Generator Cover (Option) ..9 Cylinder Head ....................29 Drive Chain (Kit) ....................................................................................................................................................36 Wiring Diagram (with Original Meter/Original Regulator) ........................................................................................................................................................9 Racing Kit Parts ............................................................................................29 Throttle Parts (Kit)......................................12 Camshafts...............................................................................................................................................................................................................................................................9 Engine Parts Installation...........................................................................Table of Contents General Specifications .........................................................................................................................................................................................................................44 3 .................................25 Cover Gaskets ............................36 Installation of Brackets for Regulator/Rectifier and Vehicle-down Sensor...........................................9 Air Intake Parts ...........................................................................................42 Wiring Diagram (with Original Meter/Kit Regulator) ....................................................................................................................................................................................................24 Transmission Shimming.......................................................................................................................................................................................................35 Speed Limit of Pit Road ....................................................................................................................................... 500 13262-0533 13262-0534 32/23 1.391 13262-0688 13262-0689 29/23 1.200 See Gear Selection 13262-0509 37/20 1.346 See Gear Selection 13262-0685 30/19 1.696 13262-0538 13262-0539 32/22 1.167 See Gear Selection 13262-0683 32/17 1.125 Type D 1st 2nd In Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio In 13262-0677 13262-0678 36/16 2.643 13262-0527 13262-0528 39/18 2.455 13262-0540 13262-0541 35/26 1.571 13262-0536 13262-0537 34/16 2.882 See Gear Selection 13262-0530 33/20 1. 1.300 Type B 13127-0055 13262-0526 37/14 2.5°BTDC @1 300 r/min (rpm) Racing gasoline Racing oil Between upper and lower levels of oil level gauge.261 4 .421 *13262-0711 13262-0582 26/20 1.850 See Gear Selection 13262-0510 32/20 1.600 *13262-0710 13262-0380 27/19 1.900 (76/40) Transmission Gear Table STD (Type A) *13127-0068 *13262-0712 38/14 2.579 13262-0686 13262-0687 32/23 1.650 13262-0531 13262-0532 30/20 1.714 *13262-0744 13262-0508 33/15 2.25 3rd Out Teeth (Out/In) Gear Ratio In 4th 5th 6th Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio See Gear Selection 13262-0684 39/23 1.391 Type C （13127-0055） 13262-0535 36/14 2.General Specifications Item Engine: Ignition timing Fuel (Recommended) Engine oil (Recommended): Level Drive Train: Primary drive reduction ratio 2009 Ninja ZX-6R Racing 12. Input 3rd/4th Gear Selection Table 4th Gear A 3rd Gear A B *13262-0709 13262-0680 B 13262-0529 13262-0681 13262-0682 C D 13262-0679 * The transmission gears marked “ * ” of ’09 model have interchangeability with those of ’08 model. Gear Identification Slit Number Table STD (Type A) 1st 2nd 3rd 4th 5th 6th In Out In Out In Out In Out In Out In Out 0 0 0 0 0 0 0 0 0 0 0 0 Type B 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 Type C 1 2 2 2 3 3 Type D 5 . 28 mm 0. 6 .40 mm (Minimum) @11°BTDC NGK R0045Q-10. 113 in·lb) Spark plugs Spark plug tightening torque These values show the specifications when standard cylinder head and gasket are used. R0373A-10 13 N·m (1. Valves: Duration: Intake Exhaust Camshaft timing (cam lift center): Intake Exhaust Valve clearance: Intake Exhaust Valve to piston clearance: Intake Exhaust Ignition System: 288° 258° 105° (ATDC) 110° (BTDC) 0.80 mm (Minimum) @12°ATDC 1. When the clearance between the valve and the piston head is smaller than the minimum specific values.Racing Kit Service Data Item Standard Cylinder Head. turn the installed position of the camshaft sprocket on the camshaft and change the camshaft timing.3 kgf·m.16 mm 0. .adjust Drive chain .replace General lubrication of chassis .. Piston ring..clean/check* Front fork oil ...decarbonization Cylinder .replace Drive chain ..check* Piston/cylinder clearance .check* Piston..... connections .clean Fuel hose.check* Throttle grip play . bearing ...change Radiator hoses.check* Brake pad wear ..check* Brake fluid . fuel filter .check* Fuel system ....change Nut.check* Drive chain guide . and fastener tightness .check* Engine sprocket .check* Connecting rod big end bearing .replace Brake caliper piston seal and dust seal .replace Crankshaft main bearing .. FREQENCY OPERATION Engine Clutch plate .replace Steering play ..check* Brake fluid level . Piston pin .. then every 5 races ● ● ● ● ● ● If damaged ● ● ● year year year 2 years ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Each Race Every 3 races Every 5 races Every 10 races As Required (300 km) (1 000 km) (1 500 km) (3 000 km) ...lubricate Drive chain wear ..replace Front fork . bolt.replace Valve lapping Cylinder head/valve .replace Brake hose ....Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition..grease Rear sprocket .check* Spark plug .check* Transmission gear..clean/gap* Engine oil .check* Steering stem bearing ....check* Frame Brake operation .....change Oil filter .perform 7 ● ● ● ● ● First change after 2 races.change* Brake master cylinder cup and dust seal ..check* Coolant . uni-track linkage . adjust.. 8 .. or torque if necessary..grease Swingarm pivot. add.check* Each Race Every 3 races Every 5 races Every 10 races ● As Required (300 km) (1 000 km) (1 500 km) (3 000 km) ● ● *: Replace. clean. uni-track linkage .grease Swingarm pivot.FREQENCY OPERATION Wheel bearing (rear) . Racing Kit Parts Also. Wire Net (14037-0089) 9 . 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. A. Engine Parts Installation Air Intake Parts Remove the wire net of Ram – Air duct intake to reduce the air flow resistance. So please order each parts referring to the “Racing Kit Parts List” in the back of this manual.Preparation Before Installing Modify the parts based on your race regulation. connect removing Black/Yellow and Green/White Leads directly. and electric parts) for racing. To avoid misuse keep the parts replaced with the kit parts separate. we have provided the spare parts. frame. and other optional parts (engine. Remove the parts or cut the cleaner element off remaining the punching plate. Output of Secondary Air on Air Cleaner: Plug the hole. Secondary Air Passages on Cylinder Head: Plug the holes. Remove the oil receiver and plug the hole. 10 . then plug the four holes. Plug the hole. or insert the pins (92043-1506) instead of the original pins. 3. Remove the air cleaner element or cut the cleaner element off remaining punched plate to reduce the air flow resistance. 2. Remove the parts. 4. 1.Remove the secondary valves of cylinder head and relational parts. NOTE These procedures make air resistance less and intake/exhaust gas flow more smooth. Mark the throttle body holders so that they can be installed in their original positions. air flow speed will be reduced and the engine performance at the high speed range may be down. Grind off and smooth the stepped portions at the mating surface between valve seat and the port. Do not port it. Use #200 oil stone for eliminating any stepped portions. It may be done to the extent of getting rid of uneven surfaces. Use #200 oil stone for smoothing and #300 oil stone for finishing. 1. To extend the intake port. Stepped Portions of throttle body holder and cylinder head. Use the hand grinder. 2. However. Grind off the stepped portion only at the mating surface between the throttle body holder and the intake port. Stepped Portions of valve seat and cylinder head.Cylinder Head Grind off the stepped portions of the ports and smooth the inside of ports to make intake/exhaust gas flow more smooth. Smooth the inside of the intake port and exhaust port. 11 . much more effect can not be expected by excessive grinding and smoothing. 4 mm). O-ring and tensioner body. Chamfer the machining edge of the cylinder head where the valve seat is installed.The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners (Round them to about R1). The cam chain tensioner must be adjusted at every race. Check to see that the tensioner rod turns freely in the body. XXX. 12 . Install the tensioner on the cylinder head with the tensioner rod is fully pushed back. polish the tensioner rod or fine the female threads in the body with a tap (Diameter × Pitch = 6 mm × 1. NOTE Never forward the tensioner rod forcibly. if not. also smooth the dome of the combustion chamber with the valves installed. Edges NOTE When grinding the cylinder head bottom surface or using thinner gaskets.0 mm).8 mm. this will increase mechanical loss of the tensioner and may damage to the chain guide. Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to take up any gap and tighten the locknut. EX: 1. Excessive smoothing may reduce the cylinder compression. Tighten the rock nut after adjustment. adjust the valve timing to keep that the valve to piston clearance is not less than the minimum value (IN: 0. Apply the engine oil to the tensioner rod. Camshaft Chain Tensioner Replace the cam chain tensioner with the kit to gain the durability. insert them into the tensioner body. Turn the tensioner rod in with a screwdriver until it becomes hard to turn. D.20 mm 0.31 mm Kit Intake 49118-0149 Timing 288° Cam Lift 8.13 ∼ 0.A.24 ∼ 0. Original Timing Cam Lift Valve Clearance Intake 288° 8. Sprockets: Adjust the valve clearance within the specified value. E.60 mm (conformed to FIM regulation) Valve Clearance 0. B. Sprockets Camshafts.19 mm 13 . Tensioner Tensioner Rod O-ring O-ring Lock nut Camshafts.19 mm Exhaust 258° 7. but more performance is expected when adjusted from middle value to upper limit between adjustable range.13 ∼ 0. C.60 mm 0. 8 mm.5 kgf·m. The thickness of the collapsed clay is the size of the squish.8 mm Exhaust 1.80 mm [2] Left and Right 0.) Intake 0.If you don’t adjust the valve timing for racing. do not start the engine because the valves will touch the piston and the engine may be damaged. When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing. Cylinder Compression To adjust the cylinder compression. Tighten the camshaft sprocket bolts to 15 N·m (1.65 mm/[2] 0. and put a small piece of modeling clay on the shoulder of the piston.0 ft·lb) of torque.) Timing (cam lift center) Intake Exhaust When round bolt holes are used 105° 110° Recommended timing for race 107. Select proper cylinder head gasket and cylinder base gasket. Squish Measurement [1] Front and Rear 0. At this point. 11. install the sprocket to the camshaft between the adjustable range of the long bolt holes. If you adjust the valve timing. 14 . Note that by grinding the cylinder head surface only left and right squishes become narrower. Remove the cylinder head and measure the thickness of the clay.4 mm If the valve to piston clearance is less than the minimum value. Valve to Piston Clearance (Min.67 ~ 0. while by grinding the cylinder top surface or decreasing the gasket-thickness all the squishes become narrower.65 ~ 0. Keep the piston squish more than 0. grinding the cylinder top surface or using thinner gaskets. the valve to piston clearance will be minimum.5° 110° when long bolt holes are used When grinding the cylinder head bottom surface. check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly. and tighten the head bolts to the specified torque. Measure the valve to piston clearance at about 12° ATDC (Intake) and 11° BTDC (Exhaust) of crankshaft timing. Valve Springs The original machine’s valve springs should be used . Install the cylinder head gasket and cylinder head. Valve Timing (Valve Timing is the same when the standard camshaft and the kit camshaft are used.85 mm The most preferable squish measurement is [1] 0. Position the piston at Top Dead Center. 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.65 ~ 0.67 mm.65 mm. adjust the thickness of the cylinder head gasket and the cylinder base gasket or smooth the cylinder top surface to make the piston squish 0. be sure the valve to piston clearance especially. Front/Rear 2.60 mm 0. Squish.45 mm 0.55 mm 0. Color Yellow White Red Blue None Green 1. Squish.Cylinder Head Gasket Part No. Left/Right 15 .65 mm 0.70 mm Note KIT KIT KIT KIT Original KIT I.50 mm 0.D. 11004-0071 11004-0070 11004-0069 11004-0068 11004-0085 11004-0067 Thickness 0. 000 mm : over 30.000 mm within 34. 1) Crankshaft Main Journal Crankshaft Main Journal Diameter 1. Crankshaft Main Journal Diameter Marks SIZE : over 30.016 mm 16 .008 mm and over within 34. The kit bushings are improved in anti-seizuring characteristics as well as in wear-resistance as compared with the standard bushings. Main Journal Diameter Marks SIZE “ ” mark None : over 34.984 mm within 30.992 mm “1” mark None Crankcase Main Journal inside Diameter 1.008 mm : 34.992 mm within 31.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. 008 mm) (30.992 mm ~ 31.491-1.Main Journal Bush A.499-1.000 mm ~ 34.000 mm) NONE NONE (34.000 mm ~ 34.016 mm) (30.008 mm ~ 34.992 mm) 17 .984 mm ~ 30.495-1.992 mm) NONE 1 (34. Size Color Main Journal Bush Size Color blue purple black green brown yellow Bush Selection Table Crankcase Inner Diameter Crankshaft Diameter Size Color brown yellow black green black green blue purple Journal Number 1/5 2/4 3 1/5 2/4 3 1/5 2/4 3 1/5 2/4 3 Part Number (STD) 92139-0247 92139-0250 92139-0253 92139-0246 92139-0249 92139-0252 92139-0246 92139-0249 92139-0252 92139-0245 92139-0248 92139-0252 Part Number (KIT) 92139-0271 92139-0274 92139-0277 92139-0270 92139-0273 92139-0276 92139-0270 92139-0273 92139-0276 92139-0269 92139-0272 92139-0275 Thickness mm 1.992 mm ~ 31.499 1.495 Journal Number 1/5 2/4 3 1/5 2/4 3 1/5 2/4 3 Part Number (STD) 92139-0245 92139-0248 92139-0252 92139-0246 92139-0249 92139-0252 92139-0247 92139-0250 92139-0253 Part Number (KIT) 92139-0269 92139-0272 92139-0275 92139-0270 92139-0273 92139-0276 92139-0271 92139-0274 92139-0277 ○ 1 (34.008 mm ~ 34.008 mm) (30.984 mm ~ 30.016 mm) (30.503 1.000 mm) ○ NONE (34. Crankpin Diameter Marks “ ” mark None : over 29.000 mm and over within 33.485-1.992 mm within 30.480-1. Inside Diameter Mark ( or None) B.984 mm and over within 29.2) Crankpin Crankpin Diameter 1.016 mm None : 33.490 1. Alphabet (G.000 mm : 29.480 Part Number (STD) 92139-0165 92139-0166 92139-0167 Part Number (KIT) 92139-0194 92139-0195 92139-0196 18 .008 mm A.485 1.008 mm within 33.992 mm Connecting Rod Big End Inside Diameter Connecting Rod Big End Inside Diameter Marks “ ” mark : over 33. Weight Mark.H etc) Connecting Rod Big End Bushings Size Color blue black brown Thickness mm 1.475-1. 2 ±0.38 mm (0.984 mm ~ 29.008 mm) None (33. Apply a small amount of molybdenum disulfide grease to the threads of bolts.016 mm) ○ (33. Bolt Length after tightening – Bolt Length before tightening = Stretch Bolt Stretch Usable Range: 0.) Turn the big end nuts more until the bolt stretch reaches the usable range.992 mm) ○ (29.992 mm ~ 30.016 mm) Crankpin Diameter Mark ○ (29.008 mm ~ 33.Selection Table Connecting Rod Big End Inside Diameter None (33. Tighten the big end nuts at the torque of 11. The original connecting rod bolt has recesses at both ends to measure its length and determine the bolt stretch.8 ±2 N·m (1.015 in.2 kgf·m): reference Check the length of the bolts and find the bolt stretch.984 mm ~ 29.000 mm) None (29.992 mm) Size Color brown black black blue Part Number (STD) 92139-0167 92139-0166 92139-0166 92139-0165 Part Number (KIT) 92139-0196 92139-0195 92139-0195 92139-0194 Connecting Rod Bolts Use the original connecting bolts and nuts.992 mm ~ 30.000 mm ~ 33.013 ~ 0. use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch. Install the original bolts into the connecting rod.33 ~ 0. NOTE Replace the original bolts with new ones if they have already been tightened up to usable range 2 times. Before every tightening.000 mm) None (29.000 mm ~ 33. 19 .008 mm) ○ (33.008 mm ~ 33. Clutch Adjustment (Back-Torque Limiter Setting) The Ninja ZX-6R engine is equipped with the Kawasaki back-torque limiter mechanism in the clutch. The back-torque limiter works to reduce the chance of rear wheel hop caused by engine braking during hard braking and down shifting. The back-torque limiter operating condition can be changed by changing the total thickness of clutch plates and changing the number of leaf springs. Try different settings and select the best. 20 The standard setting of length [A], total thickness of clutch plates shown in the illastration, becomes about 40.7 mm. For this setting the effective stroke of clutch spring plate during the back-torque limiter operation is adjusted between 0.45 and 0.75 mm. By increasing the effective stroke the back-torque limiter causes more slip. The effective stroke increases by decreasing the length [A]. The length [A] between 39.5 and 40.7 mm is available by changing the combination of the steel plates. Replace one steel plate with a thinner one and try the setting. If the operation of the back-torque limiter is not enough replace other steel plates one by one. * Steel plates of ZX600K model’s are available. Thickness (mm) Part Number 2.0 13089-1073 For precise setting the measurement of the effective stroke of clutch spring plate is recommended. • Remove oil from clutch plates. • Hold an extra drive shaft in a vise and install the following clutch parts on the shaft. 21 Recommended Clutch [A] [B] [C] [D] [E] [F] [G] [H] [I] [J] Spacers Needle Bearing Bushing Clutch Outer Casing Clutch Hub Sub Clutch Hub Friction Plates: total 8 pcs. Steel Plates Spring Plate Steel Plate with Spring 22 two and three. using a caliper or a depth gauge. 23 . The length from the clutch spring plate to the top surface of the sub clutch hub. • Move the clutch housing gear back and forth [C]. total thickness of clutch plates. When decreasing the length [A]. try with a retainer of 5 mm. The decrease of the depth [B] from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured. Standard Selection of Spring Retainers Total Thickness of Clutch Plates Size of Spring Retainers Remarks P/No. set a dial gauge [A] against the raised center [B] of the clutch spring plate. use the optional shim (provided as optional production part) to keep the position of clutch release lever according to the table below. measure and record the depth [B] shown in the figure on page 21 and 22. 39108-0004 * If clutch slip is occurred with a retainer of 6 mm. [D] Drive Shaft After installing the clutch to the engine. The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate. total thickness of clutch plates. use the optional spring retainers (provided as optional production parts) to keep the preload of clutch springs according to the table below. • To measure the effective stroke of clutch spring plate. If you have clutch slip during acceleration use shorter spring retainers by 1 mm to increase preload of clutch springs. They are provided as optional production parts.2 mm 5 mm P/No. The number of leaf springs affects all over the operation of the back-torque limiter but especially the beginning of the operation. When decreasing the length [A]. By decreasing the number of the leaf springs the sub clutch hub operates easily and pushes the clutch operating plate causing more slip.5 ~ 40. 13091-1041 40.• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub). Manage the depth [B] to adjust the effective stroke after that.7 mm 6 mm Original Setting 39. because the friction disks would be worn and the length [A] (Total thickness of all clutch plates) would change. The standard setting of the number of leaf springs is four.2 ~ 40. Two types of nuts are available for the number of leaf springs. 6 mm 92200-0050 Original Spline washer (input) 1. Take kit and optional transmission gears are available to be closer to each gear ratio. 40.3 mm and 0. Transmission Shimming By using washers with various thickness.5 mm. Thickness Part No. 92180-0149 Original Setting P/No. to prevent the seizure of gears and to keep smooth gear-shifting. Plane washer 24 .6 mm 92022-212 Production part (input.4 mm 92200-0230 Kit 1.2 mm 39. keep the axial clearance between 0.8mm 92200-0231 Kit 1. output) 1. 92026-1590 92025-1137 Transmission Remove the three steel balls (600A0500) from the output shaft assembly.7 mm 40.0 mm 1.4 mm 92200-0138 Original Plane washer 1. 1.Standard Selection of Shim Total Thickness of Clutch Plates Approx.2 mm Remarks P/No.5 mm 1.8 mm 92202-1722 KIt 1.5 ~ 40 mm Size of Shim 2. Spline washer (input) 2. Select using the optional generator or original generator according to the situation. Muffler With recommended muffler engine performance can be improved. use the optional generator. Cover Gaskets The optional cover gaskets are available. Installing Option Generator Generator Cover (Option) Use the option generator with the optional generator cover.co.beet. The output power of the optional generator is 10A/8000 rpm (Original: 30A/5000rpm). 25 . They are made from “meta-form” and made easy to exfoliation. Recommended muffler: Beet NASSERT-R 1002-B15-00 Web Site : http://www. Use the optional regulator and optional generator cover set when using the optional generator.jp/(beetjapan) * For further information contact the manufacturer of muffler directly. NOTE When using the optional generator cover. The consume current of the racing model in running condition is 7 ~ 8A.Generator (Option) To quicken response by reducing the flywheel mass and to reduce the weight. use the optional inner rotor generator. C. * End of the hose to atmosphere should be always beyond the liquid surface. Cooling System With recommended radiator engine performance can be improved. NOTE Capacity of a reserve tank should be more than 200 cc.43014 Felegara di Medesano (PR) ITALY Tel.: +39 0525 431593 Fax: +39 0525 431792 P. e C.it * For further information contact the manufacturer of radiator directly. MB MOTORSPORT di Bagatti Marco e Silvio & C. Position of the hose to a reserve tank.) needs the output signal from the original water temperature sensor. s.Water Temperature Sensor The original water temperature sensor installed in the cylinder head must be remain and connected to the main harness because the electronic control unit (E.a. 26 .mbmotorsport.it Web site: www.I. 3 .F. Reserve Tank Installation When not using the original reserve tank. * End of the hose to the radiator should be always in the liquid.s. Reserve Tank should be equipped with a band so as not to affect the running and the handling. prepare a suitable substitue.U. Via Ugo La Malfa. IT02424740344 E-mail: mb@mbmotorsport. Oil Catch Tank Installation Fasten Oil Catch Tank (A) with Chain Cover to Crankcase by using bolt (E). Crankcase and Oil Catch Tank by using hose1 (B) and hose2 (C). In that case. A) Oil Catch Tank (52001-0007) B) Hose1 (Air Cleaner – Oil Catch Tank) (92192-0819) C) Hose2 (Crankcase – Oil Catch Tank) (92192-0820) D) Clamp (92170-1060) E) Bolt (92153-1567) F) Washer (92200-3712) G) Dumper (92075-1912) H) Collar (92152-0237) I) Washer (92022-304) J) Drain Bolt (130BD610) 27 . cut off part marked “★” of Damper and Collar (see next detail). Connect Air Cleaner. 28 .Detail Marked “★”: Cut off Dampers and Collar to prevent them running on Chain Cover arrow part. Throttle reel travel angle is marked on each part to identify. Mark 12-0270-xxxx 12-0271-xxxx 29 . grip and reels are available as optional parts. Throttle Reel Travel Angle················Effective angle excluding throttle cable free play. 32099-0046 32099-0047 120CA0518 31064-0187 2) Throttle Reels Tow types are available. 1) Throttle Case Parts Name Throttle Case. These optional parts quicken throttle response to the twist grip. Throttle Cable (Accelerator Side) 54012-0270 Throttle Cable (Decelerator Side) 54012-0271 Run the throttle cable [A] to the left side of the frame below.0/60 deg 65° 1.Frame Parts Installation Throttle Parts (Kit) The following throttle cases. I. Upper Throttle Case. Mark to Full Throttle 59101-0006 R19.D. accelerator and decelerator cables are available. Identification Mark 2) Throttle Cable Tow types. Twist Grip Turn Angle P/No. Parts Name P/No. Lower Bolts (2) Pipe (Grip) P/No.3/65 deg 65° 59101-0007 R21. I.D. 1. 2. 30 . Upper Case: 32099-0046 Lower Case: 32099-0047 Bolts: 120CA0518 Reel (65°): 59101-0006 Reel (60°): 59101-0007 Throttle Pipe: 31064-0187 Assemble the throttle cases so that the groove for identification faces upwards (see above). 3. 5. 4. It is correct to assemble the throttle cases so that the groove side have no clearance and the opposite (lower) side have clearance. 6. please make sure that the damper shall not limit the steering angle. as normally stipulated by the race regulations. Guard: 55020-0028 2. Swingarm (Left Side) Brake Pads (Kit) The front and rear brake pads for racing use are available. Because of higher braking force. and the rear pads are for lower braking force.D. When install the racing type steering damper. (Stamp) FO GG with Yellow Paint without Yellow Paint Braking Force High ↨ Low Braking Force High Rear Brake Pads P/No. since the original damper is mainly designed for street riding or at most sport riding. replace the front caliper bolts with the kit parts to make the installation of the caliper stronger. 31 . 43082-0074 Original Stamp 2508 TT2911HH I. Bolt: 130BA1020 3. The front pads are for higher braking force.Drive Chain (Kit) 1) Chain Guard 1. Original 43082-1220 43082-1192 ↨ Low Steering Damper (Kit) For race usage it is recommended to use racing type steering damper (see next page). Front Brake Pads P/No. 0 mm/2.1) Recommended Steering Damper OHLINS SD121 (Stroke: 68 mm) 1. 4.5 mm) Spacer: 92026-0140 (Standard T = 4. 4. 5. 2. Steering Damper: OHLINS SD121 Bolts: 132BA0830 O-rings: 670B2012 Washer: 410AA0800 Collar: 92152-0798 Height Adjustment Loosen the nut (1) and insert the spacer (2) as required.2 mm/4. 3. 3. 1.0 mm) Bracket: 32037-1887 (Standard) 32 . 43 ft·lb) of torque. Nut: 92015-1316 Spacer Set: 92026-1586 (T = 1.0 mm/3. 2. Tighten the nut (1) to 59 N·m (6.0 kgf·m. 25 N/mm 28 mm 2) Front Fork Spring P/No. 1) Front Fork Specifications Items Rebounded damping setting Compression damping setting Fork Spring Preload Setting Fork oil Fork oil level Spring length Spring constant Sub spring stroke Original 4 turns out from the fully clockwise position 5 1/2 turns out from the fully clockwise position 4 turns in from the fully counterclockwise position SHOWA SS05 80 mm 235 mm (Free Length) 9. Identification Mark The spring constant value is stamped on the one side surface of the spring.75 N/mm K = 9.75 N/mm 3) Front Fork Spring Replacement Replace the main spring referring to the Fork Oil Change section of the base Service Manual. 33 .25 N/mm K = 8.Front Fork Springs (Kit) The optional front fork springs are available for racing. Original 44026-0141 44026-0142 Spring Constant K = 9. Fork Spring Installation 34 . Main Harness and Sub Harness (Kit) Main harness and sub harness are available for racing use as optional parts. Select one of them in accordance with your race regulation. Main Harness (with Original Meter and Original Generator/Regulator): 26031-0789 Main Harness (with Original Meter and Kit Generator/Regulator): 26031-0790 Sub Harness (with Original Meter and Original Main Harness): 26031-0327 35 .Electric Parts Installation Battery Use the original battery or a battery with 12 V 7 Ah or more capacity. the Kit main harness (26031-0789/0790) is essential.Main Harness Combination Parts Table ○: need ×: no need. such application is possible only with the models WITHOUT the immobilizer system. (The next figure indicates the case where the original regulator/rectifier is used. push the switch in. Speed Limit of Pit Road The turn signal switch [A] on the left handlebar switch works as a speed limit switch of the pit road when the turn signal switch is turned to the left or right. 36 . However. To install Kit ECU onto the models WITH immobilizer system. Normally the models with immobilizer system carry "IMMOBILIZER" logo on the key cylinder. Install the kit regulator/rectifier on the two rear holes of the bracket when the kit regulator/rectifier is used.) Install the vehicle-down sensor using the kit bracket. Harness Part Meter Assembly (Original) Relay Box (Original) 27002-0007 Relay Assembly (Kit) 27002-3703 Harness for Original Generator /Regulator 26031-0789 ○ × ○ Harness for Kit Generator /Regulator 26031-0790 ○ × ○ Sub Harness 26031-0327 ○ ○ × Notes Concerning Sub Harness (26031-0327) Use The sub harness (26031-0327) is designed to use Kit ECU with original main harness. Install the original regulator/rectifier on the two front hole of the bracket when the original regulator/rectifier is used. To stop the speed limit. Installation of Brackets for Regulator/Rectifier and Vehicle-down Sensor Move the regulator/rectifier behind the battery box when the kit main harnesses (26031-0679/0680) are used. 7. 2. 6. 4.1. 5. 8. Bracket (for Regulator/Rectifier): 11055-1671 Dampers: 92075-209 Collars: 92152-0091 Nuts: 92210-0322 Bracket (for Vehicle-down Sensor): 11055-1665 Bolts: 132BA0620 Relay Assembly: 27002-3703 Regulator/Rectifier (Original): 21066-0028 Regulator/Rectifier (Kit): 21066-0010 37 . 3. Use the specified nuts (or similar cap nuts) to prevent the harness being damaged. φ16 mm Hole The locations of fender and its related parts are as follows.When the original fender is used. 38 . drill out the three holes of φ16 mm as shown and insert the dampers (92075-209). 1. At the same time as processing the hole opening. Boss 1. Bolt: 132BA0620 3. Nut: 92210-0322 2. cut off one mounting boss of the exhaust butterfly valve actuator. 1. Regulator/Rectifier (Original): 21066-0028 39 . Bracket (for Vehicle-down Sensor): 11055-1655 1. Bracket (for Regulator/Rectifier) : 11055-1671 2. Wiring form Generator to Regulator/Rectifier 3.Run both wirings (wiring from main harness to regulator/rectifier and wiring from generator to regulator/rectifier)in the left side of the starter relay and run them behind the frame. Starter Relay Run the main harness forwards along the inside of the main frame and run it between the throttle body and the main frame. Main Harness 40 . 1. 1. Wiring from Main Harness to Regulator/Rectifier 2. Dummy Page 41 . Wiring Diagram (with Original Meter/Original Regulator) 42 . 43 . Wiring Diagram (with Original Meter/Kit Regulator) 44 . 45 . Dummy Page 46 . Racing Kit Parts List . T=0.9 Spec Code ’09 R9FR 1 1 1 1 1 1 1 1 4 1 1 2 92055A 92055-086 (OPTION) 132 132BA0620 (OPTION) BOLT-FLANGED-SMALL.55 GASKET-HEAD.18.50 GASKET-HEAD.6X20 1 NOV.T=0.70 GASKET-HEAD.60 GASKET-HEAD.8X1.10X14 RING-O.T=0.6MM PIN.T=0. 11004-0067 (OPTION) 11004-0068 (OPTION) 11004-0069 (OPTION) 11004-0070 (OPTION) 11004-0071 (OPTION) 12048-1175 (OPTION) 49118-0149 (OPTION) 92015-1078 (OPTION) 92043-1506 (OPTION) 92055-011 (OPTION) Description GASKET-HEAD.INTAKE NUT.This catalog covers: GRID NO.T=0.12.FLANGED. This grid covers: ’09 ZX600R9FR Engine B-3 Cylinder Ref.45 TENSIONER-ASSY CAMSHAFT-COMP. 11004 11004A 11004B 11004C 11004D 12048 49118 92015 92043 92055 Quantity-ZX600 Part No.2008 . No.5MM RING-O. This catalog covers: GRID NO.CONROD.BROWN Spec Code ’09 R9FR AR 8 AR AR 4 AR AR 4 AR AR 2 AR BUSHING.BROWN BUSHING.BLACK BUSHING.BLUE BUSHING.CRANK #3.CRANK #3.CONROD.CRANK #2&#4.BLACK BUSHING.CRANK #3.CRANK #2&#4. 92139-0194 (OPTION) 92139-0195 (OPTION) 92139-0196 (OPTION) 92139-0269 (OPTION) 92139-0270 (OPTION) Description BUSHING. This grid covers: ’09 ZX600R9FR Engine B-4 Crankshaft Ref. No.BLUE BUSHING.BLUE BUSHING.CRANK #1&#5.CRANK #1&#5.12.BLUE BUSHING.BLACK BUSHING.BROWN 92139E 92139-0271 (OPTION) 92139F 92139-0272 (OPTION) 92139G 92139-0273 (OPTION) 92139H 92139-0274 (OPTION) 92139I 92139-0275 (OPTION) 92139J 92139-0276 (OPTION) 92139K 92139-0277 (OPTION) 2 NOV.CRANK #1&#5.BROWN BUSHING.BLACK BUSHING.CONROD.2008 .CRANK #2&#4. 92139 92139A 92139B 92139C 92139D Quantity-ZX600 Part No. 5X1.0) SHIM. 39108 92025 92026 Quantity-ZX600 Part No.5 6 1 1 3 NOV.0(STD-1.15. This grid covers: ’09 ZX600R9FR Engine B-5 Clutch Ref.3X27. No.This catalog covers: GRID NO. 39108-0004 (OPTION) 92025-1137 (OPTION) 92026-1590 (OPTION) Description Spec Code ’09 R9FR RETAINER-SPRING.20 SPACER.T=5.2008 .T=1.12. 3X35X1.INPUT 3RD&4TH.22.18T GEAR.3X35X1.INPUT 5TH.12.32T WASHER. This grid covers: ’09 ZX600R9FR Engine B-6 Transmission(TYPE-B) Ref.37T GEAR.14T SPROCKET-OUTPUT.39T GEAR.20T&19T GEAR. Description Spec Code ’09 R9FR 13127-0055 (OPTION) 13144 13144-0047 (OPTION) 13144A 13144-0048 (OPTION) 13262 13262-0526 (OPTION) 13262A 13262-0527 (OPTION) 13262B 13262-0528 (OPTION) 13262C 13262-0529 (OPTION) 13262D 13262-0530 (OPTION) 13262E 13262-0531 (OPTION) 13262F 13262-0532 (OPTION) 13262G 13262-0533 (OPTION) 13262H 13262-0534 (OPTION) 13262I 13262-0679 (OPTION) 13262J 13262-0680 (OPTION) 13262K 13262-0681 (OPTION) 13262L 13262-0682 (OPTION) 13262M 13262-0683 (OPTION) 92022 92022-1722 (OPTION) 92022A 92022-212 (OPTION) 92200 92200-0230 (OPTION) 92200A 92200-0231 (OPTION) SHAFT-TRANSMISSION INPUT.2008 .This catalog covers: GRID NO.INPUT 2ND.OUTPUT 6TH.22.INPUT 3RD&4TH.30T GEAR.33T GEAR.OUTPUT 5TH.INPUT 6TH.23T GEAR.17T&20T GEAR.28.INPUT 3RD&4TH.INPUT 3RD&4TH.OUTPUT LOW.0X1.8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR AR AR AR 4 NOV. No.OUTPUT 2ND.8 WASHER.6 WASHER.32T GEAR.17T&23T GEAR.15T GEAR.3X34.OUTPUT 3RD.17T&20T GEAR.16T SPROCKET-OUTPUT.4 WASHER.28.0X1.3X34.20T&20T GEAR.OUTPUT 4TH.INPUT 3RD&4TH. 13127 Quantity-ZX600 Part No.20T GEAR. 13262-0535 (OPTION) 13262-0536 (OPTION) 13262-0537 (OPTION) 13262-0538 (OPTION) 13262-0539 (OPTION) Description GEAR.INPUT 2ND.INPUT 5TH.OUTPUT LOW.35T GEAR.OUTPUT 2ND. No.This catalog covers: GRID NO.OUTPUT 6TH.INPUT 6TH.16T GEAR. This grid covers: ’09 ZX600R9FR Engine B-7 Transmission(TYPE-C) Ref.2008 .12.36T GEAR.32T GEAR.26T GEAR.OUTPUT 4TH.34T GEAR.39T Spec Code ’09 R9FR 1 1 1 1 1 1 1 1 13262E 13262-0540 (OPTION) 13262F 13262-0541 (OPTION) 13262G 13262-0684 (OPTION) 5 NOV. 13262 13262A 13262B 13262C 13262D Quantity-ZX600 Part No.OUTPUT 5TH.24T GEAR. OUTPUT 2ND.2008 .36T GEAR.INPUT 2ND.23T GEAR.OUTPUT 4TH.29T Spec Code ’09 R9FR 1 1 1 1 1 1 1 13262E 13262-0688 (OPTION) 13262F 13262-0689 (OPTION) 6 NOV. 13262 13262A 13262B 13262C 13262D Quantity-ZX600 Part No.This catalog covers: GRID NO.OUTPUT 5TH. No.INPUT 5TH.16T GEAR.32T GEAR.23T GEAR.12. 13262-0677 (OPTION) 13262-0678 (OPTION) 13262-0685 (OPTION) 13262-0686 (OPTION) 13262-0687 (OPTION) Description GEAR.OUTPUT 6TH.INPUT 6TH. This grid covers: ’09 ZX600R9FR Engine B-8 Transmission(TYPE-D) Ref.30T GEAR. LARGE COVER GASKET.SMALL COVER COVER-GENERATOR 7 NOV.GENERATOR COVER GASKET. This grid covers: ’09 ZX600R9FR Engine B-9 Engine Cover(s) Ref.12.CLUTCH COVER Spec Code ’09 R9FR 1 1 1 1 1 1 GASKET.This catalog covers: GRID NO. No.2008 . 11061 11061A 11061B 11061C 11061D 14031 Quantity-ZX600 Part No.OIL PAN GASKET. 11061-0303 (OPTION) 11061-0304 (OPTION) 11061-0305 (OPTION) 11061-0306 (OPTION) 11061-0307 (OPTION) 14031-0084 (OPTION) Description GASKET. 11055 Quantity-ZX600 Part No.SUB.MAIN.STD METER&HARNESS HARNESS.INDICATOR HARNESS.MAIN.12.This catalog covers: GRID NO.INTERFACE BOX HARNESS. This grid covers: ’09 ZX600R9FR Engine B-10 Fuel Injection Ref.KIT GENERATOR RELAY-ASSY 8 NOV.STD GENERATOR HARNESS. Description BRACKET.VDS Spec Code ’09 R9FR 11055-1665 (OPTION) 21175 21175-0248 (OPTION) 23016 23016-0006 (OPTION) 26031 26031-0240 (OPTION) 26031A 26031-0327 (OPTION) 26031B 26031-0789 (OPTION) 26031C 26031-0790 (OPTION) 27002 27002-3703 (OPTION) 1 1 1 1 1 1 1 1 CONTROL UNIT-ELECTRONIC LAMP-ASSY. No.2008 . This grid covers: ’09 ZX600R9FR Engine B-11 Generator Ref.0 NUT. 11055-1671 (OPTION) 21003-0068 (OPTION) 21007-0083 (OPTION) 21066-0010 (OPTION) 52001-0007 (OPTION) Description BRACKET.6X25 WASHER.CRANKCASE-OIL TANK WASHER.12X36X3.6X65 CLAMP TUBE.6.2 WASHER.5X16X1.2X11X1 DAMPER DAMPER BOLT.OIL TANK-AIR BOX Spec Code ’09 R9FR 1 1 1 1 1 4 1 2 3 1 3 2 2 2 1 1 1 2 3 1 2 92002-1696 (OPTION) 92022 92022-304 (OPTION) 92075 92075-1912 (OPTION) 92075A 92075-209 (OPTION) 92150 92150-1717 (OPTION) 92152 92152-0091 (OPTION) 92152A 92152-0237 (OPTION) 92153 92153-1567 (OPTION) 92170 92170-1060 (OPTION) 92192 92192-0819 (OPTION) 92192A 92192-0820 (OPTION) 92200 92200-0306 (OPTION) 92200A 92200-3712 (OPTION) 92210 92210-0322 (OPTION) 130 130BD0610 (OPTION) 132 132BA0620 (OPTION) TUBE.12X40 COLLAR COLLAR BOLT-FLANGED.6MM BOLT-FLANGED.REGULATOR STATOR ROTOR REGULATOR-VOLTAGE TANK-OIL BOLT.12.6.6X20 9 NOV.6X10 BOLT-FLANGED-SMALL. 11055 21003 21007 21066 52001 92002 Quantity-ZX600 Part No.This catalog covers: GRID NO.SOCKET. No.CAP.2008 . 16MM SPACER.FLANGED.OPENING CABLE-THROTTLE. This grid covers: ’09 ZX600R9FR Chassis C-3 Frame Fittings Ref.65DEG REEL.GRIP CASE.8X16X3.5 BOLT-SOCKET.0.60DEG NUT.8X30 WASHER-PLAIN-SMALL.2008 . 31064 Quantity-ZX600 Part No.LWR CABLE-THROTTLE.This catalog covers: GRID NO.UPP CASE.R21.8MM O RING.SET COLLAR.5X18 Spec Code ’09 R9FR 31064-0187 (OPTION) 32099 32099-0046 (OPTION) 32099A 32099-0047 (OPTION) 54012 54012-0270 (OPTION) 54012A 54012-0271 (OPTION) 59101 59101-0006 (OPTION) 59101A 59101-0007 (OPTION) 92015 92015-1316 (OPTION) 92026 92026-1586 (OPTION) 92152 92152-0798 (OPTION) 120 132 410 670 120CA0518 (OPTION) 132BA0830 (OPTION) 410AA0800 (OPTION) 670B2012 (OPTION) 1 1 1 1 1 1 1 1 1 1 2 2 1 2 BOLT-FLANGED-SMALL.3.12MM 10 NOV. Description PIPE-COMP.R19. No.12.CLOSING REEL. 12.K=8. 44026 Quantity-ZX600 Part No.75N/MM 1 1 11 NOV. This grid covers: ’09 ZX600R9FR Chassis C-4 Front Fork Ref.2008 .K=9.This catalog covers: GRID NO.75N/MM SPRING-FRONT FORK. Description Spec Code ’09 R9FR 44026-0141 (OPTION) 44026A 44026-0142 (OPTION) SPRING-FRONT FORK. No. SHOCKABSORBER. This grid covers: ’09 ZX600R9FR Chassis C-5 Other Ref.2008 .CHAIN Spec Code ’09 R9FR 43082-0074 (OPTION) 43082A 43082-1192 (OPTION) 43082B 43082-1220 (OPTION) 55020 55020-0028 (OPTION) 92145 92145-0504 (OPTION) 92145A 92145-0506 (OPTION) 92153 92153-1777 (OPTION) 130 130BA1020 (OPTION) 1 1 1 1 1 1 4 1 SPRING.C93G GUARD.FLANGED.10X20 12 NOV.RR.This catalog covers: GRID NO.K=105N/MM BOLT.10X60 BOLT-FLANGED.K=95N/MM SPRING. 43082 Quantity-ZX600 Part No.SHOCKABSORBER. No.FR PAD-ASSY-BRAKE. Description PAD-ASSY-BRAKE.RR.12.C93 PAD-ASSY-BRAKE. Doc No. 99929-0304-01 .