Kawasaki ZX-10R manual

Ninja ZX-10R Motorcycle Service Manual www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference G[...]

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Ninja ZX-10R Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical p hotocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct c[...]

EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, K awasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control system s in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally , Kawasaki has incorporated an[...]

T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair , or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise contro l prior to its s[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ............................................................................................................. ........ 1-2 Model Identification......................................................................................................... ........ 1-7 Gener[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera - tion on a motorcycle, read the precautions given below . T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each c hapter wherever [...]

GENERAL INFORMA TION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly . Storage of Remov ed Parts After all the parts including subassembly parts have been cleaned, store the parts[...]

1-4 GENERAL INFORMA TION Before Servicing Tightening Sequence Generally , when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which c an lead to malfunction. Conversely when loosening t[...]

GENERAL INFORMA TION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely nec[...]

1-6 GENERAL INFORMA TION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free[...]

GENERAL INFORMA TION 1-7 Model Identification ZX1000D6F (Europe) Left Side Vi ew ZX1000D6F (Europe) Right Side V iew www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

1-8 GENERAL INFORMA TION Model Identification ZX1000D6F (United Sta tes and Canada) Left Sid e View ZX1000D6F (United St ates and Canada) Ri ght Side V iew Frame Number Engine Number www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

GENERAL INFORMA TION 1-9 General Specifications Items ZX1000D6F (Ninja ZX-10R) Dimensions Overall Length 2 065 mm (81.3 in.) Overall Width (CA), (CAL), (US) 730 mm (28.7 in.) 705 mm (27.8 in.) Overall Height 1 130 mm (44.5 in.) Wheelbase 1 390 mm (54.7 in.) Road Clearance 120 mm (4.7 in.) Seat Height 825 mm (32.5 in.) Dry Mass 175 kg (386 lb) Curb [...]

1-10 GENERAL INFORMA TION General Specifications Items ZX1000D6F (Ninja ZX-10R) Duration 292° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Ty p e API SE, SF or SG API SH, SJ or SL with JASO MA Vis c os i t y SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive T rain Primary Reduction System: Ty p e Gear Reduction Ratio 1.61 1 (8[...]

GENERAL INFORMA TION 1-1 1 General Specifications Items ZX1000D6F (Ninja ZX-10R) Brake T ype: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Ty p e Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-h alogen) Low 12 V 55 W (quartz-halogen) T ail/Brake Light 12 V 0.5/4.1 W (LED) Alternator: Ty p e Three-phase [...]

1-12 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m ×0 . 0 0 1 micro µ × 0.000001 Units of Mass k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L× 2 . [...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart ............................................................. ...................................... 2-3 T orque and Locking Agent ...................................................................................................... 2-6 Specifications ...[...]

2-2 PERIODIC MAINTENANCE Steering Play Adjustment.................................................................................................. 2-37 Steering Stem Bearing Lubrication ................................................................................... 2-38 Steering Damper Oil Leak Inspection ......................................[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever comes first * ODOMETER READING × 1 000 km (× 1 000 mile) INSPECTI[...]

2-4 PERIODIC MAINTENANCE Periodic Mainten ance Chart FREQUENCY Whichever comes first * ODOMETER READING ×10 0 0k m (× 1 000 mile) INSPECTION Every 1 (0.6) 6 (4) 12 (7.5) 18 (12) 24 (15) 30 (20) 36 (24) See Page Brake System Brake fluid leak (brake hose and pipe)-inspect year • • • • • • • 2-33 Brake hose and pipe damage-inspect year[...]

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first * ODOMETER READING ×10 0 0k m (× 1 000 mile) CHANGE/REPLACE ITEM Every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) See Page Air cleaner element # Every 18 000 km (12 000 mile) 2-47 Fuel hose 4 years • 2-48 Coolant 3 years • 2-49 Radiator[...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: T ighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L:[...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Radiator Lower Bolt 7.0 0.71 62 in·lb Radiator Upper Bolt 7.0 0.71 62 in·lb Wa t e r H o s e C l a m p S c r e w s 2.0 0.20 18 in·lb W ater Hose Fitting Bolts 10 1.0 89 in·lb W ater Passage Plugs 19.6 2.0 14 L W ater Pump Cover Bolts 10 1.0 89 in·lb [...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Clutch Clutch Cover Mounting Bolts 10 1.0 89 in·lb S Clutch Hub Nut 130 13.3 96 R Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S Clutch Spring Bolts 9.8 1.0 87 in·lb Oil Filler Plug – – – Hand-tighten Sub Clutch Hub Bolts 25 2.5 18 L Engine Lubrica[...]

PERIODIC MAINTENANCE 2-9 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Crankcase Bolts (M6, L = 40 mm) 12 1.2 106 in·lb S Drive Shaft Cover Bolts 25 2.5 18 Gear Position Lever Bolt 12 1.2 106 in·lb Oil Passage Plugs 20 2.0 15 L Piston Oil Jet 3.0 0.31 27 in·lb Plate Screw 5.0 0.51 44 L Plug 20 2.0 15 Shift Drum Bearing Ho[...]

2-10 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Front Fork Bottom Allen Bolts 23 2.3 17 L Front Fork Clamp Bolts (Lower) 30 3.1 22 AL Front Fork Clamp Bolts (Upper) 20 2.0 15 Front Fork T op Plugs 23 2. 3 17 Piston Rod Nuts 15 1.5 11 Rear Shock Absorber Bracket Nut 59 6.0 44 Rear Shock Absorber Nut (L[...]

PERIODIC MAINTENANCE 2-1 1 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Gear Position Switch Screws 3.0 0.31 27 in·lb L Headlight Mounting Screws 1.2 0.12 11 i n · l b Idle Gear Cover Bolts 10 1.0 89 in·lb Left Handlebar Switch Housing Screws (M5, L = 25) 3.5 0.36 31 in·lb License Plate Light Cover Screws 1.2 0.12 11 i [...]

2-12 PERIODIC MAINTENANCE T orque and Locking Agent The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic T orque for General Fasten[...]

PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 100 ±50 r/min (rpm) ––– Throttle Body V acuum 31.5 ±1.3 kPa (236 ±10 mmHg) at idle speed ––– Air Cleaner Element Viscous paper element ––– Cooling System Coolant: T[...]

2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 30 ∼ 35 mm (1.2 ∼ 1.4 in.) ––– Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make RK EXCEL ––– Ty p e RK 525MFO, Endless ––– Link 108 links ––– Brakes Brake Flu[...]

PERIODIC MAINTENANCE 2-15 Special T ools Inside Circli p Pliers: 57001-143 Steering Stem Nut Wrenc h: 57001-1 100 Jack: 57001-1238 Oil Filte r Wrench : 57001-1249 V acuum Gauge: 57001-1369 Extension T ube: 57001-1578 Pilot Screw Adj uster , D: 57001-1588 Jack Attachment : 57001-1608 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.co[...]

2-16 PERIODIC MAINTENANCE Maintenance Pro cedure Fuel System (DFI) Throttle Con trol System Inspect ion • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Pl ay Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • Check that the throttle grip [B] moves smoothly from full open to close, a[...]

PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body . Special T ool - V acuum Gauge: 57001-1369 • Connect a highly accurate tachometer to one of the stick coil primary leads. • Connect: Fuel Pump Lead Connector Extension T ube [A] Special T ool - Extension [...]

2-18 PERIODIC MAINTENANCE Maintenance Pro cedure If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. Special T ool - Pilot Screw Adjuster , D: 57001- 1588 • Adjust lower vacuum between #1 and #2 t o higher vac- uum of #1 and #2. • Adjust the lower vacuum between #3 and #4 to [...]

PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw , use the “turns out” determined during disassem- [...]

2-20 PERIODIC MAINTENANCE Maintenance Pro cedure Idle Speed Adjustment • Start the engine and warm it up thoroughly . • T urn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a f ew times to make sure that the idle speed is within the specified range. Readjust if necessary . Fuel Hose Inspectio n (fuel le[...]

PERIODIC MAINTENANCE 2-21 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Inspect the canister as follows. ○ Remove the right upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). ○ Remove the canister [A], and disconnect the hoses from the can[...]

2-22 PERIODIC MAINTENANCE Maintenance Pro cedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B[...]

PERIODIC MAINTENANCE 2-23 Maintenance Procedure • Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine T op End chapter). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the lin [...]

2-24 PERIODIC MAINTENANCE Maintenance Pro cedure ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet V alve Clearance of #1 and #3 Cylinders Exhaust V alve Clearance of #1 and #2 Cylinders Measuring V alve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet V alve Clearance of #2 and #4 Cyli[...]

PERIODIC MAINTENANCE 2-25 Maintenance Procedure Adjustment Shims Thickness Par t Number Mark 1.300 92180-0108 130 1.325 92180-0109 132 1.350 92180-01 10 135 1.375 92180-01 1 1 13 8 1.400 92180-01 12 140 1.425 92180-01 13 142 1.450 92180-01 14 145 1.475 92180-01 15 148 1.500 92180-01 16 150 1.525 92180-01 17 152 1.550 92180-01 18 155 1.575 92180-01 [...]

2-26 PERIODIC MAINTENANCE Maintenance Pro cedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller , and remeasure the valve clearance. • When installing the shim, face the mark[...]

PERIODIC MAINTENANCE 2-27 Maintenance Procedure • Start the engine and run it at idle speed. • Plug [A] the air switching valve hose [B] end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching V alve Unit T est [...]

2-28 PERIODIC MAINTENANCE Maintenance Pro cedure • Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. ○ At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear . W ARNING Be sure that the outer cable end at the c[...]

PERIODIC MAINTENANCE 2-29 Maintenance Procedure Tr e a d D e p t h Standard: Front 6.0 mm (0.24 in.) Rear 6.5 mm (0.26 in.) Service Limit: Front 1 mm (0.04 i n.) (A T , CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 i n.) (Up to 130 km /h) 3 mm (0.12 in.) (Over 130 km/h) WA R N I N G T o ensure safe handling and stability , use only the recommended stan[...]

2-30 PERIODIC MAINTENANCE Maintenance Pro cedure Drive T rain Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • If the chain appears especially dirty , clean it before lubri- c[...]

PERIODIC MAINTENANCE 2-31 Maintenance Procedure Drive Ch ain Slack A djustment • Remove the cotter pin [A], and loosen the rear axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjuster [D] evenly . If the chain is too tight, turn in the left and right chain adjusters even[...]

2-32 PERIODIC MAINTENANCE Maintenance Pro cedure Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).[...]

PERIODIC MAINTENANCE 2-33 Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever[...]

2-34 PERIODIC MAINTENANCE Maintenance Pro cedure Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the l ower level line, fill the reser[...]

PERIODIC MAINTENANCE 2-35 Maintenance Procedure If it does not, adjust the brake light switch. • While holding the switch body , turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION T o avoid damaging the electrical connections in- side the swi[...]

2-36 PERIODIC MAINTENANCE Maintenance Pro cedure Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary . Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock abso[...]

PERIODIC MAINTENANCE 2-37 Maintenance Procedure Steering System Steering Pl ay Inspecti on • Remove the lower fairings (se e Lower Fairing Removal in the Frame chapter). • Lift the front wheel of f the ground using the jack. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-1608 • With the front wheel pointing straight ahead, alternate[...]

2-38 PERIODIC MAINTENANCE Maintenance Pro cedure • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer . • T ighten the stem locknut clockwise until the claws are aligned with the grooves (ranging fr[...]

PERIODIC MAINTENANCE 2-39 Maintenance Procedure Electrical System Lights and Switches Ope ration Inspection First Step • T urn on the ignition switch. • The following lights should go on according to below table. City Lig ht [A] g oes on T aillight [B] goes on License Plate Light [C] goes on Meter Panel I llumination Light (L ED) [D] goes on Me[...]

2-40 PERIODIC MAINTENANCE Maintenance Pro cedure Third Step • T urn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. • The turn signal indicator light (LED) [C] in the meter unit should flash. If the each light does not flash, i[...]

PERIODIC MAINTENANCE 2-41 Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item. Headlight [...]

2-42 PERIODIC MAINTENANCE Maintenance Pro cedure NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) [...]

PERIODIC MAINTENANCE 2-43 Maintenance Procedure If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Elect rical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System[...]

2-44 PERIODIC MAINTENANCE Maintenance Pro cedure Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, o[...]

PERIODIC MAINTENANCE 2-45 Maintenance Procedure • With the cable disconnected at both ends, the inner cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. Bolts, Nuts and Fasteners T ightness Inspection • Chec[...]

2-46 PERIODIC MAINTENANCE Maintenance Pro cedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Nut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Brake Lever Pivot Nut Brake Ped[...]

PERIODIC MAINTENANCE 2-47 Maintenance Procedure Replacement Parts Air Cleaner Element Replaceme nt NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddy roads, the element should be replaced immediately . WA R N I N G If dirt or dust is allowed to pass throug[...]

2-48 PERIODIC MAINTENANCE Maintenance Pro cedure • Install a new element [A] so that the element ends [B] insert along the rib [C] in the housing. CAUTION Use only the recommended air cleaner element (Kawasaki part number 1 1013-0004). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. • T ight[...]

PERIODIC MAINTENANCE 2-49 Maintenance Procedure • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off. WA R N I N G Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak. If it comes off, reinstall the hose joint. • Run the fuel[...]

2-50 PERIODIC MAINTENANCE Maintenance Pro cedure • Remove: Bolts [A] Coolant Reserve T ank [B] • Remove the cap [C] and pour the coolant into a container . • Install the coolant reserve tank. T orque - Coolant Reserve T ank Mounting Bol ts: 7.0 N·m (0.71 kgf·m, 62 in·lb) • T ighten the drain bolts. Replace the drain bolt gasket with a ne[...]

PERIODIC MAINTENANCE 2-51 Maintenance Procedure • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○ T ap the radiator hoses to force any air bubbles caught inside. ○ Stop the engine and add coolant up to the radiator fille[...]

2-52 PERIODIC MAINTENANCE Maintenance Pro cedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Remo val in the Frame chapter) Throttle Body Assembly (see Throttle Body Assembly Removal in the Fuel Syste [...]

PERIODIC MAINTENANCE 2-53 Maintenance Procedure Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). Replace the drain bolt gasket with a new one. ?[...]

2-54 PERIODIC MAINTENANCE Maintenance Pro cedure • Replace the filter with a new one. • Apply engine oil to the gasket [A] before installation. • T ighten the filter with the oil filter wrench. T orq ue - Oil Filter: 31 N·m (3.2 kgf·m, 2 3 ft·lb) NOTE ○ Hand tightening of the oil filter can not be allowed since it does not reach to this [...]

PERIODIC MAINTENANCE 2-55 Maintenance Procedure • Level the brake fluid reservoir . • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper . • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container . • Fill the reservoir with fresh specified brake fluid. [...]

2-56 PERIODIC MAINTENANCE Maintenance Pro cedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special T ool - Inside Circl ip Pliers: 5700 1-143 •[...]

PERIODIC MAINTENANCE 2-57 Maintenance Procedure • Apply brake fluid to the new parts and to the inner wall of the cylinder . • T ake care not to scratch the piston or the inner wall of the cylinder . • T ighten the brake lever pivot bolt and the nut. Silicone Grease - Brake Lever Pivot Bolt T orq ue - Brake Lev er Pivot Bolt: 1.0 N·m (0.10 k[...]

2-58 PERIODIC MAINTENANCE Maintenance Pro cedure NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally , with the brake hose connected to the caliper . ○ Prepare a container for brake fluid, and perform the work above it. ○ Remove the pad spring and pads (see Front Brake Pad Removal in the Brakes chapter). [...]

PERIODIC MAINTENANCE 2-59 Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). • Remove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). • Using compressed air , remove the piston. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○ R[...]

2-60 PERIODIC MAINTENANCE Maintenance Pro cedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B]. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder ho les [D] (PBC is a special high temperat[...]

FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Contents Exploded V iew ................................................................................................................... ..... 3-4 DFI System ...................................................................................................................... ....... 3-10 Speci[...]

3-2 FUEL SYSTEM (DFI) Output V oltage Inspection ................................................................................................. 3-73 Gear Position Switch (Service Code 25) ................................................................................ 3-75 Gear Position Switch Removal/Installation ...............................[...]

FUEL SYSTEM (DFI) 3-3 W arning Indicator Light (LED) .......................................................... ...................................... 3-1 1 1 Light (LED) Inspection ...................................................................................................... 3-1 1 1 Fuel Line ...............................................[...]

3-4 FUEL SYSTEM (DFI) Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Cleaner Housing Holder Clamp Screws 2.0 0.20 18 in·lb 2 Air Cleaner Element Cover Screws 1.1 0.1 1 9.7 in·lb 3 Air Inlet Duct Mounting Bolts 7.0 0.71 62 in ·lb L 4 Air Cleaner Housing Mounting Bolts 7.0 0.71 62 in·lb 5. Air Cleaner Element 6. Air Inlet Duc[...]

3-6 FUEL SYSTEM (DFI) Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Speed Sensor Bolt 10 1.0 89 in·lb 2 Crankshaft Sensor Bolts 6.0 0.61 53 in·lb L 3 Gear Position Switch Screws 3.0 0.31 27 in·lb L 4 Camshaf t Positi on Sensor Bo lt 10 1.0 89 in·lb 5 V ehicle-down Sensor Bolts 6.0 0.61 53 in·lb 6 W ater T emperature Sensor 25[...]

3-8 FUEL SYSTEM (DFI) Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Exhaust Butterfly V alve Actuator Mounting Bolts 0.8 0.08 7i n · l b 2 Exhaust Butterfly V alve Actuator Pulley Bolt 5.0 0.50 44 in·lb 3 Fuel Pump Bolts 10 1.0 89 in·lb L, S 4 Canister Bracket Mounting Bolt (M5) 4.3 0.44 38 in·lb 5 Canister Bracket Mounting Sc[...]

3-10 FUEL SYSTEM (DFI) DFI System DFI System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-1 1 DFI System 1. ECU 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle S ensor 6. Subthrottle V alve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. W ater T emperature Sensor 10. Inlet Air T emperature Sensor 1 1. Gear Position Switch 12. V ehicle-down Sensor 13. Fu[...]

3-12 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Ty p e Four barrel type Bore 43 mm (1.7 in.) Throttle Body V acuum 31.5 ±1.3 kPa (236 ±10 mmHg) Bypass Screws ––– ECU: Make Mitsubishi Electric Ty p e Digital memory type, with built in IC igniter , sealed with [...]

FUEL SYSTEM (DFI) 3-13 Specifications Item Standard V ehicle-down sensor: Detection Method Magnetic flux detection method Detection Angle More than 60 ∼ 70° for each bank Output V oltage with sensor arrow mark pointed up: 3.55 ∼ 4.45 V with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Subthrottle Sensor: Non-adjustable and non-removal In[...]

3-14 FUEL SYSTEM (DFI) Special T ools and Sealant Oil Pressure Gauge, 5 kgf/c m²: 57001-125 Fork Oil Level Gauge: 57001-1290 V acuum Gauge: 57001-1369 Hand T ester: 57001-1394 Throttle Sensor Set ting Adapter #1: 57001-1400 Peak V oltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 Throttle Sens or Setting Adapter : 57001-1538 Sensor Harness[...]

FUEL SYSTEM (DFI) 3-15 Special T ools and Sealant Fuel Pressure Gauge Adapte r: 57001-1593 Fuel Hose: 57001-1607 Speed Sensor Measuring Adapter: 57001-1667 Kawasaki Bond (Sil icone Sealant): 56019-120 Kawasaki Bo nd (Liquid Gasket - Bl ack): 92104-0002 Kawasaki Bond (Sil icone Sealant): 92104-0004 www.zxforums.com www.zxforums.com www.zxforums.com [...]

3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle V alve Actuator [C] Inlet Air Pressure Sensor [D] Stick Coils #1, #2, #3, #4 [E] W ater T emperature Sensor [A] Fuel Injectors #1, #2, #3, #4 [B] Battery [A] Relay Box (Fuel Pump Relay) [B] Immobilizer/Kawasaki Diagnostic System Connector [C] ECU [[...]

FUEL SYSTEM (DFI) 3-17 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Gear Position Switc h [B] Ignition Key [A] (T ransponder , Immobilizer Models) Ignition Switch [B] Immobilizer Antenna [C] (Immobilizer Models) Immobilizer Amplifier [D] (Immobilizer Models) Oxygen Sensor #1 [A] (Europe Models) Oxygen Senso[...]

3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Stick Coil #1,#2,#3,#4 5. Camshaft Position Sensor 6. Injector #1 7. Injector #2 8. Injector #3 9. Injector #4 10. Crankshaft Sensor 1 1. Subthrottle V alve Actuator 12. Subthrottle S ensor 13. Main Throttle Sensor 14. Inlet Air Pressure Sensor[...]

3-20 FUEL SYSTEM (DFI) DFI System T erminal Numbers of ECU Connectors T erminal Names 1. Unused 2. Subthrottle V alve Actuator 3. Subthrottle V alve Actuator 4. Gear Position Switch 5. Crankshaft S ensor (–) 6. Speed Sensor 7. Power Supply to Sensors 8. Inlet Air T emperature Sensor 9. V ehicle-down Sensor 10. Exhaust Butterfly V alve Sensor 1 1.[...]

FUEL SYSTEM (DFI) 3-21 DFI System 35. External Communication Line (Immobilizer/*KDS) 36. Immobilizer Amplifier 37. W arning Iadicator Light (LED) ( FI/Immobilizer) 38. Air Switching V alve 39. Engine Ground 40. Starter Lockout Switch 41. Exhaust Butterfly V alve Actuator (–) 42. Starter Button 43. Unused 44. Injector #3 45. Stick Coil #3 46. Inje[...]

3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○ Do no[...]

FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ Before removing the fuel system parts, blow the outer sur- faces of these parts clean with compressed air . ○ When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. ○ When install[...]

3-24 FUEL SYSTEM (DFI) T roubleshooti ng the DFI System The warning indicator light (LED) [A] is used for the FI indicator , immobilizer indicator (immobilizer models) and oil pressure warning indicator . Outline When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider . In add[...]

FUEL SYSTEM (DFI) 3-25 T roubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD (Liquid Crystal Display) by the number of two digits. When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the [...]

3-26 FUEL SYSTEM (DFI) T roubleshooti ng the DFI System Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them. • When checking the DFI parts, use a digital meter which can be read two decimal place vol[...]

FUEL SYSTEM (DFI) 3-27 T roubleshooting the DFI System • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • T rouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the probl[...]

3-28 FUEL SYSTEM (DFI) T roubleshooti ng the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity . If the harness is open, repair or replace the harne ss. ○ When check[...]

FUEL SYSTEM (DFI) 3-29 T roubleshooting the DFI System ○ Electrical Connectors: Female Connectors [A] Male Connectors [B] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

3-30 FUEL SYSTEM (DFI) T roubleshooti ng the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ T ry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this inf[...]

FUEL SYSTEM (DFI) 3-31 T roubleshooting the DFI System Sample Diagnosis Sheet Rider name: Regi stration No. (license plate No.): Y ear of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy , □ rain, □ snow , □ always, □ other: T emperature □ h[...]

3-32 FUEL SYSTEM (DFI) T roubleshooti ng the DFI System □ very low idle speed, □ very high idle speed, □ rough idle speed. Poor running at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty , broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitation [...]

FUEL SYSTEM (DFI) 3-33 DFI System T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possi ble cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○ The ECU may be involved in the DFI electrical and ignition system troubles. If these p[...]

3-34 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral whether sidestand up or not Pull the lever in and shift the gear in neutral. Though clutch lever pulled in, sidestand up and gear not in neutral Sidestand down and clutch lever pulled in whether g[...]

FUEL SYSTEM (DFI) 3-35 DFI System T roubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder head warped Inspect and replace (see chapter 5). No valve clearance Adjust (see chapter 2). V alve guide worn Inspect and replace (see chapter 5). V alve spring broken or weak Inspect and replace (see chapter 5). V alve not seating proper[...]

3-36 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed: W ater temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). [...]

FUEL SYSTEM (DFI) 3-37 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Loose injector connectors Remedy (see chapter 3). Crankshaft sensor trouble Inspect and repair or replace (see chapter 16). Stick coil trouble Inspect and repair or replace (see chapter 16[...]

3-38 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Air switching valve broken Inspect and replace (see chapter 5). Air suction valve trouble Inspect and replace (see chapter 5). After fire: Crankshaft sensor trouble Inspect (see chapter 16[...]

FUEL SYSTEM (DFI) 3-39 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Stick coil trouble Inspect (see chapter 16). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element o r inspect sealing (see chapter 3). Air cleaner duct loose Rein stall (see chapter 3). Air cleaner O-ring damage[...]

3-40 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Speed sensor trouble Inspect (see chapter 3). Throttle valves won’t fully open Inspect throttle cable and lever linkage (see chapter 3). Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see[...]

FUEL SYSTEM (DFI) 3-41 Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator , immobilizer indicator (immobilizer models) and oil pressure warning indicator . Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the ride[...]

3-42 FUEL SYSTEM (DFI) Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the warning indicator ligh[...]

FUEL SYSTEM (DFI) 3-43 Self-Diagnosis • T urn the ignition switch ON. • Push the Mode button [A] to display the odometer . • Push the RESET button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits. ○ After switching to the engine speed setting mode of the shift up indicator light ([...]

3-44 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order . ○ Then after completing all codes, the[...]

3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Code T able Service Code Prob lems 11 Throttle sensor malfunction, wiring open or short 12 Inlet Air Pressure sensor malfunction, wiring open or short 13 Inlet air temperature sensor malfunction, wiring open or short 14 W ater temperature sensor malfunction, wiring open or short 15 Atmospheric pressure [...]

FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Main Throttle Sensor Output V oltage 0.2 ∼ 4.8 V If the main throttle [...]

3-48 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 34 Exhaust Butterfly Va l v e Actuator Exhaust Butterfly V alve Output V oltage 0.2 ∼ 4.8 V If the exhaust butterfly valve system fails (the signal is out of the usable range, wiring short or open), the actuator locks exhaust bu tterfly[...]

FUEL SYSTEM (DFI) 3-49 Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 75 ECU Main Relay When the relay OFF condition, the main relay is open. – 83 Oxygen Sensor #2 (Europe Models) The oxygen sensor #2 is active and sensor must send signals (output voltage) continuously to the ECU. If the oxygen sensor #2 [...]

3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) The main throttle sensor is a rotating variable resistor th at change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity , and ignition timing according to engine rpm, and throttle opening. Input T erminal [A] Outp[...]

FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 1 1) • Remove the throttle body assy temporarily (see Throttle Body Assy Removal). • Disconnect the main throttle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and main throttle sensor connector . • Connect a digital meter to the harness adapte[...]

3-52 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) Output V oltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special T ool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output V oltage Connections to ECU Connec tor Meter ([...]

FUEL SYSTEM (DFI) 3-53 Main Throttle Sensor (Service Code 1 1) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input V oltage Inspection shows 5V exactly . ○ When the input voltage reading shows other than 5V , derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V . 0.65 × 4.75 ?[...]

3-54 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector . Special T ool - Throttle Se nsor Set ting Adapt er: 57001 -1538 • Connect a digital meter to the harness adapter leads. Throttle[...]

FUEL SYSTEM (DFI) 3-55 Main Throttle Sensor (Service Code 1 1) Resistance Inspection • T urn the ignition switch OFF . • Disconnect the main throttle sensor connector . • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Re sistance Connections: BL lead[...]

3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sens or (Service Code 12) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the part can damage it. Removal • T urn the ignition switch OFF . • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Se nsor Connector [A] Inlet Air Pressure Sensor [B][...]

FUEL SYSTEM (DFI) 3-57 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector . • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the harne[...]

3-58 FUEL SYSTEM (DFI) Inlet Air Pressure Sens or (Service Code 12) If the output voltage is far out of the usable ran ge, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 V). • Connect a digital meter to the harness adapter leads. Inlet Air Pressure Sensor [B] Special T ool - Sens[...]

FUEL SYSTEM (DFI) 3-59 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor . • Connect an auxiliary hose [B] to the i nlet air pressure sen- sor . • T emporarily install the inlet air pressure sensor . ○ Connect a digital meter [C], vacuum gauge [D], and the f[...]

3-60 FUEL SYSTEM (DFI) Inlet Air Pressure Sens or (Service Code 12) ID: Idling Pv: Throttle V acuum Pressure (abs.) Ps: Standard Atmospheric Pressure (abs.) ST : Standard of Sensor Output V oltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output V oltage (v) Vv: Inlet Air Pressure Sensor Output V oltage (V) (Digital Meter Reading) www.z[...]

FUEL SYSTEM (DFI) 3-61 Inlet Air T emperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the connector [A] from the inlet air tempera- ture sensor . • Pull out the inlet air t[...]

3-62 FUEL SYSTEM (DFI) Inlet Air T emperature Sensor (Service Code 13) If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are goo d, replace the ECU (see ECU section). If the output voltage is far out of the specified (e.g. when the wiring i[...]

FUEL SYSTEM (DFI) 3-63 Inlet Air T emperature Sensor (Service Code 13) Inlet Air T emperature Sensor Circuit 1. ECU 2. Inlet Air T emperature Sensor 3. W ater-proof Joint 2 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

3-64 FUEL SYSTEM (DFI) W ater T emperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Throttle Bo[...]

FUEL SYSTEM (DFI) 3-65 W ater T emperature Sensor (Service Code 14) • T urn the ignition switch OFF . If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). If the output voltage is far out of the s[...]

3-66 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor , especially on a hard surface. Such a shock to the sensor can damage it. Removal • T urn the ignition switch OFF . • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A] Damper [B] Atmospheric[...]

FUEL SYSTEM (DFI) 3-67 Atmospheric Pressure Sensor (Service Cod e 15) If the reading is within the standard range, remove the seat cover , and check the input voltage again at the sen- sor connector . • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure s[...]

3-68 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, remove the seat cover , and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V). • Connect a digital meter [A] to the harness adapter leads. Atmospheric Pressure S[...]

FUEL SYSTEM (DFI) 3-69 Atmospheric Pressure Sensor (Service Cod e 15) If you know the local atmospheric pressure using a barometer , substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section). And get the usable range of the atmospheric pressure sensor output vol[...]

3-70 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the[...]

FUEL SYSTEM (DFI) 3-71 Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder . • Refer to the Camshaft Position Sensor Removal/Installa- tion in the Electric System chapter (see Camshaft Position Sensor Removal/Inst[...]

3-72 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Input V oltage Inspection NOTE ○ Be sure the battery is fully charged. ○ The input voltage is the [...]

FUEL SYSTEM (DFI) 3-73 Speed Sensor (Service Code 24) • Connect the harness adapter [A] between the harness connector and speed sensor connector . Special T ool - Speed Sens or Measuring Ada pter: 57001 -1667 • Connect a digital meter to the harness adapter leads. Speed Sensor Input V oltage Connections to Adapter Meter (+) → BL lead [ A] Met[...]

3-74 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) • Connect a digital meter to the harness adapter leads. Speed Sensor Output V oltage Connections to Adapte r Meter (+) → BL/Y lead [A] Meter (–) → BK lead [B] • Measure the output voltage with the engine stopped, and with the connectors joined. • T urn the ignition switch ON. Output [...]

FUEL SYSTEM (DFI) 3-75 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection • Refer to the Gear Position Switch In[...]

3-76 FUEL SYSTEM (DFI) Gear Position Switch (Service Co de 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 1 4. Joint Connector 2 5. Frame Ground www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FUEL SYSTEM (DFI) 3-77 V e hicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal. The ECU senses this change, and stops the fuel pump, the fuel injectors,[...]

3-78 FUEL SYSTEM (DFI) V ehicle-down Sensor (Service Code 31) • Connect a digital meter [A] to t he connector of the vehicle -down sensor [B], with the needle a dapter set [C]. Special T ool - Needle Adapter Set: 57001-1457 V ehicle-down sensor Power Source V oltage Connections to Sensor Meter (+) → BL lead [ D] Meter (–) → BR/B K lead [E] [...]

FUEL SYSTEM (DFI) 3-79 V e hicle-down Sensor (Service Code 31) • T urn the ignition switch OFF . • Remove the needle adapter set, and apply silicone sealant to the seals of sensor the connector f or water- proofing. Sealant - Kawasaki Bond (Silico ne Sealant): 56019-120 If the output voltage is out of the specified, replace the vehicle-down sen[...]

3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity , and ignition timing according to engine rpm, and throttle opening. Input T erminal [A] Output T e[...]

FUEL SYSTEM (DFI) 3-81 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con - nect the harness adapter [B] between the ha rness con- nector and subthrottle sensor connector . Special T ool - Thrott le Sensor Setting Ad apter: 57001 -1538 • Connect a digital meter to the harness adapter leads. Subthrottl[...]

3-82 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal). If the output voltage is far out of the standard range (e.g. when the wiring is [...]

FUEL SYSTEM (DFI) 3-83 Subthrottle Sensor (Service Code 32) • After subthrottle sensor voltage inspection, remove the harness adapter . If the reading is out of the standard rang e, inspect the subthrottle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section). Resistance Inspect[...]

3-84 FUEL SYSTEM (DFI) Oxygen Sensor #1-not activated ( S e r v i c eC o d e3 3 )-E u r o p eM o d e l s Oxygen Sensor #1 Removal/Installatio n • Refer to the Oxygen Sensor Removal (Europe Models) in the Electrical System chapter (see Oxygen Sensor Re- moval (Europe Models) in the Electrical System chapter). Oxygen Sensor #1 Inspection NOTE ○ T[...]

FUEL SYSTEM (DFI) 3-85 Oxygen Sensor #1-not activated ( S e r v i c eC o d e3 3 )-E u r o p eM o d e l s • Connect the following parts temporary . Fuel Pump Lead Connector [A] Extension T ube [B] Special T ool - Extension T ube: 57001-1578 • T urn the ignition switch ON. • Start the engine, and let it idle. • Measure the output voltage of t[...]

3-86 FUEL SYSTEM (DFI) Oxygen Sensor #1-not activated ( S e r v i c eC o d e3 3 )-E u r o p eM o d e l s Oxygen Sensor Circuit 1. ECU 2. W ater-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www.[...]

FUEL SYSTEM (DFI) 3-87 Exhaust Butterfly V alve Actuator Sensor (Service Code 34) Exhaust Butterfly V alve Actuator Sensor Inspection • T urn the ignition switch OFF . • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • Disconnect the exhaust butterfly valve actuator sensor connector . • Connect a digital meter [A] to t[...]

3-88 FUEL SYSTEM (DFI) Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). • Disconnect the antenna lead connector [A]. • Measure the resistance of the antenna coil in the ignition switch as follows. Antenna Resista nce Connection[...]

FUEL SYSTEM (DFI) 3-89 Blank Key Detection (Service C ode 36) • This code appears in the following conditions. ○ The transponder [A] in the master and/or user key is mal- function. ○ When the spare key of unregistration is used. ○ When the master key is registered in the registered ECU. • Therefore, the s ervice code 36 will disappear whe[...]

3-90 FUEL SYSTEM (DFI) F u e lP u m pR e l a y( S e r v i c eC o d e4 6 ) Fuel Pump Relay Removal CAUTION Never drop the relay , especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay bo x. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Remove the relay b[...]

FUEL SYSTEM (DFI) 3-91 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. • Refer [...]

3-92 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 2. Stick Coil #4 3. Stick Coil #3 4. Stick Coil #2 5. Stick Coil #1 6. Engine Stop Switch 7. Ignition Switch 8. Ignition Fuse 10 A 9. Starter Relay 10. Main Fuse 30 A 10. Fuse Box 1 1. Battery 12 V 10 Ah 12. Joint Connector 3 www.zxforums.com [...]

FUEL SYSTEM (DFI) 3-93 Subthrottle V alve Actuator (Service Code 62) Subthrottle V alve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory . Never drop the actuator , especially on a hard sur- face. Such a shock to the actuator can damage it. Subthrottle V alve [...]

3-94 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (Service Code 62) Input V oltage Inspection NOTE ○ Be sure the battery is fully charged. • T urn the ignition switch OFF . • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Special T o ols - Peak V oltage Adapter: 570 01-141[...]

FUEL SYSTEM (DFI) 3-95 Subthrottle V alve Actuator (Service Code 62) Subthrottle V alve Actuator Circuit 1. ECU 2. Subthrottle V alve Actuator 3. Subthrottle S ensor 4. Main Throttle Sensor 5. W ater-proof Joint 2 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

3-96 FUEL SYSTEM (DFI) Exhaust Butterfly V alve Actuator (Service Code 63) Exhaust Butterfly V alve Actuator Remo val • Remove the seat cover (see Seat Cover Removal in the Frame chapter) • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjuster to give t he cable plenty of play [C]. • Remove: Clamp [A] Exhaust Butterfly[...]

FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly V alve Actuator (Service Code 63) • Confirm the pulley angle [A] (41.7° ±7°) as shown. It is original position of the pulley [B]. If the angle is not within the specified angle, adjust the actuator as follows. ○ Connect the actuator connectors. ○ T urn the ignition switch ON. ○ Confirm the pulley [...]

3-98 FUEL SYSTEM (DFI) Exhaust Butterfly V alve Actuator (Service Code 63) Output V oltage Inspection • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • T urn the ignition switch ON and wait until the pulley stops. • T urn the ignition switch OFF and wait until the pulley stops. It is original position of the pulley . ?[...]

FUEL SYSTEM (DFI) 3-99 Oxygen Sensor Heaters (#1 and/or #2 : Service Code 67) - Europe Models Oxygen Sensor Heaters Removal/Installation The oxygen sensor heater is built in the oxygen sensor . So, the heater itself can not be removed. Remove the oxy- gen sensors (see Oxygen Sensor Removal in the Electrical System chapter). Oxygen Sensor Heaters In[...]

3-100 FUEL SYSTEM (DFI ) Oxygen Sensor Heaters ( #1 and/or #2: Service Code 67) - Europe Models If he tester reading is specified, check the power source voltage Inspection. NOTE ○ Be sure the battery is fully charged. • Connect a digital meter [A] to each oxygen sensor con- nector [B], using the needle adapter [C]. Special T ool - Needle Adapt[...]

FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heaters (#1 and/or #2 : Service Code 67) - Europe Models Oxygen Sensor Circuit 1. ECU 2. W ater-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.c[...]

3-102 FUEL SYSTEM (DFI ) ECU Main Relay (Service Code 75) ECU Main Relay Inspection ○ The ECU main relay function is included in the ECU [A]. So, the ECU main relay function cannot inspect. • When the service code 75 is displayed on the LCD, re- place the ECU (see ECU sectionl). www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.co[...]

FUEL SYSTEM (DFI) 3-103 Oxygen Sensor #2-not activated ( S e r v i c eC o d e8 3 )-E u r o p eM o d e l s Oxygen Sensor #2 Removal/Installation • Refer to the Oxygen Sensor Removal (Europe Models) in the Electrical System chapter (see Oxygen Sensor Re- moval (Europe Models) in the Electrical System chapter). Oxygen Sensor #2 Inspe ction NOTE ○ [...]

3-104 FUEL SYSTEM (DFI ) Oxygen Sensor #2-not activated ( S e r v i c eC o d e8 3 )-E u r o p eM o d e l s • Connect the following parts temporary . Fuel Pump Lead Connector [A] Extension T ube [B] Special T ool - Extension T ube: 57001-1578 • T urn the ignition switch ON. • Start the engine, and let it idle. • Measure the output voltage of[...]

FUEL SYSTEM (DFI) 3-105 Oxygen Sensor #2-not activated ( S e r v i c eC o d e8 3 )-E u r o p eM o d e l s Oxygen Sensor Circuit 1. ECU 2. W ater-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www[...]

3-106 FUEL SYSTEM (DFI ) ECU CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear[...]

FUEL SYSTEM (DFI) 3-107 ECU ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Connectors • Insert the slits of the rubber protector to the projections [A] of the rear fender front. ECU Power Supply Inspection • Remove the ECU (see ECU Removal). • Visually inspe ct the terminals [A] of the ECU connectors. If the connector is [...]

3-108 FUEL SYSTEM (DFI ) ECU • Check the ECU power source voltage with a digital meter [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in the fig ure. Battery [C] ECU Power Source Inspection T ester Connections: between 33 (BR) T erminal and Battery (–) T erminal between 1 5 (W/BK) T erminal and Battery [...]

FUEL SYSTEM (DFI) 3-109 ECU ECU Power Source Circuit 1. ECU 2. W ater-proof Joint 1 3. Ignition Switch 4. ECU Fuse 15 A 5. Starter Relay 6. Main Fuse 30 A 7. Battery 12 V 10 Ah 8. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

3-1 10 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 15 A ECU Fuse Removal in the Electrical Sys- tem chapter (see 15 A ECU Fuse Removal in the Electri- cal System chapter). ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper ampe[...]

FUEL SYSTEM (DFI) 3-1 1 1 W arning Indicator Light ( LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator , immobilizer indicator (immobilizer models) and oil pressure warning indicator . ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the special signal sent from the EC[...]

3-1 12 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Steering Damper (see Steering Damper Removal in the Steering chapter) Fuel T ank Bolts [A] • Be sure to place a piece of cloth around the fuel supply pipe of the throttle[...]

FUEL SYSTEM (DFI) 3-1 13 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the eng ine idling. Fuel Pressure (idling ) Standard: 304 kPa (3.1 kgf/cm², 44 psi ) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than t[...]

3-1 14 FUEL SYSTEM ( DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump. • Remove the fuel hose from the fuel pump (see Fuel T ank Removal). WA R N I N G Be prepared for fuel spillage; any spilled fuel must be completely wiped up immed[...]

FUEL SYSTEM (DFI) 3-1 15 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WA R N I N G Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes [...]

3-1 16 FUEL SYSTEM ( DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • T ighten the fuel pump bolts to a snug fit following the tight- ening sequence shown. • Following the tightening se[...]

FUEL SYSTEM (DFI) 3-1 17 Fuel Pump Fuel Pump Circuit 1. ECU 2. W ater-proof Joint 1 3. Engine Stop Switch 4. Ignition Switch 5. Fuel Pump Relay 6. ECU Fuse 15 A 7. Ignition Fuse 15 A 8. Starter Replay 9. Main Fuse 30 A 10. Battery 12 V 10 Ah 1 1. Joint Connector 3 12. Fuel Pump 13. Joint Connector 2 14. Joint Connector 1 www.zxforums.com www.zxforu[...]

3-1 18 FUEL SYSTEM ( DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector , especially on a hard sur- face. Such a shock to the injector can dama ge it. Power Source V oltage Inspection NOTE ○ Be sure the battery is fully ch[...]

FUEL SYSTEM (DFI) 3-1 19 Fuel Injectors If the reading is normal, remove the fuel tank (see Fuel T ank Removal), and check the power source voltage at the injector connector [B], with a digital meter [A]. • Measure the power source voltage with the engine stopped, and the connector joined, with a digital meter and needle adapter set [C]. Special [...]

3-120 FUEL SYSTEM (DFI ) Fuel Injectors If the output voltage is out of the standard, remove the air cleaner housing, and check the output voltage at the injector connector [B] using a digital meter [A] and needle adapter set [C] (when the l ead is open, the output voltage is 0 V). Special T ool - Needle Adapter Set: 57001-1457 Injector Out put V o[...]

FUEL SYSTEM (DFI) 3-121 Fuel Injectors Injector Signal T est • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ~ 3.4 W T erminal Width [B]: 1.8 mm (0.07 in.) T erminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above. A larger terminal could damage the injector main [...]

3-122 FUEL SYSTEM (DFI ) Fuel Injectors Injector Unit T est • Use two leads [A] and the same test light set [B] as in “Injector Signal T est”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive c[...]

FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Circuit 1. ECU 2. Frame Ground 3. Joint Connector 1 4. Joint Connector 2 5. Fuel Pump 6. W ater-proof Joint 1 7. Fuel Injector #4 8. Fuel Injector #3 9. Fuel Injector #2 10. Fuel Injector #1 1 1. Engine Stop Switch 12. Ignition Switch 13. Fuel Pump Relay 14. ECU Fuse 15 A 15. Ignition Fuse 15 A 1[...]

3-124 FUEL SYSTEM (DFI ) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter [...]

FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Clean ing • Check the throttle bore for cleanliness as follows. ○ Remove the throttle body assy (see Throttle Body Assy Remov[...]

3-126 FUEL SYSTEM (DFI ) Throttle Body Assy • Remove: Air Switching V alve Hose [A] V acuum Hoses [B] (California Model) • Remove the middle fairings (see Middle Fairing Removal in the Frame chapter). • Loosen the throttle body assy holder clamp bolts [A] on both sides. • Remove the throttle case [A] to make a throttle cable slack. • Remo[...]

FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • After removing the throttle body assy , s tuff piece s of lint -free, clean cloths into the throttle body assy holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur . If the throttle body assy is to be disassembly , loosen the air cleaner housing hol[...]

3-128 FUEL SYSTEM (DFI ) Throttle Body Assy Throttle Bod y Assy Disassembly 1. Subthrottle V alve Actuator 2. Subthrottle Sensor 3. Main T hrottle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Injector Connector Harness CAUTION Do not remove, disassemble or adjust the main throttle sensor , subthrottle sensor , subthrottle valve actu[...]

FUEL SYSTEM (DFI) 3-129 Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector . • Disconnect: Subthrottle V alve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] • Separete the hoses [A] from the throttle body fittings and inlet air pressure sensor . • Remove the screws [B] to p[...]

3-130 FUEL SYSTEM (DFI ) Throttle Body Assy • Apply daphne oil or engine oil to the new dust seals [A], and insert the injectors into the throttle body , which in- stalled to the delivery pipe. NOTE ○ Replace the dust seals of the throttle body to new ones. • Install the delivery pipe to the throttle body . T orq ue - De livery Pip e Moun tin[...]

FUEL SYSTEM (DFI) 3-131 Air Line Element Rem oval • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Install ation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re[...]

3-132 FUEL SYSTEM (DFI ) Air Line • T urn the air cleaner housing [A] counterclockwise [B] and remove it. • Pull off the air ducts [A] from the frame. Air Cleaner Housing Installation • Confirm the air ducts [A] fit in the frame [B]. • Insert the air cleaner housing [C] inside th e frame as shown. • T urn the housing clockwise and positio[...]

FUEL SYSTEM (DFI) 3-133 Air Line • Install the housing on the holder then insert the ducts. ○ Apply a soap and water solution [A] to the ducts for easy installation. • Insert the projections [B] of the housing in the holes [C] of the ducts. • T ighten: T orque - Air Cleaner Housing Mounting Bolts: 7.0 N·m (0.70 kgf·m, 62 in·lb) • Insta[...]

3-134 FUEL SYSTEM (DFI ) Air Line Air Inlet Duct Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Mounting Bolts [A] (Both Sides) Air Inlet Duct [B] Air Inlet Duct Insta llation • Install the gasket [A]. • Apply non-permanent locking agent to the threads of the air inlet duct mounting bolts [B] and tighten it. [...]

FUEL SYSTEM (DFI) 3-135 Fuel T ank Fuel T ank Remova l WA R N I N G Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T urn the ignition switch OFF . Be prepared for fuel spi[...]

3-136 FUEL SYSTEM (DFI ) Fuel T ank • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly . ○ Put the hose through the fill opening [C] into the tank and draw the fuel out. Front [D] W ARNING The fuel could not be removed completel[...]

FUEL SYSTEM (DFI) 3-137 Fuel T ank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister , the canister ’ s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. ○ Be sure to plug the evap[...]

3-138 FUEL SYSTEM (DFI ) Fuel T ank • Insert the fuel hose joint [A] straigh t onto the delivery pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off. W ARNING Make sure the hose j[...]

FUEL SYSTEM (DFI) 3-139 Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe-[...]

3-140 FUEL SYSTEM (DFI ) Evaporative Emission Control Syst em Separator Operation T est W ARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot li[...]

COOLING SYSTEM 4-1 4 Cooling System T able of Contents Exploded V iew ................................................................................................................... ..... 4-2 Coolant Flow Chart ............................................................................................................... .. 4-4 Specifications .[...]

4-2 COOLING SYSTEM Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Wa t e r H o s e C l a m p S c r e w s 2.0 0.20 18 in·lb 2 Coolant Drain Bolt (Cylinder) 10 1.0 89 in·lb 3 W ater Pump Cover Bolts 10 1.0 89 in·lb 4 W ater T emperature Sensor 25 2.5 18 SS 5 Coolant Reserve T ank Mounting Bolts 7.0 0.71 62 in·lb 6 Coolant By-pass[...]

4-4 COOLING SYSTEM Coolant Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Radiator Overflow Hose 5. Reserve T ank 6. Reserve T ank Overflow Hose 7. Oil Cooler 8. Outlet Hose 9. Cylinder Head Jacket 10. Cylinder Jacket 1 1. Thermostat Housing 12. Inlet Hose 13. W ater Pump 14. Hot Coolant 15. Cold Coolant Permanent type antifreeze is used[...]

4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping T ype (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) T otal Amount 2.9 L (3.[...]

COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush t h ec o o l i n gs y s t e m . If the coolant gives off an ab[...]

4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator . When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency[...]

COOLING SYSTEM 4-9 Coolant Coolant Reserve T ank Installation • Install the following to the coolant reserve tank [A]. Rubber Dampers [B] Collars [C] Gasket [D] Cap [E] • T ighten: T orque - Coolant Reserve T ank Mounting Bolts [F]: 7.0 N· m (0.71 kgf·m, 62 in·lb) • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in th[...]

4-10 COOLING SYSTEM Wa t e r P u m p Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove the water hoses [A]. • Remove: W ater Pump Cover Bolts [A] W ater Pump Cover [B] • Remove the water hose [A]. • Remove the wat[...]

COOLING SYSTEM 4-1 1 W ater Pump • T urn the impeller shaft so that the slot [A] in its shaft fits onto the projection [B] of the oil pump gear shaft. CAUTION Do not pinch the gear position switch lead. • Install the water hose [A] and hose clamp [B] as shown. White Mark [C] • T ighten: T orque - W ater Hose Clamp Screw: 2.0 N·m (0.20 kgf·m[...]

4-12 COOLING SYSTEM Radiator Radiator and Radiato r Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Separator [A] (California Model) Clamp [B] (California Model) Radiator Cap [C] Radiator Hoses [D] Radiator Upper Bolt [E] H[...]

COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installatio n • Install the radiator fan [A]. • Install the rubber dampers [B] and collars [C] as shown. • Remove the radiator cap [A] temporarily . • Cover the heat insulation rubber plate [B] on the radiator [C] as shown. • Reinstall the radiator cap. • T rough the radiator fan le[...]

4-14 COOLING SYSTEM Radiator If the radiator bracket [A] was removed, install it. T orque - Radiator Bracket Mounting Bolt [B]: 7. 0 N·m (0.71 kgf·m, 62 in·lb) • T ighten: T orq ue - Radia tor Lowe r Bolt [C]: 7.0 N·m ( 0.71 kgf·m, 6 2 in·lb) Radiator Upper Bolt [ D]: 7.0 N·m (0.71 kgf·m, 62 in·lb) Horn [E] • Face the white mark [F] of[...]

COOLING SYSTEM 4-15 Radiator • Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter). • Install the middle fairings (see Middle Fairings Installation in the Frame chapter). • After installation, note the following. ○ Run the main harness [A] over the heat insulation rubber plate [B]. ○ Put the edges of th[...]

4-16 COOLING SYSTEM Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow , remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable ob[...]

COOLING SYSTEM 4-17 Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Pressure T esting). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom s ealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly . www.zxforums.com www.[...]

4-18 COOLING SYSTEM Thermostat Thermostat Re moval • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal [...]

COOLING SYSTEM 4-19 Thermostat • Replace the O-rings [A] with a new one. • Apply grease to the new O-rings. • Install a new O-rings into the thermostat housing [B] and Cover [C]. If the coolant by-pass fitting bolt [D] was removed, install it. ○ Apply a non-permanent locking agent to the thre ads of the coolant by-pass fitting bolt, and tig[...]

4-20 COOLING SYSTEM Thermostat • T o check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water . ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive port[...]

COOLING SYSTEM 4-21 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter . • Install the clamp [A] as near as possible to the hose e[...]

4-22 COOLING SYSTEM W ater T emperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water T emp erature Sens or Removal • Refer to the W ater T emperature Sensor Removal in the Fuel System (DFI) chapter (W ater T emperature Sensor Removal in the Fuel[...]

ENGINE TOP END 5-1 5 Engine T op End T able of Contents Exploded V iew ................................................................................................................... ..... 5-3 Exhaust System.................................................................................................................. .... 5-8 Specifications [...]

5-2 ENGINE T OP END Exhaust Butterfly V alve Cable Removal ........................................................................... 5-45 Exhaust Butterfly V alve Cable Installation ........................................................................ 5-46 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www[...]

ENGINE TOP END 5-3 Exploded View Dummy Page www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

5-4 ENGINE T OP END Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Suction V alve Cover Bolts 10 1.0 89 in·lb L 2 Cylinder Head Cover Bolts 10 1.0 89 in·lb 3 Camshaft Cap Bolts 12 1.2 106 in·lb S 4 Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb S 5 Cylinder Head Bolts (M10 New Bolts) 59 6.0 44 MO, S 5 Cylinder Head Bolts [...]

5-6 ENGINE T OP END Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE TOP END 5-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Exhaust Pipe Holder Nuts 17 1.7 13 2 Muffl er Body Assembly Nuts 22 2.2 16 3 Muffler Body Mounting Bolts 25 2.5 18 4 Middle Exhaust Pipe Clamp Bolt 17 1.7 13 5 Rear Exhaust Pipe Clamp Bolt 17 1.7 13 6 Muffler Body Cover Bolts 7.0 0.71 62 in·lb 7 Exhaust Butter[...]

5-8 ENGINE T OP END Exhaust System Exhaust System ZX1000 D6F 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb T ype Catalyst www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE TOP END 5-9 Exhaust System Manifold Mark Position [A] Silencer Mark Position [A] Manifold [A] with Holes [B] for Oxygen Sensors. Oxygen Sensor #1 [C] Oxygen Sensor #2 [D] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

5-10 ENGINE TOP END Exhaust System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE TOP END 5-1 1 Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 34.443 ∼ 34.557 mm (1.3560 ∼ 1.3605 in.) 34.34 mm (1.352 in.) Inlet 35.043 ∼ 35.157 mm (1.3796 ∼ 1.3841 in.) 34.94 mm (1.376 in.) Camshaft Journal, Camshaft Cap Clearance 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) 0.17 mm (0.0067 in.) Camshaft Jour[...]

5-12 ENGINE TOP END Special T ools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221 V alve Spring Compressor Assembly: 57001-241 Va l v e S e a t C u t t e r, 4 5 ° - 27.5: 57001-1 1 14 V alve Seat Cutter , 45° - 35: 57001-1 1 16 V alve Seat Cutter , 32° - 28: 57001-1 1 19 V alve Seat Cutter , 32° - 35: 57001-1 121 V alve Seat Cutte r Hold[...]

ENGINE TO P END 5-13 Special T ools and Sealant V alve Guide Reamer , 4.5: 57001-1333 Va l v e S e a t C u t t e r, 6 0 ° - 33: 57001-1334 Va l v e G u i d e D r i v e r : 57001-1564 V alve Spring Compressor Adapt er , 24: 57001-1586 Compression Gaug e Adapter , M10 × 1.0: 57001-1601 L-Shape Hose: 57001-1606 W asher: 57001-1612 Kawasaki Bond (Sil[...]

5-14 ENGINE TOP END Clean Air System Air Suction V alve Removal • Remove: Air Switching V alve (see Air Switching V alve Removal) Air Suction V alve Cover Bolts [A] Air Suction V alve Covers [B] • Remove the air suction valves [A]. Air Suction V alve Installation • Install the air suction valve so that opening [A] of the reed faces the rear a[...]

ENGINE TOP END 5-15 Clean Air System Air Switching V alv e Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the connector [A]. • Separate the hoses [B] from the air suction valve covers and air cleaner hous[...]

5-16 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Remova l • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Switching V alve (see Air Switching V alve Removal) Throttle Body Assy (see Throttle Body Assy Removal in the[...]

ENGINE TOP END 5-17 Cylinder Head Cover • Replace the washer [A] with new ones. • Install the new washer with the metal side faces upward. • Install the cylinder head cover . • T ighten the cover bolts [A]. T orque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters). www.zxfo[...]

5-18 ENGINE TOP END Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft c hain slack. Observe all the rules listed below: When removing the tensioner , do not take out the mounting bolts on[...]

ENGINE TOP END 5-19 Camshaft Chain T ensioner • Remove the mounting bolts [A] and take of f the camshaft chain tensioner body [B]. Camshaft Chain T ensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Release the stopper [B] and push the push rod [C] into the interior of tensioner body [D]. • [...]

5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark fo[...]

ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain T ensioner Removal). • Loosen the upper chain guid bolts and camshaft cap bolts as shown sequence [1 ∼ 20] in the figure, and remove them. • Remove: Upper Chain Guide [A] Camshaft Caps [B] Camshafts [C] • Stuff a clan cloth i nto the cha[...]

5-22 ENGINE TOP END Camshaft, Camshaft Chain • Install the cam sprockets as shown in fig ure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] • Apply a non-permanent locking agent to the threads and tighten the bolts. T orque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf· m, 11 f t · l b ) • Apply molybdenum disulfide[...]

ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○ The T iming marks must be aligned with the cylinder head upper surface [B]. EX mark [C] IN mark [D] #1[...]

5-24 ENGINE TOP END Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tempo- rally (see Camshaft Chain T ensioner Installation). • Install the camshaft caps and upp er camshaft chain guide [A] as shown. Identification Number 1 ∼ 4 (Camshaft Cap Side) [B] Identificat[...]

ENGINE TOP END 5-25 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove the camshaft cap (see Camshaft Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • T ighten the camshaft cap bolts and upper chain guide bolts to the specified torque [...]

5-26 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer . If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust 34.443 ∼ 34.55 7 mm (1.3560 ∼ 1.3605 in.) Inlet 35.043 ∼ 35. 157 mm (1.3796 ∼ 1.[...]

ENGINE TOP END 5-27 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • W arm up the engine thoroughly . • Stop the engine. • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Stick Coils [...]

5-28 ENGINE TOP END Cylinder Head Cylinder Head Remova l • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Remova[...]

ENGINE TOP END 5-29 Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install the dowel pins. • Replace the cylinder head gasket with a new one. • Apply molybdenum disulfide oil solution to both sides [...]

5-30 ENGINE TOP END Cylinder Head Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surf ace of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head W arp Standard: ––– Service Lim it: 0 .05 mm (0.002 in .) If t[...]

ENGINE TOP END 5-31 Va l v e s V alv e Clearance Inspection • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter (see V alve Clearance Inspection in the Periodic Maintenance chapter). V alv e Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the va[...]

5-32 ENGINE TOP END Va l v e s V alve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head. Soak the cylinder head and heat the oil. • Usin[...]

ENGINE TOP END 5-33 Va l v e s NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. V alve/V alve Guide Clearance (W obble Method) Standard: Exhaust 0.04 ∼ 0. 12 mm (0.0016 ∼ 0.0047 in.) Inlet 0.03 ∼ 0.10 mm (0.0012 ∼ 0. 0039 in.) Service Limit: Exhaust 0.34 mm (0.0 13 in.) Inlet 0.3[...]

5-34 ENGINE TOP END Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cut[...]

ENGINE TOP END 5-35 Va l v e s • Measure the outside diameter of the seating surface with a vernier caliper . If the outside diameter of the seating su rface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened Width [A] of engagement by machining with 45° cutter Ground V olume [B] by 32° cutter 32° [[...]

5-36 ENGINE TOP END Va l v e s If the seat width is too wide, make the 60° [A] grind de- scribed below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range. ○ T o make the 60° grind, fit 60° cutter into the holder [...]

ENGINE TOP END 5-37 Va l v e s www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

5-38 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] • Loosen the[...]

ENGINE TOP END 5-39 Muffler WA R N I N G T o avoid a serious burn,do not remove the muffler when the engine is still hot.What until the muffler cool down. Muffler Body Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Right Rear Footpeg Bracket [B] with Cover [C] • Remove: Right Muffler Body Assembly Nuts [A] [...]

5-40 ENGINE TOP END Muffler Muffler Body Installation If the muffler body cover [A] was removed, install it. ○ Fit the dampers [B] of the muffler body into the slots [C] in the muf fler cover . T orque - Muffler Body Cover Bolts [D]: 7.0 N·m (0 .70 kgf·m, 62 in·lb) • Replace the muffle r body gasket [E] with a new ones. • Install the muffl[...]

ENGINE TOP END 5-41 Muffler Middle and Rear Exhaust Pipe Removal • Remove the left muffler body (see Muf fler Body Removal). • Loosen the rear exhaust pipe clamp bolt [A]. • Remove the rear exhaust pipe [B] from left side of motor- cycle. • Remove: Right Muffler Body (see Muf fler Body Removal) Exhaust Butterfly V alve Cable Lower Ends (see[...]

5-42 ENGINE TOP END Muffler Middle and Rear Exha ust Pipe Installation • Replace the middle exhaust pipe gasket [A] with a new one. ○ Install the middle exhaust pipe gasket until it is bottomed so that the chamfer side (inner) faces front exhaust pipe [B]. • Install the middle exhaust pipe [C]. • T ighten: T orque - Middle Exhaust Pipe St a[...]

ENGINE TOP END 5-43 Muffler • Install the exhaust butterfly valve cable, and adjust (see Exhaust Butterfly V alve Cable Installation). • Throughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters). Front Exhaust Pipe Removal • Remove: Radiator (see Radiator [...]

5-44 ENGINE TOP END Muffler Front Exhaust Pipe Installation • Replace the front exhaust pipe gaskets [A] with new ones. • Replace the middle exhaust pipe gasket [B] with a new one. ○ Install the middle exhaust pipe gasket until it is bottomed so that the chamfer side (inner) faces front exhaust pipe. • Install the front exhaust pipe [C]. ?[...]

ENGINE TOP END 5-45 Muffler Exhaust Butterfly V alve Cable Removal • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjusters [C] to give the cable plenty of paly . • Remove the clamp [A]. • Remove the exhaust butterfly valve cable upper ends [B] fr[...]

5-46 ENGINE TOP END Muffler • Remove: Bolts [A] Lower Cover [B] • Loosen the locknuts [A]. • Remove the exhaust butterfly valve cable lower ends [B] from the pulley [C]. • Pull the exhaust butterfly valve cables out of frame. Front View [D] Exhaust Butterfly V alv e Cable Installation • Route the butterfly valve cables correctly (see Cabl[...]

ENGINE TOP END 5-47 Muffler CAUTION T o keep the correct exhaust butterfly valve position, adjust the open cable first. • Install the close cable (green) [A]. • Install the open cable (yellow) [B] and adjust the adjuster [C] until the clearance of part [D] of figure come to 0 mm (0 in.). CAUTION Do not overstretch. • T ighten: T orque - Exhau[...]

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CLUTCH 6-1 6 Clutch T able of Contents Exploded V iew ................................................................................................................... ..... 6-2 Specifications ................................................................................................................. ........ 6-4 Special T ool and Sealant ..[...]

6-2 CLUTCH Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S 2 Clutch Cover Mounting Bolts 10 1.0 89 in·lb S 3 Oil Filler Plug – – – Hand-tighten 4 Clutch Spring Bolts 9.8 1.0 87 in·lb 5 Clutch Hub Nut 130 13.3 96 R 6 Sub Clutch Hub Bolts 25 2.5 18 L CL: Apply cable lubricant. EO: [...]

6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) ––– Clutch Plate Assembly Length (Reference) 53.5 mm (2.1 1 in.) ––– Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.1 13 in.) 2.[...]

CLUTCH 6-5 S p e c i a lT o o la n dS e a l a n t Clutch Holder: 57001-1243 Kawasaki Bond (Sil icone Sealant): 92104-0004 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter (see Clutch Adjustment Inspection in the Periodic Maintenance chapter). Clutch Lever Free Play Adjustment • Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter (see Clutch [...]

CLUTCH 6-7 Clutch Cover Clutch Cover Remo val • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End [A] (see Cable Removal) • Loosen the clutch cover mounting bolts as shown se- quence [1 ∼ 10] in the figure,[...]

6-8 CLUTCH Clutch Cover Release Shaf t Installation • Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover . • Apply oil to the needle bearings in the hole of the clutch cover . • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft. • Install the washer [B] and spring[...]

CLUTCH 6-9 Clutch Cover Clutch Cover Assemb ly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’ s make face out. • Install the needle bearings [A] and oil seal [B] position as shown. ○ Press the lower bearing, do not protrude from the boss [C] of the clutch cover . ○ P[...]

6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] (with Bearing ) Pusher [C] • Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] • Hold the sub clutch hub [A] steady with the clutch holde[...]

CLUTCH 6-1 1 Clutch • Remove: T orque Limiter Springs [A] S u bC l u t c hH u b[ B ] Clutch Hub [C] Spacer [D] ○ Remove the sub clutch hub bolts [E] as necessary . • Using the two 4 mm (0.16 in.) screws [A], pull out the sleeve [B], needle bearing [C] and clutch housing [D]. • Remove the spacer . www.zxforums.com www.zxforums.com www.zxforu[...]

6-12 CLUTCH Clutch Clutch Installation • Install the spacer [A] so that the circle mark [B] faces out- ward. • Engage the clutch housing gear [A] and oil pump drive gear [B] with the crankshaft primary gear [C] and oil pump gear [D]. • Install: Needle Bearing [A] Sleeve [B] ○ Apply engine oil to the sleeve and needle bearing. • Install th[...]

CLUTCH 6-13 Clutch ○ Second T orque Limiter Spring Ta n g [ B ] ○ Third T orque Limiter Spring Ta n g [ B ] ○ Fourth T orque Limiter Spring Ta n g [ B ] • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special T ool - Clutch Holder: 57001-1243[...]

6-14 CLUTCH Clutch • Install the following as shown. Friction Plates (9) [A] Steel Plates (9) [B] Spring Seat [C] Spring [D] ○ Install the spring seat and spring between first steel plate and second steel plate. CAUTION If new dry friction plates and s teel plates are in- stalled, apply engine oil to the surface of each plate to avoid clutch pl[...]

CLUTCH 6-15 Clutch Spring Plate Free Play Measu rement Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy” or pulsate when pulled. • Hold an extra drive shaft in a vise and install the following c[...]

6-16 CLUTCH Clutch S p r i n gP l a t eF r e eP l a yA d j u s t m e n t NOTE ○ The free play adjustment is performed by replacing the steel plate(s). • Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range. Spring Plate F[...]

CLUTCH 6-17 Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with[...]

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ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Contents Exploded V iew ................................................................................................................... ..... 7-2 Engine Oil Flow Chart............................................................................................................. [...]

7-2 ENGINE LUBRICA TION SYSTEM Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Bolt 20 2.0 15 2 Oil Filter 31 3.2 23 G, R 3 Oil Filter Pipe 35 3.6 26 L 4 Oil Pan Bolts 10 1.0 89 in·lb 5 Oil Pressure Relief V alve 15 1.5 11 L 6 Oil Pressure Switch 15 1.5 11 SS 7 Oil Pressure Switch T erminal Bolt 1.5 0.15 13 in·lb [...]

7-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart 1. Inlet Camshaft 2. Exhaust Camshaft 3. Oil Cooler 4. Oil Filter 5. Oil Pressure Switch 6. Main Oil Passage 7. Relief V alve 8. Oil Pump 9. Oil Screen 10. Camshaft Oil Passage 11 . O i l J e t 12. Starter Clutch Oil Passage 13. Crankshaft O il Passage 14. T o Air Cleaner 15. Crankcase Oil Passag[...]

7-6 ENGINE LUBRICA TION SYSTEM Specifications Item Standard Engine Oil Ty p e API SE, SF or SG API SH, SJ or SL with JASO MA Vis c os i ty SAE 10W-40 Capacity 3.2 L (3.4 US gt) (when filter is not removed) 3.7 L (3.9 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is complete ly dry) Level Between upper and lower level lines Oil Pres[...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools and Sealant Oil Pressure Ga uge, 10 kgf/cm²: 57001-164 Oil Pressure Gau ge Adapter , PT3/8: 57001-1233 Oil Filte r Wrench : 57001-1249 Gear Holder: 57001-1599 Kawasaki Bond (Sil icone Sealant): 92104-0004 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] le[...]

ENGINE LUBRICA TION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine T op End chapter) Oil Pan Bolts [A] Clamps [B] Oil Pan [C] Oil Pan Installation • Replace the oil pan gasket [A] with a new one.[...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pressure Relief V alve Oil Pressure Relief V alve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the oil pressure relief valve [A]. Oil Pressure Relie f V alve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve [A], and tighten it. CAU[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pressure Relief V alve Oil Pressure Relief V alve I nspection • Remove the oil pressure relief valve (see Oil Pressure Relief V alve Removal). • Check to see if the valve [A] slides smoothly when push - ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NO[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Removal • Remove: Oil Pump Gear (see Oil Pump Gear Removal) Oil Pump Cover Bolts [A] • Remove the oil pump cover [A] with oil pump gear shaft [B]. ○ Stuff the cloth [C] on the hole of the crankcase so that pin [D] close not drop into the crankcase bottom. • Remove the outer rotor [E] and inn[...]

ENGINE LUBRICA TION SYSTEM 7-13 Oil Pump • Install the outer rotor [A] on the inner rotor . ○ Apply engine oil to the outer rotor . • Install the dowel pin [B]. • Fit the pin of the oil pump cover into the hole [C] in the crankcase. ○ T urn the oil pump gear shaft [A] so that the projection [B] in its shaft fits onto the slot [C] of the i[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Pump • Apply a non-permanent locking agent to the threads of the oil pump gear bolts [A]. • Hold the oil pump gear [B] steady with the gear holder [C], and tighten the bolts. Special T ool - Gear Holder: 57001-1599 T orque - Oil Pump Gear Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the clutch (see Clut[...]

ENGINE LUBRICA TION SYSTEM 7-15 Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic M ain- tenance chapter) • Remove: W ater Hoses [A] Oil Cooler Mounting Bolts [B] Oil Cooler [C] Oil Cooler Installation • Replace the O-ring [A] with a new [...]

7-16 ENGINE LUBRICA TION SYSTEM Oil Cooler Oil Cooler/Oil Filter Case Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. If the oil filter pipe [B] was removed, install it. ○ Apply a non-permanent locking agent to the threads of the oil filter pipe, and tighten it. T orque - Oil Filter Pip e: 35 N·m (3.6 [...]

ENGINE LUBRICA TION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plu g hole. Special T ools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter , PT3/8: 57001 -1233 •[...]

7-18 ENGINE LUBRICA TION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Slide out the rubber boot [A]. • Loosen the oil pressure switch terminal bolt [B], and re- m[...]

ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Contents Exploded V iew ................................................................................................................... ..... 8-2 Special T ool ...................................................................................... ........................[...]

8-2 ENGINE REMOV AL/INST ALLA TION Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Adjusting Collar Locknut 49 5.0 36 S 2 Lef Front Engine Mounting Bolt (M10, L = 42) 44 4.5 32 S 3 Right Front Engine Mounting Bolt (M10, L = 67) 44 4.5 32 S 4 Middle Engine Mounting Bolt 9.8 1.0 87 in·lb S 5 Middle Engine Mounting Nut 44 4.5 32 S 6 L[...]

8-4 ENGINE REMOV AL/INST ALLA TION Special T ool Engine Mount Nut Wrench: 57001-1450 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WA R N I N G Be sure to hold the front brake when removing the engine, or the motorcycle may fall over . It could cause an accident and injury . CAUTION[...]

8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Disconnect the sidestand switch lead connector [A]. • Remove: Gear Position Switch Lead Connector [A] Alternator Lead Connector [B] • Remove: Engine Ground Cable T erminal Bolt [A] Starter Motor Cable [B] • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto[...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/Installation • Remove: Left Engine Bracket Bolts [A] Left Engine Bracket [B] • Remove: Right Upper Inner Fairing Bracket Bolts [A] Right Upper Inner Fairing Bracket [B] • Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] • Remove: Left Front Engine Mounting Bolt [A] Middle Engi[...]

8-8 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Using the nut wrench [A], loosen the locknut [B]. Special T ool - Engine Mount Nut Wrench: 57001-145 0 • Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar . • Remove the drive chain [A] from the outpu[...]

ENGINE REMOV AL/INST ALLA TION 8-9 Engine Removal/Installation A: White M ark B: T o Radiator C: T o Right Engine Bracket (Cylinder Head Side) D: Th rough the left engine bracket bolt. E: T o Camshaft Position Sensor Lead F: T o Air Suction V alve Cover and Stick Coil G: T o Throttle Body Assy Holder H: Right Front Engine Mount I: T o Thermostat Ca[...]

8-10 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. ○ Apply 2-stroke oil to the threads of the adjusting collar [B]. ○ First, install the adjusting collars [A[...]

ENGINE REMOV AL/INST ALLA TION 8-1 1 Engine Removal/Installation ○ Fifth, tighten the middle engine mounting nut [H], and then lower engine mounting nut [I]. T orque - Middle Engine Mounting Nu t: 44 N·m (4.5 kgf·m, 32 ft·lb) Lower Engine Mounti ng Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) ○ Sixth, remove the bolt [D] temporally , and using the h[...]

8-12 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Install the left [A] and right [B] engine bracket, following the specified installing sequence. ○ First, install the adjusting collar [C] to the right engine bracket [B]. ○ Second, install the bolts [D] [E] [F] [G] temporally as shown sequence [1 ∼ 8] in the figure. ○ Third[...]

ENGINE REMOV AL/INST ALLA TION 8-13 Engine Removal/Installation • Install the left and right upper inner fairing brackets. • Run the leads, cable and hoses correctly (see Cable, Wire and Hose Routing section in Appendix chapter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System I[...]

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CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/T r ansmission T able of Contents Exploded V iew ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. .....[...]

9-2 CRANKSHAFT/TRANSMISSION Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

CRANKSHAFT/TRANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Breather Plate Bolts 10 1.0 89 in·lb L 2 Crankcase Bolts (M9) 39 4.0 29 MO, S 3 Crankcase Bolts (M8) 27 2.8 20 S 4 Crankcase Bolts (M7, L = 32) 20 2.0 15 S 5 Crankcase Bolts (M7, L = 50) 20 2.0 15 S 6 Crankcase Bolts (M7, L = 85) 20 2.0 15 S 7 Crankcase Bol[...]

9-4 CRANKSHAFT/TRANSMISSION Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

CRANKSHAFT/TRANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Shift Pedal Mounting Bolt 25 2.5 18 2 Gear Position Lever Bolt 12 1.2 106 in·lb 3 Shift Shaft Return Spring Pin 29 3.0 21 L 4 Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L 5 Shift Lever Bolt 7.0 0.71 62 in·lb 6 T ie-Rod Locknuts 7.0 0.71 62 in·lb 7 Gear [...]

9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend ––– TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod T wist ––– TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.58 mm (0.023 in.) Connecting Rod [...]

CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) ––– Black 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) ––– Blue 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) ––– Pistons Cylinder (Upper Crankcase) Inside Diameter 75.990 ∼[...]

9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Bore Diameter Marking Crankpin Diameter Marking Size Color Part Number None ○ Brown 92139-0028 None None ○ ○ Bl ack 92139-0027 ○ None Blue 92139-0026 Crankshaft Main Bearin g Insert Selection Bearing Insert Crankcase Mai[...]

CRANKSHAFT/TRANSMISSION 9-9 Special T ools and Sealants Bearing Pulle r: 57001-135 Outside C irclip Pliers: 57001-144 Bearing P uller Ada pter: 57001-317 Bearing Driver , 32: 57001-382 Piston Pin Pull er Assembly: 57001-910 Piston Ring Compres sor Grip: 57001-1095 Piston Ring Compressor Belt, 67 ∼ 79: 57001-1097 Kawasaki Bond: 92104-1064 www.zxfo[...]

9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Sta[...]

CRANKSHAFT/TRANSMISSION 9-1 1 Crankcase Splitting • Remove the lower crankcase bolts, following the specified sequence. ○ First, loosen the M6 bolts [A]. ○ Second, loosen the M7 bolts [B]. ○ Lastly , loosen the M9 bolts as shown sequence [1 ∼ 10] in the figure. • T ap lightly around the crankcase mating surface wit h a plastic mallet, a[...]

9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply a non-permanent locking agent to the treads of the breather plate bolts [A] and tighten it. T orq ue - Breather Plate Bolts: 10 N· m (1.0 kgf·m , 89 in·lb) • Install the following in the up per crankcase. Output Shaft [A] (see T ransmission Shaft Installation) Crankshaft [B] (see Crank[...]

CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the l ower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially , apply a sealant so that it shall be filled up on the grooves. CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage hole. [...]

9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • T ighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, M9 bolts [1 ∼ 10] with copper plated washers. T orque - Crankcase Bolt s (M9): 39 N·m (4.0 kgf· m, 29 ft·lb) ○ T ighten the M7 bolts. T orque - Crankcase Bolt s (M7[...]

CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • T ighten the upper crankcase bolts using the following steps. ○ The M8 bolts [A] has a w asher , replace it with a new one. ○ T ighten the M8 bolts with washers. T orque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○ T ighten the M7 bolts [B]. T orque - Crankcase Bolts (M7): 20 N[...]

9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaf t Removal • Refer to the Connecting Rod Removal (see Connecting Rod Removal). Crankshaf t Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications. CAUTION If t[...]

CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Installation CAUTION T o minimize vibration, the connecting r ods should have the same weight mark. B i gE n dC a p[ A ] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D]: “ ○ ”o rn om a r k CAUTION If the connecting rods, big end bearing inserts, or crank[...]

9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods CAUTION The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the t able below for correct bolt and nut usage. CAUTION Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the b[...]

CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the v alues to find the bolt stretch. Connecting Rod [A] Dent here with a [...]

9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods • First, tighten the nuts to the specified torque. See the table below . • Nex[...]

CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod T wist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting[...]

9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastiga[...]

CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Big End Insi de Diameter Marks None 37.500 ∼ 37.508 mm (1 .4764 ∼ 1.4766 in.) ○ 37.509 ∼ 37.51 6 mm (1.4767 ∼ 1.4770 in.) B i gE n dC a p[ A ] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “ ○ ”o rn o mark • Select the[...]

9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assem bly). ○ Do not turn the crankshaft during clearance measure- ment. ?[...]

CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Measure the main bearing inside diameter , and mark the upper crankcase half in accordance with the inside diam- eter . A: Crankcase Main Bearing Inside Diameter Marks, “ ○ ” mark or no mark. • T ighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE [...]

9-26 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splittin g). • Remove the connecting rod nuts [A] and big end caps [B]. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions. • Remove: Camshaft Chain (see Camshaf[...]

CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander , and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together . • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one ab[...]

9-28 CRANKSHAFT/TRANSMISSION Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its marking hollow [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special T ools - Piston Ring Compressor Grip: 57001-1095 [...]

CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove W idth Standard: To p [ A ] 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) Second [B] 0.82 ∼ 0.84 mm (0.0323 ∼ 0. 0331 in.) Service Limit: To p [ A ] 0 .92 mm (0.0 36[...]

9-30 CRANKSHAFT/TRANSMISSION T ransmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] o n the shift shaft so that it can be installed later in the same position. • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Shift Lever Bolt [C] Shift Lever • Remove: Shift Pedal Mounting Bolt [A] T ie-ro[...]

CRANKSHAFT/TRANSMISSION 9-31 T ransmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] W asher and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] W asher [C] Bolt [D] • T ighten: T orque - Gear Positioning L ever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) Externa[...]

9-32 CRANKSHAFT/TRANSMISSION T ransmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splittin g). • Remove the output shaft [A]. • Discard the oil seal [B] • Remove: W ater Pump (see Water Pump Removal in the Cooling System chapter) Shift Forks (see Shift Drum and Shift Forks Removal) Bolts [A] Drive Shaft Cover [B] ?[...]

CRANKSHAFT/TRANSMISSION 9-33 T ransmission • Assemble the crankcase (see Crankcase Assembly). • Press in the new oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the counterbore bottom surface [C] of the crankcase. ○ Apply high-temperature grease to the oil seal lips. Transmission Shaft Disassembly • Remove the[...]

9-34 CRANKSHAFT/TRANSMISSION T ransmission • Apply engine oil to the bushings, ball bearings and shafts. • Install the gear bushings [A] on the shaft with their holes [B] aligned. • Replace any circlips removed with new ones. • Install the circlips [A] so that the opening [B] of it is aligned with spline grooves [C]. • Install the circlip[...]

CRANKSHAFT/TRANSMISSION 9-35 T ransmission • Fit the steel balls into the 5th gear holes i n the output shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. ○ After assembling the 5t[...]

9-36 CRANKSHAFT/TRANSMISSION T ransmission 1. Output Shaft 2. Collar 3. Ball Bearing 4. 2nd Gear 5. 6th (T op) Gear 6. 4th Gear 7. 3rd Gear 8. Steel Ball 9. 5th Gear 10. 1st Gear 1 1. Needle Bearing 12. Bearing Outer Race 13. Bushing 14. Thrust Washer , 34 mm (1.34 in.) 15. Snap Ring 16. Bushing 17. T oothed Washer , 34 mm (1.34 in.) 18. Thrust Was[...]

CRANKSHAFT/TRANSMISSION 9-37 T ransmission Shift Drum and Fork Removal • Split the crankcase (see Crankcase Splitting). • Remove: Gear Position Switch (see Gear Position Switch Re- moval in the Electrical System chapter) Bolt [A] Shift Fork Holder [B] Screws [C] Shift Drum Bearing Holder [D] • Pull out the shift rods [A], and take off the shi[...]

9-38 CRANKSHAFT/TRANSMISSION T ransmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause dif ficulty in shifting, or allow the transmission to jump out of gear when under power . 90° [A] Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea- s[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able of Contents Exploded V iew ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-4 Special T o[...]

10-2 WHEELS/TIRES Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Axle Clamp Bolts 20 2.0 15 AL 2 Front Axle Nut 127 13.0 94 3 Rear Axle Nut 10 8 11 . 0 80 AL: T ighten the two clamp bolts alternately two times to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap an[...]

10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.01 in.) Wheel Balance 10 g (0.35 oz.) or less ––– Balance Weigh ts 10 g (0[...]

WHEELS/TIRES 10-5 Special T ools Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Bearing Remover Head, 20 × 22: 57001-1293 Bearing Remover Shaf t, 13: 57001-1377 Jack Attachment : 57001-1608 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] (Left and Right) • Loosen: Left Side Axle Clamp Bolts [A] Axle Nut [B] Right Side Axle Clamp Bolts • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Raise the front wheel of f the ground with [...]

WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle. • T ighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] 0.7 ∼ 4.1 mm (0.028 ∼ 0.161 in.) [E] Viewed from Rear [F] T orque[...]

10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove [...]

WHEELS/TIRES 10-9 Wheels (Rims) ○ If the coupling [A] is removed from the rear wheel, apply the grease [B] as shown. Wheel Flange Portion [C] O-ring [D] • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. ○ Insert the axle from the right side of the wheel, and tighten t h ea x l en [...]

10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel of f the ground. Special T ools - Jack: 57001-1238 Jack Attachment : 57001-1608 • Spin the wheel lightly , and check for roughness or binding. If roughness or binding is found, replace the hub bearings. • Inspect the wheel for small cracks, dents, bending, or warp.[...]

WHEELS/TIRES 10-1 1 Wheels (Rims) Balance Inspection • Remove the wheel (see wheels (Rims) section). • Support the wheel so that it can be spun freely . • Spin the wheel lightly , and mark [A] the wheel at the top when the wheel stops. ○ Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is we[...]

10-12 WHEELS/TIRES Wheels (Rims) Balance W eight Part Number Wei gh t 41075-0007 10 g (0.35 oz.) 41075-0008 20 g (0.71 oz.) 41075-0009 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbala nce of less than 10 grams (0.35 oz.) will not usually affect ru[...]

WHEELS/TIRES 10-13 Tir e s Air Pressure Inspection/Adjus tment • Refer to the T ires Air Pressure Inspection in the Periodic Maintenance chapter (see T ires Air Pressure Inspection in the Periodic Maintenance chapter). Tire Inspection • Refer to the Wheels/T ires Damage Inspection in the Pe- riodic Maintenance chapter (see Wheels/T ires Damage [...]

10-14 WHEELS/TIRES Tir e s • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lu- bricate the stem because the[...]

WHEELS/TIRES 10-15 Tir e s • Check to see that the rim lines [A] on both sides of the tire sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. • Lubricate the rim flanges and tire beads. • Install the valve core and inflate the tire again. • After the tire bead[...]

10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that t[...]

WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

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FINAL DRIVE 1 1-1 11 Final Drive T able of Contents Exploded V iew ................................................................................................................... .... 1 1-2 Specifications ................................................................................................................ . ....... 1 1-4 Special T oo[...]

11 - 2 F I N A L D R I V E Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Axle Nut 108 11 . 0 80 2 Rear Sprocket Nuts 59 6.0 44 3 Engine Sprocket Nut 125 12.7 92 MO 4 Engine Sprocket Cover Bolts 10 1.0 89 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply mo[...]

11 - 4 F I N A L D R I V E Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 30 ∼ 35 mm (1.2 ∼ 1.4 in.) ––– Drive Chain W ear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain Make RK EXCEL ––– Ty p e RK 525MFO, Endless ––– Link 108 links ––– Sprockets Rear [...]

FINAL DRIVE 1 1-5 Special T ools Inside Circli p Pliers: 57001-143 Bearing Driver Set : 57001-1 129 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

11 - 6 F I N A L D R I V E Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter (see Drive Chain [...]

FINAL DRIVE 1 1-7 Drive Chain • Using a suitable tool [A], cut the drive chain by removing the link pins. Recommended T ool: RK EXCEL 70 T ool (RK-700) CAUTION Read the T ool Manual before removing. Pressure Bolt (A) [A] Pressure Bolt (B) [B] Handle Lever [C] Pressure Holder [D] Guide Plate [E] Adjuster Bolt (Y ellow) [F] Wedge Holder [G] and W e[...]

11 - 8 F I N A L D R I V E Drive Chain ○ Screw in the pressure bolt assy [A] in the pressure bolt (A) [B]. ○ Install the handle lever [C] to the pressure bolt assy . ○ T urn in the handle lever until the link pin [D] removed at the link plate [E]. • Repeat the above steps for other link pin [A]. Drive Chain Installation • Engage new drive[...]

FINAL DRIVE 1 1-9 Drive Chain ○ Install the link plate so that the gold painted [A] faces out. ○ Fit the link plate [A] in the pressure holder [B]. ○ Fit the link plates of the chain into the wedge holder and wedge pin [D]. ○ T urn the pressure bolt (A) [C] by hand until link plate touches the link pins. ○ Install the handle lever [A] ont[...]

1 1-10 FINAL DRIVE Drive Chain • After staking, measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outsid e Diameter Standard: 5.60 ∼ 5.90 mm (0.22 ∼ 0.23 i n.) Link Plates Outsi de Width Standard: 19.70 ∼ 20.00 mm (0.775 ∼ 0.787 in.) If the reading exceeds the specified length, cut and rejoin the chain a[...]

FINAL DRIVE 1 1-1 1 Sprocket, Coupling Engine Sprocket Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Shift Lever Bolt [A] • Pull the shift lever [B]. • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer .[...]

1 1-12 FINAL DRIVE Sprocket, Coupling • Install the guide [A] into the sprocket cover [B] so that the hook [C] of the guide fits into the receiver [D]. • Install the engine sprocket cover [A] with the guide [B]. ○ Install the pins [C] into the holes [D]. • T ighten the engine sprocket cover bolts. T orque - Engine Sprocket Cover Bolts: 10 N[...]

FINAL DRIVE 1 1-13 Sprocket, Coupling Coupling Installation • Grease the following and install the coupling. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] • Apply grease to the O-ring [A]. • Install the collar [B]. Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special T ool - Inside Circlip Plie rs [B]: 5[...]

1 1-14 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special T ool - Bea ring Dri ver Set: 57001-1 12 9 Coupling Bearing Inspection Since the coupling bearing is made to ext[...]

FINAL DRIVE 1 1-15 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground (see Rear Wheel Removal in the Wheels/T ires chapter) so that it will turn freely . • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The dif f[...]

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BRAKES 12-1 12 Brakes T able of Contents Exploded V iew ................................................................................................................... .... 12-2 Specifications ................................................................................................................ ........ 12-6 Special T ools ...........[...]

12-2 BRAKES Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Bleed V alves 7.8 0.80 69 in·lb 2 Brake Hose Banjo Bolts 25 2.5 18 3 Brake Lever Pivot Bolt 1.0 0.10 9i n · l b Si 4 Brake Lever Pivot Bolt Nut 5.9 0.60 52 in·lb 5 Front Brake Disc Mounting Bolts 27 2.8 20 L 6 Front Brake Light Switch Screw 1.2 0.12 11 i n · l b 7 Front[...]

12-4 BRAKES Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Bleed V alve 7.8 0.80 69 in·lb 2 Brake Hose Banjo Bolts 25 2.5 18 3 Brake Pedal Bolt 8.8 0.90 78 in·lb 4 Rear Brake Disc Mounting Bolts 27 2.8 20 L 5 Rear Caliper Mounting Bolts 25 2.5 18 6 Rear Master Cylinder Mounting Bolts 25 2.5 18 7 Rear Master Cylinder Push Rod Lock[...]

12-6 BRAKES Specifications Item Standard Service Limit Brake Lever , Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) ––– Brake Lever Free Play Non-adjustable ––– Pedal Free Play Non-adjustable ––– Pedal Position About 90 mm (3.5 in.) below footpeg top ––– Brake Discs Thickness: Front 5.8 ∼ 6.2 mm (0.23 ?[...]

BRAKES 12-7 Special T ools Inside Circli p Pliers: 57001-143 Jack: 57001-1238 Jack Attachment : 57001-1608 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

12-8 BRAKES Brake Lever , Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so th at the brake lever position can be adjusted to suit the operator ’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder . ○ The distance from the grip to the [...]

BRAKES 12-9 Brake Lever , Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Ins tallation • Apply grease to the pivot shaft [A] and install the washe r [B]. • Install: Brake Pedal [C] W asher [D] Brake Pedal Bolt [E[...]

12-10 BRAKES Calipers Front Caliper Remo val • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. T ake out only the caliper mounting bolts for caliper re- moval. Loosening the ca[...]

BRAKES 12-1 1 Calipers WA R N I N G Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done. Front Caliper Disassembly • Refer to the Caliper Rubber[...]

12-12 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder[...]

BRAKES 12-13 Brake Pads Front Brake Pa d Removal • Loosen: Pad Pins [A] • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installatio n • Push the caliper pistons in by hand as far as they will go. • Install the outside pad [A] and insert the pad pin [B] as shown. • Set: Inside Pad [A] P a dS p r i n g[ B ] ○ Pushing[...]

12-14 BRAKES Brake Pads Rear Brake Pad Removal • Remove the caliper with the hose installed. • Remove: Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Insta llation • Push the caliper piston in by hand as far as it will go. • Install the pad spring in place. • Install the piston side pad [A] first, an d then another pad. ○ Fit the pr[...]

BRAKES 12-15 Master Cylinder Front Master Cylind er Removal • Remove the reservoir bracket nut [A]. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [B], and take off th e master cylin- der [C] as an assembly with the reservoir , brake lever , [...]

12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder • Slide out the clamp [G]. • Pull off the reservoir hose lower end [H], and drain the brake fluid into a container . Rear Master Cylinder I[...]

BRAKES 12-17 Master Cylinder Master Cylinder Inspection (V isual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the[...]

12-18 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels (Rims) section in the Wheels/T ires chapter). • Unscrew the mounting bolts, and take off the disc. B r a k eD i s cI n s t a l l a t i o n • Install the brake disc on the wheel so that the marked side [B] faces out. • Apply a non-permanent locking agent to the threads[...]

BRAKES 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter (see Brake Fluid Ch ange in the Periodic Maintena[...]

12-20 BRAKES Brake Fluid • Remove the rubber cap from the bleed valve on the front master cylinder . • Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container . • Bleed the brake line a nd the master cylinder . ○ Repeat this operation until no more air can be seen com- ing out into the plastic [...]

BRAKES 12-21 Brake Fluid • Bleed the brake line and the caliper . ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply t h eb r a k ea n dh o l di t[ A ] . 2. Quickly open and close [B] the bleed valve while hold- ing the brake applied. 3. Release the [...]

12-22 BRAKES Brake Fluid W ARNING When working with the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling poi[...]

BRAKES 12-23 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance c hapter [...]

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SUSPENSION 13-1 13 Suspension T able of Contents Exploded V iew ................................................................................................................... ..... 13-2 Specifications ................................................................................................................. ........ 13-6 Special T ools .[...]

13-2 SUSPENSION Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Axle Clamp Bolts 20 2.0 15 AL 2 Front Fork Bottom Allen Bolts 23 2.3 17 L 3 Front Fork Clamp Bolts (Lower) 30 3.1 22 AL 4 Front Fork Clamp Bolts (Upper) 20 2.0 15 5 Front Fork T op Plugs 23 2.3 17 6 Piston Rod Nuts 15 1.5 11 AL: T ighten the two clamp bolts altern[...]

13-4 SUSPENSION Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Shock Absorber Bracket Nut 59 6.0 44 2 Rear Shock Absorber Nut (Lower) 34 3.5 25 3 Rear Shock Absorber Nut (Upper) 34 3.5 25 4 Uni-T rak Rocker Arm Nut 34 3.5 25 5 Swingarm Pivot Adjusting Shaft 20 2.0 15 6 Swingarm Pivot Adjusting Collar Locknut 98 10.0 72 7 Swing[...]

13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner T ube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 10th click from the first click of the fully clockwise position (Usable range: 0 ←→ 1 1 clicks) Compression Damper Setting 10th click from the first click of t[...]

SUSPENSION 13-7 Special T ools Inside Circli p Pliers: 57001-143 Oil Seal & Bearing Remover: 57001-1058 Hook Wrench R3 7.5, R42: 57001-1 101 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Fork Cylinder Holder: 57001-1287 Fork Oil Level Gauge: 57001-1290 Bearing Remover Head, 20 × 22: 57001-1293 Fork Piston Rod Puller , M10 × 1.0: 57001-1298[...]

13-8 SUSPENSION Special T ools Fork Oil Seal Driver , 43: 57001-1530 Fork Spring Compressor: 57001-1587 Swingarm Pivot Nut Wrench: 57001-1597 Jack Attachment : 57001-1608 Needle Bearing D river , 17/ 18: 57001-1609 Stem Bearing Driver , 28: 57001-1610 Clamp: 57001-1626 Spacer , 18: 57001-1636 www.zxforums.com www.zxforums.com www.zxforums.com www.z[...]

SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • T o adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position.[...]

13-10 SUSPENSION Front Fork Spring Preload Adjustment • T urn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 17 mm (0.67 in.) [B] from the top plug nut surface as shown. Adjuster Protrusi on (from the top [...]

SUSPENSION 13-1 1 Front Fork • Loosen the handlebar bolt [A], upper fork clamp bolt [B] and lower fork clamp bolts [C]. • With a twisting motion, work the fork leg down and out. Front Fork Installation • Install the fork so that the top end [A] of the outer tube is flush with the upper surface [B] of the steering stem head bracket. • T ight[...]

13-12 SUSPENSION Front Fork • Install the clamps [A] as shown. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper , pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D]. The outer tube is used as a guide. Special T ools - Fork Spring Compressor: 57001-1587[...]

SUSPENSION 13-13 Front Fork • Screw the adjust nut [A] onto the compression shaft as shown. 20 mm (0.79 in.) [B] • Screw the locknut [C]. • Set the other side compression shaft same process. • Screw in one side nut [A] come out the piston rod nut. • Holding the piston rod nut with a wrench [A], remove the top plug [B] from the piston rod.[...]

13-14 SUSPENSION Front Fork • Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Vi scosity: KHL15-10 (KA Y ABA) or equivalent Amount (per side): When changing oil: Approx. 480 mL (16.2 U S oz.) After disas sembly and completel y dry: 5 6 7± 4m[...]

SUSPENSION 13-15 Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special T ool - Fork Pist on Rod Puller , M10 × 1.0: 57001 -1298 • Pull the puller up above the outer tube top. • Install the fork spring [A] with the smaller end facing [B] upward. • Install: Spring Seat Collar • Screw the rod nut [B] onto the[...]

13-16 SUSPENSION Front Fork • Set the holder bar [B], and compression shafts [A]. • Hold the piston rod nut [A]. • Remove the piston rod puller [B]. • Install the rebound damping adjuster rod [A]. • Screw in the top plug [A] stopped onto the piston rod. • Check the O-ring [B] on the top plug and replace it with a new one if damaged. •[...]

SUSPENSION 13-17 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). • Hold the front fork in a vise [A]. • Stop the cylinder [B] from turning by using the fork cylinder holder [C]. Special T ool - Fork C ylinder Holder: 57001-1287 • Unscrew the Allen bolt [[...]

13-18 SUSPENSION Front Fork • Install the following parts into the inner tube [A]. Dust Seal [B] Circlip [C] Oil Seal [D] Wa s h e r [ E ] • Insert the inner tube to the outer tube. • After installing the washer , install the oil seal [ A] by using the fork oil seal driver [B]. Special T ool - Fork Oil Seal Driver , 43: 57001-1530 • Install[...]

SUSPENSION 13-19 Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary . Spring T ension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be rep[...]

13-20 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • T o adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 2 turns out from the fully clo[...]

SUSPENSION 13-21 Rear Shock Absorber • T o adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 179 mm (7. 0 in.) Usable Range: Spring length 179 ∼ 191.5 mm (7.047 ∼ 7.539 in.) ○ The standard adjusting nut setting for an[...]

13-22 SUSPENSION Rear Shock Absorber • Squeeze the brake lever slowly and it with a band [A]. W ARNING Be sure to hold the front brake when removing the shock absorber , or the motorcycle may fall over . It could cause an accident and injury . • Remove: Lower Shock Absorber Nut and Bolt [A] Upper T ie-Rod Nut and Bolt [B] Upper Shock Absorber N[...]

SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/T ires chapter) Middle Exhaust Pipe (see Middle and Rear Exhaust Pipe Removal in the Engine T op End chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Bolts [A] Chain Cover [B] Inner Fender [C] • Remove: Bolt [A][...]

13-24 SUSPENSION Swingarm Swingarm Installation • Apply plenty of grease to the lip [A] of the oil seals. • Install the collar . • Place the adjusting collar [A] into the fra me [B] as shown. • Insert the pivot adjusting shaft [A] into the frame from the right side. • T ighten the pivot shaft so that the clearance between the adjusting co[...]

SUSPENSION 13-25 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip (Right Side) [D] Special T ool - In side Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special T ools - Oil Seal & Bearing Remover [A]: 57 001-1058 Bearing Remover Head: 57001-12[...]

13-26 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing installed in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually [...]

SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Exhaust Pipe (see Middle and Rear Exhaust Pipe Removal in the Engine T op End chapter) • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel of f the ground. Speci[...]

13-28 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the grease seals. • T ighten: T orque - Uni-T rak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Ti e-Rod Nuts: 59 N·m (6.0 kgf ·m, 44 ft·lb) Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod and Rocker Arm Bearing Removal • Remove[...]

SUSPENSION 13-29 Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing’s Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.) [E] NOTE[...]

13-30 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker a rm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instea[...]

STEERING 14-1 14 Steering T able of Contents Exploded V iew ................................................................................................................... ..... 14-2 Special T ools .................................................................................... ...................................... 14-5 Steering ..........[...]

14-2 STEERING Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Handlebar Switch Housing Screws 3.5 0.36 31 in·lb 2 Handlebar Bolts 25 2.5 18 3 Handlebar Position Bolts 9.8 1.0 87 in·lb L 4 Steering Stem Head Nut 78 8.0 58 5 Front Fork Clamp Bolts (Upper) 20 2.0 15 6 Steering Stem Locknut – – – Hand-tighten 7 Steering Stem Nut[...]

14-4 STEERING Exploded View Item Standard Steeri ng Damp er Damper Set 18 turns out from the fully clockwise position (Usable range: 0 ←→ 18 tuns ou t) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

STEERING 14-5 Special T ools Bearing P uller Ada pter: 57001-136 Bearing Pulle r: 57001-158 Head Pipe Oute r Race Press Sh aft: 57001-1075 Steering Stem Nut Wrenc h: 57001-1 100 Bearing Driver Set : 57001-1 129 Steering Stem Bear ing Driver , 42.5: 57001-1344 Steering Stem Bear ing Driver Adapter , 41.5: 57001-1345 Head Pipe Outer R ace Driver , 55[...]

14-6 STEERING Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter (see Steering Play Inspection in the Pe- riodic Maintenance chapter). Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter (see Steering Play Adjustment in the Periodic Maintenance c[...]

STEERING 14-7 Steering Damper Steering Damper Re moval • Remove the TORX bolt [A] and washer [B]. • Remove the bolt [C], washer , collar and steering damper [D]. Steering Damper Installation • Install the steering damper [F] and parts as shown. Collar [A] W asher [B] Fuel T ank Bracket [C] Bolt [D] W asher [E] • T ighten a new TORX bolt [G][...]

14-8 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Steering Damper (see Steering Damper Removal) Steering Stem Head Nut [A] and W asher [B] Steering Stem Head [C] Handlebars [D] • Remove: Brake Hose Clamp [A] Right Switch Housing Lead Clamp [B] • Remove the left switch housing lead and ignition switch lead clamp [A]. • Remove:[...]

STEERING 14-9 Steering Stem • Remove the lock washer [A]. • Pushing up the stem base, and remove the steering stem nut with stem cap [A]. • Remove: Steering Stem [C] Upper Ball Bearing Inner Race Special T ool - Steering Stem Nut Wrench [B]: 5 7001-1 100 • T o remove the bearing outer races [A] pressed into the head pipe [B], insert a bar [[...]

14-10 STEERING Steering Stem • Replace the bearing inner races with new ones. • Install the oil seal [D] on the steering stem, and drive the lower ball bearing inner race [A] applied the grease onto the stem. Special T ools - Steering Stem Bearing Driver [B]: 57001 -1344 Steering Stem Bearing Driver Adap ter [C]: 57001-1345 • Install the lowe[...]

STEERING 14-1 1 Steering Stem • Install the lock washer [A] so that claw [B] of washer fit the notch [C] of steering stem locknut [D]. • First tighten the steering stem locknut by hand until the resistance is felt fully , then tighten the steering stem lock- nut so that align the claw [A] of stem locknut to the notch [B] of stem nut by hand. ?[...]

14-12 STEERING Steering Stem Steering Stem Bearing Lubrication • Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter (see Steering Stem Bearing Lubrication in the Periodic Maintenance chapter). Steering Stem W arp • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, [...]

STEERING 14-13 Handlebar Handlebar Removal • Remove: Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Brake Reservoir Bracket Nut [A] Front Brake Master Cylinder [B] Front Brake Light Switch Connector [C] Right Switch Housing [D] Thr[...]

14-14 STEERING Handlebar • Install the left and right switch housings. ○ Fit the projection [A] into a small hole [B] in the handlebar . T orque - Handlebar Switch Hous ing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Connect the front brake light switch connector . • Install the clutch lever [A] so that the mating surface [B] of the clutch [...]

FRAME 15-1 15 Frame T able of Contents Exploded V iew ................................................................................................................... ..... 15-2 Seats ................................................................................................ .............................. ........ 15-8 Rear Seat Removal....[...]

15-2 FRAME Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Footpeg Bracket Bolts 25 2.5 18 2 Rear Footpeg Bracket Bolts 25 2.5 18 3 Rear Frame Bolts 44 4.5 32 4 Rear Master Cylinder Mounting Bolts 25 2.5 18 5 Sidestand Bolt 44 4.5 32 G 6 Sidestand Switch Bolt 8.8 0.90 78 in·lb L 7 Sidestand Bracket Bolts 49 5.0 36 L 8. Immobi[...]

15-4 FRAME Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FRAME 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fender Mounting Bolts 3.9 0.40 35 in·lb 2. United States and Canada Models 3. Australian Models www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

15-6 FRAME Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FRAME 15-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Windshield Mounting Bolts 0.4 0.04 4i n · l b www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lo ck, turning the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Put the rear seat hook [A] on the rib [B]. • Insert the seat pin [C] into the latch hole [D]. Front Seat Removal • Remov[...]

FRAME 15-9 Fairings Lower Fairing Removal • Pull up the core [A] by the thin blade driver [B]. • Remove: Quick Rivets [A] Bolts [B] with W ashers Screws [C] • Separate the right lower fairing [D] from the left lower fair- ing. • Clear the hook portion and projection [E] from the slots. • Remove the right lower fairing. Lower Fairing Insta[...]

15-10 FRAME Fairings For the California Model ○ Remove: Band [A] Canister [B] ○ Clear the right switch housing lead from the clamp [A]. ○ Disconnect the right turn signal lead connector [B]. • Disconnect the left turn signal lead connector [A]. • Clear the left switch housing lead and ignition switch lead from the clamp [B]. Middle Fairin[...]

FRAME 15-1 1 Fairings Windshield Installation • Put the front tongue [A] into the hollow [B]. T orque - Windshield Mounting B olts: 0.4 N·m (0.04 kgf·m, 4i n · l b ) Upper Fairing Removal • Remove: Lower Fairings (see Lower Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Middle Fair[...]

15-12 FRAME Fairings Upper Inner Fairing Removal • Remove the bolts [A] with washers. • Remove the upper inner fairing [B]. ○ Remove the upper inner fairing by pulling the rear of it up and upward to clear the projection from the stopper [C]. ○ Remove the upper inner fairing by sliding the front of it up and backward to clear the projection[...]

FRAME 15-13 Fairings Right and Left Inner Fairing Removal • Remove: Right and Left Middle Fairings (see Middle Fairing Re- moval) Bolts [A] Inner Fairing [B] Right and Left Inner Fairing Installation • T ighten the bolts [A]. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

15-14 FRAME Side Covers Side Cover Removal • Remove: Bolt and W asher [A] • Pull out the side cover [B]. Side Cover Installation • Insert the projections [A] into the holes [B]. • T ighten the bolt with washer . www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

FRAME 15-15 Seat Cover Seat Cover Removal • Remove: Seats (see Seats section) Bolts [A] Quick Rivets [B] • Pull the seat cover backward, and clear the projections from the holes. • Disconnect: T ail/Brake Light Lead Connector [A] T urn Signal Light Lead Connectors [B] • Remove: Seat Lock Cable [A] • Pull the seat cover backward. • Remov[...]

15-16 FRAME Seat Cover • Remove: Screws [A] Seat Lock Assy [B] Seat Cover Installation • Install the seat lock assy with screws. • Connect the tail/brake light lead connector . • Install the tail/brake light [A] inserting the hooks [B] into the stoppers [C]. • Connect the both turn signal light lead connectors. • Install the seat cover [...]

FRAME 15-17 Fenders Front Fe nder Rem oval • Remove: Brake Hose Clamps [A] (Left and Right) Bolts [B] with W ashers (Left and Right) • Remove the front fender assy [C]. • Remove: Bolts [A] • Separate the front fender cover [B] and front fender [C]. Front Fen der Inst allation • Install the front fender assy to the front fork. • T ighten[...]

15-18 FRAME Fenders • Pull out the rear fender rear [A] assembled turn signal lights and license plate light downward. Rear Fender Rear Installation • Install the harness clamp in accordance with Harness Routing section in Appendix chapter . Rear Fender Front Removal • Remove: Seat Cover (see Seat Cover Removal in the chapter) Middle Exhaust [...]

FRAME 15-19 Fenders • Remove: Bolts and Nuts [A] Collars [B] Dampers [C] Upper Heat Guard [D] • Remove: Bolt [E] Bolts [F] Fender Bracket [G] • Remove: Rivet [H] Nut [I] Bolt [J] Rear Fender Front [K] Front [L] Viewed from Upside [M] Rear Fender Front Installation • Insert the on the chassis. • Install the removed parts (see appropriate c[...]

15-20 FRAME Frame Rear Frame Removal • Remove: V ehicle-down Sensor (see V ehicle-down Sensor Re- moval in the Fuel System (DFI) chapter) Seat Cover (see Seat Cover Removal) Rear Fender Front (see Rear Fender Front Removal) Clamps for Main Harness Frame Bolts [A] Rear Frame Installation • T ighten: T orque - R ear Frame Bolts: 44 N·m (4.5 kgf?[...]

FRAME 15-21 Sidestand Sidestand Removal • Raise the rear wheel of f the ground with the stand. • Remove: Lower Fairings (see Lower Fairing Removal) • Disconnect the sidestand switch lead connector [A] and clear the lead from the clamps [B]. • Remove: Sidestand Switch Bolt [A] Spring [B] Sidestand Bolt [C] Sidestand [D] Switch Bracket Bolt [[...]

www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Contents Exploded V iew ................................................................................................................... ..... 16-4 Parts Location................................................................................................................. . ....... 16-10 W[...]

16-2 ELECTRICAL SYSTEM Starter Idle Gear Installation ............................................................................................. 16-49 Starter Clutch Removal ..................................................................................................... 16-51 Starter Clutch Installation .....................................[...]

ELECTRICAL SYSTEM 16-3 Relay Box ....................................................................................................................... ........ 16-107 Relay Box Removal .................................................................................................. ........ 16-107 Relay Circuit Inspection .......................[...]

16-4 ELECTRICAL SYSTEM Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Meter Unit Mounting Screws 1.2 0.12 11 i n · l b 2 Headlight Mounting Screws 1.2 0.12 11 i n · l b 3 Front T urn Signal Light Mounting Screws 1.2 0.12 11 i n · l b 4 Rear T urn Signal Light Mounting Screws 1.2 0.12 11 i n · l b 5 Rear T urn Signal Light Lens [...]

16-6 ELECTRICAL SYSTEM Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Position Sensor Bolt 10 1.0 89 in·lb 2 W ater T emperature Sensor 25 2.5 18 SS 3 Oxygen Sensors (Europe Models) 25 2.5 18 4 V ehicle-down Sensor Bolts 6.0 0.61 53 in·lb 5 Gear Position Switch Screws 3.0 0.31 27 in·lb L 6 Spark Plugs 13 1.3 11 5 i n ·[...]

16-8 ELECTRICAL SYSTEM Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Brake Light Switch Screw 1.2 0.12 11 i n · l b 2 Right Handlebar Switch Housing Screws (M5, L = 45) 3.5 0.36 31 in·lb 3 Left Handlebar Switch Housing Screws (M5, L = 25) 3.5 0.36 31 in·lb 4 Starter Clutch Bolt 49 5.0 36 5 Starter Motor Mounting Bolts 10 [...]

16-10 ELECTRICAL SYSTEM Parts Location 1. Starter Lockout Switch 2. Ignition Switch with Immobilizer Antenna (Im- mobilizer Models) 3. Stick C oils 4. W ater T emperature Sensor 5. Alternator 6. Starter Relay with Main Fuse 7. Battery 12 V 10 Ah 8. Relay Box 9. ECU (Electric Control Unit) 10. Fuse Box with ECU Main Fuse 1 1. Immobilizer Amplifier ([...]

ELECTRICAL SYSTEM 16-1 1 Wiring Diagram (United States, Canada, New Zealand, Colombia and T aiwan) Dummy Page www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-12 ELECTRICAL SYSTEM Wiring Diagram (United States, Canad a, New Zealand, Colombia and T aiwan) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-13 Wiring Diagram (United States, Canada, New Zealand, Colombia and T aiwan) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than United State s, Canada, New Zealand, Colombia, T ai- wan, Australia and Malaysia ) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than United State s, Canada, New Zealand, Co lombia, T ai- wan, Australia and Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-16 ELECTRICAL SYSTEM Wiring Diagram (Australia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-17 Wiring Diagram (Australia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-20 ELECTRICAL SYSTEM Specifications Item Standard Battery Ty p e Sealed battery Model Name YT12B-BS Capacity 12 V 10 Ah V oltage 12.8 V or more Charging System Ty p e Three-phase AC Alternator Output V oltage 60 V or more @4 000 r/min (rpm) Stator Coil Resistance 0.1 ∼ 0.2 Ω Charging V oltage (Regulator/Rectifier Output V oltage) 14.2 ∼ 15[...]

ELECTRICAL SYSTEM 16-21 Special T ools and Sealant Hand T ester: 57001-1394 Flywheel Pull er Assembly , M38 × 1.5/M35 × 1.5: 57001-1405 Peak V oltage Adapter: 57001-1415 Lead Wire - Peak V oltage Adapter: 57001-1449 Key Regis tration Uni t: 57001-1582 Grip: 57001-1591 Rotor Holder: 57001-1658 Rotor Holder: 57001-1666 Kawasaki Bond (Sil icone Seal[...]

16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an ele[...]

ELECTRICAL SYSTEM 16-23 Precautions Male Connectors [B] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosio n, dirt, and damage. If the connector is corroded or dirty , clean it carefully . If it is damaged, replace [...]

ELECTRICAL SYSTEM 16-25 Battery Battery Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Relay Box [A] • Slide the black and red caps [A] o ut. • Disconnect the negative (–) cable [B] and then positive (+) cable [C]. CAUTION Be sure to disconnect the negative (–) cable first. • R e m o v et h eb a n d[ D ] . [...]

16-26 ELECTRICAL SYSTEM Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery . These names must be the same. Battery Model Name f or ZX1000D: YT12B-BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since[...]

ELECTRICAL SYSTEM 16-27 Battery • Check the electrolyte flow . If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely , tap the container [B] a few times. • Keep the container in place for 20 minutes or more. Don’t remove the container from the battery until it’ s empty , the battery[...]

16-28 ELECTRICAL SYSTEM Battery • After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the s trip of the caps will be level with the top of the battery . CAUTION Once the strip of the caps [A] is installed onto the battery , never remove t[...]

ELECTRICAL SYSTEM 16-29 Battery WA R N I N G Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger , connect the battery to the charger before turning on the charger . This procedure prevents sparks at the battery terminals which c[...]

16-30 ELECTRICAL SYSTEM Battery T erminal V oltage: 1 1.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5A×1h CAUTION If possible, do not quick charge. If quick charge is done unavoidably , do standard charge later on. T erminal V oltage: less than 1 1.5 V Charging Method: 1 . 2A×2 0h NOTE ○ Increas[...]

ELECTRICAL SYSTEM 16-31 Charging System Alternator Cover Removal • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Coolant Reserve T ank (see Coolant Reserve T ank Re- moval in the Cooling System chapter) Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Alternator Lead Connector [A] For the Europe[...]

16-32 ELECTRICAL SYSTEM Charging System Stator Coil Installation • T ighten the stator coil bolts to the specified torque. T orq ue - Stator Coil B olts: 12 N·m (1 .2 kgf·m , 106 i n·lb) • Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into th e notch of the cover securely . Sealant - Kawasa[...]

ELECTRICAL SYSTEM 16-33 Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry if with a clean cloth. • Install the washer . NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • Install the rotor bolt [B] and tighten it with 70 N·m (7.0 kgf·m,[...]

16-34 ELECTRICAL SYSTEM Charging System • T o check the alternator output voltage, do the following procedures. ○ T urn off the ignition switch. ○ Remove the fuel tank (see Fuel T ank Removal in the Fuel System (DFI) chapter). ○ Disconnect the alternator lead connector [A]. ○ Connect the hand tester as shown in the table 1. ○ Start the [...]

ELECTRICAL SYSTEM 16-35 Charging System Regulator/Rectifier Inspection • Remove the Bolts [A]. • Disconnect the connectors [A]. • Remove the regulator/rectifier [B]. • Set the hand tester to the × 1 k Ω range and make the measurements shown in the table. Special T ool - Hand T ester: 57001-1394 • Connect the hand tester to the regulato[...]

16-36 ELECTRICAL SYSTEM Charging System Charging V oltage Inspection • Check the battery condition (see Charging Condition In- spection). • W arm up the engine to obtain actual alternator operating conditions. • Remove the Front seat (see Front Seat Re moval in the Frame chapter). • Check that the ignition switch is turned off, and connect [...]

ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Ignition Switch 2. Main Fuse 30 A 3. Starter Relay 4. Battery 12 V 10 Ah 5. Frame Ground 6. Load 7. Alternator 8. Regulator/Rectifier www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-38 ELECTRICAL SYSTEM Ignition System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

ELECTRICAL SYSTEM 16-39 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while[...]

16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). • Set the hand tester [A] to the × 100 Ω range and connect it to the crankshaft sensor lead connector [B]. Special T ool - Hand T ester: 57001-1394 Crankshaft Sensor Resi stance: 380 ∼ 570 [...]

ELECTRICAL SYSTEM 16-41 Ignition System • Disconnect the stick coil connectors [A]. • Pull the stick coils #2, #3 [B] off the spark plugs. CAUTION Do not pry the connector part of the coil while re- moving the coil. • For remove the stick coil #1 as follows. ○ Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Har[...]

16-42 ELECTRICAL SYSTEM Ignition System ○ Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] ○ Pull out the stick coil #4 [A] to forward. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation • Apply grease to the stick coils. • Insert the stick coils [A] as shown being careful of the coil heads directions. ○ A[...]

ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ign ition Coil together with S park Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Co il to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the[...]

16-44 ELECTRICAL SYSTEM Ignition System W ARNING T o avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • T urn the ignition switch and engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage. • Repeat the me[...]

ELECTRICAL SYSTEM 16-45 Ignition System Camshaft Position Sensor Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the camshaft position sensor lead connector [A]. • Remove: Right Middle Fairing (see Middle [...]

16-46 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Peak V oltage Inspection • Disconnect the camshaft position sensor connector (see Camshaft Position Sensor Removal). • Set the hand tester [A] to the 10 V DC range. • Connect the peak voltage adapter [B] to the hand tester and camshaft position sensor leads in the terminals. Spe[...]

ELECTRICAL SYSTEM 16-47 Ignition System 2nd Check • Start the engine to the following conditions. Condition: T ransmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ T urn the ignition switch ON and push the starter button. ○ Then the starter motor should turn when the starter sys- tem circuit is normality . If the st[...]

16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Joint Connector 1 3. Starter Lockout Switch 4. Fuse Box 5. ECU Fuse 15 A 6. Ignition Fuse 15 A 7. Relay Box 8. Fuel Pump Relay 9. Main Fuse 30 A 10. Starter Relay 11 . B a t t e r y 1 2 V 1 0 A h 12. Frame Ground 13. Fuel Pump 14. V ehicle-down Sensor 15. Joint Co[...]

ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Idle Gear Removal • Remove: Right Middle Fairing (see Right Middle Fairing Removal in the Frame chapter) Bolts [A] Idle Gear Cover [B] • Pull out the idle gear (starter motor side) [A] with the shaft [B]. • Remove: Clutch Cable Lower End (see Cable Removal in the Clutch chapter) Bolts [A[...]

16-50 ELECTRICAL SYSTEM Electric Starter System • Install the idle gear (starter clutch side) [A] on the shaft. • Engage the idle gear with the starter clutch gear . • Apply silicone sealant to the following portion. Crankshaft Sensor Lead Grommet [B] Crankcase Halves Mating Surfaces [C] Sealant - Kawasaki Bond (Silicon e Sealant): 9210 4-000[...]

ELECTRICAL SYSTEM 16-51 Electric Starter System Starter Clutch Removal • Remove: Starter Clutch Cover (see Idle Gear Removal) Idle Gear (Starter Clutch Side, see Idle Gear Removal) • Unscrew the starter clutch bot [A], while holding the al- ternator rotor steady with the rotor holder (see Alternator Rotor Removal). Special T ools - Grip: 57001-[...]

16-52 ELECTRICAL SYSTEM Electric Starter System • Push [A] the starter clutch gear [B] in and turn it counter- clockwise [C] and install it. • Install the washer [A]. • T ighten the starter clutch bot [B], while holding the alterna- tor rotor steady with the rotor holder (see Alternator Rotor Installation). Special T ools - Grip: 57001-1591 R[...]

ELECTRICAL SYSTEM 16-53 Electric Starter System • Disassemble the starter clutch (see Starter Clutch Disas- sembly), and visually inspect the clutch parts. One-way Clutch [A] Starter Clutch Case [B] If there is any worn or damaged part, replace it. ○ Examine the starter clutch gear [C] as well. Replace the clutch gear if it is worn or damaged. [...]

16-54 ELECTRICAL SYSTEM Electric Starter System • Remove the starter motor mounting bolts [A]. • Pull out the starter motor from the right side. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Clean the starter motor legs [A] and crankcase [B] where the star[...]

ELECTRICAL SYSTEM 16-55 Electric Starter System • Pull the armature [A] out of the yoke [B]. • Remove: Brush Plate T erminal Nut [A] Brush Plate Assembly [B] Starter Motor Assembly • Pry the spring end [A] and insert the brush [B]. • Install the brush plate assembly [A] into the right-hand end cover [B]. • Replace the O-ring [C] with a ne[...]

16-56 ELECTRICAL SYSTEM Electric Starter System • Replace the O-rings [A] with new ones. • Put the armature [B] among the brushes [C]. • Apply a thin coat of grease to the oil seal [A]. • Fit the toothed washer [B] into the left-hand end cover . • Align the marks [A] to assembly the yoke and the end covers. • Replace the O-rings [A] wit[...]

ELECTRICAL SYSTEM 16-57 Electric Starter System Brush Inspection • Measure the length [A] of each brush [B]. If any is worn down to the service limit, replace the brush holder assembly . Starter Motor Brush Lengt h Standard: 10 mm (0.39 in .) Service Limit: 5.0 mm (0.20 i n.) Commutator Cleaning and Inspection • Smooth the commutator surface [A[...]

16-58 ELECTRICAL SYSTEM Electric Starter System B r u s hL e a dI n s p e c t i o n • Using the × 1 Ω hand tester range, measure the resis- tance as shown. T erminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B] Special T ool - Hand T ester: 57001-1394 If there is not close to zero ohms, the brush lead has an open. Re[...]

ELECTRICAL SYSTEM 16-59 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Joint Connector 1 3. Starter Lockout Switch 4. Fuse Box 5. Ignition Fuse 15 A 6. Relay Box 7. Starter Circuit Relay 8. Starter Motor 9. Main Fuse 30 A 10. Starter Relay 1 1. Battery 12 V 10 Ah 12. Frame Ground 13. Joint Connector 2 14. ECU 15. Gear Positi[...]

16-60 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The hea[...]

ELECTRICAL SYSTEM 16-61 Lighting Syst em • T urn the headlight bulb [A] clockwise. • Connect the headlight connector . • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement • Remove the upper inner fairing (see Upper Inner Fairing Removal in the Fram[...]

16-62 ELECTRICAL SYSTEM Lighting System T ail/Brake Light (LED) Removal • Refer to the Seat Cover Removal in the Frame chapter (see Seat Cover Removal in the Frame chapter). T ail/Bra ke Light (LED ) Installation • Refer to the Seat Cover Installation in the Frame chapter (see Seat Cover Installation in the Frame chapter). License Plate Light B[...]

ELECTRICAL SYSTEM 16-63 Lighting Syst em Headlight/T ail Light Circuit 1. Ignition Switch 2. High Beam Indicator Light (LED) 3. Joint Connector 1 4. Right City Light 6. Headlight (High Beam) 5. Headlight (Low Beam) 7. Left City Light 8. Passing Button 9. Dimmer Switch 10. Headlight Fuse 10 A 1 1. T ail Light Fuse 10 A 12. Fuse Box 13. Relay Box 14.[...]

16-64 ELECTRICAL SYSTEM Lighting System • Push and turn the front turn signal light bulb [A] counter- clockwise and remove it. • Replace the bulb with new ones. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the soket, and turn the bulb clockwise. ○ T urn the bulb about 15° degree[...]

ELECTRICAL SYSTEM 16-65 Lighting Syst em • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○ T urn the bulb about 15° degrees. • Fit the projections [A] of the lens into the grooves [B] of the turn signal light. • T ighten: T orque - Rear T ur[...]

16-66 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit 1. Ignition Switch 2. T urn Signal Indicator Lights (Right and Left) 3. Joint Connector 1 4. Front Right T urn Signal Light 5. Front Left T urn Signal Light 6. T urn Signal Switch 7. Fuse Box 8. T urn Signal Relay Fuse 10 A 9. Main Fuse 30 A 10. Battery 12 V 10 Ah 1 1. Frame Ground [...]

ELECTRICAL SYSTEM 16-67 Air Switching V alve Air Switching V alve Operation T est • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter (see Air Suction System Damage Inspection in the Periodic Maintenance chapter). Air Switching V alve Unit Test • Remove the air switching valve (see Air Switching V alve Remova[...]

16-68 ELECTRICAL SYSTEM Radiator Fan Sys tem Fan Motor Inspection • Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor . If the fan does not rotate, the fan motor is defective and must be replaced. Radia[...]

ELECTRICAL SYSTEM 16-69 Meter , Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Screws [A] with W ashers CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction. • T ighten: T or[...]

16-70 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit (see Meter Unit Removal) [A]. [1] Ignition [2] Fuel Level W arning Indicator Light (LED) (–) [3] Stop W atch (+) [4] Lap T ime (+) [5] Neutral Indicator Light (LED) (–) [6] ECU Communication Signal [7] T achometer Signal [...]

ELECTRICAL SYSTEM 16-71 Meter , Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segments [A] appear for three seconds. If the LCD segments will not appear , replace the meter assembly . • Disconnect the terminal [1]. ○ All the LCD segments disappear . If the segments do not disappear , replace the meter as- sembly . MODE[...]

16-72 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit • In the HOUR setting mode, press the REST button to ef- fect the MINUTE setting mode. ○ The minute display flashes on the display . • Press the MODE button to set the minute. • In the MINUTE setting mode, press the REST button to return to the HOUR/MINUTE setting mode. • Press the MOD[...]

ELECTRICAL SYSTEM 16-73 Meter , Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground, using the jack. ○ T urn on the ignition switch. ○ Rotate the rear wheel by hand. ○ Check that the speedometer shows the speed. If the spee[...]

16-74 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit T achometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". ○ When the terminals are connected, the tachometer nee- dle momentary points to the last reading, and then return to the 0 position. [...]

ELECTRICAL SYSTEM 16-75 Meter , Gauge, Indicator Unit Stop W atch Check • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • P r e s st h e M O D E b u t t o ne a c ht i m et os e tt h es t o pw a t c h mode. • Connect the insulated auxiliary lead processed ins[...]

16-76 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit Neutral Indicator Light (LED) Inspection ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check.” • Using the insulated auxiliary lead, 12 V battery to the me- ter unit connector as follows. ○ Connect the battery[...]

ELECTRICAL SYSTEM 16-77 Meter , Gauge, Indicator Unit High Beam Indicator Light (LED) ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check.” • Using the insulated auxiliary lead, 12 V battery to the me- ter unit connector as follows. ○ Connect the battery positive[...]

16-78 ELECTRICAL SYSTEM Meter , Gauge, Indicator Unit Shift Up Indicator Light (LED) ○ Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (ill[...]

ELECTRICAL SYSTEM 16-79 Meter , Gauge, Indicator Unit Meter Unit C ircuit 1. Ignition Switch 2. T urn Signal Indicator Light (LED) 3. High Beam Indicator Light (LED) 4. Neutral Indicator Light (LED) 5. Fu el Level W arning Indicator Light (LED) 6. W arning Indicator Light (LED) (FI/Immobi- lizer/Oil Pressure W arning) 7. Odometer/T rip Meter/Clock/[...]

16-80 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) This motorcycle is equipped with an immobilizer system to protect th e motorcycle from theft. This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU (Electronic Control Unit). If the code does not match, ignition system, injectors[...]

ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) • Connect the key registration unit [A]. Special T ool - Key Registration Unit: 57001-1582 • Insert the master key to the ignition switch and turn it ON. Ve r i f i e d ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the registration mode (go[...]

16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Insert the user key 1 to the ignition switch and turn it ON. NOTE ○ Keep the other user key away from the immobilizer an- tenna. ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation erro[...]

ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) • T urn the user key 1 OFF and remove the user key 1. ○ The warning indicator light (LED) [A] blinks to display the registration mode. NOTE ○ T urn off the ignition switch and wait for the period of 15 seconds or more. The registration mode automatically finishes and the warning ind[...]

16-84 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • The user key 2 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks 3 times and stops for 1 second and then repeats this cycle. ○ This procedure has registered the master key and 2 user keys. • Continue with the procedure to reg[...]

ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) Spare User Key Regis tration Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Case 2: When the ignition switch is faulty and to be replaced. • Prepare a new ignition switch [A] and two new user keys [B]. ○ These parts are available as a set. Prepare the curre nt master key [C]. • Remove: Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts [...]

ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) Not V erified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation e rror . Immobilizer Amplifier Failure Master Key Collation Error • T urn OFF and remove the new user key 1. • T emporarily place the antenna [A] on the new ignition [...]

16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error . Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error • The user key 1 is successfully reg[...]

ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error . Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error • The user key 2 is successfully reg[...]

16-90 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector . NOTE ○ T urn the ignition switch ON with the registered user key . ○ Check that the engine can be started using all regis- tered user keys. • Install the new ignition switch and[...]

ELECTRICAL SYSTEM 16-91 Immobilizer System (Equipped Models) • The master key is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key . • T urn OFF the master key and remove it. ○ The[...]

16-92 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) User Key Collation Error • The user key 1 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 2 times and stops for 1 second and then repeats this cycle to indica te successful registration of user key . • T urn OFF and remove th[...]

ELECTRICAL SYSTEM 16-93 Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 2 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of u[...]

16-94 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE ○ The key registration unit is not required. ○ The key registration process is same as the electric con- trol unit replacement. Case 5: When replacing the antenna. • Prepare a new antenna. • Refer to the[...]

ELECTRICAL SYSTEM 16-95 Immobilizer System (Equipped Models) All Keys Initial Registration F low Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-96 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replac ement Immobilizer Antenna • Remove the left middle fairing (see Middle Faring R e- moval in the Frame chapter). • Disconnect the lead connectors [A]. • Remove: Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter) Handlebar (see [...]

ELECTRICAL SYSTEM 16-97 Immobilizer System (Equipped Models) ECU (Electric Control Unit) Replacement (for Immobi- lizer Models) • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Relay Box [A] • Using a small chisel or other suitable tool, cut off the screws [A]. • Remove: Upper Guard Bracket [B] Lower Guard Bracket [C] • [...]

16-98 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Install: Lower Guard Bracket [A] Upper Guard Bracket [B] CAUTION Do not pinch the leads. • T ighten new screws [C] use Kawasaki genuine screws of which threads are coated with locking agent. Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master Key (Red) User Key[...]

ELECTRICAL SYSTEM 16-99 Immobilizer System (Equipped Models) Immobilizer System Circuit 1. Ignition Switch 2. Immobilizer Antenna 3. Meter Unit 4. Immobilizer Amplifier 5. Joint Connector 1 6. Fuse Box 7. ECU Fuse 15 A 8. Ignition Fuse 15 A 9. Main Fuse 30 A 10. Starter Relay 1 1. Battery 12 V 10 Ah 12. Joint Connector 2 13. Joint Connector 3 14. I[...]

16-100 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Peri[...]

ELECTRICAL SYSTEM 16-101 Switches and Sensors Water T emperature Sensor Insp ection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged. • Suspend an accura[...]

16-102 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove: Bolt [A] Speed Senor [B] Speed Sensor Installation • Apply grease to the new O-ring [A]. • Set the speed sensor bolt [B]. • T ighten: T orq ue - Speed Sensor Bolt: 10 N ·m (1.0 k gf·m, 89 in ·lb) • Install the removed parts (see appropriate chapte[...]

ELECTRICAL SYSTEM 16-103 Switches and Sensors • Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter). • Connect the test light (12 V 3.4 W bulb in a socket w ith leads) and the 12 V battery to the fuel pump connector as shown. 12 V Battery [A] T est Light [B] Fuel Pump Connector [C] Fuel Reserve Switch [D] If the test l[...]

16-104 ELECTRICAL SYSTEM Switches and Sensors • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine T op End chapter) Oxygen Sensor #2 [A] Oxygen Sensor Installation (Europe Models) CAUTION Never drop the oxygen sensor [A], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B][...]

ELECTRICAL SYSTEM 16-105 Switches and Sensors • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel T ank Re- moval in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect: W ater T emperature Sensor Connector [A] Gear Position Switch Lead Connector [B] • Remove:[...]

16-106 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Inspection NOTE ○ Be sure the transmission mechanism is good conditio n. • Remove the fuel tank (see Fuel T ank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Set the hand tester [A] to the 1 k Ω or × 100 Ω range and connect it to the termi[...]

ELECTRICAL SYSTEM 16-107 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove the front seat (see Front Seat Removal in the Frame chapter). • T ake out the relay box [A] and disconnect the co nnectors [B]. Relay Circuit Inspection NOTE ○ The ECU main relay function is included[...]

16-108 ELECTRICAL SYSTEM Relay Box Relay Circuit I nspection (wi th the battery connected) Battery Connection (+) (–) Te s t e r Connection Te s t e r Reading ( Ω ) Fuel Pump Relay 6- 7 4-5 0 Fan Relay 15-16 14-17 0 Battery Connection (+) (–) T ester Connection DC 25 V Range Te s t e r Reading (V) Starter Circuit Relay 13-9 8-9 Battery Vo l t[...]

ELECTRICAL SYSTEM 16-109 Relay Box Relay Box Internal Circuit A. Headlight Relay B. Fuel Pump Relay C. Starter Circuit Relay D. Fan Relay www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

16-1 10 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) 30 A Main Fuse Connector [A] • Pull out the main fuse [A] from the starter relay with needle nose pliers. Fuse Box Fuse Removal • Remove the front seat [...]

ELECTRICAL SYSTEM 16-1 1 1 Fuse • Pull the ECU fuse [A] straight out of the fuse box with needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • Install the junction box fuses on the original position as specified o[...]

www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-1 17 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 17-2 T roubleshooting Guide ........................................................................................................... 17-30 www.zxforums.com www.zxforums.com www.[...]

17-2 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clamp 3. Meter Connector 4. Clamp the right switch housing lead. 5. Right Switch Housing Lead 6. City Light Connector 7. Right Headlight Connector 8. Right T urn Signal Light Connector 9. Clamp the right turn signal light lead (Other than California Model only). 10. Heat Pad 1 1. Run[...]

17-4 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Throttle Cable (Accelerator) 2. Throttle Cable (Decelerator) 3. Run the throttle cables above the harness and hose, and under the ignition switch lead. 4. Clutch Cable 5. Clamp 6. Throttle Cables 7. Viewed A 8. Through the clutch cable into the bracket. 9. Through the clutch cable into the engine brack[...]

17-6 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Right Headlight Connector 2. Right City Light Connector 3. Right T urn Signal Light Connector 4. Right Switch Housing Lead 5. Clamp the right switch housing lead. 6. Horn 7. Engine Subharness Joint Connector (T o the Throttle Assy) 8. Inlet Air T emperature Sensor (T o the Air C leaner Box) 9. Starter [...]

17-8 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Battery Positive (+) T erminal 2. Relay Box 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Fuse Box 5. T urn Signal Relay 6. Right T urn Signal Light Connector 7. T ail/Brake Light Connector 8. Clamp (The clamp attached on the main harness.) 9. License Plate Light Connector 10. Left T urn Signa[...]

17-10 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17 -1 1 Cable, Wire, and Hose Routing 1. Left City Light Connector 2. Meter Connector 3. Clamp 4. Headlight Connector 5. Clamp 6. Run the fan motor lead connector above the main harness. 7. Immobilizer Amplifier 8. Joint Connector for the stick coil and air switching valve leads (Install it into the bracket). 9. Clamp (The clamp attached o[...]

17-12 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Insert the radiator coolant return hose to the corner portion of the radiator pipe. 2. Clamp 3. Radiator Overflow Hose 4. Clamp 5. Run the radiator coolant return hose inside the engine mount. 6. Clamp 7. Clamp 8. Clamp 9. Radiator Hose 10. Clamp 1 1. Install the clamp so that the clamp and the crankc[...]

17-14 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Clamp 2. Air Cleaner Drain Hose 3. Breather Hose 4. Joint Connector (W ater T emperature Sensor Lead, Gear Position Sensor Lead, Speed Sensor Lead, and Oil Pressure Switch Lead) 5. Right Side 6. Front 7. Rear 8. Left Side 9. Clamp 10. Clamp 1 1. Radiator Hose 12. Clamp 13. Face the paint mark to the f[...]

17-16 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Stick Coil #1 2. Stick Coil #2 3. Stick Coil #3 4. Stick Coil #4 5. Air Switching V alve 6. Evaporative Hose (White) 7. Evaporative Hose (Green) 8. Clamp 9. Through the crankshaft sensor lead into the clamp (attached on the air switch ing valve). 10. Crankshaft Sensor Lead Connector 1 1. Through the c[...]

17-18 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Install the air switching valve after i nstalling the heat insulation rubber plate. 2. Throttle Body Assy 3. Hang down the shaded portions of the heat insultaion rubber plate. 4. For Left Engine Bracket Bolt 5. For Radiator 6. For Air Suction V alve C overs and Stick Coils 7. For Right Engine Bracket [...]

17-20 APPENDIX Cable, Wire, and Hose Routing 1. Heat Insulation Rubber Plate 2. Run the starter motor cable into the hole of the heat insulation rubber plate. 3. Run the starter motor cable under the adjusting collar . 4. Engine Ground Cable 5. Install the engine ground cable as shown. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums[...]

APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Ignition Coil Lead 2. Run the ignition coil lead. 3. Do not pinch the ignition coil lead. 4. Idle Adjusting Cable 5. Radiator Hose 6. Install the idle adjuster screw direction as shown. 7. Clamp 8. Viewed A 9. Speed Sensor 10. Align the clamp with the speed sensor . www.zxforums.com www.zxforums.com w[...]

17-22 APPENDIX Cable, Wire, and Hose Routing 1. Fuel T ank Drain H ose 2. Run the drain hose inside the radiator hose. 3. Run the drain hose inside the water hose. 4. Put the hose through the cut hole of the under fairing. 5. Radiator Hoses 6. W ater Hose www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxfor[...]

APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Air Switching V alve 2. Face the paint mark upward. 3. Air Switching V alve Hose 4. T o the fitting of the holder assy . 5. Holder Assy 6. Clamp 7. Throttle Body Assy 8. T o the Radiator 9. Install the starter cover bolt with the clamp. 10. Run the water hose through the clamp. 1 1. W ater Hose 12. In[...]

17-24 APPENDIX Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hos e 2. Clamp 3. Clamps 4. Brake Hoses 5. Face the paint mark outside. 6. Viewed Right Side 7. Viewed Left Side 8. Brake Hos e 9. Rubber Dumper 10. Clamps 1 1. Brake Hose 12. Face the paint mark outside. 13. Viewed A www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforu[...]

17-26 APPENDIX Cable, Wire, and Hose Routing California Model www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com[...]

APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Front 2. T o the Fuel T ank 3. Hose (Blue) 4. Hose (Red) 5. Hose (White) 6. T o the fitting of the Throttle Body #3 (Run the hose over the subthrottle valve actuator connector .) 7. Hose (Green) 8. T o the fitting of the Throttle Body #4 (Run the hose under the harness.) 9. Bolt 10. Clamp 1 1. Band 12[...]

17-28 APPENDIX Cable, Wire, and Hose Routing California Model 1. Fuel T ank 2. Clamps 3. Hose (Red) 4. Canister 5. Clamp 6. T o the Fitting of the Throttle Body #3 7. T o the Fitting of the Throttle Body #4 8. Clamps 9. Throttle Bodies 10. Hose (Blue) 1 1. Hose (Blue ) 12. Separator 13. Hose (Green) 14. Hose (White) 15. Fitting 16. Hose (Green) www[...]

APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Adjusters 2. Closing Cable 3. Y ellow 4. Dark Green 5. Rear Frame 6. Dust Covers 7. Opening Cable 8. Clamp 9. Exhaust Butterfly V alve Actuator 10. 41.7° ±7° (Original Position of Pulley) 1 1. Right Side 12. 6 mm (0.24 in.) 13. Close 14. Open 15. Exhaust Manifold 16. Clamp 17. Viewed Right Side 18.[...]

17-30 APPENDIX T roubleshooting Guide NOTE ○ Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting [...]

APPENDIX 17-31 T roubleshooting Guide No valve clearance Cylinder , piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged V alve spring broken or weak V alve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other: I[...]

17-32 APPENDIX T roubleshooting Guide Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect: Oil cooler clogged Gauge incorrect: W ater temperature gauge broken W ater temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Wrong coolant mixed ratio [...]

APPENDIX 17-33 T roubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating (KLEEN) Abnormal Drive T rain Noise:[...]

17-34 APPENDIX T roubleshooting Guide Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder sc[...]

MODEL APPLICA TION Y ear Model Beginning Frame No. 2006 ZX1000D6F JKAZXCD1 □ 6A000001 JKAZXT00DDA000001 ZXT00D-000001 □ :This digit in the frame number changes from one machine to another . Part No.99924-1365-02 P r i n t e di nJ a p a n www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zx[...]