2009 Ninja ZX-10R Racing Kit Manual
Contents
1. 21 Tra SII coc oer bnt P P e 27 Changing Tre Sm DE Z uuu uha ode bales ebsites Qata 28 tus vo aV a PUE Val uuo uve vete use Suv Pu Vasa E reed 29 RR ERROR ERE EE RR ERG REED Ra garda aM abd a a do 33 Water Temperature Sensor E RR VER EV EN AER ae 33 Radiator Kit aco e ea ied 33 Oil Catch TAAK ud 38 Gover Gaskels Kit a aQ aaa qaa 42 ECU Kit e 42 Frame Parts Installation aa ado o abel 43 FAOS PASARI cc 43 Final Drive Parts CII sis Ss Si m SEED SD ED ay aya 44 Brake Pads aa bs 45 Steering Damper eto optet pto at apti antes 45 46 Front Fork Springs Ki set slated iat eh ee ae 48 Electric Paris lnstalldlOE uito eo qu 50 LEID ELI LLENAS I Oey mara 50 Main Harness and Sub Harness Kit t t EE EE E RD EOD 50 Meter Kit Installation de eee ered tec tester eter ee tree2. l gt SN UG Y 4 Y A J OCT 31 2008 This catalog covers 08 09 ZX1000 ESFR E9FR Engine E1230 13116A a m 12048 s ee a lt EAM oo 29 92055 Z 4 92153 92153 GRID This grid covers Camshaft s Tensioner Ref Part No No art No 12046 12046 0034 OPTION 12048 0028 OPTION 13116 1160 OPTION 13116 1166 OPTION 49118 0045 OPTION 12048 13116 13116A 49118 49118A 49118 0134 OPTION 92015 1078 OPTION 92055 0053 OPTION 92055 011 OPTION 92153 0455 OPTION 92015 92055 92055A 92153 Description SPROCKET 32T TENSIONER ASSY ROD PUSH ROD PUSH CAMSHAFT COMP EXHAUST CAMSHAFT COMP INTAKE NUT FLANGED 6MM RING O 20 8X1 9 RING O 5MM BOLT FLANGED 6X8 OCT 31 2008 Spec Code Quantity ZX1000 e This catalog covers 08 09 ZX1000 ESFR E9FR Engine Co 13008 2 13002 ps 13001 13251 92139 A B ENS CHINE 92139J M 92139 A B 921396 E 0 92139 4 OQ a 92139C E Qao GRID NO This grid covers Crankshaft Piston s E1320 Ref Part No No art No 13001 13001 0100 OPTION 13002 0013 OPTION 13008 0034 OPTION 13251 0015 OPTION 92015 1311 OPTION 13002 13008 13251 92015 92033 92033 1161 OPTION 92139 0109 OPTION 92139 0110 OPTION 92139 0111 OPTION 92139 0146 OPTI
3. groove one Identification groove enlarged Identification thread 1067008W5 C Input 3rd 4th Gear Selection Table 4th Gear A B 13262 0630 13262 0665 STD 13262 0631 3rd B 13262 0633 13262 0632 13262 0634 Gear 13262 0638 13262 0637 13262 0639 D 13262 0641 13262 0640 ES Gear Identification Slit Number Table TypeD TypeG Input 1 2 3 4 0 STD 5 Output 1 2 3 4 0 STD Input 1 STD 0 3 2 2nd Output 0 STD 1 3 2 3rd Input 1 STD 2 0 3 Output 0 STD 1 2 3 Input 1 0 STD 2 Ath STD Output 1 0 STD 2 Input 2 0 1 STD 2 5th npu STD Output 2 1 0 STD 3 Gth Input 0 STD 1 2 3 5 6 Output 2 STD 1 0 3 2 STD 1 Engine Sprocket 13144 0021 520 16 13144 0022 520 17 Shift Drum For 2009 model ZX 10R kit parts the racing shift drum 13141 0048 is available to improve reliability of shifting and reverse shifting Reverse shifting is available on exchange of shift drums and reliability of shifting is improved however touch of shifting becomes slightly heavier Racing Kit Service Data Item Standard Cylinder Head Valves Valve timing Duration Intake 292 Exhaust 280 Cams
4. Retainer Height Total thickness of clutch plates 1064498W2 C The standard setting of length A total thickness of clutch plates shown below becomes about 53 5 mm t 2 9 x 7 pcs t 2 6 x 2 pcs For this setting the effective stroke of clutch spring plate during the back torque limiter operation is adjusted between 0 45 and 0 75 mm By increasing the effective stroke the back torque limiter causes more slip The effective stroke increases by decreasing the length A The length A between 51 9 and 53 5 mm is available by changing the combination of the steel plates Replace one steel plate with a thinner one and try the setting If the operation of the back torque limiter is not enough replace other steel plates one by one Thickness mm Part Number 2 3 13089 0008 STD 2 6 13089 0009 STD 2 9 13089 1093 STD 21 When decreasing the length A total thickness of clutch plates use the kit spring retainers provided as optional production parts to keep the preload of clutch springs according to the table below Length A Part Number Height H 53 0 53 5 mm 13091 1840 STD 8mm 1 F 52 5 52 9 mm 3091 1041 Washer 92022 304 7 mm 6 mm 1 mm 39108 0005 7 mm 51 9 52 4 mm 13091 1041 6 mm f you have clutch slip during acceleration use shorter spring retainers by one size to increase preload of clutch springs 22 F
5. 5 x lt lt ff ss rege 33 gees Meter Unit erez 1 Turn Signal Indicator Light LED 2 High Beam Indicator Light LED 3 Neutral Indicator Light LED gt 4 Level Warning Indicator Light LED 5 Warning Indicator Light LED 8 0dometer Trip Meter Clock Stop Watch Coo 7 Water Temperature Meter 8 Tachometer 9 Speedometer 10 Tlumination Light LED 11 Shift Up Indicator Light LED Meter Unit ES BR R o LL n d BR Sy 0 M LED Light Emitting Diode ee ligniton 1541 Ex BK Y R G omar BK W BK Y aY R BK BL Y BK BK R BR Horn Button 2 Passing Button 3 Turn Signal Switch 4 Dimmer Switch ie Ni 5 Starter Lockout Switch ON 6 legu l SM gt rere 5 5555 28 Baa Rev Spike Control gt Frame Starter Morot Battery 12V10Ah 1088868W5 C Starter Relay 56 Sub throttle Sub Valve throttle Throttle Actuator Sensor 5 Sensor BL BR BK Y BL 5 2 zt aos ExXal Seer zaz 2 M lt 25 dr uris B 9 55458 5 Sas 3522 A i Shift Sensor SW ESI G BK BK Y Inlet Air Pressure Water Tempereture Sensor Speed 2 Sensor 5 g a BL it BR 0 BL Y
6. 1 Guard 55020 0028 2 Bolt 130BB1020 3 Swingarm Left Side Brake Pads Kit The front and rear brake pads for racing use are available The front pads are for higher braking force and the rear pads are for lower braking force Front Brake Pads P No Stamp Braking Force 43082 0088 F9633 High t Original C93YW Low Rear Brake Pads P No I D Stamp Braking Force Original FO GG High 43082 1220 with Yellow Paint t 43082 1192 without Yellow Paint Low Steering Damper Kit For race usage it is recommended to use racing type steering damper see next page since the original damper is mainly designed for street riding or at most sport riding When install the racing type steering damper please make sure that the damper shall not limit the steering angle as normally stipulated by the race regulations 45 1 Recommended Steering Damper OHLINS SD100 Stroke 120 mm Install the steering damper as shown in the figure below 1068738W5 C 1 Steering Damper OHLINS SD100 5 O ring 670B2012 2 Holder 13280 0291 6 Bolt 132BA0635 3 Boss 13061 0292 Bolt 132BA0825 4 Washer 410AA0800 Weld the boss 3 to the original bracket 32190 0196 by referring to the figure below S106674BW5 C Seat Height Adjustment Loosen the nut 1 and insert the spacer 2 as required Tighten the nut 1 to 59 N m 6 0 kgf m 43 ft lb of torque O
7. 2009 Ninja ZX 10R Racing Kit Manual This manual contains only the information of the racing kit parts Refer to the base Kawasaki Ninja zx 10R manual listed below for information of the original model Base Manual Part Number Ninja ZX 10R Motorcycle Service Manual 99924 1388 02 2008 Kawasaki Heavy Industries Ltd First Edition 1 Nov 25 2008 Congratulation on your purchase of racing kit parts for the 2009 Ninja ZX 10R IMPORTANT This manual provides how to install racing kit parts for the 2008 Ninja ZX 10R and how to tune up basically As for the basic knowledge refer to the base Service Manual for the Ninja ZX 10R P No 99924 1388 02 When you participate in a race it is necessary to modify the machine for the regulation So we want you to ask for the tuning up shop A WARNING AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE IT SHOULD NOT BE USED ON PUBLIC STREETS ROADS OR HIGHWAYS THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE CAUTION When operating the engine be careful not to trouble persons with noise Do not turn the engine with loud engine and exhaust noise DISCLAIMER OF WARRANTY ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED BASIC WORKS IN INSTALLING KIT PARTS We are going to make up the original Ninja ZX 10R for the racing machine
8. Pinch the terminal of the kit water temperature sensor ground lead 26011 0071 between the water hose and the kit water pipe and clamp it on the hose as shown in the illustration Install the other side terminal of the ground lead with the starter cover by the bolt To Meter 26011 1779 R Engine 39192 0011 To Starter Gover Bolt ey 51067088 2 C Water Outlet of Radiator Body Same situation of the original radiator Use the kit sub radiator with the main radiator Water Inlet of Radiator Body Divide the original water hose 39062 0256 between the cylinder head and the radiator and insert the water pipe 39192 0093 Install the kit water temperature sensor for water temperature gauge of kit meter 21176 1099 to the kit water pipe Pinch the terminal of the kit water temperature sensor ground lead between the water hose and the kit water pipe and clamp it on the hose as shown in the illustration Install the other side terminal of the ground lead with the starter cover 36 16 Meter To Radiator 26011 1779 x To Engine Starter Cover Bolt lt 26011 0071 S106709BW5 C Water Outlet of Main Radiator Remove the original water pipe 39192 0089 and install the kit water pipe 39192 0092 Install the kit water hose 39062 1617 between the water pipe and the kit sub radiator Remove the hose 39062 0228 between the water p
9. HOLDER STEERING DAMPER SWITCH SPEED CONTROL PIPE COMP GRIP CASE UPP CASE LWR GRIP THROTTLE HOUSING ASSY CONTROL RH CABLE THROTTLE OPENING CABLE THROTTLE CLOSING REEL R21 5 60DEG REEL R20 0 65DEG DAMPER SPEED CONTROL BOLT SOCKET 6X25 BOLT FLANGED SMALL 6X35 BOLT FLANGED SMALL 8X25 SCREW PAN CROSS 5X22 WASHER PLAIN SMALL 8MM O RING 12MM OCT 31 2008 This catalog covers 08 09 ZX1000 E8FR E9FR Chassis 59101 32099A 32099 T 120 NS X es CN 132A N NN N wD e VA Sy TES ON 132 13280 132A 31064 54012 54012 GRID NO This grid covers Handlebar ZX1000E9FR Ref No 13061 13280 27010 31064 32099 32099A 46091 54012 59101 59101A 92160 120 132 132A 220 410 670 20 Part No 13061 0292 OPTION 13280 0291 OPTION 27010 0040 OPTION 31064 0187 OPTION 32099 0046 OPTION 32099 0047 OPTION 46091 1809 OPTION 54012 0276 OPTION 59101 0008 OPTION 59101 0009 OPTION 92160 1625 OPTION 120CA0518 OPTION 132BA0635 OPTION 132BA0825 OPTION 220AB0522 OPTION 410AA0800 OPTION 67082012 OPTION Description BOSS HOLDER STEERING DAMPER SWITCH SPEED CONTROL PIPE COMP GRIP CASE UPP CASE LWR HOUSING ASSY CONTROL RH CABLE THROTTLE REEL R19 7 65DEG REEL R21 4 60DEG DAMPER SPEED CONTROL BOLT SOCKET 5X18 BOLT FLANGED SMALL 6X
10. AR This catalog covers 08 09 ZX1000 ESFR E9FR Engine E1361C 92200D G lt Bs AE Ww Or ki 13144A J 922000 6 13262C E IW SA 13262A 13262D GRID This grid covers Transmission TYPE D Ref Part No No art No 13127 13127 0043 OPTION 13144 0021 OPTION 13144A 13144 0022 OPTION 13262 0279 OPTION 13262A 13262 0626 OPTION 13144 13262 13262B 13262 0629 OPTION 13262C 13262 0644 OPTION 13262D 13262 0651 OPTION 13262E 13262 0654 OPTION 13262F 13262 0660 OPTION 92200 92200 0225 OPTION 92200A 92200 0226 OPTION 92200B 92200 0227 OPTION 92200C 92200 0228 OPTION 92200D 92200 0229 OPTION 92200E 92200 0230 OPTION 92200F 92200 0231 OPTION 92200G 92200 0232 OPTION Description Spec Code SHAFT TRANSMISSION INPUT 16T SPROCKET OUTPUT 16T 520 SPROCKET OUTPUT 17T 520 GEAR INPUT 2ND 18T GEAR OUTPUT LOW 37T GEAR OUTPUT 2ND 36T GEAR OUTPUT 3RD 36T GEAR OUTPUT 5TH 30T GEAR INPUT 6TH 22T GEAR OUTPUT 6TH 28T WASHER 28 1X34 0X0 8 WASHER 28 1X34 0X1 0 WASHER 28 1X34 0X1 4 WASHER 28 1X34 0X1 6 WASHER 28 3X34 0X1 2 WASHER 28 3X34 0X1 4 WASHER 28 3X34 0X1 8 WASHER 28 3X34 0X2 0 OCT 31 2008 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR This catalog covers GRID This grid covers 0
11. Crankshaft Main Journal Bushings The kit bushings are improved in anti seizuring characteristics as well as in wear resistance as compared with the standard bushings Crankshaft Main Journal Clearance When adjust the clearance by measurement in case aiming the clearance 0 035 mm Crankshaft Main Journal Diameter Marks None 34 984 34 992 mm 1 34 993 35 000 mm 6105280851 C 16 Crankcase Main Bearing Inside Diameter Marks Be None 38 009 38 016 mm 38 000 38 008 mm Mark portion 1 5 A Color Mark ELA 2 N78 H Rr Set THHE 5106688851 C amp A Crankshaft Main Journal Bushings Kit Bushing Kit Bushing Standard Sangara Color 1 35 42 4 Bushing Bushing Thickness m 1 3 5 2 4 Blue 92139 0146 92139 0149 92139 0217 92139 0032 1 499 1 503 mm Black 92139 0147 92139 0150 92139 0218 92139 0033 1 495 1 499 mm Brown 92139 0148 92139 0151 92139 0219 92139 0034 1 491 1 495 mm Crankshaft Main Journal Bushing Selection Crankshaft 1 1 None None Crankcase O None O None Crankshaft Main Journal Bushing Brown Black Blue Clearance recommend 10 34um 10 34um 10 34um NOTE O Make the clearances between the crankshaft main journals within the prescribed allowances Excessive clearances will cause the oil pressure at the crankshaft main jo
12. BK Y CMN T q T K BL R 0 8 0 BK Y BR Y Color Code BK Black BL Blue BR Brown 55 255 5 55 555555 4555 555 Green ae 5 cs i i Fan ann GY Gray LB Light Blue E EL den inter tees LG Light Green 55 B Diagnositic 0 Orange Atmospheric System Venicle Pes Pressure Connect or Pink DI Sensor Sensor Pump PU Purple Fuel Relay R Red Reserve 4 Switeh Cual Violet ue W White Pump Y Yellow S106685BW5 C 55 Wiring Diagram with Original Meter Assembly Secondary Fuel Camshaft Postion Sensor Injectors Primary Fuel Injectors Indicator Light S EA Left Switch Housing Lap Time Button 1 2 3 a4 1 2 4 i 1 Front Brake a gt Light Switch 22 22 25 z2 zi RS cil zz 2 Engine Stop 2 Switch 3 Starter Button 4 Stop Watch cast Button Inlet Air panes Temperature rankshaft Spark Plugs Sensor Sensor sake L iiio 5 o r Hi 1 Subharness ford dors te at SUR 2 RT At Coils Sy gal 4 5565 e gt x
13. FS O3 2 Inlet Air Crankshaft Temperature Sensor Sensor gt m X mM NE 2 Engine Subharness gt PPEN 55555 lt Back gt gt X z 5 Tachometer Indicator Light Igniton lFuse 15al e cie BK Y Rev Spike Control BK Y BK Y BK Y BK Y N Frame Ground Starter Morot Starter Relay Battery 12V10 h 81066884845 C 54 Sub Main ab throttle Throttle Inlet Air Sear Position Sensor Sensor Sensor Pressure Water Sensor Tempereture Sensor oil 5 Spara Pressure ensor switch ws FEES t a 58 ae gt Regulator a E Rectifier Meee Rater Shift EXZSR Sensor 54 5 2525 wots 5 E 253282 222 E 55 Engine 38 Subharness Saage 1 x x 55 moin mp ECU BK BL BL Y 8 G W BL Y Y R BR W R Y BK Y Y BK P R BK R o Y W BL W Y BL R BL BK BR W 18 BR BK LB G BK R amp BK Y BL BK BL G 0 8 BL Y BK BK 8 Y R BK R BR
14. x 5 5 91 Position G R La BK Y wy Engine Subhaeness Sensor Regulator Rectifier Alternator BK BL ECU wY LG 8K BK Y 8 BL Y G BR BK BK R Fuel Reserve Switch BK W BK Y Vehicle down Sensor BR Y R BR W 8 Fuel Pump Relay BR W BR W BR W BR W BR W BR W ZA BR BK BL Atmospheric Pressure Sensor E R Y BK Y BR W Kawasaki Diagnositic System Connector LB BR R a BK BK Y BL BK BL G 0 8 BL Y BK R BL BK G X 9 R BK R BR BK Y 0 BK BL R O R 0 Y BK W BR Y Color BK Black BL Blue BR Brown 5520 6 ST GY Gray LB Light Blue Interface LG Light Green Box Orange Pink Purple Red Violet White lt lt gt lt slo Yellow 51086887845 C Dummy page 58 Racing Kit Parts List GRID This grid covers valves Spec Code This catalog covers 08 09 ZX1000 ESFR E9FR Engine E1210 Ref Part No D ipti No art No escription 12004 12004 0038 VALVE INTAKE 8 8 OPTION 12032 12032 0002 TAPPET 16 16 OPTION gt a Uu
15. 1 488 mm Brown 92139 0205 1 478 1 483 mm Pink 92139 0206 1 473 1 478 mm A Color Mark S106447BS1 C Connecting Rod Big End Bushings KIT Con rod Color ali Thickness Number Blue 92139 0109 1 488 1 493 mm Black 92139 0110 1 483 1 488 mm Brown 92139 0111 1 478 1 483 mm Pink 92139 0156 1 473 1 478 mm A Color Mark 9100173881 0 Big End Bushing Selection Crankshaft O O None None Connecting Rod None O None Bushing Brown Black Blue Clearance recommend 34 60 um 32 58 um 30 56um Use the pink bushings when the clearances cannot adjusted within the prescribed allowances even if the brown bushings are used Original Con rod Pink Bushing 92139 0206 Kit Con rod Pink Bushing 92139 0156 NOTE Make the clearances between the connecting rod big ends within the prescribed allowances Excessive clearances will cause the oil pressure at the connecting rod big end to drop and lead to the damage of the bearing 20 Clutch Adjustment Back Torque Limiter Setting The Ninja ZX 10R engine is equipped with the Kawasaki back torque limiter mechanism in the clutch The back torque limiter works to reduce the chance of rear wheel hop caused by heavy engine braking and down shifting The back torque limiter operating condition can be changed by changing the total thickness of clutch plates and changing the number of leaf springs Try different settings and select the best
16. 11004 0026 0 65mm STD KIT None 11004 0052 0 60 mm KIT Blue 11004 0022 0 55 mm KIT Red 11004 0034 0 50 mm KIT White 11004 0023 0 45 mm KIT Yellow SQUISH 1 7 5 PISTON TOP 106127BW2 C 15 Pistons Kit Piston 13001 0100 SB Kit pistons are exclusive the two piston rings for reduce the compression height between the center of piston pin hole and the shoulder of the piston and the mechanical friction loss Kit piston has more reduced the weight compared the original piston Use the kit piston together with the kit connecting rod and the kit intake valve Use the kit piston rings and kit piston pins To adjust the cylinder compression to 14 5 use the kit pistons and grind off the cylinder head under surface to 0 4 mm O Always use the higher octane rating gasoline for prevent the knocking When replacing the kit pistons with the original pistons inspect the squish refer to the Cylinder Compression section 13001 0100 51066588 5 C Note Use the kit pistons 13001 0100 following below Use the kit connecting rod assemblies 13251 0015 O Use the kit intake valve 12004 0038 O Use kit piston pin 13002 0013 and the snap ring 92033 1161 Use the kit piston rings 13008 0034 There the machining edges for the valve relief portions of the piston heads Must be hand finished for smooth corners Round the corner to R1
17. 1546 Kit 7 Bolt 92150 1717 Standard 29 106292BW2 C Stator Installation The stator is fixed to the cover by the bolts Run the alternator lead from the inside of the cover as shown in the illustration 106293BW2 C A Fix the stator to the cover by the bolts 30 Regulator Installation Use the kit alternator and the kit regulator 21066 0010 as a set On installing modify the standard regulator bracket by referring to the figure as shown and connect the regulator to the bracket with the bolts 130AA0625 and nuts 92015 1339 Connect the kit sub harness 26031 0323 between the kit regulator and the kit alternator To Alternator Possible 0 oppsite down TO Main Harness Harness 26031 0323 4 K 1 _ E Bracket 11054 1960 SI06706BW5 C 31 2 In case of without Starter Motor Remove the related parts of the starter motor and insert the plugs to the hole of the starter motor inserted as shown in the illustration L d 1066908W4 C 1 Remove the parts 32 Part Name Part No Remark 1 Plug 92066 1332 Kit 2 Plug 92066 1333 Kit 3 O ring 92055 1262 Kit 4 Bolt 130BA0625 Kit 5 Nut 312AA0600 Kit e Calk the bolt for unplug the plug Insert the plug into the hole of the starter motor and tighten the nut Ap
18. 35063 0570 O When using a kit generator cover insert the collars 92027 3705 between the stay 35063 0568 and the generator cover 14031 0063 O When using an original generator cover the collars are not necessary 92027 3705 35063 0568 92027 3705 39063 0568 14031 0063 51066938 5 C 34 Connect the main radiator and sub radiator with the bolt 130BB0622 and nut 92015 3767 Fix the radiators on the center stay 35063 0570 with the bolt 130BB0622 and also on the left and right stay with the pins and R pins S106661BW5 C Dampers 92075 1123 Collars 92027 194 Bolts 130BB0622 Nut 92015 3767 com Fix a wire netting in front of sub radiator for prevent the fin damages due to the stepping stone Machine the original cowl to meet the outline of radiator Fill the space between the cowl and the sides of radiator by fixing a sponge or the like NOTE O After radiator s installation be sure to check that there is no interference between the radiator and the manifold tire and the front fork full bottomed 35 Water Pipe Installation Use the main radiator only Divide the original water hose 39062 0256 between the cylinder head and the radiator and insert the water pipe 39192 0011 Install the kit water temperature sensor for water temperature gauge of kit meter 21176 1099 to the kit water pipe
19. Original camshaft Original camshaft 110 102 When the long bolt holes are used Kit camshaft Kit camshaft When grinding the cylinder head bottom surface grinding the cylinder top surface using thinner gaskets be sure the valve to piston clearance especially When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly 12 Valve to Piston Clearance Min Intake 0 7 mm Exhaust 1 2 mm If the valve to piston clearance is less than the minimum value do not start the engine because the valves will touch the piston and the engine may be damaged Adjust the valve timing again to keep the valve to piston clearance more than the minimum value Method of measuring clearance of valve and piston 1 Holding the crankshaft at 10 ATDC intake and 10 BTDC exhaust of crankshaft timing measure the amount of the tappet movement until the valve comes in contact with the piston pushing the tappet IN 10 10 BTDC 5106122803 C Method of measuring clearance of valve and piston 2 Adjust the valve clearance and valve timing Remove the cylinder head and put a small piece of modeling clay on the hollow of piston to prevent valve from coming in contact Install the cylinder head and adjust th
20. SUB RAD 1 1 OPTION 39060 39060 0063 RADIATOR SUB 1 1 OPTION 39062 39062 0103 HOSE COOLING PIPE W PUMP SUB 1 1 OPTION 39062A 39062 1104 HOSE COOLING SUB 1 1 OPTION 39062B 39062 1617 HOSE COOLING RADIATOR UPP LWR SUB 1 1 OPTION 39192 39192 0011 PIPE WATER 1 1 OPTION 39192A 39192 0092 PIPE WATER LH SUB 1 1 GIUM OPTION 350638 391928 39192 0093 PIPE WATER RH SUB 1 1 OPTION 92171 49085 49085 1078 CAP ASSY PRESSURE 1 1 OPTION 92015 92015 3767 NUT 6MM SUB 1 1 OPTION 92027 92027 194 COLLAR L 11 1 SUB 2 2 OPTION 92027A 92027 3705 COLLAR 6 2X10X10 SUB 2 2 OPTION 92043 92043 1436 PIN SUB 2 2 39062A OPTION 92075 92075 1123 DAMPER RUBBER 4 4 Ni P 6 OPTION 2 92171 92171 0179 CLAMP 8 8 35063A OPTION 39192A 130 130880622 BOLT FLANGED 6X22 2 2 OPTION 554 554DA1000 PIN SNAP 10MM 2 2 O s2171 OPTION yum 554 n ni O 2171 17 OCT 31 2008 This catalog covers GRID NO This grid covers 08 09 ZX1000 E8FR E9FR Chassis Rear Hub T Fest Ref Quantity ZX1000 amp amp 43082 N Part No Description Spec Code oo erje L Co O 43082 43082 0088 PAD ASSY BRAKE FR F9633 2 2 OPTION 43082A 43082 1192 PAD ASSY BRAKE RR C93 1 1 OPTION Es 430828 43082 1220 PAD ASSY BRAKE RR C93G 1 1 OPTION 11 44026 44026 0119 SPRING FRONT FORK K 9 5N MM 2 2 pg OPTION k 44026A 44026 0120 SPRING FRONT FORK K 10 5N MM 2 2 tJ O
21. We recommend that the rider himself should do the basic works removing parts or installing parts etc given advices by the tuning shop In a race although trouble will be apt to happen if you participate in basic works you can discriminate cause of trouble so you can return the race soon But concerning difficult technical works you should ask to tuning shop Dummy page Table of Contents amp bien Ste 4 Racing Kit Service D ala cott eet e et tot etu tette 7 Periodic Maintenance PEPPER 8 Engine Parts PrN Leal MUON Ns he ac eene hod iac Font Fea Dd Fed ad Fes Fed Dd Fd fo css 10 10 Camshaft Chain Tensioner eue quee en deiade iu qd cae RR 11 Sprockets a e t tu a viae ai ea M 12 CYNIC OS s x u PPM 14 Cylinder Compression u na SS 15 FISIOPIS iid ass m Sa i GR E ua a death 16 Crankshaft Main Journal Bushings e ER Vr Re Y eR A NR ER ER 16 Connecting Rod u oie p lop optet teta eds 18 Connecting Rod Big secu e de ti err ett ei detuvo eti t et dera your eaae 19 Clutch Adjustment Back Torque Limiter Setting
22. gt Ath Out 13262 0645 STD 13262 0646 Teeth _ 3 EN Out In 32 21 31 20 33 21 Gear Ratio 1 525 1 550 1 571 In 13262 0648 13262 0647 13262 0648 13262 0621 E 5th Out 13262 0650 13262 0649 STD 13262 0651 Teeth _ Out In 29 21 29 20 28 20 30 21 Gear Ratio 1 381 1 450 1 400 1 429 A Type B Type C Type D Type E Type F Type G In 13262 0652 13262 0653 13262 0654 13262 0655 13262 0656 13262 0657 13262 0623 13262 0623 Out STD 13262 0658 13262 0659 13262 0660 13262 0661 13262 0658 onus 30 23 29 21 28 21 28 22 26 21 30 24 29 22 Gear Ratio 1 304 1 381 1 333 1 273 1 238 1 250 1 318 The difference between the 151 input shaft type E 13127 0060 Standard and 13127 0062 is that 13127 0062 is based on the shim adjustment against 13127 0060 Standard Refer to the Transmission Shimming in the Transmission section 13127 0062 has one thread identification groove on the shaft so identify the gear whether the groove is provided or not See the illustration below The transmission gears of 08 09 model have not interchangeability with those of 05 07 models because the taper angle the dog and dog hole of the gear is difference from that of 05 07 models Only the 1st input shaft and the 2nd input gear has interchangeability 13127 0062
23. 0231 ECU Kit The 2009 model ZX 10R kit ECU has following functions Refer to the Kawasaki FI Calibration Tool Instruction manual for the ECU function set up method 1 Auto Shift Functions Be sure use the point type sensor Recommended Dynojet mode or Battle Factory mode Part installation is refer to the Electrical Part Installation section in this Manual 2 Pit Road Engine Revolution Limit Functions ON Off Changing Switch Part Number 27010 0040 use the kit meter Part installation is refer to the Electrical Part Installation section in this Manual 3 Shift Indicator Functions Part installation is refer to the Electrical Part Installation section in this Manual NOTE O When using the original meter lit the shift up indicator light so that the shift up indicator lamp of the kit does not used Use the shift up indicator lamp of the kit together with the kit meter but do not function as the FI indicator light 42 Frame Parts Installation Throttle Parts Kit The following throttle cases grip and reels are available as optional parts These optional parts quicken throttle response to the twist grip 1 Throttle Case Parts Name P No Throttle Case Upper 32099 0046 Throttle Case Lower 92099 0047 Bolts 2 120CA0518 Pipe Grip 31064 0187 2 Throttle Reels Tow types are available Throttle reel travel angle is marked on each part to identify Throttle Reel Travel Angl
24. 13262F 6 OCT 31 2008 GRID This grid covers Transmission TYPE C Ref Quantity ZX1000 PartNo Descripton Spec Code sspe T dent TT 13127 This catalog covers 08 09 ZX1000 E8FR E9FR Engine E1361B 13127 0042 OPTION 13144 13144 0021 OPTION 13144A 13144 0022 SHAFT TRANSMISSION INPUT 14T 1 1 SPROCKET OUTPUT 16T 520 1 1 SPROCKET OUTPUT 17T 520 1 1 REON C IW SA SP 1326206 13262 13262 13262 13262 13262 13262D 13262E 13262F 13262G 13262H 92200 92200A 92200B 92200C 92200D 92200E 92200F 92200G OPTION 13262 0515 OPTION 13262 0620 OPTION 13262 0621 OPTION 13262 0625 OPTION 13262 0628 OPTION 13262 0643 OPTION 13262 0646 OPTION 13262 0653 OPTION 13262 0659 OPTION 92200 0225 OPTION 92200 0226 OPTION 92200 0227 OPTION 92200 0228 OPTION 92200 0229 OPTION 92200 0230 OPTION 92200 0231 OPTION 92200 0232 OPTION GEAR INPUT 2ND 18T GEAR INPUT 5TH 20T GEAR OUTPUT 5TH 28T GEAR OUTPUT LOW 34T GEAR OUTPUT 2ND 38T GEAR OUTPUT 3RD 28T GEAR OUTPUT 4TH 33T GEAR INPUT 6TH 21T GEAR OUTPUT 6TH 28T WASHER 28 1X34 0X0 8 WASHER 28 1X34 0X1 0 WASHER 28 1X34 0X1 4 WASHER 28 1X34 0X1 6 WASHER 28 3X34 0X1 2 WASHER 28 3X34 0X1 4 WASHER 28 3X34 0X1 8 WASHER 28 3X34 0X2 0 OCT 31 2008 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR
25. 35 BOLT FLANGED SMALL 8X25 SCREW PAN CROSS 5X22 WASHER PLAIN SMALL 8MM O RING 12MM OCT 31 2008 Spec Code Quantity ZX1000 L This catalog covers 08 09 ZX1000 E8FR E9FR Chassis GRID This grid covers F2530 Meter s Ref Part No No 11055 11055 0921 OPTION 13061 13061 0124 OPTION 23016 23016 0006 OPTION 25031 25031 1142 OPTION 39156 39156 0098 OPTION 92039 92039 1231 OPTION 92152 92152 0058 OPTION 92153 92153 1275 OPTION 554 554DA1200 OPTION 670 670E2014 OPTION 21 Description Spec Code BRACKET METER amp COWLING STAY BOSS LAMP ASSY INDICATOR METER ASSY PAD KIT METER RIVET COLLAR BOLT SOCKET 6X12 PIN SNAP 12MM O RING 14MM OCT 31 2008 Quantity ZX1000 L Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Doc No 99929 0305 01
26. 44 FITTING 1 1 OPTION 92015 92015 1339 NUT LOCK FLANGED 6MM 2 2 OPTION 92022 92022 304 WASHER 6 2X11X1 1 5 OPTION 22071 ps 92027 92027 194 COLLAR L 11 1 1 1 92072 OPTION 92071 92071 1028 GROMMET AIR FILTER 1 1 OPTION 92072 92072 1419 BAND L 50 1 1 52001 OPTION 92075 92075 277 DAMPER 2 2 OPTION 92143 92143 1291 COLLAR SPROCKET 1 1 92075 1G 0K 92153 92153 0386 BOLT TORX M6X28 4 4 OPTION 92171 92171 0338 CLAMP 3 3 92143 OPTION 21007A ov 92191 92191 1182 TUBE RH 1 1 A OPTION 92192 92192 0641 TUBE CASE TANK 1 1 OPTION 92200 92200 0306 WASHER 12X36X3 2 1 A OPTION 120 120 0520 BOLT SOCKET 5X20 2 2 OPTION 120A 120CA0620 BOLT SOCKET 6X20 1 1 OPTION 15 OCT 31 2008 GRID This grid covers This catalog covers 08 09 2 1000 EBFR E9FR Engine Generator 2 2 ec Part No Description Spec Code i T T 130 130 0625 BOLT FLANGED 6X25 2 2 OPTION 130A 130BD0610 BOLT FLANGED 6X10 1 1 OPTION 6 gt 207 S 52001 92022 92075 130A 92143 210074 ov lt 16 OCT 31 2008 GRID This grid covers This catalog covers 08 09 2 1000 E8FR EQFR Engine Radiator 92075 e Ref Ref Fuel Part No Description Spec Code roa os eje 1 1 ii es 35063 35063 0568 STAY LH SUB RAD 1 1 OPTION 35063A 35063 0569 STAY RH SUB RAD 1 1 OPTION 35063B 35063 0570 STAY CNT
27. 6 1166 Kit 5 Locknut 3 O ring Camshafts Sprockets Valve Camshafts Sprockets Valve 12004 0035 STD Intake 12005 0052 STD KIT Exhaust 12004 0038 Kit Intake Camshaft Duration Lift 49118 0116 STD Intake 292 9 7 mm 49118 0117 STD Exhaust 280 8 5 mm 49118 0134 Kit Intake 296 9 7mm 49118 0045 Kit Exhaust 292 8 5 mm Valve In case of using kit camshaft IN 49118 0134 EX 49118 0045 be sure to use kit camshaft sprocket IN EX 12046 0034 and kit tappet 12032 0002 as a set Intake valve 12004 0038 is available as a kit part connecting rod and a kit intake valve as a kit set Adjust the valve clearance within the specified value Intake 0 15 0 22 mm Exhaust 0 17 0 22 mm More performance is expected when adjusted from middle value to upper limit between adjustable range If you can not adjust the valve timing for racing install the camshaft sprocket to the camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX 10R Service Manual If you adjust the valve timing install the sprocket to the camshaft between the adjustable range of the long bolt holes Tighten the camshaft sprocket bolts to 15 N m 1 5 kgf m 11 ft lb of torque Be sure to use a kit piston a Valve Timing Timing cam lift center Intake Exhaust When the round bolt holes are used Original 122 9
28. 8 09 2 1000 E8FR E9FR Engine Transmission TYPE E F G ERE Ref No Part No Description Spec Code emf 13127 13127 0062 SHAFT TRANSMISSION INPUT 15T 1 1 OPTION JU 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0615 GEAR OUTPUT LOW 39T 1 1 OPTION 13262A 13262 0655 GEAR INPUT 6TH 21T 1 1 OPTION 13262B 13262 0656 GEAR INPUT 6TH 24T 1 1 OPTION 13262C 13262 0657 GEAR INPUT 6TH 22T 1 1 OPTION 13262D 13262 0661 GEAR OUTPUT 6TH 26T 1 1 OPTION 92200 92200 0225 WASHER 28 1 X34 0X0 8 AR AR OPTION 92200 92200 0226 WASHER 28 1X34 0X1 0 AR AR OPTION 92200B 92200 0227 WASHER 28 1X34 0X1 4 AR AR OPTION 92200C 92200 0228 WASHER 28 1X34 0X1 6 AR AR OPTION 92200D 92200 0229 WASHER 28 3X34 0X1 2 AR AR Z OPTION PUN NN 92200E 92200 0230 WASHER 28 3X34 0X1 4 AR AR ANA OPTION 92200F 92200 0231 WASHER 28 3X34 0X1 8 AR AR OPTION 92200G 92200 0232 WASHER 28 3X34 0X2 0 AR AR OPTION 9 OCT 31 2008 This catalog covers GRID This grid covers 08 09 ZX1000 E8FR EQFR Engine Transmission INPUT3RD 4TH GEAR N IP Part No Description Spec Code osjo LES L 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 1 OPTION 13262 13262 0630 GEAR INPUT 3RD amp 4TH 19T amp 21T A A 1 1 OPTION 13262A 13262 0631 GEAR INPU
29. ER SPRING STD 1MM WASHER 6 2X11X1 OCT 31 2008 Quantity ZX1000 6 6 6 6 6 6 GRID NO This grid covers Transmission TYPE A E1361 This catalog covers 08 09 ZX1000 ESFR E9FR Engine Spec Code Part Description fer S P a Ref N amp No 92200D G 132626 9 Z lt S X S 2 13262 132626 13127 13144 13144A 13262 13262A 13262B 132626 13262 13262 13262F 13262G 13262H 92200 92200A 92200B 92200C 92200D 92200E 92200F 92200G 13127 0063 OPTION 13144 0021 OPTION 13144 0022 OPTION 13262 0350 OPTION 13262 0616 OPTION 13262 0618 OPTION 13262 0622 OPTION 13262 0623 OPTION 13262 0645 OPTION 13262 0648 OPTION 13262 0650 OPTION 13262 0664 OPTION 92200 0225 OPTION 92200 0226 OPTION 92200 0227 OPTION 92200 0228 OPTION 92200 0229 OPTION 92200 0230 OPTION 92200 0231 OPTION 92200 0232 OPTION SHAFT TRANSMISSION INPUT 15T SPROCKET OUTPUT 16T 520 SPROCKET OUTPUT 17T 520 GEAR INPUT 2ND 19T GEAR OUTPUT 2ND 39T GEAR OUTPUT 3RD 33T GEAR INPUT 6TH 23T GEAR OUTPUT 6TH 30T GEAR OUTPUT 4TH 32T GEAR INPUT 5TH 21T GEAR OUTPUT 5TH 29T GEAR OUTPUT LOW 38T WASHER 28 1X34 0X0 8 WASHER 28 1X34 0X1 0 WASHER 28 1X34 0X1 4 WASHER 28 1X34 0X1 6 WASHER 28 3X34 0X1 2 WASHER 28 3X34 0X1 4 WASHER 28 3X34 0X1 8 WASHER 28 3X34 0X2 0 OCT 31 2008 A
30. ON 92139 92139A 92139B 92139C 92139D 92139 0147 OPTION 92139 0148 OPTION 92139 0149 OPTION 92139 0150 OPTION 92139 0151 OPTION 92139E 92139F 92139G 92139H 921391 92139 0156 OPTION 92139 0203 OPTION 92139 0204 OPTION 92139 0205 OPTION 92139 0206 OPTION 92139J 92139K 92139L 92139M 92153 92153 0809 OPTION Description Spec Code PISTON ENGINE SB PIN PISTON RING SET PISTON ROD ASSY CONNECTING L 1 10 45 NUT FLANGED 8MM RING SNAP PISTON PIN BUSHING SB CONROD BLUE BUSHING SB CONROD BLACK BUSHING SB CONROD BROWN BUSHING CRANK 1 amp 3 amp 5 BLUE BUSHING CRANK 1 amp 38 amp 5 BLACK BUSHING CRANK 1 amp 3 amp 5 BROWN BUSHING CRANK 2 amp 4 BLUE BUSHING CRANK 2 amp 4 BLACK BUSHING CRANK 2 amp 4 BROWN BUSHING SB CONROD PINK BUSHING STD CONROD BLUE BUSHING STD CONROD BLACK BUSHING STD CONROD BROWN BUSHING STD CONROD PINK BOLT CON ROD M8X45 5 OCT 31 2008 epe rf AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR This catalog covers 08 09 ZX1000 ESFR E9FR Engine GRID NO This grid covers E1350 Clutch Ref Part No No 13089 13089 0011 OPTION 13089A 13089 0012 OPTION 13091 13091 1041 OPTION 39108 39108 0005 OPTION 92022 92022 304 Description Spec Code PLATE CLUTCH STD 40 PLATE CLUTCH STD 60 HOLDER CLUTCH SPRING RETAIN
31. One turn of the spring adjusting nut changes the spring length by 1 5 mm Rear Suspension Condition of Seat Height Adjustment When the seat height adjusts spacer applied the rear suspension should be softened 46 Seat Height Adjustment Spacer Set 92026 1586 P No Quantity Thickness 92026 1582 1 1 0 mm 92026 1583 1 2 0 mm 92026 1584 1 3 2 92026 1585 2 4 5 VYY 2 2 S106675BW5 C 3 Collar 4 Bracket 47 Front Fork Springs Kit The optional front fork springs are available for racing 1 Front Fork Specifications Items Original Fork oil Fork oil level Oil lock Oil seal Spring length Rebounded damping setting Upper Compression damping setting Lower position position KHL15 10 Oil lock piece 232 3 mm Free Length 10th click from the first click of the fully clockwise 10th click from the first click of the fully clockwise 107 mm from the top of inner tube Spring constant 9 9 N mm Sub spring stroke 20 5 mm 2 Front Fork Spring Number of P No A x B x C mm Winding Spring Constant Original 4 8 x 28 5 x 232 3 14 2 K 9 9 N mm 44026 0119 4 8 x 28 5 x 232 3 14 8 K 9 5 N mm 44026 0120 4 9 x 28 3 x 232 3 14 7 K 10 5 N mm A Coil Diameter B Spring Inside Diameter C Spring Free Length 3 Front Fork Spring Replacement Replace the main spring referring to the For
32. PTION 14 43082A B 55020 P OR GUARD CHAIN 1 1 gt 92057 92057 1529 CHAIN DRIVE 120L 520 1 OPTION 44026 92058 92058 1090 JOINT CHAIN DRIVE 520 1 OPTION 08 92057 130 130 1020 BOLT FLANGED 10X20 1 OPTION 130A 130BB1020 BOLT FLANGED 10X20 1 92058 OPTION o Ge oh _ ee E gt a Z PSY l m ui 1 1 a M G T 7 2 M Ge ay Y gt ap k amp 18 OCT 31 2008 This catalog covers 08 09 ZX1000 E8FR E9FR Chassis F2310 46091 32099 OPENING 54012 132A 54012A CLOSING 132 13280 132A GRID This grid covers Handlebar ZX1000E8FR Ref No 13061 13280 27010 31064 32099 32099A 46075 46091 54012 54012A 59101 59101A 92160 120 132 132A 220 410 670 19 Part No 13061 0292 OPTION 13280 0291 OPTION 27010 0040 OPTION 31064 1151 OPTION 32099 0004 OPTION 32099 0005 OPTION 46075 1143 OPTION 46091 1809 OPTION 54012 0249 OPTION 54012 0250 OPTION 59101 0001 OPTION 59101 0002 OPTION 92160 1625 OPTION 120CB0625 OPTION 132BA0635 OPTION 132BA0825 OPTION 220AB0522 OPTION 410AA0800 OPTION 670B2012 OPTION Description BOSS Spec Code
33. R AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR This catalog covers GRID NO This grid covers 08 09 2 1000 E8FR E9FR Engine Transmission TYPE B diem No Part No Description Spec Code o 13127 13127 0041 OPTION 19144 13144 0021 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 1 SHAFT TRANSMISSION INPUT 13T 1 4 SPROCKET OUTPUT 16T 520 1 1 ON 13262 13262A 13262B 13262C 13262D 13262E 13262F 13262G 13262H 92200 92200A 92200B 92200C 92200D 92200E 92200F 92200G OPTION 13262 0513 OPTION 13262 0619 OPTION 13262 0624 OPTION 13262 0627 OPTION 13262 0642 OPTION 13262 0647 OPTION 13262 0649 OPTION 13262 0652 OPTION 13262 0658 OPTION 92200 0225 OPTION 92200 0226 OPTION 92200 0227 OPTION 92200 0228 OPTION 92200 0229 OPTION 92200 0230 OPTION 92200 0231 OPTION 92200 0232 OPTION GEAR INPUT 2ND 19T GEAR OUTPUT 4TH 31T GEAR OUTPUT LOW 31T GEAR OUTPUT 2ND 37T GEAR OUTPUT 3RD 34T GEAR INPUT 5TH 20T GEAR OUTPUT 5TH 29T GEAR INPUT 6TH 21T GEAR OUTPUT 6TH 29T WASHER 28 1X34 0X0 8 WASHER 28 1X34 0X1 0 WASHER 28 1X34 0X1 4 WASHER 28 1X34 0X1 6 WASHER 28 3X34 0X1 2 WASHER 28 3X34 0X1 4 WASHER 28 3X34 0X1 8 WASHER 28 3X34 0X2 0 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 13262B
34. T 3RD amp 4TH 19T amp 21T A C 1 1 OPTION 13262B 13262 0632 GEAR INPUT 3RD amp 4TH 19T amp 20T B B 1 1 OPTION 13262C 13262 0633 GEAR INPUT 3RD amp 4TH 19T amp 21T B A 1 1 OPTION 13262D 13262 0634 GEAR INPUT 3RD amp 4TH 19T amp 21T B C 1 1 OPTION 13262E 13262 0637 GEAR INPUT 3RD amp 4TH 16T amp 20T C B 1 1 OPTION 13262F 13262 0638 GEAR INPUT 3RD amp 4TH 16T amp 21T C A 1 1 OPTION 13262G 13262 0639 GEAR INPUT SRD amp 4TH 16T amp 21T C C 1 1 OPTION 13262H 13262 0640 GEAR INPUT 3RD amp 4TH 21T amp 20T D B 1 1 OPTION 132621 13262 0641 GEAR INPUT 3RD amp 4TH 21T amp 21T D A 1 1 OPTION 13262J 13262 0665 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 1 OPTION 92200 92200 0225 WASHER 28 1X34 0X0 8 AR AR OPTION 92200A 92200 0226 WASHER 28 1X34 0X1 0 AR AR OPTION 92200B 92200 0227 WASHER 28 1X34 0X1 4 AR AR OPTION 92200C 92200 0228 WASHER 28 1X34 0X1 6 AR AR OPTION 92200D 92200 0229 WASHER 28 3X34 0X1 2 AR AR OPTION 92200E 92200 0230 WASHER 28 3X34 0X1 4 AR AR OPTION 92200F 92200 0231 WASHER 28 3X34 0X1 8 AR AR OPTION 92200G 92200 0232 WASHER 28 3X34 0X2 0 AR AR OPTION 10 OCT 31 2008 This catalog covers GRID This grid covers 08 09 ZX1000 E8FR E9FR Engine Gear Change Drum Shift Fork s No Part No Description Spec Code 13141 13141 0048 DRUM CHANGE 1 1 OPTION 13145 13145 0044 CAM CHANGE DRUM 1 OPTION 13151 13151 0043 SWITCH COMP GEAR POSITION 1 1 OPTION 11 OCT 31 2008 This c
35. TION 21176 1099 OPTION 26011 0071 OPTION 26011 1779 OPTION 26031 0240 OPTION 26031 0698 OPTION 26031 0699 OPTION 26031 0700 OPTION 27002 1062 OPTION Description Spec Code CONTROL UNIT ELECTRONIC SENSOR TEMP WIRE LEAD TEMP SENSOR EARTH WIRE LEAD METER TEMP SENSOR HARNESS INTERFACE BOX HARNESS STD METER HARNESS KIT METER HARNESS STD RELAY ASSY OCT 31 2008 Quantity ZX1000 Oil Pump 4 1710 GRID This grid covers 08 09 ZX1000 ESFR E9FR Engine This catalog covers Quantity ZX1000 Spec Code Ref No L Description Part No SHAFT 13107 0127 13107 OPTION 16142 0036 COVER PUMP 16142 OPTION 16154 0082 ROTOR PUMP 16154 OPTION OCT 31 2008 14 S et J y lt N 75 X65 doo a NT gt RA DM oo A 16142 This catalog covers GRID This grid covers 5 5 08 09 ZX1000 E8FR E9FR Engine Generator 1 2 ENS Ref N Part No Description Spec Code d refers 11055 11055 0542 BRACKETOIL TANK 1 1 OPTION 21003 21003 0044 STATOR 1 1 OPTION 21007 21007 0083 ROTOR 1 1 OPTION 21007A 21007 0085 ROTOR 1 1 OPTION 21066 21066 0010 REGULATOR VOLTAGE 1 1 OPTION 26031 26031 0323 HARNESS 1 1 OPTION 52001 52001 0005 TANK OIL 1 1 OPTION 92005 92005 00
36. and passing switch functions as well In case of using the kit meter harness 26031 0699 firstly connect the speed limit switch 4 coupler with the switch 27010 0040 Make A side stamped on the switch means OFF the speed limit and B side means ON the speed limit O In case of using Rev Spike Control 5 connect the switch 27010 0040 For functions in detail see manual of Kawasaki FI Calibration Tool 52 S106679BW5 C 1 ECU 2 Setting Tool Black 3 Atmospheric Pressure Sensor Black 4 Relay Assembly 27002 1062 5 Vehicle down Sensor Black The relay assembly 4 should make sure to avoid the interference with other parts When apply the measuring instruments the power source 6 available as a 12 V power source The setting tool should be used according to the manual of Kawasaki FI Calibration Tool 53 Wiring Diagram with Kit Meter Water Temperature Gauge Engine Starter Stop Button Switch re em n Ti Stick Coils e R W R W BK BL M BR W R R BK R Spark Plugs 0000 54 BK G R R BK 0 Camshaft Postion Sensor ub throttle Valve Actuator Seconday Fuel Injectors Primary Fuel Injectors 1 2 a3 4 1 2 3 4 xf ae ef em wt gt Sf 1 2 55 55555 x 5 15 33 45 zi
37. atalog covers GRID This grid covers 5 08 09 2 1000 E8FR E9FR Engine Engine Cover s Ret N Part No Description Spec Code roa os 11004 11004 0022 GASKET HEAD T 0 55 1 1 OPTION 11004A 11004 0023 GASKET HEAD T 0 45 1 1 OPTION 11004B 11004 0026 GASKET HEAD T 0 65 1 1 OPTION 11004C 11004 0034 GASKET HEAD T 0 50 1 1 OPTION 11004D 11004 0052 GASKET HEAD T 0 60 1 1 OPTION 11061 11061 0229 GASKET IDLE GEAR COVER 1 1 OPTION 11061A 11061 0231 GASKET GENERATOR COVER 1 1 OPTION 11061B 11061 0232 GASKET CLUTCH COVER 1 1 OPTION 11061C 11061 0233 GASKET OIL PAN 1 1 OPTION 11061D 11061 0342 GASKET LARGE COVER 1 1 OPTION 14031 14031 0063 COVER GENERATOR 1 1 OPTION 92055 92055 1262 RING O 24 4X3 1 1 1 OPTION 92066 92066 1005 PLUG 4 4 11061D 22068A OPTION 11061B S 92066A 92066 1332 PLUG STARTER HOLE i OPTION 92066B 92066 1333 PLUG STARTER HOLE 1 1 A OPTION 11061A e e 92151 92151 1546 BOLT FLANGED 6X25 7 7 1 OPTION 130 130 0625 BOLT FLANGED 6X25 14 OPTION 312 312AA0600 NUT HEX 6MM 1 1 OPTION 14031 12 OCT 31 2008 This catalog covers 08 09 2 1000 EBFR E9FR Engine 260316 51230 Ref N 21175 21176 21175 26011 26011A 21176 Rater Radiator 26011A 26031 26011 7 N 26031A 5 260318 26031 27002 FOR KIT METER 13 GRID This grid covers Fuel Injection Part No 21175 0212 OP
38. below 130BB0518 Remove the upper 2 bolts of 4 bolts 92005 1238 To remove 1067028W5 C A Bracket 11055 0542 B Bolts 120CA0520 C Fitting 92005 0044 38 O Prepare the parts A D shown in the figure below Make each parts D or additional machining the part listed below is available Part Name Part No Additional machining A Bolt 92153 1570 or 92151 1583 Cut off the flange Add a slit see the figure below Plug 92066 1332 Add a center hole 6 5 C Collar 92152 0182 D Nut 92015 3797 md 9 10 5 Filing or Grinding M6 1 0 40 iM 1 LO N T r iv S 5 8 45 S106665BW5 C 39 Assemble the parts as shown in the figure below and remove the fitting Fix the damper A and the collar B to the tank bracket and then fasten to the bracket mounted on the fitting by the bolt C Cut the damper in half and hold each piece in the tank bracket and then put it on the engine mount bolt Fasten the tank to the engine mount bolt by the band D Connect the tank and the air cleaner box with the tube F and clamp the tube With the tube G connect the fitting installed the above and the tank Route the tube around the cooling hose as shown
39. check Brake operation Brake fluid level check Brake fluid year Brake master cylinder cup and dust seal replace m Brake caliper piston seal and dust seal replace ad Brake hose replace 2 years Drive chain adjust e Drive chain lubricate Drive chain wear Drive chain guide replace If damaged Front fork clean check Front fork oil change First change after 2 races then every 5 races Nut bolt and fastener tightness check Fuel system clean e Fuel hose fuel filter replace Steering play check OPERATION FREQENCY Each Race Every 2races Every 3races Every 5races Every 10races As Required Steering stem bearing grease Rear sprocket replace General lubrication of chassis perform Wheel bearing rear grease Swingarm pivot uni track linkage grease Swingarm pivot uni track linkage check Replace add adjust clean or torque if necessary Engine Parts Installation Air Intake Parts Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance 106671BW5 C 1 Relational Parts of Secondary Air Remove the Parts 2 R
40. clearance between 0 3 mm and 0 4 mm to prevent the inclination of gears and to keep smooth gear shifting SI06180BW2 C Thickness mm Part No Remarks D Spline washer 1 2 92200 0229 Kit 1 4 92200 0230 Kit 1 6 92200 0050 Original 1 8 92200 0231 Kit 2 0 92200 0232 Kit 2 Plane washer 0 8 92200 0225 Kit 1 0 92200 0226 Kit 1 2 92200 0051 Original 1 4 92200 0227 Kit 1 6 92200 0228 Kit Plane washer B 1 4 92200 0138 Original 27 Use the kit input shafts of the type A E with the shim adjustment since their sizes are different from the standard shaft designed taking the shim adjustment into account in order to make the dog lengths of the 3rd 5th amp 2nd 6th gear dogs equal Adjust the dog length of each gears to smooth gear shifting Dog Length Dog Length 106208BM3 C 106207 3 C Standard Adjusting 0 2 Use the standard spline washer 1 6 mm 92200 0050 2 2 Use the standard spline washer 1 2 mm 92200 0051 When thin the washer of D 1 1 from the standard washer and thickly the washer of D 2 2 2 from the standard washer to increase the dog length of gears also reverse the combination to reduced the dog length of gear Changing The Shift Drum In 2009 model ZX 10R kit parts shift drum 13141 0048 is available for the reverse shifting Reverse shifting is available o
41. e Effective angle excluding throttle cable free play Twist Grip Turn Angle 155 to Full Throttle 59101 0008 R19 7 65deg 65 59101 0009 R21 4 60deg 60 O The kit parts throttle cases throttle pipe and reels of 09 model have not interchangeability with those of 08 model because those are new parts 5106849812 1 Identification Mark 3 Throttle Cable Accelerator and decelator cables are the same It is possible to use the cable even if the cable is installed on either the accelerator side or decelator side because the cable of the same length is used Part Name P No I D Mark Throttle Cable 54012 0276 12 0276 xxxx O The kit parts throttle cases of 09 model have not interchangeability with those of 08 model because those are new parts 43 106829BM9 Upper Case 32099 0046 Lower Case 32099 0047 Bolt 120CA0518 Reel 65 59101 0008 Reel 60 59101 0009 Throttle Pipe 31064 0187 Groove for Identification on Mating Surface 106854BN2 C Assemble the throttle cases so that the identification groove faces upwards see above It is correct to assemble the throttle cases so that the groove side have no clearance and the opposite lower side have clearance Final Drive Parts Kit 1 Drive Chain 520 Joint endless drive chain is available as an optional parts 44 2 Chain Guard S106672BW5 C
42. e camshaft chain timing Turn the crankshaft by two rotations or more Remove the cylinder head and measure the thickness of the clay The thickness of the collapsed clay is a clearance of the valve and the piston 13 Cylinder Head Before reassemble the cylinder head grind off the stepped portions of the port and smooth the inside of ports to make intake exhaust gas flow smooth Grind off the stepped portions only at the mating surface between the throttle body holder and the intake port Mark the throttle body holders so that they can be installed in their original positions Grind off and smooth the stepped portions at the mating surface between the valve seat and the port Smooth the inside of the intake port and exhaust port Chamfer the machining edge of the cylinder head where the valve seat installed also smooth the dome of the combustion chamber with the valves installed Excessive smoothing may reduce the cylinder compression Use the hand grinder Use 200 oil stone for eliminating any stepped portion and 300 oil stone for finishing NOTE These procedures make air resistance less and intake exhaust gas flow more smooth However much more effect can not be expected by excessive grinding and smoothing It may be done to the extent of getting rid of uneven surfaces 51062158 8 C A Stepped Portions The combustion chambers are modified by cutting work but the edges shown
43. emove the parts or cut the cleaner element off remaining the wire net 3 Secondary Air Passages on Cylinder Head Plug the holes or press fit the plugs 92066 1005 instead of the original pins Output of Secondary Air on Air Cleaner Plug the hole 4 Air Cleaner Drain Tube Use it cutting it in suitable length Camshaft Chain Tensioner Replace the cam chain tensioner with the kit to decrease the flutter of tensioner Apply the engine oil to the tensioner rod O ring and tensioner body insert them into the tensioner body Check to see that the tensioner rod turns freely in the body if not polish the tensioner rod or fine the female threads in the body with a tap Diameter x Pitch 6 mm 1 0 mm Install the tensioner on the cylinder block with the tensioner rod is fully pushed back Turn the tensioner rod in with a screwdriver until it becomes hard to turn Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to take up any gap and tighten the locknut After adjusting the tensioner rod if the tensioner rod does not stick out from the tensioner body use the kit long tensioner rod 13116 1166 NOTE Never forward the tensioner rod forcibly this will increase mechanical loss of the tensioner and may damage to the chain guide The cam chain tensioner must be adjusted at every race S8106121BN3 C 1 Tensioner Body 4 O ring 2 Tensioner Rod 1311
44. ess i Sub Harness Part Original Meter Kit Meter 26031 0700 26031 0698 26031 0699 Meter Assembly Kit O x O Tachometer with Water Temperature Gauge Kit x O x 25031 1142 Water Temperature Gauge Lead Kit O T 26011 1779 Water Temperature Sensor Ground Lead Kit x Q x 26011 0071 Water Temperature Sensor 21176 1099 2 5 Relay Box Original 27002 0007 2 2 Relay Assembly Original 27002 1062 e e i 51 Wiring Routing S106678BW5 C Q N Meter Black 9 Shift Up Indicator Light Green 10 Right Switch Housing Black 11 Left Switch or Speed Limit Switch Black 12 Rev Spike Control Switch Half transparent 13 Ignition Coil Black 14 Air Intake Temperature Sensor Black 15 Injector Secondary Black 16 Crank Shaft Position Sensor Black Engine Harness Brown Auto Shifter Blue Engine Harness Gray Regulator Black Fuel Pump Frame Ground Magnetic Switch Red n case of using harness 26031 0698 for the original meter connect the right switch housing 3 coupler with the original switch and of using kit meter harness 26031 0699 connect with the kit set housing switch 46091 1809 n case of using harness 26031 0698 for the original meter the head light beam Hi Lo change switch on the left switch housing 4 functions as a speed limit switch of the pit road
45. haft timing cam lift center Intake 111 ATDC Exhaust 104 BTDC Valve clearance Intake 0 22 mm Exhaust 0 22 mm Squish 0 85 mm Valve to piston clearance Intake 1 45 mm 10 ATDC Exhaust 1 80 mm 10 BTDC Ignition System Spark plugs Spark plug tightening torque CR9EIA 9 STD R0045Q 10 or R0373A 10 13 1 3 113 16 These values show the specifications when standard cylinder head and gasket are used Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQENCY Each Every Every Every Every As OPERATION Race 2races 3races 5races 10races Required Engine Clutch plate check Throttle grip play check Spark plug clean gap Engine oil change Oil filter replace Valve lapping Cylinder head valve decarbonization Cylinder check Piston cylinder clearance check Piston ring piston and piston pin replace When pistons 13001 0100 are used Crankshaft main bearing check Connecting rod big end bearing Transmission gear bearing Engine sprocket Coolant change Radiator hoses connections
46. in the figure below Box ATO r IL Tess k S106704BW5 C A Damper 92075 277 E Damper 92075 277 B Collar 92027 194 F Tube 92191 1182 C Bolt 120CA0620 G Tube 92192 0641 D Band 92072 1419 H Grommet 92071 1028 Plug the drain boss on the oil catch tank with the M6 bolt 130BB0610 and the washer 92022 304 and then do wiring to prevent pulling off Oil Catch Tank Tube Installation 1 92192 0641 Crankcase to oil catch tank 2 92191 1182 Oil catch tank to air cleaner Remove the original breather hose 92192 0237 Install the tube 92192 0641 between the crankcase and the oil catch tank by using the clamp 92171 0338 Install the tube 92192 1182 with one end inserting the grommet of the oil catch tank and the other end to the air cleaner by using the clamp 92171 0338 Run the hoses as shown in the illustration above NOTE O Protect the hose and check the no blockade at the its curved part when the hose is afraid of interfering with edge part on the way of the hose routing Specially about the hose toward the crankcase check the no blockage by the fuel pump 41 Cover Gaskets Kit The kit cover gasket are available of the 2009 model ZX 10R They are made from metal foam and made easy to separate Starter Clutch Cover 11061 0342 Idle Gear Cover 11061 0229 Clutch Cover 11061 0232 Oil Pan 11061 0233 Alternator Cover 11061
47. ipe and the water pump and install the hose 39062 0103 This is the same hose as one between the water pipe and the water pump for ZX 10R of the year 2006 2007 39192 0092 To Radiator 39062 0103 To Sub Radiator 4 To Water Pump 1067018W5 C Reserve tank Installation When using the radiator Kit the original reserve tank cannot be used Prepare a suitable substitute reserve tank Reserve Tank should be equipped with a band so as not to affect the running and the handling NOTE O Capacity of a reserve tank should be more than Radiator ih 200 cc O Position of the hose to a reserve tank End of the hose to the radiator should be always in the coolant End of the hose to atmosphere should be always beyond the coolant surface To Atmosphene Hose Inner Reservoir diamter 5 5 Substitute Coolant 5106710851 C 37 Oil Catch Tank Kit Use the oil catch tank for the engine blowby gas Oil Catch Tank 52001 0005 Tank Capacity Approximately 510 cc Oil Catch Tank Installation Tighten the mounting bracket 11055 0542 together with the thermo case Use the bolts 120CA0520 Remove the fitting 92005 1238 pressed into the upper case For the fitting removal pull out it by tapping the back side of the upper case on the occasion that the crankcase is opened up for maintenance work Otherwise make a jig to remove the fitting as shown in the
48. k Oil Change section of the base Service Manual Identification Mark The identification slit for a spring constant valve is stamped on the one end face of the spring One slit K 9 5 N mm Two Slits K 10 5 N mm se N Mjn 106212BM1 C 48 Fork Spring Installation Kit Spring with Stamp L 232 3mm S106711BW5 C 49 Electric Parts Installation Battery Use the original battery or a battery with 12 V 7 Ah or more capacity Main Harness and Sub Harness Kit Main harness and sub harness are available for racing use as optional parts Select one of them in accordance with your race regulation Main Harness for Original Meter 26031 0698 Main Harness for Kit Meter 26031 0699 Sub Harness for Original Meter and Original Main Harness 26031 0700 Meter Kit Installation S106677BW5 C Lamp Assembly Kit 23016 0006 Tachometer with Water Temperature Gauge Kit 25031 1142 Pad Kit 39156 0098 Bracket Kit 11055 0921 Collar Kit 92152 0058 Rivet Kit 92039 1231 Q Insert the three collars 5 into the pad 3 Insert the rivet 6 from the backside of the bracket 4 and fix them Fix the bracket 4 to the original air duct 50 Main Harness Combination Parts Table Main Harness and Kit Part Combination Table need x no need Harness for Harness for Harn
49. must be hand finished for smooth corners Smooth corner by shaping Section A A Enlarged 106705BW5 C 14 NOTE When grinding the cylinder head surface or using thinner gasket adjust the valve timing to keep that the valve to piston clearance is not less than the minimum value IN 0 7 mm EX 1 2 mm Cylinder Compression To adjust the cylinder compression adjust the thickness of the cylinder head gasket or smooth the cylinder head under surface or cylinder top surface to make the piston squish 0 65 mm Keep the piston squish more than 0 65 mm Grind off the cylinder head under surface to 0 4 mm Do not grind the cylinder upper surface This can raise the compression ratio while keeping the clearance of the piston and valve and one of the squish Although as the engine machining is uneven determine the cutting dimension after confirmation the recess and the squish before machining Position the piston at Top Dead Center and put a small piece of modeling clay on the shoulder of the piston Install the cylinder head gasket and cylinder head and tighten the head bolts to the specified torque Remove the cylinder head and measure the thickness of the clay The thickness of the collapsed clay is the size of the squish The most preferable squish measurement is 0 65 mm Select proper cylinder head gasket Cylinder Head Gasket Part No Tightening thickness Remarks ID Color
50. n exchange of shift drums n case of changing the shift drums be sure to change the gear position switch 13151 0043 to the kit set one Kit 13151 0043 Kit 13141 0048 1066598W5 C 28 Changing The Shift Drum Cam In 2009 model ZX 10R kit parts shift drum cam 13145 0044 is available to improve reliability of shifting Exchange of shift drum cams allow ZX 10R to improve reliability of shifting however to become slightly difficult to find the neutral position Kit 13145 0044 106848BN2 Alternator Racing kit of the 2008 model ZX 10R are available the alternator To quicken response by reducing the flywheel mass and to reduce the weight use the kit alternator Also use the kit alternator improve the engine ability Kit Alternator Rated Output 10A 48000 rpm original 30 A 5 000 rpm Effective current 7 8 A for running the race method vehicle Select and use the kit alternator or original alternator for racing conditions 1 Kit Alternator Installation When using the kit alternator remove the related parts of the original alternator and changing the around parts of the starter from original parts to kit parts Install the kit alternator as shown in the illustration Used Parts Table Part Name Part No Remark 1 Cover 14031 0063 Kit 2 Rotor 21007 0083 Kit 3 Stator 21003 0044 Kit 4 Washer 92200 0306 Kit 5 Bolt 92153 0386 Kit 6 Bolt 92151
51. or precise setting the measurement of the effective stroke of clutch spring plate is recommended Remove oil from clutch plates Hold an extra drive shaft in a vise and install the following clutch parts on the shaft e A Spacers H Steel Plates t 2 6 mm 2 Plates B Needle Bearing I Washer C Bushing J Spring D Clutch Housing K Friction Plates 36 Slots 8 Plates E Clutch Hub L Steel Plates t 2 9 mm 7 Plates F Sub Clutch Hub M Spring Plate G Friction Plates 48 Slots 2 Plates N Spring Retainer 23 e Engage the cam followers Clutch Hub with the cams Sub Clutch Hub e To measure the effective stroke of clutch spring plate set a dial gauge A against the center B of the clutch spring plate e Move the clutch housing gear back and forth C The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate D Drive Shaft GF060318 S After installing the clutch to the engine measure and record the depth B shown below the length from the clutch spring plate to the top surface of the sub clutch hub using a caliper or a depth gauge Manage the depth B to adjust the effective stroke after that because the friction disks would be worn and the length A would change The decrease of the depth B from the initial setting shows the increase of the effective stroke of clutch spring plate from the val
52. original connecting rod bolt 92153 0491 When using the original connecting rod bolts make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch Connecting rod 13251 0015 Bolt 92153 0809 Attached Recess Nut 92015 1311 2 5106172801 C Installation of the kit connecting rod bolt is same as installation of the original connecting rod bolt in the 1 original connecting rod section Refer to the 1 original connecting rod section Connecting Rod Big End Bushings The connecting rod bushing in the kit has improved its anti seizure feature than standard one NOTE Material of Connecting Rod in the kit is different from original one Connecting Rod Big End Bushing Crankpin Clearance When adjust the clearance by measurement in case aiming the clearance 0 050 mm Crankpin Diameter Marks O 34 493 34 500 mm None 34 484 34 492 mm 6105271851 C 19 Connecting Rod Big End Bore Diameter Marks 37 509 37 516 None 37 500 37 508 A Diameter Mark or no mark B Weight Mark Alphabet E F et Connecting Rod Big End Bushings Original Con rod 5106174851 C Color Pan Thickness Number Blue 92139 0203 1 488 1 493 mm Black 92139 0204 1 483
53. ply liquid gasket Replace the pulsing rotor with the kit rotor 21007 0085 Rotor 21007 0085 Kit Collar 92143 1291 Kit Washer 92200 0238 Original Bolt 92153 1521 Original a 5106692851 C Muffler With recommended muffler engine performance can be improved Recommended muffler NASSERT R JSB 1002 B14 GT Home Page http www beet co jp beet japan For further information contact the manufacture of muffler directly Water Temperature Sensor The original water temperature sensor installed in the cylinder head must be remain and connected to the main harness because the electronic control unit E C U needs the output signal from the original water temperature sensor Radiator Kit 2009 model ZX 10R racing kit provides the sub radiator 39060 0063 to improved the cooling function 33 Radiator Installation Sub Radiator Install the sub radiator stays as shown in the illustration Fix the center kit stay 35063 0570 on the crankcase by the bolt O Fix the right side kit stay 35063 0569 on the starter cover A by the bolt Fix the left side kit stay 35063 0568 on the alternator cover B by the bolts If the stay contacts the around parts grind the stay to prevent the contact As some stays may not be able to install according to the applied muffler modify the stay or suitable one of your make 35063 0569 39063 0568
54. t reset ese 50 Wiring RN MO 52 Wiring Diagram with Kit 54 Wiring Diagram with Original Meter I 56 General Specifications Item 2009 Ninja ZX 10R Racing Engine Ignition timing Fuel Recommended Engine oil Recommended Level Racing oil 10 BTDC 1 100 r min rpm Racing gasoline Between upper and lower levels of oil level gauge Drive Train Primary drive reduction ratio 1 611 87 54 Transmission Gear Table A Type B Type C Type D Type E Type F Type G 13127 0062 In 13127 0063 13127 0041 13127 0042 13127 0043 13127 0060 STD 1st Out 13262 0664 13262 0624 13262 0625 13262 0626 oen Teeth E B Out In 38 15 31 13 34 14 37 16 39 15 Gear Ratio 2 533 2 385 2 429 2 313 2 600 E In 13262 0513 13262 0515 13262 0279 13262 0616 ond Out STD 13262 0627 13262 0628 13262 0629 Teeth _ Out In 39 19 37 19 38 18 36 18 Gear Ratio 2 053 1 947 2 111 2 000 In See Gear See Gear See Gear See Gear Selection Selection Selection Selection 13262 0618 3rd Out STD 13262 0642 13262 0643 13262 0644 Teeth _ Out In 33 19 34 19 28 16 36 21 Gear Ratio 1 737 1 789 1 750 1 714 ES In See Gear See Gear See Gear _ _ _ Selection Selection Selection 13262 0619 8 E
55. ue initially measured Depth B N Length A Total Thickness of Clutch Plates 1063028W2 C 24 Spring Plate Assembly The spring plate assembly are available for increase the spring constant When outbreak the starting judder use the spring plate assembly of the kit parts Whenever the plate thickness is difference for adjusting the clutch plate take care the length A Part Number Spring Constant ID Color 13089 0003 2004 2005 ZX 10R Standard None 13089 0011 40 up comparison standard White 13089 0012 60 up comparison standard Blue dentification Color The ID marks are on the springs between the steel plates ID Color Section A A 5106204841 C 25 1061758W4 C A Spacers B Needle Bearing C Bushing D Clutch Housing E Clutch Hub F Sub Clutch Hub G Friction Plates H Spring Plate Assembly I Steel Plates J Spring Plate K Spring Retainer 26 Transmission Type G of the kit gears are available of the 2009 model ZX 10R To change the gear ratios with combination the gears Remove the three steel balls 600A0500 from the output shaft assembly This is done to start easily the engine with the second gear Replace the circlips with new ones if they were removed Transmission Shimming By using washers with various thickness keep the axial
56. urnals to drop and lead to the damage of the bearing 17 Connecting Rod Bolts 1 Original Connecting Rod Use the original connecting bolts and nuts Make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch Connecting Rod 13251 0023 Bolt 92153 0491 92153 0809 Spare Part Attached Recess Nut 92015 1311 S106289BW1 Install the original bolts into the connecting rod Before every tightening use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch Apply a small amount of molybdenum disulfide grease to the threads and seating surfaces of nuts and bolts Tighten the big end nuts at the torque reference torque of 20 N m 2 0 kgf m 14 5 16 Check the length of the bolts and find the bolt stretch Bolt Length after tightening Bolt Length before tightening Stretch Bolt Stretch Usable Range 0 32 mm 0 0126 in target Turn the big end nuts more until the bolt stretch reaches the usable range NOTE Replace the original bolts with new ones if they have already been tightened up to usable range 2 times Replace the bolts with new ones if they are used for the engine with a not clear feature 18 2 Kit Connecting Rod Connecting Rod Bolt Use the kit connecting rod bolts with the original connecting rod bolts and nuts The kit connecting rod can use the
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