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Kawasaki Ninja ZX-6R 636 (1st gen, 2003-2007) Maintenance Schedule and Service Intervals

2005-2006 Kawasaki Ninja ZX-6R and Ninja ZX-6RR Stock Image

This is the maintenance schedule with associated service intervals for the Kawasaki Ninja ZX-6R 636 made between 2003-2007 (Looking for the later ZX-6R 636 made from 2013 onward?). During that period Kawasaki also made the Kawasaki Ninja ZX-6RR with 599cc, to satisfy racing requirements.

The Kawasaki Ninja ZX-6R was introduced in 1995 and has been constantly updated throughout the years. The year 2003 was the first time Kawasaki used the 636cc “cheater” displacement for their road motorcycles (replacing the earlier 1998-2002 Ninja ZX-6R), gaining a power and mid-range torque advantage over the middleweight supersport rivals.

The ZX-6R stayed largely the same in between 2003 and 2004. In 2005 Kawasaki surprised everyone by re-doing the 636 already, giving the motorcycle a re-tuned engine (larger cams, a new head, polished ports) to give it a quite insane 130 hp, plus a slipper clutch, upgraded suspension, new wheels, better brakes, oh and also that sweet under-seat exhaust.

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Maintenance Schedule for Kawasaki Ninja ZX-6R 636 (1st gen, 2003-2007)

Below is the maintenance schedule for the Kawasaki Ninja ZX-6R 636 (made between 2003 and 2007).

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

Legend on reading this maintenance schedule

  • K: Kawasaki recommends you get these serviced by an authorized Kawasaki dealer.
  • *: For higher odometer readings, repeat at the frequency interval established here.
  • #: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • (e): Engine related item

The maintenance for the Kawasaki Ninja ZX-6R 636 is broken into three sections: Engine Related Items, Chassis Related Items, and Change/Replacement Items.

Engine-related items

OperationEvery1000 km (600 mi)6000 km (4000 mi)12000 km (7500 mi)18000 km (12000 mi)24000 km (15000 mi)30000 km (20000 mi)36000 km (24000 mi)
Valve clearance – inspect (e)
Throttle control system (play, smooth return, no drag) – inspect (e)year
Engine vacuum synchronization – inspect (e)
Idle speed – inspect (e)
KFuel leak (fuel hose and pipe) – inspectyear
KFuel hoses damage – inspectyear
KFuel hoses installation condition – inspectyear
Coolant level – inspect
Coolant leak – inspectyear
Radiator hose damage – inspectyear
Radiator hoses installation condition – inspectyear
Evaporative emission control system – function (California) (e)
Air suction system damage – inspect (e)
Spark plug condition – inspect (e)
Engine maintenance – Kawasaki Ninja ZX-6R 636

2. Chassis-related items

OperationEvery1000 km (600 mi)6000 km (4000 mi)12000 km (7500 mi)18000 km (12000 mi)24000 km (15000 mi)30000 km (20000 mi)36000 km (24000 mi)
Clutch and drive train:
Clutch operation (play, engagement, disengagement) – inspect
Drive chain lubrication condition – inspect #600 km (400 mile)
Drive chain slack – inspect #1000 km (600 mile)
Drive chain wear – inspect #
KDrive chain guide wear – inspect
Wheels and tires:
Tire air pressure – inspectyear
Wheels/tires damage – inspect
Tire tread wear, abnormal wear – inspect
KWheel bearings damage – inspectyear
Brake system:
Brake fluid leak – inspectyear
Brake hoses damage – inspectyear
Brake pad wear – inspect #
Brake hose installation condition – inspectyear
Brake fluid level – inspect6 months
Brake operation (effectiveness, play, drag) – inspectyear
Brake light switch operation – inspect
Suspensions:
Front forks/rear shock absorber operation (damping and smooth stroke) – inspect
Front forks/rear shock absorber oil leak – inspectyear
KUni-trak rocker arm operation – inspect
KUni-trak tie rods operation – inspect
Steering System:
KSteering play – inspectyear
KSteering stem bearings – lubricate2 years
Electrical System:
Lights and switches operation – inspectyear
Headlight aiming – inspectyear
Side stand switch operation – inspectyear
Engine stop switch operation – inspectyear
Chassis:
Chassis parts – lubricateyear
Bolts and nuts tightness – inspect
Chassis-related maintenance — Kawasaki ZX-6R 636

3. Periodic replacement items

Change/Replacement ItemsEvery1000 km (600 mi)12000 km (7500 mi)24000 km (15000 mi)36000 km (24000 mi)48000 km (30000 mi)
Air cleaner element # – replace (e)every 18000 km (12000 mile)
KEngine oil #year
KOil filteryear
KFuel hoses4 years
KCoolant3 years
KRadiator hoses and O-rings3 years
KBrake hoses4 years
KBrake fluid (front and rear)2 years
KRubber parts of master cylinder
and caliper
4 years
Spark plug (e)
Items to periodically replace on the ZX-6R 636

Tyre size and tyre pressure for the Kawasaki Ninja ZX-6R 636

The Kawasaki Ninja ZX-6R 636 has the following tyres and tyre sizes standard:

  • Front: 120/65 ZR17 M/C (56W) BRIDGESTONE “BT014 F RADIAL J”
  • Rear: 180/55 ZR17 M/C (73W) BRIDGESTONE “BT014 R RADIAL J”

The manual for the 2005-2006 Kawasaki Ninja ZX-6R and Ninja ZX-6RR recommends the following tyre pressures (when cold):

  • Front: 250 kPa/36psi
  • Rear: 290 kPa/42psi

General information about the Kawasaki Ninja ZX-6R 636

The Kawasaki Ninja ZX-6R had already made a name for itself.

Expanding to 636cc was an unuisual move for Kawasaki, but one that let it get a power and mid-range torque advantage over its rivals. For street riders for whom complying to a 600cc maximum wasn’t a critical requirement, this was a win.

The Kawasaki ZX-6R636 (2003-2007) had Ram Air, an under-seat exhaust, petal-style disc brakes, inverted forks, striking looks.

For the 2006 model year Kawasaki has also added a ZX-6R “Special Edition” model with titanium silver paint and a different wheel finish.

Manual for the Kawasaki Ninja ZX-6R 636

2005-2006 Kawasaki Ninja ZX-6R and Ninja ZX-6RR Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2005-2006 Kawasaki Ninja ZX-6R, which is available here.

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