Kawasaki NINJA ZX-6R (2000-2002) [10/332] 2 general information
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Kawasaki NINJA ZX-6R (2000-2002) [10/332] 2 general information

Kawasaki NINJA ZX-6R (2000-2002) [10/332] 2 general information

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1 2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle careful reading of the applicable section is recommended to eliminat unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been include wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is als required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine or other parts will work as a abrasive and shorten the life of the motorcycle For the same reason before installing a new part clean off any dus or metal filings 2 Battery Leads Remove the ground lead from the battery before performing any disassembly operations on the motorcycle When installing connect the positive lead first then the negative lead to the battery This prevents a th possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connection which will occur when they are disconnected c damage to electrical parts 3 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly But if this Service Manual ha installation or assembly procedures follow them Note parts locations and cable wire and hose routing durin removal or disassembly so they can be installed or assembled in the same way It is preferable to mark and recor the locations and routing as much as possible 4 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them t a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and or causing gas o oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter turn an then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screw must be tightened in the order and method indicated 5 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead t serious damage Use a good quality reliable torque wrench 6 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especial difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary ta lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screw held by a locking agent in order to avoid damaging the screw heads 7 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with glove or a piece of thick cloth when lifting the engine or turning it over 8 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in Nort America is Standard solvent generic name Always follow manufacturer and container directions regarding the us of any solvent 9 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should b free of foreign matter and perfectly smooth to avoid oil or compression leakage 10 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used App sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 11 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or Inn circumference so that it will go into place smoothly 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or need bearings that were removed with new ones as removal generally damages bearings Install bearings with the marke side facing out applying pressure evenly with a suitable driver Only press on the race that forms the press fit wi the base component to avoid damaging the bearings This prevents severe stress on the bails or needles and race and prevent races and balls or needles from being dented Press a ball bearing until it stops at the stops in the ho or on the shaft 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals Whe pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be presse into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even wi the end of the hole Before a shaft passes through a seal apply a little high temperature grease on the lips to reduc rubber to metal friction

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