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Kawasaki ZX-6R - 2005

Kawasaki ZX-6R

DESIGNED FOR NO.1 PERFORMANCE ON THE CIRCUIT AND WINDING ROADS

Engine

Uprated, liquid-cooled, DOHC, 16-valve 636 cm3 In-Line Four engine delivers increased performance, especially in the higher rpm ranges. New cylinder head design locates each pair of intake/exhaust valves farther apart for improved breathing and higher combustion efficiency.

Complementing the new head are new pistons with reshaped crowns and improved, low-friction skirt profiles.

Larger diameter intake and exhaust valves, together with new cam profiles, contribute to the new engine's enhanced performance. The new 6R gets the 03MY racing kit intake and exhaust cams.

Large-bore 38 mm throttle bodies feature oval-shaped sub-throttles that allow airflow to be increased without the need to increase the throttle body pitch (hence the engine width does not need to increase and a slim riding position can be maintained). The additional intake area improves intake efficiency by 20%, contributing to the new engine's increased performance. The use of oval-shaped sub-throttles is the first adoption of this technology in the middleweight supersport class.

Dual-injector fuel injection system uses fine atomising injectors for the main injectors and features a set of secondary injectors located in the airbox. The result is improved cylinder filling, crisper throttle response and higher power output. The new fuel tank design improves mass centralisation and allows the use of a larger-capacity airbox, which further improves intake efficiency.

Another important new feature is the addition of an exhaust valve. Integral with the new under-seat muffler, this device controls the pressure waves inside the exhaust system, contributing to improved low- and mid-range power characteristics.

Larger capacity radiator improves cooling efficiency. The new radiator is 40 mm taller and features more tightly packed cores.

Controlling the new engine is a new ECU, with added memory for the exhaust valve and for the second set of fuel injectors.

Transmission

Like the 6RR, the new 6R clutch is fitted with a back-torque limiter. This reduces rear-wheel hop that may occur when downshifting at high rpm.

Shifting quality is also better, thanks to a bearing fitted to the shift-drum locator arm. 3rd gear ratio is taller, for better spacing between the gears. Strong needle bearings used at the ends of the transmission shafts contribute to transmission durability.

Suspension

Fully adjustable Showa fork delivers improved ride quality and outstanding cornering performance.

Race-developed Bottom-Link type Uni-Trak rear suspension delivers a smooth ride and excellent cornering performance. New linkage ratios give more linear action, and improved settings for the rear shock improve both ride quality and track performance.

Frame

New all-aluminium perimeter frame offers exceptional strength and torsional rigidity while delivering responsive and stable handling performance. The new frame reduces the distance between the swingarm pivot and steering head by 13 mm, contributing to the shorter wheelbase and allowing use of a longer swingarm. Wheelbase: 1,397 > 1,390; Rake: 24.5 > 25; Fork offset: 26 mm. Forward-located swingarm pivot and long swingarm reduce the leverage of the rear sprocket on the rear suspension, resulting in superb rear suspension action.

New braced aluminium swingarm is significantly more rigid and resembles that used on the Ninja ZX-10R. The new swingarm uses a cast section at the pivot, with bracing on the right side. The left arm is a reinforced extrusion. The exhaust pipe for the under-seat exhaust passes through the swingarm.

Improved, centrally mounted Ram Air duct is integral with the steering head. By reducing air resistance inside the Ram Air ducts, Ram Air efficiency has been improved, contributing to the increase in power output. Steering head uses ball bearings for light, responsive steering.

Brakes

Radial-mounted, 4-piston front brake calipers deliver exceptional feel and performance - widely used in racing, the 03MY 6R and 6RR were the first production bikes in their class to feature this style of brake caliper. Four independent brake pads are used - one for each piston - for more even wear and improved heat resistance.Large-diameter, semi-floating, drilled, 300 mm stainless steel front disc rotors are 5.5 mm thick for high heat capacity and mount on disc carriers without offset to reduce weight.

Radial piston front brake master cylinder uses direct action for improved control and better feel at the lever. (Photo 19, Illustration C) Brake lever is 5-way adjustable.

Small diameter rear brake disc measures 220 mm in diameter for low unsprung weight. Compact, lightweight rear brake caliper mounts directly to the swingarm, negating the need for an independent brake tie-rod.

Wheels / Tyres

New, ZX-10R-type wheels are light and increase the family resemblance of the Ninja series. The front is the same as the ZX-10R's, but with a smaller 25 mm axle. The rear wheel features the same design as the 10R's, but with a smaller rim size. Rear wheel features a wide 5.5-inch rim. Front rim measures 3.5 inches. High-spec front and rear tyres deliver exceptional cornering performance. Tyre sizes:

  • Front: 120/65ZR17M/C (56W)
  • Rear: 180/55ZR17M/C (73W)
  • Bodywork

    New cowling design dramatically improves the bike's aerodynamic performance, while enhancing the "Ninja family" look. The new ZX-6R has the lowest CdA of any Ninja released to date.

    The new cowl moves the point where the boundary layer separates from the cowling forward, which significantly shortens the point of convergence at the rear of the machine, greatly improving the bike's aerodynamic efficiency. This also reduces turbulence around the rider, but more importantly, this design allows a greater possible top speed and quicker acceleration.

    THE RACY NINJA LOOK

    Engine

    Under-seat muffler contributes to improved aerodynamics and gives the new 6R a slim, racy look.

    Bodywork

    All-new bodywork with MotoGP styling elements gives the machine a distinctively racy look. 10R-style cowling with "hungry" central Ram Air duct and very bright dual multi-reflector headlight gives the front of the bike a very aggressive look.

    European models feature front turn signals stylishly integrated in the bodywork for improved aerodynamics. Rear turn signals are extremely compact and feature a conical design. (North American models feature compact new front and rear turn signals like those on the Z750S.) (Photo 21)

    Flush-surface LED tail light like that of the 10R curves up slightly over the top of the seat cowl, making the 6R very visible to the drivers of high vehicles.

    Aerodynamic front fender is the same as on the Ninja ZX-10R. Optional single seat cover can replace the tandem seat for an even more aggressive image.

    Instruments

    Racing-style instrument panel features a bar-type LCD tachometer, digital LCD speedometer, an adjustable shift indicator lamp, and a stopwatch-style lap timer - this in addition to digital temp gauge, clock, tripmeter and a comprehensive range of indicator lamps. The shift indicator lamp has three settings: Off, Low and Bright.

    Other Touches

    Matt-black frame and swingarm enhance the 6R's racy look. Upper triple clamp has holes for a stylish appearance and lighter weight. Newly designed passenger peg brackets are very stylish. All-stainless exhaust system.

    RIDER AND MACHINE ARE ONE = FUN TO RIDE

    Ergonomics

    Revised riding position is based on that of the Ninja ZX-10R. The pulled back steering head reduces the distance between the handlebars and the footpegs. The new frame, seat and fuel tank locate the rider "in" the bike, giving the rider a very confident feel. Handlebar, seat and footpeg locations give an ideal position for high performance riding with a good level of comfort.

    The redesigned fuel tank features a depression in the top surface of the tank cover so the rider is able to tuck in better, for improved aerodynamics.

    The new cases mount the cylinder at a more vertical angle (25 to 20), allowing the engine to be mounted further forward in the frame.

    Specificatrions

  • Engine Type - Liquid-cooled, 4-stroke In-Line Four
  • Displacement - 636 cm3
  • Bore and Stroke - 68 x 43.8 mm
  • Compression ratio - 12.9:1
  • Valve system - DOHC, 16 valves
  • Fuel system - Fuel injection: 38 mm x 4 (Keihin), twin injection
  • Ignition - Digital
  • Starting - Electric
  • Lubrication - Forced lubrication, wet sump
  • Transmission - 6-speed, return
  • Final drive - Sealed Chain
  • Primary reduction ratio - 1.891 (87/46)
  • Gear ratios: 1st, 2.923 (38/13), 2nd, 2.055 (37/18), 3rd, 1.666 (35/21), 4th, 1.450 (29/20), 5th, 1.272 (28/22), 6th, 1.153 (30/26)
  • Final reduction ratio - 2.866 (43/15)
  • Clutch - Wet multi-disc, manual
  • Frame Type - Perimeter, pressed-aluminium
  • Wheel travel: front - 120 mm, rear, 130 mm
  • Tyre: front - 120/65ZR17M/C (56W), rear - 180/55ZR17M/C (73W)
  • Caster (rake) - 25
  • Trail - 106 mm
  • Steering angle (left/right) - 27/27
  • Suspension - Front: 41 mm inverted cartridge fork with rebound and compression damping, spring preload adjustability and top-out springs, Rear: Bottom-Link Uni-Trak with gas-charged shock, spring preload adjustability and top-out
  • Brakes - Front: Dual semi-floating 300 mm discs. Caliper Dual radial-mount, opposed 4-piston, 4-pad, rear: Single 220 mm disc Caliper, Single-bore pin-slide
  • Fuel capacity - 17 litres