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2011 Ninja ZX-10R Racing Kit Manual

1. 46 Vehicle down Sensor Installation 47 Main Harness Installation 48 Front Rear Speed Sensor 49 Wiring Diagram 52 4 General Specifications Item 2011 Ninja ZX 10R Racing Engine Ignition timing 10 BTDC 1 100 r min rpm Fuel Recommended Racing gasoline Engine oil Recommended Racing oil Oil Level Between upper and lower levels of oil level gauge Drive Train Primary drive reduction ratio 1 681 79 47 Transmission Gear Table Type A Type B Type C Type D Type E Type F Type G 1st In 13127 0638 13127 0639 13127 0640 13127 0641 13127 0642 13127 0636 STD Out 13262 0664 13262 0624 13262 0625 13262 0626 13262 0615 STD Teeth Out In 38 15 31 13 34 14 37 16 39 15 Gear Ratio 2 533 2 385 2 429 2 313 2 600 2nd In 13262 0856 STD 13262 0895 13262 0896 13262 0279 Out 13262 0880 STD 13262 0898 13262 0899 13262 0900 Teeth Ou
2. 38 Frame Parts Installation 40 Throttle Parts Kit 40 Drive Chain Parts Kit 42 Brake Pads Kit 43 Steering Damper Kit 43 Height Adjustment 44 Front Fork Springs Kit 45 Electric Parts Installation 46 Battery 46 Main Harness 46 Shift Up Indicator Light 46 Handle Switch
3. 18 Crankshaft Main Journal Bushings 20 Connecting Rod Bolts 22 Connecting Rod Big End Bushings 23 Clutch Adjustment Back Torque Limiter Setting 25 Transmission 32 Muffler 34 Radiator 34 Water Temperature Sensor 34 Cover Gaskets Kit 35 Oil Catch Tank Kit 35 Idle Adjusting Screw Kit 36 ECU Kit
4. Output 2 1 0 3 6th Input 0 1 2 STD 3 4 5 6 Output 2 1 0 3 4 2 1 Both the 5th input gear type A 13262 0648 and the 5th input gear type B 13262 0891 Standard have two gear Identification slits so identify the type by the number of teeth 13262 0648 21T 13262 0881 18T Shift Forks 13140 0625 When combining the 3rd 4th input racing kit gear with the standard shift fork 13140 0063 the shift fork interferes with the gear s corner because the chamfer of the shift fork is small When using the 3rd 4th input racing kit gear enlarge the chamfer of the shift fork or use the racing kit shift fork 13140 0625 13140 0625 has enlarged chamfer compared to 13140 0063 Standard See the illustration below Output Shaft 13128 0671 When using the 3rd 4th output gear for the racing kit use the output shaft 13128 0671 for the racing kit If the standard output shaft 13128 0670 is used the shim between the 3rd 4th output gears may fall in the groove of the circlip resulting in a serious failure 8 Engine Sprocket 13144 0021 520 16T 13144 0022 520 17T 9 Racing Kit Service Data Item Standard Cylinder Head Valves Valve timing Duration Intake 296 Exhaust 293 Camshaft timing cam lift center Intake 112 ATDC Exhaust 104 BTDC Valve clearance Intake 0 15 0 22 mm 0 20 mm recommended Exhaust 0 17 0 22 mm 0 20 mm recommended
5. metal foam and made easy to separate Alternator Cover 11061 0755 Clutch Cover 11061 0754 Crankshaft Sensor Cover 11061 0756 Oil Pan 11061 0757 Oil Catch Tank Kit Use the oil catch tank for the engine blowby gas Oil Catch Tank 52001 0553 Tank Capacity Approximately 650 cc A Dampers 92075 277 G Clamps 92171 0338 B Collars 92027 194 H Hose 92192 1025 C Bolts 130BA0620 J Hose 92192 1026 D Oil Catch Tank 52001 0553 K Washer 92022 304 E Bracket 11056 1233 L Bolt 130BD0610 F Bracket 11056 1232 36 Oil Catch Tank Installation Temporarily tighten the mounting bracket E together with the chain cover Tighten the mounting bracket F together with the starter cove Install the damper A and collar B on the bracket of the tank D and fix them to the bracket E and F with the bolt C Tighten the mounting bracket E Cap the draining boss of the oil catch tank with the M6 bolt L and washer K and wire to prevent them from falling out Hose Installation Remove the original breather hose 92192 0889 Install the hose J between the air cleaner and oil catch tank by using the clamp G Install the hose H between the crankcase and the oil catch tank by using the clamp G Run the hoses as shown in the illustration above Regulator Installation Install the standard regulator 21066 0028 on the tank D with the bolt C NOTE Protect the hose and check the no blockade at the
6. 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 12 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 3 Transmission 1 2 TYPE E F G Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13127 13127 0642 SHAFT TRANSMISSION INPUT 15T 1 OPTION 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0615 GEAR OUTPUT LOW 39T 1 OPTION 13262A 13262 0655 GEAR INPUT 6TH 21T 1 OPTION 13262B 13262 0656 GEAR INPUT 6TH 24T 1 OPTION 13262C 13262 0657 GEAR INPUT 6TH 22T 1 OPTION 13262D 13262 0909 GEAR OUTPUT 6TH 26T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J
7. 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 5 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 8 Transmission 2 2 TYPE A Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 6 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 9 Transmission 1 2 TYPE B Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13127 13127 0639 SHAFT TRANSMISSION INPUT 13T 1 OPTION 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0619 GEAR OUTPUT 4TH 31T 1 OPTION 13262A 13262 0624 GEAR OUTPUT LOW 31T 1 OPTION 13262B 13262 0642 GEAR OUTPUT 3RD 34T 1 OPTION 13262C 13262 0652 GEAR INPUT 6TH 21T 1 OPTION 13262D 13262 0881 GEAR INPUT 5TH 18T 1 OPTION 13262E 13262 0895 GEAR INPUT 2ND 19T 1 OPTION 13262F 13262 0898 GE
8. Crankshaft Main Journal Bushing Brown Black Blue Clearance recommend 10 34 m 10 34 m 10 34 m Use the pink bushings when the clearances cannot adjusted within the prescribed allowances even if the brown bushings are used NOTICE Make the clearances between the crankshaft main journals within the prescribed allowances Excessive clearances will cause the oil pressure at the crankshaft main journals to drop and lead to the damage of the bearing 22 Connecting Rod Bolts 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 Make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch or replace the original with the connecting rod bolt 92513 0809 with recesses Connecting Rod 13251 0031 Bolt 92153 0809 Spare Part Attached Recess Nut 92015 1311 Install the 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 ft lb Check the length of the bolts and find the bolt stretch Bolt Length after tightening Bolt Length before tightening Stretch
9. Kit 2 0 92200 0232 Kit 2 Spline washer 2 2 6 92200 0748 Kit 2 8 92200 0749 Kit STD 3 0 92200 0750 Kit 3 Plane washer 0 8 92200 0225 Kit 1 0 92200 0226 Kit 1 2 92200 0051 Kit STD 1 4 92200 0227 Kit 1 6 92200 0228 Kit 33 Use the kit input shafts of the racing kit with the washer adjustment since their sizes are different from the standard shaft designed taking the washer adjustment into account in order to make the dog lengths of the 3rd 5th amp 2nd 6th input gear dogs equal Adjust the dog length of each gears to smooth gear shifting to the 5th and 6th gear Standard Adjusting A 2 Use the standard spline washer t 2 8 mm 92200 0749 B 2 Use the standard spline washer t 1 2 mm 92200 0051 When thin the washer of A 1 B 1 from the standard washer and thickly the washer of A 2 B 2 from the standard washer to increase the dog length of gears Use the kit input shafts of the racing kit with the washer adjustment since their sizes are different from the standard shaft designed taking the washer adjustment into account in order to make the dog lengths of the 3rd 5th amp 2nd 6th input gear dogs equal Adjust the dog length of each gears to smooth gear shifting to the 3rd and 4th gear Standard Adjusting C 1 C 3 Use the standard spline washer t 1 6 mm 92200 0050 Thinner washer for C 1 C 3 increases the dog length Adjust the axial clearance at C 2 34 Engine Sprocket When us
10. 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 1 Tensioner Body 4 O ring 2 Tensioner Rod 5 Locknut 3 O ring 15 Camshafts Sprockets Valve Camshafts Sprockets Camshaft Duration Lift 49118 0718 STD Intake 296 10 3 mm 49118 0719 STD Exhaust 293 9 1 mm 49118 0728 Kit Intake 301 10 5 mm 49118 0729 Kit Exhaust 306 9 1 mm Valve Valve 12004 0044 STD Intake 12005 0059 STD Exhaust In case of using kit camshaft IN 49118 0728 EX 49118 0729 be sure to use kit camshaft sprocket IN EX 12046 0034 as a 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 attached ZX1000JBF KBF Motorcycle Service Manual 99924 1443 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 Valve Timing Timing cam lift center Intake Exhaust When the round bolt hole
11. lowest gauge readings is the amount of the effective stroke of clutch spring plate D Drive Shaft 29 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 value initially measured 30 Spring Plate Assembly The racing kit includes the spring plate assembly to cope with a judder at startup Remove the judder spring washer and innermost steel plate refer to C above figure installed in 11ZX 10R and replace them with the spring plate assembly There are three types of the spring plate assembly with different spring load Decide which one to be used depending on the condition of a judder at startup When adjusting be careful of the length A above figure because the plate thickness is different by the type Measure the length of the spring plate assembly with the spring stuck together by using a vice The standard thickness and number of the spring plate are as follows Adjust as necessary Spring plate 2 6mm 8pcs 13089 0003 Part Number Spring Constant ID Color 13089 0003 Standard None 13089 0011 40 u
12. 1 OPTION 13262 13262 0620 GEAR INPUT 5TH 20T 1 OPTION 13262A 13262 0625 GEAR OUTPUT LOW 34T 1 OPTION 13262B 13262 0643 GEAR OUTPUT 3RD 28T 1 OPTION 13262C 13262 0646 GEAR OUTPUT 4TH 33T 1 OPTION 13262D 13262 0869 GEAR INPUT TOP 23T 1 OPTION 13262E 13262 0896 GEAR INPUT 2ND 18T 1 OPTION 13262F 13262 0899 GEAR OUTPUT 2ND 38T 1 OPTION 13262G 13262 0903 GEAR OUTPUT 5TH 28T 1 OPTION 13262H 13262 0907 GEAR OUTPUT 6TH 31T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 9 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 12 Transmission 2 2 TYPE C Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 10 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1
13. 12046 0034 SPROCKET 32T 2 OPTION 12048 12048 0082 TENSIONER ASSY 1 OPTION 13116 13116 1166 ROD PUSH 1 OPTION 49118 49118 0728 CAMSHAFT COMP INTAKE 1 OPTION 49118A 49118 0729 CAMSHAFT COMP EXHAUST 1 OPTION 92055 92055 0053 RING O 20 8X1 9 1 OPTION 92055A 92055 011 RING O 5MM 1 OPTION 92153 92153 0455 BOLT FLANGED 6X8 4 OPTION 92210 92210 0630 NUT FLANGED 6MM 1 OPTION 2 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 5 Crankshaft Piston s Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92139 92139 0746 BUSHING 1 amp 3 amp 5 BLUE AR OPTION 92139A 92139 0747 BUSHING 1 amp 3 amp 5 BLACK 6 OPTION 92139B 92139 0748 BUSHING 1 amp 3 amp 5 BROWN AR OPTION 92139C 92139 0749 BUSHING 1 amp 3 amp 5 PINK AR OPTION 92139D 92139 0750 BUSHING 2 amp 4 BLUE AR OPTION 92139E 92139 0751 BUSHING 2 amp 4 BLACK 4 OPTION 92139F 92139 0752 BUSHING 2 amp 4 BROWN AR OPTION 92139G 92139 0753 BUSHING 2 amp 4 PINK AR OPTION 92139H 92139 0754 BUSHING CONROD BLUE AR OPTION 92139I 92139 0755 BUSHING CONROD BLACK AR OPTION 92139J 92139 0756 BUSHING CONROD BROWN 8 OPTION 92139K 92139 0757 BUSHING CONROD PINK AR OPTION 3 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 6 Clutch Quantity ZX1000 11 Ref No Part
14. 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 13 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 4 Transmission 2 2 TYPE E F G Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 14 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 5 Transmission 1 2 INPUT3RD 4TH GEAR Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13140 13140 0625 FORK SHIFT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0630 GEAR INPUT 3RD amp 4TH 19T amp 21T A A 1 OPTION 13262A 13262 0632 GEAR INPUT 3RD amp 4TH 19T amp 20T B B 1 OPTION 13262B 13262 0633 GEAR INPUT 3RD amp 4TH 19T amp 21T B A 1 OPTION 13262C 13262 0634 GEAR INPUT 3RD amp 4TH 19T amp 21T B C 1 OPTION 13262D 13262 0637 GEAR INPUT 3RD amp 4TH 16T amp 20T C B 1 OPTION 13262E 13262 0638 GEAR INPUT 3RD amp 4TH 16T amp 21T C A 1 OPTION 13262F 13262 0639 GEAR INPUT 3RD amp 4TH 16T amp 21T C C 1 OPTION 13262G 13262 0640 GEAR INPUT 3RD amp 4TH 21T amp 20T D B 1 OPTION 13262H 13262 0641 GEAR INPUT 3RD amp 4TH 21T amp 21T D A 1 OPTION 13262I 13262 0665 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 OPTION 13262J 13262 089
15. 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 23 Connecting Rod Big End Bushings The connecting rod bushing in the kit has improved its anti seizure feature than standard 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 34 493 34 500 mm None 34 484 34 492 mm Connecting Rod Big End Bore Diameter Marks 37 509 37 516 mm None 37 500 37 508 mm A Diameter Mark or no mark B Weight Mark Alphabet E F etc A Size Color Connecting Rod Big End Bushings Color Kit Bushing Part Number Original Bushing Part Number Thickness Blue 92139 0754 92139 0719 1 488 1 493 mm Black 92139 0755 92139 0720 1 483 1 488 mm Brown 92139 0756 92139 0721 1 478 1 483 mm Pink 92139 0757 1 473 1 478 mm 24 Big End Bushing Selection Crankshaft None None Connecting Rod None None Bushing Brown Black Blue Clearance recommend 30 60 m 30 60 m 30 60 m Use the pink bushings when the clearances cannot adjusted within the prescr
16. Squish 0 85 mm Valve to piston clearance Intake 1 65 mm 10 ATDC Exhaust 1 65 mm 10 BTDC Ignition System Spark plugs NGK CR9EIA 9 STD R0045Q 10 or R0373A 10 Spark plug tightening torque 13 N m 1 3 kgf m 113 in lb These values show the specifications when standard cylinder head and gasket are used 10 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQENCY OPERATION Each Race Every 2races Every 3races Every 5races Every 10races As Required Engine Clutch plate check Throttle grip play check Spark plug clean gap Engine oil change Oil filter replace Cylinder head valve decarbonization Cylinder check Piston cylinder clearance check Piston ring piston and piston pin replace Crankshaft main bearing check Connecting rod big end bearing check Transmission gear bearing check Engine sprocket check Coolant change Radiator hoses connections check Frame Brake operation check Brake pad wear check Brake fluid level check Brake fluid change year Brake master cylinder cup and dust seal replace year Brake caliper piston seal and dust seal
17. 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 For the oil catch tank installation it is necessary for the ABS KIBS equipped motorcycle to remove the ABS unit so that the brake hose routing is the same as the ABS KIBS non equipped motorcycle Be fully aware that the ABS does not work in this case Idle Adjusting Screw Kit The 2011 model ZX 10R provides the idle adjusting screw as the racing kit WARNING This idle adjusting screw works properly only when it is used together with the racing kit ECU 21175 0737 This idle adjusting screw cannot work properly with the standard ECU because the idle control program and fuel cut program in deceleration etc are incorporated in the ECU Moreover unexpected failure may happen which leads to a serious accident Never use this idle adjusting screw together with the standard ECU Idling engine speed and engine characteristics in full closing throttle can be changed by changing the racing kit ECU setting without using this idle adjusting screw Use the idle adjusting screw supplementarily only when the racing kit ECU cannot adjust enough For the deatils refer to the racing kit ECU instruction manual Be careful when adjusting to increase engine speed If the engine speed does not decrease enough excessive speed may lead to a serious accident 37 A
18. replace year Brake hose replace 2 years Drive chain adjust Drive chain lubricate Drive chain wear check 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 Fuel hose fuel filter replace Steering play check Steering stem bearing grease Rear sprocket replace 11 FREQENCY OPERATION Each Race Every 2races Every 3races Every 5races Every 10races As Required General lubrication of chassis perform Wheel bearing rear grease Swingarm pivot uni track linkage grease Swingarm pivot uni track linkage check in the above table means you need to replace add adjust clean or torque if necessary 12 Preparation Before Installing Modify the parts based on your race regulation To avoid misuse keep the parts replaced with the kit parts separate When reusing parts clean them and check them for damage or deterioration Main Removal Parts Lights Rear View Mirrors Side Stand Starter Lockout Switch Remove the side stand switch When the optional main harness is not used connect removing Black Yellow and Green White Leads directly Racing Kit Parts Also we have provided the spare parts
19. 0008 REEL R19 7 65DEG 1 OPTION 59101A 59101 0009 REEL R21 4 60DEG 1 OPTION 92026 92026 0724 SPACER REAR HEIGHT ADJ SET 1 OPTION 92152 92152 0798 COLLAR 8X16X3 5 1 OPTION 120 120CA0518 BOLT SOCKET 5X18 2 OPTION 132 132BA0830 BOLT FLANGED SMALL 8X30 2 OPTION 670 670B2012 O RING 12MM 1 OPTION 20 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Chassis D 4 Front Fork Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 43082 43082 0088 PAD ASSY BRAKE FR F9633 2 OPTION 44026 44026 0163 SPRING FRONT FORK K 9 75N MM 2 OPTION 44026A 44026 0164 SPRING FRONT FORK K 10 75N MM 2 OPTION 55020 55020 0795 GUARD CHAIN 1 OPTION 130 130BA0820 BOLT FLANGED 8X20 1 OPTION 21 DEC 1 2010 Doc No 99929 0547 01
20. 000JBFR Engine B 13 Transmission 1 2 TYPE D Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13127 13127 0641 SHAFT TRANSMISSION INPUT 16T 1 OPTION 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0626 GEAR OUTPUT LOW 37T 1 OPTION 13262A 13262 0644 GEAR OUTPUT 3RD 36T 1 OPTION 13262B 13262 0654 GEAR INPUT 6TH 22T 1 OPTION 13262C 13262 0897 GEAR INPUT 2ND 18T 1 OPTION 13262D 13262 0900 GEAR OUTPUT 2ND 36T 1 OPTION 13262E 13262 0904 GEAR OUTPUT 5TH 30T 1 OPTION 13262F 13262 0908 GEAR OUTPUT 6TH 28T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 11 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 14 Transmission 2 2 TYPE D Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR
21. 1 OPTION 11061B 11061 0756 GASKET PULSER COVER 1 OPTION 11061C 11061 0757 GASKET OIL PAN 1 OPTION 11061D 11061 0758 GASKET STARTER COVER 1 OPTION 92066 92066 1005 PLUG 4 OPTION 17 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 8 Throttle Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 16021 16021 0055 SCREW THROTTLE STOP 1 OPTION 92172 92172 0745 SCREW 1 OPTION 92172A 92172 0746 SCREW REMOTE TYPE 1 OPTION 18 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 9 Fuel Injection Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 11056 11056 1243 BRACKET TIP OVER SENSOR 1 OPTION 21175 21175 0756 CONTROL UNIT ELECTRONIC 1 OPTION 23016 23016 0006 LAMP ASSY INDICATOR 1 OPTION 26031 26031 0999 HARNESS INTERFACE 1 OPTION 26031A 26031 1219 HARNESS KIT 1 OPTION 27002 27002 1062 RELAY ASSY 1 OPTION 130 130BA0616 BOLT FLANGED 6X16 2 OPTION 19 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Chassis D 3 Frame Fittings Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 31064 31064 0187 PIPE COMP GRIP 1 OPTION 32099 32099 0046 CASE UPP 1 OPTION 32099A 32099 0047 CASE LWR 1 OPTION 54012 54012 0570 CABLE THROTTLE HI 2 OPTION 59101 59101
22. 1 GEAR INPUT 3RD amp 4TH 19T amp 21T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 15 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 6 Transmission 2 2 INPUT3RD 4TH GEAR Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 16 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine C 7 Engine Cover s Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 11004 11004 0719 GASKET HEAD T 0 65 1 OPTION 11004A 11004 0720 GASKET HEAD T 0 60 1 OPTION 11004B 11004 0721 GASKET HEAD T 0 55 1 OPTION 11004C 11004 0722 GASKET HEAD T 0 50 1 OPTION 11061 11061 0754 GASKET CLUTCH COVER 1 OPTION 11061A 11061 0755 GASKET GENERATOR COVER
23. AR OUTPUT 2ND 37T 1 OPTION 13262G 13262 0902 GEAR OUTPUT 5TH 26T 1 OPTION 13262H 13262 0906 GEAR OUTPUT 6TH 29T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION 92200C 92200 0227 WASHER 28 1X34 0X1 4 AR OPTION 92200D 92200 0228 WASHER 28 1X34 0X1 6 AR OPTION 92200E 92200 0229 WASHER 28 3X34 0X1 2 AR OPTION 92200F 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 7 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 10 Transmission 2 2 TYPE B Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 92200G 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200H 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 92200I 92200 0748 WASHER 28 3X34 0X2 6 AR OPTION 92200J 92200 0749 WASHER 28 3X34 0X2 8 AR OPTION 92200K 92200 0750 WASHER 28 3X34 0X3 0 AR OPTION 8 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 11 Transmission 1 2 TYPE C Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13127 13127 0640 SHAFT TRANSMISSION INPUT 14T 1 OPTION 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520
24. Factory made 2 Pit lane Engine Revolution Limit Functions The speed control function is activated by pushing the turn signal switch 3 Shift Indicator Functions The standard meter can be used as the shift up indicator The shift up indicator light can be used together with it or whichever can be used 4 Launch Control Functions The engine revolution limit can be set at start up 5 Engine Brake Control Functions By setting the ISC opening angle the engine characteristics can be adjusted when the engine brake is applied 6 Traction Control Setting Functions The traction control S KTRC setting can be changed Any three modes can be selected from the preset 33 modes and can be switched during riding 3 modes OFF 7 Power Mode Setting Functions In addition to the engine brake control mentioned above the fuel injection compensation fuel compensation in acceleration ignition timing correction and subthrottle opening correction etc can be set in three modes independently Any three preset modes can be switched during riding NOTE The racing kit ECU does not operate excluding the combination with the racing kit harness 26031 1219 For the kit harness installation refer to Electric Parts Installation in this manual The kit ECU can be installed on both ABS KIBS equipped non equipped motorcycles by using the kit harness However the ABS stops functioning There is no ABS compliant kit ECU Be fully aware that the ABS do
25. Ninja ZX 10R Ninja ZX 10R ABS 2011 Ninja ZX 10R Racing Kit Manual This manual contains only the information of the racing kit parts Refer to the base manual listed below for information of the original model Base Manual Part Number Ninja ZX 10R Ninja ZX 10R ABS Motorcycle Service Manual 99924 1443 01 2010 Kawasaki Heavy Industries Ltd First Edition 0 Dec 28 2010 1 How to Use This Manual Whenever you see symbols heed their instructions Always follow safe operating and maintenance practices DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the proc
26. No Description Spec Code JBFR 13089 13089 0003 PLATE CLUTCH STD 1 OPTION 13089A 13089 0011 PLATE CLUTCH STD 40 1 OPTION 13089B 13089 0012 PLATE CLUTCH STD 60 1 OPTION 13091 13091 1041 HOLDER CLUTCH SPRING 6 OPTION 39108 39108 0005 RETAINER SPRING STD 1MM 6 OPTION 92022 92022 304 WASHER 6 2X11X1 6 OPTION 4 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 7 Transmission 1 2 TYPE A Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 13127 13127 0638 SHAFT TRANSMISSION INPUT 15T 1 OPTION 13128 13128 0671 SHAFT TRANSMISSION OUTPUT 1 OPTION 13144 13144 0021 SPROCKET OUTPUT 16T 520 1 OPTION 13144A 13144 0022 SPROCKET OUTPUT 17T 520 1 OPTION 13262 13262 0618 GEAR OUTPUT 3RD 33T 1 OPTION 13262A 13262 0622 GEAR INPUT 6TH 23T 1 OPTION 13262B 13262 0645 GEAR OUTPUT 4TH 32T 1 OPTION 13262C 13262 0648 GEAR INPUT 5TH 21T 1 OPTION 13262D 13262 0664 GEAR OUTPUT LOW 38T 1 OPTION 13262E 13262 0856 GEAR INPUT 2ND 19T 1 OPTION 13262F 13262 0880 GEAR OUTPUT 2ND 39T 1 OPTION 13262G 13262 0901 GEAR OUTPUT 5TH 29T 1 OPTION 13262H 13262 0905 GEAR OUTPUT 6TH 30T 1 OPTION 92152 92152 1522 COLLAR SPROCKET 1 OPTION 92200 92200 0051 WASHER 28 1X34 0X1 2 AR OPTION 92200A 92200 0225 WASHER 28 1X34 0X0 8 AR OPTION 92200B 92200 0226 WASHER 28 1X34 0X1 0 AR OPTION
27. STD 2 6 13089 0009 STD 2 9 13089 1093 STD 26 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 8 mm 52 5 52 9 mm 13091 1041 Washer 92022 304 7 mm 6 mm 1 mm 39108 0005 7 mm 51 9 52 4 mm 13091 1041 6 mm If you have clutch slip during acceleration use shorter spring retainers by one size to increase preload of clutch springs 27 For 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 A Collar I Washer B Needle Bearing J Judder Spring C Bushing K Friction Plates 36 Slots 8 Plates D Clutch Housing L Steel Plates t 2 9 mm 7 Plates E Spacer M Steel Plates t 2 6 mm 2 Plates F Clutch Hub N Spring Retainer G Sub Clutch Hub P Spring Retainer H Friction Plates 48 Slots 2 Plates 28 Engage the cam followers Clutch Hub with the cams Sub Clutch Hub To measure the effective stroke of clutch spring plate set a dial gauge A against the center B of the clutch spring plate Move the clutch housing gear back and forth C The difference between the highest and
28. Stopper Original E Locknut Kit B Locknut Original F Spring C Idle Adjust Screw Set 16021 0055 G Adjust Screw 92172 0745 D Stopper Kit H Remote Adjusting Screw 92172 0746 Idle Adjusting Screw Kit Installation Before the installation check if the input output voltage is within the proper range For the confirmation refer to the attached ZX1000JBF KBF Motorcycle Service Manual 99924 1443 Put a cloth between the throttle valve and body to prevent the throttle valve from interfering with the body Remove the standard stopper A and lock nut B Install the stopper of the kit D Tighten enough the stopper so that the throttle valve does not interfere with the body when removing the cloth Remove the cloth and adjust the stopper D position so that the output voltage is within the proper range DC 0 645 0 675 V Fix it with the lock nut E Install the spring F and adjusting screw G The adjusting screw G can be replaced with the remote adjusting screw H if necessary When decreasing the idling engine speed always use the adjusting screw in contact with the throttle pulley The stopper does not contact throttle pulley 38 ECU Kit The 2011 model ZX 10R kit ECU has following functions Refer to the Kawasaki FI Calibration Tool Instruction Manual 99929 0549 01 for the ECU function set up method 1 Auto Shift Functions Be sure use the point type sensor Recommended Dynojet made or Battle
29. ads are for higher braking force Front Brake Pads P No Stamp Braking Force 43082 0088 F9633 High Original C93YW 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 1 Recommended Steering Damper OHLINS SD001 Stroke 68 mm Install the steering damper as shown in the figure below 1 Steering Damper OHLINS SD001 2 Bolts 130BA0830 3 Washer 410AA0800 4 O ring 670B2012 5 Collar 92152 0798 44 Height Adjustment Remove the nut 1 and replace the nut with a new one Insert the spacer 2 as required Tighten the new nut 1 to 59 N m 6 0 kgf m 43 ft lb of torque 1 Nut 92015 1316 Standard 2 Spacer Set 92026 0724 3 Bracket 32037 0149 Standard Spacer Set 92026 0724 P No Quantity Thickness 92026 0721 3 1 0 mm 92026 0722 3 2 0 mm 92026 0723 3 3 0 mm 45 Front Fork Springs Kit The optional front fork springs are available for racing 1 Front Fork Spring P No Spring Constant Original K 10 25 N mm 44026 0163 K 9 75 N mm 44026 0164 K 10 75 N mm 2 Front Fork Spring Replacement Replace the main spring referring to the Fork Oil Change section
30. and other optional parts engine frame and electric parts for racing So please order each parts referring to the Racing Kit Parts List in the back of this manual 13 Engine Parts Installation Air Intake Parts Remove the air cleaner element or cut the cleaner element off remaining the air cleaner element plate to reduce the air flow resistance 1 Relational Parts of Secondary Air Remove the Parts 2 Remove the parts or cut the cleaner element off remaining the air cleaner element plate 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 14 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 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 NOTICE
31. deg 65 59101 0009 R21 4 60deg 60 The throttle cases throttle pipe and reels are interchangeable with those of 10 model 1 Identification Mark 1 Upper Case 32099 0046 4 Reel 65 59101 0008 2 Lower Case 32099 0047 5 Reel 60 59101 0009 3 Bolts 120CA0518 6 Grip 31064 0187 41 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 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 The throttle cable is newly designed for 11 model and incompatible with the kit parts for 10 model See the illustration below for installation Run the accelerator cable over the master cylinder and run the decelator cable under the master cylinder 42 Run the both cables between the left side of the head pipe and the front fork and connect it to the throttle body from the left of the frame Drive Chain Parts Kit 1 Chain Guard 1 Guard 55020 0795 2 Bolt 130BA0820 3 Swingarm Left Side 43 Brake Pads Kit The front and rear brake pads for racing use are available The front p
32. edural step or sub step it follows 2 Congratulation on your purchase of racing kit parts for the 2011 Ninja ZX 10R IMPORTANT This manual provides how to install racing kit parts for the 2011 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 1443 01 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 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 NOTE 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 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 3 Table of Contents Gen
33. eral Specifications 4 Racing Kit Service Data 9 Periodic Maintenance Chart 10 Preparation 12 Before Installing 12 Racing Kit Parts 12 Engine Parts Installation 13 Air Intake Parts 13 Camshaft Chain Tensioner 14 Camshafts Sprockets Valve 15 Cylinder Head 17 Cylinder Compression
34. es not work and drive carefully when the kit ECU is installed on the ABS KIBS equipped motorcycle In circuit racing on ABS KIBS equipped motorcycle without the racing ECU be fully aware as follows The ABS is designed to prevent wheel lock when the brakes are suddenly applied in straight running The ABS is not designed to shorten the braking distance The braking distance can be longer in the ABS equipped motorcycle than in non equipped motorcycle on slipperly rough or downhill road surface Drive carefully on such road conditions 39 WARNING ABS KIBS cannot protect the rider from all possible hazards and is not a substitute for safe riding practices Be aware of how the ABS KIBS system operates and its limitations It is the rider s responsibility to ride at appropriate speeds and manner for weather road surface and traffic conditions 40 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 throttle grip 1 Throttle Case Parts Name P No Throttle Case Upper 32099 0046 Throttle Case Lower 92099 0047 Bolts 2 120CA0518 Grip 31064 0187 2 Throttle Reels Tow types are available Throttle Reel Travel Angle Effective angle excluding throttle cable free play P No I D Mark Throttle Grip Turn Angle to Full Throttle 59101 0008 R19 7 65
35. ibed allowances even if the brown bushings are used NOTICE 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 25 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 The standard setting of length A total thickness of clutch plates shown below becomes about 53 5 mm t 2 9 7 pcs t 2 6 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
36. ing the engine sprocket for the racing kit combine it with the dedicated collar and be careful of the direction of the sprocket Install the sprocket so that the teeth number mark 16 or 17 faces to the outside of the body A Engine Sprocket 13144 0021 16T or 13144 0022 17T Install the sprocket so that the teeth number mark 16 or 17 faces to the outside of the body B Dedicated Collar 92152 1522 with identification groove Muffler With recommended muffler engine performance can be improved Recommended muffler LeoVince Home Page http www leovince com LeoVince For further information contact the manufacture of muffler directly Radiator 2011 model ZX 10R racing kit provides the recommended radiator to improved the cooling function Recommended radiator Taleo Tecnoracing made Home Page http www taleotecnoracing com For further information about the radiator contact the manufacturer 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 Be sure to connect the water temperature sensor to the main harness either race kit main harness for race kit E C U or original main harness for original E C U 35 Cover Gaskets Kit The kit cover gasket are available of the 2011 model ZX 10R They are made from
37. 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 1 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 With the compression ratio rise the maximum horsepower increases while handling of the throttle in the slight opening range tends to become harder It is recommended to drive with only squish adjustment by the gasket without grinding the cylinder head at first 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 19 Cylinder Head Gasket Part No Tightening thickness Remarks ID Number 11004 0719 0 65 mm STD KIT 65 11004 0720 0 60 mm KIT 60 11004 0721 0 55 mm KIT 55 11004 0722 0 50 mm KIT 50 As for the cylinder head casket of the racing kit oil supply hole to the cam is smaller than the standard one to change the fuel di
38. 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 17 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 A Stepped Portions 18 NOTE These procedures make air resistance less and intake exhaust gas flow more smooth However much more effect cannot be expected by excessive grinding and smoothing It may be done to the extent of getting rid of uneven surfaces 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
39. of the base Service Manual ZX1000JBF KBF Motorcycle Service Manual 99924 1443 Identification Mark The identification slit for a spring constant valve is stamped on the one end face of the spring 46 Electric Parts Installation Battery Use the original battery or a battery with 12 V 6 Ah or more capacity Main Harness Main harness 26031 1219 is available for racing use as a kit The kit ECU does not operate excluding the combination with the kit main harness The relay assy 27002 1062 is needed to use the kit harness See the upper illustration of page 48 The ABS KIBS does not work with the kit ECU and kit harness To install the oil catch tank mentioned in another section the ABS KIBS unit must be removed Shift Up Indicator Light Use the original shift up indicator light functions of the meter The kit light 23016 0006 can be connected as a rider s option When using the kit shift up indicator light fix it near the meter Handle Switch Use the original handlebar switch housing Push the turn signal switch on the left handlebar switch housing to the right or left to activate the speed limiting function on a pit lane Push the turn signal switch in the center position to deactivate the speed limit function 47 Vehicle down Sensor Installation When using the kit main harness move the vehicle down sensor to the back of the meter 1 Bracket 11056 1243 5 Collars 92152 0134 2 Bolts 130BA0616 6 Dam
40. p comparison standard White 13089 0012 60 up comparison standard Blue Identification Color The ID marks are on the springs between the steel plates 31 A Collar G Sub Clutch Hub B Needle Bearing H Friction Plates C Bushing I Spring Plate Assembly D Clutch Housing J Steel Plates E Spacer K Spring Plate F Clutch Hub L Spring Retainer 32 Transmission The 2011 model ZX 10R adopts the cassette transmission and the gears can be changed with the engine equipped For the engine assembly and disassembly refer to the attached ZX1000JBF KBF Motorcycle Service Manual 99924 1443 Type A G of the kit gears are available of the racing kit To change the gear ratios with combination the gears The output shaft and 5th output gear for the racing kit have no space to install of the steel balls Remove the three steel balls 600A0500 from the output shaft assembly This is done to start easily the engine with the second gear The output shaft and 5th output gear for the racing kit have no space to install of the steel balls Replace the circlips with new ones if they were removed Transmission Shimming By using washers with various thickness keep the axial clearance between 0 3 mm and 0 4 mm to prevent the inclination of gears and to keep smooth gear shifting Thickness mm Part No Remarks 1 Spline washer 1 1 2 92200 0229 Kit 1 4 92200 0230 Kit 1 6 92200 0050 Original 1 8 92200 0231
41. pers 92075 1912 3 Vehicle down Sensor 21176 0026 7 Nuts 92210 0007 4 Bolts 120CA0522 48 Main Harness Installation 1 Connect to the fuel pump Black 4 Connect to the relay assy Black 2 Connect to the rear speed sensor Black 5 Connect to the starter relay Black 3 Fuse Natural 6 Connect to the interface harness Black For use of the setting tools refer to the attached Kawasaki FI Calibration Tool Kawasaki Racing Tool Instruction Manual 99929 0549 01 49 Front Rear Speed Sensor The sensors attached on the side of the front rear wheel are related to the control functions such as the traction control S KTRC and pit lane speed limit so they are removable in both the ABS KIBS equipped or non equipped motorcycles Refer to the dimensions illustrated below to change the components around the front rear wheels Even if a replacement is installed properly the speed sensor may malfunction due to noise etc Ask a tuning shop to make parts Front Speed Sensor Sensor detecting point 138 8 139 2 from the center of the axle The number of the rotor teeth for speed detection 48 The distance from the sensor end to the rotor 0 4 1 6 mm 0 02 0 06 in Sensor installation angle 90 See the illustration below 50 Rear Wheel Speed Sensor Sensor detecting point 89 8 90 2 from the center of the axle The number of the rotor teeth for speed detection 50 The di
42. s are used Original 112 Original camshaft 104 Original camshaft When the long bolt holes are used 113 Kit camshaft 108 Kit camshaft NOTE When grinding the cylinder head bottom surface grinding the cylinder top surface or 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 16 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 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 the camshaft chain timing Turn the crankshaft by two rotations or
43. shifting to the 1st to 4th is improved The 5th 6th output gears have interchangeability with other standard gears However the racing kit gear is recommended for use in the shifting reliability point of view Other 5th 6th output gear types for the racing kit gear have also adopted the machined dogs Input 3rd 4th Gear Selection Table Gear Identification Sulit Number 3rd 4th 4th Gear A B C 3rd Gear A 13262 0630 1 1 13262 0665 1 0 13262 0891 0 0 STD B 13262 0633 2 1 13262 0632 2 0 13262 0634 2 2 C 13262 0638 0 1 13262 0637 0 0 13262 0639 0 2 D 13262 0641 3 1 13262 0640 3 0 Both the 3rd 4th input gear type A C 13262 0891 Standard and the type C B 13262 0637 have no gear Identification slits so identify the type by the number of teeth 13262 0891 19T 21T 13262 0637 16T 20T 7 Gear Identification Slit Number Table Type A Type B Type C Type D Type E Type F Type G 1st Input 1 2 3 4 0 Output 1 2 3 4 0 STD 2nd Input 0 STD 1 2 3 Output 0 STD 1 2 3 3rd Input See Gear Selection See Gear Selection See Gear Selection See Gear Selection Output 0 1 2 3 4th Input See Gear Selection See Gear Selection See Gear Selection Output 1 0 2 5th Input 2 2 STD 1 2
44. stance from the sensor end to the rotor 0 4 1 6 mm 0 02 0 06 in Sensor installation angle 90 See the illustration below 51 Front Rear Speed Detection Rotor The standard rotor is recommended for the front rear speed detection NOTE Because the front rear wheel speed sensors are magnetic type use magnetic iron material and conform the number and shape of the teeth to those of the standard rotor Front Wheel Rotor 21007 0166 Rear Wheel Rotor 21007 0167 52 Wiring Diagram 53 54 Dummy page Racing Kit Parts List This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 3 Oil Catch Tank Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 11056 11056 1232 BRACKET OIL TANK UPP 1 OPTION 11056A 11056 1233 BRACKET OIL TANK LWR 1 OPTION 52001 52001 0553 TANK OIL 1 OPTION 92022 92022 304 WASHER 6 2X11X1 1 OPTION 92027 92027 194 COLLAR L 11 1 2 OPTION 92075 92075 277 DAMPER 2 OPTION 92171 92171 0338 CLAMP 4 OPTION 92192 92192 1025 TUBE TANK A C 1 OPTION 92192A 92192 1026 TUBE CASE TANK 1 OPTION 130 130BA0620 BOLT FLANGED 6X20 4 OPTION 130A 130BD0610 BOLT FLANGED 6X10 1 OPTION 1 DEC 1 2010 This catalog covers GRID NO This grid covers 11 ZX1000JBFR Engine B 4 Camshaft s Tensioner Quantity ZX1000 11 Ref No Part No Description Spec Code JBFR 12046
45. stribution in the engine For circuit riding it is recommended to use the cylinder head gasket for the racing kit even when using the standard thickness cylinder head gasket NOTE When grinding the cylinder head lower 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 20 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 Crankcase Main Bearing Inside Diameter Marks 38 000 38 008 mm None 38 009 38 016 mm Mark portion 1 5 A Size Color Crankshaft Main Journal Bushings Color Kit Bushing 1 3 5 Kit Bushing 2 4 Standard Bushing 1 3 5 Standard Bushing 2 4 Thickness Blue 92139 0746 92139 0750 92139 0298 92139 0301 1 499 1 503 mm Black 92139 0747 92139 0751 92139 0299 92139 0302 1 495 1 499 mm Brown 92139 0748 92139 0752 92139 0300 92139 0303 1 491 1 495 mm Pink 92139 0749 92139 0753 1 487 1 491 mm 21 Crankshaft Main Journal Bushing Selection Crankshaft 1 1 None None Crankcase None None
46. t In 39 19 37 19 38 18 36 18 Gear Ratio 2 053 1 947 2 111 2 000 3rd In See Gear Selection See Gear Selection See Gear Selection See Gear Selection Out 13262 0618 13262 0803 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 4th In See Gear Selection See Gear Selection See Gear Selection Out 13262 0645 13262 0619 13262 0646 13262 0804 STD Teeth Out In 32 21 31 20 33 21 Gear Ratio 1 524 1 550 1 571 5th In 13262 0648 13262 0881 STD 13262 0620 13262 0648 Out 13262 0901 13262 0902 13262 0805 STD 13262 0903 13262 0904 Teeth Out In 29 21 29 20 28 20 30 21 Gear Ratio 1 381 1 450 1 400 1 429 5 Type A Type B Type C Type D Type E Type F Type G 6th In 13262 0622 13262 0652 13262 0869 STD 13262 0654 13262 0655 13262 0656 13262 0657 Out 13262 0905 13262 0906 13262 0907 13262 0806 STD 13262 0908 13262 0909 13262 0905 13262 0906 Teeth Out In 30 23 29 21 31 23 28 22 26 21 30 24 29 22 Gear Ratio 1 304 1 381 1 348 1 273 1 238 1 250 1 318 in the above table means you need to take care of gear identifica
47. tion etc The difference between the 1st input shaft type E 13127 0636 Standard and 13127 0642 is that 13127 0642 is based on the shim adjustment against 13127 0636 Standard Refer to the Transmission Shimming in the Transmission section Both types are different in tooth width so identify the type by the tooth width See the illustration below The difference between the 3rd output gear type A 13262 0803 Standard and 13262 0618 is that 13262 0618 is based on the shim adjustment against 13262 0803 Standard Refer to the Transmission Shimming in the Transmission section Both types are different in boss width so identify the type by the boss width See the illustration below 6 The difference between the 4th output gear type C 13262 0804 Standard and 13262 0646 is that 13262 0646 is based on the shim adjustment against 13262 0804 Standard Refer to the Transmission Shimming in the Transmission section Also the 4th output gear type B 13262 0619 has no gear identification slit like 13262 0804 Standard 13262 0804 Standard and racing kit gear are different in boss width so identify the type by the boss width See the illustration below The 5th 6th output gears for the racing kit 13262 0902 13262 0907 have machined dogs so that reliability of shifting is improved compared to the standard gears 13262 0805 13262 0806 By using the 5th 6th output gears with the machined dogs reliability of

2011 Ninja ZX-10R Racing Kit Manual

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