The Kawasaki ZX600, 636 (ZX-6R) repair manual by Haynes covers: U.S. models:
Book Excerpt: 1995-2002 Kawasaki Ninja ZX600, 636 (ZX-6R) Repair Manual FUEL AND EXHAUST SYSTEMS
ELECTRICAL SYSTEM
Subject: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Kawasaki ZX600, 636 (ZX-6R) service, maintenance, repair. ISBN-10: 1844250652 | ISBN-13: 9781844250653 | Haynes 3541
- Kawasaki ZX600F, 1995-1997
- Kawasaki ZX600G, 1998-1999
- Kawasaki ZX600H, 1998
- Kawasaki ZX600J, 2000-2002
- Kawasaki ZX600F, 1995-1997
- Kawasaki ZX600G, 1998-1999
- Kawasaki ZX600H, 1998 (except UK)
- Kawasaki ZX600J, 2000-2001
- Kawasaki ZX636A, 2002
Book Excerpt: 1995-2002 Kawasaki Ninja ZX600, 636 (ZX-6R) Repair Manual FUEL AND EXHAUST SYSTEMS
GENERAL INFORMATION The fuel system consists of the fuel tank, fuel tap, fuel pump, filters, carburetors and the connecting hoses and control cables. The carburetors used are four constant vacuum Keihin (F models) or Mikuni (G, H, J and A models) with butterfly-type throttle valves. For cold starting, an enrichment circuit is actuated by a cable from the choke lever mounted on the left handlebar. The exhaust system is a four-into-one design. An open-loop catalytic converter is fitted in the exhaust system of California market G models, H models for Germany and Switzerland, and all J and A models except for the Australian market. The catalytic converters are protected from the intake of excess unburnt fuel by the carburetor mounted fuel cut-off valves. Many of the fuel system service procedures are considered routine maintenance items and for that reason are included in Chapter 1.
FUEL TANK AND TAP | REMOVAL, CLEANING, REPAIR, INSTALLATION WARNING: Refer to the warning in Section 1 concerning contact with fuel. REMOVAL
- Turn the fuel tap to the OFF position.
- Remove the seats (see Chapter 8).
- On California models, mark and disconnect the evaporative emission hoses.
- On F models, remove the two screws securing the tap to the bracket and detach the tap (see illustration). Release the clamp securing the fuel hose to the union on the side of the fuel tap and detach the hose (see illustration).
- On G, H, J and A models, remove the screw from the center of the fuel tap knob using a small Phillips screwdriver, then detach the knob from the tap (see illustration). Release the clamp securing the fuel hose to the union on the side of the fuel tap and detach the hose (see illustration).
ELECTRICAL SYSTEM
TURN SIGNAL BULBS | REPLACEMENT
- Remove the screw securing the turn signal lens and remove the lens, noting how it fits (see illustration). Remove the rubber gasket if it is free, and discard it if it is damaged or deteriorated.
- Push the bulb into the holder and twist it anti-clockwise to remove it (see illustration). Check the socket terminals for corrosion and clean them if necessary. Line up the pins of the new bulb with the slots in the socket, then push the bulb in and turn it clockwise until it locks into place.
- Fit the lens onto the holder, using a new rubber gasket if required, and make sure it is properly seated and not pinched by the lens.
Subject: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Kawasaki ZX600, 636 (ZX-6R) service, maintenance, repair. ISBN-10: 1844250652 | ISBN-13: 9781844250653 | Haynes 3541
TABLE of CONTENTS:
KAWASAKI ZX600, 636 (ZX-6R) MAINTENANCE
Introduction
- Engine/transmission oil level check
- Brake fluid level checks
- Specifications
- Recommended lubricants and fluids
- Maintenance schedule
- Component locations
- Maintenance procedures
- Engine, clutch and transmission
- Fuel and exhaust systems
- Ignition system
- Frame and suspension
- Fuel and exhaust system
- Ignition systems
- Frame and suspension
- Final drive
- Brakes
- Tires
- Fairing and bodywork
- Tools and workshop tips
- Storage
- Troubleshooting