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

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)	Every	1000 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)	Every	1000 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:
K	Steering play – inspect	year	•		•		•		•
K	Steering stem bearings – lubricate	2 years					•
	Brake system:
	Hydraulic brake system (no leaks): inspect		•	•	•	•	•	•	•
K	Brake hoses (no damage): inspect		•	•	•	•	•	•	•
K	Brake hoses (connections): inspect		•	•	•	•	•	•	•
	Brake operation (effectiveness, no drag): inspect	year	•	•	•	•	•	•	•
	Brake pads (wear) – inspect #			•	•	•	•	•	•
	Brake fluid level – inspect	6 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				•		•		•
K	Wheel bearings (no damage): inspect				•		•		•
	Suspension:
	Front forks/rear shock absorber (damping, smooth stroke): inspect				•		•		•
	Front forks/rear shock absorber (no oil leak): inspect	year			•		•		•
K	Uni-trak bearing: lubricate						•
K	Uni-trak rocker arm (operation): inspect				•		•		•
K	Uni-trak tie rods (operation): inspect				•		•		•
K	Uni-trak tie rod bearing: lubricate						•
K	Swing 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 #				•		•		•
K	Drive chain guide wear: inspect				•		•		•
	Electrical System:
	Lights and switches (operation) – inspect	year			•		•		•
	Headlight aim: inspect	year			•		•		•
	Side stand switch (operation): inspect	year			•		•		•
	Engine stop switch (operation): inspect	year			•		•		•
	Fuel system:
	Fuel hoses (no leak): inspect	year	•		•		•		•
K	Fuel hoses (no damage): inspect	year	•		•		•		•
	Fuel hoses connections: inspect	year	•		•		•		•
	Cooling system:
	Coolant level: Inspect		•		•		•		•
	Radiator hoses (no leak): inspect	year	•		•		•		•
	Radiator hoses (no damage): inspect	year	•		•		•		•
	Radiator hoses: inspect	year	•		•		•		•
	Chassis:
	Chassis parts: lubricate	year			•		•		•
	Bolts and nuts tightness: inspect		•		•		•		•

Change/replacement items

	Change/Replacement Items	Every	1000 km (600 mi)	12000 km (7500 mi)	24000 km (15000 mi)	36000 km (24000 mi)	48000 km (30000 mi)
K	Brake hoses – replace	4 years					•
K	Brake fluid (front and rear) – change	2 years			•		•
K	Rubber parts of master cylinder and caliper	4 years					•
K	Engine oil # – change	year	•	•	•	•	•
K	Oil filter – replace	year	•	•	•	•	•
K	Fuel hoses – replace	4 years					•
K	Coolant – change	3 years				•
K	Radiator hoses and O-rings – replace	3 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.