1986 Kawasaki Ninja 600 Service Manual

The 1986 Kawasaki Ninja 600 is a high-performance sport motorcycle featuring a liquid-cooled, four-stroke, inline-four engine with DOHC, 16 valves, 599cc displacement, 6-speed transmission, and advanced chassis design. This service manual covers comprehensive maintenance procedures, specifications, troubleshooting, and repair guidelines for proper servicing and optimal performance. Below are key sections for safety, technical specifications, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

General Information

Key components: 599cc liquid-cooled inline-four engine, 6-speed transmission, dual front disc brakes, Uni-Trak rear suspension, digital instrumentation.

Specifications

• Overall Length: 2,130 mm (83.9 in)
• Overall Width: 710 mm (28.0 in)
• Overall Height: 1,175 mm (46.3 in)
• Wheelbase: 1,465 mm (57.7 in)
• Ground Clearance: 135 mm (5.3 in)
• Seat Height: 770 mm (30.3 in)
• Dry Weight: 198 kg (436 lbs)
• Fuel Capacity: 16 liters (4.2 US gal)
• Oil Capacity: 3.2 liters (3.4 US qt) with filter change
• Maximum Power: 85 hp @ 10,500 rpm
• Maximum Torque: 54 Nm @ 8,500 rpm

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

1. Every 600 miles/1,000 km or 6 months: Check engine oil level, tire pressure, chain tension, brake fluid, cables
2. Every 3,000 miles/5,000 km: Change engine oil and filter, check valve clearance, spark plugs
3. Every 6,000 miles/10,000 km: Clean air filter, check carburetor synchronization, brake pads
4. Every 12,000 miles/20,000 km: Replace spark plugs, check cooling system, clutch adjustment
5. Every 2 years: Replace brake fluid, check wheel bearings

WARNING! Always use genuine Kawasaki parts and recommended lubricants. Wear protective equipment during maintenance.

Engine Service

Comprehensive engine maintenance and repair procedures.

1. Valve Clearance Adjustment: Check when engine is cold. Intake: 0.10-0.15 mm, Exhaust: 0.15-0.20 mm
2. Cylinder Head Removal: Drain coolant, remove camshafts, disconnect electrical connections
3. Piston and Cylinder: Measure piston clearance (0.02-0.04 mm), check cylinder bore for wear
4. Crankshaft and Connecting Rods: Check big-end and small-end bearing clearance
5. Camshaft and Timing: Align timing marks, check chain tensioner operation
6. Oil Pump and Filter: Replace oil filter every oil change, check pump pressure
7. Cooling System: Check radiator, water pump, thermostat (opens at 80-84°C)

CAUTION! Engine components are precision parts; handle with care and use proper tools.

Fuel System

Four 32mm constant velocity carburetors with accelerator pump.

1. Carburetor Synchronization: Use vacuum gauges to balance all four carburetors
2. Float Level Adjustment: Standard float height: 15.5 mm ± 1.0 mm
3. Jet Specifications: Main jet: #112, Pilot jet: #38, Needle jet: 4FL21-3
4. Fuel Filter: Replace every 12,000 miles or if contaminated
5. Throttle Cable Adjustment: Maintain 2-3 mm free play at throttle grip
6. Air Filter: Clean foam element with solvent, re-oil with proper air filter oil

Tip: Always check for vacuum leaks after carburetor service.

Chassis & Suspension

Double cradle steel frame with advanced suspension components.

1. Front Fork Service: Check oil level (345 ml per leg), replace seals if leaking
2. Rear Suspension: Adjust preload for rider weight and riding conditions
3. Steering Head Bearings: Check for play, adjust as necessary
4. Wheel Alignment: Check and adjust chain alignment marks
5. Tire Pressure: Front: 2.25 kg/cm² (32 psi), Rear: 2.50 kg/cm² (36 psi)
6. Chain Adjustment: Maintain 25-35 mm free play at midpoint between sprockets

WARNING! Always support motorcycle securely on center stand or lift during chassis work.

Electrical System

12-volt electrical system with transistorized ignition.

Testing Procedures: Use multimeter to check voltage, resistance, and continuity.

Brake System

Dual hydraulic disc brakes front, single disc rear.

1. Front Brake Calipers: Twin-piston floating calipers, check pad wear (minimum 1.0 mm)
2. Rear Brake Caliper: Single-piston caliper, check pad wear
3. Brake Discs: Check for warpage (max 0.3 mm), minimum thickness: front 4.0 mm, rear 4.5 mm
4. Brake Fluid: DOT 4, replace every 2 years, check reservoir levels
5. Brake Lines: Inspect for cracks, leaks, or damage
6. Brake Bleeding: Use proper sequence: right front, left front, rear

CAUTION! Brake fluid is corrosive; avoid contact with painted surfaces.

Troubleshooting

Special Tools Required: Carb synchronizer, compression tester, valve adjustment tools, torque wrench.

Wiring Diagrams

Complete electrical schematics for all systems including ignition, charging, lighting, and instrumentation. Color-coded wiring with connector locations and ground points.

Key Connectors: Main harness, CDI unit, alternator, regulator/rectifier, handlebar switches.

Torque Specifications

Note: Always use a calibrated torque wrench and follow proper tightening sequences.