2004 Kawasaki ZX-6RR

2004 KAWASAKI NINJA® ZX-6RR
Engine refinements makes this Supersport contender stronger

Introduced last year with AMA SuperSport competition in mind, the NINJA® ZX-6RR sport motorcycle returns to the 2004 Kawasaki lineup with upgrades to the engine and powertrain for even better on-track performance.

With feedback from Kawasaki factory roadracers Tony Meiring and Tommy Hayden, both of whom compete aboard NINJA ZX-6RR sportbikes in AMA Supersport roadracing, several modifications have been made to the middleweight NINJA, including new cams, larger intake valves, a revised intake system and new gear ratios for the six-speed transmission.

The ZX-6RR engine is a liquid-cooled, DOHV, 16-valve, 599cc, four cylinder, four-stroke engine that delivers performance worthy of AMA Supersport competition. To give racers and sportbike enthusiasts even more power, Kawasaki engineers changed the shape of the combustion chambers, redesigned the piston crowns and added molybdenum coating to the skirts to reduce friction and mechanical loss. 

In conjunction with these changes, intake ports are smaller to further increase induction velocity, intake valves are 0.5mm larger for better breathing at all rpm and camshaft profiles have been changed to produce more lift. Gear ratios for the oil pump have also been changed to reduce mechanical loss, contributing to the engine’s high-revving nature. 

The ZX-6RR is fed by an advanced fuel injection system that utilizes large-bore 38mm throttle bodies with new twin injectors – one located near the airbox and the other at the intake manifold. A 32-bit high-speed microprocessor-controls timing and is ultra-responsive to engine needs. The integrated system helps ensure smooth linear power characteristics and high engine output and with low emissions. A centrally located ram-air duct system contributes to intake efficiency and saves weight by eliminating a number of parts needed for previous Ram Air designs.

As a production sportbike that must meet homologation rules for AMA competition, the NINJA ZX-6RR must also comply with important emissions standards. Helping to do this is the KCA (Kawasaki Clean Air) system, which routes fresh air to the ZX-6RR’s exhaust ports. What little exhaust gasses are left after combustion are expelled through a light, stainless steel exhaust system that increases engine performance.

A multi-plate wet clutch with back-torque limiter transfers power to a revised six-speed transmission with even closer gear ratios for better on-track performance. The back-torque limiter feature helps to prevent wheel hop during aggressive corner entry, while lime green coating has been added to the side plates of the X-ring drive chain for a cool, racy look.

The ZX-6RR's engine rests inside a pressed aluminum perimeter frame that is rigid and delivers crisp and stable handling performance. Sheets of aluminum are pressed to shape, then welded together, to produce remarkable strength and low weight. An aluminum subframe is also lightweight and is easily removed for conducting routine maintenance. 

The advanced, rear aluminum swingarm features internal ribbing for high torsional rigidity and low weight, and utilizes an adjustable pivot that allows riders to fine-tune handling for specific conditions. Light weight aluminum components are also used in the UNI-TRAK® linkage system, which produces progressively stiffer damping and spring rates as the fully adjustable shock is compressed. A nitrogen-gas charged Kayaba shock with a piggyback reservoir features a threaded collar spring preload adjuster and fully adjustable rebound and compression damping, while a top-out spring improves shock action. To alter ride height, various combinations of 1mm-thick shims can be inserted between the shock and its frame mount to further tune handling.

Up front, the ZX-6RR rides on a fully adjustable inverted 41mm fork to provide high rigidity and superior feedback. Top-out springs and adjustable spring preload are fitted to the fork to maximize performance throughout the stroke range.

Traditionally used for racing applications, radial-mounted, four-piston, four-pad front brake calipers grace the NINJA ZX-6RR. This high-performance braking system utilizes four independent brake pads in each caliper to clamp down on semi-floating 280mm front disc rotors, resulting in exceptional feel, high heat resistance, superior braking power and longer brake pad life. Braking power for the rear wheel is provided by a single 220mm disc brake.

The NINJA ZX-6RR’s race-inspired fairing offers an exceptionally low drag coefficient for slippery aerodynamics and the central Ram Air duct gives the front of the bike an aggressive identity. Lightweight and very bright multi-reflector dual headlights provide great visibility while enhancing the aggressive head-on appearance for which NINJA sportbikes are famous. Tucked behind the cowling is a compact instrument cluster featuring a bar-type LCD tachometer, digital LCD speedometer, programmable shift light and a stopwatch-style 99-lap timer. The cluster also includes a digital temp gauge, clock, tripmeter and indicator lamps.

Features that compliment the track-oriented ergonomics include one-piece aluminum clip-on handlebars, while the fuel tank and seat are shaped to allow the rider to mold to the chassis.

Features and Benefits:

Four-Cylinder 599cc Engine

• Reshaped combustion chambers and redesigned piston crowns help produce more power
• Molybdenum coating added to piston skirts to reduce friction and mechanical loss, contributing to the ZX-6RR’s high-revving nature
• Intake and exhaust valves are larger for better breathing at all rpm
• Camshaft profile has higher lift for more performance
• Gear ratios for the oil pump changed to reduce mechanical loss
• Cut-outs added to the cylinder skirts to reduce pumping loss

Crankcase

• Crankcase is light and rigid, allowing piston oil jets to be positioned closer to pistons

Optimal Intake

• Short intake and exhaust valves reduce weight and improve high-rpm performance
• Larger intake valves help increase performance
• Single springs of oval-shape are lighter providing improved intake valve control at high rpm
• Stepped spring seats replace previous plain type to better stabilize the valve springs

Fuel Injection System

• Large-bore 38mm throttle bodies produce high engine output and low emissions
• Sub-throttle bodies ensure smooth, linear power characteristics
• New twin injectors improve cylinder filling for more power

Six-Speed Transmission w/Clutch Back-Torque Limiter

• Closer gear ratios for 2004 provide for more aggressive, competition-style performance
• Clutch back-torque limiter helps prevent wheel hop during quick deceleration

Digital Ignition

• 32-bit high-speed microprocessor-controlled timing is ultra-responsive

Lightweight Exhaust System

• Light exhaust system contributes to engine performance
• Stainless muffler housing improves catalyzer performance and reduces emissions

KLEEN™ (Kawasaki Low Exhaust Emission) System

• Helps keep exhaust emissions environmentally friendly
• KCA (Kawasaki Clean Air) system routes fresh air to the exhaust ports for reduced exhaust emissions

Ram Air Intake

• Centrally located ram-air duct reduces number of parts and weight to improve intake efficiency
• Greater resistance to wind side-drafts

Pressed Aluminum Perimeter Frame

• Rigid aluminum frame delivers crisp and stable handling
• Centrally mounted Ram Air duct is integrated with steering head to reduce weight and improve Ram Air efficiency
• Lightweight aluminum sub-frame facilitates maintenance
• Adjustable swingarm pivot for fine-tuning handling
• Steering head bearings use ball bearing type for light, responsive steering
• Threaded steering damper mount incorporated into left frame spar

Aerodynamic Cowling

• Race-inspired fairing and bodywork give the machine a distinctively racy look

• Fairing offers an exceptionally low drag coefficient for slippery aerodynamics

• Central Ram Air duct gives the front of the bike an aggressive identity
• Lightweight and powerful dual multi-reflector headlights provides exceptional visibility

41mm Inverted Kayaba Fork

• Fully adjustable fork runs stiff tubes for high fork rigidity and superior steering feedback
• Top-out springs and adjustable spring preload are fitted for stable performance throughout the stroke range
• Super-hard DLC (Diamond-Like Carbon) coating added to inner fork tubes to reduce friction
• Revised damping for improved action

Bottom-Link UNI-TRAK® Rear Suspension

• Nitrogen-gas charged Kayaba shock with piggyback reservoir is fully adjustable for rebound and compression damping
• Shock utilizes a threaded collar spring preload adjuster
• A top-out spring on the rear shock improves shock action
• Stepless damping adjuster with check valve instead of needle valve for improved damping
• Adjustable ride height with 1mm shims

Stopping Power

• Radial-mounted, four-piston, four-pad front brake calipers
• Four independent brake pads are used in each caliper for more even wear and improved heat resistance
• Semi-floating 280mm steel front disc rotors are 6mm thick for high heat capacity and mount on flat disc carriers without offset for reduced weight
• Brake lever is five-way adjustable
• Small diameter rear brake disc measures 220mm in diameter without offset for low unsprung weight
• Front brake hose routing eliminates interference with radiator

Instrument Cluster

• Instrument cluster features a bar-type LCD tachometer, digital LCD speedometer, programmable shift indicator light and stopwatch-style 99 lap timer
• Cluster also includes digital temp gauge, clock, tripmeter and comprehensive range of indicator lamps

Details

• Handlebar, seat and footpeg location enhance a track oriented riding position
• One-piece forged aluminum handlebars
• Ergonomically shaped seat and tank allow rider to mold to bike
• LED taillight is very light, highly compact, very durable and looks exceptionally cool
• Tamper resistant ignition switch
• Quick-detach rear seat allows easy mounting of standard aerodynamic single-seat cover
• Extruded aluminum swingarm with internal ribbing offers strong, torsional rigidity and low weight
• Friction-reducing sealant on the front brake caliper pistons improves brake feel
• Lime green coating added to side plates of X-ring drive chain for cool, racy look

 

2004 KAWASAKI NINJA® ZX-6RR SPECIFICATIONS
Engine	Four-stroke, DOHC, inline four cylinder
Displacement	599cc
Starting	Electric
Bore x stroke	67.0 x 42.5mm
Compression ratio	13.5: 1
Cooling	Liquid
Induction	Fuel injection with four 38mm throttle bodies
Ignition	Digital
Transmission	Six-speed
Frame	Perimeter, pressed-aluminum
Rake / trail	24.5° / 3.7 in.
Suspension, front	41mm inverted cartridge fork with adjustable compression and rebound damping, adjustable spring preload
Suspension, rear	Bottom-link UNI-TRAK® system with gas-charged shock, stepless rebound and compression adjustability
Wheel travel, front	4.7 in.
Wheel travel, rear	5.3 in.
Tire, front	120/65 x 17
Tire, rear	180/55 x 17
Front brake	280mm dual hydraulic discs
Rear brake	220mm single hydraulic disc
Overall length	79.7 in.
Overall width	28.3 in.
Overall height	43.7 in.
Ground clearance	5.1 in.
Seat height	32.5 in.
Dry weight	355 lbs.
Fuel capacity	4.8 gal.
Wheelbase	55.1 in.
MSRP	$8,399
Available	TBA
Colors	Lime Green

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