This 2003-2006 Kawasaki Ninja repair and service manual by Haynes covers:
- Ninja ZX636B1, 2003
- Ninja ZX636B2, 2004
- Ninja ZX636C1, 2005
- Ninja ZX636C6, 2006
Book Excerpt: 2003-2006 Kawasaki Ninja ZX636, ZX-6R, ZX600, ZX-6RR Repair Manual
- Ninja ZX600K1, 2003
- Ninja ZX600M1, 2004
- Ninja ZX600N1, 2005
- Ninja ZX600N6, 2006
ENGINE, CLUTCH AND TRANSMISSION
BRAKES, WHEELS AND FINAL DRIVE
The engine/transmission unit is a liquid-cooled in-line four cylinder. The sixteen valves are operated by double overhead camshafts which are chain driven off the right-hand end of the crankshaft.
The engine/transmission is a unit assembly constructed from aluminum alloy. The crankcase divides horizontally.
The crankcase incorporated a wet sump, pressure-fed lubrication system which uses a dual rotor trochoidal oil pump that is gear-driven off the back of the clutch.
The system has an oil strainer in the pick-up, a pressure relief valve in the feed from the pump to the filter, an oil filter, an oil cooler, and an oil pressure switch off the main gallery.
The alternator is on the left-hand end of the crankshaft and the rotor carries the starter clutch. The water pump is on the left-hand side of the engine, and its drive shaft is keyed to the oil pump.
The ignition timing triggers are on a rotor on the right-hand end of the crankshaft.
Power from the crankshaft is routed to the transmission via the clutch. The clutch is of the wet, multi-plate type and is gear-driven off the crankshaft.
The clutch is operated by cable. The transmission is a six-speed constant-mesh unit. Final drive to the rear wheel is by chain and sprockets.
FRONT BRAKE PADS
- Work on one caliper at a time. Slacken the pad retaining pins (see illustration).
- Unscrew the caliper mounting bolts and slide the caliper off the disc (see illustrations).
- Work on one pair of pads at a time. Unscrew and remove the pad pin, then remove the pad spring and lift the pads from the caliper (see illustrations).
NOTE: Do not operate the brake lever while the pads are out of the caliper.
- Inspect the surface of each pad for contamination and check that the friction material has not worn beyond its service limit (see Chapter 1, Section 2 - see illustration).
If any pad is worn down to, or beyond, the service limit wear indicator (i.e. the war indicator is no longer visible), is fouled with oil or grease, or heavily scored or damaged, fit a complete set of new pads.
NOTE: It is not possible to degrease the friction material; if the pads are contaminated in any way they must be replaced with new ones.
Subject: 2003, 2004, 2005, 2006 Kawasaki Ninja ZX636, ZX-6R, ZX600, ZX-6RR service, maintenance, repair. ISBN-10: 1844257428 | ISBN-13: 9781844257423 | Haynes 4742