The 1990-2006 Kawasaki ZX600, ZZ-R600, Ninja ZX-6 sportbike repair manual by Haynes covers:
Book Excerpt: 1990-2006 Kawasaki Ninja ZX-6, ZZ-R600 Repair Manual COOLING SYSTEM
STEERING AND SUSPENSION
Subject: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Kawasaki ZX600, ZZ-R600, Ninja ZX-6 service, maintenance, repair. ISBN-10: 1844253880 | ISBN-13: 9781844253883 | Haynes 2146
- Kawasaki ZX600D (ZZ-R600), U.K. 1990-1993
- Kawasaki ZX600D (Ninja ZX-6), U.S. 1990-1993
- Kawasaki ZX600E (ZZ-R600), U.K. 1993-2006
- Kawasaki ZX600E (Ninja ZX-6, ZZ-R600), U.S. 1993-2004
Book Excerpt: 1990-2006 Kawasaki Ninja ZX-6, ZZ-R600 Repair Manual COOLING SYSTEM
COOLING FAN AND THERMOSTATIC SWITCH-CHECK AND REPLACEMENT CHECK
- If the engine is overheating and the cooling fan isn't coming on, remove the seat and check the (10A) fan fuse (see Chapter 9). If the fuse is blown, check the fan circuit for a short to ground (see the Wiring diagrams at the end of this book). If the fuse is good, remove the lower fairing (see Chapter 8) and unplug the electrical leads from the thermostatic fan switch. Using a jumper wire, connect these two leads (see illustration). If the fan still doesn't come on, check the wiring , connectors and fan motor.
- To check motor, remove the fuel tank and trace the wiring harness from the fan motor to its electrical connector, located between the steering head and the cross brace and accessible from above (it's a two wire black connector). Unplug the connector and, using two jumper wires connected to the battery terminals, apply battery voltage to the fan-side of the electrical connector. If the fan doesn't rotate, the problem is either in the wiring, connectors or the thermostatic fan switch.
- To check the fan switch, remove the switch (see Step 10) and test it as shown (see illustration). Note the temperature at which the switch closes the circuit and compare this to the temperature listed in this Chapter's Specifications. If the switch doesn't perform as described, replace it.
STEERING AND SUSPENSION
SUSPENSION-ADJUSTMENTFRONT FORK PRE-LOAD ADJUSTMENT-E3-ON MODELS
- Spring preload is adjusted by rotating the fork top bolt using an open-end wrench on the two flats provided. Turning the adjuster in (clockwise) increases preload, and turning it out decreases preload.
- The adjuster has 8 preload positions, indicated by grooves around the adjuster body. Position 8 (adjuster fully extended) is the softest position, and position 1 (fully in) is the hardest. The standard position for a rider of average build (68 kg, 150 lb.) is 5 grooves exposed, ie 16 mm from the top of the preloader adjuster to the top of the fork top bolt hex. Set both forks to the same preload setting otherwise dangerous handling will result.
FRONT FORK DAMPING ADJUSTMENT-E3-ON MODELS- The damping adjuster is located in the center of the preload adjuster and is adjusted using a flat-bladed screwdriver. There are four damping settings, identified by clicks (see illustration). Turn the adjuster fully clockwise to identify the hardest damping position no. 4, then one click back to the standard setting (no. 3), and further clicks back to settings no. 2 and 1. Set both forks to the same damping setting otherwise dangerous handling will result.
Subject: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Kawasaki ZX600, ZZ-R600, Ninja ZX-6 service, maintenance, repair. ISBN-10: 1844253880 | ISBN-13: 9781844253883 | Haynes 2146
TABLE of CONTENTS:
KAWASAKI ZX600 NINJA MAINTENANCE
Routine maintenance and servicing
- Specifications
- Recommended lubricants and fluids
- Maintenance schedule
- Component locations
- Maintenance procedures
- Engine, clutch and transmission
- Cooling system
- Fuel and exhaust systems
- Ignition system
- Suspension and steering
- Final drive
- Brakes
- Tires
- Fairing, bodywork and frame
- Dimensions and weights
- Tools and workshop tips
- Storage
- Motorcycle chemicals and lubricants
- Troubleshooting