🏷️ Basic Information Identification Make: Kawasaki Model: ZX-6RR Model Designation: ZX600-M1/M2 Model Code: ZX600-M Year: 2005-2006 Codes Kawasaki Internal Model Codes: ZX600-M1 (2005), ZX600-M2 (2006) 👋 Introduction Market Position Segment: Supersport / Middleweight Sportbike Target Audience: Enthusiast riders, track day participants, mechanics Competitive Analysis Key Competitors: Yamaha R6, Honda CBR600RR, Suzuki GSX-R600, Triumph Daytona 600/650 Key Features Model Distinction: Known for its high-revving engine, advanced chassis, and racing pedigree Manual Value Proposition: Essential guide for maintaining peak performance and executing repairs accurately 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair for Kawasaki ZX-6RR (2005-2006 models) Engine Coverage: Engine assembly, disassembly, tuning, diagnostics, internal components Transmission Coverage: Clutch, gearbox, shifting mechanism, lubrication Chassis Coverage: Frame, suspension (front/rear), steering, wheels, brakes Electrical Coverage: Wiring diagrams, ignition system, charging system, lighting, sensors, ECU Bodywork Coverage: Fairings, seat, fuel tank, body panel removal and installation Maintenance Coverage: Scheduled maintenance, fluid changes, filter replacements, chain adjustment Troubleshooting Coverage: Diagnostic procedures, symptom-based troubleshooting, common fault identification Page Count Estimated Page Count: 400-500 Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Inline 4-cylinder, DOHC, 16-valve; Cylinder head; Piston/Crankshaft assembly; Lubrication system; Cooling system; Fuel injection system (EFI); Exhaust system Transmission Systems: 6-speed constant mesh transmission; Clutch operation and maintenance; Gear selection mechanism Chassis Systems: Semi-double cradle frame; 41mm inverted cartridge front forks (fully adjustable); Bottom-link Uni-Trak rear suspension (fully adjustable); Radial-mount front brake calipers; Single rear brake caliper; Steering head bearings; Wheel hub assembly Electrical Systems: Digital CDI ignition; Electric starter; DC-CDI; Alternator; Battery charging system; Headlights, taillights, turn signals; Instrument panel; ECU diagnostics Procedures Included Engine Procedures: Top-end overhaul, piston ring replacement, valve clearance adjustment, crankshaft bearing inspection, oil pump service, fuel injector cleaning, throttle body synchronization Transmission Procedures: Clutch plate replacement, transmission gear inspection, shift drum and fork alignment, final drive chain adjustment and lubrication Chassis Procedures: Front fork disassembly and seal replacement, rear shock absorber adjustment and rebuild, steering head bearing service, brake pad replacement, brake caliper servicing, wheel bearing replacement Electrical Procedures: Wiring harness inspection, starter motor testing, alternator output check, battery testing and replacement, diagnostic code retrieval, sensor testing Maintenance Procedures: Oil and filter changes, air filter cleaning/replacement, spark plug replacement, coolant flush and refill, brake fluid replacement, chain maintenance, general inspection checklist Troubleshooting Procedures: Engine performance issues, electrical system faults, starting problems, braking system anomalies, suspension behavior diagnostics Technical Depth Depth: Comprehensive; covers routine maintenance to full engine and transmission rebuilds Diagnostics: Detailed diagnostic charts, DTC (Diagnostic Trouble Code) interpretation Specifications: Includes all necessary torque specifications, clearances, fluid capacities, and electrical values 📊 Manual Specifications File Format Format: PDF Searchability: Fully searchable text content Resolution: High-resolution scans of original factory manual pages Interactivity: Hyperlinked table of contents for easy navigation Print Quality Print Recommendation: Printable on standard office printers Binding Type Binding Type For Print: N/A (Digital Format) Paper Type Paper Type For Print: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, inline-four cylinder, DOHC, 16 valves Displacement: 599 cc Bore X Stroke: 67.0 x 42.5 mm Compression Ratio: 12.9:1 Valve Train: DOHC, 16 valves, shim-under-bucket adjustment Performance Horsepower Peak: Approximately 118 hp @ 13,000 rpm (claimed) Torque Peak: Approximately 64 Nm @ 11,500 rpm (claimed) Fuel System Fuel Delivery: Fuel Injection with Dual Injectors per Cylinder (Mikuni) Fuel Type: Unleaded gasoline, minimum 91 AKI (Octane) Ignition System: Digital CDI, Twin Spark Plugs per Cylinder Carburetor Type: N/A (Fuel Injected) Lubrication Oil Type Spec: SAE 10W-40, API SG or higher, JASO MA approved motorcycle oil Oil Capacity W Filter: 3.5 L (3.7 US qt) Oil Capacity Wo Filter: 3.2 L (3.4 US qt) Cooling Cooling System: Liquid-cooled Coolant Type Spec: Ethylene glycol-based coolant, 50/50 mix with distilled water Coolant Capacity: 1.8 L (1.9 US qt) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Primary Drive: Gear Final Drive: O-ring sealed chain Features Clutch Type: Wet, multi-plate Clutch Fluid Spec: DOT 4 brake fluid 📐 Dimensions Exterior Length: 2,090 mm (82.3 in) Width: 720 mm (28.3 in) Height: 1,120 mm (44.1 in) Wheelbase: 1,405 mm (55.3 in) Ground Clearance: 130 mm (5.1 in) Seat Height: 820 mm (32.3 in) Weights Dry Weight: 164 kg (361.6 lbs) Wet Weight: 192 kg (423.3 lbs) (estimated) Fuel Tank Capacity: 18 L (4.8 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle specific safety ratings are not typically standardized like automotive) Active Features Braking System: Dual front 300mm petal discs with radial-mount 4-piston calipers; Single rear 220mm petal disc with 2-piston caliper ABS: Optional on some markets/configurations, typically not standard on this model Lighting: Multi-reflector halogen headlights, LED taillight Passive Features Frame Construction: Rigid semi-double cradle frame for stability Suspension Stability: Fully adjustable suspension provides tunable feedback and stability 💡 Technology Features...