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2006 - 2007 Kawasaki ZX-10R Service Manual

1. 340 FUEL SXSTEM DFI www zxforums com www zxforums com DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Speed sensor trouble Inspect see chapter 3 Throttle valves won t fully open Inspect throttle cable and lever linkage see chapter 3 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17 Engine oil level too high Repair see chapter 7 Engine oil viscosity too high Change see chapter 2 Drive train trouble Inspect drive chain see chapter 2 and sprockets see chapter 11 Camshaft cam worn Inspect and replace see chapter 5 Air switching valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Catalytic converters melt down due to muffler Replace muffler see chapter 5 overheating KLEEN Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Replace the guide see chapter 5 Engine oil level too high Repair see chapter 7 Black smoke Air cleaner clogged Clean see chapter 3 Too high fuel pressure Inspect see chapter 3
2. GP30167BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRI CAL SYM 6 93 Immobilizer System Equipped Models When Registered User Key is Inserted 0 5second 0 5second ttt ae 9 EE EE GP30166BS1 User Key Collation Error 0 3second gt CORA il GP30168BS1 e The user key 2 is registered in the ECU OThe warning indicator light LED and immobilizer warn ing symbol A blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends GP30170BS1 e Warning indicator light LED goes off A GP30171BS1 NOTE OTurn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys Case 4 When master key is faulty or lost The master key replacement is considered very rare case However if it is required the following is necessary NOTE OThe ECU must be replaced with a new one because the master key code that is registered in the current ECU can not be rewritten www zxforums com www zxforums com www zxforums com 1 6 94 ELEGTRIGAL SYSTEM www zxforums com www zxforums com Immobilizer Sys
3. O a N K ged BK Y 2 BR R haga anl 1 Meter Unit 2 Warning Indicator Light LED 3 Frame Ground 4 ECU www zxforums com www zxforums com www zxforums com 3 11 AMES EM DFI www zxforums com www zxforums com Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Front Seat see Front Seat Removal in the Frame chap ter Steering Damper see Steering Damper Removal in the Steering chapter Fuel Tank Bolts A e Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assy and fuel pump e Remove the fuel hose see Fuel Tank Removal A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel supply pipes of the fuel pump and throttle body assy e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Do not try to start the engine with the fuel hoses disconnected e Turn the ignition switch ON The fuel pump will tu
4. HLL Gn GS07022BS1 e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows a b c d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value 0 195 d Replace Shim Thickness Example 1 600 0 31 0 195 1 715 mm OExchange the shim for the 1 725 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 25 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1 300 92180 0108 130 1 325 92180 0109 132 1 350 92180 0110 135 1 375 92180 0111 138 See 1 400 92180 0112 140 1 425 92180 0113 142 E 1 450 92180 0114 145 1 475 92180 0115 148 1 500 92180 0116 150 1 525 92180 0117 152 1 550 92180 0118 155 1 575 92180 0119 158 1 600 92180 0120 160 1 625 92180 0121 162 1 650 92180 0122 165 1 675 92180 0123 168 1 700 92180 0124 170 1 725 92180 0125 172 1 750 92180 0126 175 1 775 92180 0127 178 1 800 92180 0128 180 1 825 92180 0129 182 1 850 92180 0130 185 1 875 92180 0131 188 1 900 92180 0132 190 1 925 92180 0133 192 1 950 92180 0134 195 1 975 92180 0135 198 2 000 92180 0136 200
5. Piston Diameter Standard 75 959 75 974 mm 2 9905 2 9911 in Service Limit 75 81 mm 2 9846 in GE16162BS1 Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance GE16163BS1 Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 03 0 07 mm 0 0012 0 0028 in Service Limit Top 0 17 mm 0 0067 in Second 0 17 mm 0 0067 in www zxforums com www zxforums com www zxforums com www zxforums com www zxforum Ed AN KSHAFT TRANSMISSION 9 29 Pistons Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 82 0 84 mm 0 0323 0 0331 in Second B 0 82 0 84 mm 0 0323 0 0331 in Service Limit Top A 0 92 mm 0 036 in Second B 0 92 mm 0 036 in lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standar
6. 6017152081 www zxforums com www zxforums com www zxforums com FUEL SYSTEMUREN 3 65 Water Temperature Sensor Service Code 14 e Turn the ignition switch OFF x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section x If the output voltage is far out of the specified e g when the wiring is open the voltage is about 5V check the wiring see wiring diagram in this section x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the ECU connector for waterproof ing Sealant Kawasaki Bond Silicone Sealant 56019 120 Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter see Water Temperature Sen sor Inspection in the Electrical System chapter Water Temperature Sensor Circuit Y 6C17153CW2 1 ECU 2 Meter Unit 3 Water Temperature Sensor 4 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 66 MESS TEM DFI www zxforums com www zxforums com Atmospheric Pressure Sensor Service Code 15 CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Removal e Turn the
7. Immobilizer Amplifier KLED Light Emitting Diode Joint Connector 1 ota Hi Front Right Turn Signal Light 12 21 Right City Light 12V5N S casilla Headlight LO 12Y55 Left City Light 12458 Front Left Turn Signal Light 124218 Left Switch Housing Horn Button Passing Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Lap Time Button Relay Box Oxygen Sensor Heater Fuse 104 Headlight Fuse 104 Relay Box Fan Fuse 15A 6 Taillight Fuse 104 7 8 Fan Relay Headlight Relay Unused Fuel Pump Relay EGU Fuse 154 Igniton Fuse 154 Turn Signal Relay Horn Fuse 104 Fuse 104 LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Starter Lockout SritchLap Time Button Bassing Button Horn Button Starter Circuit Relay Color BK WBK Y olor GY Color Al SEH Color BK R Color W R Color BL YR BK HI Clutch Lever Push DFF on Released Push R a O LO Pulled inj O www zxforums com www zxforums com W2L0223EW5 C www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 15 Wiring Diagram Other than United States Canada New Zealand Colombia Tai wan Australia and Malaysia Sub Crankshaft throttle Sub Main Sensor Valve throttle Throttle Inlet Air Fuel Injectors Weeer Sensor Sensor Pressure E Gear Position Swit
8. Do not tap the coil head while installing the coil Se e Connect the stick coil connectors e Run the hoses and harness correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the left and right engine bracket see Engine Instal lation in the Engine Removal Installation chapter e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 43 Ignition System Stick Coil Ignition Coil together with Spark Plug Cap Inspection e Remove the stick coils see Stick Coil Ignition Coil to gether with Spark Plug Cap Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 kQ range and read the tester Ignition Coil Winding Resistance Primary Windings 1 2 1 60 Secondary Windings 8 5 11 5 KQ x If the tester does not read as specified replace the coil Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Ignition Coil to gether with Spark Plug Cap Removal ODo not remove the spark plug e Measure the primary peak voltage as follow
9. OAfter making the 32 grind return to the seat O D mea surement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat lf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above www zxforums com www zxforums com GE15011981 GE15012181 A GE15012281 www zxforums com 5 36 ENGINE TOP E N D www zxforums com www zxforums com Valves x If the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B GE15012381 CAUTION Do not lap the exhaust valve to the exhaust valve seat using the grinding compound It will come off oxide film treated surface of the valve e Lap the inlet valve to the inlet valve seat once the seat width and O D are within the ranges specified above OPut a little coarse grinding c
10. 92139 0033 2 3 4 92139 0029 1 5 92139 0032 2 3 4 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums QRAN KSHAFT T RANSMISSION 9 9 Special Tools and Sealants Bearing Puller Piston Pin Puller Assembly 57001 135 57001 910 ST5701358T S ST5709108T Outside Circlip Pliers Piston Ring Compressor Grip 57001 144 57001 1095 ST5701448T ST5710958T Bearing Puller Adapter Piston Ring Compressor Belt 67 79 57001 317 57001 1097 ST570317ST ST571097ST Bearing Driver 32 Kawasaki Bond 57001 382 92104 1064 T5703828T ST9210648T www zxforums com www zxforums com www zxforums com 9 1 0 GRANKRHAFT T RANSM ISSN sorums com www zxforums com Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Crankshaft Sensor see Crankshaft Sensor Removal in the Electrical System chapter Starter Clutch see Starter Clutch Removal in the Elec trical System chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Clutch see Clutch Removal in the Clutch chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Alternator Rotor se
11. Chain Guide Wear Inspection e Remove Swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A and fittings x If the brake fluid leaked from any position inspect or re place the problem part Brake Hose Damage and Installation Condition Inspection e Inspect the brake hoses and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any crack B bulge C or leakage is noticed x Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Inspect the brake hose routing x If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter GL10020181 Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road x lf the brake operation is insufficiency inspect the brake system When inspecting by running the vehicle note a surrounding traffic situation eno
12. e Connect a digital meter A to the connector of the vehicle down sensor B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Vehicle down sensor Power Source Voltage Connections to Sensor Meter BL lead D Meter CH BR BK lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Power Source Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF x lf there is no voltage check the following Battery see Charging Condition Inspection in the Elec trical System chapter ECU Main Fuse 15 A see Fuse Inspection in the Elec trical System chapter x If the power source is normal check the output voltage 6017357BS2 C e Turn the ignition switch OFF e Remove the vehicle down sensor ODo not disconnect the sensor connector e Connect a digital meter A to the connector with needle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down sensor Output Voltage Connections to Sensor Meter Y G lead C Meter CH BR BK lead D e Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more E right or left then hold the sensor almost vertical with the arrow mark pointed up and measure the output voltage Output Voltage at Sensor Standard with sensor arrow mark poin
13. www zxforums com www zxforums com www zxforums com 3 42 FUEL SXSTE M D Fl www zxforums com www zxforums com Self Diagnosis Dealer Mode The LCD Liquid Crystal Display display the service code s A to show the problem s which the DFI system ignition system and immobilizer system has at the moment of diagnosis Self diagnosis Procedures OWhen a problem occurs with the DFI system and ignition system the warning indicator light LED A and Fl warn ing symbol B blinks OFor models equipped with an immobilizer system when a problem occurs with the system the warning indicator light LED and immobilizer warning symbol C blinks NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light LED and symbol blinks very slowly or do not blink www zxforums com www zxforums com 6017269082 Est CLOCK D Fit Zu nn gt Tae HH 6017197082 www zxforums com www zxforums com www zxforums com FU EL SYR TEM RE 3 43 Self Diagnosis e Turn the ignition switch ON e Push the Mode button A to display the odometer ODO LILA 6017199082 e Push the RESET button A for more than two seconds e The service code B is displayed on the LCD by the num ber of two digits OAfter switching to the engine speed setting mode of the shift up indicator light LED from odometer display the s
14. Maintenance Procedure Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assembly see Throttle Body Assembly Removal in the Fuel System DFI chapter Thermostat Housing A see Thermostat Housing Re moval in the Cooling System chapter Oil Cooler B see Oil Cooler Removal in the Engine Lubrication System chapter Water Pump C see Water Pump Removal in the Cool ing System chapter Fitting D Hoses E O rings F e Apply grease to the new O rings and install them e Instal the new hoses and tighten the clamps securely Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in lb e Fill the coolant see Coolant Change e Check the cooling system for leaks E E GER XX al www zxforums com www zxforums com WWww zxforemg e www zxforums com www zxforums com PERIODIC MAINTENANCE 2 53 Maintenance Procedure Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 20 N m 2 0 kgf m 15 ft Ib
15. NA GE04032BS1 www zxforums com 16 68 ELECTRICAL SYSTEM www zxforums com www zxforums com Radiator Fan System Fan Motor Inspection e Remove the left upper inner fairing see Upper Inner Fair ing Removal in the Frame chapter e Disconnect the connector A e Using an auxiliary leads supply battery power to the fan motor x lf the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Circuit GP15040BW3 C 1 Ignition Switch 2 Joint Connector 1 3 Fuse Box 4 Fan Fuse 10 A 5 Relay Box 6 Radiator Fan Relay 7 Main Fuse 30 A 8 Battery 12 V 10 Ah 9 Frame Ground 10 ECU 11 Water Temperature Sensor 12 Water proof Joint 2 13 Radiaidorhans com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 69 Meter Gauge Indicator Unit Meter Unit Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Screws A with Washers CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction e Tighten Torque Meter Unit Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Installation Screws A Lower Meter Cover B e Separate the meter assembly A and upper meter cover B www zxfor
16. www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING AR IEM 4 9 Coolant Coolant Reserve Tank Installation e Install the following to the coolant reserve tank A Rubber Dampers B Collars C Gasket D Cap E e Tighten Torque Coolant Reserve Tank Mounting Bolts F 7 0 N m 0 71 kgf m 62 in Ib e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Fill the coolant reserve tank with coolant see Coolant Change in the Periodic Maintenance chapter www zxforums com www zxforums com GD05019BS2 C www zxforums com 4 1 O GPQLING SYSTEM www zxforums com www zxforums com Water Pump Water Pump Removal e Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove the water hoses A e Remove Water Pump Cover Bolts A Water Pump Cover B e Remove the water hose A e Remove the water pump body B with impeller C Water Pump Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Route the gear position switch lead A as shown GD06072BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING SYSTEM 4 11 Water Pump e Turn the impeller shaft so that the slot A in its shaft fits onto the
17. 0 3second gt CORA il GP30168BS1 e Turn OFF and remove the new user key 1 e Temporarily place the antenna A on the new ignition switch B e Insert the user key 1 C again into the new ignition switch and turn it ON NOTE OPlace the antenna on the ignition switch insert the next key and turn ON within 15 seconds after previous key is turned off and removed otherwise registration mode will be ended and the warning indicator light LED stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration OKeep other user keys away from the immobilizer an tenna www zxforums com www zxforums com www zxforums com 16 88 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure 0 2second 0 Hnnnnnnnn LUULU GP30167BS1 When Registered User Key is Inserted 0 5second 0 5second Ee FE GE e pa mn Eine D pa ewe D GP30166BS1 User Key Collation Error 0 3second HF T COCHA rnan narn GP30168BS1 C e The user key 1 is successfully registered in the ECU OThe warning indicator light LED
18. 0 5second 0 5second gt os TE DAA GP30201BS1 OHF ne LU LI j GP30167BS1 0 5second 0 5second ON Beete GP30166BS1 0 3second ON Hbhnnnnnn UUU GP30168BS1 www zxforums com 16 84 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models e The user key 2 is registered in the ECU OThe warning indicator light LED and immobilizer warning symbol A blinks 3 times and stops for 1 second and then repeats this cycle OThis procedure has registered the master key and 2 user keys e Continue with the procedure to register an additional 3 user keys ARTO LI GP30170BS1 NOTE OThe ECU can store up the six key codes master key x 1 and user key x 5 User Key Indicator Light and Symbol Flashes Indicator Light and Indicator 9 Light and Remarks symbol Symbol Sto Blinks y p User Key 3 4 times 1 seconds Repeat User Key 4 5 times 1 seconds Repeat User Key 5 6 times 1 seconds Repeat e Turn OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends e Warning indicator light LED goes off A GP30171BS1 e Remove the key registration unit and connect the immo bilizer Kawasaki diagnostic system connector NOTE
19. A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Unscrew the fuel pump bolts A and take out the fuel pump assembly B and gasket e Discard the fuel pump gasket CAUTION Do not pull the leads C of the fuel pump and fuel reserve switch Ifthey are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air e Replace the fuel pump gasket with a new one www zxforums com www zxforums com www zxforums com 3 116 FUEL SYSTEM DFI WW ZXTOrums com www zxforums com www zxforums com Fuel Pump e Check that the fuel pump terminals A fuel reserve switch terminal B and ba
20. ECU e Check the ECU power source voltage with a digital meter A OPosition the terminal in accordance with terminal numbers of ECU connectors B in the figure Battery C ECU Power Source Inspection Tester Connections between 33 BR Terminal and Battery Terminal between 15 W BK Terminal and Battery Terminal between 32 W BK and Battery Terminal Ignition Switch OFF 33 BR Terminal 0 V 15 W BK Terminal Battery Voltage 32 W BK Terminal Battery Voltage Ignition Switch ON 33 BR Terminal Battery Voltage 15 W BK Terminal Battery Voltage 32 W BK Terminal Battery Voltage x If the tester does not read as specified check the follow ing Power Source Wiring see wiring diagram in this section Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see ECU Fuse Inspection x If the wiring and fuse are good replace the ECU see ECU section www zxforums com Ge www zxforums com GC171800S1 www zxforums com www zxforums com www zxforums com FU EL SYRTEMARED 3 1 09 ECU ECU Power Source Circuit 3 JON PARK leNITION Gol Fur BATTERY OST 1 2 3 4 5 6 7 8 www zxforums com www zxforums com www zxforums com 6C17181CW2 C ECU Water proof Joint 1 Ignition Switch ECU Fuse 15A Starter Relay Main Fuse 30 A Battery 12 V 10 Ah
21. The ignition coil primary winding must send signals output voltage 32 or more times continuously to the ECU If the ignition primary winding 4 has failures no signal wiring short or open the ECU shuts off the injector 4 to stop fuel to the cylinder 4 though the engine keeps running Subthrottle Valve Actuator The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the subthrottle actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator Exhaust Butterfly Valve Actuator The actuator operates open and close of the exhaust butterfly valve by the pulse signal from the ECU If the exhaust butterfly valve actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator www zxforums com Oxygen Sensor Heaters 1 and or 2 Europe Models The oxygen sensor heaters 1 and or 2 raise If the oxygen sensor heaters 1 and or 2 temperature of the sensor fails wiring short or open the ECU stops the for its earlier activation 12 current to the heaters V 36 W 1 5A x 2 www zxforums com www zxforums com www zxforums com www zxforums com FU EL SYNEM RE 3 49 Self Diagnosis Output Signal Usable Codes Range or Criteria When the relay OFF condition the main relay is open The oxygen sensor 2 i
22. Torque No Fast R k o astener Nan kgfm ftlb emarks 1 Exhaust Butterfly Valve Actuator Mounting Bolts 0 8 0 08 7 in lb 2 Exhaust Butterfly Valve Actuator Pulley Bolt 5 0 0 50 44 in lb 3 Fuel Pump Bolts 10 1 0 89 in lb L S 4 Canister Bracket Mounting Bolt M5 4 3 0 44 38 in lb 5 Canister Bracket Mounting Screws M5 4 3 0 44 38 in lb 6 Separator Bracket Mounting Bolts 7 0 0 71 62 in lb 7 Separator Canister Hose Clamp Bolt 7 0 0 71 62 in lb 8 Canister 9 Separator 10 Fitting 11 Red Hose 12 Blue Hose 13 Green Hose 14 White Hose L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence www zxforums com www zxforums com www zxforums com 3 10 MEL AS EM DFI www zxforums com www zxforums com DFI System DFI System f y T Ce gt y o gt NS ae Na RE 2 6017188CW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEN 3 11 DFI System JO O1 P ND A www zxforums com ECU Crankshaft Sensor Camshaft Position Sensor Main Throttle Sensor Subthrottle Sensor Subthrottle Valve Actuator Inlet Air Pressure Sensor Atmospheric Pressure Sensor Water Temperature Senso
23. e Remove Clamp A Exhaust Butterfly Valve Cables B Connectors C e Remove Bolts A Exhaust Butterfly Valve B e Remove exhaust butterfly valve actuator pulley A OHold the pulley with a suitable tool CAUTION If the pulley bolt is removed without holding the actuator damage will occur Exhaust Butterfly Valve Actuator Installation e Install the pulley A on the actuator e Hold the pulley with a suitable tool B and tighten the bolt Torque Exhaust Butterfly Valve Actuator Pulley Bolt 5 0 N m 0 50 kgf m 44 in Ib CAUTION If the pulley bolt is tightened without holding the actuator damage will occur www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TAM RE 3 97 Exhaust Butterfly Valve Actuator Service Code 63 e Confirm the pulley angle A 41 7 7 as shown It is original position of the pulley B x lf the angle is not within the specified angle adjust the actuator as follows OConnect the actuator connectors OTurn the ignition switch ON OConfirm the pulley turns clockwise and then counterclock wise and clockwise again OTurn the ignition switch OFF OConfirm the pulley turns counterclockwise little EE OThe position is original position of the pulley x If the position is not within the specified angle above re place the exhaust butterfly valve actuator e Install the actuator A on
24. www zxforums com www zxforums com www zxforums com 1 6 GENERAL INFORMATION www zxforums com www zxforums com Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color E 602022 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GBO2062BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 7 Model Identification ZX1000D6F Europe Left Side View Gong P ZX1000D6F Europe Right Side View 008220 P www zxforums com www zxforums com www zxforums com 1 8 GENERAL INFORMATION www zxforums com www zxforums com Model Identification ZX1000D6F United States
25. Connections BL lead C BR BK lead D Standard 4 6kQ 6017165081 x If the reading is out of the range replace the throttle body assy see Throttle Body Assy section lf the reading is within the range but the problem still exists replace the ECU see ECU section Main Throttle Sensor Circuit 6C17147CW2 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 56 MES EM DFI www zxforums com www zxforums com Inlet Air Pressure Sensor Service Code 12 CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it Removal e Turn the ignition switch OFF e Remove Air Cleaner Housing see Air Cleaner Housing Removal Inlet Air Pressure Sensor Connector A Inlet Air Pressure Sensor B Vacuum Hose Installation NOTE OThe inlet air pressure sensor is the same part as the at mospheric sensor except that the sensor has a vacuum hose and different wiring e Install the vacuum hose e Put the inlet air pressure sensor in the stay plate A of throttle body assy Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor and the atmospheric pressure sen sor COOLA E e Turn the ignition switch OFF
26. GE16061BS1 GE16160BS1 GE16161BS1 www zxforums com 9 28 GRANKRHAFT TRANSM ISSIQNxforums com www zxforums com Pistons e Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt e Install the piston with its marking hollow A facing exhaust side e Using the piston ring compressor assembly B to install the piston from the cylinder head side Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Install Crankshaft see Crankshaft Installation Connecting Rod Big End Cap see Connecting Rod In stallation Cylinder Wear Upper Crankcase e Since there is a difference in cylinder wear upper crankcase in different directions take a side to side and a front to back measurement at each of the two locations total of four measurements shown in the figure x lf any of the cylinder inside diameter measurements ex ceeds the service limit replace the crankcase 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 75 990 76 006 mm 2 9917 2 9924 in Service Limit 76 09 mm 2 9957 in GE16063BS1 Piston Wear e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton
27. Item Standard Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 3 2 L 3 4 US gt when filter is not removed 3 7 L 3 9 US gt when filter is removed 4 0 L 4 2 US gt when engine is completely dry Level Between upper and lower level lines Oil Pressure Measurement Oil Pressure 150 230 kPa 1 5 2 4 kgf cm 22 33 psi at 4 000 r min rpm Oil Temperature 90 C 194 F www zxforums com www zxforums com www zxforums com www zxforums com www zxforumE EINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Gear Holder 57001 164 57001 1599 ST5701648T ST5715998T Oil Pressure Gauge Adapter PT3 8 Kawasaki Bond Silicone Sealant 57001 1233 92104 0004 8757123397 ST9200048T Oil Filter Wrench 57001 1249 T5712498T www zxforums com www zxforums com www zxforums com 7 8 ENGINE UBRI CATION SYS VFM torums com www zxforums com Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait seve
28. X1 000ft l l l l l 0 0 2 0 4 0 6 0 8 1 1 2 1 4 1 6 1 8 2 2 2 2 4 2 6 2 8 X1 000m Altitude GC17A435W4 www zxforums com www zxforums com www zxforums com 3 70 MES EM DFI www zxforums com www zxforums com Crankshaft Sensor Service Code 21 Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter see Crankshaft Sensor Re moval Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft have no power source and when the en gine stops the crankshaft generates no signals e Crank the engine and measure the peak voltage of the crankshaft sensor see Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter in order to check the sensor e Check the wiring for continuity see wiring diagram in this section Crankshaft Sensor Circuit ai m se Ka pd e R7BL DK EP x ES R BK Y R BK BK BK 6C17156CW2 1 ECU 2 Crankshaft Sensor www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DE 3 71 Camshaft Position Sensor Service Code 23 Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e Refer to the Camshaft Position Sensor Removal Installa tion in
29. e Check the radiator core x If there are obstructions to air flow remove them lf the corrugated fins A are deformed carefully straighten them x lf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection e Remove the radiator cap see Pressure Testing e Check the condition of the bottom A and top B valve seals and valve spring C x If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm
30. e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply brake fluid to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply brake fluid to the dust seals and install them into the cylinders by hand e Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O rings e Tighten Torque Front Caliper Assembly Bolts 22 N m 2 2 kgf m 16 ft Ib e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth www zxforums com www zxforums com GL05040281 GLO5050BS1 www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 59 Maintenance Procedure Rear Caliper Disassembly e Remove the rear caliper see Rear Caliper Removal in the Brakes chapter e Remove the pads and pad spring see Rear Brake Pad Removal in the Brakes chapter e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper A WARNING To avoid serious injury never place your fingers or palm inside the caliper o
31. ss 14 8 Stem Stem Bearing Installaton 14 9 Steering Stem Bearing Lubrication us 14 12 Steering Stem EE 14 12 Stem Cap Deterioration Damage 14 12 Handle 14 13 Handlebar Removal see 14 13 Handlebar Installation E 14 13 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 14 2 ERRIN Gm Exploded View 6N02075BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wi DR RING 1 4 3 Exploded View Torque No Fastener N m kgf m Pe Remarks 1 Handlebar Switch Housing Screws 3 5 0 36 31 in lb 2 Handlebar Bolts 25 2 5 18 3 Handlebar Position Bolts 9 8 1 0 87 in lb L 4 Steering Stem Head Nut 78 8 0 58 5 Front Fork Clamp Bolts Upper 20 2 0 15 6 Steering Stem Locknut Hand tighten 7 Steering Stem Nut 20 2 0 15 8 Front Fork Clamp Bolts Lower 30 3 1 22 AL 9 Lock Washer 10 United States and Canada Models AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts www zxforums com www zxforums com www zxforums com 14 4 NA ERRIN Gm www zxforums com www zxforums com Exploded View Item Standard Steering Damper Damper Set 18 turns out from the fully clockwise position Usable range 0 18 tuns out www zxforums com
32. www zxforums com www zxforums com www zxforums com 9 20 GRANKRHAFTIT RANSM ISSN ms vom www zxforums com Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods 6105040481 6105088BS1 e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 150 OMark A the connecting rod big end caps and nuts so that nuts can be turned 150 B properly Connecting Torque Angle Rod Assy N m kgf m ft lb Use the bolts Attached to attached to new con rod new con rod New 20 2 0 15 150 Replace the Used 20 2 0 15 150 bolts with new ones 20 2 0 15 150 New 20 2 0 15 150 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the pi
33. 5 44 ENGINE IOP END www zxforums com www zxforums com Muffler Front Exhaust Pipe Installation e Replace the front exhaust pipe gaskets A with new ones e Replace the middle exhaust pipe gasket B with a new one Olnstall the middle exhaust pipe gasket until it is bottomed so that the chamfer side inner faces front exhaust pipe e Install the front exhaust pipe C e Install the middle exhaust pipe clamp bolt D as shown Upside E Outside F 35 55 G Front View H e Tighten Torque Front Exhaust Pipe Holder Nuts I 17 N m 1 7 kgf m 13 ft lb Middle Exhaust Pipe Clamp Bolt 17 N m 1 7 kgf m 13 ft lb e For the Europe Models Route the oxygen sensor leads correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the radiator see Radiator and Radiator Fan Instal lation in the Cooling System chapter e Throughly warm up the engine wait until the engine cools down retighten all the bolt and nuts www zxforums com www zxforums com 6E180418W2 C www zxforums com www zxforums com www zxforums com EN GINE TOR END 5 45 Muffler Exhaust Butterfly Valve Cable Removal e Remove the seat cover see Seat Cover Removal in the Frame chapter e Slide the dust covers A e Loosen the locknuts B and turn the adjusters C to give the cable plenty of paly e Remove the clamp A e Remove the exhaust butterfly valve cable upper ends B from
34. Service Limit 0 58 mm 0 023 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin B clearance with plastigage A e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement CAUTION After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 030 0 060 mm 0 0012 0 0024 in Service Limit 0 10 mm 0 0039 in www zxforums com www zxforums com G105040781 6105041851 www zxforums com 9 22 GRANKRHAFTIT RANSM ISSN ms vom www zxforums com Crankshaft and Connecting Rods x If the clearance is within the standard no bearing replace ment is required x lf the clearance is between 0 061 mm 0 0024 in and the service limit 0 10 mm 0 0039 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x lf the clearance exceeds the service limit measure
35. Special Tool Steering Stem Nut Wrench 57001 1100 e Adjust the steering x If the steering is too tight loosen the stem nut a fraction of a turn x If the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum www zxforums com www zxforums com www zxforums com 2 38 REBIODILGMAI NTE NAN C E www zxforums com www zxforums com Maintenance Procedure e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E GS15029BS1 e Tighten Torque Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb Handlebar Bolts 25 N m 2 5 kgf m 18 ft lb Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb e Check the steering again x lf the steering is still too tight or too loose repeat the ad justment Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the ou
36. crea 3 70 Crankshaft Sensor Removallnstallation 3 70 Crankshaft Sensor Inspection ss 3 70 Camshaft Position Sensor Service Code 23 us 3 71 Camshaft Position Sensor Removal Installation 3 71 Camshaft Position Sensor Inspection ssseeereerrterrrerrrrrtrrrrrrttttrttrttttttttrtttrtttttttrttnnn 3 71 Speed Sensor Service Code 24 rene nena 3 72 www Dep ae ep Removal InstallatiOR yw forums emm www zxforums com 3 72 Input Voltage INSPECtON EE A aaa 3 72 3 2 EVEL Se IEN DFI www zxforums com www zxforums com Output Voltage Inspection 3 73 Gear Position Switch Service Code 25 iii 3 75 Gear Position Switch Removal Installation oonoooncccnnnnnnnnnicnoncccccnnnanananrnncnnnnnnnnnnnnarn nono 3 75 Gear Position Switch Inspection 3 75 Input Voltage Inspection 3 75 Vehicle down Sensor Service Code 31 aise 3 77 A O 3 77 SAM ici A A AA A A er nee si 3 77 A A anne ent teen ets sue 3 77 Subihrottle Sensor Service E rennes repondre dite 3 80 Subthrottle Sensor Removal Adjustment 3 80 Input Voltage Inspection 3 80 Output Voltage Inspection 3 81 Resistance Inspection 3 83 Oxygen Sensor 1 not activated Service Code 33 Europe Models 3 84 Oxygen Sensor 1 Removal Installation 3 84 Oxygen Sensor 1 Inpec Macondo 3 84 Exhaust Butterfly Valve Actuator Sen
37. e Apply the tip of a screwdriver A to the injector B Put the grip end onto your ear and listen whether the injector is clicking or not e A sound scope can also be used e Do the same for the other injector x If all the injectors click at a regular intervals the injectors are good OThe click interval becomes shorter as the engine speed rises x If either injector doesn t click perform the Injector Signal Test for injector operation www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYRMEMARED 3 1 21 Fuel Injectors Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb A 12 V x 3 3 4 W Terminal Width B 1 8 mm 0 07 in Terminal Thickness C 0 8 mm 0 03 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair SC or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Disconnect the connectors for injector A e Connect each test light set B to the injector sub harness connector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights lf the test lights flicker at regular intervals the injector circuit in the ECU an
38. e Replace the O ring of the timing inspection cap and starter clutch bolt cap with new ones e Apply grease to the new O rings e Install the timing inspection cap and starter clutch bolt cap Torque Timing Inspection Cap Hand tighten Starter Clutch Bolt Cap Hand tighten e Install the cylinder head cover see Cylinder Head Cover Installation www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TOP END 5 25 Camshaft Camshaft Chain Camshaft Camshaft Cap Wear e Remove the camshaft cap see Camshaft Removal e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position e Tighten the camshaft cap bolts and upper chain guide bolts to the specified torque see Camshaft Installation NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap e Remove the camshaft cap again measure each clear ance between the camshaft journal and the camshaft cap using plastigage press gauge A Camshaft Journal Camshaft Cap Clearance Standard 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 17 mm 0 0067 in x If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 940 23 962 mm 0 9425 0 9434 in Service Limit 23 91 mm 0 941 in If the camshaft journal dia
39. www zxforums com wan zk takt 6 5 www zxforums com www zxforums com Special Tool and Sealant Kawasaki Bond Silicone Sealant Clutch Holder 92104 0004 57001 1243 ST9200048T ST5712438T www zxforums com www zxforums com www zxforums com 6 6 ek LG com www zxforums com www zxforums com Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter see Clutch Adjustment Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter see Clutch Adjustment Inspection in the Periodic Maintenance chapter Cable Removal e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Slide the dust cover A at the clutch cable lower end out of place e Loosen the nuts B and slide the lower end of the clutch cable to give the cable plenty of play e Screw in the adjuster e Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Cable Installation e Run the clutch cable correctly see Ca
40. 57001 1238 57001 1608 ST5712388ST ST571608ST Bearing Remover Head 20 x 22 57001 1293 ST571293ST www zxforums com www zxforums com www zxforums com 1 0 6 WHEEL LIRES www zxforums com www zxforums com Wheels Rims Front Wheel Removal e Remove Brake Caliper Mounting Bolts A Front Brake Calipers B Left and Right e Loosen Left Side Axle Clamp Bolts A Axle Nut B Right Side Axle Clamp Bolts e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Raise the front wheel off the ground with the jack A Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the axle nut and pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke e Check the wheel rotation mark on the front wheel and install it GJ04053BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHEELRITIRES 10 7 Wheels Rims e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub OThe collars are identical e Insert the axle e Tighten the axle nu
41. 7 Gear Position Switch Screws 3 0 0 30 27 ml L Install the bearing into the drive shaft cover so that the shield side faces in 8 O Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts www zxforums com www zxforums com www zxforums com 9 6 GRANKSRARTTRANSMISSION zxforums com www zxforums com Specifications Item Standard Service Limit Crankcase Crankshaft Connecting Rods Connecting Rod Bend EE TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist EE TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side 0 13 0 38 mm 0 0051 0 0150 in 0 58 mm Clearance 0 023 in Connecting Rod Big End Bearing 0 030 0 060 mm 0 0012 0 0024 in 0 10 mm Insert crankpin Clearance 0 0039 in Crankpin Diameter 34 484 34 500 mm 1 3576 1 3583 in 34 47 mm 1 3571 in Marking None 34 484 34 492 mm 1 3576 1 3579 in SE O 34 493 34 500 mm 1 3580 1 3583 in Connecting Rod Big End Inside 37 500 37 516 mm 1 4764 1 4770 in Diameter Marking None 37 500 37 508 mm 1 4764 1 4766 in O 37 509 37 516 mm 1 4767 1 4770 in SE Connecting Rod Big End Bearing Insert Thickness Brown 1 478 1 483 mm 0 05819 0 05839 in Black 1 483 1 488 mm 0 05839 0 05858 in Blue 1 488 1 493 mm 0 05858 0 05878 in Connecting Rod Bolt Stretch Usable Range New Connecting Rod 0 24 0 34 mm 0 0094 0
42. Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter in ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Air switching valve trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect Camshaft position sensor trouble IC igniter in ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner O ring damaged Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient DFI Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble DFI Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped wwWakrergm n roken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor qualit
43. Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace www zxforums com www zxforums com Charge Time h 1 1 1 1 L 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V GP08021BS1 GP080113S1 www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 31 Charging System Alternator Cover Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI c
44. Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in 6113161BS1 Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove x If the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in 6113162BS1 Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs A and gear dog holes B x Replace any damaged gears or gears with excessively worn dogs or dog holes 6113163BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHEELSITIRES 1 0 1 Wheels Tires Table of Contents Exploded EE 10 2 SA le 10 4 ee Nr iii AAA A AE A A AAA 10 5 Wheels RIOS EEN 10 6 Front Wheel Remo alii AA A EA 10 6 Front Wheel Installation oooooooninininnnnninicinnnnnnnninacinnccna rr nannr nr 10 6 Rear W
45. delivery pipe by sliding the joint or the fuel could leak x lf it comes off reinstall the hose joint e Connect the fuel pump lead connector and the battery terminal see Battery Installation in the Electrical System chapter Fuel Tank and Cap Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B and fuel breather pipe C California Model in the tank are not clogged Check the tank cap breather also x If they are clogged remove the tank and drain it and then blow the breather free with compressed air CAUTION Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove Fuel Tank see Fuel Tank Removal Fuel Pump see Fuel Pump Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install Fuel Pum see Fuel Pump Installation W Z ms co 2 www zxforums com Fuel Tank see Fuel Tank Installatio
46. e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom e Do not mix up the top and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up OApply molybdenum disulfide oil solution to the piston rings NOTE Olf a new piston is used use new piston ring e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D Hollow E 30 40 F www zxforums com www zxforums com GE16060BS1
47. e Discard the used balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation e Check if the weight portion has any play on the blade A and clip B x lf it does discard it A WARNING If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition 6J04076BS1 GJ04077BS1 www zxforums com www zxforums com 6J04088BS1 www zxforums com 10 12 WHEELSSHRES www zxforums com www zxforums com Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 gram 0 35 oz 0 71 oz and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram Ifthe wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A on to the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F e Be sure to install the balance weight OCheck that the blade A and clip B are fully seated on the rim C and that
48. e Pull the stick coils 2 3 B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil e For remove the stick coil 1 as follows ORemove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Harness Joint Connector A Camshaft Position Sensor Lead Connector B Immobilizer Amplifier Connector Immobilizer Models Left Upper Inner Fairing Bracket Bolts C Left Upper Inner Fairing Bracket D ORemove Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter Left Engine Bracket Bolts A Left Engine Bracket B OPull out the stick coil 1 A to forward e For remove the stick coil 4 as follows ORemove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Right Upper Inner Fairing Bracket Bolts A Right Upper Inner Fairing Bracket B www zxforums com www zxforums com www zxforums com 1 6 42 FLEG TRIGAL SYSTEM www zxforums com www zxforums com Ignition System ORemove Right Engine Bracket Bolts A Right Engine Bracket B OPull out the stick coil 4 A to forward 108475 P Stick Coil Ignition Coil together with Spark Plug Cap Installation e Apply grease to the stick coils Dre d e Insert the stick coils A as shown being careful of the coil ah heads directions Ba O u ce S OAlign the lines B of the cylinder head cover and coil el heads ooo d CAUTION
49. e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 6017145051 Inlet Air Pressure Sensor Input Voltage Connections to ECU Connector Meter gt BL lead terminal 7 Meter gt BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V x lf the reading is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 57 Inlet Air Pressure Sensor Service Code 12 x If the reading is within the standard range and check the input voltage again at the sensor connector e Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the inlet air pressure sensor connector and connect the harness adapter A between the harness connector and inlet air pressure sensor connector Special Tool Sensor Harness Adapter 57001 1561 e Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor B Inlet Air Pressure Sensor Input Voltage Connections to Adapter
50. ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install Diaphragm A Diaphragm Plate B Front Brake Reservoir Cap C e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the brake fluid reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in lb e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is do
51. rums com zxforums com www zxforums com Kawasaki Ninja ZX 10R Motorcycle Service Manual www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a ala la NIO A OQO N O O O0O J O OI A QO N Appendix This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com Kawasaki Ninja ZX 10R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechan
52. www zxforums com www zxforums com www RAME 1 5 5 Exploded View No Fastener Jorane Remarks N m kgf m ft lb 1 Front Fender Mounting Bolts 3 9 0 40 35 in lb 2 United States and Canada Models 3 Australian Models www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 1 5 6 ERAM Ens com Exploded View 6002172BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wwzhRAMF 15 7 Exploded View Torque No Fast R k o astener Re kaf ftlb emarks 1 Windshield Mounting Bolts 0 4 0 04 4 in lb www zxforums com www zxforums com www zxforums com 1 5 8 EF RAMEns com www zxforums com www zxforums com Seats Rear Seat Removal e Insert the ignition switch key A into the seat lock turning the key counterclockwise pulling the front part of the seat B up and pull the seat forward Rear Seat Installation e Put the rear seat hook A on the rib B e Insert the seat pin C into the latch hole D Front Seat Removal e Remove Side Covers Left and Right see Side Cover Removal Mounting Bolts A Left and Right e Remove the front seat by pulling the front of it up and forward Front Seat Installation e Slip the front seat hook A under the rib B e Tighten the mounting bolts e Install the side covers www zxforums com www zxforu
53. 0 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A If any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 43 5 mm 1 71 in Service Limit 42 1 mm 1 66 in Damper Cam Inspection e Remove the clutch see Clutch Removal e Visually inspectthe damper cam A cam follower B and the torque limiter spring C e Replace the part if it appears damaged www zxforums com www zxforums com GFO6O0603S1 GFO6O33BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxftorumE EINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded VIS Wi iia A A ee rome E di 7 2 Engine Ol Flow en 7 4 ene le E 7 6 Special Todls and Sealant iii a IRE 1 7 Engine Oil and Oil Fillers cotas dd 7 8 Oil tevel Inspection ea a eps a aa a cri ia 7 8 Engine Oil Change coito iia 7 8 Oil Filter Replacement ricreare e a aA ea ea a iar a a aa aai 7 8 A a E a dts E e aA 7 9 Oil Fan Removal oac nha A a EEN AE 7 9 OlPan Rn CO UE e e aaa ek eek EE 7 9 Oil Pressure Relief Valve ed 7 10 Oil Pressure Relief Valve HRemoval narco no nono narco na nanana nnana 7 10 Oil Pressure Relief Valve Installation ooo nnn o nnnnnnnononnncn
54. 0 20 in Service Limit 1 mm 0 04 in Brake Light Switch Operation Inspection e Turn on the ignition switch e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 35 Maintenance Procedure x lf it does not adjust the brake light switch e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri d j cal System chapter e e A Si lt Main Fuse 30 A and Taillight Fuse 10 A see Fuse In 4 Ty Y spection in the Electrical System chapter AN Front Brake Light Switch A see Switch Inspection in e 4 the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspensions Front Forks Rear Shock Absorber Operation Inspection e Pump the forks do
55. 16 48 FLECTRICAL SYSTEM www zxforums com www zxforums com Ignition System Ignition System Circuit RA y ye fa e L J sro i wt ts ts ve wy BK BK Y LL Y D 4 AE ayy c a D ag BG 6P103318W4 C www zxforums com www zxforums com 1 Ignition Switch 12 Frame Ground 23 Fuel Injector 3 2 Joint Connector 1 13 Fuel Pump 24 Fuel Injector 2 3 Starter Lockout Switch 14 Vehicle down Sensor 25 Main Fuse 30 A 4 Fuse Box 15 Joint Connector 2 26 Camshaft Position Sensor 5 ECU Fuse 15A 16 ECU 27 Spark Plugs 6 Ignition Fuse 15 A 17 Water proof Joint 1 28 Stick Coils 7 Relay Box 18 Gear Position Switch 29 Engine Stop Switch 8 Fuel Pump Relay 19 Water proof Joint 2 30 Immobilizer Antenna 9 Main Fuse 30 A 20 Sidestand Switch Immobilizer Models 10 Starter Relay 21 Crankshaft Sensor 31 Immobilizer Amplifier 11 Battery 12 V 10 Ah 22 Fuel Injector 4 Immobilizer Models www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 49 Electric Starter System Starter Idle Gear Removal e Remove Right Middle Fairing see Right Middle Fairing Removal in the Frame chapter Bolts A Idle Gear Cover B CA e Pull out the idle gear starter motor side A with the shaft B e Remove Clutch Cable Lower End see Cable Removal in the Clutch chapter Bolts A Clamp B Starter Clutch Cov
56. 57001 1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector I Meter BK BL lead 1 Meter gt Battery Terminal Il Meter gt G lead 2 Meter gt Battery Terminal Ill Meter Y BK lead 3 Meter Battery Terminal IV Meter P lead 4 Meter gt Battery Terminal Gc17171CS2 e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage Standard About DC 10 5 12 5 V x If the reading is out of the range check the wiring to ECU see wiring diagram in this section x If the wiring is good replace the ECU see ECU section www zxforums com www zxforums com www zxforums com FUEL SYSTEMURE 3 95 www zxforums com www zxforums com Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit 6C17147CW2 C 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 96 MESS TEM DFI www zxforums com www zxforums com Exhaust Butterfly Valve Actuator Service Code 63 Exhaust Butterfly Valve Actuator Removal e Remove the seat cover see Seat Cover Removal in the Frame chapter e Slide the dust covers A e Loosen the locknuts B and turn the adjuster to give the cable plenty of play C
57. B upward e Install Spring Seat Collar 6S14020BS1 e Screw the rod nut B onto the piston rod A as shown 11 mm 0 43 in C e Check the distance C between the bottom end A of the top plug and rebound damping adjuster B with a pair of vernier caliper 13 mm 0 51 in C e Set the fork spring compressor on the washer using the outer tube as a guide Special Tools Fork Spring Compressor 57001 1587 Clamp 57001 1626 NOTE OSet the clamps so that the cutout A of the upper side does not fit the hole B of washer C pull up the outer tube D to hold it by the clamps and then tighten the two bolts E The outer tube is used as a guide www zxforums com www zxforums com www zxforums com 13 1 ERURRENSIO N www zxforums com www zxforums com Front Fork e Set the holder bar B and compression shafts A e Hold the piston rod nut A e Remove the piston rod puller B e Install the rebound damping adjuster rod A e Screw in the top plug A stopped onto the piston rod e Check the O ring B on the top plug and replace it with a new one if damaged e Holding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Piston Rod Nuts 15 N m 1 5 kgf m 11 ft lb e While holding up the fork spring compressor pull out the fork spring stopper e Remove the fork spring compressor e Raise the outer tube and screw the top plug
58. BRAKE Som www zxforums com www zxforums com Brake Fluid e Remove the rubber cap from the bleed valve on the front master cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container e Bleed the brake line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Front Master Cylinder Bleed Valve 5 4 N m 0 55 kgf m 48 in lb e Remove the rubber cap A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wmBRAKES A 2 21 Brake Fluid e Bleed the brake line and the caliper j ORepeat this operation until no more air can be seen com
59. C 12 V x 3 3 4 W 12 V MF Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the injector E as shown e Open and connect F the end of the lead to the battery terminal repeatedly The injector should click x If the injector does not click replace the injector Injector Fuel Line Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends connected with the clamps D as shown OApply soap and water solution to the areas E as shown OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed e Watch the gauge for at least 6 seconds x lf the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found in the area the line is leaking Replace the delivery pipe injectors and related parts ORepeat the leak test and check the fuel line for no leak age
60. F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil 6E15045BS1 Special Tool Valve Guide Arbor 64 5 57001 1331 www zxforums com www zxforums com www zxforums com 5 32 ENGINE TOP E N D www zxforums com www zxforums com Valves Valve Guide Installation e Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This Will warp the cylinder head Soak the cylinder head and heat the oil GE15046BS1 e Using the valve guide driver A and washer B press and insert the valve guide in until the valve guide driver surface C touches the head surface D 13 3 13 5 mm 0 52 0 53 in E Special Tools Valve Guide Driver 57001 1564 Washer 57001 1612 6E15062BS1 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 5 57001 1333 6E15046BS1 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated belo
61. Frame chapter Shift Lever Bolt C Shift Lever e Remove Shift Pedal Mounting Bolt A Tie rod B e Gey saat Fi Shift Pedal Installation e Apply grease to the sliding surfaces A on the shift pedal mounting bolt B e Tighten Torque Shift Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft lb Footpeg Bracket C Shift Pedal D Washer E 6113282BS1 e Install the shift lever A aligning the mark previously marked e Tighten Torque Shift Lever Bolt 7 0 N m 0 70 kgf m 62 in Ib e Install the shift pedal B as shown About 90 C About 8 25 D OTo adjust the pedal position loosen the front locknut E left hand threads and rear locknut F and then turn the tie rod G e Tighten Torque Tie Rod Locknuts 7 0 N m 0 70 kgf m 62 in Ib External Shift Mechanism Removal e Remove Shift Pedal see Shift Pedal Removal Clutch see Clutch Removal in the Clutch chapter Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter Snap Ring A Special Tool Outside Circlip Pliers 57001 144 e Remove the shift shaft assembly and spacers B while pulling out the shift mechanism arm C www zxforums com www zxforums com www zxforums com www zxforums com www zxforu mERAN KSHAFT TRANS MIR RON 9 31 Transmission e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Washer and Spring External Shift Mechanism Installation e Install the
62. Injector stuck open Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 Brown smoke Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Too low fuel pressure Inspect fuel line and fuel pump see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FU EL SYRLEM RE 3 41 Self Diagnosis The warning indicator light LED A is used for the Fl indicator immobilizer indicator immobilizer models and oil pressure warning indicator 6017195081 Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system ig nition system and immobilizer system by blinking the warn ing indicator light LED A Fl warning symbol B and im mobilizer warning symbol C when DFI ignition and immo bilizer system parts are faulty and initiates fail safe func tion In case of serious troubles ECU stops the injection ig nition starter motor operation lock D FLE On icuu 6017197082
63. Lights LED Inspection e Connect the 12 V battery and terminals in the same man ner asspecified in the Liquid Crystal Display LCD Seg ments check Shift Up Indicator Light LED A Fuel Level Warning Indicator Light LED B Neutral Indicator Light LED C Turn Signal Indicator Light D High Beam Indicator Light LED E Warning Indicator Light LED Fl Immobilizer Oil Pres sure Warning F Illumination Light LED G Illumination Light LED Inspection OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check OWhen the terminals are connected the illumination light LED should go on lf the illumination light LED does not go on replace the meter assembly e Check whether the level of the illumination light LED can be adjusted in four levels by pushing the RESET button each time If the light level does not changes replace the meter as sembly www zxforums com www zxforums com GP17424BS1 GP17426BS1 www zxforums com 16 76 ELECTRICAL SYSTEM www zxforums com www zxforums com Meter Gauge Indicator Unit Neutral Indicator Light LED Inspection OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check e Using the insulated auxiliary lead 12 V battery to the me ter unit connector as follows OCo
64. Purpose increase width of seat on seat area beyond spec to increase O D 60 Grind Tool 60 Cutter Purpose reduce seat Tool Valve Lapper Grinding Compound Purpose perfectly match inlet valve and inlet valve FINISHED seat are check valve head for damage GE15061B F www zxforums com www zxforums com www zxforums com 5 38 ENGINE IOP END www zxforums com www zxforums com Throttle Body Assy Holder Throttle Body Assy Holder Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy Throttle Body Assy Removal in the Fuel System DEI chapter Clamps A e Loosen the throttle body assy holder bolts as shown se quence 1 3 in the figure and remove them e Remove the throttle body assy holders B Throttle Body Assy Holder Installation e Be sure to install the new O rings A e Apply grease to the new O ring e Install the clamps B as shown e Tighten the holder bolts following the tightening sequence 1 3 Torque Throttle Body Assy Holder Bolts C 10 N m 1 0 kgf m 89 in Ib Throttle Body Assy Holder Clamp Bolts D 2 0 N m 0 20 kgf m 18 in Ib Upside View E GE17016BS2 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com EN GINE TOR END 5 39 Muffler A WARNING To avoid a
65. Rear View C e Tighten Torque Oil Pan Bolts 10 N m 1 0 kgf m 89 in Ib GG06023BS2 C www zxforums com www zxforums com www zxforums com 7 1 ENGINE UB RI CATIO N SYSTEM ms com www zxforums com Oil Pressure Relief Valve Oil Pressure Relief Valve Removal i e Remove Oil Pan see Oil Pan Removal Oil Screen A e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of the oil pressure relief valve A and tighten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb e Clean the oil screen B e Install the O ring C and damper D to the oil screen e Install the oil screen so that the crankcase rib E and relief valve fits the oil screen e Install the oil pan see Oil Pan Installation GG08002BS2 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforu NN GI NE LU BRICATIQN SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection e Remove the oil pressure relief valve see Oil Pressure Relief Valve Removal e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled
66. Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Check that the dampers A and pad B are in place on the fuel tank as well lf the dampers are damaged or deteriorated replace them e For the California Model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed www zxforums com www zxforums com www zxforums com 3 1 38 FUEL ARNO EM DFI www zxforums com www zxforums com Fuel Tank e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks e Push and pull A the hose joint B back and forth more than two times and make sure it is locked and doesn t come off WARNING Make sure the hose joint is installed correctly on the
67. Telescopic fork upside down 120 mm 4 7 in Swingarm uni trak 125 maw 2xfor ims com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 11 General Specifications Items ZX1000D6F Ninja ZX 10R Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W 65 W quartz halogen Low 12 V 55 W quartz halogen Tail Brake Light 12 V 0 5 4 1 W LED Alternator Type Three phase AC Rated Output 31 A 14 V 5 000 r min rpm Specifications subject to change without notice and may not apply to every country www zxforums com www zxforums com www zxforums com 1 1 2 GENERALINFORMATION www zxforums com www zxforums com Unit Conversion Table Prefixes for Units Units of Length Symbol Bower km x 0 6214 mile mega M x 1 000 000 A SE OS kilo k x 1000 mm x 0 03937 in centi e x 0 01 milli e x 0 001 Units of Torque micro p x 0 000001 Nm x 0 1020 kgfm N m x 0 7376 ft lb N m x 8 851 in Ib Units of Mass kgf m x 9 807 N m kg x 2 205 Ib kgf m x 7 233 ft lb g x 0 03527 OZ kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal imp kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt imp kgf cm x 98 07 kPa L x 2 113 pint US kgf cm x 14 22 psi L x 1 816 pint imp c
68. The clamp attached on the main harness License Plate Light Connector Left Turn Signal Light Connector Vehicle down Sensor Clamp the exhaust butterfly valve actuator connector and push it between the left side of rear fender and the vehicle down sensor Exhaust Butterfly Valve Actuator Connector Atmospheric Pressure Sensor ECU Connectors Trim Unused ECU Leads Upper Under Viewed B Battery Negative Terminal Clamp the fuel pump lead connector to the bracket Relay Box Lead www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 17 10 ABRENDIS Cable Wire and Hose Routing EL L Y dy r SC e mg S NE HSE RER EE ER E d Y Q A EU le Neo AER RUE N een 7 GU N e G AN i 12e SAY d Ab Ka SC Ma RES We AS LT SES A AS Y 6B098878W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com w EENS 1 7 11 Cable Wire and Hose Routing OO J O O1 P ND Left City Light Connector Meter Connector Clamp Headlight Connector Clamp Run the fan motor lead connector above the main harness Immobilizer Amplifier Joint Connector for the stick coil and air switching valve leads Install it into the bracket Clamp The clamp attached on the main harness Fuel Pump C
69. Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com 3 1 28 URANO EM DFI www zxforums com www zxforums com Throttle Body Assy Throttle Body Assy Disassembly 6C17187CW2 1 Subthrottle Valve Actuator 2 Subthrottle Sensor 3 Main Throttle Sensor 4 Throttle Body Assy 5 Injector 6 Delivery Pipe 7 Injector Connector Harness CAUTION Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the injector connectors A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYAEM RER 3 1 29 Throttle Body Assy e Disconnect the main throttle sensor A and subthrottle sensor B connector e Disconnect Subthrottle Valve Actuator Lead Connector A Inlet Air Pressure Sensor Connector B e Separete the hoses A from the throttle body fittings and inlet air pressure sensor e Remove the screws B to pull out the injector assi
70. and Hose Routing OO Joo P ND A Stick Coil 1 Stick Coil 2 Stick Coil 3 Stick Coil 4 Air Switching Valve Evaporative Hose White Evaporative Hose Green Clamp Through the crankshaft sensor lead into the clamp attached on the air switching valve Crankshaft Sensor Lead Connector Through the crankshaft sensor lead into the hole of the heat insulation rubber plate Heat Insulation Rubber Plate Radiator Hose Crankshaft Sensor Lead Through the crankshaft sensor lead inside the radiator hose Radiator Hose Heat Insulation Rubber Plate Through the crankshaft sensor lead into the hole of the heat insulation rubber plate Viewed A www zxforums com www zxforums com www zxforums com 1 7 1 SABRENDIA www zxforums com www zxforums com Cable Wire and Hose Routing www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX A 7 1 9 Cable Wire and Hose Routing OMNOOARWN Install the air switching valve after installing the heat insulation rubber plate Throttle Body Assy Hang down the shaded portions of the heat insultaion rubber plate For Left Engine Bracket Bolt For Radiator For Air Suction Valve Covers and Stick Coils For Right Engine Bracket Cylinder Head Side For Throttle Body Holders Set the projection into the hole For Right Front Engine Mount Crankshaft Sensor Lead Through the
71. and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the front rear brake fluid reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in lb e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines www zxforums com www zxforums com GS13137B82 C Ni cy ROUE T
72. e Install the throttle body assy see Throttle Body Assy In stallation e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter www zxforums com www zxforums com 6017024481 d Co NEC Ce ty a E md Co gt 6017185082 www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 123 Fuel Injectors Fuel Injector Circuit BL Y W R BL BK W R BL G N R Ls ON PARK IGNITIONI S e BR BATTERY E tT D BL R W R ECU Frame Ground Joint Connector 1 Joint Connector 2 Fuel Pump Water proof Joint 1 Fuel Injector 4 Fuel Injector 3 Fuel Injector 2 10 Fuel Injector 1 11 Engine Stop Switch 12 Ignition Switch 13 Fuel Pump Relay 14 ECU Fuse 15A 15 Ignition Fuse 15 A 16 Starter Relay 17 Main Fuse 30 A 18 Battery 12 V 10 Ah 19 Joint Connector 3 00 JO O1 P ND www zxforums com www zxforums com 6C17186CW2 www zxforums com 3 1 24 URL EM DFI www zxforums com www zxforums com Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter see Throttle Control System Inspection in the Periodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter see Thrott
73. e Remove the oil filler plug A e Pour in the specified type and amount of oil Recommended Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA 0 Viscosity SAE 10W 40 0 Capacity 3 2 L 3 4 US qt when filter is not removed SAE 10W30 3 7 L 3 9 US qt when filter is removed E RE A Ta 4 0 L 4 2 US qt when engine is completely soso ost c dry NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Replace the O ring of the oil filler plug with a new one e Apply engine oil to the new O ring e Install the oil filler plug Torque Oil Filler Plug Hand tighten Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 www zxforums com www zxforums com www zxforums com 2 54 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 31 N m 3 2 kgf m 23 ft lb NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening
74. e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector e Connect a digital meter A to the subthrottle sensor con nector B e Measure the subthrottle sensor resistance Subthrottle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6k0 x If the reading is out of the range replace the throttle body assy see Throttle Body Assy section x lf the reading is within the range but the problem still exists replace the ECU see ECU section Subthrottle Sensor Circuit GC171890S1 P BR BK 6C17147CW2 C 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 84 FUEL SXSTEM DFI www zxforums com www zxforums com Oxygen Sensor 1 not activated Service Code 33 Europe Models Oxygen Sensor 1 Removal Installation e Refer to the Oxygen Sensor Removal Europe Models in the Electrical System chapter see Oxygen Sensor Re moval Europe Models in the Electrical System chapter Oxygen Sensor 1 Inspection NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness side is different e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch OFF e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Connect a digit
75. in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the water hose A e Remove the starter clutch cover see Starter Idle Gear Removal e Slide out the rubber cap A e Remove the starter motor cable terminal nut B www zxforums com www zxforums com www zxforums com 1 6 54 LEG TRIGAL SYSTEM www zxforums com www zxforums com Electric Starter System e Remove the starter motor mounting bolts A e Pull out the starter motor from the right side Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Clean the starter motor legs A and crankcase B where the starter motor is ground e Replace the O rings A with new ones e Apply grease to the new O rings e Set the starter motor mounting bolts B e Temporary tighten the starter motor mounting bolts e Install the starter clutch cover see Idle Shaft Installation e Tighten Torque Starter Motor Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Position the starter motor cable A as shown About 45 B Front C e Tighten Torque Starter Motor Cable Terminal Nut 6 0 N m 0 61 kgf m 53 in Ib e Slide back the rubber cap to the original position Starter Motor Disassembly e Remove the starter motor see
76. retighten all the bolts and nuts e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com EN GINE TOR END 5 41 Muffler Middle and Rear Exhaust Pipe Removal e Remove the left muffler body see Muffler Body Removal e Loosen the rear exhaust pipe clamp bolt A e Remove the rear exhaust pipe B from left side of motor cycle e Remove Right Muffler Body see Muffler Body Removal Exhaust Butterfly Valve Cable Lower Ends see Exhaust Butterfly Valve Cable Removal Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Exhaust Pipe Stay Bolt A e Loosen the middle exhaust pipe clamp bolt B e Remove the middle exhaust pipe C from right side of motorcycle www zxforums com www zxforums com www zxforums com 5 42 ENGINE TOP END www zxforums com www zxforums com Muffler Middle and Rear Exhaust Pipe Installation e Replace the middle exhaust pipe gasket A with a new one Olnstall the middle exhaust pipe gasket until it is bottomed so that the chamfer side inner faces front exhaust pipe B e Install the middle exhaust pipe C e Tighten Torque Middle Exhaust Pipe Stay Bolt D 25 N m 2 5 kgf m 18 ft lb e Install the middle exhaust pipe clamp bolt E as shown Upside F Outside G 35 55 H Front View I e Tighten Torque Middle Exhaust Pipe Clamp Bolt 17 N m 1 7 kgf
77. www zxforums com www zxforums com www zxforums com www zxforums com wit LR RING 14 5 Special Tools Bearing Puller Adapter Bearing Driver Set 57001 136 57001 1129 ST5701368T ST5711298T Bearing Puller Steering Stem Bearing Driver 42 5 57001 158 57001 1344 T5713448T ST570158ST Head Pipe Outer Race Press Shaft Steering Stem Bearing Driver Adapter 441 5 57001 1075 57001 1345 ST571075ST C ST571345ST Steering Stem Nut Wrench Head Pipe Outer Race Driver 655 57001 1100 57001 1446 7571100ST ST5714468T www zxforums com www zxforums com www zxforums com 146 3 ERRIN Gm www zxforums com www zxforums com Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter see Steering Play Inspection in the Pe riodic Maintenance chapter Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter see Steering Play Adjustment in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wRTRERING 14 7 Steering Damper Steering Damper Removal e Remove the TORX bolt A and washer B e Remove the bolt C washer collar and steering damper D Steering Damper Installation e Install the steering damper F and parts as shown Collar A Washer B Fuel Tank Bracket C Bolt D Washer E e Ti
78. www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums QRAN KSHAFT T RANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded E S10 le Special Tools and Sealants aa Aia Crank ase SIUC ai cd a ld dl tte Crankcase Spina cries sostes A A oat Me ele GrankK ase Assembly EE Crankshaft and Connecting ROS nic si cis siecs eit de ALEA NAAA Mate ntm LR E eiS Crankshaft Installation sise Connecting BR ET Connecting Rod Installation TEE Grankshiatl Connecting Rod CIS aa sti Connecting Rod BONA BE Ree ie Bee E EE Connecting Rod Big End Side Clearance cccccccesseecencceeeeeeneeeseeeceeeeeeeeeneeneneeeenes Connecting Rod Big End Bearing Insert Crankpin Wear Crankshaft Side ClearanGe sra ota Crankshaft RUNOUTTA zeg iaa aid e de Crankshaft Main Bearing Insert Journal Wear Pistons 3 AAA PONS MM INN GR ER RP en Piston Remya ANN MN a a AMEN ZE NAS o a ANA A cc Piston LEE de DEE Cylinder Wear Upper CrankCase icono ege EES PiStonNNear er E Re ege ee eege ee Piston Ring Piston Ring Groove Wear unes tt ei Piston Ring Groove Le en EE Piston RING Melle e PIStOM PINGING GAD EE TRANSMISSION A Aer dE nays Shift Pedal Removal usina rita tdi Shift Pedal Installation siens External Shi
79. 0134 in EE Used Connecting Rod 0 24 0 34 mm 0 0094 0 0134 in Crankshaft Side Clearance 0 05 0 20 mm 0 0020 0 0079 in 0 40 mm 0 0157 in Crankshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 05 mm 0 0020 in Crankshaft Main Bearing 0 010 0 034 mm 0 0004 0 0013 in 0 06 mm Insert journal Clearance 0 0024 in Crankshaft Main Journal Diameter 34 984 35 000 mm 1 3773 1 3780 in 34 96 mm 1 3764 in Marking None 34 984 34 992 mm 1 3773 1 3776 in SE 1 34 993 35 000 mm 1 3777 1 3780 in Crankcase Main Bearing Inside 38 000 38 016 mm 1 4961 1 4967 in Diameter Marking O 38 000 38 008 mm 1 4961 1 4963 in None 38 009 38 016 mm 1 4964 1 4967 in www zxforums com www zxtorums GRAN KSHAFT ITRANSMISSION 9 7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness Brown Black Blue Pistons Cylinder Upper Crankcase Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Transmission Shift Fork Ear Thickness Gear Groove Width Shift Fork Guide Pin Diameter Shift Drum Groove Width 1 491 1 495 mm 0 0587 0 0589 in 1 495 1 499 mm 0 0589 0 0590 in 1 499 1 503 mm 0 0590 0 0592 in 75 990 7
80. 13 Front Fork e Screw the adjust nut A onto the compression shaft as shown 20 mm 0 79 in B e Screw the locknut C e Set the other side compression shaft same process e Screw in one side nut A come out the piston rod nut e Holding the piston rod nut with a wrench A remove the top plug B from the piston rod e Remove Washer A Collar B Rebound Damping Adjuster Rod C Fork Spring D DUT 6S14021BS1 e Drain the fork oil into a suitable container OPump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M10 x 1 0 A 57001 1298 GM04021281 www zxforums com www zxforums com www zxforums com 13 14 QURRENSION www zxforums com www zxforums com Front Fork e Hold the fork tube upright press the inner tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Fork Oil Viscosity KHL15 10 KAYABA or equivalent Amount per side WT My py gt My My 77 When changing oil Approx 480 mL 16 2 US oz After disassembly and completely dry 567 4 mL 19 2 0 14 US oz 6M04042851 x If necessary measure the oil level as follows OHold the inner tube vertically in a vise OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the f
81. 2 5 18 L Engine Lubrication System Engine Oil Drain Bolt 20 2 0 15 Oil Cooler Mounting Bolts 20 2 0 15 L Oil Filter 31 3 2 23 EO R Oil Cooler Oil Filter Case Mounting Bolts 20 2 0 15 L Oil Filter Pipe 35 3 6 26 L Oil Pan Bolts 10 1 0 89 in lb Oil Passage Plugs 20 2 0 15 L Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Oil Pump Cover Bolts 10 1 0 89 in lb Oil Pump Gear Bolts 10 1 0 89 in lb L Engine Removal Installation Adjusting Collar Locknut 49 5 0 36 S Left Engine Bracket Bolts M10 L 30 mm 44 4 5 32 S Left Front Engine Mounting Bolt M10 L 42 mm 44 4 5 32 S Lower Engine Mounting Bolt 9 8 1 0 87 in lb S Lower Engine Mounting Nut 44 4 5 32 S Middle Engine Mounting Bolt 9 8 1 0 87 in lb S Middle Engine Mounting Nut 44 4 5 32 S Right Engine Bracket Bolt M10 L 35 mm 44 4 5 32 S Right Engine Bracket Bolts M10 L 30 mm 44 4 5 32 S Right Engine Bracket Bolts Cylinder Head Side 10 1 0 89 in lb L Right Front Engine Mounting Bolt M10 L 67 mm 44 4 5 32 S Crankshaft Transmission Bearing Position Plate Screws 5 0 0 51 44 in lb L Breather Plate Bolts 10 1 0 89 in lb E Connecting Rod Bid End Bolts see Text lt MO Coolant Drain Plug Cylinder 10 1 0 89 in lb Crankcase Bolts M9 39 4 0 29 MO S Crankcase Bolts M8 27 2 8 20 S Crankcase Bolts M7 L 85 mm 20 2 0 15 S Crankcase Bolts M7 L 50 mm 20 2 0 15 S Crankcase Bolts M7 L 32
82. 5 200 r min rpm CA CAL US FI Fuel injection MIKUNI 43EIDW x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter in ECU From 10 BTDC 1 100 r min rpm NGK CR9EIA 9 Left to right 1 2 3 4 1 2 4 3 46 BTDC 74 ABDC 300 66 BBDC 4G Drums com NWW_ZXTOrum om 1 1 0 GENERALINFORMATION www zxforums com www zxforums com General Specifications Items ZX1000D6F Ninja ZX 10R Duration 292 Lubrication System Forced lubrication wet sump with cooler Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE10W 40 Capacity 4 0 L 4 2 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd Ath 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio Gear 1 611 87 54 Wet multi disc 6 speed constant mesh return shift 2 533 2 053 1 737 1 524 1 381 1 304 38 15 39 19 33 19 32 21 29 21 30 23 _ a ae fn fn Chain drive 2 353 40 17 4 945 Top gear Frame Type Caster Rake Angle Trail Front Tire Type Size Rear Tire Type Size Rim Size Front Rear Front Suspension Type Wheel Travel Rear Suspension Type Wheelzkravehs com Tubular diamond 24 5 102 mm 4 0 in Tubeless 120 70 ZR17 M C 58 W Tubeless 190 55 ZR17 M C 75 W 17 x 3 50 17 x 6 00
83. 7 047 7 539 in OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 180 mm 7 0 in spring length e Remove the bolts A chain cover B and left foot guard C for turning the hook wrench easily e To adjust the spring preload turn in the adjusting nut to the desired position and tighten the locknut using by hook wrenches A with the rear shock absorber attached the frame Special Tool Hook Wench 57001 1101 x If the spring action feels too soft or too stiff adjust it Spring Adjustment Adjuster Damping Position Force Setting Load Road Speed 191 5 mm 7 539 in Weak Soft Light Good Low T d ji T T il y y y y y 2 179 mm 7 047 in Strong Hard Heavy Bad High Rear Shock Absorber Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Exhaust Pipe see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 www zxforums com www zxforums com GMO5215BS1 www zxforums com 1 3 22 RUSRENSIO N www zxforums com www zxforums com Rear Shock Absorber e Squeeze the brake lever slowly and it with a band A A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause
84. A Clutch Springs with Clutch Spring Holders Clutch Spring Plate B with Bearing Pusher C e Remove Friction Plates 10 A Steel Plates 9 B Spring C Spring Seat D e Hold the sub clutch hub A steady with the clutch holder B and remove the nut C Special Tool Clutch Holder 57001 1243 OUse the clutch holder with sharpened hook nose by grind ing Special Tool Clutch Holder 57001 1243 OGrind the hook nose by 0 5 mm 0 02 in as shown in the figure SIZXTO4081 e www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www FbUTCH 6 11 Clutch e Remove Torque Limiter Springs A Sub Clutch Hub B Clutch Hub C Spacer D ORemove the sub clutch hub bolts E as necessary e Using the two 4 mm 0 16 in screws A pull out the sleeve B needle bearing C and clutch housing D e Remove the spacer www zxforums com www zxforums com GFO6126BS2 C GFO6O107S1 www zxforums com 6 1 2 Qk HG com www zxforums com www zxforums com Clutch Clutch Installation e Install the spacer A so that the circle mark B faces out ward e Engage the clutch housing gear A and oil pump drive gear B with the crankshaft primary gear C and oil pump gear D e Install Needle Bearing A Sleeve B OApply engine oil to the sleeve and needle bearing e Install the spacer C so that the steppe
85. Bearing Sleeve Inspection in the Suspen sion chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 37 Maintenance Procedure Steering System Steering Play Inspection e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Lift the front wheel off the ground using the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Steering Damper see Steering Damper Removal inthe Steering chapter Stem Head Nut A and Washer B e Loosen the upper fork clamp bolts C and handlebar bolts D e Remove the stem head E with handlebar e Bend the claws A of lock washer straighten e Remove the steering stem locknut B and claw washer C
86. Blue e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage www zxforums com www zxforums com www zxforums com 9 26 GRANKRHAFT TRANSM ISSN sorums com www zxforums com Pistons Piston Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A and big end caps B NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove Camshaft Chain see Camshaft Chain Removal in the engine Top End chapter Crankshaft A e Remove the connecting rods with pistons to the cylinder head side B e Remove the piston pin snap rings A 108146 P e Using the piston pin puller assembly A remove the pis ton pins Special Tool Piston Pin Puller Assembly 57001 910 e Remove the pistons GE16158BS1 e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16159BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforum Ed AN KSHAFT TRANSMISSION 9 27 Pistons Piston Installation e Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B butt together
87. Chain Guide Bolts 12 1 2 106 in lb S 5 Cylinder Head Bolts M10 New Bolts 59 6 0 44 MO S 5 Cylinder Head Bolts M10 Used Bolts 57 5 8 42 MO S 6 Cylinder Head Bols M8 12 m2 fin s 14 19 6 2 0 7 Water Passage Plugs 8 Throttle Body Assy Holder Bolts 1 0 89 in lb 10 DEN Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb Starter Clutch Cover Bolts M6 L 30 10 Starter Clutch Cover Bolts M6 L 20 10 20 Coolant Drain Plug Cylinder 10 1 0 89 in lb 21 Starter Clutch Bolt Cap Hand tighten 22 Timing Inspection Cap Hand tighten 23 Right Engine Bracket Bolts Cylinder Head Side 10 1 0 89 in lb L G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant Kawasaki Bond 92104 0004 www zxforums com www zxforums com www zxforums com 5 6 ENGINE AQ EN D www zxforums com www zxforums com Exploded View 6E022138W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com E N GINEFOREND 5 7 Exploded View Torque No Fastener ES kgfm ftlb Remarks 1 Front Exhaust Pipe Holder Nut
88. DC 0 65 V or slightly higher with the throttle at the idle position DC 3 90 V or slightly lower with the throttle at the fully open position CAUTION Do not remove or adjust the main throttle sensor It has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface A shock to the sensor can damage it NOTE OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5V exactly OWhen the input voltage reading shows other than 5V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 65 x 4 75 5 00 0 62 V 3 90 x 4 75 5 00 3 71 V Thus the valid range is 0 62 3 71 V e After main throttle sensor voltage inspection remove the harness adapter x lf the reading is out of the standard range inspect the main throttle sensor resistance x If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 55 Main Throttle Sensor Service Code 11 Resistance Inspection e Turn the ignition switch OFF A e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B PTS TNH S e Measure the main throttle sensor resistance q Ga Main Throttle Sensor Resistance SE
89. ENGINE TOP END www zxforums com www zxforums com Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the radiator hose A from the radiator pipe B e Put out the radiator hose outside of the clutch cable C e Remove Cap Bolt A Washer B e Remove Spring A Rod B www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TQP END 5 19 Camshaft Chain Tensioner e Remove the mounting bolts A and take off the camshaft chain tensioner body B Camshaft Chain Tensioner Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Release the stopper B and push the push rod C into th
90. Europe Models 16 104 Oxygen Sensor Inspection Europe Models 16 104 Oxygen Sensor Heater Inspection Europe Model 16 104 Gear Position Switch Removal cnica latina 16 104 Gear Position Switch Installation EE 16 105 GARE EEGENEN Inspection WAN SITUS COP EES www zxforums com www zxforums com ELECTRICAL Sv EM 1 6 3 Rel y Ee ee ee 16 107 Relay BOX Removal tt oia 16 107 Relay Circuit Inspection sd dad pdas 16 107 Diode Circuit ne EE 16 108 A E 16 110 30 A Main Fuse Remova siemens 16 110 Fuse Box Fuse Removal sise 16 110 15 A ECU FUSE REMOVAL uti avon Eeer eet gege ice 16 110 FUSC UNS Talat OM aii hy ieee RSR tad E aces tadin san EN 16 111 SE Ee e DEE 16 111 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 16 4ELERLRICAL SYSTEM Exploded View a s a 4 ES Y 2 TE WY fet Wwe GPO2245BH5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SEM 1 6 5 Exploded View Torque No Fastener No kgf m Pe Remarks 1 Meter Unit Mounting Screws 1 2 0 12 11 in Ib 2 Headlight Mounting Screws 1 2 0 12 11 in lb 3 Front Turn Signal Light Mounting Screws 1 2 0 12 11 in lb 4 Rear Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib 5 Rear Turn Signal Light Lens Screws 1 2 0 12 11 in lb 6 License Plate Light Mounting Screws 1
91. Front Exhaust Pipe see Front Exhaust Pipe Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal e Remove the front camshaft chain guide bolt upper A e Remove Crankshaft Sensor see Crankshaft Sensor Removal in the Electrical System chapter Starter Clutch see Starter Clutch Removal in the Elec trical System chapter Left and Right Front Engine Mounting Bolts see Engine Removal in the Engine Removal Installation chapter Front Camshaft Chain Guide Bolt Lower A Front Camshaft Chain Guide B e Loosen the M6 and M10 cylinder head bolts as shown sequence 1 10 in the figure and remove them e Take off the cylinder head to forward www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com EN GINE TOR END 5 29 Cylinder Head Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install the dowel pins e Replace the cylinder head gasket with a new one e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the threads of the head bolts C 6E14027BS1 e Install the left engine bracket cylinder head side A so that the boss side B faces outward Front C gt 0 GE14082BS1 e Tighten the M10 cylinder head bolts fo
92. GQOLING SYSTEM www zxforums com www zxforums com Specifications Item Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 C 31 F 2 9 L 3 1 US qt Reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 14 18 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 58 62 C 136 144 F 8 mm 0 31 in or more at 75 C 167 F www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING A ATEN 4 7 Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve tank x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x lf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter see Coolant Level Inspection in the Pe riodic Maintenance chapter Coolant Draining e Re
93. Joint Connector 3 3 1 1 HEURE SYSTEM DFI www zxforums com www zxforums com DFI Power Source ECU Fuse Removal e Refer to the 15 A ECU Fuse Removal in the Electrical Sys tem chapter see 15 A ECU Fuse Removal in the Electri cal System chapter ECU Fuse Installation x If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Fuse installation in the Electrical System chapter see Fuse Installation in the Electrical System chapter ECU Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter see Fuse Inspection in the Electrical System chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM ARE 3 111 Warning Indicator Light LED Light LED Inspection OThe warning indicator light LED A is used for the Fl indicator immobilizer indicator immobilizer models and oil pressure warning indicator Oln this model the warning indicator light LED Fl immo bilizer blink by the special signal sent from the ECU e Refer to the warning indicator light LED oil pressure waming inspection procedure see Electronic Combina tion Meter Unit Inspection in the Electrical System chap ter for the warning indicator light LED Fl immobilizer inspection Warning Indicator Light LED Fl Immobilizer Circuit GC17195C81
94. Meter G sensor BL lead C Meter CH BK sensor BR BK lead D e Measure the input voltage with the engine stopped e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V lf the reading is out of the standard range check the wiring see wiring diagram in this section x If the reading is good the input voltage is normal Check the output voltage e Turn the ignition switch OFF Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connector B E Gren Special Tool Needle Adapter Set 57001 1457 P Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter gt Y BL lead terminal 28 Meter BR BK lead terminal 34 6017148051 Output Voltage at ECU Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure OThe vacuum sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute vacuum pressure x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section
95. O1 P ND Brake Hose Clamp Clamps Brake Hoses Face the paint mark outside Viewed Right Side Viewed Left Side Brake Hose Rubber Dumper Clamps Brake Hose Face the paint mark outside Viewed A www zxforums com www zxforums com www zxforums com E 3 E 9 gt E E lt Q g gt 5 ki S TES S a Ke A EE S E gt PE E ly ir HW D EY 3 TG e e no EST 8 A 3 V gt SIE YN 3 y Nay HE o el GEAR SA A AE gt de Nils S a Rio bal IO IO www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX Al 7 27 Cable Wire and Hose Routing Front To the Fuel Tank Hose Blue Hose Red Hose White To the fitting of the Throttle Body 3 Run the hose over the subthrottle valve actuator connector Hose Green To the fitting of the Throttle Body 4 Run the hose under the harness Bolt 10 Clamp 11 Band 12 Canister 13 Bracket 14 Face the point mark white to the right 15 Bolt 16 Right Inner Fairing 17 Nut 18 Run the hoses inside the engine bracket 19 Separator 20 Bracket 21 Run the white hose to the forward 22 Run the red hose to the rearward 23 Install the clamps as shown illustration noting to the direction of clip 00 J O O1 P ND A www zxforums com www zxforums com www zxforums com 17 28 ABRENDIS www zxforums com
96. Plate Light Bulb Replacement nan nan 16 62 Turn Signal Light Bulb Replacement tn er falo de Meet etes 16 63 Turn Signal Relay Inspection m p mx UIT YA REY em A RE 16 65 Air Switching Valve ANM NM NM Loe AN aad NA ADA ARAB 16 67 Air Switching Valve Operation Test 16 67 Air Switching Valve Unit EE 16 67 R diator EE a Gece npa con id 16 68 Ean Motor Ier EE 16 68 Meter Gauge Indicator Un 16 69 Meter Unit Removal Installation sise 16 69 Meter Unit Disassem EE dist cetiecst tare tadessualeast aces 16 69 Electronic Combination Meter Unit Inspection 16 70 Immobilizer System Equipped Models cdi teens creer nee ae bees 16 80 Operational Cautions See 16 80 A EE nee due tt ae na D An AE ASSET Uhlan alate dt dut 16 80 Immobilizer System Parts Replacement nn rnccnnnnns 16 96 Immobilizer System Inspection ica idol 16 98 Switches EE 16 100 Brake Light Timing ln Ee EE 16 100 Brake Light Timing Greet ee edessgdek Se ai eEE ld 16 100 SMWitch ue te EE 16 100 Water Temperature Sensor Inspection ses 16 101 Speed Sensor Remova trt ttt rt rtt rrtt trett tertEterenent 16 101 Speed Sensor Installation sens 16 102 Speed Sensor Inspection sise 16 102 Fuel Reserve Switch Inspection 16 102 Oxygen Sensor Removal Europe Models coooooooocccccccccccconononcccncconananano nono ncnnnanonnnnnnnnnnno 16 103 Oxygen Sensor Installation
97. Replacement in the Electrical System chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DE 3 107 ECU ECU Installation e Install ECU A In rubber protector B ECU Connectors e Insert the slits of the rubber protector to the projections A of the rear fender front ECU Power Supply Inspection e Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU connectors x lf the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connectors are cracked bent or otherwise damaged e With the ECU connectors B connected check the fol lowing ground lead for continuity with the ignition switch OFF using a digital meter A and needle adapter set Battery C Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection 17 39 or 52 Terminal lt Battery Terminal 0 Q Engine Ground lt Battery Terminal 0 Q x If no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary www zxforums com www zxforums com GC171790S1 www zxforums com 3 108 EUEL SYSTEM DFI www zxforums com www zxforums com
98. Satin 4 21 Hose InStallation WEE 4 21 HOSE Ee 4 21 Water Temperature Sensor sisi 4 22 Water Temperature Sensor Removal ses 4 22 Water Temperature Sensor Inspection see 4 22 www zxforums com www zxforums com www zxforums com 4 2 GROLING SYSTEM www zxforums com www zxforums com Exploded View www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING AA RTEN 4 3 Exploded View Torque No Fastener Ne kgf m ftlb Remarks 1 Water Hose Clamp Screws 2 0 0 20 18 in lb 2 Coolant Drain Bolt Cylinder 10 1 0 89 in lb 3 Water Pump Cover Bolts 10 1 0 89 in lb 4 Water Temperature Sensor 25 2 5 18 SS 5 Coolant Reserve Tank Mounting Bolts 7 0 0 71 62 in lb 6 Coolant By pass Fitting Bolt 9 0 0 92 80 in lb L 7 Thermostat Housing Cover Bolts 6 0 0 61 53 in lb 8 Thermostat Housing Mounting Bolts 10 1 0 89 in lb 9 Oil Cooler Mounting Bolts 20 2 0 15 10 Water Hose Fitting Bolts 10 1 0 89 in lb 11 Water Passage Plugs 19 6 2 0 14 L 12 Radiator Bracket Mounting Bolt 7 0 0 71 62 in lb 13 Radiator Upper Bolt 7 0 0 71 62 in lb 14 Radiator Lower Bolt 7 0 0 71 62 in lb 15 Coolant Drain Bolt Water Pump 10 1 0 89 in lb 16 Thermostat G Apply grease www zxforums com Apply a non permanent locking agent Replacement Parts Apply silicone sealant www zxforums com www zxforums com 4 4 GROL
99. Seat Removal Frame chapter Battery Cable Caps see Battery Removal e Disconnect the battery terminals j CAUTION Set 7 Be sure to disconnect the negative cable first ue e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x lf the reading is 12 8 V or more no refresh charge is re quired however ifthe read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below po900i1281 www zxforums com www zxforums com www zxforums com 16 30 LES IRIGAL SYSTEM www zxforums com www zxforums com Battery Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 2 A x 5 10 h see following chart Quick Charge 5Ax1h CAUTION If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 2A x 20 h NOTE
100. Starter Motor Removal e Take off the starter motor through bolts A and remove both end covers B GP11080BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 55 Electric Starter System e Pull the armature A out of the yoke B e Remove Brush Plate Terminal Nut A Brush Plate Assembly B SIN P Starter Motor Assembly e Pry the spring end A and insert the brush B Pies P e Install the brush plate assembly A into the right hand end cover B e Replace the O ring C with a new one e Install Insulators D Washer E e Tighten Torque Starter Motor Terminal Locknut F 6 9 N m 0 70 kgf m 61 in lb GP11081BS1 e Install the armature A into the yoke B e Install the slip C and thrust washers D onto each side of the shaft www zxforums com www zxforums com www zxforums com 16 56 ELECTRICAL SYSTEM www zxforums com www zxforums com Electric Starter System e Replace the O rings A with new ones e Put the armature B among the brushes C e Apply a thin coat of grease to the oil seal A e Fit the toothed washer B into the left hand end cover e Align the marks A to assembly the yoke and the end covers e Replace the O rings A with new ones e Tighten Torque Starter Motor Through Bolts B 3 4 N m 0 35 kgf m 30 in lb e Replace the O r
101. Swingarm Pivot Nut Wrench Clamp 57001 1597 57001 1626 ST571597ST ST571626ST Jack Attachment Spacer p18 57001 1608 57001 1636 eZ ST571608ST ST571636ST www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SWRE ENRON 13 9 Front Fork Rebound Damping Force Adjustment e To adjust the rebound damping force turn the rebound damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Force Adjustment Adjuster Damping Position Force Setting Load Road Compression Damping Force Adjustment e To adjust the compression damping force turn the com pression damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position A WARNING If both adjusters are
102. Switching Valve Installation EE ET 5 15 Air Switching Valve Operation et or os 5 15 Air Switching Valve Unit EE 5 15 Clean Air System Hose Inspection issues 5 15 Cylinder e Ee EE 5 16 Cylinder Head Cover Removal cacon a rique tonne iaa 5 16 Cylinder Head Cover Installation coo aii in esd ere 5 16 Camshaft Chain Tensioner ooconincncccccccnncnnncnninnnnnnnn rn rre 5 18 Camshaft Chain Tensioner Removal ococcccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnniss 5 18 Camshaft Chain Tensioner Installations ss 5 19 Camshaft Camsha t Ohain Af ZM INR RNCS SN A a 5 20 Camshat Rem 2 eg geg nina ronald cid CARTES 5 20 Camshaft Installation siens 5 21 Camshaft Camshaft Cap Wear ns 5 25 Camshaft RUNOUL bein UI aE aa EVEN dit E aE Ea aa A aa A lens dette tete tuners gets 5 25 Gam EE 5 26 Camshaft Chain Remova ss 5 26 C linder Hogan AA AAA AAA erect ae 5 27 Cylinder Compression Measurement 5 27 Cylinder Head ne EE 5 28 Cylinder Plead Installaatio M sianie nasienia aaa aaraa dee 5 29 Cylinder e EE RT EE 5 30 NAIVES E E E AEE a ts 5 31 Valve Clearance Inspection ooccnonccinininnnnnicncccnncc cnc 5 31 Valve REMOVAL EE EE 5 31 Valve Installation dd ado adan 5 31 Valve Guide Removal ee 5 31 Valve Guide IS 5 32 Valve to Guide Clearance Measurement Wobble Method 5 32 VENCE 5 33 Valve Seat Re pal Pisa AAA A A aed dec ee ee ae 5 33 Throttle Body Assy Holde tacita EE ut d
103. Throttle Sensor Setting Adapter 1 57001 Y 1400 i GY G R F W BL Connections to Adapter Meter gt BL actuator Y lead G B Meter gt BK BL actuator BK lead H e Turn the ignition switch ON GC17408BS1 Actuator Output Voltage Pulley Original Position Standard 3 46 3 76 V lf the output voltage is out of the standard remove the actuator and check the original position of the pulley see Exhaust Butterfly Valve Actuator Installation Exhaust Butterfly Valve Actuator Circuit x a d S gt a gt e 6C17174CW2 C 1 ECU 2 Exhaust Butterfly Valve Actuator 3 Water proof Joint 2 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SY MAR EW 3 99 Oxygen Sensor Heaters 1 and or 2 Service Code 67 Europe Models Oxygen Sensor Heaters Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensors see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heaters Inspection NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness Side is different e Turn the ignition switch OFF e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the oxygen sensor lead connectors A e Set the hand tester
104. V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Connect the variable rheostat A to the terminal 8 as shown e Check that the number of segments matches the resis tance value of the variable rheostat Resistance Value 0 Temperature Meter Warning Indicate Se A B B Fash C 17 HI Flash D e If any display function does not work replace the meter assembly www zxforums com www zxforums com 8757 GP17418BS1 TRIP GP17420BS1 www zxforums com 16 74 6 LEG TRIGAL SYSTEM www zxforums com www zxforums com Meter Gauge Indicator Unit GP17421BW2 C Tachometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OWhen the terminals are connected the tachometer nee dle momentary points to the last reading and then return to the 0 position If the needle function does not work replace the meter assembly e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 Olndicates approximately 4 000 rpm in case the input fre quency would be approximately 133 3 Hz elt the oscillator is not available the tachometer can be checked as follow
105. Valve 39 Engine Ground 40 Starter Lockout Switch 41 Exhaust Butterfly Valve Actuator 42 Starter Button 43 Unused 44 Injector 3 45 Stick Coil 3 46 Injector 1 47 Stick Coil 1 48 Unused 49 Immobilizer Amplifier 50 Immobilizer Amplifier 51 Meter Unit Tachometer 52 Engine Ground 53 Sidestand Switch 54 Exhaust Butterfly Valve Actuator 55 Ground 56 Oxygen Sensor Heater 57 Injector 4 58 Stick Coil 4 59 Injector 2 60 Stick Coil 2 KDS Kawasaki Diagnostic System KDS that runs on Windows personal computer PC diagnostic tool for motorcycle with Kawasaki DFI system www zxforums com www zxforums com www zxforums com 3 22 FVEL JEM DFI www zxforums com www zxforums com DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging rem
106. Valve Seat Cutter 45 427 5 Valve Seat Cutter 60 p25 57001 1114 57001 1328 ST571114ST T5713288T Valve Seat Cutter 45 635 Valve Seat Cutter Holder 4 5 57001 1116 57001 1330 ST571116ST ST571330ST Valve Seat Cutter 32 628 Valve Guide Arbor 64 5 57001 1119 57001 1331 ST5711198T ST5713318T www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE LOF END 5 1 3 Special Tools and Sealant Valve Guide Reamer 4 5 Compression Gauge Adapter M10 x 1 0 57001 1333 57001 1601 ST571333ST ST5716018T Valve Seat Cutter 60 p33 L Shape Hose 57001 1334 57001 1606 ST5713348T ST5716068T Valve Guide Driver Washer 57001 1564 57001 1612 ST571564ST ST571612ST Valve Spring Compressor Adapter 24 Kawasaki Bond Silicone Sealant 57001 1586 92104 0004 ST571586ST ST9200048T www zxforums com www zxforums com www zxforums com 5 1 4 ENGINE IOP END www zxforums com www zxforums com Clean Air System Air Suction Valve Removal e Remove Air Switching Valve see Air Switching Valve Removal Air Suction Valve Cover Bolts A Air Suction Valve Covers B e Remove the air suction valves A Air Suction Valve Installation e Install the air suction valve so that opening A of the reed faces the rear and downward e Apply a non permanent locking agent to
107. When Registered User Key is Inserted gt Gli LE CE re 1 GP30166BS1 www zxforums com www zxforums com www zxforums com 16 92 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models User Key Collation Error Eege py GP30168BS1 e The user key 1 is registered in the ECU OThe warning indicator light LED and immobilizer warn ing symbol A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 0 3 1second OnE LI SE GP30169BS1 e Turn OFF and remove the user key 1 OThe warning indicator light LED A blinks to display the registration mode codes NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned off and removed otherwise registra 0 5second 0 5second tion mode will be ended and the warning indicator light SE goes off Le A Harara rte OTo return to the registration mode start the master key apsozo1nsi verification procedure This applies to all user key reg istration e Insert the user key 2 to the ignition switch and turn it ON Olf there is any problem in the registration the warning indicator light LED and immobilizer warning symbol A blinks to display the collation error code Immobilizer Amplifier Failure 0 2second o Hhnnnnnnnn LUUT
108. accidentally turning over Disconnect the ground A DAR cable first and then the positive When completed Wal TT E with the service first connect the positive cable to the 9 Pol 4 positive terminal of the battery then the negative ca AA sie ble to the negative terminal DISASSEMBLY ASSEMBLY 6602024B_ S Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 05020048 S Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 66020058 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or H other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle C0200 S www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreig
109. an accident and injury e Remove Lower Shock Absorber Nut and Bolt A Upper Tie Rod Nut and Bolt B Upper Shock Absorber Nut and Bolt C e Remove the shock absorber downward Rear Shock Absorber Installation e Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Inspection e Remove the rear shock absorber e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x lf it show any signs of damage replace it Rear Shock Absorber Scrapping A WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode e Remove the valve cap and release the nitrogen gas com pletely from the gas reservoir eMo5114851 e Remove the valve A A WARNING Since the high pressure gas is dangerous do not point the valve toward your face or body www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSEENGION 3 23 Swingarm Swingarm Removal e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Middle Exhaust Pipe see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter Engine Sprocket see Engine Sprocket Re
110. and immobilizer systems are operating correctly Olf the warning indicator light LED and Fl warning symbol flashes about 3 seconds after the ignition key is turned ON this shows a fault in the DFI system Refer to the service code to identify the faulty component Olf the warning indicator light LED and immobilizer warning symbol flashes about 3 seconds after the ignition key is turned ON this shows a fault in the immobilizer system Refer to the service code to identify the faulty component e The warning indicator light LED will flash for a period of 24 hours once the ignition switch has been switched off and the key removed This flashing can be set to on or off as desired by holding the Mode and Reset buttons down for two seconds within twenty seconds of switching the ignition off e If all coded keys master key and user keys are lost the ECU and ignition switch will have to be replaced e The immobilizer system can not function until the master key code is registered in the ECU e A total of six keys can be registered in the ECU at any one time one master key and five user keys e If the master key is lost it is not possible to register new user keys Operational Cautions Do not put two keys of any immobilizer system on the same key ring Do not submerge any key in water Do not expose any key to excessively high temperature Do not place any key close to magnet Do not place a heavy item on any key Do not grind any key o
111. and immobilizer warn ing symbol A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1 0 30 3 0 3 1second OH LI Se GP30169BS1 e Turn OFF and remove user key 1 OThe warning indicator light LED A blinks to display the registration mode NOTE OTurn off the ignition switch and wait for the period more than 15 seconds The registration mode automatically 0 5second 0 5second ends and warning indicator light LED goes off SEN OThis procedure has registered the master key and one O Oe e e D e user key GP30201ES1 OContinue the procedure to program the second and later keys e Insert the user key 2 to the ignition switch and turn it ON www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYS HEM 16 89 Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered User Key is Inserted User Key Collation Error e The user key 2 is successfully registered in the ECU OThe warning indicator light LED and immobilizer warning symbol A blinks 3 times and stops for 1 second and then repeat this cycle to indicate successful programming of user key 2 e Turn OFF the ignition swit
112. any coolant that spills on the frame engine wheels or other painted parts Radiator Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib 6S06000BS1 Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 23 Maintenance Procedure e Remove the cylinder head cover see Cylinder Head l Cover Removal in the Engine Top End chapter e Remove the timing inspection cap A and starter clutch bolt cap B on the starter clutch cover C e Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notch C in the edge of the timing inspection hole D in the crank shaft sensor cover
113. as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 416 109 www zxforums com www zxforums com Relay Box Relay Box Internal Circuit ORONO QUISO GP190118 2 C A Headlight Relay B Fuel Pump Relay C Starter Circuit Relay D Fan Relay www zxforums com www zxforums com www zxforums com 16 140 EL 56 RJf AL SYSTEM www zxforums com www zxforums com Fuse 30 A Main Fuse Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter 30 A Main Fuse Connector A e Pull out the main fuse A from the starter relay with needle nose pliers Fuse Box Fuse Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Push the hook A to lift up the lid B e Pull the fuses A straight out of the fuse box with needle nose pliers 15 A ECU Fuse Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Pull the hook A to lift up the lid B www zxforums com www zxforums com www zxforums com www zxforums co
114. before x If all vacuums are within the specification range finish the engine vacuum synchronization x If any vacuum cannot be adjusted within the specification remove the bypass screws 1 4 and clean them e Turn in the bypass screw A with counting the number of turns until it seals fully but not tightly Record the number of turns Torque Bypass Screw 0 2 N m 0 02 kgf m 1 7 in Ib CAUTION Do not over tighten them They could be damaged requiring replacement 6S05015BS1 e Remove Bypass Screw Spring B Washer C O ring D e Check the bypass screw and its hole for carbon deposits x If any carbons accumulate wipe the carbons off from the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent e Replace the O ring with a new one e Check the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly Torque Bypass Screw 0 2 N m 0 02 kgf m 1 7 in Ib www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 1 9 Maintenance Procedure e Back out the same number of turns counted when first turned in This is to set the screw to its original position NOTE OA throttle body has different turns out of the bypass screw for each individual unit On setting the byp
115. canister A is designed to work well through the motorcycle s life without any maintenance if it is used under normal conditions www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING SYNIM 4 1 Cooling System Table of Contents Exploded VIS Wii A A A A E Ee 4 2 Coolant Flow Chat IA 4 4 eene le EE 4 6 El A D 4 7 Coolant Deterioration Inspechon 4 7 Goolant Level Inspection setuatearebgetdoadadeyecuebean shart Eden 4 7 Coolant Draining EE 4 7 Coolant UMN EE 4 7 Pressure Testa REES 4 7 Cooling System FS MUNG EE 4 8 Coolant Reserve Tank Removal seen 4 8 Coolant Reserve Tank Installation ooooonocccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininnnos 4 9 Water PUDE cios tallada did diia cada 4 10 Water Pump Removal 4 10 Water Pump Installation seen 4 10 Water Pump Impeller Inspection ses 4 11 el re 4 12 Radiator and Radiator Fan Removal ss 4 12 Radiator and Radiator Fan Installaton eenen eene eeereerreernreseresrrenrrenernerreneene 4 13 Radiator Inspection ANE dw EOD LAT E ee IAS eee 4 16 Radiator Cap 4 970 1101 ti rt o A pa dre ege edd 4 16 Radiator Filler Neck Inspection 4 17 ANA ue EE 4 18 Thermostat Removal seen 4 18 Thermostat Installation ss 4 18 Thermostat Inspection iii AER Ronnie 4 19 HOSES ANd PIPES ssl guava entente he rentes tte dont athe
116. center groovetin the shift drum C OThe two forks D on the output shaft are identical e Install the forks as shown e Apply a non permanent locking agent to the threads of the shift drum bearing holder screws and shift fork holder bolt and tighten them Torque Shift Fork Holder Bolt 12 N m 1 2 kgf m 106 in Ib Shift Drum Bearing Holder Screws 5 0 N m 0 50 kgf m 44 in lb Shift Drum Disassembly e Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the shift drum cam holder bolt Shift Drum Cam Holder Bolt A Dowel Pin B Y 6113160BS1 Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 104 in 1b www zxforums com www zxforums com www zxforums com 9 38 GRANKRHAFT IT RANSM ISSN sorums com www zxforums com Transmission OO Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced
117. chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide worn or stem seal damaged Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on seating surface inspect and replace see chapter 6 Hesitation Too low fuel pressure Inspect see chapter 3 Clogged fuel line Inspect and repair see chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble inspect see chapter 3 www zxforums com www zxforums com FUEL STEYL RE 3 37 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air pressure sensor trouble Inspect see chapter 3 Loose i
118. com www zxforums com www zxforums com FUEL SYSTEM RE 3 91 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil 3 Service Code 53 Stick Coil 4 Service Code 54 Removal Installation CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coil can damage it e Refer to the Stick Coil Ignition Coil together with Spark Plug Cap Removal Installation in the Electrical System chapter see Stick Coil Ignition Coil together with Spark Plug Cap Removal Installation in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A as shown with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Stick Coil Input Voltage at ECU Connections for Stick Coil 1 Meter BK lead terminal 47 Meter gt BK Y lead terminal 52 Connections for Stick Coil 2 Meter BK G lead terminal 60 Meter gt BK Y lead terminal 52 Connections for Stick Coil 3 Meter gt BK W lead terminal 45 Meter BK Y lead terminal 52 Connections for Stick Coil 4 Meter BK O lead terminal 58 Meter BK Y lead terminal 52 e Measure the input voltage to each primary winding of
119. connected directly to the battery positive termi nal even when the ignition switch off so take care not to short the removed cable to chassis ground e Pull out the starter relay from the damper e Connect the hand tester A and 12 V battery B to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x1 Q range Criteria When battery is connected 0 Q 6P11019BS1 When battery is disconnected Q e Tighten Torque Starter Motor Cable Mounting Bolt 4 0 N m 0 41 kgf m 35 in lb Battery Cable Mounting Bolt 4 0 N m 0 41kgf m 35 in lb www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 59 Electric Starter System Electric Starter Circuit y BK R G BK en CEE LE EI er if ar Eat x JO 2 GP11082BW3 C Ignition Switch Joint Connector 1 Starter Lockout Switch Fuse Box Ignition Fuse 15 A Relay Box Starter Circuit Relay Starter Motor Main Fuse 30 A 10 Starter Relay 11 Battery 12 V 10 Ah 12 Frame Ground 13 Joint Connector 2 14 ECU 15 Gear Position Switch 16 Sidestand Switch 17 Starter Button 18 Engine Stop Switch OOANOARWN www zxforums com www zxforums com www zxforums c
120. do the following procedures OTurn off the ignition switch ORemove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tester Reading Range Tester to Tester to 04 000 rpm 250 V AC One Black lead Another Black lead x If the output voltage shows the value in the table the al ternator operates properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OComnect the commercially available tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Reading Range Tester to Tester to One Black lead Another Black lead 0 1 0 2 Q lf there is more resistance than shown in the table or no tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the blac
121. e Using a thickness gauge A measure the valve clearance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 15 0 24 mm 0 0059 0 0094 in NOTE OThickness gauge is horizontally inserted on the valve lifter Appropriateness A Inadequacy B Thickness Gauge C Horizontally Inserts D Cam E Valve Lifter F 6S07024BS1 Hits the Valve Lifter Ahead G www zxforums com www zxforums com www zxforums com 2 24 REBIORIG MAINTENANCE www zxtorums com www zxforums com Maintenance Procedure OWhen positioning 1 piston TDC at the end of the compression stroke Inlet Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A OWhen positioning 4 piston TDC at the end of the compression stroke Inlet Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve A x lf the valve clearance is not within the specified range first record the clearance and then adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions OG ee 2098 6S07016BS1 CO eo 998 6S07015BS1
122. even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem e www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 29 Battery WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Front Seat see Front
123. gear positioning lever A as shown Spring B Washer C Bolt D e Tighten Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib G113264BS1 External Shift Mechanism Inspection e Examine the shift shaft A for any damage x lf the shaft is bent straighten or replace it x If the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them x lf the shift mechanism arm D is damaged in any way replace the shaft e Check the return spring pin A is not loose xf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 N m 3 0 kgf m 21 ft lb e Check the gear positioning lever B and its spring for breaks or distortion x lf the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam C x If they are badly worn or if they show any damage replace it www zxforums com www zxforums com www zxforums com 9 32 GRANKRHAFT TRANSM ISSN sorums com www zxforums com Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Remove the output shaft A e Discard the oil seal B e Remove Water Pump see Water Pump Removal in the Cooling System chapter Shift Forks see Shift Drum and Shift Forks Removal Bolts A Drive Shaft Cover B e Pull out the drive shaft C Transmissio
124. ignition switch OFF e Remove Seat Cover see Seat Cover Removal in the Frame chapter Atmospheric Pressure Sensor Connector A Damper B Atmospheric Pressure Sensor C Installation NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has a inlet air pressure hose and dif ferent wiring e Installation is reverse of removal Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor and the inlet air pressure sensor e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 6017145081 Atmospheric Pressure Sensor Input Voltage Connections to ECU Connector Meter gt BL lead terminal 7 Meter gt BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V xlf the reading of input voltage is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU sec tion www zxforums com www zxf
125. is faulty and to be replaced e Prepare a new ignition switch A and two new user keys B OThese parts are available as a set Prepare the current master key C e Remove Ignition Switch and Immobilizer Antenna see Immobi lizer System Parts Replacement Front Seat see Front Seat Removal in the Frame chap ter e Disconnect the immobilizer Kawasaki diagnostic system connector e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 e Connect New Ignition Switch Lead Connector A Immobilizer Antenna Lead Connector B NOTE OKeep the antenna more than 15 cm from the ignition switch e Put the current master key A at the antenna B Insert the new user key 1 C to the new ignition switch D and turn it ON Verified OThe warning indicator light LED and immobilizer warning symbol A blinks to display the ECU is in the registration mode go to the next step 0 5second 0 5second T lit pt tE EE GP30166BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 87 Immobilizer System Equipped Models Not Verified OThe warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure 0 2second 0 Hhannnnnnn UY GP30167BS1 Master Key Collation Error
126. is out of the range check the wiring see wiring diagram in this section x If the reading is good check the output voltage e Turn the ignition switch OFF Output Voltage Inspection e Before this inspection inspect the input voltage see Input Voltage Inspection in this section NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Using the stand raise the rear wheel off the ground e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Special Tool Speed Sensor Measuring Adapter 57001 1667 www zxforums com www zxforums com 6017158051 www zxforums com 3 74 FUEL SXSTE M D Fl www zxforums com www zxforums com Speed Sensor Service Code 24 e Connect a digital meter to the harness adapter leads Speed Sensor Output Voltage Connections to Adapter Meter BL Y lead A Meter CH BK lead B e Measure the output voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Output Voltage at Sensor Standard DC 0 05 0 09 V or DC 4 5 4 9V e Rotate the rear wheel by hand confirm the output voltage will be raise or lower x If the reading is out of the range replace the speed sensor see Speed Sensor Removal Installation in the Electrical System chapter and check the wiring to ECU see wiring diagram in this section x I
127. is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Macnee Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar 57001 1128 C Valve Seat Cutter Holder 64 5 57001 1330 B For Exhaust Valve Seat Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 28 57001 1119 Valve Seat Cutter 60 25 57001 1328 For Inlet Valve Seat Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter 60 33 57001 1334 If the manufacturer s instructions are not available use the following procedure GE15048BS1 www zxforums com www zxforums com www zxforums com 5 34 ENGINE IOP EN D www zxforums com www zxforums com Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter I
128. non permanent locking agent Handlebar Position Bolts Torque Handlebar Bolts 25 N m 2 5 kgf m 18 ft Ib Handlebar Position Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the front brake master cylinder see Front Master Cylinder Installation in the Brakes chapter www zxforums com www zxforums com www zxforums com 14 1 ARTRERINA www zxforums com www zxforums com Handlebar e Install the left and right switch housings OFit the projection A into a small hole B in the handlebar Torque Handlebar Switch Housing Screws 3 5 N m 0 36 kgf m 31 in Ib e Connect the front brake light switch connector e Install the clutch lever A so that the mating surface B of the clutch lever clamps with punch mark C on the handlebar e Install Throttle Grip Throttle Cable Tips A Throttle Cases B OFit the projection C into a small hole D in the handlebar e Tighten Handlebar Weights e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxto AME 1 5 1 Frame Table of Contents Exploded WEE 15 2 ICE E Sei E E S NE E EARO A eeh e ee eebe es 15 8 Rear Seal Removal ti total 15 8 Rear Seat sta ains 15 8 Front Seat Removal 15 8 Front Seat Installation ii ias 15 8 o A O A 15 9 Lower Fairing Removal criado dan 15 9 Lower Fairing Installation rra ras crewing 15 9 Middle Fairing e e 15 9 Middle Fairing
129. not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Compression Damping Force Adjustment Adjuster Damping Position Force Setting Load Road T T t T ij T l y y Y y 0 Strong Hard Heavy Bad High www zxforums com www zxforums com Counterclockwise Softer lt lt Harder Clockwise Seated position adjuster turned fully clockwise GM04328BS1 Counterclockwise Softer lt lt Harder STD 131211109 8 7 6 5 4 3 2 HA Clockwise HH Seated position adjuster turned fully clockwise GM04327BS1 www zxforums com 13 1 QRURPENSION www zxforums com www zxforums com Front Fork Spring Preload Adjustment e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 17 mm 0 67 in B from the top plug nut surface as shown Adjuster Protrusion from the top plug nut surface Standard 17 mm 0 67 in Usable Range 4 19 mm 0 16 0 75 in A WARNING If both adjusters are not adjusted equally han
130. of the crankcase halves and wipe dry A WARNING Clean the crankcase in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent e Using compressed air blow out the oil passage in the crankcase halves e Apply liquid gasket to the breather plate mating surface A 1 mm 0 04 in or more thick and then install the breather plate Sealant Three Bond TB1207B NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied OMoreover fit the plate and tighten the bolts just after wwwgpliratisncofithe liquid gasket www zxforums com www zxforums com G104225BS1 9 1 2 RRANKSHAFTIT RANSM ISSIQN toru ms com www zxforums com Crankcase Splitting e Apply a non permanent locking agent to the treads of the breather plate bolts A and tighten it Torque Breather Plate Bolts 10 N m 1 0 kgf m 89 in Ib e Install the following in the upper crankcase Output Shaft A see Transmission Shaft Installation Crankshaft B see Crankshaft Installation Pistons and Connecting Rods C see Connecting Rod Installation Camshaft Chain D see Camshaft Chain Removal In stallation in the Engine Top End chapter Dowel Pins E e Install the following in the lower crankcase Drive Shaft A See T
131. of the lens into the grooves B of the turn signal light e Tighten Torque Rear Turn Signal Light Lens Screws 1 2 N m 0 12 kgf m 11 in Ib Turn Signal Relay Inspection e Remove Seat Cover see Seat Cover Removal in the Frame chapter Turn Signal Relay A e Disconnect the connector B e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay P12040281 Flashing Times Wattage W c m Signal Lights 21 or 23 140 250 42 or 46 Cycle s per minute Correspond to one light burned out www zxforums com www zxforums com www zxforums com 1 6 68 ELEGTRIGAL SYSTEM www zxforums com www zxforums com Lighting System Turn Signal Light Circuit DO NO O SD 6 ay BK Y BK Y G 6 BK Y BK Y Ignition Switch Turn Signal Indicator Lights Right and Left Joint Connector 1 Front Right Turn Signal Light Front Left Turn Signal Light Turn Signal Switch Fuse Box Turn Signal Relay Fuse 10 A Main Fuse 30 A Battery 12 V 10 Ah Frame Ground Joint Connector 2 Rear Left Turn Signal Light Rear Right Turn Signal Light Turn Signal Relay www zxforums com www zxforums c
132. of washer fit the notch C of steering stem locknut D e First tighten the steering stem locknut by hand until the resistance is felt fully then tighten the steering stem lock nut so that align the claw A of stem locknut to the notch B of stem nut by hand e Check that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearing may be damaged e Bend the claw of lock washer C to steering stem nut notch e Install the stem head A with handlebars to the steering stem B e Install the washer and temporary tighten the stem head nut C e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the fork upper clamp bolts A first next the stem head nut B last the fork lower clamp bolts C and the handlebar bolts D OTighten the two lower fork clamp bolts alternately two times to ensure even tightening torque Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb Handlebar Bolts 25 N m 2 5 kgf m 18 ft lb A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ap pendix chapter e Install the steering damper E see Steering Damper In stallation www zxforums com www zxforums com www zxforums com 14 1 aut LE RING
133. rear fender front e Remove Starter Relay C see Starter Relay Inspection in the Electrical System chapter Relay Box D see Relay Box Removal in the Electrical System chapter Turn Signal Relay E see Turn Signal Relay Inspection in the Electrical System chapter ECU see ECU Removal in the Fuel System DFI chap ter Fuel Pump Connector F see Fuel Tank Removal in the Fuel System DFI chapter and Bracket Exhaust Butterfly Valve Actuator G see Exhaust But terfly Valve Actuator Removal in the Fuel System DFI chapter Owner s Tool H Atmospheric Pressure Sensor I see Atmospheric Pressure Sensor section in the Fuel System DFI chapter Vehicle down Sensor J see Vehicle down Sensor Re moval in the Fuel System DFI chapter Bolts K www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www ERANE 1 5 19 Fenders e Remove Bolts and Nuts A Collars B Dampers C Upper Heat Guard D e Remove Bolt E Bolts F Fender Bracket G e Remove Rivet H Nut I Bolt J Rear Fender Front K Front L Viewed from Upside M Rg aed D gy er degt ric d a XS NM Ae SE NA 6008015BW2 C Rear Fender Front Installation e Insert the on the chassis e Install the removed parts see appropriate chapters e Run the harness correctly see Cable Wire and Hose Routing section in the Appendix chapter www zxforums com www
134. see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Pull the air switching valve hose A out of the air cleaner housing holder e Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 27 Maintenance Procedure e Start the engine and run it at idle speed e Plug A the air switching valve hose B end with your finger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter e Apply a soap and water solution or rubber lubricant to the end of the air switching hose and install the hose on the fitting Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder lf the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in WARNING To avoid a seriou
135. sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Air Cleaner Housing see Air Cleaner Housing Removal Throttle Body Assy see Throttle Body Assy Removal Connector A Water Temperature Sensor B e Apply silicone sealant to the threads of the water temper ature sensor and tighten it Sealant Kawasaki Bond Silicone Sealant 92104 0004 Torque Water Temperature Sensor 25 N m 2 5 kgf m 18 ft lb e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the ECU connectors B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Water Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 25 Meter gt BR BK lead terminal 34 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine www zxforums com www zxforums com
136. shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the pad spring A in the caliper as shown e Install the pads see Rear Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement e Remove Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter e Remove the spark plug using the 16 mm 0 63 in plug wrench A vertically Owner s Tool Spark Plug Wrench 16 mm 92110 1132 e Replace the spark plug with a new one Standard Spark Plug Type NGK CR9EIA 9 e Insert new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Install the stick coils securely OBe sure the stick coils are installed by pulling up it lightly PT subia P www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SPE MCR 3 1 Fuel System DFI Table of Contents Exploded VIS We ii A A A EE E nt aes 3 4 Ee E 3 10 eene le 3 12 Special Tools and Sealant iii A welt an Aia 3 14 DEI Parts Location aec0efe7et geseit RER See EEN 3 16 O ee sement r eee 3 18 DFI Servicing
137. state Disassembly and assembly may change the valve performance x If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent lf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts www zxforums com www zxforums com 6608060251 www zxforums com 7 1 2 ENGINE LUBRICATION SY SE Miorums com www zxforums com Oil Pump Oil Pump Removal e Remove Oil Pump Gear see Oil Pump Gear Removal Oil Pump Cover Bolts A e Remove the oil pump cover A with oil pump gear shaft B OStuff the cloth C on the hole of the crankcase so that pin D close not drop into the crankcase bottom e Remove the outer rotor E and inner rotor F Oil Pump Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump gear shaft B and crankcase C e Install the following to the oil pump gear shaft A Oil Pump Cover B Washer C GG09
138. the stick coils with the engine stopped and with the connec tors joined e Turn the ignition switch ON Input Voltage at ECU Standard Battery Voltage x If the reading is out of the standard check the wiring see wiring diagram in this section x If the reading is good the input voltage is normal Crank the engine and check the peak voltage of the stick coils see Stick Coil Primary Peak Voltage Inspection in the Electrical System chapter in order to check the primary way gxforums com www zxforums com 6017168051 www zxforums com 3 92 HE GEM DFI www zxforums com www zxforums com Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil Circuit lt e BK 0 R R IGNITION rar ER BATTERY_ 6c017169CW2 ECU Stick Coil 4 Stick Coil 3 Stick Coil 2 Stick Coil 1 Engine Stop Switch Ignition Switch Ignition Fuse 10 A Starter Relay 10 Main Fuse 30 A 10 Fuse Box 11 Battery 12 V 10 Ah 12 Joint Connector 3 I O O1 HE ND www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL Sal EN RED 3 93 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the actuator especially
139. the Allen bolt and tighten it Torque Front Fork Bottom Allen Bolts 23 N m 2 3 kgf m 17 ft lb www zxforums com www zxforums com www zxforums com 13 18 RUSRENSION www zxforums com www zxforums com Front Fork e Install the following parts into the inner tube A Dust Seal B Circlip C Oil Seal D Washer E e Insert the inner tube to the outer tube e After installing the washer install the oil seal A by using the fork oil seal driver B Special Tool Fork Oil Seal Driver 643 57001 1530 e Install the circlip and dust seal e Pour in the specified type of oil see Front Fork Oil Change GM040420S1 Inner Tube Inspection e Visually inspect the inner tube A and repair any dam age e Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage x lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION GM04332BS1 If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation elt you feel binding or catching the inner and outer tubes must be replaced WARNING A
140. the fuel hose joint out D of the outlet pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Remove Fuel Tank Bolt A Drain Hose B e Close the fuel tank cap e Remove the fuel tank C and place a it on a flat surface ODo not apply the load to the outlet pipe of the fuel pump www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 137 Fuel Tank e For the California Model note the following CAUTION For the California model if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contaminated replace it with a new one OBe sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal A WARNING For the California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air California model OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump A WARNING
141. the pulley C e Remove Bolts A Bracket Bolts B Right Footpeg Bracket C with Rear Brake Reservoir D e Remove the brake hose E from the clamp F e Unscrew the mounting bolts A and detach the rear caliper B from the disc e Remove Right Rear Footpeg Bracket see Muffler Body Removal Bolts A Upper Cover B Lower Heat Guard C CAL JE www zxforums com www zxforums com www zxforums com 5 46 ENGINE IOP END www zxforums com www zxforums com Muffler e Remove Bolts A Lower Cover B e Loosen the locknuts A e Remove the exhaust butterfly valve cable lower ends B from the pulley C e Pull the exhaust butterfly valve cables out of frame Front View D Exhaust Butterfly Valve Cable Installation e Route the butterfly valve cables correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the exhaust butterfly valve cable lower ends to the pulley of middle exhaust pipe A Open Cable Yellow B Close Cable Dark Green C 6 mm 0 24 in D Front View E e Tighten Torque Exhaust Butterfly Valve Cable Locknuts 7 0 N m 0 70 kgf m 62 in Ib GE18042BS2 e Confirm whether it is an angle shown in figure NOTE OCorrect the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure x lf the angle is wrong adjust the pulley see Exhaust But terfly Va
142. the release shaft be careful not to remove the spring of the oil seal e Fit the spring A as shown Viewed from Rear B Release Shaft C Clutch Cover D e Install the clutch cover see Clutch Cover Installation Clutch Cover Disassembly e Remove Clutch Cover see Clutch Cover Removal Release Lever and Shaft Assembly see Release Shaft Removal Oil Seal A Oil Filler Plug B e Remove the needle bearings A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wan zb hGH 6 9 Clutch Cover Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s make face out e Install the needle bearings A and oil seal B position as shown OPress the lower bearing do not protrude from the boss C of the clutch cover OPress the upper bearing so that the bearing surface D is flush with the housing end of clutch cover E OPress the oil seal until the bottom e Replace the O ring A of the oil filler plug B with a new one e Apply engine oil to the new O ring e Install the oil filler plug Torque Oil Filler Plug Hand tighten www zxforums com www zxforums com GFO5026BS1 FOBI P www zxforums com 6 1 Deck HG com www zxforums com www zxforums com Clutch Clutch Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts
143. the threads of the air suction valve cover bolts and tighten them with the specified torque Torque Air Suction Valve Cover Bolts 10 N m 1 0 kgf m 89 in lb eh A S0882 P Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage e f there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE OP END 5 15 Clean Air System Air Switching Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the connector A e Separate the hoses B from the air sucti
144. the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours e Install the air valve cap x Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold 6JO5007851 Front Up to 180 kg 397 Ib 250 kPa 2 50 kgf cm 36 psi Rear Up to 180 kg 397 Ib 290 kPa 2 90 kgf cm 42 psi Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age x If any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxfo
145. throttle opening is correct Idle Speed Standard 1 100 r min rpm x lf the idle speed is out of the specified range adjust the idle speed see Idle Speed Inspection in Periodic Mainte nance chapter e Turn the ignition switch OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at ECU Standard DC 0 65 3 90 V at idle throttle opening to full throttle opening GC17146CS1 NOTE OThe throttle sensor is operating correctly if the following voltages are obtained e DC 0 65 V or slightly higher with the throttle at the idle position e DC 3 90 V or slightly lower with the throttle at the fully open position CAUTION Do not remove or adjust the main throttle sensor It has been adjusted and set with precision at the factory Never drop the sensor can especially on a hard sur face A shock to the sensor can damage it www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM REN 3 53 Main Throttle Sensor Service Code 11 NOTE OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5V exactly OWhen the input voltage reading shows other than 5V derive a voltage range as follows Example In the case of a input volta
146. to adjust the pedal position but always adjust it when push rod locknut has been loosened e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x lf the length C shown is 70 1 mm 2 8 0 04 in the pedal position will be within the standard range E e Tighten Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 13 PID e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove Rear Master Cylinder Mounting Bolts A Right Footpeg Bracket Bolts B www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www BRAKES 12 9 Brake Lever Brake Pedal e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D e Remove the mounting bolt E and take out the brake pedal Brake Pedal Installation e Apply grease to the pivot shaft A and install the washer B e Install Brake Pedal C Washer D Brake Pedal Bolt E Torque Brake Pedal Bolt 8 8 N m 0 90 kgf m 78 in Ib e Hook the lower end of the rear brake light switch spring A on the pedal hook Olnstall the spring so that the hook turns outside e Hook the upper end of the return spring B on the pedal hook e Replace the cotter pin with a new one Olnsert the cotter pin A and bend the pin ends B e Install the
147. torque e Pour in the specified type and amount of oil see Engine Oil Change Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses A temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e There are washers on each side of the brake hose fitting Replace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e When installing the hose A avoid sharp bending kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for RAZAS com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 55 Maintenance Procedure e Level the brake fluid reservoir e Remove the reservoir cap e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve
148. until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x lf the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding
149. using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends 6004040351 Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 6004011481 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 45 Maintenance Procedure e With the cable disconnected at both ends the inner cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x If there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque s
150. valve actuator malfunction wiring open or short 63 Exhaust butterfly valve actuator malfunction wiring open or short 67 Oxygen sensor heaters 1 and or 2 malfunction wiring open or short Europe Models 75 ECU main relay malfunction relay is stuck 83 Oxygen sensor 2 inactivation wiring open or short Europe Models Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect www zxforums com www zxforums com www zxforums com FUEL SY RE EMUAR ES 3 47 www zxforums com www zxforums com Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI ignition or immo bilizer system parts have troubles Output Signal Usable Range or Criteria Backups by ECU Main Throttle Sensor Inlet Air Pressure Sensor Main Throttle Sensor Output Voltage 0 2 4 8V Inlet Air Pressure absolute Pv 100 mmHg 900 mmHg If the main throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method If the inlet air
151. water must be used with the an tifreeze see below for antifreeze in the cooling sys tem If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 6 L 2 7 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 51 Maintenance Procedure e Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down x lf the coolant level is lower than the low level line add coolant to the full level line GD050109S1 CAUTION Do not add more coolant above the full level line www zxforums com www zxforums com www zxforums com 2 52 RERIORIGMAI NTENAN CE www zxforums com www zxforums com
152. with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down O o When brake pedal is released Sidestand Switch Connections Sidestand Switch Connections Color BK G When sidestand is down WEE E When sidestand is up O O Oil Pressure Switch Connections Oil Pressure Switch Connections Color SW Terminall Ground When engine is stopped O When engine is running Engine lubrication system is in good condition www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 6 1 01 Switches and Sensors Water Temperature Sensor Inspection e Remove the water temperature sensor see Removal In stallation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the temperature sensing projection E and threaded por tion E are submerged e Suspend an accurate thermometer B in the coolant NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor OThe sensor sends electric signals to the ECU and coolant temperature gauge in t
153. www zxforums com Cable Wire and Hose Routing California Model Fuel Tank Clamps Hose Red Canister Clamp To the Fitting of the Throttle Body 3 To the Fitting of the Throttle Body 4 Clamps ONDAN www zxforums com GB09895BW4 C Throttle Bodies Hose Blue Hose Blue Separator Hose Green Hose White Fitting Hose Green www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX 11 7 29 Cable Wire and Hose Routing GB09896BW3 C Adjusters Closing Cable Yellow Dark Green Rear Frame Dust Covers Opening Cable Clamp Exhaust Butterfly Valve Actuator 10 41 7 7 Original Position of Pulley 11 Right Side 12 6 mm 0 24 in 13 Close 14 Open 15 Exhaust Manifold 16 Clamp 17 Viewed Right Side 18 10 mm 0 40 in or less 19 15 mm 0 60 in or less 20 Starter Motor Cable 21 Through the exhaust butterfly valve cables inside of the starter motor cables OOO CH Bol www zxforums com www zxforums com www zxforums com 17 30 ABRENDIS Troubleshooting Guide www zxforums com www zxforums com NOTE Camshaft position sensor trouble ORefer to the Fuel System chapter for most Neutral starter lockout or sidestand switch of DFI trouble shooting guide trouble OThis is not an exhaustive list giving every Crankshaft sensor trouble possible cause for each problem listed It is meant simply a
154. www zxforums com Maintenance Procedure Fuel System DFI Throttle Control System Inspection e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cables Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip B moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x If the throttle grip does not return properly check the throt tle cables routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increases check the throttle cable free play and the cable routing x If necessary adjust the throttle cable as follows e Loosen the locknuts A B e Screw both throttle cable adjusters C D to give the throttle grip plenty of play e Turn the decelerator cable adjuster C until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B x lf the free play cannot be adjusted with the adjusters re place the cable Engine Vacuum Synchronization Inspection NOTE O These procedures are explained on the assu
155. www zxforums com www zxfor NGINE REMOVAL INRA ALTON 8 5 Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury 6M05117BS1 CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clutch Cable Lower End see Cable Removal in the Clutch chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Front Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter Shift Lever see Shift Pedal Removal in the Crank shaft Transmission chapter Engine Sprocket see Engine Sprock
156. www zxforums com www zxforums com ELECTRICAL SYSTEM 16 71 Meter Gauge Indicator Unit OWhen the terminals are connected all the LCD segments A appear for three seconds lf the LCD segments will not appear replace the meter assembly e Disconnect the terminal 1 OAI the LCD segments disappear x If the segments do not disappear replace the meter as sembly MODE AND RESET BUTTON Operation Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Check that the display B change to the ODO TRIP and CLOCK and STOP WATCH displays each time the MODE button A is pressed OWhen the fuel level warning indicator light LED blinked display change to FUEL ODO TRIP CLOCK and STOP WATCH and FUEL x lf the display function does not work replace the meter assembly e Indicate the clock mode e Check that when the RESET button A in CLOCK mode is pushed for more than two seconds the meter display turns to the clock set mode OBoth the hour and minute display start flashing e In the HOUR MINUTE setting mode press the reset but ton C again to effect the HOUR setting mode OThe hour display flashes on the display e Press the MODE button A to set the hour www zxforums com www zxforums com CLOCK CLOCK 6P17062BS1 www zxforums com 16 72 ELECTRICAL SYSTEM www zxforums com www
157. www zxforums com www zxforums com www zxforums com www zxforums com www NGINE REMOVAL INSTALLATION 8 11 Engine Removal Installation OFifth tighten the middle engine mounting nut H and then lower engine mounting nut I Torque Middle Engine Mounting Nut 44 N m 4 5 kgf m 32 ft lb Lower Engine Mounting Nut 44 N m 4 5 kgf m 32 ft lb OSixth remove the bolt D temporally and using the hexagon wrench turn the adjusting collar J until the clearance K between the cylinder head and frame come to O mm 0 in OSeventh using the engine mount nut wrench special tool tighten the adjusting collar locknut L Special Tool Engine Mount Nut Wrench 57001 1450 Torque Adjusting Collar Locknut 49 N m 5 0 kgf m 36 ft lb OLastly reinstall the bolt D and tighten it Torque Right Front Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft lb GH04062BH3 C www zxforums com www zxforums com www zxforums com 8 1 2 ENGINEREM OVALII N STALEATIQN s com www zxforums com Engine Removal Installation e Install the left A and right B engine bracket following the specified installing sequence OFirst install the adjusting collar C to the right engine bracket B OSecond install the bolts D E F G temporally as shown sequence 1 8 in the figure OThird tighten the bolts D to the tightening sequence 1 3 shown Torque Left Engine Bracket Bolts 44 N m 4 5 kgf m 32
158. www zxforums com www zxforums com www zxforums com www zxforums com wRTRERING 14 9 Steering Stem e Remove the lock washer A e Pushing up the stem base and remove the steering stem nut with stem cap A e Remove Steering Stem C Upper Ball Bearing Inner Race Special Tool Steering Stem Nut Wrench B 57001 1100 e To remove the bearing outer races A pressed into the head pipe B insert a bar C into the recesses D of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing Le damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones e Remove the lower bearing inner race with its grease seal A which is pressed onto the steering stem B with the bearing puller C and adapter D Special Tools Bearing Puller Adapter 57001 136 Bearing Puller 57001 158 Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Bearing Driver Set 57001 1129 Head Pipe Outer Race Driver 455 B 57001 1446 e Apply grease Outer Races www zxforums com www zxforums com www zxforums com 14 1 QR LER RING www zxforums com www zxforums com Steering Stem e Replace the bearing inner races with new ones e Install the oi
159. www zxforums com www zxforums com www zxforums com 3 58 FWEh SYSTEM DFI www zxforums com www zxforums com Inlet Air Pressure Sensor Service Code 12 x If the output voltage is far out of the usable range check the output voltage again at the sensor connector A when the lead is open the output voltage is about 1 8 V e Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Meter G W sensor Y BL lead C Meter BK sensor BR BK lead D Output Voltage at Sensor Connector Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa or 76 cmHg abs x If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section x lf the output voltage is out of the usable range replace the sensor e Turn the ignition switch OFF e Remove the harness adapter Inlet Air Pressure Sensor Circuit LJ I 6017143BS1 la Ao O oi 1 ECU 2 Inlet Air Pressure Sensor 3 Water proof Joint 2 x If you need to check the inlet air pressure sensor for vac uum other than 76 cmHg abs check the output voltage as follows www zxforums com www zxforums com 6C17149CW2 C www zxforums com www zxforums com www zxforums com FUEL SYR EMRE 3 59 Inlet Ai
160. zxforums com www zxforums com Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Coolant Reserve Tank Mounting Bolts A e Remove the cap B and poor the coolant into a container e Remove Radiator Overflow Hose C Reserve Tank Overflow Hose D Coolant Reserve Tank E
161. 0 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 13 Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element 2 3 mm 0 08 0 12 in 1 100 50 r min rpm 31 5 1 3 kPa 236 10 mmHg at idle speed Viscous paper element Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Inlet Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Wheels Tires Tread Depth Front Rear Air Pressure when Cold Front Rear www zxforums com Permanent type antifreeze Green Soft water 50 coolant 50 35 C 31 F 2 9 L 3 1 US qt 0 17 0 22 mm 0 0067 0 0087 in 0 15 0 24 mm 0 0059 0 0094 in 2 3 mm 0 08 0 12 in API SE SF or SG API SH SJ or SL with JASO MA SAE 10W 40 3 2 L 3 4 US qt when filter is not removed 3 7 L 3 9 US qt when filter is removed 4 0 L 4 2 US qt when engine is completely dry Between upper and lower level lines Wait 2 3 minutes after idling or running 6 0 mm 0 24 in 6 5 mm 0 26 in Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi Up to 180 kg 397 Ib load 290 kPa 2 90 kgf cm 42 psi www zxforums com 1 mm
162. 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in www zxforums com 2 1 4 REBIODIG MAINTENANCE www zxforums com www zxforums com Specifications Item Standard Service Limit Final Drive Drive Chain Slack 30 35 mm 1 2 1 4 in Drive Chain Wear 20 link 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Length Standard Chain Make RK EXCEL Type RK 525MFO Endless SE Link 108 links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON Rear On after about 10 mm 0 39 in of pedal travel Electrical System Spark Plug Type NGK CRYEIA 9 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 15 Special Tools Inside Circlip Pliers Vacuum Gauge 57001 143 57001 1369 py as ST5701438T ST5713698T Steering Stem Nut Wrench Extension Tube 57001 1100 57001 1578 ST5711008T ST5715788ST Jack Pilot Screw Adjuster D 57001 1238 57001 1588 ST5712388ST ST571588ST Oil Filter Wrench Jack Attachment 57001 1249 57001 1608 ST5712498ST ST571608ST www zxforums com www zxforums com www zxforums com 2 1 6 REBIODIG MAINTENANCE www zxforums com
163. 052BS1 e Install the pin A e Fit the pin into the slot B of the inner rotor C OApply engine oil to the inner rotor www zxforums com www zxforums com www zxforums com www zxforums com www zxforu FN NE LU BRICATION SYSTEM 7 13 Oil Pump e Install the outer rotor A on the inner rotor OApply engine oil to the outer rotor e Install the dowel pin B e Fit the pin of the oil pump cover into the hole C in the crankcase OTurn the oil pump gear shaft A so that the projection B in its shaft fits onto the slot C of the impeller shaft GG09053BS1 e Tighten the oil pump cover bolts Torque Oil Pump Cover Bolts 10 N m 1 0 kgf m 89 in Ib e Install the oil pump gear see Oil Pump Gear Installation Oil Pump Gear Removal e Remove the clutch see Clutch Removal in the Clutch chapter e Hold the oil pump gear A steady with the gear holder B and remove the bolts C Special Tool Gear Holder 57001 1599 e Remove the oil pump gear Oil Pump Gear Installation e Install the oil pump gear A direction as shown www zxforums com www zxforums com www zxforums com 7 14 ENGINE LUBRICATION SYS TE Miorums com Oil Pump www zxforums com e Apply a non permanent locking agent to the threads of the oil pump gear bolts A e Hold the oil pump gear B steady with the gear holder C and tighten the bolts Special Tool Gear Holder 57001 1599 Torque Oil Pump Ge
164. 1 2 106 in lb S 8 Crankcase Bolts M6 L 40 12 1 2 106 in Ib S 9 Shift Drum Bearing Holder Screws 5 0 0 51 44 in lb L 10 Shift Fork Hold Bolt 12 1 2 106 in lb L 11 Plate Screw 5 0 0 51 44 in lb L 12 Bearing Position Plate Screws 5 0 0 51 44 in lb L Coolant Drain Plug Cylinder 10 20 R marked side faces up 21 RN marked side faces up 22 Hollow mark faces exhaust side 23 Do not apply any grease or oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1064 MO Apply molybdenum disulfide oil solution mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant Three Bond 1207B W Apply water www zxforums com www zxforums com www zxforums com 9 4 GRANKSRARTTRANSMISSION zxforums com www zxforums com Exploded View 6102145845 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums Feb AN KSHAFT T RANSMISSION 9 5 Exploded View Torque No Fastener Nem kafin ftlb Remarks 1 Shift Pedal Mounting Bolt 25 2 5 18 2 Gear Position Lever Bolt 12 1 2 106 in lb 3 Shift Shaft Return Spring Pin 29 3 0 21 L 4 Shift Drum Cam Holder Bolt 12 1 2 106 in lb L 5 Shift Lever Bolt 7 0 0 71 62 in lb 6 Tie Rod Locknuts 7 0 0 71 62 in lb
165. 13 9 Spring Preload AUS Meis ii Ne 13 10 Front Fork Removal each TORK leg gege Seeerei belesonae dees 13 10 Eront ForK InStallation asset e a visi Ad 13 11 Front For 1 A a slag anhbuavs a nd taster ued pha tad une aaa detente 13 11 Front Fork Disassembly ada adas 13 17 Front Fork Assembly EE 13 17 Inner Tube Inspection ss 13 18 TRIER Le RE 13 19 SPOT ER 13 19 Se een TE 13 20 Rebound Damping Force Adhustment 13 20 Compression Damping Force Adjustment cc cceeceee eee eeeneneeeeeeeeeeeeeeeaeeneeeeeeeeeeeeeaaaas 13 20 Spring Preload Adjustment 28m int drid dede 13 20 Rear ShockWiggo ery ReriovalZ M EL AE O o E een 13 21 Rear Shock Absorber Installation rre rre 13 22 Rear Shock Absorber Inspection erene 13 22 Rear Shock Absorber Scrapping cece cece eeeeeeeeeeesegeseeeeeeeeeeeeeeeeseeeeeeeseeeeeees 13 22 SWINGIN ER Swingarm ae CEET Swingarm Installation Swingarm E le Le NL EE 13 25 Swingarm Bearing Installations sans need ida en 13 25 Swingarm Bearing Sleeve Inspection ii 13 26 SWINgarm Pivot EUBPGAUONM 22528 EE 13 26 Chain Guide Inspection sise 13 26 Tie Rod ROCKER ARM EE 13 27 Te Rod Remcoval 51 a ENN ECKER ENER ectewacewst capes E a E E E E EE AE e AE REN AEN 13 27 TiE RO Me EE 13 27 Rocker Arm Removal seed cian dni did ae ethernet sante at 13 27 Rocker PP teen ege 13 28 Tie Rod and Rocker Arm Bearing HRe
166. 14 18 psi x If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one www zxforums com www zxforums com GD07010481 6D07013BS1 6D07001BS1 www zxforums com COOLING SYSTEM 4 17 www zxforums com www zxforums com Radiator Radiator Filler Neck Inspection e Remove the radiator cap see Pressure Testing e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly 078171 P www zxforums com www zxforums com www zxforums com 4 1 8 FOQLING SY STEM www zxforums com www zxforums com Thermostat Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Water Hoses A Thermostat Housing Mounting Bolts B e Remove Thermostat Housing Cover Bolts A Thermostat Housing Cover B Thermostat ORemove the coolant by pass fitting bolt C as necessary Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top 6D09007BS1 w
167. 2 0 12 11 in Ib Tim _ www zxforums com www zxforums com www zxforums com 1 6 6 FLEGTRICAL SYSTEM www zxforums com www zxforums com Exploded View Qe 2 SAR e e gt ek Y A A IAS Vi Sra SL RS 6P02246BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SEM 1 6 7 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Camshaft Position Sensor Bolt 10 1 0 89 in lb 2 Water Temperature Sensor 25 2 5 18 SS 3 Oxygen Sensors Europe Models 25 2 5 18 4 Vehicle down Sensor Bolts 6 0 0 61 53 mb 5 Gear Position Switch Screws 3 0 0 31 27 in lb L 6 115 in Ib Spark Plugs 13 2 1 7 Alternator Rotor Bolt 155 15 8 114 Crankshaft Sensor Bolts 6 0 0 1 Frame Earth Mounting Bolt 10 89 in lb 10 89 in lb 3 2 D D 2 Speed Sensor Bolt 0 D D D ES 1 13 1 14 Alternator Lead Holding Plate Bolt 10 89 in lb L 15 Fuel Pump Bolts 10 89 in lb L S 16 Oil Pressure Switch 15 11 SS 17_ Oil Pressure Switch Terminal Bolt 1 5 13 in lb G 18 Battery 12 V 10 Ah 19 ECU 20 Other than Europe Models G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tighten sequence SS Apply silicone sealant www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 16 8 FLECTRIGAL SYSTEM Exploded V
168. 2 025 92180 0137 202 2 050 92180 0138 205 2 075 92180 0139 208 2 100 92180 0140 210 2 125 92180 0141 212 2 150 92180 0142 215 2 175 92180 0143 218 2 200 92180 0144 220 2 225 92180 0145 222 2 250 92180 0146 225 2 275 92180 0147 228 2 300 92180 0148 230 www zxforums com www zxforums com www zxforums com 2 26 PEBIORIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter surface and install the lifter e Install the camshafts see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Air Suction System Air Suction System Damage Inspection e Remove Fuel Tank
169. 3 135 Fuel Tank Installations sisi hassan sens dt dns Re a tes 3 137 Fuel Tank and Cap Inspection oooocicnccinininininonnnccccnccnncannrrn rra 3 138 Fuel Tank Cleaning E 3 138 Evaporative Emission Control Systems tas to nt er nn en tn nes 3 139 Parts Removal Installation ss 3 139 Hose Ee EE 3 139 Separator Inspection sseesesesseesserettetttrrtttttttttttttttttttttt tt ttttttEEEEEEEEEEEEEEEEEEEEEEEEEEEEnEEt 3 139 Separator Op ration ET 3 140 Canister Inspection sisi 3 140 www zxforums com www zxforums com www zxforums com 3 4 EVEL Se IEN DFI www zxforums com www zxforums com Exploded View 6002223BW5 www zxforums com www zxforums com www zxforums com FUEL SPAM 3 5 www zxforums com www zxforums com Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Air Cleaner Housing Holder Clamp Screws 2 0 0 20 18 in lb 2 Air Cleaner Element Cover Screws 1 1 0 11 9 7 in lb 3 Air Inlet Duct Mounting Bolts 7 0 0 71 62 in lb L 4 Air Cleaner Housing Mounting Bolts 7 0 0 71 62 in lb 5 Air Cleaner Element 6 Air Inlet Duct 7 Air Switching Valve L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 0002 WL Apply a soap and water solution www zxforums com www zxforums com www zxforums com 3 6 EVEL Se IEN DFI www zxforums com www zxforums com Exploded View 6002224BW5 C www zxforums com www zxforums com www zxf
170. 394 e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Dete riorated leads and bad connections can cause reappear ance of problems and unstable operation of the DEI sys tem x If any wiring is deteriorated replace the wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the lead or the main harness or the sub harness www zxforums com www zxforums com GC17191C82 www zxforums com 3 28 AE SES LEM DFI www zxforums com www zxforums com Troubleshooting the DFI System Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If ther
171. 41 psi with fuel pump stopped 304 kPa 3 1 kgf cm 44 psi with fuel pump running In tank pump in fuel tank or Wesco pump friction pump 72 mL 2 43 US oz or more for 4 seconds INP 286 One spray type with 10 holes About 11 7 12 3 Q at 20 C 68 F Non adjustable and non removable DC 4 75 5 25 V between BL and BR BK leads DC 0 65 3 90 V between Y W and BR BK leads at idle throttle opening to full throttle opening 4 6k0 DC 4 75 5 25 V between BL and BR BK leads DC 3 80 4 20 V at standard atmospheric pressure see this text for details 2 09 2 81 kQ at 20 C 68 F About 0 322 kQ at 80 C 176 F reference value About 2 25 2 50 V at 20 C 68 F see Electrical System chapter About 2 80 2 97 V at 20 C 68 F DC 4 75 5 25 V between BL and BR BK leads About DC 0 05 0 09 V or DC 4 5 4 9 at Ignition Switch ON and 0 km h www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM REI 3 13 Specifications Item Standard Vehicle down sensor Detection Method Detection Angle Output Voltage Subthrottle Sensor Input Voltage Output Voltage Resistance Exhaust Butterfly Valve Actuator Sensor Resistance Immobilizer Antenna Resistance Exhaust Butterfly Valve Actuator Output Voltage Subthrottle Valve Actuator Resistance Input Voltage Oxygen Sensors Europe Models Output Voltage Rich Output Voltage Lean Heater Re
172. 593 56019 120 ST5715938T ST5601208ST Fuel Hose Kawasaki Bond Liquid Gasket Black 57001 1607 92104 0002 ST571607ST ST9200028T Speed Sensor Measuring Adapter Kawasaki Bond Silicone Sealant 57001 1667 92104 0004 ST571667ST ST9200048T www zxforums com www zxforums com www zxforums com 3 1 CAMEL SEM DFI www zxforums com www zxforums com DFI Parts Location Main Throttle Sensor A Subthrottle Sensor B Subthrottle Valve Actuator C Inlet Air Pressure Sensor D Stick Coils 1 2 3 4 E Water Temperature Sensor A Fuel Injectors 1 2 3 4 B Battery A Relay Box Fuel Pump Relay B Immobilizer Kawasaki Diagnostic System Connector C ECU D Exhaust Butterfly Valve Actuator A Atmospheric Pressure Sensor B Vehicle down Sensor C Fuse Box ECU Fuse 15 A Oxygen Sensor Heater Fuse 10 A D Inlet Air Temperature Sensor A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL STEYL RE 3 17 DFI Parts Location Camshaft Position Sensor A Crankshaft Sensor B Speed Sensor A Gear Position Switch B Ignition Key A Transponder Immobilizer Models Ignition Switch B Immobilizer Antenna C Immobilizer Models Immobilizer Amplifier D Immobilizer Models Oxygen Sensor 1 A Europe Models Oxygen Sensor 2 B Europe Models www zxforums com www zxforum
173. 6 006 mm 2 9917 2 9924 in 75 959 75 974 mm 2 9905 2 9911 in 0 020 0 047 mm 0 0008 0 0019 in 0 03 0 07 mm 0 0012 0 0028 in 0 03 0 07 mm 0 0012 0 0028 in 0 82 0 84 mm 0 0323 0 0331 in 0 82 0 84 mm 0 0323 0 0331 in 0 77 0 79 mm 0 0303 0 0311 in 0 77 0 79 mm 0 0303 0 0311 in 0 15 0 30 mm 0 0059 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 5 9 6 0 mm 0 232 0 236 in 6 05 6 15 mm 0 238 0 242 in 5 9 6 0 mm 0 232 0 236 in 6 05 6 20 mm 0 238 0 244 in 76 09 mm 2 9957 in 75 81 mm 2 9846 in 0 17 mm 0 0067 in 0 17 mm 0 0067 in 0 92 mm 0 036 in 0 92 mm 0 036 in 0 70 mm 0 028 in 0 70 mm 0 028 in 0 6 mm 0 024 in 0 8 mm 0 031 in 5 8 mm 0 228 in 6 25 mm 0 246 in 5 8 mm 0 228 in 6 3 mm 0 248 in www zxforums com www zxforums com www zxforums com 9 8 GRANKSHART TRANSMISSION 2xtorums com www zxforums com Specifications Connecting Rod Big End Bearing Insert Selection Con rod Big End Bore Crankpin Diameter Bearing Diameter Marking Marking Size Color Black Insert Part Number 92139 0028 92139 0027 92139 0026 Bearing Inse rt Journal Diameter Marking Bearing Inside Diameter Marking 92139 0031 92139 0034 92139 0030 Part Number Journal Nos
174. 7 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing Air Cleaner Housing Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1601 L Shape Hose 57001 1606 Cylinder Compression Usable Range 1 100 1 670 kPa 11 2 17 0 kgf cm 159 242 psi at 20 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 115 in 1b The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression is higher than usable range combustion ch
175. 9 bolts A S Y G104227BS1 www zxforums com www zxforums com www zxforums com 9 1 4 RRANKSHAFTIT RANSM ISSN sorums com www zxforums com Crankcase Splitting e Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half M9 bolts 1 10 with copper plated washers Torque Crankcase Bolts M9 39 N m 4 0 kgf m 29 ft lb OTighten the M7 bolts Torque Crankcase Bolts M7 20 N m 2 0 kgf m 15 ft lb L 50 mm 1 97 in A L 85 mm 3 35 in B Olnstall the clamp C and tighten the M6 bolts D Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib 6104228BW2 www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANSMIS RON 9 15 Crankcase Splitting e Tighten the upper crankcase bolts using the following steps OThe M8 bolts A has a washer replace it with a new one OTighten the M8 bolts with washers Torque Crankcase Bolts M8 27 N m 2 8 kgf m 20 ft lb OTighten the M7 bolts B Torque Crankcase Bolts M7 20 N m 2 0 kgf m 15 ft lb OTighten the M6 bolts C Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib ieee SO 8 DO BS 6104229BW2 e After tightening all crankcase bolts check the following items OWipe up the liquid gasket that seeps out around the crankcase mating surface OCrankshaft and t
176. A to the x 1 O range and connect it to the terminals in each oxygen sensor lead connectors B White C White D Special Tool Hand Tester 57001 1394 Oxygen Sensor Heaters Resistance Standard About 8 Q at 20 C 68 F x If the tester reading is far out of the specified replace the oxygen sensor 6017175081 www zxforums com www zxforums com www zxforums com 3 1 ON FURR CS EM DFI www zxforums com www zxforums com Oxygen Sensor Heaters 1 and or 2 Service Code 67 Europe Models x If he tester reading is specified check the power source voltage Inspection NOTE OBe sure the battery is fully charged e Connect a digital meter A to each oxygen sensor con nector B using the needle adapter C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Heaters Power Source Voltage Connections to Oxygen Sensor Connector Tester W main harness side LG lead D Tester Battery Terminal E 6017176051 Oxygen Sensor 1 F Oxygen Sensor 2 G e Measure the power source voltage with the engine stopped and with the oxygen sensor connector joined e Turn the ignition switch ON Power Source Voltage at Sensor Connector Standard Battery Voltage 6017177081 x lf the reading is incorrect check the following Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Elect
177. A A da 17 30 www zxforums com www zxforums com www zxforums com 1 7 2 AR ENR Xm www zxforums com www zxforums com Cable Wire and Hose Routing SA de Y 6B09884BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wh BRENDIX 1 7 3 Cable Wire and Hose Routing Throttle Cables Clamp Meter Connector Clamp the right switch housing lead Right Switch Housing Lead City Light Connector Right Headlight Connector Right Turn Signal Light Connector Clamp the right turn signal light lead Other than California Model only 10 Heat Pad 11 Run the regulator rectifier harness under the engine mount 12 Run the clutch cable inside the radiator coolant return hose 13 Rear Brake Light Switch 14 Battery Positive Cable 15 Starter Relay 16 Clamp the clutch cable 17 Clutch Cable 18 Radiator Overflow Hose 19 Radiator Hose 20 Engine Mount Bracket OO J O O1 P ND A www zxforums com www zxforums com www zxforums com 1 7 4 APEENRXK m www zxforums com www zxforums com Cable Wire and Hose Routing GB09885BW4 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wh BRENDIX 1 7 5 Cable Wire and Hose Routing OOMNOAOARWN Throttle Cable Accelerator Throttle Cable Decelerator Run the throttle cables above the harness and hose and under the ig
178. AELEGTRIGAL SYSTEM www zxforums com www zxforums com Wiring Diagram Malaysia 1 Front Brake Light Switch 2 Engine Stop Switch OI PA 3 Starter Button Iesel BR d Stop Watch Ignition a Button Ke Si R BATER O Right Switoh MAILS die gece 000 bie bel Immobilizer Antenna CES ere Lis ai o D Spark Plugs Horn Air 1242 54 DQO switching Weter Unit S Valve 1 Turn Signal Stick Camshaft Indicator Light LED exe EE S Coils Postion 2 High Beam Indicator Light LED BS gt 22 Se Sensor 3 Neutral Indicator Light LED i 4 Fuel Level Warning Indicator Light LED eee Mai pan 5 Warning Indicator Light LED MME S Rotor Fl Immobilizer Gil Pressure Warning des e xk 6 Odometer Trip Weter Glock Stop Watch Saa 2 7 Water Temperature Gauge Luli I 8 Tachometer S e gt ge Sa 9 Speedometer ZE it i 10 Illumination Light LED 11 Shift Up Indicator Light LED aUa Ssa IBS a 2 gt Meter Unit 0000000 00 Immobilizer Amplifier L gt TTT R CH SeLER Licht Emitting Diode Wi i Il ul BK Y BK Y Joint eko Connector 1 BEAT BK Y BK Y Right City Light 12V5 D Front Right Light 12V21 Headlight Lo Do 12V55N Headlight Diak HI ay 12V65N Left City Light 12V5 Front Left Gr 6 e Turn Signal Light 124218 Ah
179. Bolts 22 2 2 16 Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 17 1 7 13 Suspension WER NIE Bolts www zxforums com 20 20 www xforums cqm 2 1 O RERIODIC MAI NTENAN CE www zxforums com www zxforums com Torque and Locking Agent Torque Fastener Nm Reem ftlb Remarks Front Fork Bottom Allen Bolts 23 2 3 17 L Front Fork Clamp Bolts Lower 30 3 1 22 AL Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Top Plugs 23 2 3 17 Piston Rod Nuts 15 1 5 11 Rear Shock Absorber Bracket Nut 59 6 0 44 Rear Shock Absorber Nut Lower 34 3 5 25 Rear Shock Absorber Nut Upper 34 3 5 25 Swingarm Pivot Adjusting Shaft 20 2 0 15 Swingarm Pivot Shaft Nut 108 11 0 80 Swingarm Pivot Adjusting Collar Locknut 98 10 0 72 Tie Rod Nuts 59 6 0 44 Uni Trak Rocker Arm Nut 34 3 5 25 Steering Front Fork Clamp Bolts Lower 30 3 1 22 AL Front Fork Clamp Bolts Upper 20 2 0 15 Handlebar Bolts 25 2 5 18 Handlebar Position Bolts 9 8 1 0 87 in lb L Steering Stem Nut 20 2 0 15 Steering Stem Head Nut 78 8 0 58 Steering Stem Locknut Hand tighten Switch Housing Screws 3 5 0 36 31 in lb Frame Front Fender Mounting Bolts 3 9 0 40 35 in lb Front Footpeg Bracket Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Fram
180. ECTRICAL SYSTEM www zxforums com www zxforums com Switches and Sensors Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect the connector A e Set the hand tester A to the 1 kQ or x 100 Q range and connect it to the terminals in the gear position switch lead connector B and ground 3 C Internal Circuit 3 1 Light Green Lead 2 Green Red Lead 3 Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance kQ Connections Gear Position 1 Ground 2 Ground 3 Ground Neutral about 0 1st 3 00 3 32 11 63 12 87 1 70 1 89 10 33 11 44 3rd 1 07 1 19 9 70 10 74 Ath 0 695 0 769 9 32 10 32 5th 0 430 0 476 9 06 10 03 NEE 6th 0 248 0 274 8 89 9 81 x lf the tester reading is not as specified replace the gear position switch with a new one www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 46 107 Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Take out the relay box A and disconnect the connectors B Relay Circuit Inspection NOTE OThe ECU main relay function is inclu
181. Gear Positions Standard 1st About 3 0 V 2nd About 2 5 V 3rd About 2 0 V 4th About 1 5 V 5th About 1 1 V 6th About 0 7 V x If the reading is out of the range check the gear position switch see Gear Position Switch Inspection in the Elec trical System chapter x If the switch is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section e Turn the ignition switch OFF www zxforums com www zxforums com E RG 77 TO Gees 6c171610S1 www zxforums com 3 76 FVEL GLEN DFI www zxforums com www zxforums com Gear Position Switch Service Code 25 Gear Position Switch Circuit 6C17162CW2 1 ECU 2 Gear Position Switch 3 Joint Connector 1 4 Joint Connector 2 5 Frame Ground www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL STEYL RE 3 77 Vehicle down Sensor Service Code 31 This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the motorcycle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the signal The ECU senses this change and stops the fuel pump the fuel injectors and the ignition system Hall IC B When the motorcycle is down the ignition switch is left ON If the starter button is pushed the electric sta
182. Head Thickness Exhaust 0 8 mm 0 031 in 0 4 mm 0 016 in Inlet 0 5 mm 0 020 in 0 25 mm 0 001 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less TIR 0 05 mm 0 002 in Valve Stem Diameter Exhaust 4 470 4 485 mm 0 1760 0 1766 in 4 46 mm 0 176 in Inlet 4 475 4 490 mm 0 1762 0 1768 in 4 46 mm 0 176 in Valve Guide Inside Diameter Exhaust 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Inlet 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Valve valve Guide Clearance Wobble Method Exhaust 0 04 0 12 mm 0 0016 0 0047 in 0 34 mm 0 013 in Inlet 0 03 0 10 mm 0 0012 0 0039 in 0 34 mm 0 013 in Valve Seat Cutting Angle 45 32 60 HSE Valve Seating Surface Width Exhaust 0 8 1 2 mm 0 031 0 047 in Inlet 0 5 1 0 mm 0 020 0 039 in Outside Diameter Exhaust 24 9 25 1 mm 0 980 0 988 in Inlet 29 4 29 6 mm 1 157 1 165 in Valve Spring Free Length Exhaust 44 78 mm 1 763 in 42 9 mm 1 689 in Inlet 39 15 mm 1 541 in 37 5 mm 1 476 in www zxforums com www zxforums com www zxforums com 5 1 2 ENGINE TOP END www zxforums com www zxforums com Special Tools and Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 32 35 57001 221 57001 1121 T5702218T ST5711218T Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 ST570241ST ST571128ST
183. ING SYSTEM www zxforums com www zxforums com Coolant Flow Chart 6D04039BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING SYSTEM 4 5 Coolant Flow Chart Radiator Radiator Fan Radiator Cap Radiator Overflow Hose Reserve Tank Reserve Tank Overflow Hose Oil Cooler Outlet Hose Cylinder Head Jacket 10 Cylinder Jacket 11 Thermostat Housing 12 Inlet Hose 13 Water Pump 14 Hot Coolant 15 Cold Coolant JO O1 P ND Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is less than 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 95 C 203 F the radiator fan relay conducts to op erate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cool
184. IT SEINI OO oe Left Switch Housing i Horn Button 2 Passing Button 3 Turn Signal Switch Fuse Box 2 Diener Switch l Fan Fuse 15A 4 Headlight Fuse 104 Relay Box 5 Starter Lockout Switch 2 ECU Fuse 154 5 Taillight Fuse 104 1 Fan Relay 6 Lap Time Button 3 Turn Signal Relay 6 lgniton Fuse 154 2 Headlight Fuse 104 T Horn Fuse 104 Relay 3 Unused LEFT SUI TOA HOUSING CONNECTIONS eee nee Relay Horn Button Turn Signal Switch Starter Lockout SwitchLap Time Button Passing Button Su Stak tae So Color BK WBK Y Soler GY Color BLY SH Color BK R Color W R Color BL Y R BK HI Clutch Lever W2L0266BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRI CALSYS ITEM A 6 1 9 Wiring Diagram Malaysia Sub throttle Sub Main Crankshaft Valve throttle Throttle Inlet Air Fuel Injectors Sensor Actuator Sensor Sensor Pr saure Sensor Bien ft Gear Position Switch Water ean Temperature Sensor Speed Oil Sensor Prassure ey Switch SS Te SE bi Alternator ze Regulator Rectifier S5553 sg foo Saiz Side Sadie e a Ces Stand Inlet Air Switch Temperature Sensor ir Water proof See Waterproof Joint 2 320332 CR Joint 1 rer 4 4 BR BR Y BL SEN Sg Dei CI BK Y BK BK BK BK 8K Di Electronic Control Unit ECU License Pl
185. ITCH HOUSING CONNECTIONS lgnition Battery Taili EL 12 Battery Tail3 lgnition l gnition Front Brake Light Switch Engine Stop pu Starter Button Stop Watch Button Color BR BL W BK W G G Y Color BK BK Color Y R Color BK RIBK R Color W BK BR 98052 0227D W2R02270W5 C BK Y BK Y BO BK Y BK Y R BK BK Y BK Y BR Y BR W LG BK 6 ek v BR W E BL BL R BR R BL L6 BK Bur WR aL d Y 6 BR BK KZ 18 H 4 H H Ros ae RI 35 ow BR BK SL L BR BK D LO d www zxforums com www zxforums com www zxforums com 16 14 FLECTRIGAL SYSTEM www zxforums com www zxforums com Wiring Diagram Other than United States Canada New Zealand Colombia Tai wan Australia and Malaysia Ignition Switch invobitizer Antenne ES dE Meter Unit i Turn Signal Indicator Light LED High Beam Indicator Light LED Neutral Indicator Light LED Fuel Level Warning Indicator Light LED Oil Pressure Warning Fl lamobitizer Indicator Light LED Odometer Trip Meter Clock Stop Watch Water Temperature Gauge Tachometer Speedometer Illumination Light LED Shift Up Indicator Light LED Meter Unit Front Brake Light Switch Engine Stop Switch Starter Button Stop Hatch Button Right Switch Spark Plugs 0000 vu AAN Mir Switching Valve 7 Camshaft Postion Sensor a ES Es
186. Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces 6J05044BS1 A WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHER HAIRED 10 15 Tires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Tire Inspection e Install the air valve cap e Install the brake disc s so that th
187. Lead Holding Plate Bolt 10 N m 1 0 kgf m 89 in lb e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval e Clean off the oil from the outer circumference of the rotor e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tools Grip C 57001 1591 Rotor Holder Stopper M38 x 1 5 D 57001 1658 Rotor Holder 57001 1666 e Using the flywheel puller A remove the alternator rotor from the crankshaft Special Tool Flywheel Puller M38 x 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Install the alternator rotor www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 33 Charging System e Using a cleaning fluid clean off any oil or dirt on the washer A and dry if with a clean cloth e Install the washer NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque e Install the rotor bolt B and tighten it with 70 N m 7 0 kgf
188. Lever Free Play Pedal Free Play Pedal Position 6 way adjustable to suit rider Non adjustable Non adjustable About 90 mm 3 5 in below footpeg top Brake Discs Thickness Front Rear Runout 5 8 6 2 mm 0 23 0 24 in 4 8 5 2 mm 0 19 0 20 in TIR 0 15 mm 0 006 in or less 5 5 mm 0 22 in 4 5 mm 0 18 in TIR 0 3 mm 0 01 in www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ww BRAKES 1 2 7 Special Tools Inside Circlip Pliers Jack Attachment 7 yl 57001 143 57001 1608 ST5701438T ST571608ST Jack 57001 1238 ST5712388ST www zxforums com www zxforums com www zxforums com 1 2 8 BRAKER com www zxforums com www zxforums com Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 6 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 90 mm 3 5 in C below top of footpeg x lf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary
189. Light LED TEE LL Li UUT VT FI 0i1 Pressure Warning BNtee gt S S 6 Odometer Trip Meter Clock Stop Watch fan a S o 7 Water Temperature Gauge 8 Tachometer 9 Speedometer 10 Illumination Light LED Vi Shift Up Indicator Light LEB Meter Unit BKG BKN R aK 0 vo R BL BK BL y wy BI BK 6 Pax R BK 0 WR R BL Pn BL BK Y Y R mE e te a E 10000000 000 MLED Light Emitting Diode BK Y a BK Y Joint BK Y Connector 1 Se BK Y BK Y Front Right Turn Signal Or aky Light 12V21W Headlight LO 12455 Left City Light 12 5 Front Left Turn Signal Light 124218 Left Switch Housing 1 Horn Button 2 Turn Signal Switch Relay Box 3 Dimmer Switch Fuse Box 4 Starter Lockout Switch 1 Fan Fuse 154 4 Headlight Fuse 194 Relay Box 5 Lap Time Button 2 ECU Fuse 15A 5 Taillight Fuse 194 1 Fan Relay 3 Turn Signal Relay 6 lgniton Fuse 154 2 Headlight Fuse 104 T Horn Fuse 104 Relay 3 Unused LEFT SWITCH HOUSING CONNECTIONS Re Eu Horn Button Turn Signe Switch Di i i i Starter Circuit Relay Color BK WBK Y Soler 0 GY BL Y R BK HI omo uc Lever GH AH Released Lo Pulled in W2LO227DW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 1 3 Wiring Diagram United States Canada New Zeal
190. M5 L 45 3 5 0 36 31 in lb Sidestand Switch Bolts 8 8 0 90 78 in lb L Spark Plugs 13 1 3 115 in lb Speed Sensor Bolt 10 1 0 89 in lb Starter Clutch Bolt 49 5 0 36 Starter Clutch Bolt Cap Hand tighten Starter Clutch Cover Bolts M6 L 30 10 1 0 89 in lb Starter Clutch Cover Bolts M6 L 20 10 1 0 89 in Ib Starter Motor Cable Mounting Bolt 4 0 0 41 35 in lb Starter Motor Cable Terminal Nut 6 0 0 61 53 in lb Starter Motor Mounting Bolts 10 1 0 89 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in lb Starter Motor Through Bolts 3 4 0 35 30 mb Stator Coil Bolts 12 1 2 106 in lb Vehicle down Sensor Bolts 6 0 0 61 53 in lb Water Temperature Sensor 25 2 5 18 SS www zxforums com www zxforums com www zxforums com 2 1 2 REBIOPILG MAINTENANCE www zxforums com www zxforums com Torque and Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter mm 5 3 4 4 9 0 35 0 50 30 43 in lb 5 9 7 8 0 60 0 80 52 69 in lb 14 19 1 4 1 9 10 13 5 25 34 2 6 3 5 19 25 44 61 4 5 6 2 33 45 73 98 7 4 10 0 54 72 115 155 11 5 16 0 83 115 165 225 17 0 23 0 125 165 225 325 23 0 33 0 165 24
191. Master Cylinder Front Master Cylinder Removal e Remove the reservoir bracket nut A e Remove the banjo bolt A to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation e Unscrew the clamp bolts B and take off the master cylin der C as an assembly with the reservoir brake lever and brake switch installed e Disconnect the front brake light switch connector D CAUTION Immediately wash away any brake fluid that spills e Remove Brake Lever Pivot Bolt A and Nut Brake Lever B Clamp C Slide Out Brake Hose D Front Brake Light Switch E Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebar e The master cylinder clamp must be installed with the ar row mark C upward e Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage www zxforums com www zxforums com 078177 P www zxforums com 1 2 1 RBAK Fom www zxforums com www zxforums com Master Cylinder Rear Master Cylinder Removal e Unscrew t
192. NGINE JM END 5 9 Exhaust System Manifold Mark Position A Silencer Mark Position A Manifold A with Holes B for Oxygen Sensors Oxygen Sensor 1 C Oxygen Sensor 2 D GE02215BS2 www zxforums com www zxforums com www zxforums com 5 1 O FNGINR TOP END www zxforums com www zxforums com Exhaust System Catalyst Exhaust Gas Europe Models Catalyst Other than Europe Models 240138 S www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TOR END 5 11 Specifications Item Standard Service Limit Camshafts Cam Height Exhaust 34 443 34 557 mm 1 3560 1 3605 in 34 34 mm 1 352 in Inlet 35 043 35 157 mm 1 3796 1 3841 in 34 94 mm 1 376 in Camshaft Journal Camshaft 0 038 0 081 mm 0 0015 0 0032 in 0 17 mm 0 0067 in Cap Clearance Camshaft Journal Diameter 23 940 23 962 mm 0 9425 0 9434 in 23 91 mm 0 941 in Camshaft Bearing Inside 24 000 24 021 mm 0 9449 0 9457 in 24 08 mm 0 948 in Diameter Camshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Usable Range 1 100 1 670 kPa 11 2 17 0 kgf cm 159 242 psi at 320 r min rpm Cylinder Head Warp 0 05 mm 0 002 in Valves Valve Clearance Exhaust 0 17 0 22 mm 0 0067 0 0087 in EE Inlet 0 15 0 24 mm 0 0059 0 0094 in Valve
193. O1 PS Gabi gt 390 MELO LS FM DFI www zxforums com www zxforums com Fuel Pump Relay Service Code 46 Fuel Pump Relay Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it OThe fuel pump relay is included in the relay box e Remove the front seat see Front Seat Removal in the Frame chapter e Remove the relay box A from the bracket and disconnect the connectors Fuel Pump Relay Inspection e Remove the relay box see Fuel Pump Relay Removal e Connect the hand tester A and one 12 V battery to the relay connector as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range 1 Q range El C il A Criteria When battery is connected gt 0 Q When battery is disconnected Q x lf the relay does not work as specified replace the relay box Fuel Pump Relay Circuit a TON PARK T6NITION OST f BR BR BATTERY of alje W BK W R BR Y W BK BR W Ki Ed HO 1 ECU 8 Starter Reply 2 Water proof Joint 1 9 Main Fuse 30 A 3 Engine Stop Switch 10 Battery 12 V 10 Ah 4 Ignition Switch 11 Joint Connector 3 5 Fuel Pump Relay 12 Fuel Pump 6 Ignition Fuse 15 A 13 Joint Connector 2 7 ECU Fuse 15 A 14 Joint Connector 1 www zxforums com www zxforums com www zxforums
194. OTurn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 85 Immobilizer System Equipped Models Spare User Key Registration Flow Chart Cm b 2s Ropar tales parts n case Di Connect key regatranon ur of system base FES master toy Warning indicator tg and symbol Dining NOTEZ Blinking Patterns and Number 0 2eecend gt W I Seecerd D Seecend gt 214 Rapar tales para in casa O descend Iaegrzag of system fadure a LE HIT Warming indicator ight 4 89 and symbol bining NOTES 110603903 1 303 recent 5 f CRE PTE ell 61411194 20 NEON Deeeeg HHHH nn mat 303838303 03039303 140 6 Repar tates parts n case 8 d EE 203 030363 03 63141930303 tsensnd Hi hn 9 F Turn OFF and remove user ker 2 5 Werreng incicato NOTE see NOTED 1 ECU confirms the following Amplifier O Time of Transmiting and Receiving Signals 2 ECU corifierms the following O tmmobiizer Amplifier Failure Pattern 1 O Master Key Collation Error Pattern 6 i j i O Registered User Key is inserted Pattern 2 ao F www zxforums com www zxforums com www zxforums com 16 86 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models Case 2 When the ignition switch
195. Oxygen Sensor Connectors Connect to the main harness after through the sensor leads under the bracket Clamp the sidestand switch lead and tubes US CA CAL AU and MY Model only Clamp Reserve Tank Overflow Hose Water Pipe Radiator Hose Face the white mark outside Reserve Tank Overflow Hose Radiator Return Hose Radiator Overflow Hose Clamp Clamps Radiator Coolant Return Hose Starter Motor Cable Run the starter motor cable under the adjusting collar Approx 45 Engine Ground Cable Alternator Lead Connector Speed Sensor Connector Water Temperature Sensor Connector Through the alternator harness and gear position sensor harness into the heat cover hole Clamp Front Paint Mark White Install the clamps as shown illustration noting to the direction of clip Through the radiator coolant return hose inside the ignition coil connector upside of the main harness and under the upper inner fairing bracket www zxforums com www zxforums com www zxforums com 1 7 1 GABRENDIA www zxforums com www zxforums com Cable Wire and Hose Routing i l HE pe A CA Iw GL A E 7 e Pl ER E e e J HAT Za RA GER EE LU LI e DA SEA WS 6B09946BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX Al 7 1 7 Cable Wire
196. Pr cautions endettement ant entente menus 3 22 DEI Servicing HO EE 3 22 Troubleshooting the DFI SYM iii ia ti ss iaa 3 24 QUIE en fn A 3 24 A EIE A Re ACTE E T TT 3 30 DFI System Troubleshooting Guide voicomciis ie n ane 3 33 SADE Lo Ile EE 3 41 Self diagnosis Outline contact 3 41 Self diagnosis Pr ced dret dodo bella pcs 3 42 Service Code Reading iveco a ecc 3 45 Service C de East felis 3 45 Backs 3 47 Main Throttle Sensor Service Code 11 3 50 Main Throttle Sensor Removal AdjUStMent AAR 3 50 Input Voltage Inspection a a 3 50 Output Voltage Inspection 3 52 Resistance Inspection nonea denses nee e ele aa dee a de rene 3 55 Inlet Air Pressure Sensor Service Code 12 3 56 ue VIR 3 56 le EE e EE 3 56 Input Voltage Inspection 3 56 Output Voltage INSPSCHON s i cselacacdvedcacassecewocdeee tnt menthe alien dia 3 57 Inlet Air Temperature Sensor Service Code 13 3 61 Removal InstallatiOO xiiocii tada dd 3 61 Output Voltage Inspection 3 61 Sensor Resistance Inspection ccccccceccecceceeeceeeeeeeeeeeeeeceeeeeeeeeeceeeseceeeceeeeeeeseeeeeeeeaees 3 62 Water Temperature Sensor Service Code 714 3 64 Removal Installation sssssssisesin A A da 3 64 Output Voltage Inspection 3 64 Sensor Resistance Inspection ss 3 65 Atmospheric Pressure Sensor Service Code 15 3 66 RM ai nent 3 66 le EE e EE 3 66 Input Voltage Inspection 3 66 Output Voltage Inspection 3 67 Crankshaft Sensor Service Code 21
197. S s feel 25482 Side ana e gt S e 3 gt Stand Inlet Air Switch xxx Temperature 535 Sensor E ee oJ mo d wb o 53353 55 Sous E5233 Water proof HE BA Water proof gray a e pate Joint 2 gei 2053 Joint 1 KE RANAN ns i 4 Electronic Control Unit ECU License Plate Light 12V5 Tail Brake Light LED 12V0 5 4 1 Rear Left wi Turn Signal E T Light 124218 Spee 3323 RARE Ge La SB Le EE Gi EE E ks Va 3 Se deg Se Gg zz ES N as LEE Turn SS 2322 EE Frame T LU Fei Fian Signal Joint a Ground SC Relay Connector 1 FF Vehicle Brak dora Atmos pein ia Imnobilizer Light Sensor oina Pre isine rd Kawasaki ey Gray g ensor Di iti Switch Connector 2 Butterfly Stemi nS LB Light Blue Rese Valve Connector Le Light Green eserve etuator Battery Switch GH Grange mt si Pump LPL Pink Starter Ground Pump Main Fuse SOA PU Purple R Red White IGNITION SWITCH CONNECTIONS iznition Battery Tailt Tail2 Battery Tail3 Color BL W BK W G OFF Lock RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Stop Watch Button Color Ga Y R Color BK RIBK R Color W BK Brake Lever Gro 98052 0265B W2RO265BW5 C on ee 8 fe P PARK CO www zxforums com www zxforums com www zxforums com 1 6 1 A
198. System DFI Diagnosis Flow Chart Fl and or Immobilizer Warning indicator light Warning indicator light warning symbols do not LED and Fl warning LED and Immobilizer blinks symbol blinks warning symbol blinks Conduct non self diagnosis Conduct self diagnosis Conduct self diagnosis inspection inspection DFI system inspection immobilizer system Conduct general fuel system inspection General fuel system throttle body assy air cleaner fuel tank etc 60172000 F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFI system problem or a general engine problem www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL STEYL RE 3 31 Troubleshooting the DFI System Sample Diagnosis Sheet Registration No license plate No Year of initial registration Date problem occurred Environment when problem occurred O fine E cloudy O rain O snow O always O other O hot O warm O cold O very cold O always O other m z Problem chronic O often o once frequency O street D highway O mountain ro
199. T J Sates www zxforums com 2 56 PERIODIC MAINTENANCE www zxforums com www zxforums com Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the seal cover A circlip B connector C and O ring D Special Tool Inside Circlip Pliers 57001 143 e Unscrew the locknut E and pivot bolt F and remove the brake lever e Remove the circlip G e Pull out the piston assembly H e Replace Seal Cover A Circlip B O ring D Circlip G Piston Assembly H Diaphragm I GS13134BS2 C Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e Slide the dust cover D out of place and remove the cir clip E e Pull out the push rod assembly F CAUTION Do not remove the secondary cup from the piston since removal will damage it e Replace Circlip A O ring C Circlip E Push Rod Assembly F Piston Assembly G Diaphragm H 4S13135BS2 Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alc
200. UL LI LI j GP30167BS1 Master Key Collation Error 0 3second UUU m Hhanaana GP30168BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRI CAL Sse Md 6 91 Immobilizer System Equipped Models e The master key is registered in the ECU OThe warning indicator light LED and immobilizer warning symbol A blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key GP30172BS1 e Turn OFF the master key and remove it OThe warning indicator light LED A blinks to display the registration mode NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned off and removed otherwise registra tion mode will be ended and the warning indicator light a eee E LED goes off Cie e e al OTo return to the registration mode start the master key ap302018s1 verification procedure This applies to all user key reg istration e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user keys away from the immobilizer antenna Olf there is any problem in the registration the warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure 0 annii UU GP30167BS1
201. a A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the dowel pins B e Replace the clutch cover gasket with a new one e Tighten the clutch cover mounting bolts following the tight ening sequence 1 10 Torque Clutch Cover Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Install Clutch Cable Lower End see Cable Installation Right Lower Fairing see Lower Fairing Installation in the Frame chapter Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required e Remove the clutch cover see Clutch Cover Removal e Pull the release lever and shaft assembly A straight out of the clutch cover www zxforums com www zxforums com O i Oy 4 GFO5034BS1 www zxforums com 6 8 ek LG com www zxforums com www zxforums com Clutch Cover Release Shaft Installation e Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover e Apply oil to the needle bearings in the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover CAUTION GFO5025BS1 When inserting
202. ad O uphill 0 downhill D bumpy O pebble Altitude O normal O high about 1000 m or more Motorcycle conditions when problem occurred Warning O Starts blinking about 3 seconds after from ignition switch ON and goes off after indicator light engine pressure becomes high enough with engine running LED Starts blinking about 3 seconds after from ignition switch ON and the Fl warning symbol on the LCD starts blinking DFI system problem O Starts blinking about 3 seconds after from ignition switch ON and the immobilizer warning symbol on the LCD starts blinking immobilizer system problem O Does not blink about 3 seconds after ignition switch ON O light up ECU or meter unit replace O starter motor nat rotating O starter motor rotating but engine doesn t turn over O starter motor and engine don t turn over O no fuel flow O no fuel in tank O no fuel pump sound O engine flooded do not crank engine with throttle opened which promotes engine flooding O no spark O other Engine stalls O right after starting O when opening throttle grip O when closing throttle grip O when moving off O when stopping the motorcycle www zxforums com www zxforums com www zxforums com A AZENE GLEN DFI www zxforums com www zxforums com Troubleshooting the DFI System Poor running at low very low idle speed O very high idle speed O rough idle speed s
203. age the clutch hub with the sub clutch hub e To measure the free play set a dial gauge A against the raised center B of the clutch spring plate e Move the clutch housing gear back and forth C The dif ference between the highest and lowest gauge readings is the amount of free play Drive Shaft D e Measure the spring plate free play Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in x lf the free play is not within the usable range change all of the friction plate and measure the free play again x If the free play is not whithin the usable range adjust the free play see Spring Plate Free Play Adjustment www zxforums com www zxforums com GFO6130BS2 GFO06070BS2 C www zxforums com 6 1 EG HGH com www zxforums com www zxforums com Clutch Spring Plate Free Play Adjustment NOTE OThe free play adjustment is performed by replacing the steel plate s e Measure the clutch spring plate free play see Clutch Spring Plate Free Play Measurement and then replace the steel plate s which brings the free play within the usable range Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in OReplace the following steel plate s Thickness Part Number 2 3 mm 0 090 in 13089 0008 2 6 mm 0 102 in 13089 0009 2 9 mm 0 114 in STD 13089 1093 Clutch Plate Assembly Length Reference Information e Assemble the following parts Clutc
204. ainer Do not attempt to separate individual cells 6P090006S1 e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container 6P090007S1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 27 Battery e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling Ini
205. airing Installation e Tighten the bolts A www zxforums com www zxforums com www zxforums com 1 5 1 ALBAMA com www zxforums com www zxforums com Side Covers Side Cover Removal e Remove Bolt and Washer A e Pull out the side cover B Side Cover Installation e Insert the projections A into the holes B e Tighten the bolt with washer www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www RAME A 5 15 Seat Cover Seat Cover Removal e Remove Seats see Seats section Bolts A Quick Rivets B e Pull the seat cover backward and clear the projections from the holes e Disconnect Tail Brake Light Lead Connector A Turn Signal Light Lead Connectors B e Remove Seat Lock Cable A e Pull the seat cover backward e Remove Screws and Collars A Tail Brake Light B e Remove Screws A Turn Signal Lights B Left and Right www zxforums com www zxforums com www zxforums com 1 5 1 BEROGNE com www zxforums com www zxforums com Seat Cover e Remove Screws A Seat Lock Assy B Seat Cover Installation e Install the seat lock assy with screws e Connect the tail brake light lead connector e Install the tail brake light A inserting the hooks B into the stoppers C e Connect the both turn signal light lead connectors e Install the seat cover Olnsert the projections A into the holes B e Install Bolts Q
206. al meter A to the oxygen sensor 1 lead E fe connector B sensor side using the needle adapter set E C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor 1 Output Voltage Connections to Oxygen Sensor Connector Meter BK lead Meter GY lead e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal e Separate the hoses A from the air suction valve covers B e Install the suitable plugs A on the fitting of the air suction valve covers B and shut off the secondary air www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR LEMUR Ed 3 85 Oxygen Sensor 1 not activated Service Code 33 Europe Models e Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor 1 Output Voltage with Plugs Standard 0 45 2 5V e Next remove the plugs from the fittings A with idling e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor 1 Output Voltage without Plugs Standard 0 05 0 45 V lf the reading is within range with plugs 0 45 2 5 V without plugs 0 05 0 45 V the oxygen sensor is good x If the reading is without rang
207. amber possibly due to damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head Replace damaged check gasket and compression cylinder head warp is lower than Bad condition of valve seating Repair if necessary usable range Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves www zxforums com www zxforums com Replace the piston and or the piston rings www zxforums com 5 28 FENGINE TOP END www zxforums com www zxforums com Cylinder Head Cylinder Head Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Water Temperature Sensor Lead Connector see Re moval Installation in the Fuel System DFI chapter Clutch Cable Lower End see Cable Removal in the Clutch chapter
208. and Colombia and Taiwan Sub throttle Sub Main Crankshaft Valve throttle Throttle Inlet Air Fuel Injectors SE Actuator Sensor Sensor Pressure Sensor Gear Position Switoh Water Ee Temperature Sensor Speed Oil Sensor Pressure Switch EE NS 4 l i Alternator Ragulator Rectifier Sida Stand Inlet Air Switch Temperature Sensor OFF on Water praa Waterproof EL ZOZ Joint ii ti esas e s Joint i WR BL R wr BL G WR L BK wR BLY Ka D vn Se GT y eL 8K R EK SE S du IN BL R BL G GRO BL Y BK R BL H i P 6 GH vw BL h BL BR BK Y BL WR BL R BL G GR BL Y BK R BL Y Bk P 6 GH vn BL W BL BR BK Y BL BK Y CFE Electronic Control Unit ECU License Plate Light 125 S 16 Rear Right Signal Light KE HE Su SO Hint 8 Tail Brake Light D LED 12V0 5 4 1 Rear Left E BK Y arr Turn Signal S Light 124218 sde Joint Frame SR Ground ch eles onnector 7 T Vehicle f Dr e Brown Brake toss Atnosprerie Immobilizer g ensor Si 4 Switch Connector 2 Butterfly Sb ge Wd LB Light Blue Fuel Valve Connector Lo Light Green Reserve Actuator Battery Switch Orange 12V104h Engine Fuel H RE CSR Pu Purple Wain Fuse R Red sua wW White IGNITION SWITCH CONNECTIONS RIGHT SW
209. and Canada Left Side View ZX1000D6F United States and Canada Right Side View 038224 oF www zxforums com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 9 www zxforums com General Specifications Items ZX1000D6F Ninja ZX 10R Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open OSe NANM XTOFUIT om 2 065 mm 81 3 in CA CAL US 730 mm 28 7 in 705 mm 27 8 in 1 130 mm 44 5 in 1 390 mm 54 7 in 120 mm 4 7 in 825 mm 32 5 in 175 kg 386 Ib 102 kg 225 lb 100 kg 221 lb 17 L 4 5 US gal 3 3 m 10 8 ft 4 stroke DOHC 4 cylinder Liquid cooled 76 0 x 55 0 mm 3 0 x 22 in 998 mL 60 9 cu in 7 1 128 7 KW 175 PS 11 700 r min rpm FR 78 2 kW 106 PS 10 500 r min rpm AU 128 7 KW 175 PS 11 500 r min rpm MY 120 5 kW 164 PS 10 000 r min rpm CA CAL US 115 N m 11 7 kgf m 85 ft lb 9 500 r min rpm FR 86 N m 8 8 kgf m 63 ft lb
210. andard check the oil passages for clogging e Stop the engine e Remove the oil pressure gauge and adapter Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plugs 20 N m 2 0 kgf m 15 ft Ib www zxforums com www zxforums com www zxforums com 7 1 8 ENGINELUB RI CATIO N SYSTEM ms com www zxforums com Oil Pressure Switch Oil Pressure Switch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Slide out the rubber boot A e Loosen the oil pressure switch terminal bolt B and re move the switch lead C e Remove the oil pressure switch D Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch A and tighten it Sealant Kawasaki Bond Silicone Sealant 92104 0004 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Install the switch lead B direction downward e Apply grease to the switch terminal C and tighten the bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib e Slide back the rubber boot to the original position GG13003BS1 www zxforums com www zxforums com www zxforums com www zxforums com
211. anism trouble www zxforums com Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con www zxforums carection www zxforums com Crankshaft
212. apter Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Replace the O ring of the camshaft position sensor e Apply grease to the new O ring e Tighten Torque Camshaft Position Sensor Bolt 10 N m 1 0 kgf m 89 in Ib e Route the camshaft position sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Camshaft Position Sensor Inspection e Disconnect the camshaft position sensor lead connector see Camshaft Position Sensor Removal e Set the hand tester to the x 10 Q range and connect it to the terminals Special Tool Hand Tester 57001 1394 Camshaft Position Sensor Resistance 400 460 Q x If there is more resistance than the specified value the sensor coil has an open lead and must be replaced Much less than this resistance means the sensor coil is shorted and must be replaced e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the camshaft position sen sor www zxforums com www zxforums com 6P10155BS1 www zxforums com 16 46 ELEGTRIGAL SYSTEM www zxforums com www zxforums com Ignition System Camshaft Position Sensor Peak Voltage Inspection e Disconnect the camshaft position sensor connector see Camsha
213. apter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 41 Maintenance Procedure e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The high beam indicator light LED C should go on x If the high beam headlight and or high beam indicator light LED does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter e Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high beam indicator light LED does go off inspect or replace the following item Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light LED should go off GS17064BS1 Headlight Aiming Inspection e Inspect the headlight beam for aiming x lf the headlight beam points to on
214. apter see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed www zxforums com www zxforums com GLO5096BS1 GLO5148BS1 www zxforums com 12 1 au BAKES om www zxforums com www zxforums com Calipers Rear Caliper Dust Boot and Friction Boot Damage e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x lf t
215. apter 16 Main 30 A or ignition fuse blown Inspect and replace see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose Inspect and repair or replace see chapter 3 or air cleaner drain hose Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 nl la lso anj aJJ Crankshaft sensor trouble Inspect see chapter 3 Compression low Spark plug loose Reinstall see chapter 16 Tighten see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 RBapleceofsee chapter 5 www zxforums com www zxforums com www zxforums com FUEL SYRLEM RE 3 35 DFI System Troubleshooting Guide Symptoms or possible C
216. ar Bolts 10 N m 1 0 kgf m 89 in Ib e Install the clutch see Clutch Installation in the Clutch chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforute Lal NE LU BRICATION SYSTEM 7 15 Oil Cooler Oil Cooler Removal e Drain A Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Water Hoses A Oil Cooler Mounting Bolts B Oil Cooler C Oil Cooler Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Install the oil cooler A Torque Oil Cooler Mounting Bolts 20 N m 2 0 kgf m 15 ul e Install the water hoses B as shown Front View C e Tighten Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Pour Engine Oil see Oil Change in the Periodic Maintenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter GG11004BS2 Oil Cooler Oil Filter Case Removal e Remove Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Oil Cooler see Oil Cooler Removal Bolts A Oil Cooler Oil Filter Case B ORemove the oil filter pipe C as necessary www zxforums com www zxforums com www zxforums com 7 1 6 ENGINE LUBRICATION SYST Miorums com www zxforums com Oil Cooler Oil Cooler Oil Filter Case Installation e Replace the O ring A w
217. are not required Turn the ignition switch OFF to stop the indicator light and symbol Ifthe warning indicator light LED and Fl warning symbol of the motorcycle brought in for repair still blinks check the service code When the repair has been done the Fl warning symbol goes off But the service codes stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems www zxforums com www zxforums com www zxforums com 3 26 FY Eb SG LEM DFI www zxforums com www zxforums com Troubleshooting the DFI System Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors have seals including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set Insert the needle adapter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals OAfter measurement remove the needle adapters and ap ply silicone sealant to
218. ass screw use the turns out determined during disassem bly e Repeat the same procedure for other bypass screws e Repeat the synchronization x lf the vacuums are correct check the output voltage of the main throttle sensor see Output Voltage Inspection of Main Throttle Sensor in the Fuel System DFI chapter Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 26 Meter BR BK lead terminal 34 Standard DC 0 65 0 67 V at idle throttle opening x lf the output voltage is out of the range check the input voltage of the main throttle sensor see Input Voltage In spection in the Main Throttle Sensor section in the Fuel System DFI chapter e Remove the vacuum gauge hoses and install the rubber caps on the original position e For the California Model install the vacuum hoses ORoute the vacuum hoses according to Cable Wire and Hose Routing section in the Appendix chapter Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A x lf handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result
219. atch In dicator Water Temperature Gauge Tachometer Speedmeter Illumination Light LED Shift Up Indicator Light LED Joint Connector 1 www zxforums com GP17400BW3 C Lap Switch Fuse Box Ignition Fuse 15 A Main Fuse 30 A Battery 12 V 10 Ah Frame Ground Fuel Reserve Switch Joint Connector 2 ECU Gear Position Switch Oil Pressure Switch Speed Sensor Water Temperature Sensor Stop Watch Switch Meter Unit www zxforums com 16 80 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU Electronic Control Unit If the code does not match ignition system injectors sub throttle valve actuator and exhaust butterfly valve actuator will not operate and the engine will not start Abstract e Do not keep more than one immobilizer key of any system on a key ring Jamming of the key code signal may occur and the operation of the system may be affected elt the warning indicator light LED and oil pressure warning symbol flashes about 3 seconds after the ignition key is turned ON this shows that the warning indicator light LED works as the oil pressure warning indicator As long as the Fl and immobilizer symbols do not flashes the DEI
220. ate Light 12V5 R Si 1 EC lt gt ea ig 2 Aoii ex Joint A Connector Vehicle FNA Atmospheric Imnobilizer Light Sensor Pressure ns Tail Brake Light R LED 12V0 5 4 1N Rear Left BK Y BK AY Turn Signal e amp Light 124218 BK Y GA BK Y BK Y alee we SE Bon R BK BK Y Bon Frame Ground BK Y D LG BK 6 eKsy BR W Joint Sensor Exhaust Sa EK s Switch PRE tres GE Light Blue AL al Connector Light Green Reserve Actuator BK e o dn oz oi CET Pink d CC Purpte IGNITION SWITCH CONNECTIONS RIGHT SWITCH HOUSING CONNECTIONS JanitionBattery Tail1 Tail2 Battery Tai13 Front Brake Light Switch Stop Hatch Button Color BL W BK W G OFF Loc Color CET Y R Color BK RIBK R Color W BK Brake Lever Gre on ommo HE omo P PARK OO O 98052 0266B W2RO266BW5 C www zxforums com www zxforums com www zxforums com 16 29 FLECTRICAL SYSTEM www zxforums com www zxforums com Specifications Item Standard Battery Type Sealed battery Model Name YT12B BS Capacity 12 V 10 Ah Voltage 12 8 V or more Charging System Type Three phase AC Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Camshaft Position Sensor Resistance Camshaft Position Sensor Peak Volta
221. ate first No 200 then No 400 www zxforums com www zxforums com GE14038BS1 www zxforums com www zxforums com www zxforums com ENGINE TOR END 5 31 Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter see Valve Clearance Inspection in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Adapter 24 B 57001 1586 6E15043BS1 Valve Installation CAUTION Do not lap the exhaust valve to the exhaust valve seat using the grinding compound It will come off oxide film treated surface of the valve e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E EX Purple Paint IN Green Paint Retainer F Split Keepers G 6E15028BS1 Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302
222. ater Temperature Sensor 18 5 Alternator 19 6 Starter Relay with Main Fuse 20 7 Battery 12 V 10 Ah 21 8 Relay Box 22 9 ECU Electric Control Unit 23 10 Fuse Box with ECU Main Fuse 24 11 Immobilizer Amplifier Immobilizer Models 25 12 Starter Motor 26 1 3 SN au Ms com www zxforu mS GO Sidestand Switch Gear Position Switch Turn Signal Relay Regulator Rectifier Air Switching Valve Front Brake Light Switch Meter Unit Rear Brake Light Switch Starter Clutch Crankshaft Sensor Camshaft Position Sensor Fan Motor Oxygen Sensor 1 Euro Se Oxygen Sensor 2 EUrop Sien www zxforums com www zxforums com ELECTRICAL SYSTEM 1 6 1 1 Wiring Diagram United States Canada New Zealand Colombia and Taiwan Dummy Page www zxforums com www zxforums com www zxforums com 1 6 1 WELEGIRIGAL SYSTEM www zxforums com www zxforums com Wiring Diagram United States Canada New Zealand Colombia and Taiwan i Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button 4 Stop Watch Button Right Switch Housing be o 000 Zei Ignition d Switch ZG DH Spark Plugs Horn Air 1242 54 Switching Weter Unit wy Valve i Turn Signal Stick Camshaft Indicator Light LED AAAA Postion Sensor 2 High Beam Indicator Light LED K BR BK 3 Neutral Indicator Light LEO Ko AAR a Fan 4 Fuel Level Warning Indicator Light LED LI Besele gt 32 Motor S Warning Indicator
223. ator rectifier Torque Regulator Rectifier Bolts 10 N m 1 0 kgf m 89 ft Ib www zxforums com www zxforums com BK3 BK2 BKI W BK Y GPO9154BS1 www zxforums com 16 38 ELECTRICAL SYSTEM www zxforums com www zxforums com Charging System Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Remove the Front seat see Front Seat Removal in the Frame chapter e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 15 2 V e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally l
224. auses Actions chapter Cylinder head warped Inspect and replace see chapter 5 No valve clearance Adjust see chapter 2 Valve guide worn Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on seating surface Poor Running at Low Speed Spare OOOO Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Clean element or inspect sealing see chapter 2 3 Reinstall see chapter 3 Air cleaner clogged poorly sealed or missing Air cleaner duct loose Air cleaner O ring damaged Fuel tank air vent obstructed Replace see chapter 3 Inspect and repair see chapter 3 Reinstall see chapter 3 Replace see chapter 3 Throttle body assy loose Throttle body assy O ring damage Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump see chapter 3 Unstable rough ings IL Main throttle sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 3 Throttle valves not synchronizing Inspect see chapter 2 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressu
225. b e Tighten the handlebar bolts and lower fork clamp bolts 6M04040781 Torque Handlebar Bolts 25 N m 2 5 kgf m 18 ft Ib Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque OTighten the top plug before tightening the handlebar holder bolt upper fork clamp bolt e Install the removed parts see appropriate chapters e Adjust the spring preload and the damping force Front Fork Oil Change e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vise e Unscrew the top plug A out of the outer tube www zxforums com www zxforums com www zxforums com 13 1 2 RURRENSIO N www zxforums com www zxforums com Front Fork e Install the clamps A as shown NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is used as a guide Special Tools Fork Spring Compressor 57001 1587 Clamp 57001 1626 e Insert the holder bar A into the axle hole of the front fork B e Insert the compression shaft A and install the nut e Insert the lower end of the compression shaft A into the hole B of the holder bar www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SURRENSIQN A 3
226. be approximately 575 Hz Olndicates approximately 60 mph in case the input fre quency would be approximately 920 Hz www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 73 Meter Gauge Indicator Unit e If the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit ORaise the rear wheel off the ground using the jack OTurn on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work check the speed sen sor and wiring see Speed Sensor section in the Fuel Sys tem DFI chapter x If the speed sensor and wiring are normal replace the meter assembly Odometer Check e Check the odometer with the speedometer check in the same way x If value indicated in the odometer is not added replace the meter assembly NOTE OThe data is maintained even if the battery is discon nected OWhen the figures come to 999999 they are stopped and locked Trip Meter Check e Check the trip meter with the speedometer in the same way x If value indicated in the trip meter is not added replace the meter assembly e Check that when the RESET button is pushed for more than two seconds the figure display turns to 0 0 x If the figure display does not indicate 0 0 replace the me ter assembly Water Temperature Meter Check e Connect the 12
227. ber boot A e Loosen the oil pressure switch terminal bolt B and re move the switch lead C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 46 105 Switches and Sensors e Remove Fuel Tank see Fuel Tank Removal in the Fuel Tank Re moval in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect Water Temperature Sensor Connector A Gear Position Switch Lead Connector B e Remove Water Pump see Water Pump Removal in the Cooling System chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Disconnect the speed sensor connector A e Remove Screws A Gear Position Switch B e Remove the pins A and springs from the shift drum Gear Position Switch Installation e Securely place the springs A and pins B into the holes C of the shift drum e Apply grease to the new O ring D e Apply a non permanent locking agent to the gear position switch screws You E GP18217BS1 e Tighten Torque Gear Position Switch Screws 3 0 N m 0 31 kgf m 27 in lb e Run the gear position switch oil pressure switch speed sensor and water temperature switch lead correctly see Cable Wire and Hose Routing section in the Appendix An e m www zxforums com SRE REP ed parts see appropriate DRE 16 106 EL
228. ble Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Adjustment Inspection in the Periodic Maintenance chapter e Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter see Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the mating surface B of the switch housing e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in 1b GFO4018BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wan zb hGH 6 7 Clutch Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Clutch Cable Lower End A see Cable Removal e Loosen the clutch cover mounting bolts as shown se quence 1 10 in the figure and remove them e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C Clutch Cover Installation e Apply silicone sealant to the are
229. bove steps for other link pin A Drive Chain Installation e Engage new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the position e Remove the old drive chain from the new drive chain e Apply grease to the link pins A and grease seals e Engage the drive chain on the rear sprocket through the swingarm e Install the grease seals B on the link pins e Insert the link pins in the drive chain ends e Install Grease Seals C OSet the adjuster bolt yellow A wedge holder and wedge pin B and pressure holder C on the body D OHold the wedge holder and wedge pin using the adjuster bolt yellow OApply grease to the inside E of the pressure holder GKO4050BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FINAL DRIVE 1 1 9 Drive Chain Olnstall the link plate so that the gold painted A faces out OFit the link plate A in the pressure holder B OFit the link plates of the chain into the wedge holder and wedge pin D OTurn the pressure bolt A C by hand until link plate touches the link pins Olnstall the handle lever A onto the pressure bolt A B OTurn the handle lever press in the link plate to the link pins 6K04052BS1 e Set the adjuster bolt yellow A guide plate B and flare pin C on the body e Apply greas
230. by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up t
231. c Combination Meter Unit Inspection in the Electri cal System chapter Meter Unit for Warning Indicator Light LED Oil Pres sure Warning see Electronic Combination Meter Unit Inspection in the Electrical System chapter Meter Unit for Illumination Light LED see Electric Com gt bination Meter Unit Inspection in the Electrical System SE chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Turn off the ignition switch e The all lights should go off for the immobilizer model Warning Indicator Light LED will blinks see Abstract in the Electrical System chapter x If the light does not go off replace the ignition switch Second Step e Turn the ignition switch to P Park position e The city light taillight and license plate light should go on x If the light does not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter www zxforums com www zxforums com www zxforums com 2 40 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure Third Step e Turn on the turn signal switch A left
232. cccccncccnncccnnonononcccnncncnancnnoncnno nano nancnnonann nana rancia nnncnn nacos 15 18 Rear Fender Front Installation oooooocnnncnccccncccnncnnnnncnnonocinnnccnnncnnn cnn onanon anna nonccinnanans 15 19 A deta 15 20 Rear Frame REMOVALS egene ladrar ss 15 20 Rear Frame Installaton cnn nn cn cnn nn nono nc nano no narco unera anner anena 15 20 Frame INSpeCtlon ii a 15 20 LEE AA A EE 15 21 sidestand re EE EE 15 21 Sidestand Insta TTET Sa ieee 15 21 www zxforums com www zxforums com www zxforums com 1 5 2 RAMEns com www zxforums com www zxforums com Exploded View 6002170845 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wwx RAM 1 5 3 Exploded View Torque No Fastener Nem kgfm Pe Remarks 1 Front Footpeg Bracket Bolts 25 2 5 18 2 Rear Footpeg Bracket Bolts 25 2 5 18 3 Rear Frame Bolts 44 4 5 32 4 Rear Master Cylinder Mounting Bolts 25 2 5 18 5 Sidestand Bolt 44 4 5 32 G 6 Sidestand Switch Bolt 8 8 0 90 78 in lb L 7 Sidestand Bracket Bolts 49 5 0 36 L 8 Immobilizer Models G Apply grease L Apply a non permanent locking agent R Replacement Parts www zxforums com www zxforums com www zxforums com 1 5 4 RAMEns com www zxforums com www zxforums com Exploded View ere A dach ae A SX We E che Si es 60021718W5 C www zxforums com www zxforums com www zxforums com
233. ch Water EA Temperature Sensor Speed Oil Sensor Pressure ef eS eB el z ER EEN u Switch a a cd Es T eg 392 Be WER on Alternator 53 528 2 ar des Regulator Rectifier Oxygen Oxygen ESS ve 5 02 aiuta Side Sensor 1 Sensor 2 8828 ec as Stand Inlet Air Temperature Sensor oF Switch L E Water proof y Joint 2 TT Hater proof ii Hi Joint 1 ea oral R EL foe 350323 aK Y 8K D BK er Bi Di Electronic Control Unit ECU License Plate Light 12V5 ear Right R Signal Light 1 2V2iN d EE se 5 Engine Ground ge 225 582 En 5 EE EE Em Turn eh Signal Joint a 5 gt Relay Connector 3 z Immobilizer ES i Kawasaki down Atmospheric KEE Sensor Jjoine Pressure Exhaust Sa Fou Sensor Butterfly Connector 2 value Connector Actuator Fuel Pump Rear Left Turn Signal Light 12 219 Golor Code BK Black BL Blue BR Brown G Green oO Orange P Pink WVTA Honeycomb Catalytic Gonverter Restricted Model Pu Purple R_ Red White Main Fuse 304 IGNITION SWITCH CONNECTIONS ignition Battery Tailt Tail2 Battery Tail3 Color BL W BK W G OFF Loch Front Brake Light Switch Engine Stop Switch Starter Button Stop Watch B
234. ch and wait for period more than 15 seconds e The registration mode automatically ends e Warning indicator light LED goes off A www zxforums com www zxforums com 0 2second 0 Hhannnnnnn UY GP30167BS1 0 5second 0 5second SE ee Ek D ECK GP30166BS1 0 3second HF T ALU AA GP30168BS1 C GP30170BS1 GP30171BS1 www zxforums com 1 6 90 LEG TRIGAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models e Remove the key registration unit and connect the immo bilizer Kawasaki diagnostic system connector NOTE OTurn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys e Install the new ignition switch and antenna Case 3 When the electric control unit ECU is faulty and has to be replaced e Prepare a new ECU A current master key B and cur rent user keys C NOTE OThe key registration unit is not required e Replace ECU A see Immobilizer System Parts Replacement e Insert the current master key into the ignition switch and turn it ON Olf there is any problem in the registration the warning indicator light and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure S
235. cision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Subthrottle Sensor Connector A Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Input Voltage 5 Connections to ECU Connector AAA Meter BL lead terminal 7 Meter gt BR BK lead terminal 34 e Measure the input voltage with the engine stopped and 0017145051 with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF x lf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted If the ground and power supply are good re place the ECU see ECU section x If the input voltage is within the standard range check the input voltage at the subthrottle sensor connector www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM ARE 3 81 Subthrottle Sensor Service Code 32 e Disconnect the subthrottle sensor connector A and con nect the harness adapter B between the har
236. clutch C is aligned with the mating surface D of crankcase rear side GE11176BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TOP END 5 21 Camshaft Camshaft Chain e Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal e Loosen the upper chain guid bolts and camshaft cap bolts as shown sequence 1 20 in the figure and remove them e Remove Upper Chain Guide A Camshaft Caps B Camshafts C e Stuff a clan cloth into the chain tunnel to keep any parts from dropping into the crankcase LOSLO Ve GOOG et ier e Remove the cam sprocket mounting bolts A e Remove the cam sprocket CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Be sure to install the following parts Plug Hole Gaskets A Dowel Pins B www zxforums com www zxforums com 6E111828W2 GE11173BS1 6E11071BS1 www zxforums com 5 22 ENGINE LO END www zxforums com www zxforums com Camshaft Camshaft Chain e Install the cam sprockets as shown in figure 4 Cam Positions A Inlet Cam Sprocket B Exhaust Cam Sprocket C e Apply a non permanent locking a
237. com www zxforums com FUEL SYSTEM RE 3 131 Air Line Element Removal e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter see Air Cleaner Element Re placement in the Periodic Maintenance chapter Element Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter see Air Cleaner Element Re placement in the Periodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks x lf the element has any tears or breaks replace the ele ment Air Cleaner Housing Removal e Remove Air Cleaner Element see Air Cleaner Element Replace ment in the Periodic Maintenance chapter Air Cleaner Housing Mounting Bolts A Inlet Air Temperature Sensor B ODo not disconnect the inlet air temperature sensor lead connector e Remove the hoses A e Remove the air cleaner housing B from the air ducts and holder www zxforums com www zxforums com www zxforums com ASA URLS EM DFI www zxforums com Air Line www zxforums com e Turn the air cleaner housing A counterclockwise B and remove it e Pull off the air ducts A from the frame Air Cleaner Housing Installation e Confirm the air ducts A fit in the frame B e Insert the air cleaner housing C inside the frame s
238. com www zxforums com www zxforums com www zxforums com ELECTRICAL SYS HEM 16 99 Immobilizer System Equipped Models Immobilizer System Circuit JO O1 P ND Ignition Switch Immobilizer Antenna Meter Unit Immobilizer Amplifier Joint Connector 1 Fuse Box ECU Fuse 15A Ignition Fuse 15 A Main Fuse 30 A Starter Relay Battery 12 V 10 Ah Joint Connector 2 Joint Connector 3 Immobilizer Kawasaki Diagnostic System Connector ECU Water proof Joint 1 Frame Ground www zxforums com www zxforums com GP30197BW2 C www zxforums com 16 100 ELECTRICAL SYSTEM www zxforums com www zxforums com Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it
239. ct the rim and tire and replace them if necessary e Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve www zxforums com www zxforums com GJO5040BS1 www zxforums com 10 14 WHEELSSHRES www zxforums com www zxforums com Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber GJ05041BS1 OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F GJ05030781 e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B A GJ05043BS1 e Position the tire on the rim so that the valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e
240. cycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles kno
241. d 0 5second 0 5second Kee Sa E gr Een D LS D GP30166BS1 User Key Collation Error 0 3second HF T COCHA il GP30168BS1 e The user key 1 is successfully registered in the ECU OThe warning indicator light LED and immobilizer warning symbol A blinks 2 times and stops for 1 second and then repeats this cycle 0 30 3 0 3 1second OT LI Se GP30169BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 83 Immobilizer System Equipped Models e Turn the user key 1 OFF and remove the user key 1 OThe warning indicator light LED A blinks to display the registration mode NOTE OTurn off the ignition switch and wait for the period of 15 seconds or more The registration mode automatically finishes and the warning indicator light LED will switch off OThis procedure registered the master key and one user key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed e Insert the user key 2 to the ignition switch and turn it ON Olf there is any problem in the registration the warning indicator light and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered User Key is Inserted User Key Collation Error www zxforums com www zxforums com
242. d Top A 0 77 0 79 mm 0 0303 0 0311 in Second B 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top A 0 70 mm 0 028 in Second B 0 70 mm 0 028 in lf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder upper crankcase using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 15 0 30 mm 0 0059 0 0118 in Second 0 30 0 45 mm 0 0118 0 0177 in Service Limit Top 0 6 mm 0 024 in Second 0 8 mm 0 031 in x lf the end gap of either ring is greater than the service limit replace all the rings www zxforums com www zxforums com GE160707S1 GE160708S1 GE16066BS1 www zxforums com 9 30 GRANKRHAFT TRANSM ISSN sorums com www zxforums com Transmission Shift Pedal Removal e Mark A the position of the shift lever B on the shift shaft so that it can be installed later in the same position e Remove Left Lower Fairing see Lower Fairing Removal in the
243. d Battery Voltage for 4 seconds and then 0 V x If the reading stays on battery voltage and never shows 0 V Check the ECU and fuel pump relay xlf the voltage is in specification but the pump doesn t work replace the pump x If there is still no battery voltage check the pump relay see Fuel Pump Relay Inspection www zxforums com www zxforums com www zxforums com FUEL SYSTEM REN 3 117 www zxforums com www zxforums com Fuel Pump Fuel Pump Circuit 6C17182CW2 ECU Water proof Joint 1 Engine Stop Switch Ignition Switch Fuel Pump Relay ECU Fuse 15 A Ignition Fuse 15 A Starter Replay Main Fuse 30 A 10 Battery 12 V 10 Ah 11 Joint Connector 3 12 Fuel Pump 13 Joint Connector 2 14 Joint Connector 1 E O REREN S www zxforums com www zxforums com www zxforums com 3 118 FUEL SYSTEM DFI WW ZXTOrUMS COM www zxforums com www zxforums com Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly see Throttle Body Assy Disassembly Assembly CAUTION Never drop the injector especially on a hard sur face Such a shock to the injector can damage it Power Source Voltage Inspection A NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B wi
244. d in their original positions e Remove Camshaft Chain see Camshaft Chain Removal in the engine Top End chapter Crankshaft A Pistons see Piston Removal CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANPMISAL N 9 17 Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D O or no mark CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the inner sur face of the upper and lower bearing inserts A e Apply molybdenum disulfide oil solution to the threads B and seating surface C of the connecting rod nuts e Install the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and cap CAUTION Wrong application of oil and grease could cause bearing damage OWhen installing the
245. d Pins 15 N m 1 5 kgf m 11 ft lb Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc The brake will not function on the first application of the lever if this is not done www zxforums com www zxforums com www zxforums com Val AE www zxforums com www zxforums com Brake Pads Rear Brake Pad Removal e Remove the caliper with the hose installed e Remove Clip A Pad Pin B Brake Pads C Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the pad spring in place e Install the piston side pad A first and then another pad OFit the projections B of the pad into the recesses C of the caliper holder e Install the pad pin and clip The clip must be outside of the pads e Install the caliper see Caliper Installation WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter see Brake Pad Wear Inspection in the Periodic Maintenance chapter www zxforums com www zxforums com a06n2 P www zxforums com www zxforums com www zxforums com ww BROKE SA 2 15
246. d center degree s Fahrenheit TIR total indicator reading foot feet V volt s gram s W watt s hour s Q ohm s liter s AT AU CA CAL CH DE COUNTRY AND AREA CODES Austria FR France Australia GB United Kingdom Canada MY Malaysia California US United States Switzerland WVTA Whole Vehicle Type Approval Germany www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motor
247. d side D faces outward x If the sub clutch hub bolts was removed install it OApply a non permanent locking agent to the threads of the sub clutch hub bolts and tighten it Torque Sub Clutch Hub Bolts 25 N m 2 5 kgf m 18 ft lb e Install the clutch hub A on the crankshaft e Align the damper cam B of the sub clutch hub C to the cam followers D of the clutch hub e Install the four torque limiter springs A as shown OFirst Torque Limiter Spring Tang B 6FO6092BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www Hu te Gd 6 1 3 Clutch OSecond Torque Limiter Spring Tang B GFO6O93BS1 OThird Torque Limiter Spring Tang B GFO6O94BS1 A GF06095BS1 OFourth Torque Limiter Spring Tang B e Replace the clutch hub nut A with a new one e Hold the sub clutch hub B steady with the clutch holder C and tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 130 N m 13 3 kgf m 96 ft lb www zxforums com www zxforums com www zxforums com 6 1 dek HG com www zxforums com www zxforums com Clutch e Install the following as shown Friction Plates 9 A Steel Plates 9 B Spring Seat C Spring D Olnstall the spring seat and spring between first steel plate and second steel plate CAUTION If new dry friction plates and steel plates are in stal
248. d the rear brake on e Raise the rear wheel off the ground e Remove the axle cotter pin and loosen the rear axle nut e Loosen the both chain adjuster locknut to loosen the drive chain e Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the output shaft C e Disengage the drive chain from the engine sprocket Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket onto the shaft e Apply molybdenum disulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend A the one side of the washer over the nut NOTE OTighten the nut while applying the rear brake Torque Engine Sprocket Nut 125 N m 12 7 kgf m 92 ft Ib e Adjust the drive chain slack after installing the sprocket WEP HAVE SPAIN Slack Adjustment iW We DNH WAIN tenance chapter www zxforums com 11 1 avi NAL DRIVE www zxforums com www zxforums com Sprocket Coupling e Install the guide A into the sprocket cover B so that the hook C of the guide fits into the receiver D GKO5060BS1 e Install the engine sprocket cover A with the guide B Olnstall the pins C into the holes D e Tighten the engine sprocket cover bolts Torque Engine Sprocket Cover Bolts 10 N m 1 0 kgf m 89 in lb e Install t
249. d the wiring are good Perform the Injector Resistance Inspection 6017024351 Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the engine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Hand Tester 57001 1394 lf the test light doesn t flicker or the test hand doesn t oscillates check the wiring and connectors again If the wiring is good replace the ECU see ECU section Injector Resistance Inspection e Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the connector from the injector A see Throt tle Body Disassembly Assembly e Measure the injector resistance with a digital meter Injector Resistance Connections to Injector Meter Meter 1 WIR gt BL R Terminal 2 WIR gt BL G Terminal 3 WIR gt BL BK Terminal 4 WIR gt BL Y Terminal Standard about 11 7 12 3 Q at 20 C 68 F x If the reading is out of the range perform the Injector Unit Test x lf the reading is normal perform the Injector Unit Test wiht SUD www zxforums com www zxforums com 3 1 2 KU Rum co EM DFI www zxforums com www zxforums com Fuel Injectors Injector Unit Test e Use two leads A and the same test light set B as in Injector Signal Test Rating of Bulb
250. ded in the ECU e Remove the relay box see Relay Box Removal e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit x If the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Headlight Relay 1 3 bei 4 5 co Fuel Pump Relay 6 7 Notas Starter Circuit Relay Ena 8 9 co 14 17 o0 Fan Relay 15 16 Not o The actual reading varies with the hand tester used www zxforums com www zxforums com www zxforums com 1 6 1 Nae EGE RIG AL SYSTEM www zxforums com www zxforums com Relay Box Relay Circuit Inspection with the battery connected Battery Connection H O Tester Tester Connection Reading Q Fuel Pump Relay 6 7 4 5 0 Fan Relay 15 16 14 17 0 Battery Tester Connection Tester Connection DC 25 V Range Reading V MS 9 nem Starter Circuit 13 9 Battery Relay Voltage Apply positive lead Apply negative lead Diode Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit Diode Circuit Inspection Tester Connection 1 8 2 8 9 10 9 12 9 13 10 11 10 12 x The resistance should be low in one direction and more than ten times
251. diately A WARNING If dirt or dust is allowed to pass through into the throttle assembly the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Element Cover Screws A Air Cleaner Element Cover B e Discard the air cleaner element A www zxforums com www zxforums com www zxforums com 2 48 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure e Install a new element A so that the element ends B insert along the rib C in the housing CAUTION Use only the recommended air cleaner element Kawasaki part number 11013 0004 Using another air cleaner element will wear the engine prema turely or lower the engine performance e Tighten Torque Air Cleaner Element Cover Screws 1 1 N m 0 11 kgf m 9 7 in Ib Fuel Hose Replacement e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Be sure to place a piece of cloth A around the fuel hose joint e Insert a minus screw driver B into the slit C on the joint lock e Turn A the driver to disconnect the joint lock B e Pull C the fuel hose joint D out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completel
252. dling may be impaired and a hazardous condition may result OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Adjuster Damping Position 19 mm Front Fork Removal each fork leg e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter Loosen the handlebar bolt A upper fork clamp bolt B and fork top plug C beforehand if the fork leg is to be disassembled NOTE OLoosen the top plug after loosening the handlebar bolt and upper fork clamp bolt www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSPENSION A 3 11 Front Fork e Loosen the handlebar bolt A upper fork clamp bolt B and lower fork clamp bolts C e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the top end A of the outer tube is flush with the upper surface B of the steering stem head bracket e Tighten the upper fork clamp bolt and fork top plug Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Front Fork Top Plugs 23 N m 2 3 kgf m 17 ft l
253. ds e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in 6105040351 use Bolt Length after _ Bolt Length before _ Bolt Stretch tightening tightening Connect Usable Range of ing Rod Bolt Nut Connecting Rod Assy Bolt Stretch Use the bolts Attached to 0 24 0 34 mm New attached to new con rod 0 0094 0 0134 new con rod in Replace the 0 24 0 34 mm Used bolts with new 0 0094 0 0134 ones New in 2 Rotation Angle Method x If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts nuts and connecting rods thor oughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely
254. e Install the heat pad aligned with the bolt Viewed Left Side Front Battery Negative Lead Connector Alternator Lead Engine Subharness Joint Connector Clamp The clamp attached on the main harness Camshaft Position Sensor Connector Joint Connector for the stick coil and air switching valve leads Install it into the bracket Clamp The clamp attached on the main harness Immobilizer Amplifier Left Switch Housing Lead Ignition Switch Lead Clamp the left switch housing lead and ignition switch lead Main Harness Left Headlight Connector Left City Light Connector Meter Connector Rear Brake Light Switch Lead Connector Gray Black Through the harnesses into the rib of the center inner fairing www zxforums com www zxforums com www zxforums com 1 7 8 APBEN RIX mn www zxforums com www zxforums com Cable Wire and Hose Routing e oa L a Q0 OQO e A L n Gab Mia SS l Fi z S Ng SE ES e ma A Al 6B09897BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wh BRENDIX 1 7 9 Cable Wire and Hose Routing OMNOOARWN Battery Positive Terminal Relay Box Immobilizer Kawasaki Diagnostic System Connector Fuse Box Turn Signal Relay Right Turn Signal Light Connector Tail Brake Light Connector Clamp
255. e x If the seal is torn or is leaking replace the bearing www zxforums com www zxforums com GJ06036BS1 6J06009BS1 6J06008BS1 6y06002BS1 www zxforums com www zxforums com www zxforums com WHE Fy SCARE Sil 0 17 Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FINAL DRIVE 1 1 1 Final Drive Table of Contents Exploded WEE 11 2 DSPCCHICATONS ua rs 11 4 Special TOS a di adi a a tas 11 5 Drive ON cios AAA A A da A ha 11 6 Drive Chain Slack Inspection 11 6 Drive Chain Slack Adjustment i fesse dida 11 6 Wheel Alignment Inspection Adjustment issus 11 6 Drive Chain Wear Inspection Drive Chain Ee Ile E Drive Chain HRemoval sie Drive Chain Installation eelere A A Lecce aces Ar Te ceadacuvtadaccaebetexaceecduxtsdicigedas Pad tn detente store deb Engine Sprockel Remove nent en re Me nn ans Gen te en a Engine Sprocket Installati n susana nee nat radin le ses Rear Sprocket Removal sise Rear Sprocket Installation Aa tadas Coupling MIEL TB Coupling Bearing Se CEET Coupling Bearing Installation Coupling Beaginginspechion zeg a LR em kat A
256. e A of the chain taut to install the chain e Engage the camshaft chain with the sprockets so that tim ing marks on the sprockets are positioned as shown OThe Timing marks must be aligned with the cylinder head upper surface B EX mark C IN mark D 1 pin E 2 pin F 27 pin G 28 pin H 6E111778w2 C www zxforums com www zxforums com www zxforums com 5 24 ENGINE IOP E N D www zxforums com www zxforums com Camshaft Camshaft Chain e Before installing the camshaft caps and upper chain guide install the camshaft chain tensioner body tempo rally see Camshaft Chain Tensioner Installation e Install the camshaft caps and upper camshaft chain guide A as shown Identification Number 1 4 Camshaft Cap Side B Identification Number 1 4 Cylinder Head Side C e First tighten the camshaft cap bolt 17 18 and upper chain guide bolts 19 20 evenly to seat the camshaft in place then tighten all bolts following the specified tight ening sequence Torque Camshaft Cap Bolts 1 18 12 N m 1 2 kgf m 106 in Ib Upper Camshaft Chain Guide Bolts 19 20 12 N m 1 2 kgf m 106 in Ib av KO DI NINA gt A sir Om SOA MAO 538 all Us O O 0 Lo mear 6E111788W2 C e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing
257. e Spark plug incorrect lOMY MEOH MUEEJOMbuble Air passage clogged Air cleaner clogged poorly sealed or miss ing Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Stick coil trouble Immobilizer system trouble Fuel air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Compression low Spark plug loose www zxforumseyHnder head not suffigianthforlightesed down www zxforums com www zxforums com AP BENRIX 7 31 Troubleshooting Guide No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive
258. e grease seals and tools for rejoining the chain e Remove Chain Cover A Bolts B www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FINAL PRIME 1 1 7 Drive Chain e Using a suitable tool A cut the drive chain by removing the link pins Recommended Tool RK EXCEL 70 Tool RK 700 CAUTION Read the Tool Manual before removing Pressure Bolt A A Pressure Bolt B B Handle Lever C Pressure Holder D Guide Plate E Adjuster Bolt Yellow F Wedge Holder G and Wedge Pin Grip Handle H Flare Pin I Cap J Adjuster Bolt K Pin Puller L Body N Cap Bolt M Olnstall the guide plate A on the body B OScrew the cap bolt C Olnstall the grip handle 6K04044BS1 OSet the chain A to the guide plate B OScrew in the adjuster bolt C for holding the chain OScrew in the pressure bolt A D for holding the chain 6K04045BS1 Olnsert the pin puller A to the pressure bolt B B O 6K04046BS1 www zxforums com www zxforums com www zxforums com 1 1 8 FINAL URRIME www zxforums com www zxforums com Drive Chain OScrew in the pressure bolt assy A in the pressure bolt A B Olnstall the handle lever C to the pressure bolt assy OTurn in the handle lever until the link pin D removed at the link plate E 6K04047BS1 e Repeat the a
259. e replace the oxygen sensor 1 e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 www zxforums com www zxforums com www zxforums com 3 86 FUER acd EM DFI www zxforums com www zxforums com Oxygen Sensor 1 not activated Service Code 33 Europe Models Oxygen Sensor Circuit gt K D oe NS a gt S Y a GCi7166cw2 ECU Water proof Joint 2 Oxygen Sensor 2 Oxygen Sensor 1 Ignition Switch Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Battery 12 V 10 Ah Joint Connector 3 O0ONXDARADN www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 87 Exhaust Butterfly Valve Actuator Sensor Service Code 34 Exhaust Butterfly Valve Actuator Sensor Inspection e Turn the ignition switch OFF e Remove the seat cover see Seat Cover Removal in the Frame chapter e Disconnect the exhaust butterfly valve actuator sensor connector e Connect a digital meter A to the exhaust butterfly valve actuator sensor connector B e Measure the exhaust butterfly valve actuator sensor re sistance Exhaust Butterfly Valve Actuator Sensor Resistance Connections W lead C BK lead D Standard 4 6kQ x If the reading is out of the range replace the exhaust but terfly valve act
260. e Alternator Removal in the Electri cal System chapter Oil Cooler Oil Filter Case see Oil Cooler Oil Filter Case Removal in the Engine Lubrication System chapter Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter Oil Screen see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter External Shift Mechanism see External Shift Mecha nism Removal e Remove the upper crankcase bolts following the speci fied sequence OFirstly loosen the M6 bolts A OSecondly loosen the M7 bolts B OLastly loosen the M8 bolts C Oem OOOO pe See 61042238W2 www zxforums com www zxforums com www zxforums com www zxforums com www zxforum CRAN KSHAFT TRANSMISSION 9 11 Crankcase Splitting e Remove the lower crankcase bolts following the specified sequence OFirst loosen the M6 bolts A OSecond loosen the M7 bolts B OLastly loosen the M9 bolts as shown sequence 1 10 in the figure e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase DEE HORA Sl zi 6104224BW2 Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces
261. e Bolts 44 4 5 32 Sidestand Bolt 44 4 5 32 G Sidestand Bracket Bolts 49 5 0 36 L Sidestand Switch Bolt 8 8 0 90 78 in lb L Rear Footpeg Bracket Bolts 25 2 5 18 Windshield Mounting Bolts 0 4 0 04 4 in lb Electrical System Alternator Cover Bolts 89 in lb Alternator Lead Holding Plate Bolt 89 in lb L Alternator Rotor Bolt 114 Battery Cable Mounting Bolt 35 in lb Camshaft Position Sensor Bolt E 89 in lb Crankshaft Sensor Bolts S 53 mb L Frame Earth Mounting Bolt 89 in Ib Front Turn Signal Light Mounting Screws 10 in lb Front Brake Light Switch Screw 10 in lb Euetuengcpfse com www zxforumsjcon 0 89 inWtyw zxfonums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Torque Fastener Nm kotm ftIb Remarks Gear Position Switch Screws 3 0 0 31 27 in lb L Headlight Mounting Screws 1 2 0 12 11 in lb Idle Gear Cover Bolts 10 1 0 89 in Ib Left Handlebar Switch Housing Screws M5 L 25 3 5 0 36 31 in lb License Plate Light Cover Screws 1 2 0 12 11 in lb License Plate Light Mounting Screws 1 2 0 12 11 in lb Meter Unit Mounting Screws 1 2 0 12 11 in lb Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Oxygen Sensors Europe Models 25 2 5 18 Rear Turn Signal Light Lens Screws 1 2 0 12 11 in lb Rear Turn Signal Light Mounting Screws 1 2 0 12 11 in lb Regulator Rectifier Bolts 10 1 0 89 in Ib Right Handlebar Switch Housing Screws
262. e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Visually check the drain hose end A if the water or oil accumulates in the hose If any water or oil accumulates in the hose remove the plug B from the drain hose and drain it A WARNING Be sure reinstall the plug in the drain hose after draining Oil on tires will make them slippery and WeMTE DUSESAP Accident and injury WWW zxforums com www zxforums com 3 1 IALGU RL ALS EM DFI www zxforums com www zxforums com Air Line Air Inlet Duct Removal e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Mounting Bolts A Both Sides Air Inlet Duct B Air Inlet Duct Installation e Install the gasket A e Apply non permanent locking agent to the threads of the air inlet duct mounting bolts B and tighten it Torque Air Inlet Duct Mounting Bolts 7 0 N m 0 70 kgf m 62 in Ib GCO7038BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYRMEMARED 3 1 35 Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be complete
263. e caliper CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Disassembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts Front 34 N m 3 5 kgf m 25 ft lb Rear 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage www zxforums com www zxforums com 058157 P www zxforums com www zxforums com www zxforums com wo RAKES 12 11 Calipers A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance ch
264. e grease e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 www zxforums com www zxforums com GKO5038BS1 www zxforums com 11 1 4 FINAL DRIVE www zxforums com www zxforums com Sprocket Coupling e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding x lf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage If the seal is torn or is leaking replace the bearing Coupling Bearing Lubrication NOTE OSince the coupling bearing is packed with grease and sealed lubrication is not required Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket t
265. e interior of tensioner body D e Install the tensioner body so that the stopper faces up ward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Install Rod B Spring C Washer D e Tighten the cap bolt E Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb e Run the radiator hose correctly see Cable Wire and hose Routing section in the Appendix chapter e Tighten Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com D Z0 ENGINE IOP END www zxforums com www zxforums com Camshaft Camshaft Chain Camshaft Removal e Remove the cylinder head cover see Cylinder Head Cover Removal e Remove the timing inspection cap A and starter clutch bolt cap B on the starter clutch cover C e Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notch C in the edge of the timing inspection hole D in the starter clutch cover x lf the starter clutch cover is removed perform the next procedure OUsing a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter
266. e is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part lf no abnormality is found in the wiring connectors and DFI parts replace the ECU OThe diagnosis flow chart illustrates the above procedures OAfter inspection be sure to connect all the DFI electrical connectors Do not turn the ignition switch ON while the DFI electrical connectors and ignition system connectors are disconnected Otherwise the ECU memorizes ser vice codes as open circuit OLead Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow www zxforums com www zxforums com 6017029281 www zxforums com www zxforums com www zxforums com FUEL SYXRLEM RE 3 29 Troubleshooting the DFI System OElectrical Connectors Female Connectors A Male Connectors B GPO070003S1 www zxforums com www zxforums com www zxforums com 3 30 NEL SS EM DFI www zxforums com www zxforums com Troubleshooting the DFI
267. e marked side faces out see Brake Disc Installation in the Brakes chapter e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained www zxforums com www zxforums com na 6Jy05042BS1 www zxforums com 10 16 WHEELSCHRES www zxforums com www zxforums com Hub Bearing Hub Bearing Removal e Remove the wheel and take out the following Collars Coupling out of rear hub Grease Seals e Use the bearing remover to remove the hub bearing A CAUTION Do not lay the wheel on the ground with the disc facing down This ca
268. e off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side B faces out e Apply a non permanent locking agent to the threads of the rear brake disc mounting bolts A e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear e Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 5 8 6 2 mm 0 23 0 24 in 3 Rear 4 8 5 2 mm 0 19 0 20 in E Service Limit Front 5 5 mm 0 22 in Rear 4 5 mm 0 18 in Brake Disc Warp e Jack up the motorcycle so that the wheel is offthe ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc A GL08027BS1 Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wmBRAKES A 2 19 Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter see Brake Fluid Level Inspection in the Periodic Main
269. e rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Upper Tie Rod Bolt and Nut A Lower Tie Rod Bolt and Nut B Tie Rods C Tie Rod Installation e Apply grease to the inside of the oil seals e Install the tie rods so that the marked side A faces the bolts and nuts e Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Rocker Arm Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Exhaust Pipe see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter e Squeeze the brake lever slowly and hold it with a band e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Lower Rear Shock Absorber Bolt and Nut A Lower Tie Rod Bolt and Nut B Rocker Arm Bolt and Nut C Rocker Arm D www zxforums com www zxforums com www zxforums com 1 3 28 RURRENSIO N www zxforums com www zxforums com Tie Rod Rocker Arm Rocker Arm Installation e Apply grease to the inside of the grease seals e Tighten Torque Uni Trak Rocker Arm Nut 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal Rocker Arm see Rocker Arm Removal Sleeves A Oil Seal B Swingarm C e Remove
270. e side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A in both headlights in or out until the beam points straight ahead x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster B in both headlights in or out to adjust the headlight vertically 65178174 P www zxforums com www zxforums com www zxforums com 2 42 REBIORLIG MAINTENANCE www zxtorums com www zxforums com Maintenance Procedure NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Low Beam D Height of Headlight Center E High Beam F Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to below table Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Run Continue Up Neutral Released Starts y running Continue Up Neutral Pulled in Starts running Doesn t Con
271. e to the tip D of the flare pin e Fit the adjuster bolt yellow to the link pin E 6K04053BS1 Olnstall the grip lever A onto the pressure bolt A B OStake the link pin end by the handle lever about 9 10 turns C ORepeat the above steps for other link pin D 6K04054BS1 www zxforums com www zxforums com www zxforums com 11 1 Q FINAL DRIVE www zxforums com www zxforums com Drive Chain e After staking measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 60 5 90 mm 0 22 0 23 in Link Plates Outside Width Standard 19 70 20 00 mm 0 775 0 787 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter www zxforums com www zxforums com GKO4028BS1 www zxforums com www zxforums com www zxforums com FINAL RM Ford 1 11 Sprocket Coupling Engine Sprocket Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Shift Lever Bolt A e Pull the shift lever B e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hol
272. e valve is fully opened or completely closed by hand Output Voltage at Sensor Standard DC 0 77 4 22 V at subthrottle valve full opening to closing NOTE OThe throttle sensor is operating correctly if the following voltages are obtained e DC 0 77 V or slightly higher with the subthrottle valve at the closed position e DC 4 22 V or slightly lower with the subthrottle valve at the fully open position CAUTION Do not remove or adjust the subthrottle sensor It has been adjusted and set with precision at the fac tory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it NOTE OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5V exactly OWhen the input voltage reading shows other than 5V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 77 x 4 75 5 00 0 73 V 4 22 x 4 75 5 00 4 01 V TRS Le deals age is 0 73 4 01 V www zxforums com www zxforums com www zxforums com www zxforums com FUEL SY RE EMLAR ES 3 83 Subthrottle Sensor Service Code 32 e After subthrottle sensor voltage inspection remove the harness adapter x lf the reading is out of the standard range inspect the subthrottle sensor resistance x If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section Resistance Inspection
273. earance Inspection 2 22 Valve Clearance AGIUSIM NE sara dit rra E 2 24 Air Suction Systemy A 39 8 8 PNEU ANY GR Jegen eee 2 26 Air Suction System Wardage a SpeCton Zi AA a a II Bee 2 26 Cl A AAA ee A Ae ee 2 27 Clutch Operation Inspection occcccccccncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnninininss 2 27 WEBSITES 2 AAA AA ergeet eee dede diss 2 28 Air Pressure Inspection dida 2 28 Wheel Tire Damage Inspection sine 2 28 Tire Tread Wear Inspection sise 2 28 Wheel Bearing Damage Inspection issues 2 29 EIN EE 2 30 Drive Chain Lubrication Condition Inspection 2 30 Drive Chain Slack Inspection 2 30 Drive Chain Slack En LEE 2 31 Wheel Alignment Inspection vico dc id deck 2 32 Drive Chain Wear Inspection cccccccecceccccececeeeceeeceeeeeeeceeeeceeeeeeeeseeneeeeeeeeeeeeseeaeeeeenaas 2 32 Chain Guide Wear Inspection 2 33 E EE 2 33 Brake Fluid Leak Brake Hose and Pipe Inspection 2 33 Brake Hose Damage and Installation Condition Inspection 2 33 Brake Operation Inspection ss 2 33 Brake Fluid Level Inspechon nnna nnan nnan nnan Ennn nn nnna 2 34 Brake Pad Wear Inspection ss 2 34 Brake Light Switch Operation Inspection 2 34 e Del EE 2 35 Front Forks Rear Shock Absorber Operation Inspection 2 35 Front Fork Oil Leak Inspection 2 36 Rear Shock Absorber Oil Leak Inspection 2 36 Rocker Arm Operation In
274. ectly on the delivery pipe by sliding the joint or the fuel could leak GS05092BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 21 Maintenance Procedure Evaporative Emission Control System California Model Evaporative Emission Control System Inspection e Inspect the canister as follows ORemove the right upper inner fairing see Upper Inner Fairing Removal in the Frame chapter ORemove the canister A and disconnect the hoses from the canister OVisually inspect the canister for cracks or other damage x If the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions e Check the liquid vapor separator as follows ORemove the right middle fairing see Middle Fairing Re moval in the Frame chapter ODisconnect the hoses from the separator and remove the separator A from the motorcycle right side OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in p
275. ee Drive Chain Removal in the Final Drive chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x lf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in GKO040606S1 A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make RK EXCEL Type RK 525MFO Link 108 links www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 33 Maintenance Procedure
276. eeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is probably worn also When replacing a sprocket inspect the chain www zxforums com www zxforums com 6y06002BS1 Se f y ganan P 6K05017BS1 www zxforums com www zxforums com www zxforums com FINAL RY Bord 1 15 Sprocket Coupling Rear Sprocket Warp Inspection e Raise the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp Xx If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 02 in www zxforums com www zxforums com 6K05000BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www BRAKES 12 1 Brakes Table of Contents EXp
277. eft middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect Oxygen Sensor 1 Lead Connector A Oxygen Sensor 2 Lead Connector B e Remove the oxygen sensor 1 A www zxforums com www zxforums com www zxforums com 16 104 ELECTRICAL SYSTEM www zxforums com www zxforums com Switches and Sensors e Remove Front Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter Oxygen Sensor 2 A Oxygen Sensor Installation Europe Models CAUTION Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B to prevent oil contact Oil contamination from hands can reduce sensor performance e Tighten Torque Oxygen Sensors 25 N m 2 5 kgf m 18 ft lb e Run the oxygen sensor leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection Europe Models e Refer to the Oxygen Sensor 1 2 Inspection in the Fuel System DFI chapter see Oxygen Sensor 1 2 Inspec tion in the Fuel System DFI chapter Oxygen Sensor Heater Inspection Europe Models e Refer to the Oxygen Sensor Heater Inspection in the Fuel System DFI chapter see Oxygen Sensor Heater In spection in the Fuel System DFI chapter Gear Position Switch Removal e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Slide out the rub
278. electrical and DFI parts www zxforums com www zxforums com www zxforums com 16 28 ELECTRICAL SYSTEM www zxforums com www zxforums com Battery Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for ZX1000D YT12B BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance GP08020481 CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge 6P08003BS1 e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODO not pierce or otherwise open the sealed cells B of the electrolyte cont
279. er C e Pull out the idle gear starter clutch side A with the shaft B Starter Idle Gear Installation e Apply molybdenum disulfide grease A to the idle gear shaft starter clutch side B e Fit the pin C into the groove D of the crankcase www zxforums com www zxforums com www zxforums com 16 50 LEG TRIGAL SYSTEM www zxforums com www zxforums com Electric Starter System e Install the idle gear starter clutch side A on the shaft e Engage the idle gear with the starter clutch gear e Apply silicone sealant to the following portion Crankshaft Sensor Lead Grommet B Crankcase Halves Mating Surfaces C Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the dowel pin D and new gasket e Apply grease to the O rings of starter motor e Install Starter Clutch Cover A Clamp B e Tighten Torque Starter Clutch Cover Bolts 10 N m 1 0 kgf m 89 in lb L 20 mm 0 79 in C L 30 mm 1 18 in D e Apply molybdenum disulfide grease A to the idle gear shaft starter motor side B e Fitthe pin C into the groove D of the starter clutch cover e Install the idle gear starter motor side A on the shaft e Engage the idle gear with the starter motor gear and idle gear starter clutch side e Install the dowel pin B and new gasket e Install Idle Gear Cover A Idle Gear Cover Bolts B Idle Gear Cover Bolt C with Gasket e Tighten Torque Idle Gear Co
280. ervice code can not be displayed even if pushing the RESET button for more than two seconds 6017270082 e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the RESET button for more than two seconds OWhen the ignition switch is turned OFF www zxforums com www zxforums com www zxforums com 3 44 FUEL GLEN DFI www zxforums com www zxforums com Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch OFF V Turn the ignition switch ON Display the odometer and push the RESET button for more than two seconds Then self diagnosis mode starts V The service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch OFF V Locate the problem with the service code table and inspect and repair DFI ignition and immobilizer system immobilizer models according to inspection procedure on all the service codes Y Turn the ignition switch ON NG Make sure the FI and or immobilizer symbols go off gt yK Run the engine for several minutes at idling and run the motorcycle NG at 30 km h 18 mph or above in order to confirm no problem 60172020 F www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FU EL SYR TEM RE 3 45 Self Diagnosis Service Code Reading OThe service code s is displayed on the LCD by the number of
281. es and right 3 4 throttle valves assemblies Example 1 210 mmHg 2 240 mmHg 3 200 mmHg 4 220 mmHg e With the engine at the correct idle speed equalize higher vacuum of 1 or 2 for example 240 mmHg to higher vacuum of 3 or 4 for example 220 mmHg by turning the center adjusting screw A NOTE OAfter adjustment the final vacuum measurement be tween the highest throttle valves may not be 240 mmHg for example The goal is to have the highest two vac uums between the left 1 and 2 and right 3 and 4 banks be the same and be within the service limits e Open and close the throttle after each measurement and adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect output voltage of the main throttle sensor to ensure proper operation procedure is explained at the end of this sec wAN2xforums com www zxforums com www zxforums com 2 1 8 RERIODIG MAINTENANCE www zxforums com www zxforums com Maintenance Procedure If a value of measured vacuum pressure is out of the specified range after synchronization adjust the bypass screws A Special Tool Pilot Screw Adjuster D 57001 1588 e Adjust lower vacuum between 1 and 2 to higher vac uum of 1 and 2 e Adjust the lower vacuum between 3 and 4 to higher vacuum of 3 and 4 e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary e Check the vacuums as
282. es and adapter e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down e Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 e Remove Front Seat see Front Seat Removal in the Frame chap ter Steering Damper see Steering Damper Removal in the Steering chapter Fuel Tank Bolts A www zxforums com www zxforums com www zxforums com 3 114 FUEL SYSTEM DFI WW ZXTOrums com www zxforums com www zxforums com Fuel Line e Open the fuel tank cap A to lower the pressure in the tank e Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump e Remove the fuel hose from the fuel pump see Fuel Tank Removal A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected
283. es from the throttle body assy together with the delivery pipe C NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle body e Pull out the injectors A from the delivery pipe B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Apply daphne oil or engine oil to the new O rings A of each injector insert them to the delivery pipe B and con firm whether the injectors turn smoothly or not NOTE OReplace the O rings of injectors to new ones www zxforums com www zxforums com www zxforums com 3 1 SOK Rus EM DFI www zxforums com www zxforums com Throttle Body Assy e Apply daphne oil or engine oil to the new dust seals A and insert the injectors into the throttle body which in stalled to the delivery pipe NOTE OReplace the dust seals of the throttle body to new ones e Install the delivery pipe to the throttle body Torque Delivery Pipe Mounting Screws 5 0 N m 0 50 kgf m 44 in Ib e Connect the injector connectors e Insert the each hoses to the throttle body fittings and inlet air pressure sensor e Install the throttle body assy see Throttle Body Assy In stallation www zxforums com www zxforums com www zxforums com www zxforums
284. essure Sensor Exhaust Butterfly Valve Actuator Joint Connector 3 OThe ECU main replay function is included in the ECU www zxforums com www zxforums com www zxforums com 3 20 FUEL Seed FM DFI www zxforums com www zxforums com DFI System Terminal Numbers of ECU Connectors Terminal Names 34 Unused Subthrottle Valve Actuator Subthrottle Valve Actuator Gear Position Switch Crankshaft Sensor Speed Sensor Power Supply to Sensors Inlet Air Temperature Sensor Vehicle down Sensor Exhaust Butterfly Valve Sensor Atmospheric Pressure Sensor Oxygen Sensor 2 Fuel Pump Relay Battery Monitor Power Supply to ECU from Battery Unused Ground for Control System Unused Subthrottle Valve Actuator Subthrottle Valve Actuator External Communication Line Immobilizer KDS Crankshaft Sensor Unused Camshaft Position Sensor Water Temperature Sensor Main Throttle Sensor Subthrottle Sensor Inlet Air Pressure Sensor Oxygen Sensor 1 Radiator Fan Relay Unused Power Supply to ECU from Battery i BI Mom www zxforums com or sensors roun 6C17125CW2 www zxforums com www zxforums com www zxforums com FU EL STEYL RE 3 2 1 DFI System 35 External Communication Line Immobilizer KDS 36 Immobilizer Amplifier 37 Warning ladicator Light LED Fl Immobilizer 38 Air Switching
285. et Removal in the Final Drive chapter e Pull offthe connectors from the engine and free the wiring from the clamps e Disconnect Camshaft Position Sensor Connector A Harness Joint Connector B Immobilizer Amplifier Connector Immobilizer Models www zxforums com www zxforums com www zxforums com 8 6 ENGINE REMOVAL I N STALLAWON ms com www zxforums com Engine Removal Installation e Disconnect the sidestand switch lead connector A e Remove Gear Position Switch Lead Connector A Alternator Lead Connector B e Remove Engine Ground Cable Terminal Bolt A Starter Motor Cable B e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance e Remove Left Upper Inner Fairing Bracket Bolts A Left Upper Inner Fairing Bracket B www zxforums com www zxforums com www zxforums com www zxforums com www zxfor NGINE REMOVALIIN TALLATION 8 7 Engine Removal Installation e Remove Left Engine Bracket Bolts A Left Engine Bracket B e Remove Right Upper Inner Fairing Bracket Bolts A Right Upper Inner Fairing Bracket B e Remove Right Engine Bracket Bolts A Right Engine Bracket B e Remove Left Front Engine Mounting Bolt A Middle Engine Mounting Nut B Lower Engine Mounting Nut C e Turn the middle A and lower B engine mounting bolts clockwise to make the gap between the adjusting collar and frame e Pull out the engine
286. etween the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness B C D if neces sary www zxforums com www zxforums com 6P07002BS1 GPO7022BS2 www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 25 Battery Battery Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Relay Box A e Slide the black and red caps A out e Disconnect the negative cable B and then positive cable C CAUTION Be sure to disconnect the negative cable first e Remove the band D e Pull the battery A out of the case Battery Installation e Visually inspect the surface of the battery container lf any signs of cracking or electrolyte leakage from the sides of the battery e Face the terminal upward and put the battery into the rear fender front e Install the band A e Connect the positive cable B red cap to the terminal first and then the negative cable C black cap to the terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the terminals with the black and red caps D CAUTION If each battery cable is not correctly disconnected or connected sparks can arise at electrical connec tions causing damage to
287. eus aaa E 5 38 Throttle Body Assy Holder Removal s sin init 5 38 Throttle Body Assy Holder Installation AAA 5 38 ld 5 39 M ftler B dy Removal E 5 39 Muffler Body InstallatiON lt v iii SEENEN ACE 5 40 Middle and Rear Exhaust Pipe Removal ccccccccccccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeees 5 41 Middle and Rear Exhaust Pipe Installation 5 42 www aAbaxacshPipe Removal WO WWIZX O FUMAS EEN www zxforums com 9 43 Front Exhaust Pipe Installation erene 5 44 5 2 ENGINE OP EN D www zxforums com www zxforums com Exhaust Butterfly Valve Cable Removal ss 5 45 Exhaust Butterfly Valve Cable Installation 222 ccccccccceeeeeeeeeeeeeeeceeeeeeeeeeeeseneeeeeeeeeenee 5 46 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com E N GINEFOREND 5 3 Exploded View Dummy Page www zxforums com www zxforums com www zxforums com 5 4 ENGINE AQ EN D www zxforums com www zxforums com Exploded View LA S e e S Sgr es KTK 6E022128W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE 04 END 5 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Air Suction Valve Cover Bolts 10 1 0 89 in lb L 2 Cylinder Head Cover Bolts 10 1 0 89 in lb 3 Camshaft Cap Bolts 12 1 2 106 in lb S 4 Upper Camshaft
288. f the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 37 Charging System Charging System Circuit ON PARK IGNITION OO BATTERY GP09151BW2 C Ignition Switch Main Fuse 30 A Starter Relay Battery 12 V 10 Ah Frame Ground Load Alternator Regulator Rectifier ONOOAWND www zxforums com www zxforums com www zxforums com 16 38 ELECTRICAL SYSTEM www zxforums com www zxforums com Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery Ignition system wiring Repair or replace and connector inspection damaged part Good Spark plug inspection Replace spark plug Good Stick coil winding resistance inspection Replace stick coil Good TE f Voltage is less than Stick coil primary peak voltage inspection the specified value Good Stick coil is defective Voltage is zero Inspect Replace stick c
289. f the reading speed sensor and wiring are good replace the ECU see ECU section e Turn the ignition switch OFF Speed Sensor Circuit LLL 6017159081 6c017160CW2 1 ECU 2 Meter Unit 3 Speed Sensor 4 Joint Connector 1 5 Frame Ground www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM REI 3 75 Gear Position Switch Service Code 25 Gear Position Switch Removal Installation e Refer to the Gear Position Switch Removal Installation in the Electrical System chapter see Gear Position Switch Removal Installation in the Electrical System chapter Gear Position Switch Inspection e Refer to the Gear Position Switch Inspection in the Electri cal System chapter see Gear Position Switch Inspection in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector with the nee dle adapter set Special Tool Needle Adapter Set 57001 1457 Gear Position Switch Input Voltage at 1 6 Gear Positions Connections to ECU Connector Meter gt W Y lead terminal 4 Meter Engine Ground e Measure the switch input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at 1 6
290. fer to the Coolant Change in the Periodic Maintenance chapter see Coolant Change in the Periodic Mainte nance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter see Coolant Change in the Periodic Mainte nance chapter Pressure Testing e Remove Right Upper Inner Fairing see Upper Inner Fairing Re moval in the Frame chapter Radiator Cap A ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Install the cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right x lf the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and wis al lg eco cap www zxforums com CDOSBOEt P 6D050111S1 www zxforums com 4 8 GAPLING SYSTEM www
291. forums com www zxforums com Fuel Injectors xIf the output voltage is out of the standard remove the air cleaner housing and check the output voltage at the injector connector B using a digital meter A and needle adapter set C when the lead is open the output voltage is 0 V Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage at Injector Connections to Injector 1 Meter BL R lead E Meter Battery Terminal D Connections to Injector 2 Meter BL G lead F Meter Battery Terminal D Connections to Injector 3 Meter gt BL BK lead G Meter Battery Terminal D Connections to Injector 4 Meter BL Y lead H Meter Battery Terminal D e Turn the ignition switch ON Output Voltage at Injector Connector Standard Battery Voltage for 4 seconds and then 0 V x If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section x If the wiring is good perform Audible Inspection for con firmation lf the output voltage is out of the standard perform Au dible Inspection for confirmation Audible Inspection e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal e Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 e Start the engine
292. ft Mechanism Removal External Shift Mechanism Installation External Shift Mechanism Inspection eent Transmission Shaft Hemoval ent Transmission Shaft Installation ses Transmission Shaft Disassembly uses MU eat spenshasantaeinboa ja als rifa calido Transmission Shaft ASSOMDIY cut Di A ee iden ahaa Shift Drum and Fork Removal ss Shift Drum and Fork Installaton Shift Drum DIS as SOM a als Shift Blue EE Shift Fork Bending NEE Shift Fork Gear Groove Wear site cei sss sic sees CERS EUREN datar Shift Fork Guide Pin Drum Groove Wear sus Gear Dog and Gear Dog Hole Damage www zxforums com www zxforums com www zxforums com 9 2 GRANKSRARTTRANSMISSION zxforums com www zxforums com Exploded View 6102144BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums bel AN KSHAFT T RANSMISSION 9 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Breather Plate Bolts 10 1 0 89 in lb L 2 Crankcase Bolts M9 39 4 0 29 MO S 3 Crankcase Bolts M8 27 2 8 20 S 4 Crankcase Bolts M7 L 32 20 2 0 15 S 5 Crankcase Bolts M7 L 50 20 2 0 15 S 6 Crankcase Bolts M7 L 85 20 2 0 15 S 7 Crankcase Bolts M6 L 45 12
293. ft Position Sensor Removal e Set the hand tester A to the 10 V DC range e Connect the peak voltage adapter B to the hand tester and camshaft position sensor leads in the terminals Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Camshaft Position Sensor Terminal Adapter Hand Tester White Yellow C Red gt Yellow D Black gt e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the camshaft position sensor peak voltage e Repeat the measurement 5 or more times Camshaft Position Sensor Peak Voltage Standard 0 4 V or more x If the peak voltage is lower than the standard inspect the camshaft position sensor Interlock Operation Inspection e Using the stand A raise the rear wheel off the ground 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality x lf the engine is start inspect the starter lockout switch gear position switch and relay box x lf their parts are normality replace the ECU www zxforums com www zxforums com GP10324BS1 www zxforums com
294. ft lb OForth tighten the bolts E to the tightening sequence 5 7 shown Torque Right Engine Bracket Bolts M10 L 30 44 N m 4 5 kgf m 32 ft lb OFifth tighten the bolt F Torque Left Engine Bracket Bolt 44 N m 4 5 kgf m 32 ft lb OSixth remove the bolt G temporally and using the hexagon wrench turn the adjusting collar C until the clearance H between the cylinder head and collar come to O mm 0 in OL astly reinstall the bolt G and tighten it Torque Right Engine Bracket Bolt M10 L 35 44 N m 4 5 kgf m 32 ft lb www zxforums com www zxforums com www zxforums com www zxforums com wwe INE REMOVAL INSTALLATION 8 13 Engine Removal Installation GH04066BW3 C e Install the left and right upper inner fairing brackets e Run the leads cable and hoses correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter
295. fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel supply pipe of the fuel pump e Secure the fuel hose with a clamp e Insert the fuel hose into the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e With the engine stopped turn the ignition switch ON The fuel pump should operate for 4 seconds and then should stop CAUTION Do not drive the fuel pump 4 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 4 seconds ORepeat this operation several times Amount of Fuel Flow Standard 72 mL 2 43 US oz or more for 4 seconds If the fuel flow is much less than the specified check the following Battery Condition see Charging Condition Inspection in the Electrical System chapter e After inspection connect the fuel hose see Fuel Tank Installation e Start the engine and check for fuel leakage www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEN 3 115 www zxforums com www zxforums com Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it
296. g Force Adjustment Baus ter EME Setting Load Road Speed Position Force a Weak Soft Light Good Low Counterclockwise Clockwise A Softer Harder 1 1 1 1 1 1 4 2 1 adjuster turned fully T GM05213BS1 Compression Damping Force Adjustment e To adjust the compression damping force turn the upper damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 4 turns out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Position Porce Setting Load Road Speed 4 Turns Weak Soft Light Good Low Counterclockwise Clockwise Out Softer Harder t f i T y y I y 3 i 0 Strong Hard Heavy Bad High E HH adjuster turned fully clockwise GM05214BS1 Spring Preload Adjustment e Loosen the locknut and turn out the adjusting nut to free the spring Special Tool Hook Wrench 57001 1101 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SURF ENRIQN 13 21 Rear Shock Absorber e To adjust the spring preload turn in the adjusting nut A to the desired position and tighten the locknut B Spring Length C Spring Preload Setting Standard Spring length 179 mm 7 0 in Usable Range Spring length 179 191 5 mm
297. g or noise lf roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re f Ss d moval Hub Bearing Inspection in the Wheels Tires chap ES eg AECH II P ter and coupling see Coupling Bearing Inspection in the Final Drive chapter www zxforums com www zxforums com www zxforums com 2 30 PERIODIC MAINTENANCE www zxforums com www zxforums com Maintenance Procedure Drive Train Drive Chain Lubrication Condition Inspection elt a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication elt the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe
298. ge Spark Plug Gap Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Electric Starter System Starter Motor Brush Length Commutator Diameter 60 V or more 4 000 r min rpm 0 1 0 20 14 2 15 2 V 380 570 Q 3 2 V or more 400 460 Q 0 4 V or more 0 8 0 9 mm 0 032 0 035 in 12 160 8 5 11 5 kQ 72 V or more 10 mm 0 39 in Service limit 5 0 mm 0 20 in 28 mm 1 10 in Service limit 27 mm 1 06 in Air Switching Valve Resistance 18 22 Q at 20 C 68 F Switch and Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF In the text www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 6 21 Special Tools and Sealant Hand Tester Grip 57001 1394 57001 1591 d T5713948T ST5715918T Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Rotor Holder 57001 1405 57001 1658 ST5714058T ST571658ST Peak Voltage Adapter Rotor Holder 57001 1415 57001 1666 ST5714158T ST571666ST Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 92104 0004 ST5714498T ST9200048T Key Registration Unit 57001 1582 ST5715828ST www zxforums com www zxfo
299. ge Inspection 3 119 Audible E Le EE 3 120 Injector Signal Testi iia dd 3 121 Injector Resistance Inspection EE EE 3 121 Injector Unit Test s 3 122 Injector Fuel Line Inspection DEE 3 122 Throttle Grip and Cables siens 3 124 Free Play INSPECCI N La La gen de D AAA AA AA hat 3 124 Eres Play EE du EEN 3 124 Cable Installation a Ae 3 124 Cable leier te EE EE 3 124 Throttle BODY ASSY iaa dd 3 125 Idle Speed Inpec iii ia 3 125 Throttle Bore leanings a 5 zeegp a bh em Kent Aren O STR PPR YO Eee 3 125 Synchronizayow INBRECUOM NK NA BD AANA DB eee 3 125 Synchronization Adjustment acia 3 125 Throtile Eu 3 125 Throttle Body Assy Installation 3 127 Throttle Body Assy RE ue 3 128 Throttle Body Assy Assembly EE 3 129 A le EE 3 131 Element HRemoval nc 3 131 ElementInstalla iO iii AAA 3 131 Air Cleaner Element Inspection oooocoocinininnnnnncccncccccc cnn 3 131 Air Cleaner Housing Removal s sise 3 131 Air Cleaner Housing Installation Ann cad debiles aleteo 3 132 Air Cleaner Housing Disassembly ccccccoconocccccccccccononononnnnnncncnnnonnnnn nn nnnnnnnnnnnnnnn nr nrccnnnnnn 3 133 Air Cleaner Housing Assembly atlas 3 133 A EE 3 133 Air Inlet Duct Removal esse ea Paso A A cartes SE 3 134 Air Inlet Duct Installation 2 0 0 0 0 ceccceeceee a aa aeaa cent eeeeeeeeeeeeeeneeeneeeeeeeneeeeeeeeeeeneeees 3 134 F el TANK A A A Ehe 3 135 Fuel Tank Removal see
300. ge of 4 75 V 0 65 x 4 75 5 00 0 62 V 3 90 x 4 75 5 00 3 71 V Thus the valid range is 0 62 3 71 V x lf the output voltage is within the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section x lf the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage again at the sensor connector www zxforums com www zxforums com www zxforums com 3 54 FUEL GLEN DFI www zxforums com www zxforums com Main Throttle Sensor Service Code 11 e Disconnect the main throttle sensor connector and con nect the harness adapter A between the harness con nector and main throttle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Throttle Sensor Output Voltage Connections to Adapter Meter R sensor Y W lead Meter gt BK sensor BR BK lead e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at Sensor Standard DC 0 65 3 90 V at idle throttle opening to full throttle opening NOTE OThe throttle sensor is operating correctly if the following voltages are obtained e
301. gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned www zxforums com www zxforums com 6113040851 6113158BS1 www zxforums com www zxforums com www zxforum ES AN KSHAFT TRANSMIS RON 9 35 Transmission e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes D 5th Gear A Output Shaft B Steel Balls C CAUTION Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts wi
302. gent to the threads and tighten the bolts Torque Cam Sprocket Mounting Bolts 15 N m 1 5 kgf m 11 ft lb e Apply molybdenum disulfide oil solution to all cam parts and journals If anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 1001 EX mark A and the inlet camshaft has a 1001 IN mark B Be careful not to mix up these shafts e Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notch C in the edge of the timing inspection hole D in the starter clutch cover CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket x lf the starter clutch cover is removed perform the next procedure OUsing a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch C is aligned with the mating surface D of crankcase rear side GE11176BS1 www zxforums com www zxforums com www zxforums com ENGINE TOP END 5 23 www zxforums com www zxforums com Camshaft Camshaft Chain e Pull the tension side exhaust sid
303. ght 12 5 Sec aK Y E mi io es EE Headlight d Lo AK Y 12V55W a ne H Sec 6 eh R BK Y di 6 6 die BK Y Left City Light 12V54 Front Left Turn Signal Light 124218 9 e 00 0 000 Left Switch Housing 1 Horn Button 2 Passing Button 3 Turn Signal Switch Fuse Box A Dimmer Switch i Fan Fuse 154 4 Headlight Fuse 104 Relay Box 5 Starter Lockout Switch 2 E U Fuse 154 5 Taillight Fuse 104 1 Fan Relay 6 Lap Time Button 3 Turn Signal Relay 6 lgniton Fuse 154 2 Headlight Fuse 10A 7 Horn Fuse 104 Relay 3 Unused LEFT SWITCH HOUSING CONNECTIONS E Relay Horn Button Turn Signal Switch Starter Lockout SwitchLap Time Button Bassing Button Ke Circuit Rel Color BK WBK Y DE GY Color SE Color BK R Color W R Color BL YR BK d tat HI Clutch Lever OFF T Released R a O LO Pulled inj o O W2L0265BW5 C www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 17 www zxforums com www zxforums com Wiring Diagram Australia Sub i throttle Sub Main Crankshaft Valve throttle Throttle Inlet Air Fuel Injectors Sensor Actuator Sensor Sensor Pressure Ze Sensor qu Gear Position Switch Water carters Temperature Sensor Speed Oil Sensor Pressure LE ee wf er e S SE EN Switch CS ed eg ed z reves Jaz Sas DE Ve 8 Alternator Se p25 cl s S ze KE Regulator Reotifier
304. ghten a new TORX bolt G Damping Force Adjustment e To adjust the damping force turn the damping adjuster B clockwise or counterclockwise Steering Damper A Softer counterclockwise C Harder clockwise D OThe standard adjuster setting is the 18 turns out fully counterclockwise position from the fully clockwise po sition Damping Force Adjustment Adjuster Position Damping Force Setting 18 turns out fully Weak Soft counterclockwise position T T T Steering Damper Oil Leak Inspection e Refer to the Steering Damper Oil Leak Inspection in the Periodic Maintenance chapter see Steering Damper Oil Leak Inspection in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com 1 48 5 VERRING m www zxforums com www zxforums com Steering Stem Stem Stem Bearing Removal e Remove Steering Damper see Steering Damper Removal Steering Stem Head Nut A and Washer B Steering Stem Head C Handlebars D e Remove Brake Hose Clamp A Right Switch Housing Lead Clamp B e Remove the left switch housing lead and ignition switch lead clamp A e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Forks see Front Fork Removal in the Suspension chapter e Bend the claws A of lock washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 www zxforums com
305. gine mount Clamp Clamp Clamp Radiator Hose Clamp Install the clamp so that the clamp and the crankcase mating surface align parallel Clamp Install the clamps as shown illustration noting to the direction of clip Align the paint mark white with the thermostat housing bolt Thermostat Housing Bolt Viewed A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com Cable Wire and Hose Routing 17 14 ABRENDIS ES A Z CO Zug DS 2 ent LARISA RS gt RSS WN A E SN Ne DIR ENTR F PE S E s N j 4 KS N NS a O his E Week S d SE S LEX ASN ISSN ZO go ESS 6B09889BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX Al 7 1 5 Cable Wire and Hose Routing 19 BEE 1 Clamp 2 Air Cleaner Drain Hose 3 4 Joint Connector Water Temperature Sensor Lead Gear Position Sensor Lead Speed Sensor Breather Hose Lead and Oil Pressure Switch Lead _ Right Side Front Rear Left Side Clamp 10 Radiator Hose 12 13 14 15 16 17 18 Clamp Clamp Face the paint mark to the front Clamp Water Hose To the Oil Cooler Sidestand Switch Lead Bracket Clamp for the reserver tank overflow hose oxygen sensor leads air cleaner drain hose and sidestand switch lead Other than US CA CAL AU and MY Model only
306. gnition switch ON Power Source Voltage at Injector Connector Standard Battery Voltage for 4 seconds and then 0 V e Turn the ignition switch OFF x If the reading is out of the standard check the wiring see wiring diagram in this section x lf the reading is good and the power source voltage is normal check the output voltage Output Voltage Inspection e Measure the output voltage at the ECU connector in the same way as power source voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage at ECU Connections for Injector 1 Meter gt BL R lead terminal 46 Meter CH gt Battery Terminal Connections for Injector 2 Meter gt BL G lead terminal 59 Meter Battery Terminal Connections for Injector 3 Meter BL BK lead terminal 44 Meter CH gt Battery Terminal Connections for Injector 4 Meter BL Y lead terminal 57 Meter Battery Terminal 6017184051 e Turn the ignition switch ON Output Voltage at ECU Standard Battery Voltage for 4 seconds and then 0 V lf the output voltage is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU section www zxforums com www zxforums com www zxforums com 3 1 20 URL SG EM DFI www zx
307. gs on the crankshaft make new marks on it NOTE OThere are two types C D of marking positions Crankshaft Main Journal Diameter Marks None 34 984 34 992 mm 1 3773 1 3776 in 1 34 993 35 000 mm 1 3777 1 3780 in O Crankshaft Main Journal Diameter Marks 1 or no mark G105167BS2 www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANS MIR RON 9 25 Crankshaft and Connecting Rods e Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter A Crankcase Main Bearing Inside Diameter Marks O mark or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should 6105188851 0 almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 38 000 38 008 mm 1 4961 1 4963 in None 38 009 38 016 mm 1 4964 1 4967 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041751 Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos 92139 0031 1 5 1 Brown 92139 0034 2 3 4 1 92139 0030 Black None 92139 0033 92139 0029 92139 0032 None
308. h Hub A Spring Seat B Spring C Sub Clutch Hub D Sub Clutch Hub Bolts E New Friction Plates F Steel Plates G Spring Plate H Clutch Springs I Clutch Spring Holders J Clutch Spring Bolts K Torque Clutch Spring Bolts 9 8 N m 1 0 kgf m 87 in Ib e Measure the clutch plate assembly length L Clutch Plate Assembly Length Reference 53 5 mm 2 11 in NOTE OThe length of the clutch plate assembly changes by the steel plate thickness GF06131BS2 C Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points lf any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 6 mm 0 102 in GFO606028S1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www LHC 6 17 Clutch Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard
309. hapter Air Switching Valve see Air Switching Valve Removal Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter e Remove the radiator A temporary see Radiator and Ra diator Fan Removal in the Cooling System chapter free the heat insulation rubber plate B NOTE ODo not remove radiator hoses e Remove the cylinder head cover bolts C e Remove the cylinder head cover D to forward Cylinder Head Cover Installation e Replace the head cover gasket A with a new one e Apply silicone sealant B to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 NE Sal e S Wal si a aK GE09041BS2 C e Be sure to install the following parts Dowel Pins A Plug Hole Gaskets B GE09042BS1 www zxforums com www zxforums com www zxforums com ENGINE TOP END 5 17 www zxforums com www zxforums com Cylinder Head Cover e Replace the washer A with new ones e Install the new washer with the metal side faces upward GE09033BS1 e Install the cylinder head cover e Tighten the cover bolts A Torque Cylinder Head Cover Bolts 10 N m 1 0 kgf m 89 in Ib e Install the removed parts see appropriate chapters GEO9044BS1 www zxforums com www zxforums com www zxforums com 5 1 8
310. hapter Alternator Lead Connector A For the Europe Models e Remove Bolts A Clamp B Cover C For the other than Europe Models e Remove Bolts A Clamp B Cover C Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Check that dowel pins B are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 10 N m 1 0 kgf m 89 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover www zxforums com www zxforums com www zxforums com 16 32 ELECTRICAL SYSTEM www zxforums com www zxforums com Charging System Stator Coil Installation e Tighten the stator coil bolts to the specified torque Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Secure the alternator lead with a holding plate and apply a non permanent locking agent to the thread of the plate bolt and tighten it Torque Alternator
311. he socket together with the bulb www zxforums com www zxforums com GP12220BW3 C Fuse Box Relay Box Headlight Relay Starter Relay Main Fuse 30 A Battery 12 V 10 Ah Frame Ground Tail Brake Light LED License Plate Light Joint Connector 2 Alternator www zxforums com 16 64 LEG TRIGAL SYSTEM www zxforums com www zxforums com Lighting System e Push and turn the front turn signal light bulb A counter clockwise and remove it e Replace the bulb with new ones e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the soket and turn the bulb clockwise OTurn the bulb about 15 degrees e Pushing the socket and turn it clockwise OFit the projections A of the socket into the grooves B of the turn signal light e Install the middle fairing see Middle Fairing Installation in the Frame chapter Rear Turn Signal Light e Remove Screws A Rear Turn Signal Light Lens B e Push and turn the rear turn signal light bulb A counter clockwise and remove it www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 65 Lighting System e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 degrees e Fit the projections A
312. he Periodic Maintenance chapter see Radiator Hose and Connection Inspection in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com 4 22 GOQLING MY STEM www zxforums com www zxforums com Water Temperature Sensor CAUTION The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to their parts can damage them Water Temperature Sensor Removal e Refer to the Water Temperature Sensor Removal in the Fuel System DFI chapter Water Temperature Sensor Removal in the Fuel System DFI chapter Water Temperature Sensor A Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter Water Temperature Sensor In spection in the Electrical System chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TOREND 5 1 Engine Top End Table of Contents Exploded NIEWEN REENEN ENEE EEN tnt dinars EE EE ele e EE Special Tools and Sealant nesteen eeee Clean Ait SY SUS Mii di AA AA A A AA Air Suction Valve Removal ee Air Suction Valve Installation Air Suction Valve Inspection Ae R ARES Air Switching Valve Removal sets ni nantes nt en a lt late een Air
313. he bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANSMIS RON 9 19 Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown e Before tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D e Apply a small amount of molybdenum disulfide oil solution to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Connecting ro
314. he brake hose banjo bolt A and brake hose B e Remove Cotter Pin C Joint Pin D Bolts E Foot Guard F Rear Master Cylinder e Slide out the clamp G e Pull off the reservoir hose lower end H and drain the brake fluid into a container Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers that are on each side of hose fitting with new ones e Tighten Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wmBRAKES A 2 17 Master Cylinder Master Cylinder Inspec
315. he manual s chapters The Quick Reference www zxforums com www zxforums com Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results
316. he meter unit OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table x If the hand tester does not show the specified values re place the sensor 6P18070352 C Water Temperature Sensor Resistance for ECU C Tempetatire Resistance kQ H Terminal 1 43 20 C 68 F 2 46 pese 80 C 176 F 0 32 0 011 110 C 230 F 0 1426 0 0041 Resistance for Water Temperature Gauge D There Resistance Q H Terminal 2 Body 50 C 122 F 210 40 120 C 248 F 21 2 1 5 Speed Sensor Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Water Hose A www zxforums com www zxforums com www zxforums com 16 102 ELECTRICAL SYSTEM www zxforums com www zxforums com Switches and Sensors e Disconnect the connector A e Remove Bolt A Speed Senor B Speed Sensor Installation e Apply grease to the new O ring A e Set the speed sensor bolt B e Tighten Torque Speed Sensor Bolt 10 N m 1 0 kgf m 89 in Ib e Install the removed parts see appropriate chapters Speed Sensor Inspection e Refer to the Speed Sensor section in the Fuel System DFI chapter see Speed Sensor section in the Fuel Sys tem DFI chapter Fuel Reserve Switch Inspection e Fill the fuel tan
317. he removed parts see appropriate chapters Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward e Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft lb e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FINALRRIVE 11 15 Sprocket Coupling Coupling Installation e Grease the following and install the coupling Coupling Grease Seal Lips A Coupling Internal Surface B e Apply grease to the O ring A e Install the collar B Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 e Pack the bearing with high temperatur
318. heel Removal ses 10 8 Rear Wheel Installation cio ads 10 8 Wheel Inspection s inserere nono nnonononononnnnnnnonnnonnnnnnnnnnnonnnnnnnonnnnnnnnnnnnnnnnnnnonnnnnnnos 10 10 Axle e Le ET 10 10 Balance Inspection 10 11 Balance Aumente toca Edge tetera oe tien 10 11 Balance Weight Removal ee adn EES 10 11 Balance Weight ImStal lations cor a A Ai 10 11 RI 10 13 Air Pressure Inspection Adjustment s ss 10 13 Tire Inspection LIFE REMOVAL eebe ege geev A ed A Tire Installation Tire Repair a aya ARAS NS A E I CR Rm RP cc Hub Beannmg NN MN NN La AN d NAI AA Isa NL Hub Bearing Removal is a ei 10 16 MUD Bearing INStallatio DEE 10 16 AubBearina INS PCCUO WEE 10 16 Hub Bearing LUG MC AW ON eege egene PR RARE Ne at Seed EEN 10 17 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 10 2 As Exploded View www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHEELSITIRES 10 3 Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Axle Nut 127 13 0 94 3 Rear Axle Nut 108 11 0 80 AL Tighten the two clamp bolts alternately two times to ensure even tightening G Apply grease HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant www zxfo
319. her Engine oil viscosity too high Change see chapter 2 Drive train trouble Inspect drive chain see chapter 2 and sprocket see chapter 11 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Air switching valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine wires for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Spark plug dirty broken or maladjusted Replace see chapter 2 Inspect stick coil see chapter 16 Reinstall or inspect stick coil see chapter 16 Replace it with the correct plug see chapter 16 inspect see chapter 16 De ee chapter 16 OR IM OM AMM XTO M OM www zxforums com www zxforums com FUEL STEYL RE 3 39 DEI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Stick coil trouble Inspect see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct lo
320. hey show any damage replace it Caliper Piston and Cylinder Damage e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots are not damaged x If the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket x lf the caliper holder shaft is damage replace the caliper bracket www zxforums com www zxforums com GLO5149BS1 GLO5099BS1 GLO5150BS1 GLO5151BS1 www zxforums com www zxforums com www zxforums com wBRAKES A 2 13 Brake Pads Front Brake Pad Removal e Loosen Pad Pins A e Remove Pad Pins A Pad Springs B Brake Pads C Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown e Set Inside Pad A Pad Spring B OPushing the pin holder C to hole of the pad and insert the pad pin Torque Front Brake Pa
321. hown e Turn the housing clockwise and position it GCO7026BS2 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEL 3 133 Air Line e Install the housing on the holder then insert the ducts OApply a soap and water solution A to the ducts for easy installation e Insert the projections B of the housing in the holes C of the ducts e Tighten Torque Air Cleaner Housing Mounting Bolts 7 0 N m 0 70 kgf m 62 in Ib e Install the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter Air Cleaner Housing Disassembly e Remove Air Cleaner Housing see Air Cleaner Housing Removal Air Cleaner Housing Screws A Lower Housing B Duct Holder Screws C Ducts and Duct Holders Filter Air Cleaner Housing Assembly e Install Ducts A and Duct Holders B Filter C x lf the filter is dirt clean the filter in cleaning solvent and then dry it with compressed air or squeeze it e Insert the seal A into the groove in the lower housing B e Apply liquid gasket to the mesh patterns C on the lower housing Sealant Kawasaki Bond Liquid Gasket Black 92104 0002 OWipe off any protruding liquid gasket e Fit the upper and lower housings and tighten the screws securely Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part
322. ical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2007 Kawarathideavy Industries Lid www zxforums com Second don d amp tumb bath K www zxforums com LIST OP ABBREVIATIONS www zxforums com ABDC AC ATDC BBDC BDC BTDC C DC F ft Eet ampere s Ib pound s after bottom dead center m meter s alternating current min minute s after top dead center N newton s before bottom dead center Pa pascal s bottom dead center PS horsepower before top dead center psi pound s per square inch degree s Celsius r revolution direct current rpm revolution s per minute farad s TDC top dea
323. iew 6P022478W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SEM 1 6 9 Exploded View Torque No Fastener Nav katem ftlb Remarks 1 Front Brake Light Switch Screw 1 2 0 12 11 in lb 2 Right Handlebar Switch Housing Screws M5 L 45 3 5 0 36 31 in lb 3 Left Handlebar Switch Housing Screws M5 L 25 3 5 0 36 31 in lb 4 Starter Clutch Bolt 49 5 0 36 5 Starter Motor Mounting Bolts 10 1 0 89 in lb 6 Starter Clutch Bolt Cap E 2 Pie Sidestand Switch Bolt 8 Starter Clutch Cover Bolts M6 L 20 9 Starter Clutch Cover Bolts M6 L 30 Idle Gear Cover Bolts Starter Motor Cable Mounting Bolt Starter Motor Cable Terminal Nut Battery Cable Mounting Bolt Starter Motor Terminal Locknut Starter Motor Through Bolts 16 ECU Fuse 15 A 17 Fuse Box 18 Immobilizer Models G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfuide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts www zxforums com www zxforums com www zxforums com 16 19 ELEGTRIGAL SYSTEM zxforums co m www zxforums com Parts Location 048124 P 1 Starter Lockout Switch 14 2 Ignition Switch with Immobilizer Antenna Im 15 mobilizer Models 16 3 Stick Coils 17 4 W
324. in Fuse 30 A Battery 12 V 10 Ah Joint Connector 3 OONAOAWND www zxforums com www zxforums com www zxforums com 3 1 OF URLS EM DFI www zxforums com www zxforums com ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification Parl Number Specification A Ea L Ea 6017178051 Europe WVTA Full H with Immobilizer 21175 0079 U K WVTA Full H with Immobilizer U S A except California without Immobilizer 21175 0082 A a Canada without Immobilizer 21175 0083 U S A California without Immobilizer 21175 0093 Malaysia with Immobilizer 21175 0094 Australia with Immobilizer 21175 0095 France WVTA 78 2 H with Immobilizer Full Full Power H Honeycomb Type Catalyst 78 2 Maximum Horsepower 78 2 kW 106 3 PS ECU Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Lift up the ECU A and relay box B with rubber protector C e Remove ECU Connectors A ECU B e Refer to the Immobilizer System Parts Replacement in the Electrical System chapter for the immobilizer models see Immobilizer System Parts
325. in an un safe riding condition e Check the idle speed x lf the idle speed is out of specified range adjust it Idle Speed Standard 1 100 50 r min rpm www zxforums com www zxforums com www zxforums com 2 20 PERIOPICMAI NTE NAN C E www zxforums com www zxforums com Maintenance Procedure Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed GSO5090BS1 e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B e Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it is locked x If it does not locked reinstall the hose joint A WARNING Make sure the hose joint is installed corr
326. in lb P 9 Front Caliper Assembly Bolts 22 2 2 16 10 Front Caliper Mounting Bolts 34 3 5 25 11 Front Brake Master Cylinder Bleed Valve 5 4 0 55 48 in lb 12 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease www zxforums com www zxforums com www zxforums com 12 4 RRAKER com www zxforums com www zxforums com Exploded View Soho Tt Q ei N S Se j p www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www RAKES 12 5 Exploded View Torque No Nem kotm ftlb Remarks 1 Bleed Valve 7 8 0 80 69 in lb 2 Brake Hose Banjo Bolts 25 2 5 18 8 Brake Pedal Bolt gt 0 90 78 in lb Rear Prane Disc Mounting Bolts 2 8 20 L Ser ale Maning Bos as Rear Master Cylinder Mounting Bolts 2 5 18 7 Rear Master Cylinder Push Rod Locknut 17 1 7 13 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease www zxforums com www zxforums com www zxforums com 12 6 RRA ER com www zxforums com www zxforums com Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake
327. ine Oil Drain Bolt 20 2 0 15 2 Oil Filter 31 3 2 23 G R 3 Oil Filter Pipe 35 3 6 26 L 4 Oil Pan Bolts 10 1 0 89 in lb 5 Oil Pressure Relief Valve 15 1 5 11 L 6 Oil Pressure Switch 15 1 5 11 SS 8 Oil Pump Gear Bolts 10 1 0 20 EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant Kawasaki Bond 92104 0004 www zxforums com www zxforums com www zxforums com 7 4 ENGINE UBRI CATION SYS TAM torums com www zxforums com Engine Oil Flow Chart UN KIDA O 20 LS WKY 60040778W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxtorumE MINE LUBRICATION AM ATEM 7 5 Engine Oil Flow Chart Inlet Camshaft Exhaust Camshaft Oil Cooler Oil Filter Oil Pressure Switch Main Oil Passage Relief Valve Oil Pump Oil Screen 10 Camshaft Oil Passage 11 Oil Jet 12 Starter Clutch Oil Passage 13 Crankshaft Oil Passage 14 To Air Cleaner 15 Crankcase Oil Passage 16 Drive Shaft Oil Passage 17 Output Shaft Oil Passage 18 Blowby Gas JO O1 ND www zxforums com www zxforums com www zxforums com 7 6 ENGINE UBRI CATION SYS TAM torums com www zxforums com Specifications
328. ine oil viscosityyi q Bigbrums com Drive train trouble 17 32 ABRENDIS www zxforums com www zxforums com Troubleshooting Guide Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mech
329. ing action of the radiator When the coolant temperature is below 90 C 194 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 14 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 14 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator www zxforums com www zxforums com www zxforums com 4 6
330. ings A with new ones e Apply grease to the new O rings www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 57 Electric Starter System Brush Inspection e Measure the length A of each brush B If any is worn down to the service limit replace the brush holder assembly Starter Motor Brush Length Standard 10 mm 0 39 in Service Limit 5 0 mm 0 20 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B x If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 Q hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with
331. inks to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure 0 2second o Hhannnnnnn LUUT GP30167BS1 Master Key Collation Error TUULI UUU GP30168BS1 e Turn the master key OFF and remove the master key OThe warning indicator light LED A blinks continuously to display that the ECU is in the registration mode for 15 seconds NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned off and removed otherwise registra tion mode will be ended and the warning indicator light LED stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration 0 5second 0 5second E SE Fe gp Cy a GP30201BS1 www zxforums com www zxforums com www zxforums com 16 82 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user key away from the immobilizer an tenna Olf there is any problem in the registration the warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure O Ahnannanan LUUL GP30167BS1 When Registered User Key is Inserte
332. inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Install the cap on the connecting rod aligning the weight and diameter marks e Install each connecting rod on its original crankpin OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts www zxforums com www zxforums com G105060181 de 6105037BS1 www zxforums com 9 1 8 RRANKRHAFT T RANSM ISSN sorums com www zxforums com Crankshaft and Connecting Rods CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage CAUTION Be careful not to overtighten the nuts T
333. into it and install it to the steering stem e Screw in the spring preload adjuster A of the top plug so that the distance between the adjuster top and the top plug nut surface is 17 mm 0 67 in B e Turn in the rebound damping adjuster until the fully tight ened position and turn backward the 10th click e Install the front fork see Front Fork Installation www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SURPENSIQN A 3 17 Front Fork Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Front Fork Oil Change e Hold the front fork in a vise A e Stop the cylinder B from turning by using the fork cylinder holder C Special Tool Fork Cylinder Holder 57001 1287 e Unscrew the Allen bolt D then take the bolt and gasket out of the bottom of the inner tube e Take the cylinder unit A ODo not disassemble the cylinder unit e Separate the outer tube from the inner tube e Pull out the dust seal e Remove the retaining ring A from the outer tube e Remove the oil seal B and washer C Front Fork Assembly e Replace the following parts with a new one Oil Seal Bottom Allen Bolt Gasket e Insert the cylinder unit A into the inner tube B e Stop the cylinder from turning by using the fork cylinder holder Special Tool Fork Cylinder Holder 57001 1287 e Apply a non permanent locking agent to
334. ion Immobilizer Amplifier If the immobilizer system fails no signal wiring short or open the vehicle is no start and run Master or User Key The user or master key must use register key If the blank key or broken key is used the vehicle is no start and run Fuel Pump Relay Stick Coil 1 Ignition Coil When the relay ON condition battery monitor voltage 5 V or more The ignition coil primary winding must send signals output voltage 32 or more times continuously to the ECU If the relay fails battery monitor voltage 12 V If the ignition primary winding 1 has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running Stick Coil 2 Ignition Coil Stick Coil 3 Ignition Coil The ignition coil primary winding must send signals output voltage 32 or more times continuously to the ECU The ignition coil primary winding must send signals output voltage 32 or more times continuously to the ECU If the ignition primary winding 2 has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running If the ignition primary winding 3 has failures no signal wiring short or open the ECU shuts off the injector 3 to stop fuel to the cylinder 3 though the engine keeps running Stick Coil 4 Ignition Coil
335. ith a new one e Apply grease to the new O ring x lf the oil filter pipe B was removed install it OApply a non permanent locking agent to the threads of the oil filter pipe and tighten it Torque Oil Filter Pipe 35 N m 3 6 kgf m 26 ft lb e Apply non permanent locking agent to the threads of the oil cooler oil filter case mounting bolts and tighten it Torque Oil Cooler Oil Filter Case Mounting Bolts 20 N m 2 0 kgf m 15 ft lb e Install Oil Cooler see Oil Cooler Installation Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforute Lal NE LU BRICATION SYSTEM 7 17 Oil Pressure Measurement Oil Pressure Measurement e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Oil Passage Plug A e Attach the adapter A and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge Oil Pressure Standard 150 230 kPa 1 5 2 4 kgf cm 22 33 psi at 4 000 r min rpm oil temperature 90 C 194 F x If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x If the reading is much higher than the st
336. k leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 35 Charging System Regulator Rectifier Inspection e Remove the Bolts A e Disconnect the connectors A e Remove the regulator rectifier B e Set the hand tester to the x 1 kQ range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier kl the tester readings are not as specified replace the regulator rectifier CAUTION Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit kQ Tester Lead Connection Terminal W BK1 BK2 BK3 BK Y W 20 300 20 300 20 200 20 750 0 5 20 300 20 200 20 750 0 5 20 300 20 200 20 750 Tester Lead Connection e Install the regul
337. k with fuel e Close the fuel tank cap surely e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Connect the test light A 12 V 3 4 W bulb in a socket with leads and the 12 V battery B to the fuel pump connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side BK R Lead Terminal Battery BK W Lead Terminal Special Tool Needle Adapter Set 57001 1457 lf the test light turn on the reverse switch is defective Replace the fuel pump www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 46 103 Switches and Sensors e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel pump NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for few minutes GP18216BS1 Oxygen Sensor Removal Europe Models NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness side is different e Remove the l
338. ken EA TR IRL eee Coupling Bearing Lubrication Coupling Damper Inspechon Sprocket Wear Inspechon Rear Sprocket Warp Inspection 11 15 www zxforums com www zxforums com www zxforums com 11 2 FINAL URRIME www zxforums com www zxforums com Exploded View GK02099BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FINAL PRIME 1 1 3 Exploded View Torque No Fastener SE kgfm ftlb Remarks 1 Rear Axle Nut 108 11 0 80 2 Rear Sprocket Nuts 59 6 0 44 3 Engine Sprocket Nut 125 12 7 92 MO 4 Engine Sprocket Cover Bolts 10 1 0 89 in lb G Apply grease HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 1 R Replacement Parts www zxforums com www zxforums com www zxforums com 11 4 FINAL ARIE www zxforums com www zxforums com Specifications Item Standard Service Limit Drive Chain Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain 30 35 mm 1 2 1 4 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Make RK EXCEL sae Type RK 525MFO Endless EE Link 108 links aa Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 02 in www z
339. king e Remove Right Upper Inner Fairing see Upper Inner Fairing Re moval in the Frame chapter Radiator Cap A ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Place a containers under the drain bolts A B of the wa ter pump cover and cylinder e Drain the coolant from the radiator and engine by remov ing the drain bolts www zxforums com www zxforums com www zxforums com 2 50 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure e Remove Bolts A Coolant Reserve Tank B e Remove the cap C and pour the coolant into a container e Install the coolant reserve tank Torque Coolant Reserve Tank Mounting Bolts 7 0 N m 0 71 kgf m 62 in Ib e Tighten the drain bolts Replace the drain bolt gasket with a new one Torque Coolant Drain Bolt Water Pump 10 N m 1 0 kgf m 89 in Ib Coolant Drain Bolt Cylinder 10 N m 1 0 kgf m 89 in lb e Fill the radiator up to the radiator filler neck A with coolant and install the radiator cap NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Fill the reserve tank up to the full level line with coolant and install the cap CAUTION Soft or distilled
340. l wiring short or open the speedometer shows 0 Gear Position Switch Gear Position Switch Output Voltage signal Vg 0 2 4 8 V If the speed sensor system fails no signal wiring short or open the ECU set the top 6 gear position Vehicle down Sensor Vehicle down Sensor Output Voltage signal Vd 0 2V 4 8V If the vehicle down sensor system has failures the output voltage Vd is more than usable range wiring open the ECU shuts off the fuel pump the fuel injectors and the ignition system Subthrottle Sensor See active and sensor must If the oxygen sensor 1 is not activated the Europe send signals output ECU stops feedback mode of the oxygen Models Subthrottle Sensor Output Voltage 0 2 4 8V The oxygen sensor 1 is voltage continuously to the ECU WWW Zo Pums eem If the subthrottle sensor system fails the signal is out of the usable range wiring short or open the actuator locks subthrottle valve at full open position sensor 1 and 2 348 MEL AS HEM DFI www zxforums com www zxforums com Self Diagnosis Service Output Signal Usable Codes Farts Range or Criteria SEKR Exhaust Exhaust Butterfly Valve If the exhaust butterfly valve system fails the Butterfly signal is out of the usable range wiring short 34 Output Voltage Valve or open the actuator locks exhaust butterfly 0 2 4 8 V oe Actuator valve at full closed posit
341. l seal D on the steering stem and drive the lower ball bearing inner race A applied the grease onto the stem Special Tools Steering Stem Bearing Driver B 57001 1344 Steering Stem Bearing Driver Adapter C 57001 1345 e Install the lower ball bearing A onto the stem e Apply grease Inner and Outer Races Lower and Upper Ball Bearings OThe lower and upper ball bearings are identical e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install Stem Cap D Steering Stem Nut E e Settle the bearings in place as follows OTighten the steering stem nut with 55 N m 5 6 kgf m 41 ft lb of torque first and loosen it a fraction of a turn until it turns lightly To tighten the stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 305 N 31 0 kgf 68 6 Ib B force in the direction shown Afterward tighten it again with specified torque using a special tool A Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 20 N m 2 0 kgf m 15 ft lb OFor the torque of 20 N m 2 0 kgf m 15 ft lb pull the wrench at the hole by 101 N 11 1 kgf 24 5 Ib force www zxforums com www zxforums com GNO5056BS1 o 6N05060581 o www zxforums com www zxforums com www zxforums com wit BERING 1 4 11 Steering Stem e Install the lock washer A so that claw B
342. lace the meter assembly www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 77 Meter Gauge Indicator Unit High Beam Indicator Light LED OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check e Using the insulated auxiliary lead 12 V battery to the me ter unit connector as follows OConnect the battery positive terminal to the terminal 17 OWhen the terminals are connected the high beam indica tor light LED should go on x If the turn signal high beam indicator light LED does not go on replace the meter assembly Fuel Level Warning Indicator Light LED OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check e Connect the variable rheostat A to the terminal 2 as shown e Adjust the resistance value to the approximately 10 Q OWhen the terminals are connected the fuel level warning indicator light LED A should oo op and the FUEL seg ments B flashes on the display x If the fuel level warning indicator light LED does not go on and or the Fuel segments does not displayed replace the meter assembly e Disconnect the terminal 2 OWhen the terminal is disconnected the fuel level warning indicator light LED A blinks and the FUEL segments B flashes on the display lf
343. lacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only
344. layed on the LCD re place the ECU see ECU section www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DE 3 103 Oxygen Sensor 2 not activated Service Code 83 Europe Models Oxygen Sensor 2 Removal Installation e Refer to the Oxygen Sensor Removal Europe Models in the Electrical System chapter see Oxygen Sensor Re moval Europe Models in the Electrical System chapter Oxygen Sensor 2 Inspection NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness Side is different e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch OFF e Remove left middle fairing see Middle Fairing Removal in the Frame chapter e Connect a digital meter A to the oxygen sensor 2 lead connector B sensor side using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor 2 Output Voltage Connections to Oxygen Sensor Connector Meter BK lead Meter GY lead e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal e Separate the hoses A from the air suction valve covers B e Install the suitable plugs A on the fittings of the air suction valve covers B and shut off the secondary air www zxforums com www zxforums com www zxforums com 3 1 04 FUEL RYST EM DFI www zxforums com www
345. le Control System Inspection in the Periodic Maintenance chapter Cable Installation e Install the throttle cables in accordance with the Cable Routing section in the Appendix chapter e Install the lower ends of the throttle cables in the cable bracket on the throttle assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Lubrication e Refer to the Chassis Parts Lubrication Performiin the Peri odic Maintenance chapter see Chassis Parts Lubrication Perform in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 125 Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Mainte nance chapter see Idle Speed Inspection in the Periodic Maintenance chapter Throttle Bore Cleaning e Check the throttle bore for cleanliness as follows ORemove the throttle body assy see Throttle Body Assy Removal OCheck the main throttle valves and throttle bores A for carbon deposits by opening the main throttle valves x If any carbon accumulates wipe the carbon off the throt tle bores around the throttle bores and the throt
346. le adapter set Special Tool Needle Adapter Set 57001 1457 Speed Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 7 Meter gt BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF lf the reading of input voltage is less than the standard check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power sup ply are good replace the ECU see ECU section x If the input voltage is within the standard range check the input voltage at the speed sensor connector e Disconnect the speed sensor connector A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM REI 3 73 Speed Sensor Service Code 24 e Connect the harness adapter A between the harness connector and speed sensor connector Special Tool Speed Sensor Measuring Adapter 57001 1667 e Connect a digital meter to the harness adapter leads Speed Sensor Input Voltage Connections to Adapter Meter BL lead A Meter BR BK lead B e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V x lf the reading
347. led apply engine oil to the surface of each plate to avoid clutch plate seizure e Install the last friction plate A fitting the tangs in the grooves in the housing as shown e Apply molybdenum disulfide grease to the pusher end A e Install the pusher B to the drive shaft direction as shown e Apply engine oil to the sliding surfaces of the bearing A e Align the grooves B of the spring plate C to the grooves D of the sub clutch hub E to install the spring plate on the sub clutch hub e Install the clutch springs and spring holders and tighten the clutch spring bolts Torque Clutch Spring Bolts 11 N m 1 1 kgf m 97 in Ib e Install the clutch cover see Clutch Cover Installation www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ww ECH 6 15 Clutch Spring Plate Free Play Measurement Insufficient clutch free play will cause the engine braking effect to be more sudden resulting in rear wheel hop On the other hand if the free play is excessive the clutch lever may feel spongy or pulsate when pulled e Hold an extra drive shaft in a vise and install the following clutch parts on the shaft see Clutch Installation Spacer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Sub Clutch Hub G Friction Plates H Steel Plates I Spring Seat J Spring K Clutch Spring Plate L e Eng
348. llowing the tighten ing sequence 1 10 Torque Cylinder Head Bolts M10 First 20 N m 2 0 kgf m 15 ft lb Final New Bolts 59 N m 6 0 kgf m 44 ft Ib Final Used Bolts 57 N m 5 8 kgf m 42 ft lb e Tighten the M6 cylinder head bolts 11 12 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib e Install Left and Right Front Engine Mounting Bolts see Engine Removal in the Engine Removal Installation chapter Front Camshaft Chain Guide A New O ring B Collar C OApply grease to the new O ring e Tighten Torque Front Camshaft Chain Guide Bolt Upper D 25 N m 2 5 kgf m 18 ft Ib Front Camshaft Chain Guide Bolt Lower E 1 2 N m 2 5 kgf m 106 in Ib e Install the removed parts see appropriate chapters GE14079BS2 C www zxforums com www zxforums com www zxforums com 5 30 ENGINE IOP END www zxforums com www zxforums com Cylinder Head Cylinder Head Warp e Clean the cylinder head e Lay a straightedge across the lower surface of the cylinder head at several positions e Use athickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface pl
349. loded WEE 12 2 ellene le 12 6 Special te aida di di as 12 7 Brake Lever Brake Pedal de ennn nnana 12 8 Brake Lever Position lee untada 12 8 Brake Pedal Position Inspection oococcccccccnnccnnnnnnnnnnnnnnnnnnnnnnnononononononnnnnnnnnnnnnnnnnininiss 12 8 Brake Pedal Position Adjustment omic 12 8 Brake Pedal Removal ss 12 8 Brake Pedal Installation ss 12 9 Callate Lodi NT 12 10 Front Caliper REMOVAl iii A A un ti 12 10 Rear Caliper Hemoval cnn see 12 10 Caliper Installation viciado ad 12 10 Front Caliper Disassembly EE 12 11 Lelleg EE 12 11 Rear Caliper RTE LEE 12 11 Rear Caliper E 12 11 Caliper Fluid Seal Damage ct di ale 12 11 Rear Caliper Dust Boot and Friction Boot Damage oooooccccccccccccooonaccnccononcnnnnananoncnnnnnnnnnnns 12 12 Caliper Pistemand Cylinder Damagg Zem kat 8 yay ES PR IA 12 12 Rear Caliper Holder Shaft Wear AE EE 12 12 Brake Pads human nn ne te an i a E ere ie as Front Brake Pad Removal tenn renr renere erent Front Brake Pad Installation Rear Brake Pad Removal ss Rear Brake Pad Installation Brake Pad Wear Inspection ee la EE Front Master Cylinder une ET 12 15 Front Master Cylinder Installation eeeeceeeceeeee eee eeeeeeeeeeeeeeeeeeeeeeaaaeeeeeeeeeeeesennnneeeeeeeees 12 15 Rear Master Cylinder Removal sion it 12 16 Rear Master Cylinder Installation 12 16 Front Master Cyli
350. lve Actuator Installation in the Fuel System DFI chapter a Me 41 7 7 A GE18043BS1 CAUTION Do not correct it with the tool forcibly WWW ZxXTOrUMS COM WWW ZXTOrUMS C www zxforums com www zxforums com www zxforums com ENGINE TOR END 5 47 Muffler CAUTION To keep the correct exhaust butterfly valve position adjust the open cable first e Install the close cable green A e Install the open cable yellow B and adjust the adjuster C until the clearance of part D of figure come to 0 mm 0 in CAUTION Do not overstretch e Tighten Torque Exhaust Butterfly Valve Cable Adjuster Locknut 7 0 N m 0 70 kgf m 62 in Ib e Adjust the adjuster E of the close cable until the clear ance of part D of figure come to 0 mm 0 in e After the adjust return the locknut to the half from one rotation e Tighten Torque Exhaust Butterfly Valve Cable Adjuster Locknut 7 0 N m 0 70 kgf m 62 in Ib e Cover the dust covers as shown 10 mm 0 39 in or less F 15 mm 0 59 in or less G e Install the clamp H GE180448 2 C e Apply a non permanent locking agent to the threads of the lower cover bolts and tighten it e Install the other removed parts see appropriate chap ters www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ww
351. ly wiped up immediately e Turn the ignition switch OFF e Remove the front seat see Front Seat Removal in the Frame chapter e Disconnect the battery terminal see Battery Removal in the Electrical System chapter e Remove Steering Damper see Steering Damper Removal in the Steering chapter Fuel Tank Bolts A e Disconnect the fuel pump lead connector A Goa F e For the California model remove the following Fuel Return Hose A front side red Fuel Tank Breather Hose B rear side blue e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less www zxforums com www zxforums com www zxforums com 3 1 36 FUEL SAYS EM DFI www zxforums com www zxforums com Fuel Tank e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D WARNING GCO9033BS1 The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage e Be sure to place a piece of cloth A around the fuel hose joint e Insert a minus screw driver B into the slit C on the joint lock e Turn A the driver to disconnect the joint lock B e Pull C
352. lybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Torque Fastener Se kgf m ftlb Remarks Fuel System Air Cleaner Element Cover Screws 1 1 0 11 9 7 in lb Air Cleaner Housing Holder Clamp Screws 2 0 0 20 18 in lb Air Cleaner Housing Mounting Bolts 7 0 0 71 62 in lb Air Inlet Duct Mounting Bolts 7 0 0 71 62 mb L Bypass Screws 0 2 0 02 17 in lb Camshaft Position Sensor Bolt 10 1 0 89 mb Canister Bracket Mounting Bolt M5 4 3 0 44 38 in lb Canister Bracket Mounting Screws M5 4 3 0 44 38 in lb Crankshaft Sensor Bolts 6 0 0 61 53 in lb L Delivery Pipe Mounting Screws 5 0 0 51 44 in lb Exhaust Butterfly Valve Actuator Mounting Bolts 0 8 0 08 7 in lb Exhaust Butterfly Valve Actuator Pulley Bolts 5 0 0 51 44 in lb Fuel Pump Bolts 10 1 0 89 in lb L S Gear Position Switch Screws 3 0 0 31 27 in lb L Inlet Air Pressure Sensor Bracket Screws 3 5 0 36 31 in lb Separator Bracket Mounting Bolts 7 0 0 71 62 mb Separator Canister Hose Clamp Bolt 7 0 0 71 62 in lb Speed Sensor Bolt 10 1 0 89 in lb Throttle Body Assy Holder Bolts 10 1 0 89 in lb Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb Vehicle down Sensor Bolts 6 0 0 61 53 in lb Water Temperature Sensor 25 2 5 18 SS Cooling System Coolant By pass Fi
353. m 13 ft lb e Replace the rear exhaust pipe gasket J with a new one Olnstall the rear exhaust pipe gasket until it is bottomed so that the chamfer side outer faces rear exhaust pipe K e Install the rear exhaust pipe clamp bolt L as shown OFit the projection M of the rear exhaust pipe into the slot N in the clamp e Install the rear exhaust pipe OFit the damper O of the rear exhaust pipe into the stopper P of the middle exhaust pipe e Install the left and right muffler body see Muffler Body Installation e Tighten Torque Rear Exhaust Pipe Clamp Bolt 17 N m 1 7 kgf m 13 ft lb GE180408W2 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com EN GINE TOR END 5 43 Muffler e Install the exhaust butterfly valve cable and adjust see Exhaust Butterfly Valve Cable Installation e Throughly warm up the engine wait until the engine cools down retighten all the bolts e Install the removed parts see appropriate chapters Front Exhaust Pipe Removal e Remove Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Oxygen Sensor Lead Connectors Europe Models see Oxygen Sensor Removal Europe Models in the Elec trical System chapter Front Exhaust Pipe Holder Nuts A e Loosen the middle exhaust pipe clamp bolt A e Remove the front exhaust pipe B to forward www zxforums com www zxforums com www zxforums com
354. m 52 ft lb of torque e Remove the rotor bolt and washer e Check the tightening torque with flywheel puller A lt the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Install the rotor bolt and washer e Tighten the alternator rotor bolt A while holding the alter nator rotor steadily with the holder B Special Tools Grip C 57001 1591 Rotor Holder Stopper M38 x 1 5 D 57001 1658 Rotor Holder 57001 1666 Torque Alternator Rotor Bolt 155 N m 15 8 kgf m 114 ft lb e Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output www zxforums com www zxforums com www zxforums com 16 34 ELECTRICAL SYSTEM www zxforums com www zxforums com Charging System e To check the alternator output voltage
355. m 72 ft lb e Tighten the swingarm pivot shaft nut A Torque Swingarm Pivot Shaft Nut 108 N m 11 0 kgf m 80 ft lb e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSPENSION 1 3 25 Swingarm Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeve C Circlip Right Side D Special Tool Inside Circlip Pliers 57001 143 e Remove the ball bearing and needle bearings Special Tools Oil Seal amp Bearing Remover A 57001 1058 Bearing Remover Head 57001 1293 Bearing Remover Shaft 57001 1377 GMOGO79BS1 Swingarm Bearing Installation y e Replace the ball and needle bearings with new ones e Install the ball and needle bearings so that the manufac A turer s marks face out gt Special Tool Needle Bearing Driver 628 57001 1610 SIZXTO17S1 e Install the needle bearings A ball bearing B and oil seals C position as shown Circlip D 32 mm 1 26 in E 17 mm 0 67 in F 0 5 mm 0 02 in G 1 mm 0 04 in H 10 5 mm 0 41 in I 28 mm 1 10 in J 6H06096BWi C www zxforums com www zxforums com www zxforums com 1 3 20 URRENSION www zxforums com www zxforums com Swingarm Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspecti
356. m www zxforums com ELECTRICAL SYSTEM 416 1 1 1 Fuse e Pull the ECU fuse A straight out of the fuse box with needle nose pliers Fuse Installation x If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the junction box fuses on the original position as specified on the lid Fuse Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element xlfit is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D GP20000181 NOTE Olf a mass current flows to the battery which needs re freshing charge when the engine is turned the main fuse may be blown out CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wh BRENDIX 1 7 1 Appendix Table of Contents Cable Wire and Hose Fe IER eege Eege 17 2 Troubl Shooting GUIS
357. mHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kw x 1 360 PS N x 02248 ib kW x 1341 HP kg 2 EE Er N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature 9 C 40 5 F 40 la SUERO _ 46 6 32 68 104 176 212 248 284 40 80 100 120 140 160 180 200 220 240 260 280 300 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANGE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque and Locking Be EE 2 6 Specifications miii dla aida 2 13 Special TOS EE 2 15 Maintenance Procedure miii A ii 2 16 Fuel System Delano did 2 16 Throttle Control System Inspeccion api 2 16 Engine Vacuum Synchronization Inspection 2 16 Idle Speed INSPECUON EE 2 19 Idle Speed Adjustment scene tn ie en D Rs A need nn tie de 2 20 Fuel Hose Inspection fuel leak damage installation condition 2 20 Evaporative Emission Control System California Model 2 21 Evaporative Emission Control System Inspection oooooocccocccinncicocccoccocccnonanonnnrrnnrrnnnnnn nn 2 21 oo NS RENAE C a EE E ented sans ce cateca E A ote tir secnenedlie ai aan 2 22 Coolant Level Inspection ss 2 22 Radiator Hose and Pipe Inspection coolant leak damage installation condition 2 22 Engine Top Envia os 2 22 Valve Cl
358. main throttle sensor connector A e Connect the harness adapter A between the harness connector and main throttle sensor connector e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Input Voltage Connections to Adapter Meter W sensor BL lead Meter gt BK sensor BR BK lead e Reinstall the throttle body assy See Throttle Body Assy Installation e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF x lf the reading is out of the range check the wiring see wiring diagram in this section x lf the reading is good check the output voltage of the sensor www zxforums com www zxforums com www zxforums com 3 52 FVEL GLEN DFI www zxforums com www zxforums com Main Throttle Sensor Service Code 11 Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Output Voltage Connections to ECU Connector Meter gt Y W lead terminal 26 Meter BR BK lead terminal 34 e Start the engine and warm it up thoroughly e Check idle speed to ensure
359. meter is lesssthan the service limit replace the camshaft with a new one and measure the clearance again xlf the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in www zxforums com www zxforums com GE11089BS1 GE11090BS1 www zxforums com 5 26 ENGINE IOP END www zxforums com www zxforums com Camshaft Camshaft Chain Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft O Cam Height Standard Exhaust 34 443 34 557 mm 1 3560 1 3605 in Inlet 35 043 35 157 mm 1 3796 1 3841 in amp E11012251 Service Limit Exhaust 34 34 mm 1 352 in Inlet 35 94 mm 1 376 in Camshaft Chain Removal e Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TOP END 5 2
360. mm 20 2 0 15 S Cragg Cange Cup L 45 mm www zxforumsj com 2 1 2 106 impn zxforugs com www zxforums com www zxforums com PERIODIC MAINTENANGE 2 9 Torque and Locking Agent Torque Fastener Nom KE M Pe Remarks Crankcase Bolts M6 L 40 mm 12 1 2 106 in lb S Drive Shaft Cover Bolts 25 2 5 18 Gear Position Lever Bolt 12 1 2 106 in lb Oil Passage Plugs 20 2 0 15 L Piston Oil Jet 3 0 0 31 27 in lb Plate Screw 5 0 0 51 44 L Plug 20 2 0 15 Shift Drum Bearing Holder Screws 5 0 0 51 44 in lb L Shift Drum Cam Holder Bolt 12 1 2 106 in Ib L Shift Fork Hold Bolt 12 1 2 106 in lb L Shift Lever Bolt 7 0 0 71 62 in lb Shift Pedal Mounting Bolt 25 2 5 18 Shift Shaft Return Spring Pin 29 3 0 21 L Tie Rod Locknuts 7 0 0 71 62 in lb Wheels Tires Front Axle Clamp Bolts AL Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts 10 1 0 89 in lb Engine Sprocket Nut 125 12 7 92 MO Rear Axle Nut 108 11 0 80 Rear Sprocket Nuts 59 6 0 44 Brakes Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 9 in lb Si Brake Lever Pivot Bolt Nut 5 9 0 60 52 in lb Brake Pedal Bolt 8 8 0 90 78 in lb Bleed Valves 7 8 0 80 69 in lb Front Brake Disc Mounting Bolts 27 2 8 20 L Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Brake Master Cylinder Bleed Valve 5 4 0 55 48 in lb Front Brake Pad Pins 15 1 5 11 Front Brake Reservoir Cap Stopper Screw 1 2 0 12 11 in lb Front Caliper Assembly
361. mounting bolts from the right side ORemove the collar while pulling out the middle engine mounting bolt e Remove the right front engine mounting bolts C www zxforums com www zxforums com www zxforums com 8 8 ENGINE REMOVALIINSTALLATJONums com Engine Removal Installation www zxforums com e Using the nut wrench A loosen the locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the adjusting collar A counterclockwise to make the gap between the engine and adjusting collar e Remove the drive chain A from the output shaft B e Using the stand take out the engine Engine Installation e Support the engine with a suitable stand OPut a plank onto the suitable stand for engine balance e Install the heat insulation rubber plate onto the engine as shown www zxforums com www zxforums com www zxforums com www zxforums com www zxfor eun E REMOVALII NRTALLALION 8 9 Engine Removal Installation GHO4060BW4 C A White Mark K Crankshaft Sensor Lead B To Radiator L Through the water hose under the heat insu C To Right Engine Bracket Cylinder Head lation rubber plate Side M Through the starter motor cable under the D Through the left engine bracket bolt water hose E To Camshaft Position Sensor Lead N Gear Position Switch Water Temperature F To Air Suction Valve Cover and Stick Coil Sensor Lead Harness G To Throttle Body Assy H
362. mova nn nnnnnc nano nannnnnnos 13 28 Tie Rod and Rocker Arm Bearing Installatton 13 28 Rocker Arm Tie Rod Bearing Sleeve Inspection ooooccocccocicicicicoccoconoccnnonnnonnnrrnnrnnnnnn nro 13 30 Rocker Arm Tie Rod Bearing Lubrication A 13 30 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 13 2 AUSRENSIO N Exploded View 6M02148BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SURE EN RLOM 13 3 Exploded View Torque No Fastener N m kgf m Pe Remarks 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Fork Bottom Allen Bolts 23 2 3 17 L 3 Front Fork Clamp Bolts Lower 30 3 1 22 AL 4 Front Fork Clamp Bolts Upper 20 2 0 15 5 Front Fork Top Plugs 23 2 3 17 6 Piston Rod Nuts 15 1 5 11 AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 13 4 AUSRENSIO N Exploded View www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SHRPENSIQN 1 3 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Rear Shock Absorber Bracket Nut 59 6 0 44 2 Rear Shock Absorber Nut Lower 34 3 5 25 3 Rear Shock Abso
363. moval in the Final Drive chapter Bolts A Chain Cover B Inner Fender C e Remove Bolt A Brake Hose Clamp B GMO6098BS1 e Remove Upper Tie Rod Nut and Bolt A Rear Shock Absorber B see Rear Shock Absorber Re moval e Unscrew the swingarm pivot shaft nut C e Loosen the swingarm pivot collar locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Unscrew the swingarm pivot shaft A few times OTurn out the swingarm pivot adjusting collar e Pull out the pivot shaft from the right side of the motorcycle and remove the swingarm www zxforums com www zxforums com www zxforums com 1 3 24 QUSRENSION www zxforums com www zxforums com Swingarm Swingarm Installation e Apply plenty of grease to the lip A of the oil seals e Install the collar e Place the adjusting collar A into the frame B as shown 11mm E 6M06041BS1 C e Insert the pivot adjusting shaft A into the frame from the right side e Tighten the pivot shaft so that the clearance between the adjusting collar B and the ball bearing C come to 0 mm 0 in Torque Swingarm Pivot Adjusting Shaft 20 N m 2 0 kgf m 15 ft lb e Tighten the adjusting collar locknut A with the swingarm pivot nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Adjusting Collar Locknut 98 N m 10 0 kgf
364. move Front Seat see Front Seat Removal in the Frame chap ter Relay Box A e Using a small chisel or other suitable tool cut off the screws A e Remove Upper Guard Bracket B Lower Guard Bracket C e Take out the ECU A and disconnect the connectors B e Connect the ECU connectors e Insert the slits of the rubber protector to the projections A of the rear fender front e Install the trim A to the lower guard bracket B as shown GP30206BS1 www zxforums com www zxforums com www zxforums com 16 98 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models e Install Lower Guard Bracket A Upper Guard Bracket B CAUTION Do not pinch the leads e Tighten new screws C use Kawasaki genuine screws of which threads are coated with locking agent Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Key Key Red Black Ignition An Ampli Switch tenna fier Master Key Red User Key Black Ignition Switch Replacement Part o Main Replacement Part O Additional Replacement Part Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in Fuel System DFI chapter see Immobilizer Amplifier and Blank Key Detection section in Fuel System DFI chapter www zxforums com www zxforums
365. move the circlips disassemble the transmission shafts 3 des g Special Tool Outside Circlip Pliers 57001 144 ADA e The 5th gear A on the output shaft has three steel balls ch n S y assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward G113082B e Remove the ball bearing A with collar B from the output shaft Special Tools Bearing Puller C 57001 135 Bearing Puller Adapter D 57001 317 e Discard the bearing G113266BS1 Transmission Shaft Assembly e Install the new ball bearing A and collar B on the output shaft using the bearing driver Spacial Tool Bearing Driver 632 57001 382 G113267BS1 www zxforums com www zxforums com www zxforums com 9 34 GRANIRIAF T TRANSMISSIQN storums com www zxforums com Transmission e Apply engine oil to the bushings ball bearings and shafts e Install the gear bushings A on the shaft with their holes B aligned e Replace any circlips removed with new ones e Install the circlips A so that the opening B of it is aligned with spline grooves C e Install the circlips so that the mark D on them faces to each gear side e The drive shaft gears can be recognized by size the gear with the smallest diameteris 1st gear and the largest one is 6th
366. mption that the inlet and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Pull offthe rubber caps A from the fittings of each throttle body e For the California Model pull off the vacuum hoses B e Plug the engine breather hose end A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 1 7 Maintenance Procedure e Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 e Connect a highly accurate tachometer to one of the stick coil primary leads e Connect Fuel Pump Lead Connector Extension Tube A Special Tool Extension Tube 57001 1578 e Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer B x If the idle speed is out of the specified range adjust it with the adjust screw CAUTION Do not measure the idle speed by the tachometer of the meter unit e While idling the engine inspect the throttle body vacuum using the vacuum gauge C Throttle Body Vacuum Standard 31 5 1 3 kPa 236 10 mmHg at Idle Speed 1 100 50 r min rpm lf any vacuum is not within specifications first synchro nize the balance of the left 1 2 throttle valv
367. ms com www zxforums com www zxforums com www zxforums com wwx RAM 15 9 Fairings Lower Fairing Removal e Pull up the core A by the thin blade driver B e Remove Quick Rivets A Bolts B with Washers Screws C e Separate the right lower fairing D from the left lower fair ing e Clear the hook portion and projection E from the slots e Remove the right lower fairing Lower Fairing Installation e Insert the hook portion A into the slot B and put the projection C into the hole D e Tighten the bolts with washers e Set the quick rivet A and push the core B Middle Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Upper Inner fairings see Upper Inner Fairing Removal Bolts A with Washers Quick Rivets B e Disconnect the right turn signal lead connector e Clear the hook portions D from the slots by pulling the middle fairing backward e Remove the right middle fairing C www zxforums com www zxforums com www zxforums com 15 1 ALBAME com www zxforums com www zxforums com Fairings For the California Model N ORemove AN Band A SA Canister B A mg A af ELA e OClear the right switch housing lead from the clamp A ODisconnect the right turn signal lead connector B e Disconnect the left turn signal lead connector A e Clear the left switch housing lead and ignition switch lead from the clamp B Middle Fairing Installa
368. n www zxforums com www zxforums com www zxforums com FUEL SYSTEM DED 3 139 Evaporative Emission Control System The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Al though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Connect the hoses according to the diagram of the sys tem Make sure they do not get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter see Evapo rative Emission Control System Inspection in the Periodic Maintenance chapter Separator Inspection e Refer to the Evap
369. n materials that may collect before re assembly 68020088 S Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol ES oration or other damage Refer to the appropriate sections f JN i of this manual for service limits on individual parts Replace S the parts if any damage has been found or if the part is be NT yond its service limit 680200 8 Replacement Parts Replacement Parts must be KAWASAKI genuine or Ba E recommended by KAWASAKI Gaskets O rings oil seals WE grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 S Assembly Order a In most cases assembly order is the reverse of disassem En io bly however if assembly order is provided in this Service a e Se Manual follow the procedures given 2 PE lOs SS eh lt et Le lt En SS gt k ege A LD ES A e E pa SC MAA E 1 SA 68020118 S www zxforums com www zxforums com www zxforums com 1 4 GENERAL INFORMATION www zxforums com www zxforums com Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts o
370. n Shaft Installation e Check to see that the set pin A and set ring B are in place e Install the output shaft into the upper crankcase half e Apply engine oil to the sliding surface of the gears and bearings OThe bearing set pin and ring must match properly with the hole or groove in the bearing outer races When they are properly matched there is no clearance between the crankcase and the bearing outer races e When the new ball bearing A is installed in the drive shaft cover B press and insert the new ball bearing so that seal surface side C faces to drive shaft cover bearings e Install the drive shaft into the lower crankcase half e Replace the O ring A with a new one e Apply grease to the new O ring e Install the dowel pin B e Fit the pin of the crankcase into the hole C in the drive shaft cover D e Tighten Torque Drive Shaft Cover Bolts 25 N m 2 5 kgf m 18 ft Ib www zxforums com www zxforums com www zxforums com www zxforums com www zxforu mERAN KSHAFT TRANPMISAL N 9 33 Transmission e Assemble the crankcase see Crankcase Assembly e Press in the new oil seal A onto collar B so that the surface of the oil seal is flush with the counterbore bottom surface C of the crankcase OApply high temperature grease to the oil seal lips Transmission Shaft Disassembly d e Remove the transmission shafts see Transmission Shaft Se Removal e Re
371. n damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 13 B 57001 1377 Bearing Remover Head 20 x 22 C 57001 1293 Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding x If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakag
372. nce with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection INSPECTION Fuel System Throttle control system play smooth return no drag inspect FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile Engine vacuum synchronization inspect Idle speed inspect year Fuel leak fuel hose and pipe inspect Oo Oo year e Fuel hose and pipe damage inspect Fuel hose and pipe installation aap x condition inspect y e 2 19 e 2 20 Evaporative Emission Control System CAL Evaporative emission control system function inspect Cooling System Coolant level inspect DD Coolant leak radiator hose and pipe inspect Radiator hose damage inspect Radiator hose installation condition inspect Engine Top End Valve clearance inspect Air Suction System Air suction system damage inspect Clutch Clutch operation play disengagement engagement inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect e 2 28 Wheel bearing damage inspect beet fie fie e 2 29 Every 600 km 400 mile 2 30 Every 1 000 km 600 mile 2 30 Drive chain wear inspect e e 2 32 Drive ain guide wear inspect e e 2 33 2 4 PERJQRIC MAINTENANCE www zxfo
373. nd C are in place Front D e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten the fuel pump bolts to a snug fit following the tight ening sequence shown e Following the tightening sequence tighten the pump bolts to the specified torque Torque Fuel Pump Bolts 10 N m 1 0 kgf m 89 in Ib e Tighten the pump bolts again to check the tightness in the order shown GC17380BS1 Operation Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 4 seconds and then stops e Turn the ignition switch OFF If the pump does not work as described above inspect the operating voltage Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the left side cover see Side Cover Removal in the Frame chapter e Connect the hand tester x 25 V DC to the connector A with needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Pump Operating Voltage at Pump Connections to Pump Connectors Tester BK Y Lead Tester BK W Lead e Measure the operating voltage with the engine stopped and with the connector joined e Turn the ignition switch ON OThe tester needle should indicate battery voltage for 4 seconds and then 0 V Operating Voltage at Pump Connector Standar
374. nder Disassembly 2 22 cccccceeeececcceneeeeneeseeeeceeeeeeeeenesdneeeeneereeteneas 12 16 Rear Master Cylinder Disassembly 12 16 Master Cylinder Assembly sieiecceiecessetec tenn ancoe oie ie Rada ias hades 12 16 Master Cylinder Inspection Visual Inspechon 12 17 Brake Dia 12 18 Brake Ce Removal denotar title 12 18 Brake Disc Installation a ias 12 18 Brake DISCS se Ee EE 12 18 Brake DISC UE Le E 12 18 Brake LEET 12 19 Brake Fluid Level Inspechon tEn AEAEE EEEE EEEEEE EEEE AEAEE EEEE EEEE EEEE 12 19 Brake Fluid Chang ata rt ii A ete dote 12 19 Brake Eine BISCO e EE 12 19 Brake e 12 23 Brake Hose Removal Installation ss 12 23 Brake Hose Inspection aaa e rome Oido 12 23 www zxforums com www zxforums com www zxforums com 12 2 RRARES com www zxforums com www zxforums com Exploded View CLO 19 6L021828W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www BRAKES 1 2 3 Exploded View No Fastener N m kgf m Pe Remarks 1 Bleed Valves 7 8 0 80 69 in Ib 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Lever Pivot Bolt 1 0 0 10 9 in lb Si 4 Brake Lever Pivot Bolt Nut 5 9 0 60 52 in lb 5 Front Brake Disc Mounting Bolts 27 2 8 20 L 6 Front Brake Light Switch Screw 11 in lb 7 Front Brake Pad Pins S 11 8 Front Brake Reservoir Cap Stopper Screw 11
375. ne check the brake for good braking power no brake drag and no fluid leakage www zxforums com www zxforums com GLO9037BS2 C Ni cy Z or eee www zxforums com 12 22 RBARES om www zxforums com www zxforums com Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pad
376. ness con nector and subthrottle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Meter BK sensor BL lead Meter gt W sensor BR BK lead e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF x If the reading is out of the range check the wiring see wiring diagram in this section lf the reading is good check the output voltage of the sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connectors B Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Output Voltage Connections to ECU Connector Meter BL W lead terminal 27 Meter BR BK lead terminal 34 e Turn the ignition switch ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Output Voltage at ECU Standard DC 0 77 4 22 V at subthrottle valve full opening to closing NOTE OThe throttle sensor is operating correctly if the following voltages are obtained e DC 0 77 V or slightly higher with the subthrottle valve at the closed position e DC 4 22 V or sligh
377. ng Insert Journal Wear e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance G1050304 S Crankshaft Main Bearing Insert Journal Clearance Standard 0 010 0 034 mm 0 0004 0 0013 in Service Limit 0 06 mm 0 0024 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 035 mm 0 0014 in and the service limit 0 06 mm 0 0024 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed 0105041751 0 the standard slightly but it must not be less than the min imum in order to avoid bearing seizure lf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 34 984 35 000 mm 1 3773 1 3780 in Service Limit 34 96 mm 1 3764 in x If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markin
378. nition switch lead Clutch Cable Clamp Throttle Cables Viewed A Through the clutch cable into the bracket Through the clutch cable into the engine bracket Evaporative Hoses California Model only Run the clutch cable above the evaporative hoses California Model only Attend the distribution of the front brake light switch connector www zxforums com www zxforums com www zxforums com 1 76 APBEN RIX m www zxforums com www zxforums com Cable Wire and Hose Routing a NS Dy INS NS 4 8 E y lee 5 EF AE y S d 4 SOC Er OC el 00 E el SCC 6B09886BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wh BRENDIX 1 7 7 Cable Wire and Hose Routing JO O1 PB amp ND Right Headlight Connector Right City Light Connector Right Turn Signal Light Connector Right Switch Housing Lead Clamp the right switch housing lead Horn Engine Subharness Joint Connector To the Throttle Assy Inlet Air Temperature Sensor To the Air Cleaner Box Starter Relay Frame Ground Lead Regulator Rectifier Rear Brake Light Switch Lead Battery Positive Terminal Battery Negative Terminal Clamp the fuel pump lead connector to the bracket Heat Pad Starter Relay Lead Front Frame Rear Fram
379. njector connectors Remedy see chapter 3 Crankshaft sensor trouble Inspect and repair or replace see chapter 16 Stick coil trouble Inspect and repair or replace see chapter 16 Loose terminal of battery lead or engine Inspect and repair see chapter 16 ground lead Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU see chapter 16 Poor accelerati n yO Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Clogged fuel filter or pump screen Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Stick coil trouble Inspect and replace see chapter 16 Engine oil level to high Repair see chapter 7 Spark plug dirty broken or gap maladjusted Replace see chapter 2 inspect see chapter 3 Suge Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sen
380. nnect the battery negative terminal to the terminal 5 OWhen the terminals are connected the neutral indicator light LED should go on x If the neutral indicator light LED does not go on replace the meter assembly GP17428BS1 Warning Indicator Light LED Oil Pressure Warning Inspection OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check e Using the insulated auxiliary lead 12 V battery to the me ter unit connector as follows OConnect the battery negative terminal to the terminal 13 light LED A and symbol B blinks x If the warning indicator light and or symbol do not blinks OWhen the terminals are connected the warning indicator HA replace the meter assembly gt Ss RESET Right and Left Turn Signal Indicator Light LED OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check e Using the insulated auxiliary leads 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 15 OConnect the battery negative terminal to the terminal 16 GP17431BS1 OWhen the terminals are connected the turn signal indica tor light LED should go on x lf the turn signal indicator light LED does not go on re p
381. nnnnnnanana nana nanan ana na nora no na nnn nana no 7 10 Oil Pressure Relief Valve Inspection 7 11 OI PUMP EE 7 12 Oll Pump Removale cistitis a 7 12 Ol Pump Installation deal 7 12 Oil Pump Gear Removal em sisi 7 13 Oil Pump Gear InstallatiON coo ft 48 2 LM RER EAN 7 13 SAT AMA A AA O A o O ER NE 7 15 Oll Coler Removal ici ie ias 7 15 Oil Cooler Installation cano nccanonannnnccnonanaco narco na rnn anno nn nana naniannno 7 15 Oil Cooler Oil Filter Case Removal narco no nono na nan nac na nanananns 7 15 Oil Cooler Oil Filter Case Installation oonnnnnnnnnninnonocininininnccnnnn cana nancn arca nn rn nn naa nano nana 7 16 Oil Pressure Measurement A EE 7 17 Oil Pressure Measurement cono ncnnonn nano nanna na Enn narra nn nana naanannn 7 17 OIPressure Wilhem A al io 7 18 Oil Pressure Switch Removal occcccccccncccccnccnnnccnonanaconacnnnannonacononannn nanne nn nano na ran na cnannannnnns 7 18 Oil Pressure Switch Installation o onnn nnnnnnnnananininnnccnnncana naciona nacin nana na rn n nac n cnn cana nanannnos 7 18 www zxforums com www zxforums com www zxforums com 7 2 ENGINE URRI CATION SYS TAM torums com www zxforums com Exploded View 6 020728 5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxtorumE MINE LUBRICATION A MATEM 7 3 Exploded View Torque No Fastener Nem kgfm ftIb Remarks 1 Eng
382. nsor Peak Voltage Inspection 16 46 Interlock Operation Inspection 16 46 IC ele ee EE 16 47 TAS IA WWW ZXPOFUPAS Cem www zxforums com106 49 Starter Idle Gear Rem ER tt 16 49 1 6 2 FLERTRICAL SYSTEM www zxforums com www zxforums com Starter Idle Gear Installation e a os 16 49 Starter Clutch Remova EE 16 51 Starter Clutch Installation nl A ne terne RER 16 51 Starter Clutch Disassembly apisia on ane detente ann don de tados rs tenant 16 52 Starter Clutch Assembly ann terne ennemies ntenns 16 52 Starter Clutch Inspection seen 16 52 Starter Motor Removal 16 53 Starter Motor Installation utero ai te 16 54 Starter Motor TEE 16 54 Starter Motor Assembly EE 16 55 Brush ee e EE 16 57 Commutator Cleaning and Inspection 16 57 NES 16 57 Brush Lead Inspection 16 58 Right hand End Cover Assembly Inspection AA 16 58 Starter Relay Inspection sinus on 16 58 A A 16 60 Headlight Beam Horizontal Vertical Adjustment ooonnnnnncccccnnnnncccnnncnconncnncncnnnnnanrnnccncnnnnns 16 60 Headlight Beam Vertical Adjustment 16 60 Headlight IIe Ne En LE 16 60 City Light Bulb Replacement cocidas A A 16 61 Headlight Removal Installation nnnnncccnnnn 16 61 Tall Brake Light LED ReEmOVal court a e dies 16 62 Tail Brake Light LED Installation nee ess rame entr restau 16 62 License
383. nst al tion s sas A AA AA nn 15 10 Windshield Removal o ooccccncccnncccccnccnnncccnnanononccnnnccannncononcnnnnanc conca noncnnn nana nnncc conca darki aa annaa 15 10 Windshield Installation nano nccnnncnanancnnoncnnn nano conan nnnacnnnanas 15 11 Upper Fairing Removal miii da 15 11 Upper Fairing Disassembly ecc 15 11 Upper ge E e EE 15 11 Upper Fairing Installation tenn nen erenn eneren ene 15 11 Upper Inner Fairing Removal 15 12 Upper Inner Fairing Installation 15 12 Center Inner hairna Remoyal gt 7 gy kat A ken a m IRL ee 15 12 Center one aringWnsieVatio LW NIUE AAL De RRB De 15 12 Right and Left Inner Fairing Removal ss 15 13 Right and Left Inner Fairing Installation 15 13 Side COVErS a tt DEA A A ARA AA A 15 14 SId Cover Removal itunes A Ae a 15 14 Side e ln EE UE e E 15 14 ATA A A ten calle hat ot NR cenit cy ah asennad bas 15 15 Seat Cover REMOVAl a sie Ae be ote atin ake Yee de ea aya eege AE ee ee 15 15 Seat Ein E EE e EE 15 16 A RR Front Fender Removal Front Fender Installation ooooonnccconnccnncncnincncnnnncnncnanancnnoncnnnnncnnoncnnonannn nana nan nano nann nana 15 17 Rear Fender Rear Removal iii nn conca nonano nan cnnnnann nana n nana nanacn nacos 15 17 Rear Fender Rear Installation iii iii cnn nan cn nana nana nn on anananann cnn 15 18 Rear Fender Front Removal occcco
384. oblem occurs with DFI system the warning indicator light LED A and FI warning symbol B blinks to alert the rider In addition the condition of the problem is stored in the memory of the ECU For models eqquipped with an immobilizer system the warning indicator light LED and immobilizer warning symbol C blinks when a problem occurs in the system QE st Le CLOCK Zu nn Zua al CUU 6017197082 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 25 Troubleshooting the DFI System With the engine stopped and turned in the self diagnosis mode the service code A is displayed on the LCD Liquid Crystal Display by the number of two digits 6017269082 When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line Tor no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the warning indicator light LED and Fl warning symbol Don t rely solely on the DFI self diagnosis function use common sense 6017144051 Even when the DEI system is operating normally the warning indicator light LED and Fl warning symbol may blink under strong electrical interference Additional mea sures
385. of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 1 General Information Table of Contents Before ln Le DEE Model Identification ses General Specifications EE Unit Conversion Table siennes www zxforums com www zxforums com www zxforums com 1 2 GENERAL INFORMATION www zxforums com www zxforums com Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon q nect the battery cables from the battery to prevent the en Y_ IG gine from
386. off any excess oil Oil Applied Areas A O ring B GKO040607S1 Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 30 35 mm 1 2 1 4 in 6S12021BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 31 Maintenance Procedure Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the rear axle nut e B e Loosen the both chain adjuster locknuts C lf the chain is too loose turn out the left and right chain adjuster D evenly lf the chain is too tight turn in the left and right chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may res
387. ohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 57 Maintenance Procedure e Apply brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Tighten the brake lever pivot bolt and the nut Silicone Grease Brake Lever Pivot Bolt Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Nut 5 9 N m 0 60 kgf m 52 in lb Front Brake Light Switch Screw 1 2 N m 0 12 kgf m 11 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper pad pins A and banjo bolt B and tighten them loosely e Remove Front Caliper see Front Caliper Removal in the Brakes chapter C Brake Pad Front Caliper Assembly Bolts O rings e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of
388. oil or almost zero 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester Inspect Crankshaft sensor peak voltage 1 Adapter connection is Camshaft position sensor incorrect or adapter is peak voltage defective Ignition switch and engine stop switch Crankshaft sensor peak voltage Camshaft position sensor peak voltage Replace bad parts ECU is defective Replace ECU Replace bad parts or inspect them with KAWASAKI Hand Tester www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 39 Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the ECU Crankshaft Sensor Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Crankshaft Sensor Lead Connector A e Remove Starter Clutch Cover see Starter Clutch Removal Starter Idle Gear see Starter Idle Gear Removal Bolts A Crankshaft Sensor B Crankshaft Sensor Installation e Apply a non permanent locking agent to
389. ol or soap and water solution e Replace the headlight bulb e Fit the projection A of the bulb in the hollow B of the headlight www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 61 Lighting System e Turn the headlight bulb A clockwise e Connect the headlight connector e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter City Light Bulb Replacement e Remove the upper inner fairing see Upper Inner Fairing Removal in the Frame chapter e Pull out the socket A together with the bulb e Pull the bulb A out of the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Replace the bulb with a new one e Insert the socket and to the headlight OAlign the projections A of the socket and the grooves B of the headlight Headlight Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Center Inner Fairing see Center Inner Fairing Removal in the Frame chapter Meter Bracket Screws A and Clamp Headlight Mounting Screws B Headlight C e Tighten Torque Headlight Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib www zxforums com www zxforums com www zxforums com 16 62 FLEG TRIGAL SYSTEM www zxforums com ww
390. older Stopper M38 x 1 5 57001 1658 Rotor Holder 57001 1666 Torque Starter Clutch Bolt 49 N m 5 0 kgf m 36 ft lb e Install the removed parts see appropriate chapters Starter Clutch Disassembly e Remove Starter Clutch see Starter Clutch Removal Snap Ring A e Pull the one way clutch B out of the starter clutch case C Starter Clutch Assembly e Install the one way clutch A so that its circlip side B faces in e Install the new snap ring Starter Clutch Inspection e Remove Starter Clutch Cover see Idle Gear Removal Idle Gear Starter clutch side see Idle Gear Removal e Turn the starter clutch gear A by hand The starter clutch gear should turn counterclockwise freely B but should not turn clockwise If the starter clutch does not operate as it should or if it makes noise go to the next step www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 53 Electric Starter System e Disassemble the starter clutch see Starter Clutch Disas sembly and visually inspect the clutch parts One way Clutch A Starter Clutch Case B x If there is any worn or damaged part replace it OExamine the starter clutch gear C as well Replace the clutch gear if it is worn or damaged Starter Motor Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal
391. older O Alternator Lead H Right Front Engine Mount P To Breather Tube and Middle Engine Mount I To Thermostat Case Q After installation set the projection in the hole J To Water Temperature Sensor www zxforums com www zxforums com www zxforums com BTOERGINKRENOVALUTNSTALKAUMR em www zxforums com Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing sequence OApply molybdenum disulfide grease to the threads of the adjusting collars A OApply 2 stroke oil to the threads of the adjusting collar B OFirst install the adjusting collars A B to crankcase and frame Crankcase C Frame D 6H040618W2 C OSecond hang the drive chain over the output shaft just before mounting the engine into its final position in the frame OThird install the bolts A B C D temporally and tighten the bolt C OWhen installing the middle engine mounting bolt B in stall the collar E between frame and crankcase Torque Left Front Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft lb OForth Insert the lower A and middle B engine mount ing bolts to the adjusting collars F and tighten the bolts counterclockwise NOTE OTighten the bolts until the clearance G between the engine and collar come to 0 mm 0 in Torque Middle Engine Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb Lower Engine Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb
392. om GP12221BW3 C www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 67 Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter see Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter e Set the hand tester A to the x Q range and connect it to the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 Q at 20 C 68 F x If the resistance reading is except the specified value re place it with a new one e Connect the 12 V battery A to the air switching valve terminals as shown e Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air ducts B e Disconnect the 12 V battery e Blow the air to the inlet air duct A again and make sure flow the blown air from the outlet air ducts B x lf the air switching valve dose not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve just blow through the air switching valve hose inlet side C www zxforums com www zxforums com 6E04030BS1 6E04033BS1 6E04031BS1 lt 7 gt
393. om 16 60 LEG TRIGAL SYSTEM www zxforums com www zxforums com Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove the upper inner fairing see Upper Inner Fairing Removal in the Frame chapter e Disconnect the headlight connector A e Turn the headlight bulb A counterclockwise and pull out the bulb from the headlight CAUTION When handling the quartz halogen bulb never toutch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcoh
394. om O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low www zxforums com Front fork oil insufficient fchanssaking Front fork oil viscosity too low 1 7 34 ABRENDIA www zxforums com www zxforums com Troubleshoo
395. ompound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com E pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE LOR END 5 37 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Too small Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose Measure Seating Width reduce pro seat area to spec Tool Vernier Caliper Purpose check seat width against spec Results 45 Grind Machinist s dye Tool 45 Cutter
396. on Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x lf the needle bearing and sleeve show any sings of ab normal wear discoloration or damage replace them as a set e Turn the bearing in the swingarm back and forth A while checking for plays roughness or binding x lf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage lf the seal is torn or is leaking replace the bearing Swingarm Pivot Lubrication e Refer to the Suspension in the Periodic Maintenance chapter see Suspension in the Periodic Maintenance chapter Chain Guide Inspection e Visually inspect the chain guide A Replace the chain slider if it shows any signs of abnormal wear or damage www zxforums com www zxforums com Geo P www zxforums com www zxforums com www zxforums com SURF ENRIQN 3 27 Tie Rod Rocker Arm Tie Rod Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Exhaust Pipe see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter e Squeeze the brake lever slowly and hold it with a band A e Using the jack raise th
397. on a hard sur face Such a shock to the actuator can damage it Subthrottle Valve Actuator Inspection e Remove the air cleaner housing see Air Cleaner Housing Removal e Turn the ignition switch ON e Check to see that all subthrottle valves A open and close smoothly x If the subthrottle valves do not operate check the actuator internal resistance see Resistance Inspection Resistance Inspection e Turn the ignition switch OFF e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections Y lead 1 P lead 2 BK lead 3 G lead 4 Standard About 5 7Q x If the reading is out of the range replace the throttle body assy see Throttle Body Assy section x If the reading is within the range check the input voltage see Input Voltage Inspection in this section GC171700S1 www zxforums com www zxforums com www zxforums com 3 94 FUEL SXSTEM DFI www zxforums com www zxforums com Subthrottle Valve Actuator Service Code 62 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Connect the peak voltage adapter A and a digital meter B to the connector C using the needle adapter set D Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set
398. on valve covers and air cleaner housing holder and remove the air switch ing valve C CAUTION Never drop the air switching valve especially on a hardsurface Such a shock to the air switching valve can damaged it Air Switching Valve Installation e Install the air switching valve A with hose B as shown White Mark C Front D Left Side View E e Connect the air switching valve lead connector Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter see Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter see Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers x lf they are not correct them Replace them if they are damaged www zxforums com www zxforums com GE04049BS2 C www zxforums com 5 1 6 ENGINE IOP END www zxforums com www zxforums com Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI c
399. onnector Vehicle down Sensor Clamp The clamp attached on the main harness Tail Brake Light Connector Through the license plate light lead into the rear fender hole License Plate Light Connector Run the leads to the cutted space of the rear fender rear Left and Right Trim Run the battery negative cable above the main harness Do not pinch the reserve tank Clamps Clamp the oxygen sensor 1 connector Clamp the oxygen sensor 2 connector Sidestand Switch Connector Reserve Tank Overflow Hose Install the clamp into the bracket from inside The clamp attached on the main harness Left Turn Signal Light Connector Horn Joint Connector Ignition Switch Lead and Left Switch Housing Lead Clamp the ignition switch lead and left switch housing lead Tape Gray Clamp Within 30 mm 1 2 in Run the gear position switch harness as shown before installing the water pump cover www zxforums com www zxforums com www zxforums com 1 7 1 WABRENDIA www zxforums com www zxforums com Cable Wire and Hose Routing a Y A Ter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX A 7 1 3 Cable Wire and Hose Routing OMONOOARWN Insert the radiator coolant return hose to the corner portion of the radiator pipe Clamp Radiator Overflow Hose Clamp Run the radiator coolant return hose inside the en
400. operating in severe conditions dusty wet muddy high speed or frequent starting stopping www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANGE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY CHANGE REPLACE ITEM Air cleaner element Fuel hose 4 years Coolant Whichever come first ODOMETER READING x 1 000 km x 1 000 mile y Every 3 years 36 48 24 30 Every 18 000 km 12 000 mile 2 47 Radiator hose and O ring Engine oil 3 years 2 49 e 2 52 Oil filter Brake hose and pipe Brake fluid Rubber parts of master cylinder and caliper Spark plug For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping www zxforums com www zxforums com www zxforums com 2 6 PERIODIC MAINTENANCE WW m W ZXTOrUuMS CO Torque and Locking Agent www zxforums com www zxforums com The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent MO Apply mo
401. or since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Main Throttle Sensor Connector A Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connectors B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Input Voltage 5 Connections to ECU Connector RE Meter BL lead terminal 7 Meter gt BR BK lead terminal 34 e Measure the input voltage with the engine stopped and 6617145051 0 with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF lt the reading of input voltage is less than the standard check the ECU for its ground and power supply see ECU Power Supply Inspection and wiring shorted Ifthe input voltage is within the standard range check the input volt age at the main throttle sensor connector www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM ARE 3 51 Main Throttle Sensor Service Code 11 e Remove the throttle body assy temporarily see Throttle Body Assy Removal e Disconnect the
402. or Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter see Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter see Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Condition Inspection e Visually inspect the spark plugs xlf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug x lf the spark plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge x lf the gap is incorrect replace the spark plug Spark Plug Gap 0 8 0 9 mm 0 032 0 035 in e Use the standard spark plug or its equivalent Spark Plug CR9EIA 9 www zxforums com www zxforums com GS17009BS1 www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 45 Ignition System Camshaft Position Sensor Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the camshaft position sensor lead connector A e Remove Right Middle Fairing see Middle Fairing Removal in the Frame ch
403. or right position e The left or right turn signal lights B front and rear ac cording to the switch position should flash e The turn signal indicator light LED C in the meter unit should flash lf the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Indicator Light LED see Electronic Combination Meter Assembly Inspection in the Electrical System chapter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the turn signal switch e The turn signal lights and indicator light LED should go off x lf the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on x If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System ch
404. orative Emission Control System In spection in the Periodic Maintenance chapter see Evapo rative Emission Control System Inspection in the Periodic Maintenance chapter Separator A www zxforums com www zxforums com www zxforums com 3 1 49 KURU RCS EM DFI www zxforums com www zxforums com Evaporative Emission Control System Separator Operation Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Connect the hoses to the separator and install the sepa rator on the motorcycle e Disconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the separator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Run the open end of the return hose into the container and hold it level with the tank top E e Start the engine and let it idle x If the gasoline in the separator comes out of the hose the separator works well If it does not replace the separator with a new one Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter see Evapo rative Emission Control System Inspection in the Periodic Maintenance chapter NOTE OThe
405. ork oil Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the outer tube to the oil 6M04021351 Oil Level fully compressed without spring Standard 111 2 mm 4 37 10 08 in NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end F of the outer tube C OSet the gauge stopper D so that its lower side shows the oil level distance specified E OPull the handle slowly to pump out the excess oil until the oil no longer comes out x If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above GM040417S82 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSEENGION 3 15 Front Fork e Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Pull the puller up above the outer tube top e Install the fork spring A with the smaller end facing
406. orums com www zxforums com www zxforums com FUEL SYPIEM 011 3 7 Exploded View Torque No Fastener Nem kgf m ftlb Remarks 1 Speed Sensor Bolt 10 1 0 89 in lb 2 Crankshaft Sensor Bolts 6 0 0 61 53 in lb L 3 Gear Position Switch Screws 3 0 0 31 27 in lb L 4 Camshaft Position Sensor Bolt 10 1 0 89 in lb 5 Vehicle down Sensor Bolts 6 0 0 61 53 in lb 6 Water Temperature Sensor 25 2 5 18 Ss 7 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb S 8 Throttle Body Assy Holder Bolts 10 1 0 89 in lb S 9 Inlet Air Pressure Sensor Bracket Screws 3 5 0 36 31 in lb 50 OS 02 0 02 Atmospheric Pressure Sensor Inlet Air Pressure Sensor Main Throttle Valve Sensor Fuel Injectors Subthrottle Valve Actuator Subthrottle Valve Sensor Throttle Cable Accelerator Throttle Cable Decelerator Relay Box ECU Stick Coils Apply cable lubricant Apply engine oil Apply grease Apply a non permanent locking agent Replacement Parts Follow the specified tightening sequence Apply silicone sealant Kawasaki Bond 92104 0004 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com 3 8 EMEL TM DFI Exploded View 6002209BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SPAM CRE 3 9 Exploded View
407. orums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 67 Atmospheric Pressure Sensor Service Code 15 x lf the reading is within the standard range remove the seat cover and check the input voltage again at the sen sor connector e Disconnect the atmospheric pressure sensor connector and connect the harness adapter A between the harness connector and atmospheric pressure sensor connector Special Tool Sensor Harness Adapter 57001 1561 e Connect a digital meter to the harness adapter leads Atmospheric Pressure Sensor B Atmospheric Pressure Sensor Input Voltage Connections to Adapter Meter G sensor BL lead C Meter BK sensor BR BK lead D e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V lf the reading is out of the standard range check the wiring see wiring diagram in this section x If the reading is good the input voltage is normal Check the output voltage e Turn the ignition switch OFF Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A ECU Connector B z Special Tool Needle Adapter Set 57001 1457 EHHH Atmospheric Pressure Sensor Output Voltage Connections to ECU Connector Meter G W lead te
408. ose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel pump operates intermittently and often DFI Pump bearings may wear Replace the pump fuse blows see chapter 3 Fuel pump trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose Compression AAA AE Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on the seating surface Knocking Carbon built up in combustion chamber Repair see chapter 5 Fuel poor quality or incorrect Use the gasoline Change fuel see chapter 3 recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 16 Stick coil trouble Inspect see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Inlet air temperature sensor trouble Miscellaneous ummet actuator rouble Eege see chapter 3 www 2xforums com
409. osition OReplace any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed www zxforums com www zxforums com www zxforums com 2 22 PERIOPICMAI NTENANCE www zxforums com www zxforums com Maintenance Procedure Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicular Do not use the sidestand x If the coolant level is lower than the L level line B un screw the reserve tank cap and add coolant to the F level line C L low F full CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away
410. ot erased to preserve the problem history In this model the problem history can not be erased www zxforums com www zxforums com www zxforums com 3 46 RUER GLEN DFI www zxforums com www zxforums com Self Diagnosis Service Code Table Service Code Problems 11 Throttle sensor malfunction wiring open or short 12 Inlet Air Pressure sensor malfunction wiring open or short 13 Inlet air temperature sensor malfunction wiring open or short 14 Water temperature sensor malfunction wiring open or short 15 Atmospheric pressure sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short 23 Camshaft position sensor malfunction wiring open or short 24 Speed sensor malfunction 25 Gear position switch malfunction wiring open or short 31 Vehicle down sensor malfunction wiring open or short 32 Subthrottle sensor malfunction wiring open or short 33 Oxygen sensor 1 inactivation wiring open or short Europe Models 34 Exhaust butterfly valve sensor malfunction wiring open or short 35 Immobilizer amplifier malfunction 36 Blank key detection 46 Fuel pump relay malfunction relay is stuck 51 Stick Ignition coil 1 malfunction wiring open or short 52 Stick Ignition coil 2 malfunction wiring open or short 53 Stick Ignition coil 3 malfunction wiring open or short 54 Stick Ignition coil 4 malfunction wiring open or short 62 Subthrottle
411. ove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A 6017036851 ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 23 DFI Servicing Precautions OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed ai
412. pecifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones www zxforums com www zxforums com 6004020152 C www zxforums com 2 46 PEBIODIC MAINTENANCE www zxforums com www zxforums com Maintenance Procedure Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Nut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Uni Trak Link Nuts Steering Handlebar Bolts Steering Stem Head Nut Others Footpeg Bracket Bolts Front Fender Mounting Bolts Sidestand Bolt www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 47 Maintenance Procedure Replacement Parts Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be replaced imme
413. pection in the Electrical System chapter x lf the all parts are good condition replace the ECU Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to stop position A e Push the starter button e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter lf the engine stop switch is good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter www zxforums com www zxforums com www zxforums com 2 44 REBIODLG MAINTENANCE www zxforums com www zxforums com Maintenance Procedure Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after
414. peed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging Poor running or no power at high speed apaga aya ajaja aja pa ao a pa 000 ajo po o engine overheating clutch slipping other spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect use high octane gasoline brake dragging clutch slipping engine overheating engine oil level too high engine oil viscosity too high other www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 33 DEI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Doesn t Start Starting Difficulty Symptoms or possible Causes Actions chap
415. pening If you apply com pressed air into the caliper the piston may crush your hand or fingers e Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pads and pad spring see Rear Brake Pad Removal in the Brakes chapter OPump the brake pedal to remove the caliper piston Rear Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal A with a new one OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one OApply brake fluid to the dust seal and install it into the cylinder by hand www zxforums com www zxforums com 058062 P GL05040281 www zxforums com 2 60 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure e Apply brake fluid to the outside of the piston and push it into the cylinder by hand e Replace the shaft rubber friction boot A and dust boot B e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder
416. pressure sensor system fails the signal Pv is out of the usable range wiring short or open the ECU sets the DFI in the a N method 1 Inlet Air Temperature Sensor Water Temperature Sensor Inlet Air Temperature Ta 30 C 100 C Water Temperature Tw 30 C 120 C If the inlet air temperature sensor fails the signal is out of the usable range wiring short or open the ECU sets Ta at 30 C If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 80 C Atmospheric Pressure Sensor Crankshaft Sensor Absolute Atmospheric Pressure Pa 100 mmHg 900 mmHg Crankshaft sensor cannot send the signal to the ECU during 8 crankings If the atmospheric pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 mmHg the standard atmospheric pressure If crankshaft sensor fails the engine stops by itself Camshaft Position Sensor Speed Sensor Camshaft position sensor cannot send the signal to the ECU during 24 crankings Speed sensor must send 4 signals output signal to the ECU at the one rotation of the drive shaft If the camshaft position sensor system fails the signal is missing wiring short or open the ECU continues to ignite cylinders in the same sequence following the last good signal If the speed sensor system fails no signa
417. projection B of the oil pump gear shaft CAUTION Do not pinch the gear position switch lead e Install the water hose A and hose clamp B as shown White Mark C e Tighten Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Install the water pump cover A Torque Water Pump Cover Bolts 1 0 N m 1 0 kgf m 89 in Ib e Align the line B of the water pump cover and the white mark C of the water hose D e Install the water hose E clamps F as shown White Mark G e Tighten Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib Water Pump Impeller Inspection e Remove the water pump cover see Water Pump Re moval e Visually inspect the water pump impeller A x lf the surface is corroded or if the blades are damaged replace the water pump assy www zxforums com www zxforums com GDOGO70BS2 www zxforums com 4 1 Zuel LAANG SYSTEM www zxforums com www zxforums com Radiator Radiator and Radiator Fan Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Separator A California Model Clamp B California Model Radiator Cap C Radiator Hoses D Radiator Upper Bolt E Horn F e Remove Radiator Lower Bolt A Radiator Fan Lead Connector B Radiator Hose C e Pull the radiator from the projection D and remove the
418. r Inlet Air Temperature Sensor Gear Position Switch Vehicle down Sensor Fuel Injectors Delivery Pipe Pressure Regulator Fuel Pump Fuel Filter Speed Sensor Exhaust Butterfly Valve Actuator Oxygen Sensors Europe Models Battery 12 V 10 Ah Air Flow Fuel Flow www zxforums com www zxforums com 3 12 MEL SYSTEM DFI www zxforums com www zxforums com Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Assy Type Bore Throttle Body Vacuum Bypass Screws ECU Make Type Usable Engine Speed Fuel Pressure high pressure line Right after Ignition Switch ON with fuel pump running for 4 seconds with engine idling Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Atmo spheric Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Output Voltage at ECU Water Temperature Sensor Resistance Output Voltage at ECU Speed Sensor Input Voltage at Sensor Output Voltage at Sensor www zxforums com 1 100 50 r min rpm Four barrel type p43 mm 1 7 in 31 5 1 3 kPa 236 10 mmHg Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin 100 12 987 r min rpm 304 kPa 3 1 kgf cm 44 psi with fuel pump running 280 kPa 2 9 kgf cm
419. r e Loosen the throttle body assy holder clamp bolts A on both sides e Remove the throttle case A to make a throttle cable slack e Remove the adjuster screw A from the clamp B e Pull off the throttle body assy A from the holder e Remove Clamp B Throttle Cable Lower Ends C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 127 Throttle Body Assy e After removing the throttle body assy stuff pieces of lint free clean cloths into the throttle body assy holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur x If the throttle body assy is to be disassembly loosen the air cleaner housing holder clamp bolts A and remove the air cleaner housing holder B Throttle Body Assy Installation x If the air cleaner housing holder A was removed install it Olnstall the holder clamp bolts B in the direction as shown Bolt Heads C Torque Air Cleaner Housing Holder Clamp Bolts 2 0 N m 0 20 kgf m 18 in Ib e Install the holder clamp bolts A in the direction as shown Bolt Heads B e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 Nm 0 20 kgf m 18 in Ib e Run the leads and hoses as shown in the Cable Wire and Hose Routing section of the Appendix chapter e When installing the fuel hose refer to Fuel Tank Installa tion e Adjust
420. r OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORoute the hoses according to Cable Wire and Hose Routing section in the General Information chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals OReplace the fuel hose if it has been sharply bent or kinked Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose A to burst Bend and twist the fuel hose while examining it Replace the hose if any cracks or bulges are noticed OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Clutch Cover B Torque Oil Filler Plug Hand tighten www zxforums com www zxforums com ores P www zxforums com 3 24 FUEL GLEN DFI www zxforums com www zxforums com Troubleshooting the DFI System The warning indicator light LED A is used for the FI indicator immobilizer indicator immobilizer models and oil pressure warning indicator GC171950S1 Outline When a pr
421. r Pressure Sensor Service Code 12 e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the inlet air pressure sen sor e Temporarily install the inlet air pressure sensor OConnect a digital meter C vacuum gauge D and the fork oil level gauge E to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter G W sensor Y BL lead Meter gt BK sensor BR BK lead OTurn the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output voltage using ee17119B52 the following formula and chart Suppose Pg Vacuum Pressure gauge of Throttle Assy PI Local Atmospheric Pressure abs measured by a barometer Pv Vacuum Pressure abs of Throttle Assy Vv Sensor Output Voltage v then Pv Pl Pg For example suppose the following data is obtained Pg 8 cmHg vacuum gauge reading PI 70 cmHg barometer reading Vv 3 2 V digital volt meter reading then Pv 70 8 62 cmHg abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable
422. r alter its shape Do not disassemble the plastic part of any key Do not drop the key and or apply any shocks to the key When a user key is lost the user should go to his dealer to invalidate the lost key registration in the ECU 10 When the master key is lost the user should go to his dealer and have a new ECU installed and register a new master key and user keys SP Oe Oh NOTE ONo 9 and 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When the user key has been lost or additional spare user key is required e Prepare a new spare user key e Cut the key in accordance with the shape of the current user key e Remove the front seat see Front Seat Removal in the Frame e Disconnect the immobilizer Kawasaki diagnostic system connector A www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 81 Immobilizer System Equipped Models e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 e Insert the master key to the ignition switch and turn it ON Verified OThe warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode go to the next step 0 5second 0 5second Res Ss GN mm e D men Gen Si GP30166BS1 C Not Verified OThe warning indicator light LED and immobilizer warning symbol A bl
423. r rating for 15 seconds Re check voltage and if less than 12 8 volts repeat the charging cycle and load test If still below 12 8 volts the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine
424. r screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly ANS excessive force can cause expensive or hard to repair dam A age When necessary remove screws that have a non A SIP AN permanent locking agent applied using an impact driver i SERA Use a plastic faced mallet whenever tapping is necessary WN Ki gt t M Y ke Ki SCH 66020148 Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Ki J Remove the old gaskets and clean the sealing surfaces NS thoroughly so that no gasket material or other material re mains Install the new gaskets and replace the used O rings when re assembling 68020158 Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 020168 S www zxforums com www z
425. radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency ORemove the bolt A and radiator bracket B as necessary e Remove Radiator Fan Mounting Bolts A Radiator Fan B www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com Radiator COOLING SYSTEM 4 13 Radiator and Radiator Fan Installation e Install the radiator fan A e Install the rubber dampers B and collars C as shown Ou Wi Ke ae NW SI ai N Es CLE A py q e Remove the radiator cap A temporarily e Cover the heat insulation rubber plate B on the radiator C as shown e Reinstall the radiator cap e Trough the radiator fan lead D in the heat insulation rub ber plate hole E e Connect radiator fan lead connector e Install the radiator in the projection A as shown 6DO7041BS1 www zxforums com www zxforums com www zxforums com 4 1 4 GOQLING AY STEM www zxforums com www zxforums com Radiator x If the radiator bracket A was removed install it Torque Radiator Bracket Mounting Bolt B 7 0 N m 0 71 kgf m 62 in lb e Tighten Torque Radiator Lower Bolt C 7 0 N m 0 71 kgf m 62 in Ib Radiator Upper Bolt D 7 0 N m 0 71 kgf m 62 in Ib Horn E e Face the white mark F of the radiator hose G direction a
426. ral min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter see Engine Oil Change in the Periodic Maintenance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Mainte nance chapter see Oil Filter Replacement in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxtorumE NINE LUBRICATION A MATEM 7 9 Oil Pan Oil Pan Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Front Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter Oil Pan Bolts A Clamps B Oil Pan C GG06022BS2 C Oil Pan Installation e Replace the oil pan gasket A with a new one e Install the clamps B as shown
427. range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal www zxforums com www zxforums com www zxforums com 3 60 FUEL SAS LEM DFI www zxforums com www zxforums com Inlet Air Pressure Sensor Service Code 12 30 76 80 90 cmHg 40 720 kPa De STO P abs ID Idling Pv Throttle Vacuum Pressure abs Ps Standard Atmospheric Pressure abs ST Standard of Sensor Output Voltage v TO Throttle Full Open UR Usable Range of Sensor Output Voltage v Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading www zxforums com www zxforums com GC17120B 4 www zxforums com www zxforums com www zxforums com FUEL Sal EN RED 3 61 Inlet Air Temperature Sensor Service Code 13 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the inlet air tempera ture sensor e Pull out the inlet air temperature sensor B e Install the inlet air temperature sensor A in the grommet B Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal S z ODo not disconnect the ECU connec
428. ransmission Installation Shift Drum B see Shift Drum and Fork Installation Shift Forks C and Shift Rods see Shift Drum and Fork Installation e Before fitting the lower case on the upper case check the following OCheck to see that the shift drum cam A and transmission gears are in the neutral position B OBe sure hang the camshaft chain on the crankshaft www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANSMISAL N 9 13 Crankcase Splitting e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond 92104 1064 NOTE OEspecially apply a sealant so that it shall be filled up on the grooves CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage hole VG A Or U e N EA A ES t DE B c Ya d LIIL e Fit the lower crankcase half to the upper crankcase half NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface ofthe crankcase half is applied OMoreover fit the case and tighten the bolts just after application of the liquid gasket 61042268W2 e The M9 bolts A has a copper plated washer B replace it with a new one e Apply molybdenum disulfide oil solution to both sides C of the washers and threads D of M
429. ransmission shaft turn freely OWile spinng the outputshaft gears shift smoothly from the 1st to G gear and 6th to 1st OWhen the output shaft stays still the gear cannot be shifted to 2nd gear or other higher gear positions e Install the removed parts See appropriate chapters www zxforums com www zxforums com www zxforums com 9 1 6 RRANKRHAFT T RANSM ISSIQN toru ms com www zxforums com Crankshaft and Connecting Rods Crankshaft Removal e Refer to the Connecting Rod Removal see Connecting Rod Removal Crankshaft Installation NOTE Olf the crankshaft is replaced with a new one refer to the Connecting Rod Big End Bearing Crankshaft Main Bearing Insert Selection in the Specifications CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it e Install the connecting rod big end cap B see Connecting Rod Installation Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A and big end caps B NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassemble
430. rber Nut Upper 34 3 5 25 4 Uni Trak Rocker Arm Nut 34 3 5 25 5 Swingarm Pivot Adjusting Shaft 20 2 0 15 6 Swingarm Pivot Adjusting Collar Locknut 98 10 0 72 7 Swingarm Pivot Shaft Nut 108 11 0 80 8 Tie Rod Nuts 59 6 0 44 G Apply or add grease R Replacement Parts L Apply a non permanent locking agent www zxforums com www zxforums com www zxforums com 13 6 ANSRENSION www zxforums com www zxforums com Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Compression Damper Setting Fork Spring Preload Setting Fork Oil Viscosity Amount When Changing Oil After Disassembly and Completely Dry Fork Oil Level Fully Compressed without Spring below from the Top of the Outer Tube Fork Spring Free Length 43 mm 1 7 in Atmospheric pressure non adjustable 10th click from the first click of the fully clockwise position Usable range 0 11 clicks 10th click from the first click of the fully clockwise position Usable range 0 13 clicks Adjuster protrusion is 17 mm 0 67 in Usable range 4 19 mm 0 16 0 75 in KHL15 10 KAYABA or equivalent Approx 480 mL 16 2 US oz 567 4 mL 19 2 0 14 US oz 111 2 mm 4 37 0 08 in 232 1 mm 9 14 in Service limit 227 mm 8 94 in Rear Shock Absorber Rebound Damper Set Compression Damper Set Spring Preload Setting Po
431. re sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 PANER yoa GAMM nww zxforums Vi ct and charge see ARS OrNS COm 3 36 FEVER ANAJ FM DFI www zxforums com www zxforums com DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Incorrect idle speed Water temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Engine stalls easily Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Camshaft position sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 No valve clearance Adjust see chapter 2 Cylinder piston worn Inspect and replace see
432. rical System chapter Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter lf the reading is good the power source voltage is nor mal Inspect the Red lead between the oxygen sensor connector and the ECU for continuity using the follow ing diagram x If the wiring is good inspect the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section e Remove the needle adapter set and apply silicone sealant to the connector for water proofing Sealant Kawasaki Bond Silicone Sealant 56019 120 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYRMEMARED 3 101 Oxygen Sensor Heaters 1 and or 2 Service Code 67 Europe Models Oxygen Sensor Circuit gt N oe N a a gt S Y a Ca 6c017166CW2 ECU Water proof Joint 2 Oxygen Sensor 2 Oxygen Sensor 1 Ignition Switch Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Battery 12 V 10 Ah Joint Connector 3 OONAOAWND www zxforums com www zxforums com www zxforums com 3 1 D EHEL S EM DFI www zxforums com ECU Main Relay Service Code 75 www zxforums com ECU Main Relay Inspection OThe ECU main relay function is included in the ECU A So the ECU main relay function cannot inspect e When the service code 75 is disp
433. right footpeg bracket Torque Front Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb ODepress the brake pedal A and then align the bolts holes of the master cylinder B Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the brake pedal position see Brake Pedal Position Inspection www zxforums com www zxforums com www zxforums com Val www zxforums com www zxforums com Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts D Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hoses E from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from th
434. ring insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Bearing Insert Con rod Big Crankpin Diameter End Inside Diameter Marking Size Color Part Number Marking 92139 0028 None None Black 92139 0027 O O O None Blue 92139 0026 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance e Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to de termine clearance x If the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in Crankshaft Runout e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in www zxforums com www zxforums com 6105060181 6105041751 6105019BS1 G105166BS1 www zxforums com 9 24 GRANKRHAFTIT RANSM ISSIQNforums com www zxforums com Crankshaft and Connecting Rods Crankshaft Main Beari
435. rminal 11 Meter BR BK lead terminal 34 6017154081 Output Voltage Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure OThe atmospheric sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute atmospheric pressure x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section www zxforums com www zxforums com www zxforums com 3 68 MESS TEM DFI www zxforums com www zxforums com Atmospheric Pressure Sensor Service Code 15 x If the output voltage is far out of the usable range remove the seat cover and check the output voltage atthe sensor connector A when the wiring is open the output voltage is about 1 8 V e Connect a digital meter A to the harness adapter leads Atmospheric Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Atmospheric Pressure Sensor Output Voltage Connections to Adapter Meter G W sensor G W lead Meter gt BK sensor BR BK lead Output Voltage at Sensor Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs e Turn the ignition switch OFF S
436. rn for 4 seconds and then stop CAUTION Do not drive the fuel pump 4 seconds or more with out the fuel in the fuel tank Ifthe fuel pump is driven without the fuel it may be damaged e Measure the fuel pressure with the engine stopped Fuel Pressure right after Ignition Switch ON with pump running Standard 304 kPa 3 1 kgf cm 44 psi after 4 seconds from Ignition Switch ON with pump stopped Standard 280 kPa 2 9 kgf cm 41 psi residual fuel pressure The system should hold the residual pressure about 30 seconds www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYSTEM DEI 3 113 Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure idling Standard 304 kPa 3 1 kgf cm 44 psi NOTE OThe gauge hand will fluctuate Read the pressure at the average of the maximum and minimum indications x If the fuel pressure is much higher than the specified re place the fuel pump see Fuel Pump section x If the fuel pressure is much lower than specified check the following Fuel Line Leakage Amount of Fuel Flow see Fuel Flow Rate Inspection x If the fuel pressure is much lower than specified and if inspection above checks out good replace the throttle body assy or the fuel pump and measure the fuel pres sure again see appropriate sections e Remove the fuel pressure gauge hos
437. rter turns but the engine doesn t start To start the engine again raise REELS the motorcycle turn the ignition switch OFF and then ON When the ignition switch is turned ON current flows through the latch up circuit and the transistor in the circuit is turned ON to unlock the latch up circuit Vehicle down Sensor A Ground Terminal BR BK B Output Terminal Y G C Power Source Terminal BL D Removal CAUTION Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Seat Cover see Seat Cover Removal in the Frame chapter Connector A Bolts B Vehicle down Sensor C Installation e The UP mark A of the sensor should face upward Incorrect installation of the Vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the SE sensor brackets e Tighten Torque Vehicle down Sensor Bolts 6 0 N m 0 60 kgf m 53 in Ib Inspection NOTE OBe sure the battery is fully charged e Remove the seat cover see Seat Cover Removal in the Frame chapter www zxforums com www zxforums com www zxforums com 3 78 MES EM DFI www zxforums com www zxforums com Vehicle down Sensor Service Code 31
438. rums com PERIODIC MAINTENANCE 2 29 Maintenance Procedure Tread Depth Standard Front 6 0 mm 0 24 in Rear 6 5 mm 0 26 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 3 mm 0 12 in Over 130 km h A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Using a jack and attachment raise the front wheel off the ground see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Using a stand raise the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness bindin
439. rums com www zxforums com IB IRIGAL SYSTEM www zxforums com www zxforums com Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the fail
440. rums com www zxforums com www zxforums com 10 4 WHEELS TIRES www zxforums com www zxforums com Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm Wheel Balance Balance Weights TIR 0 03 mm 0 0012 in or less 10 g 0 35 oz or less 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz TIR 0 2 mm 0 01 in Rim Size Front 17 x 3 50 Rear 17 x 6 00 Tires Air Pressure When Cold Front Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi Rear Up to 180 kg 397 Ib load Tread Depth Front Rear Standard Tires Front Rear 290 kPa 2 90 kgf cm 42 psi 6 0 mm 0 24 in 6 5 mm 0 26 in Make Type 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Size DUNLOP SPORTMAX RADIAL D209FMTJ DUNLOP SPORTMAX RADIAL D209J 120 70 ZR17 MIC 58 W 190 55 ZR17 MIC 75 W A WARNING Use the same manufacturer s tires on both front and rear wheels www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHERLSSTUIRES 1 0 5 Special Tools Bearing Driver Set Bearing Remover Shaft 13 57001 1129 57001 1377 ST5711298T ST5713778T Jack Jack Attachment
441. rums com www zxforums com Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile See Page y 1 6 12 18 24 30 36 INSPECTION Every 0 6 4 7 5 12 15 20 24 Brake System Brake fluid leak brake hose and bak Baas year e e e e o o o 2 33 pipe inspect Brake hose and pipe damage inspect year e e e e e e e 2 33 Brake pad wear inspect a e e e e e 2 34 Brake hose installation condition inspect year 2 33 Brake fluid level inspect 6 months 2 34 Brake operation effectiveness play no year 2 33 drag inspect Brake light switch operation inspect 2 34 Front forks rear shock absorber operation 2 35 damping and smooth stroke inspect Oo Front forks rear shock absorber oil 2 36 leak inspect 2 36 2 36 Rocker arm operation inspect Tie Rods operation inspect D e Steering System Steering play inspect year e o e e 2 37 Steering damper oil leak inspect e e e e e e 2 38 Electrical System Lights and switches operation inspect year e e e 2 39 Sidestand switch operation inspect year 2 42 Engine stop switch operation inspect year 2 43 Chassis parts lubricate year o e e 2 44 Bolts and nuts tightness inspect e e e e 2 45 For higher odometer readings repeat at the frequency interval established here Service more frequently when
442. runout excessive www zxforums com www zxforums com AP BENDIS A 7 33 Troubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open www zxforums c
443. s OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OWhen the terminals are connected the tachometer nee il dle momentary points to the last reading and then return A ty to the O position hy x If the needle function does not work replace the meter assembly GP17423BS1 OUsing the insulated auxiliary lead quickly open and con nect the terminal 1 to the terminal 7 repeatedly OThen the tachometer needle A should flick B x If the hand does not flick replace the meter assembly www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 75 Meter Gauge Indicator Unit Stop Watch Check e Connect the 12 V battery and terminal in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Press the MODE button each time to set the stop watch mode e Connect the insulated auxiliary lead processed insula tion to the terminal 3 as shown then stop watch start to count e While count the stop watch connect the auxiliary lead to the terminal 4 as shown then indicate the counted time during ten seconds e Connect the variable rheostat A to the terminal 8 as shown e When Set the resistance to less than 21 10 lap display segment indicate the water temperature x lf the display function does not work replace the meter assembly
444. s Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C into the hand tester D which is set to the x 250 V DC range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter BK Adapter BK to lead wire peak voltage adapter R www zxforums com www zxforums com 6P10011982 C Y 2 GP10154BS1 www zxforums com 1 6 44 ELEGTRIGAL SYSTEM www zxforums com www zxforums com Ignition System A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 72 V or more e Repeat the test for the other stick coils x If the reading is less than the specified value check the following Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Inspection Crankshaft Sensor see Crankshaft Sens
445. s active and sensor must If the oxygen sensor 2 is not activated the send signals output ECU stops feedback mode of the oxygen voltage continuously to sensor 1 and 2 the ECU Backups by ECU Oxygen Sensor 2 Europe Models Note 1 a N Method the DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum vacuum sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders www zxforums com www zxforums com www zxforums com 3 50 RUER GEM DFI www zxforums com www zxforums com Main Throttle Sensor Service Code 11 DDO The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sens
446. s 17 1 7 13 2 Muffler Body Assembly Nuts 22 2 2 16 3 Muffler Body Mounting Bolts 25 2 5 18 4 Middle Exhaust Pipe Clamp Bolt 17 1 7 13 5 Rear Exhaust Pipe Clamp Bolt 17 1 7 13 6 Muffler Body Cover Bolts 7 0 0 71 62 mb 7 Exhaust Butterfly Valve Cable Locknuts 7 0 0 71 62 in lb 8 Exhaust Butterfly Valve Cable Adjuster Locknuts 0 71 62 mb 9 Middle Exhaust E Stay Bolt 18 O e es E 11 Exhaust Pipe Manifold Mounting Bos 14 14 10 O R Replacement Parts www zxforums com www zxforums com www zxforums com 5 8 ENGINE OP EN D www zxforums com www zxforums com Exhaust System Exhaust System ZX1000D6F MANIFOLD SILENCER ITEM NAME ORG PRODUCT Non Catalyst Honeycomb Type Catalyst with Oxygen P No 18091 0305 WVTA FULL H Sensor P No 18091 0306 GB WTA FULL H P No 39178 0053 Mark KHI K 495 WVTA 78 2 H Mark KHI M102 EPA Noise Emission Control Information ZX1000D6FH ZX1000D6FH ZX1000 D6FH Non Catalyst P No 18091 0305 EEN ZX1000D6F PINO 18091 0306 pda ZX1000D6FL Mark KHI K 495 ZX1000D6F ie Australia Honeycomb Type EPA Noise Emission ZX1000D6F Catalyst without Control Information P No 39178 0055 Mark KHI M103 Non Catalyst P No 18091 0309 Malaysia ZX1000D6F P No 18091 0310 Mark KHI K 502 GE02214B8 F 78 2 Horsepower 78 2 kW 106 3 ps Full Full Power H Honeycomb Type Catalyst www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com E
447. s 7 0 0 71 62 in lb Exhaust Pipe Manifold Mounting Bolts 14 1 4 10 Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Front Camshaft Chain Guide Bolt Lower 12 1 2 106 in lb Front Exhaust Pipe Manifold Holder Nuts 17 1 7 13 Idle Gear Cover Bolts 10 1 0 89 in lb Middle Exhaust Pipe Clamp Bolt 17 1 7 13 Middle Exhaust Pipe Stay Bolt 25 2 5 18 Muffler Body Assembly Nuts 22 2 2 16 Muffler Body Cover Bolts 7 0 0 71 62 mb Muffler Body Mounting Bolts 25 2 5 18 Oxygen Sensors Europe Models 25 2 5 18 Rear Exhaust Pipe Clamp Bolt 17 1 7 13 Right Engine Bracket Bolts Cylinder Head Side 10 1 0 89 in lb L Spark Plugs 13 1 3 115 in lb Starter Clutch Bolt Cap Hand tighten Starter Clutch Cover Bolts M6 L 30 mm 10 1 0 89 in lb Starter Clutch Cover Bolts M6 L 20 mm 10 1 0 89 in lb Throttle Body Assy Holder Bolts 10 1 0 89 in Ib S Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb S Timing Inspection Cap Hand tighten Upper Camshaft Chain Guide Bolts 12 1 2 106 in lb S WEED SS SE Plugs www zxforums com 19 6 20 wwwzgxfofums com 2 8 PERIQRIC MAINTENANCE www zxforums com www zxforums com Torque and Locking Agent Torque Fastener Nm kat ftlb Remarks Clutch Clutch Cover Mounting Bolts 10 1 0 89 in lb S Clutch Hub Nut 130 13 3 96 R Clutch Lever Clamp Bolts 7 8 0 80 69 in lb S Clutch Spring Bolts 9 8 1 0 87 in lb Oil Filler Plug Hand tighten Sub Clutch Hub Bolts 25
448. s a rough guide to assist the troubleshooting for some of the more common difficulties Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Bypass screw and or idle adjusting screw maladjusted Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Immobilizer system trouble Starter clutch trouble Vehicle down sensor DEI coming off Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Immobilizer system trouble Spark plug dirty broken or gap malad justed Stick coil shorted or not in good contact Stick coil troubl
449. s burn never touch the engine or exhaust pipe during clutch adjustment e Turn the adjuster A so that 4 6 mm 0 16 0 24 in B of threads is visible e Remove the right middle fairing A see Middle Fairing Removal in the Frame chapter e Slide the dust cover B at the clutch cable lower end out of place e Loosen both adjusting nuts C at the clutch cover as far as they will go e Pull the clutch outer cable D tight and tighten the adjust ing nuts against the bracket E e Slip the rubber dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct www zxforums com www zxforums com www zxforums com 2 28 PERIOPIC MAI NTE NAN C E www zxforums com www zxforums com Maintenance Procedure e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B x If the angle is wrong check the clutch and release parts for wear A WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection e Measure the tire air pressure with an air pressure gauge A when
450. s com www zxforums com 3 1 BW ESI EM DFI www zxforums com www zxforums com DFI System DFI System Wiring Diagram OM 3 43 2 OOO TEROP ER d vazi ES D E E Il an uee i il 3 TE a II T bei ti d Hot x KS IS Sa E tt fa iss E af I 2 88 KA amp UN si LN ia Beat A E d www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SY REEMUAR ES 3 19 DFI System Part Name Ignition Switch Engine Stop Switch Starter Button Stick Coil 1 2 3 4 Camshaft Position Sensor Injector 1 Injector 2 Injector 3 Injector 4 Crankshaft Sensor Subthrottle Valve Actuator Subthrottle Sensor Main Throttle Sensor Inlet Air Pressure Sensor Water Temperature Sensor Speed Sensor Oxygen Sensor 1 Europe Models Oxygen Sensor 2 Europe Models Inlet Air Temperature Sensor Water proof Joint 2 Water proof Joint 1 ECU Warning Indicator Light LED Fl Immobilizer Water Temperature Gauge Speedometer Joint Connector 1 Oxygen Sensor Heater Fuse 10 A Europe Models ECU Fuse15 A Ignition Fuse 15 A Fuse Box Fuel Pump Relay Relay Box Main Fuse 30 A Frame Ground Battery 12 V 10 Ah Fuel Pump Vehicle down Sensor Joint Connector 2 Atmospheric Pr
451. s or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wmBRAKES A 2 23 Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hose Damage and Installation Condi tion Inspection in the Periodic Maintenance chapter see Brake Hose Damage and Installation Condition Inspec tion in the Periodic Maintenance chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SURERNRION 1 3 1 Suspension Table of Contents Exploded WEE 13 2 Specifications EE 13 6 Special ii a es de rado e 13 7 KOLIA Del 13 9 Rebound Damping Force Adjustment 13 9 Compression Damping Force Adjustment cc ceeeceee eee eeennneeeeeeeeeeeeteeaeeeeeeeeeeeeeneenaaas
452. s shown e Install the water hose clamp H Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Run the coolant return hose I under the heat insulation rubber plate and install it e Run the radiator overflow hose J over the heat insulation rubber plate and install it e For the California Model install the separator K and clamp L Torque Separator Bracket Mounting Bolt M 7 0 N m 0 71 kgf m 62 in Ib Canister Separator Hose Clamp Bolt N 7 0 N m 0 71 kgf m 62 in Ib ORoute the canister and separator hoses according to Cable Wire and Hose Routing section in the Appendix chapter www zxforums com www zxforums com www zxforums com www zxforums com Radiator www zxforums com COOLING SYSTEM 4 15 AN Pr CT e Y TU l d e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter e Install the middle fairings see Middle Fairings Installation in the Frame chapter e After installation note the following ORun the main harness A over the heat insulation rubber plate B OPut the edges of the heat insulation rubber plate on the hole of the middle fairings C GD07042BH3 C GDO7045BS1 www zxforums com www zxforums com www zxforums com 4 1 6 FOOLING SYSTEM www zxforums com www zxforums com Radiator Radiator Inspection e Remove the radiator see Radiator and Radiator Fan Re moval
453. sc The brake will not function on the first application of the lever if this is not done GJ04147BS1 www zxforums com www zxforums com www zxforums com 1 0 8 WHEEL LIRES www zxforums com www zxforums com Wheels Rims Rear Wheel Removal e Raise the rear wheel off the ground with the stand A e Remove Rear Caliper Mounting Bolts A Rear Caliper B e Remove Cotter Pin A Axle Nut B Axle C from Right Side e Remove the drive chain A from the rear sprocket toward the left e Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHEELRITIRES 10 9 Wheels Rims Olf the coupling A is removed from the rear wheel apply the grease B as shown Wheel Flange Portion C O ring D e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B Olnsert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft lb e Adjust the drive chain slack after installa
454. serious burn do not remove the muffler when the engine is still hot What until the muffler cool down Muffler Body Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter Bolts A Right Rear Footpeg Bracket B with Cover C e Remove Right Muffler Body Assembly Nuts A Right Muffler Body Mounting Bolt B e Remove the right muffler body C to backward ORemove the bolt D and muffler body cover E as neces sary e Remove Bolts A Left Rear Footpeg Bracket B e Remove Left Muffler Body Assembly Nuts A Left Muffler Body Mounting Bolt B e Remove the left muffler body C to backward ORemove the bolt D and muffler body cover E as neces sary www zxforums com www zxforums com www zxforums com 5 40 ENGINE IOP EN D www zxforums com www zxforums com Muffler Muffler Body Installation x If the muffler body cover A was removed install it OFit the dampers B of the muffler body into the slots C in the muffler cover Torque Muffler Body Cover Bolts D 7 0 N m 0 70 kgf m 62 in Ib e Replace the muffler body gasket E with a new ones e Install the muffler body OPass the muffler stay F through the hole G of the rear fender front H e Tighten Torque Muffler Body Assembly Nuts I 22 N m 2 2 kgf m 16 ft lb Muffler Body Mounting Bolts J 25 N m 2 5 kgf m 18 ft lb GE18039BW3 C e Throughly warm up the engine wait until the engine cools down
455. sistance Magnetic flux detection method More than 60 70 for each bank with sensor arrow mark pointed up 3 55 4 45 V with sensor tilted 60 70 or more 0 65 1 35 V Non adjustable and non removal DC 4 75 5 25 V between BL and BR BK leads DC 0 77 4 22 V between BL W and BR BK leads at idle throttle opening to full throttle opening 4 6kO 4 6kO About 0 6 0 9 Q 3 46 3 76 V About 5 7 Q About DC 10 5 12 5 V 0 45 2 5 V 0 05 0 45 V About 8 Q at 20 C 68 F Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in www zxforums com www zxforums com www zxforums com 3 1 AENEK SCGGLEN DFI www zxforums com www zxforums com Special Tools and Sealant Oil Pressure Gauge 5 kgf cm Peak Voltage Adapter 57001 125 57001 1415 Fork Oil Level Gauge Needle Adapter Set 57001 1290 57001 1457 ST571290ST ST571457ST Vacuum Gauge Throttle Sensor Setting Adapter 57001 1369 57001 1538 Ps A ST5713698T Hand Tester Sensor Harness Adapter 57001 1394 57001 1561 ST5713948T ST5715618T Throttle Sensor Setting Adapter 1 Extension Tube 57001 1400 57001 1578 ST5714008T ST5715788ST www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR EMUR Ed 3 15 Special Tools and Sealant Fuel Pressure Gauge Adapter Kawasaki Bond Silicone Sealant 57001 1
456. sition Standard Usable Range Gas Pressure www zxforums com www zxforums com 2 turns out from the fully clockwise position Usable range 0 2 1 2 turns out 4 turns out from the fully clockwise position Usable range 0 4 turns out Spring length 179 mm 7 0 in Spring length 179 191 5 mm 7 047 7 539 in weaker to stronger 980 kPa 10 kgf cm 142 psi non adjustable www zxforums com www zxforums com www zxforums com SURE RNRION 1 3 7 Special Tools Inside Circlip Pliers Fork Cylinder Holder 57001 143 57001 1287 ST5701438T ST571287ST Oil Seal amp Bearing Remover Fork Oil Level Gauge 57001 1058 57001 1290 ST5710588T Hook Wrench R37 5 R42 Bearing Remover Head 20 x 22 57001 1101 57001 1293 ST5712908T 5 7571101ST Bearing Driver Set Fork Piston Rod Puller M10 x 1 0 57001 1129 57001 1298 ST571293ST ST5711298T ST5712988ST Jack Bearing Remover Shaft 613 57001 1238 57001 1377 ST5712388ST ST5713778T www zxforums com www zxforums com www zxforums com 13 8 SUSPENSION www zxforums com www zxforums com Special Tools Fork Oil Seal Driver 643 Needle Bearing Driver 17 18 57001 1530 57001 1609 ST5715308T ST5716098T Fork Spring Compressor Stem Bearing Driver 28 57001 1587 57001 1610 ST571587ST ST5716108T
457. sor Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Disconnect the crankshaft sensor lead connector see Crankshaft Sensor Removal e Set the hand tester A to the x 25 V DC range and con nect the peak voltage adapter B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Connect the black lead C of the adapter to yellow lead and red lead D to black lead in the crankshaft sensor connector E e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 3 2 V or more x If the tester reading is not specified one check the crank shaft sensor Stick Coil Ignition Coil together with Spark Plug Cap Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 41 Ignition System e Disconnect the stick coil connectors A
458. sor Service Code 241 3 87 Exhaust Butterfly Valve Actuator Sensor Inspection 3 87 Immobilizer Amplifier Service Code 35 3 88 Antenna Resistance Inspection ccecccecceecceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeseeeneeeeeenes 3 88 Amplifier Input Voltage Inspection 3 88 Blank Key Detection Service Code 36 3 89 Yser Key INS PS CUON EE 3 89 Fuel Pump Relay Service Code 46 ils ressens 3 90 Fuel Pump Relay Removal E 3 90 Fuel Pump Relay Inspection see 20 9e eme IA 2 2 PRR me PP PR TAR eee 3 90 Stick Coils 1 2 3 4 Service Code 51 52 53 54 cococcccccoianconennccnadictn ARR 3 91 Removal lnstallaton see 3 91 Input Voltage inspectio penenr eee ste ai 3 91 Subthrottle Valve Actuator Service Code 62 3 93 Subthrottle Valve Actuator Removal sun 3 93 Subthrottle Valve Actuator Inspection ssssessesssessseseeeeeeeerrrrrerrrertrrrrrrrrtrrrrrrrrrrrrrrrerrrent 3 93 R sistance INSp CtIOn assister ia A a dura ee 3 93 Input Voltage Inspection 3 94 Exhaust Butterfly Valve Actuator Service Code 63 3 96 Exhaust Butterfly Valve Actuator Removal oooooocccccciccccocooccoccccnocononananononcnoncnnnnnnrn nn nrcnnnnnns 3 96 Exhaust Butterfly Valve Actuator Installation oooonnnnnnninninnnnnnncconncnccocnccnncncnananrnrrrcccnnnnns 3 96 Exhaust Butterfly Valve Actuator Inspection oooocnnnicncoccccnnncnccccnnnnanonncnnncncnananrn nn nccnnnnnns 3 97 Output Voltage Inspection 3 98 Ox
459. sor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Replace see chapter 2 Too low fuel pressure Inspect see chapter 3 Fuel pump troube inspect see chapter 3 Main tot sensor trouble Joere see chapter 3 Water temperature sensor trouble Inspect see chapter 3 AYYWGSPSHICS ASHsure sensor trouble WWwW zxforumgregiBct see chapter 3 Www zxforums com 3 38 RUER GLEN DFI www zxforums com www zxforums com DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air pressure sensor trouble Inspect see chapter 3 Air switching valve broken Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 After fire Crankshaft sensor trouble Inspect see chapter 16 Spark plug burned or gap maladjusted Replace see chapter 2 Inlet air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 16 Inspect and repair or replace see chapter 2 Inspect see chapter 3 Loose terminal of battery cable or ECU Inspect and repair see chapter 16 ground lead Carbon accumulating on valve seating surface Repair see chapter 5 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Ot
460. spection 2 36 Tie Rod Operation Inspection ss 2 36 A O Sea 2 37 WW ERG PSY Inspection a E Seis las ee 2 2 RERORIE MAINTENANCE www zxforums com www zxforums com Steering Play Ee EE 2 37 Steering Stem Bearing Lubrication usine 2 38 Steering Damper Oil Leak Inspection 2 38 O O ne nt de En 2 39 Lights and Switches Operation Inspection 2 39 Headlight Aiming Inspection EE 2 41 Sidestand Switch Operation Inspection 2 42 Engine Stop Switch Operation Inspection 2 43 RN EE 2 44 Chassis Parts LUbricalON ies e 2 44 Bolts Nuts and Fasteners Tightness Inspection 2 45 Replacement Parts EE 2 47 Air Cleaner Element Replacement EEEE EEn EEEn E EEEE 2 47 Fuel Hose Replacement ss 2 48 COR Gaga ai oline 2 49 Radiator Hose and O ring Replacement 2 52 Engine Oil Change stc aria it tes Au 2 53 Oil Filter Replacement sise 2 53 Brake Hose and Pipe Replacement nenn n ennnen 2 54 Brake Fluid Change EE 2 54 Master Cylinder Rubber Parts Replacement ccoooooonicnnccconccnnnaniccanccnnnn nana 2 56 Caliper Rubber Parts Hepnlacement 2 57 Spark Plug Replaceoment ivan aida 2 60 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANGE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accorda
461. sted Replace see chapter 2 Starting technique faulty When flooded don t crank engine with throttle fully opened No spark or spark weak A A O vomitiaxfermthengine stop switches not OkWw zxforum3gamboth switches ON www zxforums com 3 34 FUEL GLEN DFI www zxforums com www zxforums com DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral whether sidestand up or not Though clutch lever pulled in sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not Vehicle down sensor coming off Reinstall see chapter 3 inspect see chapter 3 Inspect see chapter 3 Inspect and charge see chapter 16 Replace see chapter 2 Inspect stick coil see chapter 16 Reinstall or inspect stick coil see chapter 16 Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Neutral starter lockout or sidestand switch Inspect each switch see chapter 16 trouble Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Ignition switch shorted Inspect and replace see chapter 16 Engine stop switch shorted Inspect and repair or replace see chapter 2 Starter system wiring shorted or open Inspect and repair or replace see ch
462. ston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replaced 6105040681 Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in www zxforums com www zxforums com www zxforums com www zxforums com www zxforu mERAN KSHAFT TRANPMISAL N 9 21 Crankshaft and Connecting Rods Connecting Rod Twist e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in
463. straightened inner or outer fork tube may fall in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSPENSION 1 3 1 9 Front Fork Dust Seal Inspection e Inspect the dust seals A for any signs of deterioration or damage Replace it if necessary SS S 6M04128BS1 Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition x lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length 6M04011681 Standard 232 1 mm 9 14 in Service Limit 227 mm 8 94 in www zxforums com www zxforums com www zxforums com 1 3 20 RUSRENSIO N www zxforums com www zxforums com Rear Shock Absorber Rebound Damping Force Adjustment e To adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is the 2 turns out from the fully clockwise position Rebound Dampin
464. t B Right Axle Clamp Bolts C Left Axle Clamp Bolts D 0 7 4 1 mm 0 028 0 161 in E Viewed from Rear F Torque Front Axle Nut 127 N m 13 0 kgf m 94 ft lb e Before tightening the axle clamp bolts on the right front fork leg pump the front fork up and down A 4 or 5 times to all on the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving OTighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten the axle clamp bolts on the right fork leg first Next tighten the left axle clamp bolts Torque Front Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the clearance A between the front axle nut B and the left fork leg C The clearance between the front axle nut and the left fork leg should be between 0 7 4 1 mm 0 028 0 161 in x If the between clearance is out of this range remove the front wheel again and check the axle wheel hub and other related parts for damage e Install the front brake calipers see Caliper Installation in the Brakes chapter e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the di
465. t will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following O A Cutter angle B DIO inerte Outer diameter of cutter C GE15011881 Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE TQP END 5 35 Valves e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind
466. ted up 3 55 4 45 V with sensor tilted 60 70 or more right or left 0 65 1 35 V NOTE Olf you need to test again turn the ignition switch OFF and then ON 6C17358BS3 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYREN AE 3 79 Vehicle down Sensor Service Code 31 e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of sensor the connector for water proofing Sealant Kawasaki Bond Silicone Sealant 56019 120 lf the output voltage is out of the specified replace the vehicle down sensor Vehicle down Sensor Circuit j a D H H H Lo E BR BK BL Y G BR BK 6C17163CW2 1 ECU 2 Vehicle down Sensor 3 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 80 NEL SS EM DFI www zxforums com www zxforums com Subthrottle Sensor Service Code 32 The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C OBO 6017127BS1 Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor since it has been adjusted and set with pre
467. tem Equipped Models e Prepare a new ECU A new master key B and current user keys C NOTE OThe key registration unit is not required OThe key registration process is same as the electric con trol unit replacement Case 5 When replacing the antenna e Prepare a new antenna e Refer to the Immobilizer System Parts Replacement NOTE ONO key registration is required www zxforums com www zxforums com GP30204BS1 www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 95 Immobilizer System Equipped Models All Keys Initial Registration Flow Chart Warning indicator ight and sym ol Dinking NOTES Warming inchcater light and symbol binding Pattern 4 ES Blinking Patterns and Number Zeecond e UE 17 Seecerd Seesord gt 288 iverszg isecen gt 3 3 3109 3 rennt 4 5 15306103 210 D teecave gt 5 secors gt dell NOTE 1 Key Substaute Time insert next key apd turn ON within 15 seconds after Previous key is tumea OFF 2 ECU confirms the following Amplifier O Time of Transmitting and Receeving Messages ECU confirms the w O Registered User Key is Inserted Pattern 2 6 ECU confirms the following O User Key or Not Match the Unique Code O Not Registered User Key When the ECU registered hey is tumed OFF ECU keeps the power ON for two seconds And then in two seconds afer the ke
468. tenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter see Brake Fluid Change in the Periodic Maintenance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove Screw A Clamp B Front Brake Reservoir Cap C Diaphragm Plate Diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation www zxforums com www zxforums com www zxforums com 12 20
469. ter Starter motor not rotating Ignition and engine stop switches not ON Turn both switches ON Starter lockout switch or neutral switch trouble Inspect see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Starter relays not contacting or operating Inspect the starter relay see chapter 16 Starter button not contacting Inspect and replace see chapter 16 Starter motor rotating but engine doesn t turn over Engine won t turn aer SSS S Camshaft seizure Inspect and replace see chapter 5 Connecting rod small end seizure Inspect and replace see chapter 9 Connecting rod big end seizure Inspect and replace see chapter 9 Crankshaft seizure Inspect and replace see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Balancer bearing seizure Inspect and replace see chapter 9 No fuel flow No or little fuel in tank Supply fuel see Owner s Manual Fuel pump not rotating Inspect see chapter 3 Fuel injector trouble Inspect and replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Engine flooded Spark plug dirty broken or gap maladju
470. ter races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment GS15030BS1 Steering Damper Oil Leak Inspection e Visually inspect the steering damper A for oil leakage x lf the oil leakage is found on it replace the steering damper with a new one www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 39 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step e Turn on the ignition switch e The following lights should go on according to below table City Light A goes on Taillight B goes on Oil Pressure Warning Symbol G and blinks about 3 Warning Indicator Light LED H seconds after x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Electronic Com bination Meter Unit Inspection in the Electrical System chapter Meter Unit for Neutral Indicator Light LED see Elec troni
471. th the needle adapter set Special Tool Needle Adapter Set 57001 1457 6017183051 Injector Power Source Voltage at ECU Connector Connections to ECU Connector Meter WIR lead terminal 14 Meter gt Battery Terminal e Measure the power source voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Power Source Voltage at ECU Standard Battery Voltage for 4 seconds and then 0 V x If the power source voltage is less than the standard check the fuel pump relay see Fuel Pump Relay Inspec tion wiring see wiring diagram in this section and the ECU for its ground and power supply see ECU Power Supply Inspection chapter If the relay wiring ground and power supply are good replace the ECU see ECU section www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FU EL SY EMARED 9 1 1 9 Fuel Injectors lf the reading is normal remove the fuel tank see Fuel Tank Removal and check the power source voltage at the injector connector B with a digital meter A e Measure the power source voltage with the engine stopped and the connector joined with a digital meter and needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Power Source Voltage at Injector Connections to Injector 1 2 3 4 Meter WIR lead E Meter Battery Terminal D e Turn the i
472. th the nut Torque Sidestand Bracket Bolts D 49 N m 5 0 kgf m 36 ft Ib Sidestand Bolt 44 N m 4 5 kgf m 32 ft Ib EH e Hook the spring E so that face the long spring end up ward Olnstall the spring hook direction as shown e Install the switch bracket and sidestand switch OApply a non permanent locking agent to the thread of the switch bolt Torque Sidestand Switch Bolt F 8 8 N m 0 90 kgf m 78 in Ib www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL Sv EM 1 6 1 Electrical System Table of Contents Exploded MS Wii a A A ed eae ment eats 16 4 Parts Loc o Ee 16 10 Wiring Diagram United States Canada New Zealand Colombia and Taiwan 16 11 Wiring Diagram Other than United States Canada New Zealand Colombia Taiwan Australia and Malicia dia EE 16 14 Wiring Diagram Australia EE 16 16 Wiring Diagram Malaysia cuco iaa 16 18 eent e te TEE 16 20 Special Tools and Sealant nenten eeee 16 21 Preca tlonS sa AAA AAA a eee ae 16 22 Ge AA A A ed enr den de tt Re AN EEE 16 24 Clinton EE 16 24 E 16 25 Battery Removal estonio 16 25 Battery InSAalMOnss ss Rs to ne NN ne ne a ia iTS 16 25 Battery Ee EE 16 26 el de EEN 16 28 eil Le GE Sn RS PR EN Et ren 16 29 Charging Condi
473. the diameter of the crankpins 6105041781 Crankpin Diameter Standard 34 484 34 500 mm 1 3576 1 3583 in Service Limit 34 47 mm 1 3571 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it NOTE OThere are two types C D of marking positions Crankpin Diameter Marks None 34 484 34 492 mm 1 3576 1 3579 in O 34 493 34 500 mm 1 3580 1 3583 in eg A Crankpin Diameter Marks O or no mark G105165BS2 e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement www zxforums com www zxforums com www zxforums com www zxforums com www zxforum RAN KSHAFT TRANSPMISAL N 9 23 Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 37 500 37 508 mm 1 4764 1 4766 in O 37 509 37 516 mm 1 4767 1 4770 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O or no mark e Select the proper bea
474. the Electric System chapter see Camshaft Position Sensor Removal Installation in the Electric System chap ter Camshaft Position Sensor Inspection OThe camshaft position sensor have no power source and when the engine stops the camshaft position sensor gen erates no signal e Crank the engine and measure the peak voltage of the camshaft position sensor see Camshaft Position Sensor Peak Voltage Inspection in the Electrical System chapter in order to check the sensor e Check the wiring for continuity see wiring diagram in this section Camshaft Position Sensor Circuit 1 ECU 2 Camshaft Position Sensor 3 Joint Connector 1 4 Frame Ground www zxforums com www zxforums com 6C17157CW2 www zxforums com 3 72 MEROS LEM DFI www zxforums com www zxforums com Speed Sensor Service Code 24 Speed Sensor Removal Installation e Refer to the Speed Sensor Removal Installation in the Electrical System chapter see Speed Sensor Re moval Installation in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe input voltage is the same as Input Voltage Inspec tion of the throttle sensor inlet air pressure sensor and atmospheric pressure sensor ME SERRE E e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors E e Connect a digital meter A to the connector B using the need
475. the Electrical Sys tem chapter Upper Fairing Assembly e Install the removed parts see appropriate chapters Upper Fairing Installation e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com 15 1 2 BAM com www zxforums com www zxforums com Fairings Upper Inner Fairing Removal y e Remove the bolts A with washers e Remove the upper inner fairing B ORemove the upper inner fairing by pulling the rear of it up and upward to clear the projection from the stopper C ORemove the upper inner fairing by sliding the front of it up and backward to clear the projection from the stopper D Upper Inner Fairing Installation e Fit the projections B of the upper inner fairing C into the holes A of the upper fairing e Tighten the bolts Center Inner Fairing Removal e Remove Upper Fairing see Upper Fairing Removal Screw A e Remove Quick Rivets A Center Inner Fairing B OSlide out the center inner fairing backward Center Inner Fairing Installation e Insert the tongues C of the upper fairing into the holes A of the center inner fairing B www zxforums com www zxforums com www zxforums com ww BAME 15 13 www zxforums com www zxforums com Fairings Right and Left Inner Fairing Removal e Remove Right and Left Middle Fairings see Middle Fairing Re moval Bolts A Inner Fairing B Right and Left Inner F
476. the clip is hooked over the rib D Left Side E Right Side F 6J04074BS1 6J04089BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com WHEELS DRES 10 15 Tires Air Pressure Inspection Adjustment e Refer to the Tires Air Pressure Inspection in the Periodic Maintenance chapter see Tires Air Pressure Inspection in the Periodic Maintenance chapter Tire Inspection e Refer to the Wheels Tires Damage Inspection in the Pe riodic Maintenance chapter see Wheels Tires Damage Inspection in the Periodic Maintenance chapter Tire Removal e Remove Wheel see wheels Rims section Disc s Valve Core let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacture s on both front and rear wheels e Inspe
477. the fuel level warning indicator light LED does not blinks and or the Fuel segments does not displayed re place the meter assembly www zxforums com www zxforums com GP17432BS1 GP17435BS1 www zxforums com 16 78 ELECTRICAL SYSTEM www zxforums com www zxforums com Meter Gauge Indicator Unit Shift Up Indicator Light LED OConnect the 12 V battery and terminal in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 e When set the oscillator more than 440 Hz shift up indica tor light LED go on x If the Shit Up Indicator Light LED does not go on replace the meter assembly www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 79 Meter Gauge Indicator Unit Meter Unit Circuit G G 4 5 6 Q 2 qi 42 O O1 P N A N www zxforums com Ignition Switch Turn Signal Indicator Light LED High Beam Indicator Light LED Neutral Indicator Light LED Fuel Level Warning Indicator Light LED Warning Indicator Light LED Fl Immobi lizer Oil Pressure Warning Odometer Trip Meter Clock Stop W
478. the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one www zxforums com www zxforums com GP110610S1 GP110608S1 www zxforums com 16 58 ELECTRICAL SYSTEM www zxforums com www zxforums com Electric Starter System Brush Lead Inspection e Using the x 1 Q hand tester range measure the resis tance as shown Terminal Bolt and Positive Brush A Right hand End Cover and Negative Brush B Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the brush holder assembly Right hand End Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown Terminal and Right hand End Cover A Special Tool Hand Tester 57001 1394 x If there is any reading the right hand end cover assembly have a short Replace the right hand end cover assembly Starter Relay Inspection e Remove the battery negative cable from the battery negative terminal see Battery Removal e Remove the Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect the connector A e Disconnect the starter motor cable B and battery positive cable C from the starter relay D CAUTION The battery positive cable with the rubber cap is
479. the needle bearings D using the bearing re mover head and bearing remover shaft Special Tools Bearing Remover Head 57001 1293 Bearing Remover Shaft 57001 1377 GMO7048BW2 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing and oil seals with new ones e Apply plenty of grease to the lips of the oil seals e Install the needle bearings and oil seals position as shown www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com SUSPENSION 13 29 Tie Rod Rocker Arm OScrew the needle bearing driver A into the driver holder B Olnsert the needle bearing driver into the needle bearing C and press the needle bearing into the housing until the driver contacts the end surface of the housing Bearing s Pressing Depth 5 5 mm 0 22 in D 5 0 mm 0 20 in E NOTE OFor a bearing of inner diameter 18 select the pressing side of the needle bearing driver according to ts press ing depth Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 17 18 57001 1609 Spacer 18 F 57001 1636 NOTE Olnstall the needle bearings so that the marked side faces out Needle Bearing A Oil Seals B Front C Right Side D Left Side E Rear Shock Absorber F Tie Rod G Rocker Arm H 7 5 mm 0 30 in I 5 0 mm 0 20 in J 5 5 0 22 in K GMO7030BS1 GMO7049BW2 C www zxforums com
480. the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gasket Block the hose joint opening E during this operation if the caliper half has the opening Bolt and Nut F Oil Passage Sealed by Rubber Gasket G Push down H A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand e Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D e Repeat the previous step to remove the pistons from the other side of the caliper body www zxforums com www zxforums com GLO5049BS1 www zxforums com 2 58 RERIOPIC MAINTENANCE www zxforums com www zxforums com Maintenance Procedure NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad spring and pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol
481. the rear fender Nuts B Washers C Exhaust Butterfly Valve Actuator Mounting Bolts D e Tighten Torque Exhaust Butterfly Valve Actuator Mounting Bolts 0 8 N m 0 08 kgf m 7 in lb e Install the close cable first and then open cable see Ex haust Butterfly Valve Cable Installation in the Engine Top End chapter Exhaust Butterfly Valve Actuator Inspection e Remove the seat cover see Seat Cover Removal in the Frame chapter e Turn the ignition switch ON e Check to see the pulley A clockwise B and counter clockwise C smoothly x If the pulley does not operate check the exhaust butterfly valve actuator sensor output voltage see Output Voltage Inspection www zxforums com www zxforums com www zxforums com 3 98 MESS FM DFI www zxforums com www zxforums com Exhaust Butterfly Valve Actuator Service Code 63 Output Voltage Inspection e Remove the seat cover see Seat Cover Removal in the Frame chapter e Turn the ignition switch ON and wait until the pulley stops e Turn the ignition switch OFF and wait until the pulley stops It is original position of the pulley e Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator A when the pulley is original position as follows e Disconnect 2 pins Connector B 3 pins Connector C e Connect the adapter D between the 3 pins connectors and digital meter E Main Harness F Special Tool
482. the seals A of the connector B for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Seals of Connector www zxforums com www zxforums com 6017037351 www zxforums com www zxforums com www zxforums com FUEL SYSTEM REI 3 27 Troubleshooting the DFI System e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Do not adjust or remove the throttle sensor e Do not directly connect a 12 V battery to a fuel injector Insert a resistor 5 7 Q or a bulb 12 V x 3 3 4 W in series between the battery and the injector e The DFI parts have been adjusted and set with precision Therefore they should be handled carefully never strike sharply as with a hammer or allowed to drop on a hard surface Such a shock to the parts can damage them e Check wiring and connections from the ECU connector to the suspected faulty DFI parts using the hand tester special tool analog tester rather than a digital tester Special Tool Hand Tester 57001 1
483. the threads of the crankshaft sensor bolts A and tighten it Torque Crankshaft Sensor Bolts 6 0 N m 0 61 kgf m 53 in b e Apply silicone sealant to the circumference of the crank shaft sensor lead grommet B and fit the grommet into the notch of the crankcase securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the starter clutch cover see Starter Clutch Instal lation e Route the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters www zxforums com www zxforums com www zxforums com 16 40 FLEG TRIGAL SYSTEM www zxforums com www zxforums com Ignition System Crankshaft Sensor Inspection e Disconnect the crankshaft sensor lead connector see Crankshaft Sensor Removal e Set the hand tester A to the x 100 Q range and connect it to the crankshaft sensor lead connector B Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 380 570 Q If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sen
484. the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings x lf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles e Visually inspect the front and rear axle for damages x If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 2 mm 0 01 in www zxforums com www zxforums com GJ04130BS1 GJ04043BS1 www zxforums com www zxfor
485. thout binding after assembly www zxforums com www zxforums com 6113033BS1 www zxforums com 9 36 GRANIARRAFT TRANSMISSION storums com www zxforums com Transmission A N PR OY IS eo 4 5 D 3 2 9 9 9 3 m e ES OS o UD La IN TI Output Shaft Collar Ball Bearing 2nd Gear 6th Top Gear Ath Gear 3rd Gear Steel Ball 5th Gear 1st Gear Needle Bearing Bearing Outer Race www zxforums com www zxforums com G1132688W4 C Bushing Thrust Washer 634 mm 1 34 in Snap Ring Bushing Toothed Washer 34 mm 1 34 in Thrust Washer 632 mm 1 26 in Bushing Snap Ring Bushing 3rd 4th Gear 23 24 Drive Shaft Snap Ring www zxforums com www zxforums com www zxforu mERAN KSHAFT TRANSMIS RON 9 37 Transmission Shift Drum and Fork Removal e Split the crankcase see Crankcase Splitting e Remove Gear Position Switch see Gear Position Switch Re moval in the Electrical System chapter Bolt A Shift Fork Holder B Screws C Shift Drum Bearing Holder D e Pull out the shift rods A and take off the shift forks B e Pull out the shift drum C Shift Drum and Fork Installation e Apply engine oil to the shift drum forks and rods e Install the shift rods A noting the groove position OPosition the one with shortest ears B on the drive shaft and place the pin in the
486. tial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 2 A x 5 10 hours x lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate III Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 lf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 volts repeat charging cycle www zxforums com www zxforums com 6P090008S1 6P08019BS1 www zxforums com 16 28 FLEGTRIGAL SYSTEM www zxforums com www zxforums com Battery e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 6P08012BS1 GPO8010BS1 NOTE OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hou
487. ting Guide Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery lead making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com MODEL APPLICATION Year Model Beginning Frame No JKAZXCD1016A000001 2006 ZX1000D6F JKAZXTOODDA000001 ZXTOOD 000001 O This digit in the frame number changes from one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company WW ZXTOrums com www zxforums com Part No 99924 1365 02 Printed in Japan www zxforums com
488. tinue start running Up In Gear Released Continue Up In Gear Pulled in Starts running Continue Neutral Released Starts f running Continue Neutral Pulled in Starts running In Gear Released Doesnt Stops start ngear Pula in Pes Stops start www zxforums com www zxforums com GS17062BS1 GS17063BS1 www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 43 Maintenance Procedure x If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Ins
489. tion e Connect the turn signal lead connectors e Clamp the left and right switch leads and ignition switch lead California Model e Install the canister with the band California Model e Insert the hooks A into the slots B and install the middle fairing C e Install the upper inner fairings see Upper Inner Fairing Installation e Install the washers and bolts e Install the quick rivets Windshield Removal e Remove Bolts A and Washers Windshield B www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www BRAME 1 5 11 Fairings Windshield Installation e Put the front tongue A into the hollow B Torque Windshield Mounting Bolts 0 4 N m 0 04 kgf m 4 in lb Upper Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Upper Inner Fairings see Upper Inner Fairing Removal Windshield see Windshield Removal Middle Fairings see Middle Fairing Removal Bolts A Meter Lead Connector B e Disconnect the headlight lead connectors A and city light lead connectors B Left and Right e Remove the upper fairing OPull out the upper fairing forward Upper Fairing Disassembly e Remove Center Inner Fairing see Center Inner Fairing Removal Nuts A Screws B Clamp D Rear View Mirrors Left and Right Meter Unit C with bracket see Meter Unit Removal in the Electrical System chapter Headlight see Headlight Removal in
490. tion Inspection sector coined ce ceceves nie cence eae Seed Tid dete ode eae a nr ten 16 29 Refreshing Garden AAA SM EC ALL LI E Lk OC OD ee Charging DY SUC Ee EE Alternator Cover Removal ss eee seeeeeeeeeeeeeeeeeeseceeeeeeseeeseeeeeeeeeees Alternator Cover Installation IN E terre pee ec ee lespneae EET Stator Coil Installations eee ea aaa aa a Ee EETA A EAE ATA EAE E EAER Alternator Rotor Removal AA Alternator Rotor Installation ss EE ee e de DEE Regulator Rectifier Inspection Charging Voltage Inspection DE Lee En EE Crankshaft Sensor Remova ss Crankshaft Sensor Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage Inspection 16 40 Stick Coil Ignition Coil together with Spark Plug Cap Removal 16 40 Stick Coil Ignition Coil together with Spark Plug Cap Installation 16 42 Stick Coil Ignition Coil together with Spark Plug Cap JInspechon 16 43 Stick Coil Primary Peak Voltage dci lle he oh Rianne haces 16 43 Spark Plug Removal ste sn RS dis 16 44 Spark Plug US Gall PAU EE 16 44 Spark Plug Condition Inspection 16 44 Camshaft Position Sensor Removal geesde EENEG 16 45 Camshaft Position Sensor Installation 16 45 Camshaft Position Sensor Inspection ssssssesssseeessstrrrrrrrtrrrtrrrrrrrrrtrtrrttrtttrrttrtrtrtttrtrtnnt 16 45 Camshaft Position Se
491. tion Visual Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside of each piston B x If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D x If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder I e Check the dust covers E for damage x If they are damaged replace them e Check the piston return spring F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x lf the relief port becomes plugged the brake pads will drag on the disc Blow fe ports clean with compressed air Rear Maser Cylinder J www zxforums com www zxforums com GLO7078BS1 GLO7079BS2 www zxforums com 1 2 1 B BBAKES om www zxforums com www zxforums com Brake Disc Brake Disc Removal e Remove the wheel see Wheels Rims section in the Wheels Tires chapter e Unscrew the mounting bolts and tak
492. tion see Drive Chain Slack Inspection in the Periodic Maintenance chap ter Olnsert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result e Install the rear brake caliper see Caliper Installation in the Brakes chapter e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done www zxforums com www zxforums com 1M07000BS1 6S12013BS1 www zxforums com 10 10 WHEELSSHRES www zxforums com www zxforums com Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings e Inspect
493. tle valves using a cotton pad penetrated with a high flash point sol vent Synchronization Inspection e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Synchronization Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery cable ter minal Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal e Be sure to place a piece of cloth around the delivery pipe A of the throttle body assy e Disconnect the connectors B www zxforums com www zxforums com www zxforums com 3 1 20 URL SG EM DFI www zxforums com www zxforums com Throttle Body Assy e Remove Air Switching Valve Hose A Vacuum Hoses B California Model e Remove the middle fairings see Middle Fairing Removal in the Frame chapte
494. tly lower with the subthrottle valve at the fully open position CAUTION Do not remove or adjust the subthrottle sensor It has been adjusted and set with precision at the fac tory Never drop the throttle body assy can especially wan adas usface Such a shock tevihe senser can damage it 6017164051 www zxforums com 3 82 ANHELO LS FM DFI www zxforums com www zxforums com Subthrottle Sensor Service Code 32 x If the output voltage is within the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal x If the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage again at the sensor connector e Disconnect the subthrottle sensor connector A and con nect the harness adapter B between the harness con nector and subthrottle sensor connector Special Tool Throttle Sensor Harness Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Subthrottle Sensor Output Voltage Connections to Adapter Meter R sensor BL W lead Meter W sensor BR BK lead e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the subthrottl
495. tors Kn e Connect a digital meter to the ECU connector using nee dle adapter set Special Tool Needle Adapter Set 57001 1457 6017150081 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter gt Y lead terminal 8 Meter BR BK lead terminal 34 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 25 2 50 V at inlet air temperature 20 C 68 F NOTE OThe output voltage changes according to the inlet air temperature e Turn the ignition switch OFF www zxforums com www zxforums com www zxforums com 3 62 RUER GLEN DFI www zxforums com www zxforums com Inlet Air Temperature Sensor Service Code 13 x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section x If the output voltage is far out of the specified e g when the wiring is open the voltage is about 4 6 V check the wiring see wiring diagram in this section e Remove the needle adapter set and apply silicone sealant to the seals of the ECU connector for waterproof ing Sealant Kawasaki Bond Silicone Sealant 56019 120 x If the wiring is good check the sensor resistance Sensor Resistance Inspection eRemove the inlet air temperat
496. tting Bolt 9 0 0 92 80 in Ib L Coolant Drain Bolt Cylinder 10 1 0 89 mb Coolant Drain Bolt Water Pump 10 1 0 89 in lb Coolant Reserve Tank Mounting Bolts 7 0 0 71 62 in lb Oil Cooler Mounting Bolts 20 2 0 15 Thermostat Housing Cover Bolts 6 0 0 61 53 in lb Thermostat Housing Mounting Bolts 10 1 0 89 mb Radiatarkracket Mppnting Bolt www zxforums corf 0 0 71 62 inplany zxforums com www zxforums com www zxforums com PERIODIC MAINZENANGE 2 7 Torque and Locking Agent Torque Fastener Nem kotm ft lb Remarks Radiator Lower Bolt 7 0 0 71 62 mb Radiator Upper Bolt 7 0 0 71 62 in lb Water Hose Clamp Screws 2 0 0 20 18 in lb Water Hose Fitting Bolts 10 1 0 89 in lb Water Passage Plugs 19 6 2 0 14 L Water Pump Cover Bolts 10 1 0 89 in lb Water Temperature Sensor 25 2 5 18 SS Engine Top End Air Suction Valve Cover Bolts 10 1 0 89 in Ib L Camshaft Cap Bolts 12 1 2 106 in lb S Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Chain Tensioner Mounting Bolts 10 1 0 89 in lb Camshaft Position Sensor Bolt 10 1 0 89 in lb Cam Sprocket Mounting Bolts 15 1 5 11 L Coolant Drain Plug Cylinder 10 1 0 89 in Ib Cylinder Head Bolts M6 12 1 2 106 in lb Cylinder Head Bolts M10 New Bolts 59 6 0 44 MO S Cylinder Head Bolts M10 Used Bolts 57 5 8 42 MO S Cylinder Head Cover Bolts 10 1 0 89 in Ib Exhaust Butterfly Valve Cable Adjuster Locknuts 7 0 0 71 62 in lb Exhaust Butterfly Valve Cable Locknut
497. two digits OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order OThen after completing all codes the display is repeated until the ignition switch is turned OFF or RESET button is pushed for more than two seconds OFor example if three problems occurred in the order of 46 15 35 the service codes are displayed each two seconds from the lowest number in the order listed as shown below 15 gt 35 gt 46 gt 15 gt 35 gt 46 gt repeated 4 1971919 419 193219 419419719 6C17271CW2 Olf there is no problem or when the repair has been done Fl and or immobilizer symbols go off and no service code is displayed Olf the problem is with the following parts the ECU can not memorize these problems the warning indicator light LED Fl and or immobilizer warning symbols do not blinks and no service codes can be display Warning Indicator Light LED Fl and or Immobilizer Warning Symbols for LCD Stick Coil Secondary Wiring and Ground Wiring see Stick Coil Ignition Coil together with Spark Plug Cap Inspection in the Electrical System chapter ECU Power Source Wiring and Ground Wiring see ECU power Supply Inspection Service Code Erasing OWhen repair has been done Fl and or immobilizer warning symbols go off and no service code is displayed x But the service codes stored in memory of the ECU are n
498. uator see Exhaust Butterfly Valve Actuator Removal Exhaust Butterfly Valve Actuator Sensor Circuit BR BK W R W BL 6c017167C0W2 1 ECU 2 Exhaust Butterfly Valve Actuator 3 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 88 MESS EM DFI www zxforums com www zxforums com Immobilizer Amplifier Service Code 35 Antenna Resistance Inspection e Remove the left upper inner fairing see Upper Inner Fair ing Removal in the Frame chapter e Disconnect the antenna lead connector A e Measure the resistance of the antenna coil in the ignition switch as follows Antenna Resistance Connections to Antenna Meter BK lead Meter BK lead Standard About 0 6 0 9 Q x If the resistance is out of the standard range replace the ignition switch Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Connect a digital meter to the amplifier connector A us ing the needle adapter set Special Tool Needle Adapter Set 57001 1457 Amplifier Input Voltage Connections to Connector Meter BR W lead Meter gt BK Y lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage Standard Battery Voltage e Turn the ignition s
499. ugh in the place of safety 6S13133BS1 www zxforums com www zxforums com www zxforums com 2 34 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level If the fluid level is lower than the lower level line fill the reservoir to the upper level line C e Check that the brake fluid level in the rear brake reservoir A is above the lower level B If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 Brake Pad Wear Inspection e Remove the brake pads see Front Rear Brake Pad Re moval in the Brakes chapter e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 0 mm 0 16 in 813144BS1 Rear 5 0 mm
500. uick Rivets www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ww RBAME 1 5 1 7 Fenders Front Fender Removal e Remove Brake Hose Clamps A Left and Right Bolts B with Washers Left and Right e Remove the front fender assy C e Remove Bolts A e Separate the front fender cover B and front fender C G008014BS1 Front Fender Installation e Install the front fender assy to the front fork e Tighten Torque Front Fender Mounting Bolts 3 9 N m 0 40 kgf m 35 in lb e Install the brake hose clamps to the front fender holes Rear Fender Rear Removal e Remove the seat cover see Seat Cove Removal e Disconnect the license light lead connector A e Remove the nuts A with washers www zxforums com www zxforums com www zxforums com 15 1 SK BAME com www zxforums com www zxforums com Fenders e Pull out the rear fender rear A assembled turn signal lights and license plate light downward Rear Fender Rear Installation e Install the harness clamp in accordance with Harness Routing section in Appendix chapter Rear Fender Front Removal e Remove Seat Cover see Seat Cover Removal in the chapter Middle Exhaust Pipe see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter Rear Fender see Rear Fender Rear Removal Battery A see Battery Removal in the Electrical System chapter e Remove the fuse box B from the
501. ult in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the rear axle nut Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft Ib e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin into the axle and bend its end se curely e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole IMO7000BS1 e Bend the cotter pin A over the nut GKO4001BS1 www zxforums com www zxforums com www zxforums com 2 32 REBIODILGMAI NTE NAN C E www zxforums com www zxforums com Maintenance Procedure Wheel Alignment Inspection e Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with x lf they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Remove Chain Cover s
502. ums com www zxforums com WHEELSITIRES 1 0 11 Wheels Rims Balance Inspection e Remove the wheel see wheels Rims section e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance Balance Adjustment elt the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a regular tip screwdrivers A B between the rib C and weight D as shown e Pry the balance weight with two screwdrivers and remove the balance weight
503. ums com www zxforums com www zxforums com 16 70 ELECTRICAL SYSTEM www zxforums com www zxforums com Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection e Remove the meter unit see Meter Unit Removal A 1 Ignition 2 Fuel Level Warning Indicator Light LED 3 Stop Watch 4 Lap Time 5 Neutral Indicator Light LED 6 ECU Communication Signal 7 Tachometer Signal 8 Water Temperature Sensor 9 Unused 10 Unused 11 Ground 12 Battery 13 Warning Indicator Light LED Oil Pressure Warning 14 Unused 15 Right Turn Signal indicator Light LED 16 Left Turn Signal indicator Light LED 17 High Beam Indicator Light LED 18 Speed Sensor Signal 19 Unused 20 Unused GP17399BS2 C CAUTION Do not drop the meter unit Place the meter unit so that it faces upward If the meter assembly is left up side down or sideways for a long time or dropped it will malfunction Do not short each terminals Liquid Crystal Display LCD Segments Check e Using the insulated auxiliary leads connect the 12 V bat tery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 12 OConnect the battery negative terminal to the terminal 11 e Connect the terminal 1 to the terminal 12 GP17411BS1 www zxforums com www zxforums com www zxforums com
504. ure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow OElectrical Connectors Female Connectors A www zxforums com www zxforums com GPO60101S1 www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 23 Precautions Male Connectors B GPO6010281 www zxforums com www zxforums com www zxforums com 1 6 24 ELEGTRIGAL SYSTEM www zxforums com www zxforums com Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester b
505. ure sensor see Re moval Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the table Inlet Air Temperature Sensor Resistance Standard 2 09 2 81 kQ at 20 C 68 F About 0 322 kQ at 80 C 176 F reference 601710285 value x If the measurement is out of the range replace the sensor xlf the measurement is within the specified replace the ECU see ECU section www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYNEM AE 3 63 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Circuit x FS BR BR BK o 6C17151CW2 1 ECU 2 Inlet Air Temperature Sensor 3 Water proof Joint 2 www zxforums com www zxforums com www zxforums com 3 64 FUEL SXSTE M D Fl www zxforums com www zxforums com Water Temperature Sensor Service Code 14 Removal Installation CAUTION Never drop the
506. uting Se Santis g V H L H SS A d LAY CS IN ai FA pi me 5 Y ie CT y SE val EPS E Ely E io Ss NS ND DA 2 CAES Y S As E es De 6809892844 C 1 Fuel Tank Drain Hose 2 Run the drain hose inside the radiator hose 3 Run the drain hose inside the water hose 4 Put the hose through the cut hole of the under fairing 5 Radiator Hoses 6 Water Hose www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com APPENDIX A 7 23 Cable Wire and Hose Routing ROSS el zi AA CH SC GB09893BW4 C 1 Air Switching Valve 10 Run the water hose through the clamp 2 Face the paint mark upward 11 Water Hose 3 Air Switching Valve Hose 12 Install the upper crankcase bolt with the 4 To the fitting of the holder assy clamp 5 Holder Assy 13 Oil Filter 6 Clamp 14 Oil Cooler 7 Throttle Body Assy 15 Water Hose 8 To the Radiator 16 Clamps 9 Install the starter cover bolt with the 17 Install the clamps as shown illustration clamp noting to the direction of clip www zxforums com www zxforums com www zxforums com 1 7 24 ABRENDIA www zxforums com www zxforums com Cable Wire and Hose Routing 6B09894BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com AP BENDIS 1 7 25 Cable Wire and Hose Routing 00 J O
507. utton Color Color Y R Color BK RIBK R Color W BK Brake Lever OFF 98052 0223E 98052 0228C W2R0223EW5 C on oo co feo P PARK OO C0 www zxforums com www zxforums com www zxforums com 1 6 1 AELEGTRIGAL SYSTEM www zxforums com www zxforums com Wiring Diagram Australia 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button BR 4 Stop Watch aight D Button Ignition er Switch R Right Switch Housing D 000 i lnmobiliver Antenna CES to E L d j Spark Plugs Horn Air i 12V2 5A DOOD Switohing Meter Unit X Valve 1 Turn Signal Stick Camshaft Indicator Light LED we fe S Coils Postion 2 High Beam Indicator Light LEB Baies Za O Sensor 3 Neutral Indicator Light LED i St 4 Fuel Level Warning Indicator Light LED ili ees za Esa 5 Warning Indicator Light LED ea DL gt Wotor FI Immobilizer il Pressure Warning des e S z 6 0dometer Trip Meter Clock Stop Watch 223 z Re Be 7 Water Temperature Gauge gly H 8 Tachometer 2 Ses sz Ea 9 Speedometer T LO if i 10 Illumination Light LED 11 Shift Up Indicator Light LED Sa lt gt Z E FE Heter Unit 10000000 Immobilizer Amplifier 0600 DEER E i Le J KLED Light Emitting Diode eee BK Y inl BK Y BK Y Joint BK Y Gannector 1 St BK Y BKZ Y Front Right et Turn Signal coy ote Light 124218 Right City Son Li
508. ver Bolts 10 N m 1 0 kgf m 89 in Ib e Install the removed parts see appropriate chapters geg Ed www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 51 Electric Starter System Starter Clutch Removal e Remove Starter Clutch Cover see Idle Gear Removal Idle Gear Starter Clutch Side see Idle Gear Removal e Unscrew the starter clutch bot A while holding the al ternator rotor steady with the rotor holder see Alternator Rotor Removal Special Tools Grip 57001 1591 Rotor Holder Stopper M38 x 1 5 57001 1658 Rotor Holder 57001 1666 e Remove the washer B e Pull the starter clutch gear A out of the starter clutch B e Remove Needle Bearing C Starter Clutch Starter Clutch Installation e Install the starter clutch A while fitting the alignment notch B of the splines onto the alignment tooth C e Apply molybdenum disulfide oil solution to the needle bearing A and install it www zxforums com www zxforums com www zxforums com 16 52 ELECTRICAL SYSTEM www zxforums com www zxforums com Electric Starter System e Push A the starter clutch gear B in and turn it counter clockwise C and install it e Install the washer A e Tighten the starter clutch bot B while holding the alterna tor rotor steady with the rotor holder see Alternator Rotor Installation Special Tools Grip 57001 1591 Rotor H
509. w e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide GE15007BS2 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ENGINE LOP RND 5 33 Valves NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 04 0 12 mm 0 0016 0 0047 in Inlet 0 03 0 10 mm 0 0012 0 0039 in Service Limit Exhaust 0 34 mm 0 013 in Inlet 0 34 mm 0 013 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 24 9 25 1 mm 0 980 0 988 in Inlet 29 4 29 6 mm 1 157 1 165 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width
510. w ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or rep
511. w zxforums com www zxforums com www zxforums com www HT GH 6 1 Clutch Table of Contents Exploded EE 6 2 SA OT 6 4 Special Tool and Sealant ss 6 5 Clutch Lever and Cable 6 6 Clutch Lever Free Play Inspection fais sara dese ct tae ee anes 6 6 Clutch Lever Free Play Adjustment sise 6 6 AS NA aise ni ln tn aaa a a a aa tnete E AE Cable Installation es nf nn de dus Cable Lubrication ssssis aient covaccnedaceedsiveneceneavecdenecescavesesuenentnanavedeays Clutch Lever Installation a omis te alert tte tis CALE Lo Re CAN frase A RER CR A A Clutch Cover Removal nicotina aca Clutch Cover Installation see 6 7 Release Shaft Removal ss 6 7 Release Shaft Installation 6 8 Clutch Cover Disass mbly 2er A A a 6 8 Cluich Cover tegen tl aitor 6 9 Cll AR nee A ante a 6 10 GCIUTCM Bue E UE 6 10 Clutch Installation a zm A 8 NME PRIOR OR PR RHI ci 6 12 Spring Plate F ree Play Vides um Nt 1 A AA RALL Lad a RON EE 6 15 Spring Plate Free Play Adjustment sin 6 16 Clutch Plate Wear Damage Inspection sssssessrresrterrtrrttrrrrrrrtrrrtrrtttrtttrtttrttrtrtrrrtnnn 6 16 Clutch Plate Warp Inspechon seen 6 17 Clutch Spring Free Length Measurement ss 6 17 Damper Cam Inspection connnnnccnnccnnccnnccnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninins 6 17 w
512. w zxforums com Lighting System Tail Brake Light LED Removal e Refer to the Seat Cover Removal in the Frame chapter see Seat Cover Removal in the Frame chapter Tail Brake Light LED Installation e Refer to the Seat Cover Installation in the Frame chapter see Seat Cover Installation in the Frame chapter License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B e Push and turn the bulb A counterclockwise wise and re move it e Replace the bulb with a new one e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 degrees e Tighten Torque Licence Plate Light Cover Screws 1 2 N m 0 12 kgf m 11 in Ib www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM 16 63 Lighting System Headlight Tail Light Circuit Ignition Switch High Beam Indicator Light LED Joint Connector 1 Right City Light Headlight High Beam Headlight Low Beam Left City Light Passing Button Dimmer Switch 10 Headlight Fuse 10 A 11 Tail Light Fuse 10 A Turn Signal Light Bulb Replacement Front Turn Signal Light J O1 O P ND gt e Remove the middle fairing see Middle Fairing Removal in the Frame chapter e Turn the socket A counterclockwise and pull out t
513. water hose under the heat insulation rubber plate For Middle Engine Mount For Breather Tube For Camshaft Sensor Lead Alternator Lead Gear Position Switch Lead For Thermostat Case For Water Temperature Sensor Through the starter motor cable under the water hose www zxforums com www zxforums com www zxforums com 1 7 20 ABRENDIX www zxforums com Cable Wire and Hose Routing www zxforums com d R i d ps A D d Se E RS SELLE SOO Oe COOO OOO OO OOO S ANN 40 A O TIA ei gt E ARS KOOKS DEREK SECH E 1 Heat Insulation Rubber Plate 2 Run the starter motor cable into the hole of the heat insulation rubber plate 3 Run the starter motor cable under the adjusting collar 4 Engine Ground Cable 5 Install the engine ground cable as shown www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com AP BENDIS 1 7 21 Cable Wire and Hose Routing SX CE or KA pe Zem SCH ma Sy 1 Ignition Coil Lead 2 Run the ignition coil lead 3 Do not pinch the ignition coil lead 4 Idle Adjusting Cable 5 Radiator Hose 6 Install the idle adjuster screw direction as shown 7 Clamp 8 Viewed A 9 Speed Sensor 10 Align the clamp with the speed sensor www zxforums com www zxforums com GB09944BW4 C www zxforums com 1 7 22 ABRENDIA www zxforums com www zxforums com Cable Wire and Hose Ro
514. witch OFF lt the reading is out of the range check the wiring see wiring diagram in next section x If the reading and antenna resistance are good replace the amplifier see Immobilizer System Parts Replacement in the Electrical System chapter www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR TEM RE 3 89 Blank Key Detection Service Code 36 e This code appears in the following conditions OThe transponder A in the master and or user key is mal function OWhen the spare key of unregistration is used OWhen the master key is registered in the registered ECU e Therefore the service code 36 will disappear when the above issue is solved User Key Inspection e Register the user key correctly see Key Registration in the Electrical System chapter x lf the service code 36 appears again the transponder in the key is malfunction replace it Immobilizer System Circuit GP30197BW2 C Ignition Switch Immobilizer Antenna Meter Unit Immobilizer Amplifier Joint Connector 1 Fuse Box ECU Fuse 15A Ignition Fuse 15 A Main Fuse 30 A 10 Starter Relay 11 Battery 12 V 10 Ah 12 Joint Connector 2 13 Joint Connector 3 14 Immobilizer Kawasaki Diagnostic System Connector 15 ECU 16 Water proof Joint 1 17 Frame Ground www zxforums com www zxforums com www zxforums com JO
515. wn and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly stroke or noise is found inspect the oil leak or shock absorber clamps see Rear Shock Absorber Oil Leak Inspection in this chapter www zxforums com www zxforums com www zxforums com 2 36 PERIODIC MAI NTENANCE www zxforums com www zxforums com Maintenance Procedure Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage x If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x lf the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x If the tie rod A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod
516. ww xtonke NE REMOVAL INSIARLATION 8 1 Engine Removal Installation Table of Contents Exploded VIEW ii AA A A rot 8 2 Special Olivia td la due 8 4 Engine RemovallInstallatiOn oc a cos 8 5 ne a Gun EE 8 5 Engine Installation 8 8 www zxforums com www zxforums com www zxforums com 8 2 ENGINE REMOVAL I N STALLAWONums com www zxforums com Exploded View 6H02068BW5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxfor NGINE REMOVAL INSIARLATION 8 3 Exploded View Torque No Fastener Nom kgf m ftlb Remarks 1 Adjusting Collar Locknut 49 5 0 36 S 2 Lef Front Engine Mounting Bolt M10 L 42 44 4 5 32 S 3 Right Front Engine Mounting Bolt M10 L 67 44 4 5 32 S 4 Middle Engine Mounting Bolt 9 8 1 0 87 in lb S 5 Middle Engine Mounting Nut 44 4 5 32 S 6 Lower engine Mounting Bolt 1 0 87 in lb S KEE Tat Engine Bracket Bolts M10 L 30 44 45 32 LS Riom Engine Bracket Bots MIO L 30 44 45 0 Right Engine Bracket Bolts Cylinder Head Side 10 L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply 2 stroke oil S Follow the specified tightening sequence www zxforums com www zxforums com www zxforums com 8 4 ENGINE REMOVAL I N STALLAWONums com www zxforums com Special Tool Engine Mount Nut Wrench 57001 1450 ST5714508T www zxforums com www zxforums com www zxforums com
517. ww zxforums com Thermostat e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 F GD09020282 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING SEN 4 21 Hoses and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in lb LS SSS Ste 6D100201S1 Hose Inspection e Refer to the Radiator Hose and Connection Inspection in t
518. ww zxforums com www zxforums com www zxforums com 6 2 GT khhs com www zxforums com www zxforums com Exploded View 6F020738W5 C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com www sbb hGH 6 3 Exploded View z 9 Fastener Torque R k Nm kgfm felb SE 1 Clutch Lever Clamp Bolts 7 8 0 80 69 in lb S 2 Clutch Cover Mounting Bolts 10 1 0 89 in lb S 3 Oil Filler Plug Hand tighten 4 Clutch Spring Bolts 9 8 1 0 87 in lb 5 Clutch Hub Nut 130 13 3 96 R 6 Sub Clutch Hub Bolts 25 2 5 18 L CL Apply cable lubricant EO Apply engine oil G Apply grease G Apply grease HG Apply high temperature grease R Replacement Parts S Follow the specified tightening sequence www zxforums com www zxforums com www zxforums com 6 4 GWA Ans com www zxforums com www zxforums com Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Spring Plate Free Play Clutch Plate Assembly Length Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length www zxforums com Usable Range 0 05 0 70 mm 0 002 0 028 in Reference 53 5 mm 2 11 in 2 72 2 88 mm 0 107 0 113 in 0 15 mm 0 0059 in or less 43 5 mm 1 71 in www zxforums com 2 6 mm 0 102 in 0 3 mm 0 012 in 42 1 mm 1 66 in
519. ww zxforums com www zxforums com www zxforums com www zxforums com www zxforums com COOLING SYSTEM 4 19 Thermostat e Replace the O rings A with a new one e Apply grease to the new O rings e Install a new O rings into the thermostat housing B and Cover C x If the coolant by pass fitting bolt D was removed install it OApply a non permanent locking agent to the threads of the coolant by pass fitting bolt and tighten it Torque Coolant By pass Fitting Bolt 9 0 N m 0 92 kgf m 80 in Ib e Tighten the thermostat housing cover bolts E Torque Thermostat Housing Cover Bolts 6 0 N m 0 60 kgf m 53 in lb e Install the thermostat housing Torque Thermostat Housing Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Align the thermostat housing cover bolt A and white mark B of water hose C e Install the water hose clamp D Torque Water Hose Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Install the removed parts see appropriate chapters e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat see Thermostat Removal e Inspect the thermostat valve A at room temperature x lf the valve is open replace the thermostat with a new one www zxforums com www zxforums com GDO9010BS2 GDO9011BS1 6D09000BS1 www zxforums com 4 20 COOLING aYSTEM www zxforums com w
520. www zxforums com www zxforums com 1 3 30 RURRENSIO N www zxforums com www zxforums com Tie Rod Rocker Arm Rocker Arm Tie Rod Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Visually inspect the rocker arm or tie rod sleeves A and needle bearings B e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set Rocker Arm Tie Rod Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required www zxforums com www zxforums com 6M07016BS1 www zxforums com www zxforums com www zxforums com wit LEFRING 14 1 Steering Table of Contents EXploded WEE 14 2 Special TOONS rer usuel AS A O is 14 5 A steus cere ddeegaveenee attaaes ay extees caaneiewa veces 14 6 Steering NSPS CHO EE 14 6 SISESIMG Ben EE 14 6 DSISSTING RE le EE EE 14 7 Steering Damper Renmoval Oder EEEEER adios 14 7 Steering Damper Installation dee Ee 14 7 Damping F Ores Adj StMENt mirei ii iio 14 7 Steering Damper Oil Leak Inspection 14 7 A SLI ane tea a ares de cohedoageadhetanstarsetiaceds ER 14 8 Stem Stem Bearing Removal
521. www zxforums com www zxforums com Steering Stem Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter see Steering Stem Bearing Lubrication in the Periodic Maintenance chapter Steering Stem Warp e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem Stem Cap Deterioration Damage Replace the stem cap if its grease seal A shows dam age www zxforums com www zxforums com GNO5058BS1 www zxforums com www zxforums com www zxforums com A BERING il 4 13 Handlebar Handlebar Removal e Remove Steering Damper see Steering Damper Removal Clutch Lever Clamp Bolts A Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D e Remove Front Brake Reservoir Bracket Nut A Front Brake Master Cylinder B Front Brake Light Switch Connector C Right Switch Housing D Throttle Case E Throttle Grip F Handlebar Weight G e Loosen Front Fork Clamp Bolts A Handlebar Bolts B e Remove Steering Stem Head Nut and Washer C Steering Stem Head D with Handlebars E e Remove Handlebar Position Bolts A Handlebars B Left Handlebar Grip Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Apply a
522. www zxforums com www zxforums com ELECTRICAL SYSTEM 16 47 Ignition System 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality A If the starter motor is not turn inspect the starter lockout switch gear position switch sidestand switch and relay box x lf their parts are normality replace the ECU 3rd Check e Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Up e Set the side stand on the ground then the engine will stop x If whichever may not be stopped inspect the gear position switch starter lockout switch sidestand switch and relay box x lf their parts are normality replace the ECU IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting chart and Fuel System DFI chap ter for ECU Power Supply Inspection see Interlock Op eration Inspection Ignition System Troubleshooting chart and Fuel System DFI chapter for ECU Power Supply In spection www zxforums com www zxforums com www zxforums com
523. x If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section lf the output voltage is out of the usable range replace the sensor Atmospheric Pressure Sensor Circuit o oi 1 ECU 2 Atmospheric Pressure Sensor 3 Water proof Joint 2 G W BR BK B G W el G W PREK 6C17155CW2 x If you need to check the atmospheric pressure sensor for various altitudes other than sea level check the output voltage as follows ODetermine the local altitude Elevation www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYR EMRE 3 69 Atmospheric Pressure Sensor Service Code 15 lf you know the local atmospheric pressure using a barometer substitute the atmospheric pressure for throt tle vacuum pressure in the inlet air pressure sensor chart see Inlet Air Pressure Sensor section And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of the inlet air pressure sensor If you know the local altitude use the following chart Atmospheric Pressure Altitude Relationship 750 P Atmospheric Pressure mmHg abs Z Altitude km i ___Z__ y 0 19026 P 760 1 44 07 700 650 600 Atomospheric Pressure mmHg abs 550
524. xforums com www zxforums com www zxforums com www zxforums com FINAL PRIME 11 5 www zxforums com Special Tools Bearing Driver Set Inside Circlip Pliers 57001 1129 57001 143 ST5711298T ST5701438ST www zxforums com www zxforums com www zxforums com 11 6 FINAL RIVE www zxforums com www zxforums com Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter see Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter see Drive Chain Slack Inspection in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter see Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter see Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition in the Pe riodic Maintenance chapter see Drive Chain Lubrication Condition in the Periodic Maintenance chapter Drive Chain Removal NOTE OSince the drive chain is installed through the swingarm The chain cannot be removed other than by cutting it Prepare the new link pin link plat
525. xforums com www zxforums com www zxforums com www zxforums com GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con ne tact area Be sure to maintain proper alignment and use Da Ej 8 smooth movements when installing CD Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is EN absolutely necessary Replace with new ones whenever Det removed Press bearings with the manufacturer and size N Set pa N marks facing out Press the bearing into place by putting SNS SS pressure on the correct bearing race as shown AB Gh iF Pressing the incorrect race can cause pressure between fe ei Li the inner and outer race and result in bearing damage gt 77 L 65020188 S Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal o is necessary Replace with new ones whenever removed Ja fas Press new oil seals with manufacture and size marks facing ke out Make sure the seal is aligned properly when installing N y 6602018 S Apply specified grease to the lip of seal before installing the seal Grease 6B02046BS1 Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation GB02026B S
526. y is OFF ECU turns the power OFF Ki www zxforums com www zxforums com www zxforums com 16 96 ELECTRICAL SYSTEM www zxforums com www zxforums com Immobilizer System Equipped Models Immobilizer System Parts Replacement Immobilizer Antenna e Remove the left middle fairing see Middle Faring Re moval in the Frame chapter e Disconnect the lead connectors A e Remove Steering Stem Head see Stem Stem Bearing Removal in the Steering chapter Handlebar see Handlebar Removal in the Steering chapter e Using a small chisel or punch turn out the Torx bolts A e Remove the clamp B e Cut the band A e Remove the screw B e Remove the antenna C with the cover D OPull the lower parts E of the cover outside to clear the projection F of the ignition switch e Install the clamp e Tighten a new Torx bolt A until the bolt head B is broken C e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Immobilizer Amplifier Replacement e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the connector A e Remove the amplifier B from the bracket C www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com ELECTRICAL SYSTEM A 6 97 Immobilizer System Equipped Models ECU Electric Control Unit Replacement for Immobi lizer Models e Re
527. y or incorrect Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter in ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine IC igniter in ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner O ring damaged Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high www zxforums com Eng
528. y wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage e Install the new fuel hose so that the white mark A side faces throttle body assy e Insert B the fuel hose joint C straight onto the delivery pipe until the hose joint clicks e Push D the joint lock E www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com PERIODIC MAINTENANCE 2 49 Maintenance Procedure e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and doesn t come off A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak x lf it comes off reinstall the hose joint e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Start the engine and check the fuel hose for leaks Coolant Change A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drin
529. ygen Sensor Heaters 1 and or 2 Service Code 67 Europe Models 3 99 Oxygen Sensor Heaters Removal Installati0N oooooonninnnnnnccccnnnnncconnoncccnnnnnnnnnnnnnnnnnnno 3 99 Oxygen Sensor Heaters Inspection oooonononniniocicinnonanarnrcccnccrc cr 3 99 ECU Main Relay Service Code 75 22 44e idem di ade 3 102 ECU Main Relay Inspection EE 3 102 Oxygen Sensor 2 not activated Service Code 83 Europe Models 3 103 Oxygen Sensor 2 Removal Installation us 3 103 Oxygen Sensor ln D EE 3 103 EU a iaa 3 106 ECU Identifica a A ais 3 106 ECU Removal muii dia 3 106 EGU Installatio REN 3 107 ECU Power Supply Inspection 3 107 DEl Power Source usines fentes ss ne ren Pass ae res nn tm nn ee isa 3 110 A Pi 3 110 ECU ENEE EE 3 110 JAS Il a CONN a OT E www zxforums com www zxforums com FUEL SPAM 05 3 3 Warning Indicator Light LED count bt a a 3 111 Light LEDY Wl e e is 3 111 Fuel Lines ge BEA Seeler BERENS Ree beiet dviewuadeess 3 112 Fuel Pressure Inspection ia ae te rene 3 112 Fuel Flow Rate Inspection oooocicccinnnininincnnncccccicnnicninr tee rree erene 3 113 FUE PUMP Eine ds a aaa dedos 3 115 Fuel Pump Removal sise 3 115 Evel Pump Installation asie de dede fees ads 3 115 Operation Inspection sise 3 116 Operating Voltage Inspection resume A les 3 116 EELER 3 118 Ee VEH UE re EE 3 118 Power Source Voltage Inspection 3 118 Output Volta
530. zxforums com Oxygen Sensor 2 not activated Service Code 83 Europe Models e Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 45 2 5 V e Next remove the plugs from the fittings A with idling e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor 2 Output Voltage without Plugs Standard 0 05 0 45 V lf the reading is within range with plugs 0 45 2 5 V without plugs 0 05 0 45 V the oxygen sensor is good x lf the reading is without range replace the oxygen sensor e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com FUEL SYRLEM RED 3 1 05 Oxygen Sensor 2 not activated Service Code 83 Europe Models Oxygen Sensor Circuit gt N oe gt S Y a a TON IGNITION OO BATTERY Le Ca 6c017166CW2 ECU Water proof Joint 2 Oxygen Sensor 2 Oxygen Sensor 1 Ignition Switch Oxygen Sensor Heater Fuse 10 A Ma
531. zxforums com www zxforums com 1 5 20 BAME com www zxforums com www zxforums com Frame Rear Frame Removal e Remove Vehicle down Sensor see Vehicle down Sensor Re moval in the Fuel System DFI chapter Seat Cover see Seat Cover Removal Rear Fender Front see Rear Fender Front Removal Clamps for Main Harness Frame Bolts A Rear Frame Installation e Tighten Torque Rear Frame Bolts 44 N m 4 5 kgf m 32 ft lb Frame Inspection e Visually inspect the frame for cracks dents bending or warp x If there is any damage to the frame replace it A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it 6009023BS1 www zxforums com www zxforums com www zxforums com www zxforums com www zxforums com wuwERANE 5 21 Sidestand Sidestand Removal e Raise the rear wheel off the ground with the stand e Remove Lower Fairings see Lower Fairing Removal e Disconnect the sidestand switch lead connector A and clear the lead from the clamps B e Remove Sidestand Switch Bolt A Spring B Sidestand Bolt C Sidestand D Switch Bracket Bolt E Sidestand Bracket Bolts F Sidestand Installation e Apply grease to the sliding area A of the sidestand B and thread of the sidestand bolt C e Apply a non permanent locking agent to the threads of sidestand bracket bolts e Tighten the bolt and lock them wi
532. zxforums com Meter Gauge Indicator Unit e In the HOUR setting mode press the REST button to ef fect the MINUTE setting mode CLOCK S are OThe minute display flashes on the display le 3 e Press the MODE button to set the minute AR Ox 42 9 9 e In the MINUTE setting mode press the REST button to CLOCK a a return to the HOUR MINUTE setting mode Zei y e Press the MODE button to complete the time setting gt I process OThe clock starts counting the seconds a soon as the MODE button is pressed CLOCK ki 6P17064BS1 e Indicate the ODO mode e Check that the display A B change to the mile and F Mile and C km and F km and C display each time by pushing the RESET bottom while MODE bottom pushed in NOTE OMile Km Display can alternate between English and 771000 metric modes mile and km in the digital meter Make O sure that km or mile according to local regulations is GP17417881 0 correctly displayed before riding x If the display function does not work and adjust replace the meter assembly Speedometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The speed equivalent to the input frequency is indicated in the oscillator A ifthe square wave illustrated as shown would be input into the terminal 18 Olndicates approximately 60 km h in case the input fre quency would

2006 - 2007 Kawasaki ZX-10R Service Manual

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