This document provides comprehensive service information for the Ninja ZX6R, model code ZX600R, specifically covering the 3rd Generation from 2007 to 2012. Known for its high-revving, 599cc inline-four engine and advanced twin-spar aluminum frame, the Ninja ZX6R is a prominent middleweight supersport sportbike renowned for its track-ready performance, sharp handling, and aggressive aerodynamic design. This generation, produced primarily in Japan, builds upon an extensive heritage in performance motorcycle engineering, offering features such as radial-mount front calipers, dual injectors per cylinder, and an optional ABS system, making it a competitive choice in its segment. This Factory Service Manual (FSM) is designed to be an authoritative resource for maintaining and repairing the Ninja ZX6R for the years 2009 through 2012. It covers a wide array of technical details, including in-depth engine mechanical and electrical procedures, transmission and clutch service, chassis and suspension maintenance, brake system overhauls, and complete electrical system diagnostics. The manual also details routine maintenance tasks, troubleshooting common issues, major repair procedures, and provides essential technical specifications, torque values, and clearances. This comprehensive guide is intended for professional motorcycle technicians, advanced DIY enthusiasts, and workshop owners seeking to ensure optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja ZX6R Model Code: ZX600R Generation: 3rd Generation (2007-2012) Product Type: Service Manual / Repair Manual Product Format: PDF Download 👋 Introduction Market Position Market Segment: Supersport / Superbike Category: Middleweight Sportbike Competitive Analysis Key Competitors: Honda CBR600RR, Yamaha YZF-R6, Suzuki GSX-R600, Triumph Daytona 675. Key Features Engine Type: High-revving, inline-four cylinder, DOHC, 16-valve. Chassis Design: Lightweight aluminum twin-spar frame, advanced suspension geometry. Aerodynamics: Aggressive, wind-tunnel tested fairing design for stability at high speeds. Braking System: Radial-mount front calipers, petal-style discs, optional ABS. 📋 Manual Details Coverage Areas Applicable Years: 2009, 2010, 2011, 2012 Region Applicability: Global (specific to ZX600R model variants) Page Count Estimated Page Count: Approx. 600-700 pages (typical for this model's factory service manual) Manual Type Manual Type: Factory Service Manual (FSM) Language Language: English Format File Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and overhaul procedures for the 600cc inline-four engine. Engine Electrical: Ignition system, fuel injection system (EFI), starting system, charging system, sensor diagnostics, ECU troubleshooting. Transmission: Clutch system, gearbox internal inspection and repair, shift drum and fork alignment, lubrication. Chassis And Suspension: Front fork (USD, SFF – Separate Function Fork) disassembly, assembly, and tuning; rear shock absorber service; swingarm and linkage inspection; steering system maintenance. Brakes: Front and rear brake caliper overhaul, master cylinder service, brake line replacement, ABS system (if equipped) diagnostics and bleed procedures. Electrical System: Wiring diagrams, lighting system, horn, battery, fuse box, starter relay, instrument panel operation and troubleshooting. Fuel System: Fuel pump, fuel injectors, fuel filter replacement, fuel tank maintenance, evaporative emission control system (EVAP). Cooling System: Radiator service, coolant replacement, fan operation, thermostat testing, water pump inspection. Exhaust System: Catalytic converter inspection, muffler service, lambda sensor (O2 sensor) troubleshooting. Bodywork And Trim: Fairing removal and installation, seat service, fuel tank cover, fender maintenance. Diagnostic Codes: OBD-II (On-Board Diagnostics II) fault codes, troubleshooting procedures for specific error codes. Procedures Included Routine Maintenance: Oil and filter changes, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, brake fluid flush. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptoms and probable causes, wiring harness testing. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair. Special Tools: Listing and explanation of specialized tools required for specific repair procedures. Torque Specifications: Detailed torque values for all critical fasteners across various systems. Clearances And Tolerances: Precise measurements for engine components, bearings, and other critical parts during rebuilds. Wiring Diagrams: Comprehensive, color-coded wiring diagrams for easy electrical system diagnosis. Schematics: Detailed schematics for hydraulic, pneumatic, and electrical systems. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic rider maintenance to complete engine and chassis overhauls. Target Audience: Professional motorcycle technicians, advanced DIY enthusiasts, and workshop owners. 📊 Manual Specifications File Format File Quality: High-resolution scans, text-searchable (if digitally produced). Printability: Printable pages for convenient workshop use. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, 16-valve inline-four Displacement: 599 cc (599 cubic centimeters) Bore X Stroke: 67.0 mm x 42.5 mm Compression Ratio: 12.9:1 Performance Horsepower: Approx. 128-134 PS (94-98.5 kW) at 13,500 rpm (at crankshaft, claimed) Torque: Approx. 65-67 Nm (48-49 lb-ft) at 11,700 rpm (claimed) Fuel System Fuel System: Fuel injection with dual injectors per cylinder (Keihin 43mm throttle bodies) Fuel Type: Unleaded gasoline, minimum 91 octane Ignition Ignition: Digital CDI with electronic advance Lubrication Lubrication System: Forced lubrication, wet sump 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, return shift Clutch Type: Wet, multiple disc, manual...