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2005 Kawasaki ZX6R Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the tail section by removing the undertail and removing the six screws for the tail section. 2 Prop the front of the fuel tank up. 3 Lay the PCIIIin the tail section and route theharness along side the stock wiring harness towards the throttle bodies (Fig. B&C). Fig. A Fig. B Fig. C 2005 Kawasaki ZX6R – PCIII USB – 2 i218-411 www.powercommander.com PCIII harness PCIII harness Remove these screws 4. Disconnect the stock wiring harness from the LOWERinjectors at the throttle bodies (Fig. D). 5. Plug the PCIII connectors in-line of the stock injectors and wiring harness. ORANGE – cylinder 1 YELLOW- cylinder 2 GREEN – cylinder 3 BLUE – cylinder 4 6. Locate the Throttle Position Sensor connector behind the throttle bodies. This is a WHITE 3 pin connector (Fig. F) Fig. D Fig. E Fig F 2005 Kawasaki ZX6R – PCIII USB – 3 i218-411 www.powercommander.com PCIII connectors TPS connector Disconnect Stock connectors 7. Plug the PCIII harness in-line of the stock wiring harness (Fig. G). 8. Attach the ground wire from the PCIII to the negative side of the battery (Fig. H)

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Kawasaki Exhausts – ZX-6 ZX-10 Zx-14 Exhaust – Slip-ons INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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Our favorite exhaust options for Kawasaki ZX Ninjas – ZX-10,ZX-6r, and the new horsepower king, Zx-14.. Grab your horsepower today. We love Rob Muzzy and Muzzy Exhausts.Going back to Doug Chandler and Scott Russell, Muzzy has been synonomous with Kawasaki and performance – and for years, if you rode Kawasaki,and you were on the podium, Muzzy was on your exhaust. We also feature Arrow and Yoshimura exhausts for your ZX-6R, ZX-10 and ZX-14. We love the sound of a Yosh exhaust on any Kawasaki Ninja. Yoshimura Oval (RS-3) Race Slip-On for Kawasaki ZX14R 2006 The easiest and least expensive way to experience Yoshimura performance is with our Slip-On/Bolt-On lines. Bolt-On style bolts to the O. E. M. mid-pipe Slip-On style with its stainless steel easily attaches to the mid-pipe RS-1 is available where noted Usually, no jetting or re-programming is required and installation is a snap Hindle Stainless Exhaust High Head Pipes – Kawasaki ZX6R-RR 03-04 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo North Denver News http://northdenvernews.com Powered by Joomla! Generated: 19 October, 2010, 12:28 Hindle Stainless Exhaust Low Head Pipes – Kawasaki ZX9R 00-03 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo

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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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Filed Under (Kawasaki) by admin on 30-11-2010

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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Kawasaki ZX6R/ RR 2003-2004 Frame Slider Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Locate and remove right engine stud. Tip: Both main engine studs on the ZX6R tend to be very tight from the factory, use a stubby socket to remove stud. Make sure you have good engagement or the head of the bolt can strip. 2. Mount Right side frame slider using 99-HB-SH101250110 Socket Cap 10 X 1.25 X 110 Main Engine Stud and torque down to OEM torque specs. 3. Remove the left side OEM motor mount bolt. 4. Using the 10 X 1.25 X 110 Bolt supplied in the kit: Use the 99-SP-750-4200-L Left Side Bell Type Spacer Black Anodized 5. The small end of the (99-SP-750-4200-L Left Side Bell Type Spacer Black Anodized) goes against the left side of the frame. The longer of the two frame sliders goes on top of the spacer. Using the 10 X 1.25 X 110 Socket Cap mount and torque down to OEM specs

2007 Kawasaki ZX6R Full System Installation

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Filed Under (Kawasaki) by admin on 05-11-2010

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1. Remove the faring lowers (save STD bolts for reuse) , side faring (save STD bolts for reuse) , seat faring (save front 2 STD bolts for reuse) and right silencer cover. 2. Detach the turn signal assy, (unplug the cable coupler of turn signal and brake light at the same time) 3. Remove the radiator under bracket and lightly unscrew the radiator mounting bolt. Move the radiator forward. This will make you to have enough room for detaching exhaust pipes and flange nuts. Then, take off the standard headpipes. Detach the cable of the exhaust device and l eave servomotor stayed in the motorbody. (save (3) STD bolt and nut and (8) flange nuts for reuse) 4. Assemble the enclosed head pipes 1,2,3 and 4 by matching the 4-2-1 joint. Do not install the exhaust springs at this time. Lightly attach the assembled head pipe sections to the exhaust ports. Make sure the ends of the head pipes fit snug in the ports. 5. Install the tail joint and tail pipe to the joints. Do not install the exhaust springs yet. Jiggle the whole assemble for better fitting. Lightly attach the tail pipe by standard bolt and nut saved in step 3, but do not tighten the bolt fully. (see Image 1) *Recommend to use new gasket to prevent from leaking the exhaust. *Lightly screw the (8) STD flange nuts saved in step 3. * Cylinder number is 1, 2, 3 and 4 from the left hand side with you on the motorbike. 6. Attach enclosed silencer stay A to the place where the standard silencer mounted by (2) STD bolts and nuts saved in step 3. Reinstall the seat faring and penetrate the (2) 5x45mm to the hole of a seat faring mounted. Fix the Silencer stay A by enclosed (2) M5 nuts and (2) aluminum collar using the thread of penetrated M5x45bolts. (see Image 2 and drawing 1) Image 2 7. Insert the TiForce silencer to the tail pipe. Put silencer band and band rubber to the assembled silencer stay A by enclosed (2) M8x20mm bolt and (2) M8 washer. (see drawing 1) 8. Attach the supplied springs to all the joints. Use a spring puller to prevent damage to the springs that could lead to future failure. Put the radiator back to the original position. 9. Attach the L and R license number stay to the silencer stay A. (see Image 3) (see drawing 1) 10. Reinstall the firings detached in step 1. Attach the right silencer cover to the frame by using enclosed faring stay and (1) M6x20mm. (see drawing 1) 11. Make sure the exhaust system is free and clear of the faring. If necessary, adjust for proper clearance.. Removed the fairings reinstalled in step 10. 12. Securely tighten all fasteners in this order (from exhaust pipe flange to silencer stay) Image 3 14. Attach the turn signal assy detached in step 2 to the license number stay. (Use (4) M6x15mm) (See Image 4) Plug the cable couplers.

1999-2002 Kawasaki ZX6R Engine Protection Cage installation instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Follow installation instructions for extended frame sliders. (See page 1) Note: Do not attach delron tips or tighten extended frame sliders until all components are installed. 2. Place the cage loop inside short telescoping tubes on sliders (See fig. G) , push the º”-20 x 1 Ω” bolts through the bolt holes on the telescoping tubes from the outside and start the º”-20 lock nuts to hold cage loop in place. Do not tighten lock nuts at this time. 3. Remove the lower sub frame bolt on the left side of the motorcycle. Install the M10- 1.5 X 88mm stud in place of the sub frame bolt. Place an M10 flat washer and M10-1.5 hex nut on the stud on the interior side of the sub frame. Slide the following components over the stud on the outside of the sub frame in this order: 1.1″ spacer, side strut, (marked with “L”) and M10-1.5 hex nut. (See fig. I) Do not tighten the hex nuts at this time. Repeat for other side using side strut marked with “R”. 4. Push the bottom of the cage loop towards the rear of the motorcycle while pulling the bottom of the left side strut towards the front until the bolt hole on the side strut meets the threaded hole on the tab welded to the cage loop. Attach the side strut to the outside of the tab on the cage loop with a 3/8″-24 x æ” bolt. (See fig J) Do not tighten the bolt at this time. Repeat for other side. 5. Once all components are attached tighten all bolts and nuts. Be sure to torque all engine mount bolts to factory specifications.

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Kawasaki ZX6R 2009 Frame Slider Installation and removal Instructions

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Filed Under (Kawasaki) by admin on 08-05-2012

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1. Remove mid and lower body panels Left and Right. There is a small plastic cover that is mounted over the main engine stud location on the left side. This cover requires a small notch to be cut out of the cover to clear the small end of the left side offset. Remove stock stud and mount the left side offset (with 10 X 1.25 X 60). Using a pencil, trace out the notch that you need to remove to clear the small end of the offset. We used a Dremel tool with a sanding roll and cleaned it up with an exacto knife. We removed a small amount of material at a time checking for clearance each time. The notch will not be visible after the body has been mounted. See photos below: 2. Once you have notched the small left side panel, mount the left side offset but only hand tight. You need to be able to move the offset by hand to its proper location. 3. Mount the left side bodywork and align the offset to the opening in the body. Mount the left side slider on the offset to ensure correct location. There is a flat notch in the slider so the body will clear. Remove the slider and body and torque down the offset to OEM specifications. (see above)
4. Mount the left side panel. Install the slider using one drop of blue thread locker and torque down to 30 to 32 ft lbs.

2003-2007 Kawasaki Ninja ZX6R/ RR HID Installation Removal Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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take out the original bulb and install the HID bulb. Be careful, do not touch the HID bulb at any time. Plug in the power wires into the original power plug. They go in easy and slide right in. Black wire connects into the black wire on the plug. On the right side, pink goes to red. On the left side, blue goes to red as these are positive wires. Pull the wires toward you slowly and carefully as you near the cover toward the headlight. Spin the rubber grommet if you need to line up the dust cover to the head light. Now lock it in. The arrow should point up if it is locked in properly. Left side installed the same way as the right. Mount the ballasts on the under side of the cowling covers with two nuts and bolts. Position the ballast in the proper place. Then, hold in one spot while drilling two holes for the bolts. An alternate mounting may be with industrial double sided tape or industrial Velcro. Do not use those cheap double sided tape of Velcro mounts as they will not hold the weight of the ballasts. Close up of underside of the cowling cover with ballast installed.
Top side of the cowling cover. Repeat installation on the second cowling. Then reinstall on the bike, connecting all the plug wires.

KAWASAKI STX-12F, STX-15F Riva/Vortech Supercharged STX-15F Engine INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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Our race bred Supercharger System for the Kawasaki STX-15F contains all necessary engine components to produce the ultimate 80mph closed course race craft. Kit contains the same specifications that Team Kawasaki won two 2004 Pro Runabout World Titles with. System produces over 300hp using VP MS109 race fuel (Jet X). Kit includes Vortech Supercharger & Intercooler Forged Racing Pistons, Free flow Exhaust Kit, Race programmed ECU, High volume Injectors & Fuel Pump along with all necessary hardware and detailed installation instructions. Riva/Vortech Supercharged STX-15F Engine (Team Kawi Spec) PERFORMANCE DATA Stock 61 MPH @ 7,600 RPM Supercharged 80+ MPH @ 8,300 RPM RIVA STX-15F OFFSHORE RACE KIT Our Offshore Racing Kit for the Kawasaki STX-15F contains the same components and specifications that Team Kawasaki developed to dominate the international racing circuit. This modification delivers over 200hp producing awesome acceleration and a top speed of over 700mph using VP MS109 race fuel (Jet X). Kit includes high compression racing pistons, performance intake & exhaust cam shafts, Race programmed ECU along with all necessary gaskets and detailed installation instructions

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The New Kawasaki ZX-6R Trading in gets easier and easier

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Filed Under (Kawasaki) by admin on 18-02-2011

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didn’t go to my local Kawasaki shop expecting to trade in the 2004 636 I’d been happily riding. I honestly didn’t expect there to be anything on the floor that would motivate me to bring the bike in. Some of you reading this may be able to relate to what I am saying, the day you don’t look for something is the day that you find exactly what you didn’t know you need. That was the day I decided I needed to take home the new ZX-6R. The reworking of the new ZX-6R is more than just about looking good. According to KMC the engine has been redesigned from the crankcase up for the first time in ten years. Racing technology built into the new bike is a close-ratio cassette transmission that can be removed without the needing to split the main crankcases in case you needed to make repairs or adjustments at the track. They also tell us that the fuel injection system has shorter throttle bodies with a smaller diameter bore which claim to give this new smaller sized engine more torque in the mid-range. It also comes with a GPS – Gear Position Sensor. The new ZX-6R comes stock with a slipper clutch which is one difference between the 2004 and 2007. My 2004′s rear wheel would hop if I geared down before a corner and my engine rpms were too high. The slipper clutch allows quicker downshifts. To experience the gains of a slipper clutch you don’t have to buy a 2007 Kawasaki – it was introduced to the 636 in 2005. A quick glance at the exhaust might leave the impression that the ZX-6R comes stock with stacked twin small diameter exhaust cans but if you look closely you will see it is a single oval pipe with a shotgun styled end cap. The titanium pipe has the pre-chamber and catalyser located below the engine to keep the weight on the bike low and centered and the temperature of the under seat silencer reduced. Looking at the new Kawasaki with its fairing removed, I wonder how much more it would have cost the consumer to have an exhaust system that not only works wonders but would be worth showing off? Even if some of the systems of the new 600 look better hidden by plastic the bike does have a cohesive look and every year the fit and finish of Kawasaki’s bikes seem to get better. You can look at this bike from almost any angle and nothing jumps out at you – unless you are on the right side of the bike looking at the rear brake reservoir. It seems odd to me that they would leave the rear brake reservoir exposed. Another design feature of the smooth body of the 2007 ZX-6R is the lack of tie down points for any luggage. It can be argued that this is a bike intended for Sunday morning canyon rides or track days on weekends but if you want to take the 600 out for a weekend away then there is aftermarket solution. Ventura Racks allow you go on vacation with your bike. A Ventura Rack provides you with a frame that you attach to your bike that you can secure luggage to. There is no drilling of body work and the Ventura rack I got fit onto the bike perfectly the first try. One of the things I really like about the Ventura Rack is that you can easily attach bags that you may already have or you have the option of buying the Ventura luggage system. Just give yourself time before a motorcycle trip to pack

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