Segment:
Supersport / Performance Motorcycle
Target Audience:
Enthusiast owners, independent motorcycle repair shops, technical college students.
Competitors:
Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600RR.
Dealer Level Information:
Provides the same authoritative information used by authorized Kawasaki dealer technicians.
Diagnostic Capabilities:
Facilitates accurate diagnosis and repair of complex mechanical and electrical issues.
Illustration Quality:
Features detailed diagrams and in-depth illustrations for clear procedural understanding.
Completeness:
Offers a complete suite of information, including maintenance schedules, TSBs, and recall data.
Engine:
Complete engine disassembly, inspection, repair, and reassembly including: cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system.
Transmission:
Gearbox inspection, repair, clutch operation, shift mechanism.
Chassis:
Frame, swingarm, rear suspension, front suspension (forks), steering system.
Brakes:
Front and rear brake system diagnosis, repair, fluid replacement, caliper and master cylinder service.
Electrical:
Wiring diagrams, ignition system, lighting, starting system, charging system, battery, instrument panel, ECU diagnosis.
Fuel System:
Fuel injection system components, fuel pump, injectors, throttle body service.
Cooling System:
Radiator, cooling fan, thermostat, coolant replacement and bleeding.
Exhaust System:
Exhaust components, O2 sensor locations (if applicable).
Maintenance:
Scheduled maintenance, oil changes, filter replacement, chain adjustment, brake fluid service, coolant service, spark plug replacement, air filter service.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues, electrical system diagnostics.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Disassembly Reassembly:
Complete overhaul procedures for engine, transmission, forks, and other major assemblies.
Technical Service Bulletins:
Inclusion of relevant TSBs for known manufacturing defects or improvements.
Recall Information:
Information related to manufacturer recalls for the covered model years.
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and gearbox rebuilds, electrical system diagnostics, and chassis component overhaul.
Searchability:
Likely text-searchable if professionally produced.
Print Recommendation:
High-quality printing recommended for clarity of diagrams and illustrations.
Physical Format Analogue:
Comb or spiral binding recommended for shop use to lay flat.
Physical Format Analogue:
Durable, coated paper stock for shop environment resistance.
Engine Type:
4-stroke, DOHC, 4-valve per cylinder, inline-four.
Displacement:
599 cc (36.6 cu. in.)
Bore X Stroke:
67.0 mm x 42.5 mm
Compression Ratio:
12.9:1
Horsepower Claimed:
Approximately 113-118 PS (83-87 kW) @ 13,000 rpm (at crankshaft, varies by region/spec).
Torque Claimed:
Approximately 6.2-6.5 kgf·m (61-64 Nm) @ 11,500 rpm (at crankshaft).
Fuel Delivery:
Fuel Injection with two injectors per cylinder (down-draft).
Throttle Body Diameter:
40 mm
Fuel Type:
Unleaded premium gasoline
Ignition System:
Digital CDI with electronic advance.
Lubrication System:
Forced lubrication, wet sump.
Cooling Method:
Liquid-cooled.
Transmission Type:
6-speed, constant mesh, sequential gearbox.
Clutch Type:
Wet, multi-plate, manual.
Gear Ratios:
Specific gear ratios will be detailed within the manual.
Length Overall:
Approx. 2,025 mm (79.7 in)
Width Overall:
Approx. 720 mm (28.3 in)
Height Overall:
Approx. 1,115 mm (43.9 in)
Dry Weight:
Approx. 169 kg (372.6 lbs)
Curb Weight Estimated:
Approx. 192 kg (423.3 lbs) (with all fluids and fuel)
Wheelbase:
Approx. 1,395 mm (55.0 in)
Ground Clearance:
Approx. 135 mm (5.3 in)
Rake Trail:
25° / 104 mm (4.1 in)
Frame Construction:
Twin-spar aluminum frame.
Suspension Front:
43mm inverted cartridge fork with adjustable preload, compression and rebound damping.
Suspension Rear:
Bottom-link Uni-Trak with adjustable preload, compression and rebound damping.
Brakes Front:
Dual 300mm petal-type discs with radial-mount 4-piston calipers.
Brakes Rear:
Single 220mm petal-type disc with 2-piston caliper.
Wheel Type:
Cast aluminum wheels.
Tire Size Front:
120/65ZR17M/C (58W)
Tire Size Rear:
180/55ZR17M/C (73W)
Instrument Panel:
Digital speedometer, analog tachometer, odometer, trip meter, clock, coolant temperature gauge, neutral indicator, high beam indicator, turn signal indicators, oil pressure warning lamp, FI warning lamp.
ABS Availability:
ABS was an optional feature on some models/markets; manual should cover both ABS and non-ABS configurations if applicable.
ECU Interface:
Diagnostic connector for ECU interrogation (requires specific Kawasaki diagnostic tools or compatible aftermarket devices).
Oil Change Interval:
Refer to manual, typically 3,000-5,000 miles or 6-12 months.
Chain Cleaning Lubrication:
Every 500-700 miles or after riding in wet conditions.
Air Filter Inspection:
Refer to manual, typically every 7,500 miles or annual inspection.
Spark Plug Replacement:
Refer to manual, typically around 15,000 miles.
Engine Oil Type:
API SG, SH, SJ or higher, JASO MA certified, SAE 10W-40 or 20W-50 recommended (specific grades depend on ambient temperature).
Engine Oil Capacity:
Approx. 3.0-3.4 Liters (3.2-3.6 US qt) with filter change.
Coolant Type:
High-quality ethylene glycol-based antifreeze coolant, mixture of 50% coolant and 50% distilled water.
Fork Oil Type Viscosity:
Refer to manual for specific type and viscosity (e.g., Showa SS-01 or equivalent, SAE 5W).
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals (due to high-performance nature).
Engine Performance Factors:
Proper maintenance of the fuel injection system and cooling system is critical for optimal performance and longevity.
Electrical Considerations:
As with many sportbikes of this era, ensure wiring harness integrity and proper battery voltage.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Generation:
This ZX600J represents a significant evolution from earlier 600cc Ninjas, focusing on higher revving performance and advanced chassis design.
Key Updates For J Model:
Updated engine internals for higher RPM capability, revised chassis geometry, and radial-mount brake calipers were hallmarks of this generation.
Production Years Covered:
Specifically for 2003-2004 model years.
