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Kawasaki Ninja ZX-6RR (599cc, 2003-2007) Maintenance Schedule and Service Intervals

2004 Kawasaki Ninja ZX-6RR Stock Image

This is the maintenance schedule with associated service intervals for the Kawasaki Ninja ZX-6RR made between 2003-2007.

The ZX-6RR was the 599cc racing stablemate to the Kawasaki Ninja ZX-6R 636 made during the same period. Whereas the “cheater” displacement ZX-6R 636 motorcycle was the street bike (that you still rev the snot out of), the ZX-6RR was the bike dedicated to the track. It’s a similar motor, just with less midrange, but almost as much top end power.

The maintenance schedules for the ZX-6RR and its contemporary ZX-6R are quite similar.

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Maintenance Schedule for Kawasaki Ninja ZX-6RR

Below is the maintenance schedule for the Kawasaki Ninja ZX-6RR.

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

The maintenance for the 2004 Kawasaki Ninja ZX-6RR is broken into three sections: Engine Related Items, Chassis Related Items, and Change/Replacement Items.

Notes:

  • For higher odometer readings, repeat at the frequency interval established here
  • K: Should be serviced by an authorized Kawasaki dealer (… but won’t be)
  • †: Replace. add. adjust, or torque if necessary.
  • (c): California model only
  • #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
  • (e): Emission related item

Engine related items

Operation (Engine Items)Every1000 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)
Engine vacuum synchronization: inspect †
Idle speed: inspect †
Throttle control system: inspect †
Spark plug–clean and gap †
Valve clearance: inspect †
Air suction valve: inspect †
Evaporative emission control system: inspect † (c)
Air cleaner element: replace # (e)
Maintenance table — engine of ZX-6RR 599cc

Chassis-related items

Operation (Chassis Items)Every1000 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)
Steering System:
KSteering play – inspectyear
KSteering stem bearings –
lubricate
2 years
Brake system:
Hydraulic brake system (no leaks): inspect
KBrake hoses (no damage): inspect
KBrake hoses (connections): inspect
Brake operation
(effectiveness, no drag):
inspect
year
Brake pads (wear) – inspect #
Brake fluid level – inspect6 month
Brake light switch (operation): inspect
Wheels and tires:
Tire (air pressure): inspect
Wheels/tires (no damage): inspect
Tire (tread wear, no abnormal
wear): inspect
KWheel bearings (no damage): inspect
Suspension:
Front forks/rear shock absorber (damping, smooth stroke): inspect
Front forks/rear shock absorber (no oil leak): inspectyear
KUni-trak bearing: lubricate
KUni-trak rocker arm (operation): inspect
KUni-trak tie rods (operation): inspect
KUni-trak tie rod bearing: lubricate
KSwing pivot: lubricate
Drive chain and clutch:
Clutch (play, disengagement, engagement): inspect
Drive chain lubrication condition: inspect #600 km (400 mile), or when chain is dry
Drive chain slack: inspect #1000 km (600 mile)
Drive chain wear: inspect #
KDrive chain guide wear: inspect
Electrical System:
Lights and switches
(operation) – inspect
year
Headlight aim: inspectyear
Side stand switch (operation): inspectyear
Engine stop switch (operation): inspectyear
Fuel system:
Fuel hoses (no leak): inspectyear
KFuel hoses (no damage): inspectyear
Fuel hoses connections: inspectyear
Cooling system:
Coolant level: Inspect
Radiator hoses (no leak): inspectyear
Radiator hoses (no damage): inspectyear
Radiator hoses: inspectyear
Chassis:
Chassis parts: lubricateyear
Bolts and nuts tightness: inspect

Change/replacement items


Change/Replacement Items
Every1000 km (600 mi)12000 km (7500 mi)24000 km (15000 mi)36000 km (24000 mi)48000 km (30000 mi)
KBrake hoses – replace4 years
KBrake fluid (front and rear) – change2 years
KRubber parts of master cylinder
and caliper
4 years
KEngine oil # – changeyear
KOil filter – replaceyear
KFuel hoses – replace4 years
KCoolant – change3 years
KRadiator hoses and O-rings – replace3 years
ZX-6RR Change/replacement items

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

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

Front:

  • Size:120/65 ZR17 (56W)
  • MICHELIN Radial “PILOT SPORT M”
  • BRIDGESTONE “BT019F RADIAL”
  • DUNLOP “D208F”

Rear:

  • Size: 180/55 ZR17 (73W)
  • MICHELIN Radial “PILOT SPORT M”
  • BRIDGESTONE “BT012R RADIAL G”
  • DUNLOP “D208A”

The manual for the 2004 Kawasaki Ninja ZX-6RR recommends the following tyre pressures (when cold):

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

General information about the Kawasaki Ninja ZX-6RR

In keeping with its original concept of No. 1 performance on the circuit, for 2004, the concept of the Ninja ZX-6RR diverges from that of the street-use ZX-6R, becoming even more race-oriented than before. A series of engine and chassis upgrades significantly enhance this lime green racer’s winning potential. The 2004 Ninja ZX-6RR sport motorcycle returns to the 2004 Kawasaki lineup with upgrades to the engine and powertrain for even higher on-track performance.

The ZX-6RR engine is a liquid-cooled, DOHV, 16-valve, 599cc, four cylinder, four-stroke engine that delivers performance worthy of AMA Supersport competition. To give racers and sportbike enthusiasts even more power, Kawasaki engineers changed the shape of the combustion chambers, redesigned the piston crowns and added molybdenum coating to the skirts to reduce friction and mechanical loss. In conjunction with these changes, intake ports are smaller to further increase induction velocity, intake valves are 0.5mm larger for better breathing at all rpm and camshaft profiles have been changed to produce more lift.

Gear ratios for the oil pump have also been changed to reduce mechanical loss, contributing to the engine’s high-revving nature. Several modifications have been made to the middleweight ZX-6RR, including new cams, larger intake valves, a revised intake system, and new gear ratios for the six-speed transmission.

Manual for the Kawasaki Ninja ZX-6RR

2004 Kawasaki Ninja ZX-6RR Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2004 Kawasaki Ninja ZX-6RR, which is available here.

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