http://www.gstwins.com/zx6r/zx6r_shim.htm
How to Shim Kawasaki
ZX6R Carb Needles
(specific to years 2000-2002 but should work for earlier models too)
This relatively easy job helps smooth out the power dip felt in the
ZX6R at about 5k rpm -this should work fine with zx6R's with stock or bolt-on
systems or even full systems. On other bikes I have owned this mod has had varying degrees
of success so I decided to try it with the ZX6R. My wife's 2002 ZX6R always had a
*gulp* when I whacked open the throttle and once I made this small mod the problem went
away. If you have some mechanical ability you will want to do this mod as the
difference is very noticeable in throttle response. Shims are .020" thick
and 3mm ID you can find something close enough at Radio Shack or you can purchase shims
for $2.37 ($2 + postage) HERE
| Remove the seat by unbolting the seat bracket |  |
| Remove the two bolts that hold the bracket at the rear of the gas tank. Remove the little breather hose at the rear of the gas tank. |  |
| Remove the two gas tank bolts under the top triple clamp. |  |
| Turn fuel petcuck to the OFF position. Remove fuel petcock knob with a phillips head screwdriver. Don't forget this or you'll probably snap it off when removing the tank! |  |
| Raise the gas tank and identify fuel hose by the fuel petcock (see pic below) . Now you can prop up the tank and might be able to do the job without removing the tank but why? You risk tearing the fuel hose and make the job harder. (don't ask me how I know this) |  |
| Once you get the fuel line off the petcock you're ready to remove the air box. Remove the breather hose and start taking the bolts off. |  |
| A 10mm socket and a ratchet makes the air box removal easier. Remove all the bolts from around the air box. |  |
| Remove the air box cover and the air filter. May be a good time to inspect the filter and make sure its clean and doesn't need replacement (a restrictive air filter can cause the bike to run rich and lose power).. |  |
 | |
| Remove the velocity stacks from the carbs -they are easy to remove with a good screwdriver. They are held on with two screws and note the taller ones are in the middle. |  |
| Now remove the bottom half of the air box. There a number of screws around the carbs and the hoses for the ram air need to be removed (its easy, just pull them off). |  |
| Remove vacuum valve cover by removing 2 screws. *WARNING* there is one tiny o-ring under the vacuum valve cover that will fall down into the motor. It is imperative you find it or order a couple from your dealer ahead of time (Kaw p/n 16038-022). I located all of them and had to fish them out with tape on the end of a long screwdriver. I used a tiny smear of contact cement in the cover to hold o-ring in place to reinstall. Also, after I did the job I thought about using silicone sealant instead due to ease of use (just a tiny smear on the o-ring then stick it to the cover). You must put them back and whatever you do, don't block the air port! THIS IS THE TRICKIEST PART OF THE JOB. |  |
| Remove the vacuum valve by carefully pulling on the diaphragm. |  |
| The vacuum valve will easily slide out. |  |
| Time to shim! Remove needle holder with a pair of needle nose pliers. Use a gentle rocking motion while pulling and watch for the little spring under it. Watch this Shim procedure in Windows *consider right clicking and saving to your disk for |  |
| Pry off the plastic spacer and insert the shim. The ZX6R seemed to work best with one per needle. |  |
| Now repeat the process for the remaining 3 needles and you're done! Now you simply reassemble the carbs, the air box and gas tank and enjoy. If you need shims you can buy for $2.37 ($2 + postage) HERE |  Exploded to show shim -these items |
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