2006-2007 KAWASAKI NINJA ZX-10R Service Repair Manual Motorcycle PDF Download
Refer to the base manual listed below for information of the original model. First Edition 1 : Feb. This manual provides how to install racing kit parts for the Ninja ZXR and how to tune up basically.
Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Page 9: Engine Parts Installation Engine Parts Installation Air Intake Parts Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance.
Page Camshaft Chain Tensioner Camshaft Chain Tensioner Replace the cam chain tensioner with the kit to decrease the flutter of tensioner. Apply the engine oil to the tensioner rod, O-ring and tensioner body, insert them into the tensioner body. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range of the long bolt holes.
Page 12 Method of measuring clearance of valve and piston —2. Adjust the valve clearance and valve timing. Install the cylinder head and adjust the camshaft chain timing.
Page Cylinder Compression The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners. Page Pistons Pistons Kit Piston: SB 1 Kit pistons are exclusive the two piston rings for reduce the compression height between the center of piston pin hole and the shoulder of the piston and the mechanical friction loss.
Kit piston has more reduced the weight compared the original piston. To adjust the cylinder compression to Page 16 2 Kit pistons are exclusive the two piston rings for reduce the compression height dimension between the center of piston pin hole to shoulder of the piston and the mechanical friction loss.
Use the kit connecting rod assemblies Excessive clearances will cause the oil pressure at the crankshaft main journals to drop and lead to the damage of the bearing.
Connecting Rod Bolts 1. Page 20 2. Kit Connecting Rod Connecting Rod Bolt Use the kit connecting rod bolts with the original connecting rod bolts and nuts. The kit connecting rod can use the original connecting rod bolt When using the original connecting rod bolts, make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch.
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.
Page 23 When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers provided as optional production parts to keep the preload of clutch springs according to the table below. Length [A] The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate.
Add Your Answer
Page 26 Spring Plate Assembly The spring plate assembly are available for increase the spring constant. When outbreak the starting judder, use the spring plate assembly of the kit parts.
Whenever the plate thickness is difference for adjusting the clutch plate, take care the length [A]. To change the gear ratios with combination the gears.
KAWASAKI NINJA ZX-10R Service Manual
Remove the three steel balls A from the output shaft assembly. This is done to start easily the engine with the second gear.
2006 Kawasaki Ninja ZX10R
To quicken response by reducing the flywheel mass and to reduce the weight, use the kit alternator. Page 31 Installation Stator The stator is fixed to the cover by the bolts. Run the alternator lead from the inside of the cover as shown in the illustration.
Fix the stator to the cover by the bolts.
2006 kawasaki ninja zx10r manual
Regulator Installation Use the kit alternator and the kit regulator as a set. Page 32 2. Kit Alternator Installation. Remove the related parts of the starter motor and insert the plugs to the hole of the starter motor inserted as shown in the illustration.
Page 33 Part Name Part No.
6 Suggested Answers
Insert the plug into the hole of the starter motor and tighten the nut. Apply liquid gasket. Replace the pulsing rotor with the kit rotor Page Water Temperature Sensor 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. Radiator Kit model ZXR racing kit provides the sub radiator to improved the cooling function. Page 35 Connect the main radiator and sub radiator with the brackets Fix the brackets on the sub radiator by the bolts L Page 36 Water Pipe Installation Use the main radiator only.
Divide the original water hose between the cylinder head and the radiator and insert the water pipe Install the kit water temperature sensor for water temperature gauge of kit meter, to the kit water pipe. Page 37 Use the kit sub radiator with the main radiator. Water Inlet of Radiator Body Divide the original water hose between the cylinder head and the radiator and insert the water pipe Oil Catch Tank: Tank Capacity: Approximately cc Oil Catch Tank Installation Install the mounting bracket with regulator under the cross pipe of the frame by the bolts use the original regulator mounting bolts.
Auto Shift Functions Be sure use the point type sensor. These kit parts quicken throttle response to the twist grip. Guard: 2. Bolt: J 3. The front pads are for higher braking force, and the rear pads are for higher braking force.
When changing the seat height, adjust the spring preload of the rear shock absorber. Page 44 Seat Height Adjustment Page 46 Fork Spring Installation Select one of them in accordance with your race regulation. Page 48 Main Harness Combination Parts Table Use the kit main harness or sub harness with the following parts as a set. Page 49 When using the kit main harness Original meter: , the following original parts are not required.
Page 50 Kit Main Harness Installation Page 51 When using the recommended auto shifter to connect the  auto shifter connector. Page 52 1. To connect the Fuel Pump. To connect the E. U Black.
To connect the atmospheric pressure sensor Black. To connect the inter face box Black. To connect the vehicle down sensor Gray. Relay Box 7. To connect the original meter Black.
Kawasaki 2006 NINJA ZX-10R Manuals
To connect the right switch housing Black. To connect the left switch housing Black. Semitransparent connector not use 5.
To connect the shift up indicator Green. Install the harness for the original meter as shown in the illustration. Shift up Indicator Lamp 2. To connect the shift up indicator lamp Green. Tachometer with Water Temperature Gauge 4. To connect the tachometer with water temperature gauge Black.
Page 55 Kit Sub Harness Installation Install the kit sub harness as shown in the illustration. Sub Harness 3.
To connect the auto-shifter Blue. To connect the speed limit switch Black.