Basic Information Identification Make: Kawasaki Model: Ninja ZX-6R Model Code: ZX636-C1 Year: 2004 Codes Chassis Code: ZX636-C1 Introduction Market Position Category: Supersport Motorcycle Segment: Middleweight Supersport (600cc class) Competitive Analysis Key Rivals 2004: Honda CBR600RR, Yamaha YZF-R6, Suzuki GSX-R600, Triumph Daytona 600 Key Features Design Philosophy: High-performance, track-focused sportbike with advanced technology for its class. Engine Type: Inline-Four Cylinder, Liquid-Cooled, DOHC, 16 Valves Manual Details Coverage Areas Primary Coverage: Kawasaki ZX636-C1 (Ninja ZX-6R) Secondary Coverage: Likely covers variations within the 2004 ZX-6R model line based on its chassis code. Page Count Estimated Pages: Refer to product listing for exact page count, but typically service manuals of this era are substantial (e.g., 400-800 pages). Manual Type Type: Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: PDF Download (within a RAR archive) Manual Coverage Systems Covered Engine Systems: Engine Disassembly, Engine Overhaul, Engine Reassembly, Engine Timing, Fuel System (Electronic Injection), Lubrication System, Cooling System Drivetrain Systems: Transmission, Clutch (Disengaging Hydraulic Clutch) Chassis Systems: Suspension & Wheels, Brakes, Frame Electrical Systems: Ignition System, Electric Systems, Fuse Box, Wiring Diagrams (implied by 'Electric Systems') Frame And Bodywork: Frame inspection, fairing removal/installation, fuel tank service, seat replacement. Wheels And Tires: Wheel bearing replacement, tire mounting/balancing, spoke adjustment (if applicable), rim specifications. Fuse Box Information: Location and function of all fuses, essential for electrical troubleshooting. Procedures Included Routine Maintenance: Oil Changes, Fluid Checks, Filter Replacements, Chain Adjustments, Spark Plug Service Diagnostic Procedures: Troubleshooting, Fault Diagnosis, Electrical System Diagnostics Repair Procedures: Component Replacement, System Overhaul, Reassembly Procedures Adjustment Procedures: Settings & Adjustments (e.g., suspension settings, throttle cable adjustment) Specific Tool Requirements: The manual lists specific tools required for various procedures (e.g., torque wrenches, specialized engine tools, suspension adjustment tools). Torque Figures: Comprehensive torque specifications for all critical fasteners are provided throughout the manual. Performance Data: Includes general performance data and specifications relevant to maintenance and tuning. Topping Up Lubrications: Specific instructions and quantities for topping up engine oil, coolant, and brake fluid. Technical Depth Depth: Comprehensive; covers everything from basic maintenance to complete engine and chassis rebuilds. Equivalent to dealership technician level. Engine Rebuild: Detailed instructions for complete engine disassembly, cleaning, inspection, machining, and reassembly, including piston ring replacement, valve job, bearing replacement. Suspension Service: Instructions for fork seal replacement, fork oil changes, shock absorber servicing, and suspension adjustments. Electrical Diagnostics: Wiring diagrams, troubleshooting guides for ignition and electrical faults, component testing procedures. Manual Specifications File Format Primary Format: PDF Compression Format: RAR (requires WinRAR or equivalent) Print Quality Quality Description: High-quality PDF with clear diagrams, schematics, and text. Designed for clarity during repair. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Code: ZX636-C1 (implies 636cc displacement) Displacement: 636 cc (based on model designation ZX636) Performance Bore X Stroke: Refer to manual for exact figures, but typically around 66 x 46 mm for this generation. Compression Ratio: Refer to manual for exact figures, likely around 12.5:1 or higher. Horsepower: Estimated 110-115 HP (at crank) for the 636cc model. Torque: Estimated 50-55 lb-ft (at crank) for the 636cc model. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder. Ignition: Digital CDI with electronic advance. Transmission Standard Type: 6-Speed, Return Shift Features Clutch Type: Wet, Multi-Plate Clutch (Hydraulic Actuation) Dimensions Weights Dry Weight: Approximately 355 lbs (161 kg) - refer to manual for exact specification. Curb Weight: Approximately 410 lbs (186 kg) - refer to manual for exact specification. Overall Dimension Length: Refer to manual for exact figures, typically around 81.7 inches (2075 mm). Width: Refer to manual for exact figures, typically around 28.0 inches (710 mm). Height: Refer to manual for exact figures, typically around 43.1 inches (1095 mm). Wheelbase Wheelbase: Refer to manual for exact figures, typically around 54.7 inches (1390 mm). Safety Features Ratings Safety Features Overview: As a sportbike, primary safety relies on rider skill and chassis dynamics. No formal crash ratings apply like cars. Equipped with standard safety features for its class. Active Features Braking System: Dual Front Disc Brakes (Hydraulic), Single Rear Disc Brake (Hydraulic) Suspension Features: Adjustable Front Telescopic Forks (Inverted), Adjustable Rear Uni-Trak Swingarm Suspension Passive Features Lighting: Dual Halogen Headlights, LED Taillight Technology Features Infotainment Infotainment Features: N/A - Focus is on performance and handling. Basic digital/analog instrument cluster. Driver Assistance Assistance Features: N/A - No electronic rider aids like ABS or traction control were standard on this model. Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Refer to manual, typically every 3,000-4,000 miles or 6 months. Spark Plug Replacement: Refer to manual, typically around 15,000-20,000 miles. Air Filter Service: Refer to manual, often recommended every 7,500-10,000 miles or as needed based on riding conditions. Fluid Specifications Engine Oil Type: Refer to manual; typically API SG/SH/SJ or JASO...