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. But of course, if you’re taking your Kawasaki ZX-6RR to the track, you’ll want to make sure you’re feeding it the best oils, coolants, and brake pads.

2005-2006 Kawasaki Ninja ZX-6R and Ninja ZX-6RR Stock Image
2005 Kawasaki ZX-6R

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Maintenance Schedule for Kawasaki Ninja ZX-6RR

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

The maintenance for the 2004 Kawasaki Ninja ZX-6RR is broken into multiple sections for convenience.

Notes:

  • For higher odometer readings, repeat at the frequency interval established here
  • When inspecting items, replace, adjust, or torque if necessary.
  • The break-in schedule is not shown

Core maintenance

km x 100061218243036
mi x 100047.512152024Every
Engine oil – changeyear. More often if riding in harsh conditions.
Oil filter – replaceyear
Air cleaner element: replaceMore often if riding in dusty / wet conditions
Spark plug–clean and gap
Engine vacuum sync: inspect
Valve clearance: inspect
Brake fluid (front and rear) – change2 years
Brake hoses – replace4 years
Rubber parts of master cylinder and caliper4 years
Fuel hoses – replace4 years
Coolant – change3 years
Radiator hoses and O-rings – replace3 years
Kawasaki ZX-6RR Maintenance Schedule – Core

Brakes, Cooling, and Other Engine Maintenance

km x 100061218243036
mi x 100047.512152024Every
Brake hoses (no damage): inspect
Brake hoses (connections): inspect
Brake operation (effectiveness, no drag): inspectyear
Brake pads (wear) – inspectMore often if riding in dusty / wet conditions
Brake fluid level – inspect6 months
Fuel hoses (no leak): inspectyear
Fuel hoses (no damage): inspectyear
Fuel hoses connections: inspectyear
Coolant level: Inspect
Radiator hoses (no leak): inspectyear
Radiator hoses (no damage): inspectyear
Radiator hoses: inspectyear
Throttle control system: inspect
Side stand switch (operation): inspectyear
Engine stop switch (operation): inspectyear
Chassis parts: lubricateyear
Bolts and nuts tightness: inspect
Air suction valve: inspect
Evaporative emission control system: inspect (c)
Idle speed: inspect
Kawasaki ZX-6RR Engine systems maintenance

Steering, Wheel, and Chassis Maintenance

km x 100061218243036
mi x 100047.512152024Every
Drive chain wear: inspect
Drive chain guide wear: inspect
Steering play – inspectyear
Steering stem bearings: lubricate2 years
Hydraulic brake system (no leaks): inspect
Brake light switch (operation): inspect
Tire (air pressure): inspect
Wheels/tires (no damage): inspect
Tire (tread wear, no abnormal wear): inspect
Wheel bearings (no damage): inspect
Front forks/rear shock absorber (damping, smooth stroke): inspect
Front forks/rear shock absorber (no oil leak): inspectyear
Uni-trak bearing: lubricate
Uni-trak rocker arm (operation): inspect
Uni-trak tie rods (operation): inspect
Uni-trak tie rod bearing: lubricate
Swing pivot: lubricate
Clutch (play, disengagement, engagement): inspect
Lights and switches (operation) – inspectyear
Headlight aim: inspectyear
Kawasaki ZX-6RR Brakes, Wheels, and Chassis Maintenance

Chain Maintenance

Inspection itemEvery
Drive chain lubrication condition: inspect600 km (400 mile)
Or when chain is dry, or after riding in rain / drt
Drive chain slack: inspect #1000 km (600 mile)
Kawasaki ZX-6RR Drive Chain Maintenance

Tire size and tire pressure for the Kawasaki Ninja ZX-6RR

The Kawasaki ZX-6RR shipped with sport tires that aren’t really available these days. Sport or aggressive sport touring tyres would suite best.

Below are the recommended tire pressures and sizes.

WheelTyre (Tire) sizeTyre (Tire) pressure (cold)
Front120/65-ZR17 (56W)2.5 bar / 250 kPa / 36 psi
Rear180/55 ZR17 (73W)2.9 bar / 290 kPa / 42 psi
Tire sizes and pressures for the ZX-6RR

About the Kawasaki Ninja ZX-6RR

2003 Kawasaki Ninja ZX-6R and Ninja ZX-6RR Stock Image
2003 Kawasaki ZX-6RR

The Kawasaki ZX-6RR is based on the Kawasaki ZX-6R streetbike, but more oriented exclusively towards track use.

The engine in the ZX-6RR is a liquid-cooled, DOHC, 16-valve 599 cc inline four-cylinder engine with fuel injection — a relative rarity on small engines of the time. Kawasaki made a bunch of changes to the engine block and the breathing.

Inside the engine, Kawasaki reshaped the combustion chambers, redesigned the piston crowns, and coated the skirts with molybdenum to reduce friction and mechanical losses.

Kawasaki also reduced the size of the intake ports, enlarged the intake valves by 0.5mm, and changed the camshaft profiles to allow for more lift. The engine has a sky-high (particularly for the time) compression ratio of 13.0:1.

Kawasaki even changed the gear ratios for the oil pump to reduce mechanical loss, letting the engine rev higher, and made changes to the six-speed transmission to maximise torque.

The result is an engine that revs very high and makes a lot of power despite its diminutive size! It makes a peak of 86.8 kW / 118 bhp at 13200 rpm, and peak torque of 64.4 Nm / 47.5 lb-ft at a very high 12000 rpm. This is is an engine designed to sing.

Kawasaki of course gave the ZX-6RR fully adjustable suspension, with a 41 mm inverted cartridge fork up front, and a bottom-link uni-trak suspension unit at the rear.

The front brakes are twin 280 mm discs with 4-piston calipers. The brakes are radial-mounted and the discs are semi-floating. It’s very high-spec, again for the time and for this class of bike. It just shows how committed Kawasaki was to making this a track-ready bike.

The Kawasaki ZX-6RR was sold alongside the first gen ZX-6R 636, which was the larger capacity more street-oriented sportbike.

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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