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Kawasaki KX65 Motorcycle User Manual

1. 23 Water Temperature SENSON uu aetates 27 27 er ae kuy xu s as sasana usan a as 30 C OV I Cc 32 dine T MM 32 Frame Parts Installation 33 Boreas dedico 33 pVed ats E 34 Brake Fads SIE alts uu u u un n u a uD DN 34 Sleeririg Darn5er r KICGP3rSEuuuu 35 seat FEIGNU AGJUSUMEIM 38 40 ElecuicaliSySI lt TTE 42 42 Main Harness and Sub Harness Kit 42 Lett Switch Housing Winng Change certe oen rede en u u ERE e RR e RR e pea nds 52 SHINEE Install tiOlt sos eis donet reo inc baubau 53 Wiring Diagram with Original 54 Wiring Diagram with Kit 56 General Specifications 2005 Ninja ZX 10R Racing Engine Ignition timing Fuel Recommended 10 BTDC 91 100 r min rpm Racing gasoline Engine oil Recommended Racing oil Level Between upper and lower levels of oil level gauge Drive Train Primary drive reduction ratio 1 611 8
2. TT 1 38 vr ss IH IHI ji j Ill ii ji i o 2 18 4 e A 3B MEC 38 38 A 8 gt 18 c lt K MB o KMH a AMB 2 N A 2 j Ll 38 38 uu 18 m b 2 5 E gt 18 4 10 4 PET eT TT TT El 4 18 4 18 a T i S 14 18 18 55 ill gt j jiji j i m SS ji ji j i zo cow 18 8 18 38 18 8 Dm y y lli jji j 3 lt m gt m 33 18 33 18 38 48 LTTTTII T Wi wis EE ES ll asta 1 9 38 18 8 18 jj jl j j j j j j 9 18 5 18 al J J J vi 38 18 H m dk AJI l1 L E _ jl t gt wed 9 18 EPA s xa LL 78 38 38 i I j 8 MW Regulator gt BR Brown GH Chocolate DG Dark Green 38 38 38 4 u i
3. Standard Cylinder Head Valves Valve timing Duration Intake 300 Exhaust 292 Camshaft timing cam lift center Intake 104 ATDC Exhaust 102 BTDC Valve clearance Intake 0 22 mm Exhaust 0 20 mm Squish 0 85 mm Valve to piston clearance Intake 1 45 mm 10 ATDC Exhaust 1 80 mm 10 BTDC Ignition System NGK CR9EIA 9 STD R0045Q 10 or 10 opark plug tightening torque 13 N m 1 3 kgf m 113 in Ib Spark plugs These values show the specifications when standard cylinder head and gasket are used Periodic Maintenance Chart scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQENCY Each Every Every Every As OPERATION Race 3 races 5 races 10 races Required Clutch plate check e Throttle grip play check e Spark plug clean gap Engine oil change Oil filter replace Valve lapping Vavelapping 00 5 Cylinder head valve decarbonizaton 5 J ___ 002400000 Piston oylinderclearance check J J lef J Piston ring piston and piston pin replace Crankshaft main bearing Connecting rod big end bearing check Transmission gear bearing check Engine sprocket check FREQENCY Each Every Every Every As OPERATION Race 3 races 5 races 10 races Required Coolant change 4 Ra
4. DG Dark Green 187i 38 4 u i Arya A u8 M uB A 38 Ary 51 x o D 2 o yay gt o gt w Light Blue LB Self diagnositic Indicator Terminal ot CaL m X TL c x Joint 14 49 448 fit Gonnector 2 3 Exhaust Atmospheric Pressure Sensor Fuse Box Ignition Fuse 20 1 Butterfly Valve 15 2 ECU Fuse Relay Box Actuator SI086233BW5 C 57 Racing Kit Parts List This catalog covers 05 ZX1000 CR2 Engine 13116A 12048 GRID NO This grid covers Camshaft s Tensioner E1230 Hef 12048 13116 13116A 49118 92015 92055 92055A Part No 12048 0011 OPTION 13116 1160 OPTION 13116 1166 OPTION 49118 0034 OPTION 92015 1078 OPTION 92055 0053 OPTION 92055 011 OPTION Description TENSIONER ASSY ROD PUSH ROD PUSH CAMSHAFT COMBINTAKE NUT FLANGED 6MM RING O 20 8X1 9 RING O 5MM DEC 16 2004 opec Code Quantity ZX1000 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Crankshaft Piston s e T Part No Description Spec Code 13001 13001 0061 PISTON ENGINE 4 OPTION 13002 13002 0008 PIN PISTON 4 OPTION 13008 13008 0019 HING SET PISTON 4 OPTION 13251 13251 0015 ROD ASSY CONNECTING L 110 45 4 OP
5. R B BK Y Diode 2 DR m Speed Control Switoh TERES puli EI o H LB BK BK Y W R BL Y7 BR BK wr bor BK Y BK Y x gt Steater S Frame Motor O 777 Ground Battery Vehicle Fuel 12V10Ah Engine down Bias dns Ground Sensor j Fuel Switch Pump Main Fuse 30A 81068232BW5 C 56 Pressure Inlet Sensor Air Throttle Sensor 4908 Alternator gt em Engine Subharness EMT tn gt Em gt m Regulator Main Subthrottle Sensor Subthrottle Yalve Actuator Inlet Air Tempera ture Sensor Injecters Fuel 38 0 A 38 A 38 A 38 A 3H A 3H A 3H K MB A 3H ASHE A 9HB AZAB AAB 78 4 7H Joint Gonnector 1 a ae 38 38 18 78 4 3 718 8 1 8 18 38 38 1H 78 18 W A 78 38 18 38 38 18 19 18 4 14 18 718 9 718 4 18 LP 4 8 4 38 18 3 9 718 H R 3 8 3 4 718 1 duy non 3 18 38 38 38 A 938 48 MW C Y BL G W Y 8 Le R Y BL Y R W Y R BL W R Y R BK R R G Y BK R G BK BR W BR BK R BK BR Y 678 BK BL O lt BR Brown GH Chocolate
6. Kawasaki Ninja zx 10R 2005 Ninja ZX 10R Racing Kit Manual This manual contains only the information of the racing kit parts Refer to the base manual listed below for information of the original model Part Number Ninja ZX 10R Motorcycle Service Manual 2005 Kawasaki Heavy Industries First Edition 1 Feb 7 2005 Congratulation on your purchase of racing kit parts for the 2005 Ninja ZX 10R IMPORTANT This manual provides how to install racing kit parts for the 2005 Ninja ZX 10R and how to tune up basically As for the basic knowledge refer to the base Service Manual for the Ninja ZX 10R P No 99924 1322 02 When you participate in a race it is necessary to modify the machine for the regulation 50 we want you to ask for the tuning up shop WARNING AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE IT SHOULD NOT BE USED ON PUBLIC STREETS ROADS OR HIGHWAYS THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE CAUTION When operating the engine be careful not to trouble persons with noise Do not turn the engine with loud engine and exhaust noise DISCLAIMER OF WARRANTY ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED BASIC WORKS IN INSTALLING KIT PARTS We are going to make up the original Ninja ZX 10R for the racing machine We recommend that the rider himself should do the
7. 49118 0023 STD Exhaust 49118 0034 Kit Intake Adjust the valve clearance within the specified value Intake 0 15 0 24 mm Exhaust 0 17 0 22 mm More performance is expected when adjusted from middle value to upper limit between adjustable range 9 f you can not adjust the valve timing for racing install the camshaft sprocket to the camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX 10R Service Manual If you adjust the valve timing install the sprocket to the camshaft between the adjustable range of the long bolt holes Tighten the camshaft sprocket bolts to 15 N m 1 5 kgf m 11 ft lb of torque Valve Timing Timing cam lift center Original when the round bolt holes are used 104 100 102 108 102 Race use when the long bolt holes are used Recommended Recommended O When grinding the cylinder head bottom surface grinding the cylinder top surface or using thinner gaskets be sure the valve to piston clearance especially O When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly Valve to Piston Clearance Min Intake Exhaust If the valve to piston clearance is less than the minimum value do not start the engine because the valves will touch the piston and the engine may be dama
8. 92200 0225 OPTION 92200A 92200 0226 OPTION 92200B 92200 0227 OPTION 92200C 92200 0228 OPTION 92200D 92200 0229 OPTION Description opec Code SHAFT TRANSMISSION INPUT 13T 1 SPROCKET OUTPUT 16T 520 1 SPROCKET OUTPUT 17T 520 1 GEAR OUTPUT 2ND 39T 1 GEAR INPUT 2ND 19T 1 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 GEAR INPUT 5TH 20T 1 GEAR INPUT 6TH 21T 1 GEAR OUTPUT LOW 31T 1 GEAR OUTPUT 3RD 34T 1 GEAR OUTPUT 4TH 31T 1 GEAR OUTPUT 5TH 29T 1 GEAR OUTPUT 6TH 29T 1 GEAR INPUT 3RD amp 4TH 19T amp 21T 1 GEAR INPUT 3RD amp 4TH 16T amp 20T 1 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 WASHER 28 1X34 0X0 8 AR WASHER 28 1X34 0X1 0 AR WASHER 28 1X34 0X1 4 AR WASHER 28 1X34 0X1 6 AR WASHER 28 3X34 0X1 2 AR DEC 16 2004 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Transmission 2 2 TYPE B 13262B J L E1361 Ref OS Part No Description Spec Code o No cel 92200E 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200F 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200G 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 13262H 5 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine E1361A 132626 J L 132626 a icc Sa v7 e 13262F 13262H GRID NO This grid covers Transmission 1 2 TYPE C Ref i Part No 13127 13127 0031 OPTION 13144 13144 0021 OPTION 13144A 13144 0022 OPTION 13262 13262 0152
9. OPTION 13262A 13262 0166 OPTION 13262B 13262 0185 OPTION 13262C 13262 0272 OPTION 13262D 13262 0273 OPTION 13262 13262 0274 OPTION 13262F 13262 0275 OPTION 13262G 13262 0276 OPTION 13262H 13262 0277 OPTION 132621 13262 0278 OPTION 13262 13262 0284 OPTION 13262K 13262 0285 OPTION 13262L 13262 0286 OPTION 92200 92200 0225 OPTION 92200A 92200 0226 OPTION 92200B 92200 0227 OPTION 92200C 92200 0228 OPTION 92200D 92200 0229 OPTION Quantity ZX1000 Description opec Code SHAFT TRANSMISSION INPUT 14T 1 SPROCKET OUTPUT 16T 4520 1 SPROCKET OUTPUT 17T 520 1 GEAR OUTPUT 2ND 39T 1 GEAR OUTPUT 4TH 32T 1 GEAR INPUT 2ND 19T 1 GEAR INPUT 3RD amp 4TH 16T amp 21T 1 GEAR INPUT 5TH 20T 1 GEAR INPUT 6 21 1 GEAR OUTPUT LOW 34T 1 GEAR OUTPUT 3RD 28T 1 GEAR OUTPUT 5TH 28T 1 GEAR OUTPUT 6TH 28T 1 GEAR INPUT 3RD amp 4TH 19T amp 21T 1 GEAR INPUT 3RD amp 4TH 16T amp 20T 1 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 WASHER 28 1X34 0X0 8 AR WASHER 28 1X34 0X1 0 AR WASHER 28 1X34 0X1 4 AR WASHER 28 1X34 0X1 6 AR WASHER 28 3X34 0X1 2 AR DEC 16 2004 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Transmission 2 2 TYPE C 132620 J L E1361A Ref 6 Part No Description Spec Code o No cel 92200E 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200F 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200G 92200 0232 WASHER 28 3X
10. pcs t 2 6 x 8 pcs For this setting the effective stroke of clutch spring plate during the back torque limiter operation is adjusted between 0 45 and 0 75 mm By increasing the effective stroke the back torque limiter causes more slip The effective stroke increases by decreasing the length A The length A between 52 8 and 03 6 mm is available by changing the combination of the steel plates Replace one steel plate with a thinner one and try the setting If the operation of the back torque limiter is not enough replace other steel plates one by one Thickness mm Part Number 13069 1004 13089 1093 17 When decreasing the length A total thickness of clutch plates use the kit spring retainers provided as optional production parts to keep the preload of clutch springs according to the table below Length A Part Number Height B 03 1 53 6 mm 13092 1041 6 mm standard 52 6 53 0 mm 39108 0004 52 0 52 5 mm 39108 0006 you have clutch slip during acceleration use shorter spring retainers by one size to increase preload of clutch springs 9 he original springs and retainers can be used if the length A is between 52 8 53 6 mm 9 For precise setting the measurement of the effective stroke of clutch spring plate is recommended e Remove oil from clutch plates e Hold an extra drive shaft in a vise and install the following clutch parts on the shaft 18 A Spacers B Needle Bearing C Bus
11. terminal of the kit water temperature sensor ground lead 26011 0071 between the water hose and the kit water pipe and clamp it on the hose as shown in the illustration Install the other side terminal of the ground lead with the crankshaft sensor cover by the bolt To NETEP yy To 26011 1779 Radiator R Engine 39192 0011 To Crankshaft Sensor Cover 1 2 i 26011 0071 5106205802 Water Outlet of Radiator Body same situation of the original radiator 28 Use the kit sub radiator with the kit main radiator Water Inlet of Radiator Body 9 Divide the original water hose 39062 0022 between the cylinder head and the radiator and insert the water pipe 39192 0039 e Install the kit water temperature sensor for water temperature gauge of kit meter 21176 1099 to the kit water pipe e Pinch the terminal of the kit water temperature sensor ground lead 26011 0071 between the water hose and the kit water pipe and clamp it on the hose as shown in the illusturation Install the other side terminal of the ground lead with the crankshaft sensor COVer To dU Mc 26011 1779 39192 0039 Z Subradiator To Crankshaft yi Sensor Cover 3 26011 0071 SI08203BW1 C Water Outlet of Kit Main Radiator Remove the original water pipe 39192 0029 and install the kit water pipe 39192 0038 Install the kit water hose 39062 1072 between the water pipe and the kit sub radiator Reserve tank Installation R
12. the base Service Manual NOTE O Install the kit springs facing the smaller spring end diameter side upward Identification Mark The following ID marks are on the springs Sprin ID Mark Smaller pring diameter end side 44026 0046 K 9 0 One slit 44026 0048 K 9 75 Three slit 40 Fork Spring Installation Kit Original Spring E eun Spring with IlDmark slit without IDmark slit L 245 3mm L 245 3mm 245 3mm L SI086246BW5 C 41 Electrical System Battery Use the original battery with 12 V 10 Ah or more capacity Main Harness and Sub Harness Kit Part Main harness and sub harness are available for racing use as kit parts Select one of them in accordance with your race regulation Main Harness with Original Meter and Kit Meter 26031 0328 sub Harness with Throttle Bodies 26031 0329 oub Harness with Kit Meter 26031 0307 Sub Harness with Original Meter 26031 0308 Sub Harness with Original Meter and Original Main Harness 26031 0244 Meter Kit Parts Installation 5106194802 C 1 Shift Up Indicator Lamp Kit 23016 0006 2 Tachometer with Water Temperature Gauge Kit 25031 1142 3 Damper Kit 39156 0098 4 Meter Bracket Kit 11053 1673 5 Collar Kit 92152 0058 6 Rivet Kit 92039 1106 7 Bracket Kit 11053 1747 8 Bracket Kit 11053 1748 9 Bolt Kit 130J0618 10 Nut Kit 92015 1233 11 Ram Air Duct Original 3904
13. 0 32 mm 0 0126 in target Turn the big end nuts more until the bolt stretch reaches the usable range NOTE O Replace the original bolts with new ones if they have already been tightened up to usable range 2 times O Replace the bolts with new ones if they are used for the engine with a not clear feature 14 2 Kit Connecting Rod Connecting Rod Bolt Use the kit connecting rod bolts with the original connecting rod bolts and nuts The kit connecting rod can use the original connecting rod bolt 92153 0491 When using the original connecting rod bolts make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch Connecting rod 13251 0035 Bolt 92153 0809 Attached Recess Nut 92015 1311 8108172BW1 C Installation of the kit connecting rod bolt is same as installation of the original connecting rod bolt in the 1 original connecting rod section Refer to the 1 original connecting rod section 15 Connecting Rod Big End Bushings The connecting rod bushing in the kit has improved its anti seizure feature than standard one Connecting Rod Big End Bushing Crankpin Clearance When adjust the clearance by measurement in case aiming the clearance 0 050 mm Crankpin Diameter Marks 0 34 493 34 500 mm None 34 484 34 492 mm 0105084851 Connecting Rod Big End Bore Diameter Marks O 37 509 37 516 mm None 37 50037 508 mm A Diameter Mark O or no m
14. 171 0391 are other side on the hoses e Run the hoses as shown in the illustration NOTE O Protect the hose and check the no blockade at the its curved part when the hose is afraid of interfering with edge part on the way of the hose routing Specially about the hose toward the crankcase check the no blockage by the fuel pump 30 31 Cover Gaskets The kit cover gasket are available of the 2005 model ZX 10R They are made from metal foam and made easy to separate Starter Clutch Cover 11061 0168 Idle Gear Cover 11061 0711 Clutch Cover 11061 0134 Oil Pan 11061 0169 ECU Kit The 2005 model ZX 10R kit ECU has following functions Refer to the Kawasaki FI Calibration Tool Instruction manual for the ECU function set up method 1 Auto Shift Functions Be sure use the point type sensor Recommended Dynojet mode or Battle Factory mode Part installation is refer to the Electrical Part Installation section in this Manual 2 Pit Road Engine Revolution Limit Functions ON Off Changing Switch Part Number 27010 0040 use the kit meter Part installation is refer to the Electrical Part Installation section in this Manual 3 Shift Indicator Functions Part installation is refer to the Electrical Part Installation section in this Manual NOTE O When using the original meter lit the shift up indicator light so that the shift up indicator lamp of the kit does not used O Use the shift up indicator lamp of the kit together w
15. 2 PIN 3 DAMPER RUBBER 3 CLAMP 11 BOLT FLANGED M6X12 2 PIN SNAP 10MM 3 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Chassis 13271 GRID NO This grid covers Swingarm F2141 Ref Part No Description No 13271 13271 0581 PLATE OPTION 16 DEC 16 2004 opec Code Quantity ZX1000 cel This catalog covers 05 ZX1000 CR2 Chassis 17 9 C 44026 A B ub C 59 10009 AY U 43082 43082A B Al 25 92057 92058 X lt efe S age 130 55020 8 9 4 N ww pv A AD S N NU X aA Sy GRID NO This grid covers F2240 Hef 43082 43082 43082 44026 44026 44026 55020 92057 92058 130 17 Rear Hub Part No 43082 0005 OPTION 43082 1192 OPTION 43082 1220 OPTION 44026 0046 OPTION 44026 0047 OPTION 44026 0048 OPTION 55020 0028 OPTION 92057 1529 OPTION 92058 1090 OPTION 13001020 OPTION Description PAD ASSY BRAKE FR F9633 PAD ASSY BRAKE RR C93 PAD ASSY BRAKE RR C93G SPRING FRONT FORK K 9 00N MM SPRING FRONT FORK K 9 50N MM SPRING FRONT FORK K 9 75N MM GUARD CHAIN CHAIN DRIVE 120L 520 JOINT CHAIN DRIVE 520 BOLT FLANGED 10X20 DEC 16 2004 Spec Code Quantity ZX1000 This catalog covers GRID
16. 3 GEAR SPUR IDLE 1 OPTION lt 92046 92046 1217 BEARING NEEDLE 6BTM109 1 2 OPTION CA FN 92139 92139 0121 BUSHING 1 J OPTION 480 4801300 CIRCLIP TYPE C 13MM 1 Y OPTION 92139 13107B Ref Engine Cover s 14 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine E3032 92075 gt 9085 39060A Ref Fuel Inject ion 92171 92171 92171 92171 39192 lt 92171 b 91 92171 35063 m 39192B 92171 e 92171 39192A 39062 fS 92171 8 35063A 0921 71 a N NP S SUB 35063 Hef 35063 35063A 35063B 39060 39060A 39062 39192 39192A 39192B 49085 92015 92043 92075 92171 130 554 15 GRID NO This grid covers Radiator Part No 35063 0216 OPTION 35063 0217 OPTION 35063 0218 OPTION 39060 0021 OPTION 39060 0022 OPTION 39062 1072 OPTION 39192 0011 OPTION 39192 0038 OPTION 39192 0039 OPTION 49085 1066 OPTION 92015 1487 OPTION 92043 1436 OPTION 92075 1123 OPTION 92171 0179 OPTION 130L0612 OPTION 554 1000 Quantity ZX1000 Description opec Code STAY MAIN 1 STAY RH SUB RAD 1 STAY LH SUB RAD 1 RADIATOR SUB 1 RADIATOR MAIN 1 HOSE COOLING 2 PIPE WATER 1 PIPE WATER LH SUB RAD 1 PIPE WATER RH SUB RAD 1 CAP ASSY PRESSURE 1 NUT
17. 34 0X2 0 AR OPTION 13262H 7 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine 13262 J L E1361B Sen QU 9220006 13262F A N x Z 13262D a icc Sa v7 e 132626 132626 GRID NO This grid covers Transmission 1 2 TYPE D Ref i Part No 13127 13127 0032 OPTION 13144 13144 0021 OPTION 13144A 13144 0022 OPTION 13262 13262 0134 OPTION 13262A 13262 0135 OPTION 13262B 13262 0166 OPTION 13262C 13262 0183 OPTION 13262D 13262 0218 OPTION 13262 13262 0279 OPTION 13262F 13262 0280 OPTION 13262G 13262 0281 OPTION 13262H 13262 0282 OPTION 132621 13262 0283 OPTION 13262 13262 0284 OPTION 13262K 13262 0285 OPTION 13262L 13262 0286 OPTION 92200 92200 0225 OPTION 92200A 92200 0226 OPTION 92200B 92200 0227 OPTION 92200C 92200 0228 OPTION 92200D 92200 0229 OPTION Quantity ZX1000 Description opec Code SHAFT TRANSMISSION INPUT 16T 1 SPROCKET OUTPUT 16T 520 1 SPROCKET OUTPUT 17T 520 1 GEAR INPUT 3RD amp 4TH 19T amp 21T 1 GEAR INPUT 5TH 21T 1 GEAR OUTPUT 4TH 32T 1 GEAR OUTPUT 5TH 29T 1 GEAR OUTPUT 3RD 33T 1 GEAR INPUT 2ND 18T 1 GEAR INPUT 6TH 22T 1 GEAR OUTPUT LOW 37T 1 GEAR OUTPUT 2ND 36T 1 GEAR OUTPUT 6TH 28T 1 GEAR INPUT 3RD amp 4TH 19T amp 21T 1 GEAR INPUT 3RD amp 4TH 16T amp 20T 1 GEAR INPUT 3RD amp 4TH 19T amp 20T 1 WASHER 28 1X34 0X0 8 AR WASHER 28 1X3
18. 4 0X1 0 AR WASHER 28 1X34 0X1 4 AR WASHER 28 1X34 0X1 6 AR WASHER 28 3X34 0X1 2 AR DEC 16 2004 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Transmission 2 2 TYPE D 13262 J L E1361B Ref OS Part No Description Spec Code o No cel 92200E 92200 0230 WASHER 28 3X34 0X1 4 AR OPTION 92200F 92200 0231 WASHER 28 3X34 0X1 8 AR OPTION 92200G 92200 0232 WASHER 28 3X34 0X2 0 AR OPTION 13262H 132626 9 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine E e pum ue NS Qe N MN ae a us 2 lt s NC NN XN 5 5 SMI 29 X y yv 11 SE S SNS U AW n n fe 2 A M 13145 e p amp SN AN A p gt A gt x 7 GRID NO This grid covers Gear Change Drum Shift Fork s E1362 Hef Part No NO art No Description Spec Code 13145 13145 0021 OPTION CAM CHANGE DRUM 10 DEC 16 2004 Quantity ZX1000 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Engine Cover s No Part No Description opec Code 92066 11004 11004 0022 GASKET HEAD T 0 55 1 OPTION 11004A 11004 0023 GASKET HEAD T 0 45 1 OPTION 11004B 11004 0026 GASKET HEAD T 0 65 1 OPTION 11004C 11004 0034 GASKET HEAD T 0 50 1 OPTION 11061 11061 0117 GAS
19. 5 0014 9 Insert the three collars 5 into the damper 3 e Insert the rivet 6 from the backside of the meter bracket 4 and fix them Install the bracket 4 to the original air duct 11 42 Main Harness Combination Parts Table Use the kit main harness or sub harness with the following parts as a set Main Harness Main Harness Sub Harness Paris 26031 0328 26031 0328 26031 0244 Sub Harness Sub Harness 26031 0308 26031 0307 Meter Assembly Original Tachometer with Water temperature Gauge Kit Water temperature sensor Kit Relay Box Kit NOTE O When using the main harness 26031 0328 with the sub harness 26031 0329 of the throttle bodies and relay box 27002 3703 required O When using the sub harness 26031 0244 no kit parts required Water Temperature Gauge Lead Kit Removal Parts When using the kit main harness and sub harness kit meter 26031 0307 the following Original parts are not required Original Main Harness Meter Assembly Bracket Rear View Mirror amp Meter Assembly Ignition Switch Left Switch Housing Rear Brake Light Switch Side Stand Switch Relay Box Turn Signal Relay Head Light Tail Brake Light License Plate Light Front Right Turn Signal Light Front Left Turn Signal Light Rear Right Turn Signal Light Rear Left Turn Signal Light Horn 43 When using the kit main harness and sub harness Original meter 26031 0308 the following origin
20. 7 54 Transmission Gear Table In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio In Out Teeth Out In Gear Ratio STD Type A 13127 0020 13262 0170 38 15 2 533 13262 0185 13262 0152 39 19 2 053 oee Gear Selection 13262 0182 33 19 1 737 oee Gear Selection 13262 0166 32 21 1 525 13262 0135 13262 0183 29 21 1 381 13262 0136 13262 0171 30 23 1 304 Type B 13127 0030 13262 0267 31 13 2 385 oee Gear Selection 13262 0268 34 13 1 789 oee Gear Selection 13262 0269 31 20 1 550 13262 0265 13262 0270 29 20 1 450 13262 0266 13262 0271 29 21 1 381 13127 0031 13262 0275 34 14 2 429 oee Gear Selection 13262 0276 28 16 1 750 13262 0273 13262 0277 28 20 1 400 13262 0274 13262 0278 28 21 1 333 13127 0032 13262 0281 37 16 2 313 13262 0279 13262 0282 36 18 2 000 13262 0280 13262 0283 28 22 1 273 Input 3 4 Gear Selection Table 4th Gear Oo B A C AGC 3rd Gear 13262 0134 19 21 13262 0286 19 20 B 13262 0284 19 21 13262 0264 19 20 13262 0272 16 21 13262 0285 16 20 Gear Identification Slit Number Table Standard Type A Type B Type C Type D o Input Engine Sprocket 13144 0021 20 16 13144 0022 520 17T Racing Kit Service Data J
21. ARNESS INTERFACE BOX HARNESS FOR STD HARNESS HARNESS KIT METER HARNESS STD METER HARNESS MAIN HARNESS ENGINE SUB RELAY ASSY DEC 16 2004 Quantity ZX1000 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Generator E1810 Quantity ZX1000 Hef No Part Description Spec Code 11053 11053 1557 BRACKET OIL TANK 1 OPTION 13271 13271 0149 PLATE 1 OPTION 21001 21001 0033 GENERATOR 1 OPTION 21066 21066 0010 REGULATOR VOLTAGE 1 OPTION 26031 26031 0323 HARNESS 1 OPTION 52001 52001 0002 TANK OIL 1 OPTION gt 92022 92022 304 WASHER 6 2X11X1 1 OPTION 92192A 92192 92066 92066 0052 PLUG 1 OPTION bh 92071 92071 0022 GROMMET 1 92171 OPTION 92150 92150 1880 BOLT SOCKET 6X20 3 OPTION 92171 92171 0338 CLAMP 2 OPTION 92192 92192 0226 TUBE CASE TANK 1 OPTION 92192A 92192 0227 TUBE TANK AIR CLEANER 1 OPTION 130 130 0508 BOLT FLANGED M5X8 1 OPTION 130A 130Y0610 BOLT FLANGED M6X10 1 OPTION 132 132L0608 BOLT FLANGED SMALL M6X8 2 OPTION FQ 670 670 2020 O RING 20MM 1 OPTION YS 130 y S g 13271 oU Yol 670 13 DEC 16 2004 This catalog covers GRID NO This grid covers 05 ZX1000 CR2 Engine Starter Motor E1840 Ref Part No Description opec Code Quantity ZX1000 13107 13107 0096 SHAFT 1 OPTION 13107A 13107 0097 SHAFT 1 OPTION 13107B 13107 0098 SHAFT IDLE GEAR 1 OPTION 59051 59051 005
22. Aua A 788 A 38 Ary 51 x o D 2 o yay 38 8 gt o gt w Light Blue LB Self diagnositic Indicator Terminal ot CaL m x Joint 14 49 448 nri EP Connector 2 3 Exhaust Atmospheric Pressure Sensor Fuse Box Ignition Fuse 20 1 Butterfly Valve 15 2 ECU Fuse Relay Box Actuator 5106231BW5 C 55 Wiring Diagram with Kit Meter Spark Plugs 06 0 Gear Position Switch Oil Pressure Sensor zu Shift Sensor S W Ignition Colis Crankshaft Water I TEN x Position FES T Sensor X 2 Z Speed Temperature x en en n m Sensor Sensor Cam Angle Z Sensor Shift T Sensor A D E gt ox en gt T in ore pep Se gt m gt Right Switch Housing 1 Engine Stop Switch 2 8tarter Button FF LI o N rl O y y Y R BK R BK R BR W R R BK R Water Temperature Sensor kit BK Y BK Y L R G R ye BK R BK R HR R BR R BR R LG BK BK LB FR LB LB BK Y BK Y ll HR W BR W R R Tachometer BL W BL Y Front Subharness R R R BR R Shift Up Indicator Lamp R
23. KET STARTER COVER B 1 OPTION 2 11061 11061 0134 GASKET CLUTCH COVER 1 OPTION 11004 A C n 110618 ui GASKET STARTER COVER SMALL 1 amp e oq 11061 11061 0169 GASKET PAN OIL 1 OPTION 13271 13271 0149 PLATE 1 OPTION 14091 14091 0443 COVER STARTER SMALL 1 OPTION 14091A 14091 0444 COVER STARTER LARGE 1 OPTION 92055 92055 1262 RING O 24 4X3 1 1 OPTION 92066 92066 1005 PLUG 4 OPTION 92066A 92066 1332 PLUG STARTER HOLE 1 OPTION 92066B 92066 1333 PLUG STARTER HOLE 1 11061A 130 13000625 BOLT FLANGED 6X25 1 OPTION 2 e 4 130A 130Y0508 BOLT FLANGED M5X8 1 Y i OPTION N yh 312 312 0600 NUT HEX 6MM 1 Y Xo sll 4 62 11 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine ERU gt 7 r lt 26031 lt E1530 NS k gt a 21176 Rater Radiator 26031E FOR STANDARD METER 260310 GRID NO This grid covers Fuel Injection Hef 21175 21176 26011 26011 26031 26031A 26031B 26031C 26031D 26031E 27002 12 Part No 21175 0073 OPTION 21176 1099 OPTION 26011 0071 OPTION 26011 1779 OPTION 26031 0240 OPTION 26031 0244 OPTION 26031 0307 OPTION 26031 0308 OPTION 26031 0328 OPTION 26031 0329 OPTION 27002 3703 OPTION Description opec Code CONTROL UNIT ELECTRONIC SENSOR TEMP WIRE LEAD TEMP SENSOR EARTH WIRE LEAD H
24. NO This grid covers 05 ZX1000 CR2 Chassis Handlebar Ref u Quantity ZX1000 Part No Description opec Code 11053 11053 1241 BRACKET STEERING DAMPER 1 OPTION 13280 13280 0090 HOLDER STEERING DAMPER 1 OPTION 13280A 13280 0091 HOLDER STEERING DAMPER 1 OPTION 27010 27010 0040 SWITCH SPEED CONTROL 1 59101 A OPTION 31064 31064 1151 PIPE COMP GRIP 1 OPTION SN S 32099 32099 0004 CASE UPP I OPTION 32099A CASE LWR 1 54012 13280 46075 46075 1143 GRIP THROTTLE 1 OPTION 13280A 46091 46091 1809 HOUSING ASSY CONTROL RH 1 OPTION 54012 54012 0150 CABLE THROTTLE OPENING 1 S OPTION 54012A 54012A 54012 0151 CABLE THROTTLE CLOSING 1 CLOSING OPTION 59101 59101 0001 REEL R21 5 60DEG 1 OPTION 59101A 59101 0002 REEL R20 0 65DEG 1 OPTION 92160 92160 1625 DAMPER KILL SWITCH 1 OPTION 120 120 0635 BOLT SOCKET 6X35 2 OPTION 120A 12050625 BOLT SOCKET 6X25 BLACK 2 OPTION 220 220 0522 SCREW PAN CROS 2 OPTION 18 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Chassis 130 11053B GRID NO This grid covers F2530 Meter s Ref E Part No 11053 11053 1673 OPTION 11053A 11053 1747 OPTION 11053B 11053 1748 OPTION 13061 13061 0124 OPTION 23016 23016 0006 OPTION 25031 25031 1142 OPTION 39156 39156 0098 OPTION 92015 92015 1233 OPTION 92039 92039 1106 OPTION 92152 92152 0058 OPTION 92153 92153 1275 OP
25. TION 130 130J0618 OPTION 554 554 1200 OPTION 670 670 2014 OPTION 19 Description BRACKET KIT METER BRACKET COWLING STAY LH opec Code BRACKET COWLING STAY RH BOSS LAMP ASSY INDICATOR METER ASSY PAD KIT METER NUT FLANGED 6MM BLACK RIVET COLLAR BOLT 6X12 BOLT FLANGED 6X18 PIN SNAP O RING 14MM DEC 16 2004 Quantity ZX1000 IH Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Doc No 99929 1870 01
26. TION 92015 92015 1311 NUT FLANGED 8MM 8 OPTION 92033 92033 1161 RING SNAP PISTON PIN 8 OPTION 92139 92139 0109 BUSHING CRANK PIN BLUE AR OPTION 92139A 92139 0110 BUSHING CRANK PIN BLACK 8 OPTION 92033 92139B 92139 0111 BUSHING CRANK PIN BROWN AR OPTION 92153 92153 0809 BOLT CON ROD 8X45 5 8 OPTION Nf 2 DEC 16 2004 This catalog covers 05 ZX1000 CR2 Engine 39108 A o GRID NO This grid covers E1350 Clutch Ref E Part No 13089 13089 0011 OPTION 13089A 13089 0012 OPTION 39108 39108 0004 OPTION 39108A 39108 0006 OPTION Description opec Code PLATE CLUTCH STD 40 PLATE CLUTCH STD 60 RETAINER SPRING T25 0 STD 1 0 RETAINER SPRING T 4 5 STD 1 5 DEC 16 2004 Quantity ZX1000 This catalog covers 05 ZX1000 CR2 Engine 13262B J L E1361 13262F a icc Sa v7 e 13262E 13262H GRID NO This grid covers Transmission 1 2 TYPE B Ref i Part No 13127 13127 0030 OPTION 13144 13144 0021 OPTION 13144A 13144 0022 OPTION 13262 13262 0152 OPTION 13262A 13262 0185 OPTION 13262B 13262 0264 OPTION 13262C 13262 0265 OPTION 13262D 13262 0266 OPTION 13262E 13262 0267 OPTION 13262F 13262 0268 OPTION 13262G 13262 0269 OPTION 13262H 13262 0270 OPTION 132621 13262 0271 OPTION 13262 13262 0284 OPTION 13262K 13262 0285 OPTION 13262L 13262 0286 OPTION 92200
27. _ 11 Busing 921390121 12 Starter clutch cover 14091 0444 e Remove the original starter clutch related parts When removing the original starter clutch from the case carefully remove the snap ring For disassembly replace the new one when the reuse is hard for damaging etc 19 19 14 12 D 19 9 7 8 6 5 EE OO D 3106183852 24 Stator Installation The stator is fixed to the cover 12 14091 0444 by the bolts Run the alternator lead from the inside of the cover as shown in the illustration and fix the grommet by the plate 13271 0149 original part and bolt 130Y0508 original part Be careful not to give too much torsion to the lead wire Kit Alternator Installation Install the alternator lead position on the grommet Bas shown 108209BW1 C 9 Regulator Use the kit alternator and the kit regulator 21066 0010 as a set Install the kit regulator same position of the original regulator Connect the kit sub harness 26031 0323 between the kit regulator and the kit alternator Alternator O Possible opposite down To Main Harness lt Subharness 26031 0323 Regulator 21066 0010 8108234BW1 25 1 In case of without Starter Motor X Refer to the illustration of 1 Kit Alternator Installation Remove the 2 6 8 parts and insert the plugs to the hole of the starter motor inserted as shown in the illus
28. adiator When using the radiator Kit the original reserve Side Side tank cannot be used Prepare a suitable substitute Resever reserve tank Diameter Reserve Tank should be equipped with a band so as not to affect the running and the handling 106200BS1 NOTE O Capacity of a reserve tank should be more than 200 cc O Position of the hose to a reserve tank End of the hose to the radiator should be always in the coolant End of the hose to atmosphere should be always beyond the coolant surface 29 Oil Catch Tank Kit Use the oil catch tank for the engine blowby gas Oil Catch tank 52001 0002 Tank Capacity Approximately 570 cc Oil Catch Tank Installation e Install the mounting bracket with regulator under the cross pipe of the frame by the bolts use the original regulator mounting bolts e Install the oil catch tank to the bracket as shown in the illustration Used Bolts 13061 0113 X3 9 After installing the oil catch tank make sure not to interface with the drive chain swingarm suspension at fully bottomed 9 Close the boss of oil drain of the oil catch tank with M6 bolt and gasket add the wiring not to be missing Oil Catch Tank Hose Installation 92192 0226 Crankcase to oil catch tank 92192 0227 Oil catch tank to air cleaner e Remove the original breather hose 92192 0035 Install the hose clamps so that the kit clamps 92171 0338 are catch tank side and the original clamps 92
29. al parts are not required Original Main Harness Ignition Switch Rear Brake Light Switch oide Stand Switch Relay Box Turn Signal Relay Head Light Tail Brake Light License Plate Light Front Right Turn Signal Light Front Left Turn Signal Light Rear Right Turn Signal Light Rear Left Turn Signal Light Horn Kit Meter When using the kit tachometer with water temperature gauge the following kit parts kit main harness 26031 0328 and kit sub harness 26031 0307 are required Tachometer with Water Temperature Gauge Kit 25031 1142 Water Temperature Gauge Lead Kit 26011 1779 Water Temperature Gauge Ground Lead Kit 26011 0071 Water Temperature Sensor Kit 21176 1099 44 Throttle Bodies SIO06195BW2 C 1 Injector 1 2 White Tape 3 Injector 2 4 Injector 3 5 Injector 4 6 Inlet Air Temperature Sensor Black 7 Main Harness Brown 8 Main Throttle Sensor White 9 Inlet Air Pressure Sensor Black 10 Subthrottle Sensor Black 11 Subthrottle Valve Actuator Black e Remove the original sub harness 26031 0195 from the throttle bodies Install the kit sub harness 26031 0329 as shown in the upside illustration NOTE 0 Injector lead connector 1 marked the white tape O Install the bands same position after install the kit sub harness however clamp the band so that the harness tube are not crush O Be careful that the sub harness does not to interference the throttle cables 45 Kit Main Harness In
30. ark B Weight Mark Alphabet E F et 5106174851 Connecting Rod Big End Bushings Color x E Thickness Number 92139 0109 1 488 1 493 mm 92139 0110 1 483 1 488 mm 92139 0111 1 478 1 483 mm A Color Mark 5106173851 Big End Bearing Bushing Selection Crankshaft O O Nm Nn Connecting Rod Noe O Nm O Clearance recommend 32 58 30 56 NOTE O Make the clearances between the crankshaft main Journals and the connecting rod big ends within the prescribed allowances Excessive clearances will cause the oil pressure at the connecting rod big end to drop and lead to the damage of the bearing 16 Clutch Adjustment Back Torque Limiter Setting The Ninja ZX 10R engine is equipped with the Kawasaki back torque limiter mechanism in the clutch The back torque limiter works to reduce the chance of rear wheel hop caused by engine braking during hard braking and down shifting The back torque limiter operating condition can be changed by changing the total thickness of clutch plates and changing the number of leaf springs Try different settings and select the best E T ii Id N Retainer Height Length Total thickness of clutch plates SI06235BW2 he standard setting of length A total thickness of clutch plates shown below becomes about 53 6 mm Supposed combination of steel plates is the plate with spring x 1
31. ary Air Passages on Cylinder Head Plug the holes or press fit the plugs 92066 1005 instead of the original pins Output of Secondary Air on Air Cleaner Plug the hole 4 Air Cleaner Drain Tube Use it cutting it in suitable length Camshaft Chain Tensioner 9 Replace the cam chain tensioner with the kit to decrease the flutter of tensioner Apply the engine oil to the tensioner rod O ring and tensioner body insert them into the tensioner body O Check to see that the tensioner rod turns freely in the body if not polish the tensioner rod or fine the female threads in the body with a tap Diameter x Pitch 6 mm x 1 0 mm e Install the tensioner on the cylinder block with the tensioner rod is fully pushed back 9 Turn the tensioner rod in with a screwdriver until it becomes hard to turn Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to take up any gap and tighten the locknut e After adjusting the tensioner rod if the tensioner rod does not stick out from the tensioner body use the kit long tensioner rod 13116 1166 NOTE Never forward the tensioner rod forcibly this will increase mechanical loss of the tensioner and may damage to the chain guide O The cam chain tensioner must be adjusted at every race S106121BW3 C 1 Tensioner Body 4 O ring 2 Tensioner Rod 13116 1166 Kit 5 Locknut 3 O ring Camshafts Sprockets Camshafts Sprockets 49118 0008 STD Intake
32. aw for unlock the lead 0 Be sure to lock the leads after pull off the 22 pin lead Claw White 8106228 2 C Left Switch Housing Wiring Change When using the sub harness 26031 0244 change the wiring of the original main harness for the function of speed control switch 9 Change the pin lead position refer to right figure From D Red Green Lead to 2 Position From 3 Black Yellow Lead to 4 Position 106222BS1 52 Auto Shifter Installation 5106226BW3 G 1 Side Stand Switch Connector 2 Speed Sensor Connector 9 When using the auto shifter connect the shifter connector to the side stand switch connector of the Original main harness Change the shape of the shifter connector for mismatch connectors 53 Wiring Diagram with Original Meter Spark Plugs Gear Position Switch Oil dm Pressure Sensor 06 0 Shift Sensor S W Right Switch Housing BABB Colis dic R 1 Stop Switch Water EA w osition 2 8tarter Button x 2 SS Speed Temperature at Sensor 3 8top Watch Switch TITIT Sensor Sensor C E 2 gt Q Angle 5 5 r4 1 1 Sensor Shift T At Sensor A D Meter Unit ou 1 Turn Signal Indicator Light LED VEL AE o 0 9 am x x 2 High Beam mc Indicator Light LED fess 22 3 Neutral m Indicator Light LED 4 011 Pressure War
33. basic works removing parts or installing parts etc given advices by the tuning shop In a race although trouble will be apt to happen if you participate in basic works you can discriminate cause of trouble so you can return the race soon But concerning difficult technical works you should ask to tuning shop Table of Contents General SPECHICATIONS PUR REVISE MERI DII M p RI s 3 PAGING KitSemnice DG u u uuu 5 Periodic Maintenance 5 Engine Ipo GllGIIG 7 Ar Intake 7 acea TT 8 gt uuu cer 9 C 11 VINO C 12 Fi Ip s 13 Mam JOUnMall BUSHINGS trato aan ss 13 TO 14 Rod BIG End BUSMINGS uuu onu e D 16 Clutch Adjustment Back Torque Limiter Setting 17 544 E 21
34. ch function O Hold the stop watch function of the stop watch switch 49 Sub Harness Kit Meter Installation SIO6198BW3 G Shift up Indicator Lamp 23016 0006 To connect the shift up indicator lamp Green Tachometer with Water Temperature Gauge 25031 1142 To connect the tachometer with water temperature gauge Black To connect the right switch housing Black To connect the speed control switch 27010 0040 Black To connect the main harness 26031 0328 Gray NO OI gt e Install the front sub harness for the original meter as shown in the illustration NOTE O When using the kit front sub harness 26031 0307 possible use the Original 46094 0040 and kit 46091 1809 of the right switch housing 50 Kit Sub Harness 26031 0244 Installation Install the kit sub harness 26031 0244 as shown in the illustration 1 E C U 2 Sub Harness 26031 0244 3 To connect the inter face box Black 4 Bullet Terminal Pull off the 22 pin Red Green Lead from the main harness side connector Mark 22 Pin Position Mark Unused e Install the bullet terminal in the packing of the sub harness to the 22 pin Connect the 22 bullet terminal to the bullet terminal of the sub harness XA UTM TTT Viewed Main Harness S108229BW1 C 51 NOTE O When pull off the 22 pin lead from the connector pulling up the white cl
35. der surface to 0 4 mm Do not grind the cylinder upper surface This can raise the compression ratio while keeping the clearance of the piston and valve and one of the squish Although as the engine machining is uneven determine the cutting dimension after keeping the recess and the squish before machining O Position the piston at Top Dead Center and put a small piece of modeling clay on the shoulder of the piston Install the cylinder head gasket and cylinder head and tighten the head bolts to the specified torque O Remove the cylinder head and measure the thickness of the clay The thickness of the collapsed clay is the size of the squish O The most preferable squish measurement is 0 65 mm O Select proper cylinder head gasket Cylinder Head Gasket Tightening thickness 11004 0026 0 65 mm Original 11004 0022 0 55 mm 11004 0023 0 45 mm 11004 0034 0 40 mm 12 8106127BW2 C Piston 1 Kit Piston 13001 0061 SB Method 9 Kit piston are exclusive the two piston ring for reduce the compression height dimension between the center of piston pin hole to shoulder of the piston and the mechanical friction loss e Kit piston has more reduced the weight compared the original piston 9 Establish the cylinder compression in 14 3 to use the this piston and grind off the cylinder head under surface to 0 4 mm O Always use the higher octane rating gasoline for prevent the knocking Use the kit piston rings and the kit pist
36. diator hoses connections check Brake operation check Brkepadwear chec Brake fluid level check Brake master cup and dust seal replace brake piston sel and dust seal replace Brake hose replace 2 years Drivechain adust Drive chain lubricate Drive chain Drive chain guide replace If damaged Frntfok ceanchek o L e L L L o y Nut bolt and fastener tightness check e L y Fuelsystem clean Fuel hose fuel filter replace Steering Steering stem bearing grease J J lef J Rearsprocket replace Jo J Je General lubrication of chassis perform e J J __ Wheel bearing rear grease J Swingarm pivot uni track linkage grease Swingarm pivot uni track linkage chec e l Replace add adjust clean or torque if necessary Engine Parts Installation Air Intake Parts 9 Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance O When removing the air cleaner element remove the element and relational parts as shown below 5106120 4 C 1 Relational Parts of Secondary Air Remove the Parts 2 Remove the parts or cut the cleaner element off remaining the wire net 3 Second
37. e stepped portions at the mating surface between the valve seat and the port O Smooth the inside of the intake port and exhaust port e Chamfer the machining edge of the cylinder head where the valve seat installed also smooth the dome of the combustion chamber with the valves installed Excessive smoothing may reduce the cylinder compression 9 Use the hand grinder O Use 200 oil stone for eliminating any stepped portion and 300 oil stone for finishing NOTE O These procedures make air resistance less and intake exhaust gas flow more smooth However much more effect can not be expected by excessive grinding and smoothing It may be done to the extent of getting rid of uneven surfaces SI085215BW8 C A Stepped Portions Grind Area All around port The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners 20 Smooth corner y Section magnification SI085216BW8 C NOTE O When grinding the cylinder head surface or using thinner gasket adjust the valve timing to keep that the valve to piston clearance is not less than the minimum value IN 0 7 EX 1 2 Cylinder Compression adjust the cylinder compression adjust the thickness of the cylinder head gasket or smooth the cylinder head under surface or cylinder top surface to make the piston squish 0 65 mm Keep the piston squish more than 0 65 mm O Grind off the cylinder head un
38. erformance more Radiator Installation Main Radiator Install the kit radiator mounting stay 35063 0216 to the same position of the original radiator mounting stay on the crankcase and tighten it some stays may not be able to install according to the applied muffler remodel the stay or make suitable one by your owe Sub Radiator e Install the sub radiator stays as shown in the lt Subradiator Stay illustration Installation O Fix the right side kit stay 35063 0217 on the crankshaft sensor cover A by the bolts O Fix the left kit side stay 35063 0217 on the starter cover B by the bilts Fix a wire netting in front of sub radiator for prevent the fin damages due to the stepping stone e Machine the original cowl to meet the outline of radiator e Fill the space between the cowl and the sides of radiator by fixing a sponge or the like 81068202852 After radiator s installation be sure to check that there is no interference between the radiator and the manifold tire and the front fork full bottomed The original radiator cannot combine with the kit sub radiator 27 Water Pipe Installation Use the kit main radiator only 9 Divide the original water hose 39062 0022 between the cylinder head and the radiator and insert the water pipe 39192 0011 e Install the kit water temperature sensor for water temperature gauge of kit meter 21176 1099 to the kit water pipe e Pinch the
39. ged Adjust the valve timing again to keep the valve to piston clearance more than the minimum value e Method of measuring clearance of valve and piston 1 O Holding the crankshaft at 10 ATDC intake and 10 BTDC exhaust of crankshaft timing measure the amount of the tappet movement until the valve comes in contact with the piston pushing the tappet IN 10 ATDC EX 10 BTDC S 108122BW3 e Method of measuring clearance of valve and piston 2 Adjust the valve clearance and valve timing O Remove the cylinder head and put a small piece of modeling clay on the hollow of piston to prevent valve from coming in contact O Install the cylinder head and adjust the camshaft chain timing O Turn the crankshaft by two rotations or more O Remove the cylinder head and measure the thickness of the clay The thickness of the collapsed clay is a clearance of the valve and the piston 10 Cylinder Head 9 Before reassemble the cylinder head grind off the stepped portions of the port and smooth the inside of ports to make intake exhaust gas flow smooth O Grind off the stepped portions only at the mating surface between the carburetor holder and the intake port O When using the kit camshaft 12044 0043 grind off the inside of the intake port to extent 1mm from the original port diameter for improve the performance O Mark the carburetor holders so that they can be installed in their original positions O Grind off and smooth th
40. hing D Clutch Housing E Clutch Hub F Sub Clutch Hub G H 1 19 5106175804 Friction Plates opring Plate Assembly Steel Plates opring Plate opring Retainer e Engage the cam followers Clutch Hub with the cams Sub Clutch Hub e o measure the effective stroke of clutch spring plate 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 difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate D Drive Shaft GFOG031B 5 e After installing the clutch to the engine measure and record the depth B shown below the length from the clutch spring plate to the top surface of the sub clutch hub using a caliper or a depth gauge Manage the depth B to adjust the effective stroke after that because the friction disks would be worn and the length A would change The decrease of the depth B from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured DEPTH B LENGTH TOTAL THICKNESS OF CLUTCH PLATES SI06128BW2 C 20 Spring Plate Assembly The ZX 10R engine is used with the leaf sprig built in type steel plate assembly spring plate assembly in the clutch The spring plate assembly are available for increase the spring constant When outbreak the starting judder use the spring
41. ith the kit meter but do not function as the FI indicator light 32 Frame Parts Installation Throttle Parts Kit Parts The following throttle cases grip and reels are available as kit parts These kit parts quicken throttle response to the twist grip 1 Throttle Case Throttle Case Upper 32099 0004 Throttle Case Lower 32099 0005 Bolts 2 12050625 Grip Right 46075 1143 2 Throttle Reels Tow types are available Twist Grip Turn Angle 99101 0001 99101 0002 Throttle Reel Travel Angle 1 Identification Mark Upper Case 32099 0004 Lower Case 32099 0005 Reel 60 59101 0001 Reel 65 59101 0002 Throttle Cable Acceleration 54012 0150 Throttle Cable Deceleration 54012 0151 Bolt 12050625 Install the upper case and lower case which mating clearance backward N O Q 33 Final Drive Parts Kit Parts 1 Drive Chain 520 Joint endless drive chain is available as an kit parts 2 Chain Guard 1 Guard 55020 0028 2 Bolt 130J1020 3 Swingarm Left Side Brake Pads Kit Parts The front and rear brake pads for racing use are available The front pads are for higher braking force and the rear pads are for higher braking force Front Brake Pads Braking Force 43082 0005 Original 43082 1293 ZX 6RR Original NOTE O Removing the plate 13271 0365 from original front brake pads of ZX 10R is permissible Rear Brake Pads Braking F
42. lick 3 Seat Height Adjustment Loosen the nut 1 and insert the spacer 2 as required Tighten the nut 1 to 59 6 0 kgf m 43 ft lb of torque e When changing the seat height adjust the spring preload of the rear shock absorber O As the rear suspension tends to be softer when raising the seat height with the adjusting spacer of the seat height applied adjust the spring preload of the rear shock absorber as required O One turn of the spring adjusting nut changes the spring length by 1 5 mm 38 Seat Height Adjustment Spacer Set 92026 005 7 1053 1278 Spacer for seat height adjust insert between collar and bracket SIO06115BW5 C 39 Front Fork Springs Kit Parts The kit front fork springs are available for racing 1 Front Fork Specifications ltems Original Rebounded damping setting Upper 9th 0 13 Compression damping setting Lower fth 0 16 Fork oil KAYABA KHL 15 10 Fork oil level 91 mm Cil lock Oil lock piece Oil seal opring length 240 3 mm muount 245 3 mm free Spring constant 9 25 N mm Spacer length 101 mm Sub spring stroke 20 5 mm 2 Front Fork Spring A x B x C mm Original 48 287 24553 15 7 K 925Nmm 44026 0048 4 9 x 28 5 x 245 3 K 9 75 N mm A Coil Diameter B Spring Inside Diameter C Spring Free Length 3 Front Fork Spring Replacement Replace the main spring referring to the Fork Oil Change section of
43. ning L u Indicator Light LED o ve m m B Fuel Level Warning m IIl LL 1 Indicator Light LED up 7 gt 6 Indicator Light LED 7 0dometer Trip Meter Glock Stop Watch 8 Water Temperature Gauge 9 Tachometer 11 Meter Light LED 12 Shift Up Indicator Light LED L K ol Lo i l TII RC d 2 EL M p i 1 8 sva L amp BK LG BK LG BK l H T3 T T g BL BK vs L JL W R BL W TL TT 81 9 BL W BL Y BL Y BL Y 10 ELL Subharness 9 Le s BK Y 0 GY BK BK R W R BR x m Left Switch Housing 1 Horn Button 2 Speed Control Switch 3 Turn Signal Switch 4 S8tarter Lockout Switch 5 Lap Time Button Main Fuse 30A o4 BK Y W R gt x gt gt MM E 8 MM x m gt x m x gt Zr S Frame Ground Battery Vehicle Fue 12V10Ah Engine down Ground Sensor j Fuel Switch Pump SI086230BW5 C Electronic R G Y BK R G BK BR W BR BK R BK BR Y 38 0 Nu IL A 8 Mee lli l 5 18 III TTI
44. onnect the water temperature sensor at the cylinder head rear side For recommended auto shifter refer to the Kawasaki FI Calibration Tool Instruction Manual of another sheet 47 8106197BW2 Relay Box Original Turn Signal Relay Original Exhaust Butterfly Valve Actuator Original To connect the E C U Black Fuse Box To connect the relay box Gray Relay Box 27002 3703 To Connect atmospheric pressure sensor Black Atmospheric Pressure Sensor Original To connect the inter face box Black O Q gt 9 Remove the original relay box and original turn signal relay e Remove the 3 exhaust butterfly valve actuator except the exhaust pipes are used e Drill the rear fender for the relay box 27002 3703 installation however be careful that the relay box does not to interference the around parts 48 Sub Harness Original Meter Installation SIO6198BW3 G 1 To connect the original meter Black 2 To connect the right switch housing Black 3 To connect the left switch housing Black 4 To connect the main harness 26031 0328 Gray e Install the front sub harness 26031 0328 for the original meter as shown in the illustration When using the original meter use the left and right original switch housings NOTE O When using the original meter function the head light dimmer switch or and passing button for the speed control swit
45. ons e Change the kit pistons from the original pistons inspect the squish refer to the Cylinder Compression section Use the kit pistons 13001 0061 following below O Use the kit connecting rod assemblies 13251 0015 O Use the kit piston rings 13008 0019 O Use the kit piston pins and snap rings O There are the machining edge for the valve relief portions of the piston heads Must be hand finished for smooth corners Round the corner to R1 Crankshaft Main Journal Bushings e Crankshaft Main Journal Bushings Use original bushings 13 Connecting Rod Bolts 1 Original Connecting Rod Use the original connecting bolts and nuts Make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch Connecting Rod 13251 0005 Bolt 92153 0491 92153 0809 Kit Part Attached Recess Nut 92015 1311 8106124BW1 C Install the original bolts into the connecting rod 9 Before every tightening use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch Apply a small amount of molybdenum disulfide grease to the threads and seating surfaces of nuts and bolts Tighten the big end nuts at the torque reference torque of 20 N m 2 0 kgf m 14 5 16 9 Check the length of the bolts and find the bolt stretch Bolt Length after tightening Bolt Length before tightening Stretch Bolt Stretch Usable Range
46. orce Original FO GG High 43082 1220 C93G t 43082 1192 C93 Low 34 Steering Damper Kit Parts The steering damper is useful at high speeds to prevent handlebar vibration The steering damper should be installed to do not the steering handle movement stop by the steering damper itself at the fully locked position both left and right side 1 Recommended Steering Damper OHLINS SD2005 2 Stroke SD2005 150 mm 3 Installation e Install the steering damper carefully to avoid the steering damper as a stopper 8106114 4 Steering Damper OHLINS SD2005 Holder 13280 0090 Holder 13280 0091 Bolt Allen 120P0635 Steering Damper Bracket 11053 1241 WN 35 NOTE 0 holder s one side mating surface are shifted from center about 1 5 mm to ensure tightening force O Install the holder properly shown below to avoid steering damper operation stick 5106049851 C 1 No Gap 2 Gap 3 mm or less O Install the holder to 31mm range below to avoid the journal position SI06113BN9 1 Journal 36 O When install the steering damper which stroke less than 150 mm apply the suitable stopper as shown below SI06112BN9 Steering Damper Holder Holder Bolt Allen Stopper Apply and tighten with ram duct installation bolt WN 4 Damper Adjuster otandard Position 8th click 1st click harder is fully clockwise click Usable Range 1st to 12 17th c
47. plate assembly of the kit parts Whenever the plate thickness is difference for adjusting the clutch plate take care the length Part Number Spring Constant ID Color 13089 0003 Standard 13089 0011 40 9e up comparison standard White 13089 0012 60 up comparison standard X Identification Color The ID marks on the springs between the steel plates ID Color Section S108204BW1 C Transmission B D of the kit gears are available of the 2005 model ZX 10R To change the gear ratios with combination the gears 9 Remove the three steel balls 600A0500 from the output shaft assembly This is done to start easily the engine with the second gear 9 Replace the circlips with new ones if they were removed 21 Transmission Shimming By using washers with various thickness keep the axial clearance between 0 3 mm and 0 4 mm to prevent the inclination of gears and to keep smooth gear shifting Jes all H L E mr H OS SIO6180BW2 C Thiknes mm PartNo Remarks D Spline washer Plane washerA 08 7 922000255 22 Use the type B D input shafts with the shim adjustment since their sizes are different from the standard shaft designed taking the shim adjustment into account in order to make the dog lengths of the 3 5 amp 2 _ 6 gear dogs equal Adjust the dog length of each gea
48. rs to smooth gear shifting Dog Length Dog Length SIO8208BM3 6 SI08207BM3 Standard Adjusting D 2 Use the standard spline washer t1 6 mm 92200 0050 2 2 Use the standard spline washer t1 2 mm 92200 0051 When thin the washer of D 1 2 1 from the standard washer and thickly the washer of 2 5 2 from the standard washer to increase the dog length of gears also reverse the combination to reduced the dog length of gear Alternator Racing kit of the 2005 model ZX 10R are available the alternator to install the left end of the crankshaft To quicken response by reducing the flywheel mass and to reduce the weight use the kit alternator Also use the kit alternator improve the engine ability Kit Alternator Rated Output 10A 8000 rpm original 30A 5 000 rpm X Effective current 7 8 A for running the race method vehicle 9 Select and use the kit alternator or original alternator for racing conditions 23 1 Kit Alternator Installation When using the kit alternator remove the related parts of the original alternator and changing the around parts of the starter from original parts to kit parts Install the kit alternator as shown in the illustration Used Parts Table PatName Remark 2 Shaftt 7 131070007 3 Shaft2 13107 0000 4 Circip 48001300 1 5 Needlebearing 92046 1217 6 Shaft3 7 1310700088 7 ldlegearcover 4401043 ME 9908 9083
49. stallation ullum 46 0 0 To throttle bodies connector Gray Crankshaft Sensor Connector Brown Battery Ground Cable Use Original Part 4 Frame Ground Regulator Starter Relay To front sub harness connector 26031 0307 or 26031 0308 Camshaft Position Sensor Gray 9 Ignition Coils Gray 10 Water Temperature Sensor Black 11 Vehicle down Sensor Gray 12 Fuel Pump Black 13 To battery Ground terminal Semitransparent 14 Auto Shifter Yellow 15 Auto Shifter Blue 16 To speed sensor connector Black 17 Speed Sensor Original 18 To gear position switch connector Green 19 Gear Position Switch Lead Original N CON O Remove the original main harness from the frame Install the kit main harness 26031 0328 as shown in the illustration Connect the 2 crankshaft sensor connector to the original crankshaft sensor connector Use the original part for the 3 battery ground cable Connect the 8 camshaft position sensor connector to the camshaft position sensor at the cylinder head front side Use the original part for 9 ignition coil connector at the cylinder head upper side Connect the 10 water temperature sensor connector to the water temperature sensor at under the 1 2 intake ducts of cylinder When using the recommended auto shifter to connect the 15 auto shifter connector Do not use the 14 auto shifter NOTE When using the kit tachometer always c
50. tration PartNo Remark 92066 1332 92066 1333 Kit 13060625 Caulking the bolt for unplug the plug Insert the plug into the hole of the starter motor and tighten the nut 9 Apply liquid gasket Liquid Gasket 106201B32 2 Original Alternator removal Remove the original alternator related parts for use the kit alternator Close the holes of the alternator cover and crankcase as shown in the illustration Used parts as following table oealed Parts for Alternator PartNo Remark 92071 0022 13271 0149 2 130Y0508 x 6 Sealed Parts for Crankcase PartNo Remark 6 Alternator shaft lever 13168 0035 Original 8 Bot 92153 0758 5106185852 26 Water Temperature Sensor The original water temperature sensor installed in the cylinder head must be remain and connected to the main harness because the electronic control unit E C U needs the output signal from the original water temperature sensor Radiator 2005 model ZX 10R racing kit provides the capacity increased type main radiator and added the sub radiator to improved the cooling function Replace of the kit main radiator 39060 0022 is enough effectives of the cooling performance but at high ambient temperature using the kit sub radiator 39060 0021 with kit main radiator increase cooling p

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