"All-out sportbike performance and aggressive styling" is the best way to sum up the all-new 2003 Kawasaki NINJA® ZX-6R sportbike. Based on the limited edition NINJA® ZX-6RR, the radical new ZX-6R boasts a redesigned engine and crankcase with 37 extra cubic centimeters of displacement, an electronic fuel injection system and an all-new chassis. These new features, plus a host of additional design changes, are sure to leave the competition hung out to dry.

Powering the ZX-6R is a liquid cooled, DOHC, 16-valve, 636cc, four-cylinder engine tuned for optimum performance, especially in the high rpm ranges. Engine modifications such as reducing the cylinder head height by 10mm, reshaping the camshaft oil supply line, shortening the cylinder 5mm, and shortening the intake valves by 10mm, result in a lightweight, more compact engine that produces more muscle all around. The ZX-6R's six-speed transmission shifts smoother due to new shift cam shape, spring loads and shift lever ratio. Plus, new gear ratios tighten up the clearances between third and sixth gear.

Performance increases were also achieved by switching to a new fuel injection system fed by large-bore 38mm throttle bodies with sub-throttle valves. A new centrally located ram-air duct system increases performance, improves intake efficiency and saves weight by eliminating a number of parts needed for the prior Ram-air system.
Exhaust emissions are reduced by use of the KCA (Kawasaki Clean Air) system, which routes fresh air to the exhaust ports. A reshaped secondary air reed valve also aides in reducing emissions. What little exhaust gasses remain exit through a new, lighter stainless exhaust system that increases engine performance and enhances the ZX-6R's high-tech appearance.

A more rigid aluminum perimeter frame inspires tighter handling, more confident cornering, and better overall sportbike ride quality. To produce this new frame design, sheets of aluminum are pressed to shape, then welded together, producing remarkable strength and low weight. An aluminum subframe also keeps weight down and can be removed easily to perform routine maintenance.

Lightweight aluminum components are also used in the design of the new swingarm. The swingarm design features internal ribbing, exceptional torsional rigidity, and low weight, and also utilizes Kawasaki's UNI-TRAK® rear suspension system. The race-developed rear suspension system consists of a nitrogen-gas charged Kayaba shock that delivers a smooth ride and excellent cornering performance. A top-out spring has also been added to the rear shock for improved action. The shock also features fully adjustable rebound and compression damping settings, and a threaded collar spring preload adjuster so suspension settings can be dialed in to suit rider preference. Ride height is adjustable via combinations of optional 1mm-thick shims that can be inserted between the shock and its frame mount.

A fully adjustable, inverted 41mm Kayaba fork provides high rigidity and superior feedback on the front of the ZX-6R. Stable performance throughout the stroke range is enhanced by top-out springs and a spring preload adjuster, while new compression and rebound damping rates improve steering and overall fork action.

Traditionally used for racing applications only, a new radial-mount, four-piston, four-pad front brake assembly graces the ZX-6R. A first for a production motorcycle, the four independent brake pads are used in each caliper to clamp down on new semi-floating 280mm dual front disc rotors. The race-proven braking system improves heat resistance, braking performance and lengthens pad life. In the rear, a brake pedal ratio change actuates a single 220mm disc and features an improved feel.

Styling of the new ZX-6R is as progressive and performance oriented as the engine and suspension upgrades. A new fairing of GP origin offers exceptional aerodynamic efficiency and the reshaped central Ram-air duct gives the front of the bike an aggressive identity befitting a Kawasaki Ninja sportbike. Lightweight and powerful multi-reflector dual headlights enhance the sleek front-end appearance. Tucked behind the cowling is an all-new instrument cluster that features a bar-type LCD tachometer, digital LCD speedometer, a programable shift indicator light and a stopwatch-style 99 lap timer. The new instrument panel also includes a digital temperature gauge, clock, tripmeter, and a comprehensive range of indicator lamps.

Providing a new more-track oriented riding position is a new handlebar, seat and relocated footpegs. The new one-piece forged aluminum handlebar is lighter and mounted slightly more rearward, while the tank and reshaped seat allow rider and machine to be as one.

Features

4-Cylinder 636cc Engine

• More compact, lightweight engine revs higher and produces more power
  
• Engine delivers increased performance, especially in high rpm range
  
• Plated, all-aluminum cylinder has 5mm shorter skirts for reduced weight and the water passage ways have been reshaped for improved cooling performance
  
• Outer surface of cam-chain tunnel curved, reducing vibration, engine noise and reducing cylinder weight

Redesigned Crankcase

• New crankcase lighter and more rigid, allowing piston oil jets to be positioned closer to pistons
  
• Engine oil pan capacity reduced providing a more compact design

Optimal Intake

• Intake and exhaust valves 10mm shorter, for less weight and improved high-rpm 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

Six-Speed Transmission

• New transmission uses closer ratios for gears three and up, for improved track performance
  
• Cam shape for shift drum has been modified for improved shifting performance
  
• Shift lever ratio changed providing smooth and easy shifting

Digital Ignition

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

Lightweight Exhaust System

• New lighter exhaust system with a reconfigured collector contributes to the increase engine performance
  
• Muffler housing changed from aluminum to stainless for improved catalyzer performance and reduced emissions

KLEEN (Kawasaki Low Exhaust Emission) System

• Helps keep exhaust emissions environmentally friendly
  
• Reductions in exhaust emissions also aided by reshaping the guide for the secondary air reed valve
  
• KCA (Kawasaki Clean Air) system routes fresh air to the exhaust ports for cleaner exhaust emissions

Ram Air Intake

• Ram-air duct centrally located reducing number of parts, weight and improving intake efficiency
  
• Greater resistance to wind side-drafts

Pressed Aluminum Perimeter Frame

• New frame rigid yet delivers crisp and stable handling performance
  
• Centrally mounted Ram Air duct is integrated with steering head resulting in reduced weight and improved Ram Air efficiency
  
• Lightweight aluminum sub-frame facilitates maintenance
  
• Steering head bearings use ball bearing type for light, responsive steering

Reshaped Aerodynamic Cowling

• GP-styled fairing and bodywork give the machine a distinctively racy look
  
• Fairing offers an exceptionally low drag coefficient for slippery aerodynamics
  
• Reshaped central Ram Air duct gives the front of the bike an aggressive identity
  
• Lightweight and very bright dual multi-reflector headlights provides great 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
  
• New damping rates improve steering feedback and fork 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 added to rear shock for improved action
  
• Stepless damping adjuster with check valve instead of needle valve for improved damping
  
• Extruded aluminum swingarm with internal ribbing offers high stiffness and low weight
  
• Ride height adjustable with 1mm shims

Stopping Power

• Radial-mount, four-piston, four-pad front brake assembly a first for any production motorcycle
  
• Traditionally used for racing applications, four independent brake pads are used in each caliper for more even wear and improved heat resistance
  
• New 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
  
• Rear brake pedal ratio changed for improved feel
  
• Front brake hose routing eliminates interference with radiator

All-new Instrument Cluster

• New 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 enchance a track oriented riding position
  
• New, one-piece forged aluminum clip-on handlebars are lighter and mounted in a slightly more rearward position
  
• Ergonomically shaped seat and tank allow rider to mold to bike
  
• LED taillight is very light, highly compact, durable and exceptionally attractive
  
• Tamper resistant ignition switch
  
• Quick-detach rear seat allows easy mounting of standard aerodynamic single-seat cover
  
• Friction-reducing sealant on the front brake caliper pistons improves brake feel
  

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