www.zxforums.com www.zxforums.com www.zxforums.com Ninja ZX-10R www.zxforums.com Motorcycle Service Manual www.zxforums.com www.zxforums.com www.zxforums.
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www.zxforums.com www.zxforums.com www.zxforums.com Quick Reference Guide General Information 1 j Periodic Maintenance 2 j Fuel System (DFI) 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j Engine Removal/Installation 8 j Crankshaft/Transmission 9 j www.zxforums.com Final Drive Wheels/Tires This quick reference guide will assist you in locating a desired topic or procedure.
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www.zxforums.com www.zxforums.com www.zxforums.com Ninja ZX-10R www.zxforums.com Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
www.zxforums.com A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L LIST www.zxforums.com OF ABBREVIATIONS ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W Ω www.zxforums.
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 emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
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.
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 information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
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www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications.........................................................................................................
1-2 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 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.
1-4 GENERAL INFORMATION www.zxforums.com 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 sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them.
www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 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 contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed.
1-6 GENERAL INFORMATION www.zxforums.com 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. Lubrication 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.
www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 1-7 Model Identification ZX1000D6F (Europe) Left Side View ZX1000D6F (Europe) Right Side View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
1-8 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Model Identification ZX1000D6F (United States and Canada) Left Side View ZX1000D6F (United States and Canada) Right Side View www.zxforums.com Frame Number www.zxforums.com Engine Number www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 1-9 General Specifications Items 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 ZX1000D6F (Ninja ZX-10R) 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.
1-10www.zxforums.com GENERAL INFORMATION www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com GENERAL INFORMATION www.zxforums.com 1-11 General Specifications Items Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb: High Low Tail/Brake Light Alternator: Type Rated Output ZX1000D6F (Ninja ZX-10R) Dual discs Single disc 12 V 10 Ah Semi-sealed beam 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) 12 V 0.5/4.
1-12www.zxforums.com GENERAL INFORMATION www.zxforums.com www.zxforums.com Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro Symbol M k c m µ Units of Length × × × × × km m mm Power 1 000 000 1 000 0.01 0.001 0.000001 × × 2.205 0.03527 = = N·m N·m N·m kgf·m kgf·m kgf·m lb oz Units of Volume L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 × × × × = = = mile ft in × × × × × × 0.1020 0.7376 8.851 9.807 7.233 86.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications .........................................................................................................................
2-2 PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com www.zxforums.com Steering Play Adjustment.................................................................................................. Steering Stem Bearing Lubrication ................................................................................... Steering Damper Oil Leak Inspection ............................................................................... Electrical System ..........................................................
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever comes first INSPECTION Fuel System Throttle control system (play, smooth return, no drag)-inspect Every year * ODOMETER READING × 1 000 km (× 1 000 mile) 1 6 (0.
2-4 PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first CHANGE/REPLACE ITEM Air cleaner element # Every * ODOMETER READING × 1 000 km (× 1 000 mile) 1 (0.6) 12 (7.
2-6 PERIODIC MAINTENANCE www.zxforums.com 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 molybdenum disulfide oil solution.
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2-8 PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com www.zxforums.com Torque and Locking Agent Fastener N·m Clutch Clutch Cover Mounting Bolts 10 Clutch Hub Nut 130 Clutch Lever Clamp Bolts 7.8 Clutch Spring Bolts 9.
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2-12www.zxforums.com PERIODIC 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 6 8 10 12 14 16 18 20 N·m 3.4 ∼ 4.9 5.9 ∼ 7.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-13 Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner 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 Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 1 100 ±50 r/min (rpm) 31.5 ±1.
2-14www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Specifications Item Standard Final Drive Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug Type 30 ∼ 35 mm (1.2 ∼ 1.4 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Service Limit – – – 323 mm (12.7 in.) RK EXCEL RK 525MFO, Endless 108 links – – – – – – – – – DOT4 – – – 4.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-15 Special Tools Inside Circlip Pliers: 57001-143 Vacuum Gauge: 57001-1369 Steering Stem Nut Wrench: 57001-1100 Extension Tube: 57001-1578 Jack: 57001-1238 Pilot Screw Adjuster, D: 57001-1588 www.zxforums.com Oil Filter Wrench: 57001-1249 www.zxforums.com Jack Attachment: 57001-1608 www.zxforums.com www.zxforums.
2-16www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection the throttle grip free play [A]. • Check If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) that the throttle grip [B] moves smoothly from full • Check open to close, and the throttle closes quickly and com- • • • • • • • pletely by the return spring in all steering positions.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-17 Maintenance Procedure a vacuum gauge (special tool) and hoses [A] to • Connect the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 a highly accurate tachometer to one of the stick • Connect coil primary leads. • Connect: Fuel Pump Lead Connector Extension Tube [A] Special Tool - Extension Tube: 57001-1578 the engine and warm it up thoroughly. • Start Check • [B].
2-18www.zxforums.com PERIODIC 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 lower vacuum between #1 and #2 to higher vac• Adjust uum of #1 and #2. the lower vacuum between #3 and #4 to higher • Adjust vacuum of #3 and #4.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-19 Maintenance Procedure out the same number of turns counted when first • Back turned in. This is to set the screw to its original position. NOTE ○A throttle body has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “turns out” determined during disassembly. the same procedure for other bypass screws. • Repeat the synchronization.
2-20www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Idle Speed Adjustment the engine and warm it up thoroughly. • Start Turn the screw [A] until the idle speed is correct. •○Open andadjusting close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-21 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection the canister as follows. •○Inspect Remove the right upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). ○Remove the canister [A], and disconnect the hoses from the canister. ○Visually inspect the canister for cracks or other damage.
2-22www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○Check the level when the engine is cold (room or ambient temperature). the coolant level in the reserve tank [A] with the • Check motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F” level line [C].
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-23 Maintenance Procedure the cylinder head cover (see Cylinder Head • Remove Cover Removal in the Engine Top End chapter). the timing inspection cap [A] and starter clutch • Remove bolt cap [B] on the starter clutch cover [C].
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www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 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 1.400 92180-0112 140 1.425 92180-0113 142 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.
2-26www.zxforums.com PERIODIC MAINTENANCE 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. ○If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. installing the shim, face the marked side toward the • When valve lifter.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-27 Maintenance Procedure the engine and run it at idle speed. • Start Plug [A] switching valve hose [B] end with your • finger andthefeelairvacuum pulsing in the hose. • If there is no vacuum pulsation, check the hose line for leak.
2-28www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure the release lever [A] toward the front of the motor• Push cycle until it becomes hard to turn. ○At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 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) WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.
2-30www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Drive Train Drive Chain Lubrication Condition Inspection a special lubricant is not available, a heavy oil such as • IfSAE 90 is preferred to a lighter oil because it will stay on • the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. CAUTION The O-rings between the side plates seal in the lubricant between the pin and the bushing.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-31 Maintenance Procedure Drive Chain Slack Adjustment the cotter pin [A], and loosen the rear axle nut • Remove [B]. the both chain adjuster locknuts [C]. • Loosen If the chain is too loose, turn out the left and right chain • adjuster [D] evenly. If the chain is too tight, turn in the left and right chain adjusters evenly, and kick the wheel forward.
2-32www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Wheel Alignment Inspection that the notch [A] on the left alignment indicator [B] • Check aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment). NOTE ○Wheel alignment can be also checked using the straightedge or string method.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-33 Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension • chapter) Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection the brake lever or pedal and inspect the brake fluid • Apply leak from the brake hoses [A] and fittings.
2-34www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Brake Fluid Level Inspection that the brake fluid level in the front brake reservoir • Check [A] is above the lower level line [B]. NOTE ○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-35 Maintenance Procedure • If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
2-36www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Front Fork Oil Leak Inspection inspect the front forks [A] for oil leakage. • Visually Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection inspect the shock absorber [A] for oil leakage. • Visually If the oil leakage is found on it, replace the shock absorber with a new one.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-37 Maintenance Procedure Steering System Steering Play Inspection the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). • Lift the front wheel off the ground using the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 the front wheel pointing straight ahead, alternately • With tap each end of the handlebar.
2-38www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure the claw washer [A] so that its bent side [B] faces • Install upward, and engage the bent claws with the grooves of • • stem locknut [C]. Hand tighten the stem locknut until it touches the claw washer. 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].
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-39 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step Turn on the ignition switch. The following lights should go on according to below table.
2-40www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Third Step Turn on the turn signal switch [A] (left or right position). The left or right turn signal lights [B] (front and rear) according to the switch position should flash. The turn signal indicator light (LED) [C] in the meter unit should flash. If the each light does not flash, inspect or replace the following item.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-41 Maintenance Procedure the dimmer switch to high beam position. • Set The • go on.low beam [A] and high beam [B] headlights should high beam indicator light (LED) [C] should go on. • The If the high beam headlight and/or high beam indicator light • • • • (LED) does not go on, inspect or replace the following item.
2-42www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure NOTE ○ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations. ○For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-43 Maintenance Procedure If the sidestand switch operation does not work, inspect or replace the following item.
2-44www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Others Chassis Parts Lubrication lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-45 Maintenance Procedure the cable disconnected at both ends, the inner cable • With should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. Bolts, Nuts and Fasteners Tightness Inspection the tightness of the bolts and nuts listed here.
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www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-47 Maintenance Procedure Replacement Parts Air Cleaner Element Replacement NOTE ○In dusty areas, the element should be replaced more frequently than the recommended interval. ○After riding through rain or on muddy roads, the element should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle assembly, the throttle may become stuck, possibly causing an accident.
2-48www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure a new element [A] so that the element ends [B] • Install 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 prematurely or lower the engine performance. • Tighten: Torque - Air Cleaner Element Cover Screws: 1.1 N·m (0.11 kgf·m, 9.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-49 Maintenance Procedure and pull [A] the fuel hose joint [B] back and forth • Push more than two times and make sure it is locked and doesn’t come off. WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak. • • • If it comes off, reinstall the hose joint. Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
2-50www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure • Remove: Bolts [A] • Coolant Reserve Tank [B] Remove the cap [C] and pour the coolant into a container. • Install the coolant reserve tank. Torque - Coolant Reserve Tank Mounting Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) the drain bolts. • Tighten Replace the drain bolt gasket with a new one. Torque - Coolant Drain Bolt (Water Pump): 10 N·m (1.0 kgf·m, 89 in·lb) Coolant Drain Bolt (Cylinder): 10 N·m (1.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-51 Maintenance Procedure the air from the cooling system as follows. •○Bleed Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○Tap the radiator hoses to force any air bubbles caught inside. ○Stop the engine and add coolant up to the radiator filler neck. Install the radiator cap.
2-52www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Radiator Hose and O-ring Replacement the coolant (see Coolant Change).
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-53 Maintenance Procedure Engine Oil Change the motorcycle so that it is vertical after warming • Situate up the engine. the engine oil drain bolt [A] to drain the oil. •○Remove The oil in the oil filter can be drained by removing the filter • (see Oil Filter Replacement). Replace the drain bolt gasket with a new one. Tighten the drain bolt. Torque - Engine Oil Drain Bolt: 20 N·m (2.
2-54www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure the filter with a new one. • Replace Apply engine oil to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. • Torque - Oil Filter: 31 N·m (3.2 kgf·m, 23 ft·lb) NOTE ○Hand tightening of the oil filter can not be allowed since it does not reach to this tightening torque. in the specified type and amount of oil (see Engine • Pour Oil Change).
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-55 Maintenance Procedure the brake fluid reservoir. • Level Remove reservoir cap. • Remove the the • caliper. rubber cap from the bleed valve [A] on the a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a container. • Fill the reservoir with fresh specified brake fluid. the brake fluid. •○Change Repeat this operation until fresh brake fluid comes out 1. 2. 3. 4.
2-56www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. • • Special Tool - Inside Circlip Pliers: 57001-143 the locknut [E] and pivot bolt [F], and remove the • Unscrew brake lever. the circlip [G].
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-57 Maintenance Procedure brake fluid to the new parts and to the inner wall of • Apply the cylinder. care not to scratch the piston or the inner wall of the • Take cylinder. • 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·lb) 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.
2-58www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure NOTE ○If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○Prepare a container for brake fluid, and perform the work above it. ○Remove the pad spring and pads (see Front Brake Pad Removal in the Brakes chapter). ○Pump the brake lever until the pistons come out of the cylinders, and then disassemble the caliper.
www.zxforums.com www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com 2-59 Maintenance Procedure Rear Caliper Disassembly Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). Remove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). Using compressed air, remove the piston. ○Cover the caliper opening with a clean, heavy cloth [A]. ○Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.
2-60www.zxforums.com PERIODIC MAINTENANCE www.zxforums.com www.zxforums.com Maintenance Procedure brake fluid to the outside of the piston, and push it • Apply into the cylinder by hand. the shaft rubber friction boot [A] and dust boot • Replace [B]. a thin coat of PBC (Poly Butyl Cuprysil) grease to • Apply the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease). the pad spring [A] in the caliper as shown.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-1 www.zxforums.com Fuel System (DFI) Table of Contents Exploded View........................................................................................................................ DFI System............................................................................................................................. Specifications ...................................................................................................................
3-2 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Output Voltage Inspection................................................................................................. 3-73 Gear Position Switch (Service Code 25) ................................................................................ 3-75 Gear Position Switch Removal/Installation ....................................................................... 3-75 Gear Position Switch Inspection ................................
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-3 www.zxforums.com Warning Indicator Light (LED) ................................................................................................ Light (LED) Inspection ...................................................................................................... Fuel Line................................................................................................................................. Fuel Pressure Inspection ...................
3-4 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FUEL SYSTEM (DFI) 3-5 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 Fastener Air Cleaner Housing Holder Clamp Screws Air Cleaner Element Cover Screws Air Inlet Duct Mounting Bolts Air Cleaner Housing Mounting Bolts N·m 2.0 1.1 7.0 7.0 Torque kgf·m 0.20 0.11 0.71 0.71 ft·lb 18 in·lb 9.7 in·lb 62 in·lb 62 in·lb Remarks L 5. Air Cleaner Element 6. Air Inlet Duct 7. Air Switching Valve L: Apply a non-permanent locking agent.
3-6 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FUEL SYSTEM (DFI) 3-7 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 Fastener Speed Sensor Bolt Crankshaft Sensor Bolts Gear Position Switch Screws Camshaft Position Sensor Bolt Vehicle-down Sensor Bolts Water Temperature Sensor Throttle Body Assy Holder Clamp Bolts Throttle Body Assy Holder Bolts Inlet Air Pressure Sensor Bracket Screws Delivery Pipe Mounting Screws Bypass Screws N·m 10 6.0 3.0 10 6.0 25 2.0 10 3.5 5.0 0.2 Torque kgf·m 1.0 0.61 0.31 1.
3-8 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FUEL SYSTEM (DFI) 3-9 www.zxforums.com www.zxforums.com Exploded View No. Fastener 1 2 3 4 5 6 7 Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Pump Bolts Canister Bracket Mounting Bolt (M5) Canister Bracket Mounting Screws (M5) Separator Bracket Mounting Bolts Separator/Canister Hose Clamp Bolt N·m 0.8 5.0 10 4.3 4.3 7.0 7.0 Torque kgf·m 0.08 0.50 1.0 0.44 0.44 0.71 0.
3-10www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com DFI System DFI System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-11 www.zxforums.com DFI System 1. ECU 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10. Inlet Air Temperature Sensor 11. Gear Position Switch 12. Vehicle-down Sensor 13. Fuel Injectors 14. Delivery Pipe 15. Pressure Regulator 16. Fuel Pump 17. Fuel Filter 18. Speed Sensor 19.
3-12www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore Throttle Body Vacuum Bypass Screws ECU: Make Type Standard 1 100 ±50 r/min (rpm) Four barrel type 43 mm (1.7 in.) 31.5 ±1.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-13 www.zxforums.
3-14www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Peak Voltage Adapter: 57001-1415 Fork Oil Level Gauge: 57001-1290 Needle Adapter Set: 57001-1457 Vacuum Gauge: 57001-1369 Throttle Sensor Setting Adapter: 57001-1538 www.zxforums.com Hand Tester: 57001-1394 Sensor Harness Adapter: 57001-1561 Throttle Sensor Setting Adapter #1: 57001-1400 Extension Tube: 57001-1578 www.zxforums.com www.zxforums.com www.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-15 www.zxforums.com Special Tools and Sealant Fuel Pressure Gauge Adapter: 57001-1593 Kawasaki Bond (Silicone Sealant): 56019-120 Fuel Hose: 57001-1607 Kawasaki Bond (Liquid Gasket - Black): 92104-0002 Speed Sensor Measuring Adapter: 57001-1667 Kawasaki Bond (Silicone Sealant): 92104-0004 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-16www.zxforums.com FUEL SYSTEM (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] www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-17 www.zxforums.com 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) www.zxforums.com Oxygen Sensor #1 [A] (Europe Models) Oxygen Sensor #2 [B] (Europe Models) www.zxforums.com www.zxforums.com www.zxforums.
3-18www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com DFI System DFI System Wiring Diagram www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-19 www.zxforums.com DFI System Part Name 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Stick Coil #1,#2,#3,#4 5. Camshaft Position Sensor 6. Injector #1 7. Injector #2 8. Injector #3 9. Injector #4 10. Crankshaft Sensor 11. Subthrottle Valve Actuator 12. Subthrottle Sensor 13. Main Throttle Sensor 14. Inlet Air Pressure Sensor 15. Water Temperature Sensor 16. Speed Sensor 17. Oxygen Sensor #1 (Europe Models) 18.
3-20www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Unused 2. Subthrottle Valve Actuator 3. Subthrottle Valve Actuator 4. Gear Position Switch 5. Crankshaft Sensor (–) 6. Speed Sensor 7. Power Supply to Sensors 8. Inlet Air Temperature Sensor 9. Vehicle-down Sensor 10. Exhaust Butterfly Valve Sensor 11. Atmospheric Pressure Sensor 12. Oxygen Sensor #2 13. Fuel Pump Relay 14. Battery Monitor 15.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-21 www.zxforums.com DFI System 35. External Communication Line (Immobilizer/*KDS) 36. Immobilizer Amplifier 37. Warning Iadicator Light (LED) (FI/Immobilizer) 38. Air Switching 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.
3-22www.zxforums.com FUEL SYSTEM (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. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-23 www.zxforums.com DFI Servicing Precautions ○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. ○When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage.
3-24www.zxforums.com FUEL SYSTEM (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. Outline When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-25 www.zxforums.com 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. 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.
3-26www.zxforums.com FUEL SYSTEM (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. checking the DFI parts, use a digital meter which • When can be read two decimal place voltage or resistance. ○The DFI part connectors have seals, including the ECU.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-27 www.zxforums.com Troubleshooting the DFI System check battery condition before replacing the DFI • Always parts. A fully charged battery is a must for conducting • • • • • • accurate tests of the DFI system. Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem.
3-28www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Troubleshooting the DFI System ○If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness is open, repair or replace the harness.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-29 www.zxforums.com Troubleshooting the DFI System ○Electrical Connectors: Female Connectors [A] Male Connectors [B] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-30www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Troubleshooting the DFI System DFI Diagnosis Flow Chart www.zxforums.com Inquiries to Rider ○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-31 www.zxforums.com Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred.
3-32www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed □ very low idle speed, □ very high idle speed, □ rough idle speed. □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitation when acceleration. □ engine oil viscosity too high. □ brake dragging.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-33 www.zxforums.com DFI System Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○The 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.
3-34www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-35 www.zxforums.com DFI System Troubleshooting Guide Symptoms or possible Causes Cylinder head warped No valve clearance Valve guide worn Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulating on seating surface) Actions (chapter) Inspect and replace (see chapter 5). Adjust (see chapter 2). Inspect and replace (see chapter 5). Inspect and replace (see chapter 5). Inspect and repair or replace (see chapter 5).
3-36www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com FUEL SYSTEM (DFI) 3-37 www.zxforums.com www.zxforums.
3-38www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-39 www.zxforums.com DFI System Troubleshooting Guide Symptoms or Possible Causes Stick coil trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter in fuel Actions (chapter) Inspect (see chapter 16). Clean element or inspect sealing (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Change fuel.
3-40www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-41 www.zxforums.com Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit.
3-42www.zxforums.com FUEL SYSTEM (DFI) 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 ○When a problem occurs with the DFI system and ignition system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-43 www.zxforums.com Self-Diagnosis the ignition switch ON. • Turn Push • the Mode button [A] to display the odometer. the RESET button [A] for more than two seconds. • Push The service code [B] is displayed on the LCD by the num• ber of two digits. ○After switching to the engine speed setting mode of the www.zxforums.
3-44www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Self-Diagnosis Self-Diagnosis Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-45 www.zxforums.com Self-Diagnosis Service Code Reading ○The service code(s) is displayed on the LCD by the number of two digits. ○When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. ○Then after completing all codes, the display is repeated until the ignition switch is turned OFF or RESET button is pushed for more than two seconds.
3-46www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-47 www.zxforums.com Self-Diagnosis Backups ○The ECU takes the following measures to prevent engine damage when the DFI, ignition or immobilizer system parts have troubles. Service Codes 11 12 13 14 15 21 23 24 25 Parts Output Signal Usable Range or Criteria Main Throttle Sensor Main Throttle Output Voltage Sensor 0.2 ∼ 4.
3-48www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-49 www.zxforums.com Self-Diagnosis Service Codes Parts 75 ECU Main Relay 83 Oxygen Sensor #2 (Europe Models) Output Signal Usable Range or Criteria When the relay OFF condition, the main relay is open. The oxygen sensor #2 is active and sensor must send signals (output voltage) continuously to the ECU. Backups by ECU – If the oxygen sensor #2 is not activated, the ECU stops feedback mode of the oxygen sensor #1 and #2.
3-50www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Main Throttle Sensor (Service Code 11) 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 injection quantity, and ignition timing according to engine rpm, and throttle opening.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-51 www.zxforums.com Main Throttle Sensor (Service Code 11) the throttle body assy temporarily (see Throttle • Remove Body Assy Removal). • Disconnect the main throttle sensor connector [A]. the harness adapter [A] between the harness • Connect connector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads.
3-52www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Main Throttle Sensor (Service Code 11) Output Voltage Inspection the output voltage at the ECU in the same way • Measure 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 (+) → Y/W lead (terminal 26) Meter (–) → BR/BK lead (terminal 34) the engine and warm it up thoroughly.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-53 www.zxforums.com Main Throttle Sensor (Service Code 11) NOTE ○The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5V exactly. ○When the input voltage reading shows other than 5V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V. 0.65 × 4.75 ÷ 5.00 = 0.62 V 3.90 × 4.75 ÷ 5.00 = 3.71 V Thus, the valid range is 0.62 ∼ 3.
3-54www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Main Throttle Sensor (Service Code 11) the main throttle sensor connector and con• Disconnect nect the harness adapter [A] between the harness connector and main throttle sensor connector. Special Tool - Throttle Sensor Setting Adapter: -1538 57001 • Connect a digital meter to the harness adapter leads.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-55 www.zxforums.com Main Throttle Sensor (Service Code 11) Resistance Inspection the ignition switch OFF. • Turn Disconnect the main throttle sensor connector. • Connect a digital • connector [B]. meter [A] to the main throttle sensor • Measure the main throttle sensor resistance.
3-56www.zxforums.com FUEL SYSTEM (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 the ignition switch OFF.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-57 www.zxforums.com Inlet Air Pressure Sensor (Service Code 12) • • If the reading is within the standard range, and check the input voltage again at the sensor connector. Remove the air cleaner housing (see Air Cleaner Housing Removal). Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the harness connector and inlet air pressure sensor connector.
3-58www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Inlet Air Pressure Sensor (Service Code 12) • 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). Connect a digital meter to the harness adapter leads.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-59 www.zxforums.com Inlet Air Pressure Sensor (Service Code 12) the inlet air pressure sensor [A] and disconnect • Remove the vacuum hose from the sensor. an auxiliary hose [B] to the inlet air pressure sen• Connect sor. install the inlet air pressure sensor. •○Temporarily Connect a digital meter [C], vacuum gauge [D], and the fork oil level gauge [E] to the inlet air pressure sensor.
3-60www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Inlet Air Pressure Sensor (Service Code 12) www.zxforums.com 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 www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-61 www.zxforums.com 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. the fuel tank (see Fuel Tank Removal). • Remove Disconnect • ture sensor.the connector [A] from the inlet air tempera• Pull out the inlet air temperature sensor [B]. the inlet air temperature sensor [A] in the grommet • Install [B].
3-62www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Inlet Air Temperature Sensor (Service Code 13) • If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). 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).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-63 www.zxforums.com Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor 3. Water-proof Joint 2 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-64www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-65 www.zxforums.com Water Temperature Sensor (Service Code 14) the ignition switch OFF. • Turn If the output voltage is out of the specified, check the ECU • for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). If the output voltage is far out of the specified (e.g.
3-66www.zxforums.com FUEL SYSTEM (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 the ignition switch OFF.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-67 www.zxforums.com Atmospheric Pressure Sensor (Service Code 15) • If the reading is within the standard range, remove the seat cover, and check the input voltage again at the sensor connector. 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 a digital meter to the harness adapter leads.
3-68www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Atmospheric Pressure Sensor (Service Code 15) • If the output voltage is far out of the usable range, remove the seat cover, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V). Connect a digital meter [A] to the harness adapter leads.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-69 www.zxforums.com Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throttle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section).
3-70www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation to the Crankshaft Sensor Removal/Installation in • Refer the Electrical System chapter (see Crankshaft Sensor Removal/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○The crankshaft have no power source, and when the en- • • gine stops, the crankshaft generates no signals.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-71 www.zxforums.com Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. Refer to the Camshaft Position Sensor Removal/Installation in the Electric System chapter (see Camshaft Position Sensor Removal/Installation in the Electric System chapter).
3-72www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Speed Sensor (Service Code 24) Speed Sensor Removal/Installation to the Speed Sensor Removal/Installation in • Refer the Electrical System chapter (see Speed Sensor Removal/Installation in the Electrical System chapter). Input Voltage Inspection NOTE ○Be sure the battery is fully charged.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-73 www.zxforums.com Speed Sensor (Service Code 24) the harness adapter [A] between the harness • Connect connector and speed sensor connector. Special Tool - Speed Sensor Measuring Adapter: 57001 -1667 • 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] the input voltage with the engine stopped, and • Measure with the connectors joined.
3-74www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Speed Sensor (Service Code 24) • Connect a digital meter to the harness adapter leads. Speed Sensor Output Voltage Connections to Adapter Meter (+) → BL/Y lead [A] Meter (–) → BK lead [B] the output voltage with the engine stopped, and • Measure with the connectors joined. • Turn the ignition switch ON. Output Voltage at Sensor Standard: DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-75 www.zxforums.com Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation to the Gear Position Switch Removal/Installation in • Refer the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter).
3-76www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 1 4. Joint Connector 2 5. Frame Ground www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-77 www.zxforums.com 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.
3-78www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Vehicle-down Sensor (Service Code 31) a digital meter [A] to the connector of the vehicle • Connect -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 (–) → BR/BK lead [E] the ignition switch ON, and measure the power • Turn source voltage with the connector joined.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-79 www.zxforums.com Vehicle-down Sensor (Service Code 31) the ignition switch OFF. • Turn Remove adapter set, and apply silicone • sealant tothethe needle seals of sensor the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the output voltage is out of the specified, replace the vehicle-down sensor. Vehicle-down Sensor Circuit www.zxforums.com 1. ECU 2. Vehicle-down Sensor 3. Water-proof Joint 2 www.zxforums.
3-80www.zxforums.com FUEL SYSTEM (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 injection quantity, and ignition timing according to engine rpm, and throttle opening.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-81 www.zxforums.com Subthrottle Sensor (Service Code 32) the subthrottle sensor connector [A] and con• Disconnect nect the harness adapter [B] between the harness connector and subthrottle sensor connector. Special Tool - Throttle Sensor Setting Adapter: -1538 57001 • Connect a digital meter to the harness adapter leads.
3-82www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal). If the output voltage is far out of the standard range (e.g. when the wiring is open, the reading is 0 V), check the output voltage again at the sensor connector.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-83 www.zxforums.com Subthrottle Sensor (Service Code 32) subthrottle sensor voltage inspection, remove the • After harness adapter. If the reading is out of the standard range, inspect the subthrottle sensor resistance. If the output voltage is normal, check the wiring for continuity (see wiring diagram in this section). Resistance Inspection the ignition switch OFF. • Turn Disconnect the subthrottle sensor connector.
3-84www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Oxygen Sensor #1-not activated (Service Code 33) - Europe Models Oxygen Sensor #1 Removal/Installation to the Oxygen Sensor Removal (Europe Models) • Refer in the Electrical System chapter (see Oxygen Sensor Removal (Europe Models) in the Electrical System chapter). Oxygen Sensor #1 Inspection NOTE ○The oxygen sensor itself is the same for #1 [A] and #2 [B], but wiring of the main harness side is different.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-85 www.zxforums.com Oxygen Sensor #1-not activated (Service Code 33) - Europe Models the following parts temporary. • Connect Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578 the ignition switch ON. • Turn Start the engine, and let it idle. • Measure the output voltage of the sensor with the con• nector joined. Oxygen Sensor #1 Output Voltage (with Plugs) Standard: 0.45 ∼ 2.
3-86www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Oxygen Sensor #1-not activated (Service Code 33) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-87 www.zxforums.com Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Inspection the ignition switch OFF. • Turn the seat cover (see Seat Cover Removal in the • Remove Frame chapter). the exhaust butterfly valve actuator sensor • Disconnect connector. a digital meter [A] to the exhaust butterfly valve • Connect actuator sensor connector [B].
3-88www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection the left upper inner fairing (see Upper Inner Fair• Remove ing Removal in the Frame chapter). the antenna lead connector [A]. • Disconnect 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.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-89 www.zxforums.com Blank Key Detection (Service Code 36) code appears in the following conditions. •○This The transponder [A] in the master and/or user key is mal- function. ○When the spare key of unregistration is used. ○When the master key is registered in the registered ECU. Therefore, the service code 36 will disappear when the above issue is solved.
3-90www.zxforums.com FUEL SYSTEM (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. ○The fuel pump relay is included in the relay box. the front seat (see Front Seat Removal in the • Remove Frame chapter). the relay box [A] from the bracket and disconnect • Remove the connectors. Fuel Pump Relay Inspection the relay box (see Fuel Pump Relay Removal).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-91 www.zxforums.com Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Stick Stick Stick Coil Coil Coil Coil #1: #2: #3: #4: Service Service Service Service Code Code Code Code 51 52 53 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it.
3-92www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 2. Stick Coil #4 3. Stick Coil #3 4. Stick Coil #2 5. Stick Coil #1 6. Engine Stop Switch 7. Ignition Switch 8. Ignition Fuse 10 A 9. Starter Relay 10. Main Fuse 30 A 10. Fuse Box 11. Battery 12 V 10 Ah 12. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-93 www.zxforums.com 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 on a hard surface. Such a shock to the actuator can damage it. Subthrottle Valve Actuator Inspection the air cleaner housing (see Air Cleaner Housing • Remove Removal). the ignition switch ON.
3-94www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn the peak voltage adapter [A] and a digital meter • Connect [B] to the connector [C], using the needle adapter set [D].
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-95 www.zxforums.com Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 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 www.zxforums.
3-96www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal the seat cover (see Seat Cover Removal in the • Remove Frame chapter) the dust covers [A]. • Slide Loosen the locknuts [B], and turn the adjuster to give the • cable plenty of play [C]. • Remove: Clamp [A] Exhaust Butterfly Valve Cables [B] Connectors [C] • Remove: Bolts [A] Exhaust Butterfly Valve [B] www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-97 www.zxforums.com Exhaust Butterfly Valve Actuator (Service Code 63) the pulley angle [A] (41.7° ±7°) as shown. • Confirm original position of the pulley [B]. It is If the angle is not within the specified angle, adjust the actuator as follows. ○Connect the actuator connectors. ○Turn the ignition switch ON. ○Confirm the pulley turns clockwise and then counterclockwise, and clockwise again ○Turn the ignition switch OFF.
3-98www.zxforums.com FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com Exhaust Butterfly Valve Actuator (Service Code 63) Output Voltage Inspection the seat cover (see Seat Cover Removal in the • Remove Frame chapter). the ignition switch ON and wait until the pulley stops. • Turn Turn switch OFF and wait until the pulley • stops.theIt isignition original position of the pulley.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-99 www.zxforums.com 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 oxygen sensors (see Oxygen Sensor Removal in the Electrical System chapter).
3-100 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Europe Models If he tester reading is specified, check the power source voltage Inspection. NOTE ○Be sure the battery is fully charged. a digital meter [A] to each oxygen sensor con• Connect nector [B], using the needle adapter [C].
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-101 www.zxforums.com Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-102 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com ECU Main Relay (Service Code 75) ECU Main Relay Inspection ○The ECU main relay function is included in the ECU [A]. • So, the ECU main relay function cannot inspect. When the service code 75 is displayed on the LCD, replace the ECU (see ECU sectionl). www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-103 www.zxforums.com Oxygen Sensor #2-not activated (Service Code 83) - Europe Models Oxygen Sensor #2 Removal/Installation to the Oxygen Sensor Removal (Europe Models) • Refer in the Electrical System chapter (see Oxygen Sensor Removal (Europe Models) in the Electrical System chapter). Oxygen Sensor #2 Inspection NOTE ○The oxygen sensor itself is the same for #1 [A] and #2 [B], but wiring of the main harness side is different.
3-104 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Oxygen Sensor #2-not activated (Service Code 83) - Europe Models the following parts temporary. • Connect Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578 the ignition switch ON. • Turn Start the engine, and let it idle. • Measure the output voltage of the sensor with the con• nector joined. Oxygen Sensor Output Voltage (with Plugs) Standard: 0.45 ∼ 2.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-105 www.zxforums.com Oxygen Sensor #2-not activated (Service Code 83) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7. Main Fuse 30 A 8. Battery 12 V 10 Ah 9. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-106 FUEL SYSTEM (DFI) www.zxforums.com 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 ○Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Otherwise, the motorcycle cannot clear the regulation.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-107 www.zxforums.com ECU ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Connectors the slits of the rubber protector to the projections • Insert [A] of the rear fender front. ECU Power Supply Inspection the ECU (see ECU Removal). • Remove Visually inspect terminals [A] of the ECU connectors. • If the connector the is clogged with mud or dust, blow it off www.zxforums.com with compressed air.
3-108 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com ECU the ECU power source voltage with a digital meter • Check [A]. ○Position the terminal in accordance with terminal numbers of ECU connectors [B] in the figure.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-109 www.zxforums.com ECU ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Ignition Switch 4. ECU Fuse 15 A 5. Starter Relay 6. Main Fuse 30 A 7. Battery 12 V 10 Ah 8. Joint Connector 3 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-110 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com DFI Power Source ECU Fuse Removal to the 15 A ECU Fuse Removal in the Electrical Sys• Refer tem chapter (see 15 A ECU Fuse Removal in the Electrical System chapter). ECU Fuse Installation • If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-111 www.zxforums.com Warning Indicator Light (LED) Light (LED) Inspection ○The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○In this model, the warning indicator light (LED) (FI/immobilizer) blink by the special signal sent from the ECU.
3-112 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Fuel Line Fuel Pressure Inspection NOTE ○Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal in the Frame chap• • ter) Steering Damper (see Steering Damper Removal in the Steering chapter) Fuel Tank Bolts [A] Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assy and fuel pump. Remove the fuel hose (see Fuel Tank Removal).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-113 www.zxforums.com Fuel Line the engine, and let it idle. • Start Measure the fuel pressure with the engine idling. • Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. • • If the fuel pressure is much higher than the specified, replace the fuel pump (see Fuel Pump section).
3-114www.zxforums.com FUEL SYSTEM (DFI) Fuel Line www.zxforums.com www.zxforums.com the fuel tank cap [A] to lower the pressure in the • Open tank. sure to place a piece of cloth around the fuel supply • Be pipe of the fuel pump. the fuel hose from the fuel pump (see Fuel Tank • Remove Removal). 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.
www.zxforums.com www.zxforums.com Fuel Pump FUEL SYSTEM (DFI) 3-115 www.zxforums.com Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive 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.
3-116www.zxforums.com FUEL SYSTEM (DFI) Fuel Pump www.zxforums.com www.zxforums.com that the fuel pump terminals [A], fuel reserve switch • Check terminal [B] and band [C] are in place. • • • Front [D] Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the fuel pump bolts to a snug fit following the tightening sequence shown. Following the tightening sequence, tighten the pump bolts to the specified torque. Torque - Fuel Pump Bolts: 10 N·m (1.
www.zxforums.com Fuel Pump www.zxforums.com FUEL SYSTEM (DFI) 3-117 www.zxforums.com Fuel Pump Circuit 1. ECU 2. Water-proof Joint 1 3. Engine Stop Switch 4. Ignition Switch 5. Fuel Pump Relay 6. ECU Fuse 15 A 7. Ignition Fuse 15 A 8. Starter Replay 9. Main Fuse 30 A 10. Battery 12 V 10 Ah 11. Joint Connector 3 12. Fuel Pump 13. Joint Connector 2 14. Joint Connector 1 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
3-118www.zxforums.com FUEL SYSTEM (DFI) Fuel Injectors www.zxforums.com www.zxforums.com Removal/Installation to the Throttle Body Assy Disassembly/Assembly • Refer (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE ○Be sure the battery is fully charged. the ignition switch OFF. • Turn Remove the ECU (see ECU Removal). •○Do not disconnect the ECU connectors.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-119 www.zxforums.com Fuel Injectors • If 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]. Measure the power source voltage with the engine stopped, and the connector joined, with a digital meter and needle adapter set [C].
3-120 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Fuel Injectors If the output voltage is out of the standard, remove the air cleaner housing, and check the output voltage at the injector connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-121 www.zxforums.com Fuel Injectors Injector Signal Test two test light sets with male terminals as shown. • Prepare Rating of Bulb [A]: 12 V × 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 harness connector (female), leading to harness repair or replacement. Be sure to connect bulbs in series.
3-122 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Fuel Injectors Injector Unit Test two leads [A] and the same test light set [B] as in • Use “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current. the test light set to the injector [E] as shown.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-123 www.zxforums.com Fuel Injectors Fuel Injector Circuit 1. ECU 2. Frame Ground 3. Joint Connector 1 4. Joint Connector 2 5. Fuel Pump 6. Water-proof Joint 1 7. Fuel Injector #4 8. Fuel Injector #3 9. Fuel Injector #2 10. Fuel Injector #1 11. Engine Stop Switch 12. Ignition Switch 13. Fuel Pump Relay 14. ECU Fuse 15 A 15. Ignition Fuse 15 A 16. Starter Relay 17. Main Fuse 30 A 18. Battery 12 V 10 Ah 19. Joint Connector 3 www.zxforums.com www.
3-124 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Throttle Grip and Cables Free Play Inspection to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter).
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-125 www.zxforums.com Throttle Body Assy Idle Speed Inspection to the Idle Speed Inspection in the Periodic Mainte• Refer nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning the throttle bore for cleanliness as follows. •○Check Remove the throttle body assy (see Throttle Body Assy Removal).
3-126 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Throttle Body Assy • Remove: Air Switching Valve Hose [A] Vacuum Hoses [B] (California Model) the middle fairings (see Middle Fairing Removal • Remove in the Frame chapter). the throttle body assy holder clamp bolts [A] on • Loosen both sides. the throttle case [A] to make a throttle cable • Remove slack. www.zxforums.com • Remove the adjuster screw [A] from the clamp [B]. off the throttle body assy [A] from the holder.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-127 www.zxforums.com Throttle Body Assy removing the throttle body assy, stuff pieces of lint • After -free, clean cloths into the throttle body assy holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur. If the throttle body assy is to be disassembly, loosen the air cleaner housing holder clamp bolts [A], and remove the air cleaner housing holder [B].
3-128 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Injector Connector Harness www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-129 www.zxforums.com Throttle Body Assy the main throttle sensor [A] and subthrottle • Disconnect sensor [B] connector. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] the hoses [A] from the throttle body fittings and • Separete inlet air pressure sensor. the screws [B] to pull out the injector assies from • Remove the throttle body assy together with the delivery pipe [C]. www.zxforums.
3-130 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Throttle Body Assy daphne oil or engine oil to the new dust seals [A], • Apply and insert the injectors into the throttle body, which installed to the delivery pipe. NOTE ○Replace the dust seals of the throttle body to new ones. • Install the delivery pipe to the throttle body. Torque - Delivery Pipe Mounting Screws: 5.0 N·m (0.50 kgf·m, 44 in·lb) the injector connectors.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-131 www.zxforums.com Air Line Element Removal to the Air Cleaner Element Replacement in the Pe• Refer riodic Maintenance chapter (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Element Installation to the Air Cleaner Element Replacement in the Pe• Refer riodic Maintenance chapter (see Air Cleaner Element Replacement in the Periodic Maintenance chapter).
3-132 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Air Line the air cleaner housing [A] counterclockwise [B] and • Turn remove it. • Pull off the air ducts [A] from the frame. www.zxforums.com Air Cleaner Housing Installation the air ducts [A] fit in the frame [B]. • Confirm Insert the • shown. air cleaner housing [C] inside the frame as • Turn the housing clockwise and position it. www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-133 www.zxforums.com Air Line the housing on the holder then insert the ducts. •○Install Apply a soap and water solution [A] to the ducts for easy • • installation. Insert the projections [B] of the housing in the holes [C] of the ducts. Tighten: Torque - Air Cleaner Housing Mounting Bolts: 7.0 N·m (0.70 kgf·m, 62 in·lb) the air cleaner element (see Air Cleaner Element • Install Replacement in the Periodic Maintenance chapter).
3-134 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Air Line Air Inlet Duct Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Mounting Bolts [A] (Both Sides) Air Inlet Duct [B] Air Inlet Duct Installation the gasket [A]. • Install Apply non-permanent agent to the threads of the • air inlet duct mountinglocking bolts [B] and tighten it. Torque - Air Inlet Duct Mounting Bolts: 7.0 N·m (0.70 kgf·m, 62 in·lb) www.zxforums.com www.zxforums.com www.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-135 www.zxforums.com Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explosive 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. the ignition switch OFF.
3-136 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Fuel Tank the fuel out from the fuel tank with a commercially • Draw available pump [A]. ○Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly. ○Put the hose through the fill opening [C] into the tank and draw the fuel out. Front [D] WARNING The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-137 www.zxforums.com Fuel Tank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. ○Be sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal.
3-138 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Fuel Tank the fuel hose joint [A] straight onto the delivery pipe • Insert until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. and pull [A] the hose joint [B] back and forth more • Push 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 delivery pipe by sliding the joint, or the fuel could leak.
www.zxforums.com www.zxforums.com FUEL SYSTEM (DFI) 3-139 www.zxforums.com Evaporative Emission Control System The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
3-140 FUEL SYSTEM (DFI) www.zxforums.com www.zxforums.com www.zxforums.com Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be explosive 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. the hoses to the separator, and install the sepa• Connect rator on the motorcycle.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-1 www.zxforums.com Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow Chart................................................................................................................. Specifications .........................................................................................................................
4-2 COOLING SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com COOLING SYSTEM 4-3 www.zxforums.com www.zxforums.com Exploded View No.
4-4 COOLING SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Coolant Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-5 www.zxforums.com Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Radiator Overflow Hose 5. Reserve Tank 6. Reserve Tank Overflow Hose 7. Oil Cooler 8. Outlet Hose 9. Cylinder Head Jacket 10. Cylinder Jacket 11. Thermostat Housing 12. Inlet Hose 13. Water Pump 14. Hot Coolant 15. Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
4-6 COOLING SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Specifications Item Coolant Provided when Shipping Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Valve Full Opening Lift Standard 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.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-7 www.zxforums.com Coolant Coolant Deterioration Inspection inspect the coolant in the reserve tank. • Visually 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. If 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.
4-8 COOLING SYSTEM www.zxforums.com www.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 cooling system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the efficiency of the cooling system. Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter).
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-9 www.zxforums.com Coolant Coolant Reserve Tank Installation the following to the coolant reserve tank [A]. • Install Rubber Dampers [B] • Collars [C] Gasket [D] Cap [E] Tighten: Torque - Coolant Reserve Tank Mounting Bolts [F]: 7.0 N·m (0.71 kgf·m, 62 in·lb) the hoses correctly (see Cable, Wire, and Hose Rout• Run ing section in the Appendix chapter).
4-10www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte• nance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Remove the water hoses [A]. • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] the water hose [A]. • Remove Remove the water pump body [B] with impeller [C]. • www.zxforums.com Water Pump Installation the O-ring [A] with a new one.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-11 www.zxforums.com Water Pump the impeller shaft so that the slot [A] in its shaft fits • Turn onto the projection [B] of the oil pump gear shaft. CAUTION Do not pinch the gear position switch lead. the water hose [A] and hose clamp [B] as shown. • Install White Mark [C] • Tighten: Torque - Water Hose Clamp Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb) • Install the water pump cover [A]. Torque - Water Pump Cover Bolts: 1.0 N·m (1.
4-12www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Radiator Radiator and Radiator Fan Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-13 www.zxforums.com Radiator Radiator and Radiator Fan Installation the radiator fan [A]. • Install Install the rubber dampers [B] and collars [C] as shown. • the radiator cap [A] temporarily. • Remove Cover the heat insulation rubber plate [B] on the radiator • [C] as shown. the radiator cap. • Reinstall the radiator fan lead [D] in the heat insulation rub• Trough ber plate hole [E]. • Connect radiator fan lead connector. www.zxforums.
4-14www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Radiator 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) • Tighten: Torque - Radiator Lower Bolt [C]: 7.0 N·m (0.71 kgf·m, 62 in·lb) Radiator Upper Bolt [D]: 7.0 N·m (0.71 kgf·m, 62 in·lb) • • Horn [E] Face the white mark [F] of the radiator hose [G] direction as shown. Install the water hose clamp [H]. Torque - Water Hose Clamp Screw: 2.0 N·m (0.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-15 www.zxforums.com Radiator www.zxforums.com the radiator with coolant (see Coolant Change in the • Fill Periodic Maintenance chapter). the middle fairings (see Middle Fairings Installation • Install in the Frame chapter). installation, note the following. •○After Run the main harness [A] over the heat insulation rubber plate [B]. ○Put the edges of the heat insulation rubber plate on the hole of the middle fairings [C]. www.zxforums.com www.
4-16www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Radiator Radiator Inspection the radiator (see Radiator and Radiator Fan Re• Remove moval). the radiator core. • Check If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-17 www.zxforums.com Radiator Radiator Filler Neck Inspection the radiator cap (see Pressure Testing). • Remove Check the filler neck for signs of damage. • Check the radiator 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. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
4-18www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Thermostat Thermostat Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-19 www.zxforums.com Thermostat the O-rings [A] with a new one. • Replace Apply grease to the new O-rings. • Install a new O-rings into the thermostat housing [B] and • Cover [C]. If the coolant by-pass fitting bolt [D] was removed, install it. ○Apply a non-permanent locking agent to the threads of the coolant by-pass fitting bolt, and tighten it. Torque - Coolant By-pass Fitting Bolt: 9.0 N·m (0.
4-20www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Thermostat check valve opening temperature, suspend the ther• To mostat [A] in a container of water and raise the temperature of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth. It must not touch the container, either.
www.zxforums.com www.zxforums.com COOLING SYSTEM 4-21 www.zxforums.com Hoses and Pipes Hose Installation the hoses and pipes, being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening or twisting. Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose.
4-22www.zxforums.com COOLING SYSTEM www.zxforums.com www.zxforums.com Water Temperature Sensor CAUTION The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal to the Water Temperature Sensor Removal in the • Refer Fuel System (DFI) chapter (Water Temperature Sensor Removal in the Fuel System (DFI) chapter).
www.zxforums.com www.zxforums.com ENGINE TOP END 5-1 www.zxforums.com Engine Top End Table of Contents Exploded View........................................................................................................................ Exhaust System...................................................................................................................... Specifications .........................................................................................................................
5-2 ENGINE TOP END www.zxforums.com www.zxforums.com www.zxforums.com Exhaust Butterfly Valve Cable Removal ........................................................................... Exhaust Butterfly Valve Cable Installation ........................................................................ 5-45 5-46 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-3 www.zxforums.com Exploded View Dummy Page www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
5-4 ENGINE TOP END www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-5 www.zxforums.com Exploded View No.
5-6 ENGINE TOP END www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com ENGINE TOP END 5-7 www.zxforums.com www.zxforums.com Exploded View No. Fastener 1 2 3 4 5 6 7 8 9 10 11 Front Exhaust Pipe Holder Nuts Muffler Body Assembly Nuts Muffler Body Mounting Bolts Middle Exhaust Pipe Clamp Bolt Rear Exhaust Pipe Clamp Bolt Muffler Body Cover Bolts Exhaust Butterfly Valve Cable Locknuts Exhaust Butterfly Valve Cable Adjuster Locknuts Middle Exhaust Pipe Stay Bolt Oxygen Sensors (Europe Models) Exhaust Pipe Manifold Mounting Bolts N·m 17 22 25 17 17 7.0 7.
5-8 ENGINE TOP END www.zxforums.com www.zxforums.com www.zxforums.com Exhaust System Exhaust System ZX1000D6F www.zxforums.com 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb Type Catalyst www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-9 www.zxforums.com Exhaust System Manifold Mark Position [A] Silencer Mark Position [A] Manifold [A] with Holes [B] for Oxygen Sensors. Oxygen Sensor #1 [C] Oxygen Sensor #2 [D] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
5-10www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Exhaust System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-11 www.zxforums.
5-12www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Special Tools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221 Valve Seat Cutter, 32° 57001-1121 Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter, 45° 57001-1114 Valve Seat Cutter, 60° 57001-1328 27.5: 35: 25: www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-13 www.zxforums.com Special Tools and Sealant Valve Guide Reamer, 57001-1333 Valve Seat Cutter, 60° 57001-1334 4.5: Compression Gauge Adapter, M10 × 1.0: 57001-1601 33: L-Shape Hose: 57001-1606 Valve Guide Driver: 57001-1564 Washer: 57001-1612 www.zxforums.com Valve Spring Compressor Adapter, 57001-1586 www.zxforums.com 24: Kawasaki Bond (Silicone Sealant): 92104-0004 www.zxforums.com www.zxforums.
5-14www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Air Suction Valve Covers [B] • Remove the air suction valves [A]. Air Suction Valve Installation the air suction valve so that opening [A] of the reed • Install faces the rear and downward.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-15 www.zxforums.com Clean Air System Air Switching Valve Removal • 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) Disconnect the connector [A]. Separate the hoses [B] from the air suction valve covers and air cleaner housing holder, and remove the air switching valve [C].
5-16www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-17 www.zxforums.com Cylinder Head Cover the washer [A] with new ones. • Replace Install the new washer with the metal side faces upward. • the cylinder head cover. • Install Tighten the cover bolts [A]. • Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters). www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
5-18www.zxforums.com 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.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-19 www.zxforums.com Camshaft Chain Tensioner the mounting bolts [A] and take off the camshaft • Remove chain tensioner body [B]. Camshaft Chain Tensioner Installation the O-ring [A] with a new one. • Replace Apply grease to the new O-ring. • Release the stopper and push the push rod [C] into • the interior of tensioner[B]body [D]. Install the tensioner body so that the stopper faces up• ward. • Tighten the tensioner mounting bolts [A].
5-20www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Camshaft, Camshaft Chain Camshaft Removal the cylinder head cover (see Cylinder Head • Remove Cover Removal). the timing inspection cap [A] and starter clutch • Remove bolt cap [B] on the starter clutch cover [C].
www.zxforums.com www.zxforums.com ENGINE TOP END 5-21 www.zxforums.com Camshaft, Camshaft Chain the camshaft chain tensioner (see Camshaft • Remove Chain Tensioner Removal). the upper chain guid bolts and camshaft cap bolts • Loosen as shown sequence [1 ∼ 20] in the figure, and remove • • them. Remove: Upper Chain Guide [A] Camshaft Caps [B] Camshafts [C] Stuff a clan cloth into the chain tunnel to keep any parts from dropping into the crankcase. www.zxforums.com the cam sprocket mounting bolts [A].
5-22www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Camshaft, Camshaft Chain the cam sprockets as shown in figure. • Install #4 Cam Positions [A] • Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] Apply a non-permanent locking agent to the threads and tighten the bolts. Torque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) molybdenum disulfide oil solution to all cam parts • Apply and journals.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-23 www.zxforums.com Camshaft, Camshaft Chain the tension side (exhaust side) [A] of the chain taut • Pull to install the chain. the camshaft chain with the sprockets so that tim• Engage ing marks on the sprockets are positioned as shown. ○The 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] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
5-24www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Camshaft, Camshaft Chain installing the camshaft caps and upper chain • Before guide, install the camshaft chain tensioner body tempo- • • rally (see Camshaft Chain Tensioner Installation). Install the camshaft caps and upper camshaft chain guide [A] as shown.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-25 www.zxforums.com Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear the camshaft cap (see Camshaft Removal). • Remove Cut strips of plastigage to journal width. Place a strip • on each journal parallel to the camshaft installed in the • correct position. Tighten the camshaft cap bolts and upper chain guide bolts to the specified torque (see Camshaft Installation).
5-26www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Camshaft, Camshaft Chain Cam Wear the camshaft (see Camshaft Removal). • Remove Measure [A] of each cam with a micrometer. • If the camstheareheight worn down past the service limit, replace the camshaft. 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.) Service Limit: Exhaust 34.34 mm (1.352 in.) Inlet 35.94 mm (1.376 in.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-27 www.zxforums.com Cylinder Head Cylinder Compression Measurement NOTE ○Use the battery which is fully charged. up the engine thoroughly. • Warm the engine.
5-28www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Cylinder Head Cylinder Head Removal the coolant (see Coolant Change in the Periodic • Drain Maintenance chapter).
www.zxforums.com www.zxforums.com ENGINE TOP END 5-29 www.zxforums.com Cylinder Head Cylinder Head Installation NOTE ○The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. the dowel pins. • Install Replace the cylinder head gasket with a new one. • Apply molybdenum oil solution to both sides [A] • of the cylinder headdisulfide bolt washers [B] and the threads of the head bolts [C].
5-30www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Cylinder Head Cylinder Head Warp the cylinder head. • Clean Lay a straightedge across the lower surface of the cylinder • head at several positions. a thickness gauge [A] to measure the space between • Use the straightedge [B] and the head. Cylinder Head Warp ––– Standard: Service Limit: 0.05 mm (0.002 in.) If the cylinder head is warped more than the service limit, replace it.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-31 www.zxforums.com Valves Valve Clearance Inspection to the Valve Clearance Inspection in the Periodic • Refer Maintenance chapter (see Valve Clearance Inspection in the Periodic Maintenance chapter). Valve Removal the cylinder head (see Cylinder Head Removal). • Remove Remove valve lifter and shim. •○Mark andthe record the valve lifter and shim locations so they • can be installed in their original positions.
5-32www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Valves Valve Guide Installation oil to the valve guide outer surface before installa• Apply tion. the area around the valve guide hole to about 120 ∼ • Heat 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.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-33 www.zxforums.com Valves NOTE ○The 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 the valve (see Valve Removal).
5-34www.zxforums.com ENGINE TOP END 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 diamond 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.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-35 www.zxforums.com Valves the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range.
5-36www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Valves If the seat width is too wide, make the 60° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° angle until the seat width is within the specified range. ○To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide. ○Turn the holder, while pressing down lightly.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-37 www.zxforums.com Valves www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
5-38www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Throttle Body Assy Holder Throttle Body Assy Holder Removal • 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 (DFI) chapter) Clamps [A] Loosen the throttle body assy holder bolts as shown sequence [1 ∼ 3] in the figure, and remove them.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-39 www.zxforums.com Muffler WARNING To avoid a serious burn,do not remove the muffler when the engine is still hot.What until the muffler cool down. Muffler Body Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Right Rear Footpeg Bracket [B] with Cover [C] • Remove: Right Muffler Body Assembly Nuts [A] Right Muffler Body Mounting Bolt [B] Remove the right muffler body [C] to backward.
5-40www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Muffler Muffler Body Installation If the muffler body cover [A] was removed, install it. ○Fit the dampers [B] of the muffler body into the slots [C] in the muffler cover. Torque - Muffler Body Cover Bolts [D]: 7.0 N·m (0.70 kgf·m, 62 in·lb) the muffler body gasket [E] with a new ones. • Replace Install the muffler body. •○Pass the muffler stay [F] through the hole [G] of the rear • fender front [H].
www.zxforums.com www.zxforums.com ENGINE TOP END 5-41 www.zxforums.com Muffler Middle and Rear Exhaust Pipe Removal the left muffler body (see Muffler Body Removal). • Remove Loosen the exhaust pipe clamp bolt [A]. • Remove therear rear exhaust pipe [B] from left side of motor• cycle.
5-42www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Muffler Middle and Rear Exhaust Pipe Installation the middle exhaust pipe gasket [A] with a new • Replace one. ○Install the middle exhaust pipe gasket until it is bottomed • • so that the chamfer side (inner) faces front exhaust pipe [B]. Install the middle exhaust pipe [C]. Tighten: Torque - Middle Exhaust Pipe Stay Bolt [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) the middle exhaust pipe clamp bolt [E] as shown.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-43 www.zxforums.com Muffler the exhaust butterfly valve cable, and adjust (see • Install Exhaust Butterfly Valve Cable Installation). warm up the engine, wait until the engine cools • Throughly down, retighten all the bolts. • Install the removed parts (see appropriate chapters).
5-44www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Muffler Front Exhaust Pipe Installation the front exhaust pipe gaskets [A] with new ones. • Replace Replace • one. the middle exhaust pipe gasket [B] with a new ○Install the middle exhaust pipe gasket until it is bottomed • • • so that the chamfer side (inner) faces front exhaust pipe. Install the front exhaust pipe [C]. Install the middle exhaust pipe clamp bolt [D] as shown.
www.zxforums.com www.zxforums.com ENGINE TOP END 5-45 www.zxforums.com Muffler Exhaust Butterfly Valve Cable Removal the seat cover (see Seat Cover Removal in the • Remove Frame chapter). the dust covers [A]. • Slide Loosen locknuts [B], and turn the adjusters [C] to give • the cabletheplenty of paly. the clamp [A]. • Remove Remove the exhaust butterfly valve cable upper ends [B] • from the pulley [C].
5-46www.zxforums.com ENGINE TOP END www.zxforums.com www.zxforums.com Muffler • Remove: Bolts [A] Lower Cover [B] the locknuts [A]. • Loosen Remove exhaust butterfly valve cable lower ends [B] • from the the pulley [C]. the exhaust butterfly valve cables out of frame. • Pull Front View [D] Exhaust Butterfly Valve Cable Installation the butterfly valve cables correctly (see Cable, Wire • Route and Hose Routing section in the Appendix chapter).
www.zxforums.com www.zxforums.com ENGINE TOP END 5-47 www.zxforums.com Muffler CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first. the close cable (green) [A]. • Install the open cable (yellow) [B] and adjust the adjuster • Install [C] until the clearance of part [D] of figure come to 0 mm (0 in.). CAUTION Do not overstretch. • Tighten: Torque - Exhaust Butterfly Valve Cable Adjuster Locknut: 7.0 N·m (0.
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www.zxforums.com www.zxforums.com CLUTCH www.zxforums.com 6-1 Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool and Sealant ........................................................................................................
6-2 CLUTCH www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com CLUTCH www.zxforums.com www.zxforums.com 6-3 Exploded View No. 1 2 3 4 5 6 Fastener N·m 7.8 10 – 9.8 130 25 Clutch Lever Clamp Bolts Clutch Cover Mounting Bolts Oil Filler Plug Clutch Spring Bolts Clutch Hub Nut Sub Clutch Hub Bolts Torque kgf·m 0.80 1.0 – 1.0 13.3 2.5 ft·lb 69 in·lb 89 in·lb – 87 in·lb 96 18 Remarks S S Hand-tighten R L CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. G: Apply grease. HG: Apply high-temperature grease.
6-4 CLUTCH www.zxforums.com www.zxforums.com www.zxforums.com Specifications Item Clutch Lever Free Play Clutch Spring Plate Free Play Clutch Plate Assembly Length Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) (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.) Service Limit – – – – – – – – – 2.6 mm (0.102 in.) 0.3 mm (0.
www.zxforums.com www.zxforums.com CLUTCH www.zxforums.com Special Tool and Sealant Clutch Holder: 57001-1243 Kawasaki Bond (Silicone Sealant): 92104-0004 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
6-6 CLUTCH www.zxforums.com www.zxforums.com www.zxforums.com Clutch Lever and Cable Clutch Lever Free Play Inspection to the Clutch Adjustment Inspection in the Periodic • Refer Maintenance chapter (see Clutch Adjustment Inspection in the Periodic Maintenance chapter). Clutch Lever Free Play Adjustment to the Clutch Adjustment Inspection in the Periodic • Refer Maintenance chapter (see Clutch Adjustment Inspection in the Periodic Maintenance chapter).
www.zxforums.com www.zxforums.com CLUTCH www.zxforums.com Clutch Cover Clutch Cover Removal the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the • Frame chapter) Clutch Cable Lower End [A] (see Cable Removal) Loosen the clutch cover mounting bolts as shown sequence [1 ∼ 10] in the figure, and remove them. the release lever [A] toward the rear as shown, and • Turn remove the clutch cover [B].
6-8 CLUTCH www.zxforums.com www.zxforums.com www.zxforums.com Clutch Cover Release Shaft Installation high-temperature grease to the oil seal lips on the • Apply upper ridge of the clutch cover. oil to the needle bearings in the hole of the clutch • Apply cover. molybdenum disulfide grease to the pusher-holding • Apply portion [A] on the release shaft. the washer [B] and spring [C]. • Install Insert the release shaft straight into the upper hole of the • clutch cover.
www.zxforums.com www.zxforums.com CLUTCH www.zxforums.com Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○Install the needle bearings so that the manufacture’s make face out. the needle bearings [A] and oil seal [B] position as • Install shown. ○Press the lower bearing, do not protrude from the boss [C] of the clutch cover. ○Press the upper bearing so that the bearing surface [D] is flush with the housing end of clutch cover [E].
6-10www.zxforums.com CLUTCH www.zxforums.com www.zxforums.com Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] (with Bearing ) Pusher [C] • Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] www.zxforums.com the sub clutch hub [A] steady with the clutch holder • Hold [B], and remove the nut [C].
www.zxforums.com www.zxforums.com CLUTCH 6-11 www.zxforums.com Clutch • Remove: Torque Limiter Springs [A] Sub Clutch Hub [B] Clutch Hub [C] Spacer [D] ○Remove the sub clutch hub bolts [E] as necessary. the two 4 mm (0.16 in.) screws [A], pull out the • Using sleeve [B], needle bearing [C] and clutch housing [D]. • Remove the spacer. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
6-12www.zxforums.com CLUTCH www.zxforums.com www.zxforums.com Clutch Clutch Installation the spacer [A] so that the circle mark [B] faces out• Install ward. the clutch housing gear [A] and oil pump drive • Engage gear [B] with the crankshaft primary gear [C] and oil pump gear [D]. • Install: Needle Bearing [A] Sleeve [B] ○Apply engine oil to the sleeve and needle bearing. www.zxforums.com the spacer [C] so that the stepped side [D] faces • Install outward.
www.zxforums.com www.zxforums.com CLUTCH 6-13 www.zxforums.com Clutch ○Second Torque Limiter Spring Tang [B] ○Third Torque Limiter Spring Tang [B] ○Fourth Torque Limiter Spring Tang [B] www.zxforums.com the clutch hub nut [A] with a new one. • Replace 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.
6-14www.zxforums.com CLUTCH www.zxforums.com www.zxforums.com Clutch the following as shown. • Install Friction Plates (9) [A] Steel Plates (9) [B] Spring Seat [C] Spring [D] ○Install the spring seat and spring between first steel plate and second steel plate. CAUTION If new dry friction plates and steel plates are installed, apply engine oil to the surface of each plate to avoid clutch plate seizure. the last friction plate [A] fitting the tangs in the • Install grooves in the housing as shown. www.
www.zxforums.com www.zxforums.com CLUTCH 6-15 www.zxforums.com 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. Hold an extra drive shaft in a vise and install the following clutch parts on the shaft (see Clutch Installation).
6-16www.zxforums.com CLUTCH www.zxforums.com www.zxforums.com Clutch Spring Plate Free Play Adjustment NOTE ○The free play adjustment is performed by replacing the steel plate(s). the clutch spring plate free play (see Clutch • Measure 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.) ○Replace the following steel plate(s). Thickness Part Number 2.3 mm (0.
www.zxforums.com www.zxforums.com CLUTCH 6-17 www.zxforums.com Clutch Clutch Plate Warp Inspection each friction plate or steel plate on a surface plate • Place and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp Standard: 0.15 mm (0.0059 in.) or less Service Limit: 0.3 mm (0.
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www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-1 www.zxforums.com Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ........................................................................................................
7-2 ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
ENGINE www.zxforums.com www.zxforums.com LUBRICATION SYSTEM 7-3 www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Engine Oil Drain Bolt Oil Filter Oil Filter Pipe Oil Pan Bolts Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Pump Gear Bolts Oil Passage Plugs Oil Pump Cover Bolts Oil Cooler/Oil Filter Case Mounting Bolts Oil Cooler Mounting Bolts N·m 20 31 35 10 15 15 1.5 10 20 10 20 20 Torque kgf·m 2.0 3.2 3.6 1.0 1.5 1.5 0.15 1.0 2.0 1.0 2.0 2.
7-4 ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Engine Oil Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-5 www.zxforums.com Engine Oil Flow Chart 1. Inlet Camshaft 2. Exhaust Camshaft 3. Oil Cooler 4. Oil Filter 5. Oil Pressure Switch 6. Main Oil Passage 7. Relief Valve 8. Oil Pump 9. 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 www.zxforums.com www.zxforums.com www.
7-6 ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Specifications Item Standard Engine Oil Type Viscosity Capacity Level Oil Pressure Measurement Oil Pressure API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 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) Between upper and lower level lines 150 ∼ 230 kPa (1.5 ∼ 2.
www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-7 www.zxforums.com Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Gear Holder: 57001-1599 Oil Pressure Gauge Adapter, PT3/8: 57001-1233 Kawasaki Bond (Silicone Sealant): 92104-0004 Oil Filter Wrench: 57001-1249 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
7-8 ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection that the engine oil level is between the upper [A] • Check and lower [B] levels in the gauge. NOTE ○Situate the motorcycle so that it is perpendicular to the ground.
www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-9 www.zxforums.com Oil Pan Oil Pan Removal the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Clamps [B] Oil Pan [C] Oil Pan Installation the oil pan gasket [A] with a new one. • Replace Install the [B] as shown. • Rear Viewclamps [C] • Tighten: www.zxforums.com Torque - Oil Pan Bolts: 10 N·m (1.
7-10www.zxforums.com ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation a non-permanent locking agent to the threads of • Apply the oil pressure relief valve [A], and tighten it. CAUTION www.zxforums.com Do not apply too much non-permanent locking agent to the threads.
ENGINE www.zxforums.com www.zxforums.com LUBRICATION SYSTEM 7-11 www.zxforums.com Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection the oil pressure relief valve (see Oil Pressure • Remove Relief Valve Removal). to see if the valve [A] slides smoothly when push• Check ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance.
7-12www.zxforums.com ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com Oil Pump Oil Pump Removal • Remove: Oil Pump Gear (see Oil Pump Gear Removal) Oil Pump Cover Bolts [A] the oil pump cover [A] with oil pump gear shaft • Remove [B]. ○Stuff the cloth [C] on the hole of the crankcase so that pin • [D] close not drop into the crankcase bottom. Remove the outer rotor [E] and inner rotor [F].
www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-13 www.zxforums.com Oil Pump the outer rotor [A] on the inner rotor. •○Install Apply engine oil to the outer rotor. the dowel pin [B]. • Install the pin of the oil pump cover into the hole [C] in the • Fit crankcase. ○Turn the oil pump gear shaft [A] so that the projection [B] in its shaft fits onto the slot [C] of the impeller shaft. • Tighten the oil pump cover bolts. Torque - Oil Pump Cover Bolts: 10 N·m (1.
7-14www.zxforums.com ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com Oil Pump a non-permanent locking agent to the threads of • Apply the oil pump gear bolts [A]. the oil pump gear [B] steady with the gear holder [C], • Hold and tighten the bolts. Special Tool - Gear Holder: 57001-1599 Torque - Oil Pump Gear Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) the clutch (see Clutch Installation in the Clutch • Install chapter). www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com ENGINE www.zxforums.com LUBRICATION SYSTEM 7-15 www.zxforums.com Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte• nance chapter) Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Remove: Water Hoses [A] Oil Cooler Mounting Bolts [B] Oil Cooler [C] Oil Cooler Installation the O-ring [A] with a new one. • Replace Apply grease to the new O-ring. • • Install the oil cooler [A]. Torque - Oil Cooler Mounting Bolts: 20 N·m (2.
7-16www.zxforums.com ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com Oil Cooler Oil Cooler/Oil Filter Case Installation the O-ring [A] with a new one. • Replace Apply grease to the new O-ring. • If the oil filter pipe [B] was removed, install it. ○Apply a non-permanent locking agent to the threads of the oil filter pipe, and tighten it. Torque - Oil Filter Pipe: 35 N·m (3.
ENGINE www.zxforums.com www.zxforums.com LUBRICATION SYSTEM 7-17 www.zxforums.com Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 the engine and warm up the engine. • Start Run the at the specified speed, and read the oil • pressureengine gauge.
7-18www.zxforums.com ENGINE LUBRICATION SYSTEM www.zxforums.com www.zxforums.com Oil Pressure Switch Oil Pressure Switch Removal the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). the left lower fairing (see Lower Fairing Removal • Remove in the Frame chapter). out the rubber boot [A]. • Slide Loosen oil pressure switch terminal bolt [B], and re• move thetheswitch lead [C]. Remove the oil pressure switch [D].
www.zxforums.com ENGINE www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-1 Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Special Tool ............................................................................................................................ Engine Removal/Installation ................................................................................
8-2 ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
ENGINE www.zxforums.com www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-3 Exploded View No.
8-4 ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com www.zxforums.com Special Tool Engine Mount Nut Wrench: 57001-1450 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
ENGINE www.zxforums.com www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-5 Engine Removal/Installation Engine Removal the rear part of the swingarm with a stand. • Support Squeeze • [A]. the brake lever slowly and hold it with a band 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. CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
8-6 ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com www.zxforums.com Engine Removal/Installation • Disconnect the sidestand switch lead connector [A]. • Remove: Gear Position Switch Lead Connector [A] Alternator Lead Connector [B] • Remove: Engine Ground Cable Terminal Bolt [A] Starter Motor Cable [B] www.zxforums.com the engine with a suitable stand [A]. •○Support Put a plank [B] onto the suitable stand for engine balance.
www.zxforums.com ENGINE www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-7 Engine Removal/Installation • Remove: Left Engine Bracket Bolts [A] Left Engine Bracket [B] • Remove: Right Upper Inner Fairing Bracket Bolts [A] Right Upper Inner Fairing Bracket [B] • Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] www.zxforums.
8-8 ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com www.zxforums.com Engine Removal/Installation • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 the Hexagon Wrench, turn the adjusting collar [A] • Using counterclockwise to make the gap between the engine and adjusting collar. the drive chain [A] from the output shaft [B]. • Remove Using the stand, take out the engine. • www.zxforums.
www.zxforums.com ENGINE www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-9 Engine Removal/Installation www.zxforums.com A: White Mark B: To Radiator C: To Right Engine Bracket (Cylinder Head Side) D: Through the left engine bracket bolt. E: To Camshaft Position Sensor Lead F: To Air Suction Valve Cover and Stick Coil G: To Throttle Body Assy Holder H: Right Front Engine Mount I: To Thermostat Case J: To Water Temperature Sensor www.zxforums.
8-10www.zxforums.com ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com Engine Removal/Installation the engine mounting bolts and nuts, following the • Install specified installing sequence. ○Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. ○Apply 2-stroke oil to the threads of the adjusting collar [B]. ○First, install the adjusting collars [A] [B] to crankcase and frame. Crankcase [C] Frame [D] www.zxforums.
www.zxforums.com ENGINE www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-11 Engine Removal/Installation ○Fifth, 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) ○Sixth, 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 0 mm (0 in.
8-12www.zxforums.com ENGINE REMOVAL/INSTALLATION www.zxforums.com www.zxforums.com Engine Removal/Installation the left [A] and right [B] engine bracket, following • Install the specified installing sequence. ○First, install the adjusting collar [C] to the right engine bracket [B]. ○Second, install the bolts [D] [E] [F] [G] temporally as shown sequence [1 ∼ 8] in the figure. ○Third, tighten the bolts [D] to the tightening sequence [1 ∼ 3] shown. Torque - Left Engine Bracket Bolts: 44 N·m (4.
www.zxforums.com ENGINE www.zxforums.com REMOVAL/INSTALLATION www.zxforums.com 8-13 Engine Removal/Installation www.zxforums.com the left and right upper inner fairing brackets. • Install Run the cable and hoses correctly (see Cable, Wire • and Hoseleads, Routing section in Appendix chapter). Install the removed parts (see appropriate chapters).
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www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-1 Crankshaft/Transmission Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealants ..........................................................................................
9-2 CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.com 9-3 Exploded View No.
9-4 CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.com 9-5 Exploded View No. 1 2 3 4 5 6 7 Fastener Shift Pedal Mounting Bolt Gear Position Lever Bolt Shift Shaft Return Spring Pin Shift Drum Cam Holder Bolt Shift Lever Bolt Tie-Rod Locknuts Gear Position Switch Screws N·m 25 12 29 12 7.0 7.0 3.0 Torque kgf·m 2.5 1.2 3.0 1.2 0.71 0.71 0.30 ft·lb 18 106 in·lb 21 106 in·lb 62 in·lb 62 in·lb 27 in·lb Remarks L L L 8.
9-6 CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.com Specifications Item Crankcase, Crankshaft, Connecting Rods ––– Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert/crankpin Clearance Crankpin Diameter: Marking: None ○ Connecting Rod Big End Inside Diameter: Marking: None ○ Standard Service Limit TIR 0.2/100 mm (0.008/3.94 in.) ––– TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.
www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-7 Specifications Item Crankshaft Main Bearing Insert Thickness: Brown Black Blue Pistons Cylinder (Upper Crankcase) Inside Diameter Piston Diameter Piston/Cylinder Clearance Piston Ring/Groove Clearance: Top Standard Service Limit 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 ∼ 76.006 mm (2.9917 ∼ 2.9924 in.) 75.959 ∼ 75.974 mm (2.9905 ∼ 2.9911 in.
9-8 CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Special Tools and Sealants Bearing Puller: 57001-135 Piston Pin Puller Assembly: 57001-910 Outside Circlip Pliers: 57001-144 Piston Ring Compressor Grip: 57001-1095 Bearing Puller Adapter: 57001-317 Piston Ring Compressor Belt, 57001-1097 67 ∼ 79: www.zxforums.com Bearing Driver, 57001-382 32: www.zxforums.com Kawasaki Bond: 92104-1064 www.zxforums.com www.zxforums.
9-10www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankcase Splitting Crankcase Splitting the engine (see Engine Removal in the Engine • Remove Removal/Installation chapter). the engine on a clean surface and hold the engine • Set steady while parts are being removed.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-11 www.zxforums.com Crankcase Splitting the lower crankcase bolts, following the specified sequence. •○Remove First, loosen the M6 bolts [A]. ○Second, loosen the M7 bolts [B]. ○Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10] in the figure. lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take • Tap care not to damage the crankcase. www.zxforums.
9-12www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankcase Splitting a non-permanent locking agent to the treads of the • Apply breather plate bolts [A] and tighten it. Torque - Breather Plate Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) the following in the upper crankcase.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-13 www.zxforums.com Crankcase Splitting liquid gasket [A] to the mating surface of the lower • Apply crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○Especially, apply a sealant so that it shall be filled up on the grooves. CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage hole. www.zxforums.com • Fit the lower crankcase half to the upper crankcase half.
9-14www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankcase Splitting the lower crankcase bolts using the following • Tighten steps. ○Following 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) ○Tighten 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.
www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-15 Crankcase Splitting the upper crankcase bolts using the following • Tighten steps. ○The M8 bolts [A] has a washer, replace it with a new one. ○Tighten the M8 bolts with washers. Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○Tighten the M7 bolts [B]. Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb) ○Tighten the M6 bolts [C]. Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) www.
9-16www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankshaft and Connecting Rods Crankshaft Removal to the Connecting Rod Removal (see Connecting • Refer Rod Removal). Crankshaft Installation NOTE ○If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-17 www.zxforums.com Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark.
9-18www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.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. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-19 www.zxforums.com Crankshaft and Connecting Rods new bolts in reused connecting rods. • Install Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the • length of new connecting rod bolts and record the values • • • to find the bolt stretch. Connecting Rod [A] Dent here with a punch [B]. Nuts [C] Fit micrometer pins into dents [D].
9-20www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankshaft and Connecting Rods new bolts in reused connecting rods. • Install 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 tighten the nuts to the specified torque. See the • First, table below. tighten the nuts 150°.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-21 www.zxforums.com Crankshaft and Connecting Rods Connecting Rod Twist the big-end arbor [A] still on V block [C], hold the • With 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 determine the amount of connecting rod twist. If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
9-22www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-23 www.zxforums.com Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 37.500 ∼ 37.508 mm (1.4764 ∼ 1.4766 in.) ○ 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]: “○” or no mark the proper bearing insert [A] in accordance with the • Select combination of the connecting rod and crankshaft coding.
9-24www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear a plastigage (press gauge) [A], measure the bear• Using ing insert/journal [B] clearance. NOTE ○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the crankshaft during clearance measurement. ○Journal clearance less than 0.025 mm (0.00098 in.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-25 www.zxforums.com Crankshaft and Connecting Rods the main bearing inside diameter, and mark the • Measure upper crankcase half in accordance with the inside diameter. A: Crankcase Main Bearing Inside Diameter Marks, “○” mark or no mark. the crankcase bolts to the specified torque (see • Tighten Crankcase Assembly). NOTE ○The mark already on the upper crankcase half should almost coincide with the measurement.
9-26www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Pistons Piston Removal the crankcase (see Crankcase Splitting). • Split Remove the connecting rod nuts [A] and big end caps [B]. • NOTE ○Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-27 www.zxforums.com Pistons Piston Installation molybdenum disulfide oil solution to the oil ring ex• Apply pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. ○Spread the rail with your thumbs, but only enough to fit the rail over the piston.
9-28www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Pistons molybdenum disulfide oil solution to the cylinder • Apply bore and piston skirt. the piston with its marking hollow [A] facing exhaust • Install side. the piston ring compressor assembly [B] to install • Using the piston from the cylinder head side.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-29 www.zxforums.com Pistons Piston Ring Groove Width the piston ring groove width. •○Measure Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) Top [A] 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.
9-30www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Transmission Shift Pedal Removal [A] the position of the shift lever [B] on the shift shaft • Mark so that it can be installed later in the same position. • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Shift Lever Bolt [C] Shift Lever • Remove: Shift Pedal Mounting Bolt [A] Tie-rod [B] Shift Pedal Installation grease to the sliding surfaces [A] on the shift pedal • Apply mounting bolt [B].
www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-31 Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Washer and Spring External Shift Mechanism Installation the gear positioning lever [A] as shown. • Install Spring [B] • Washer [C] Bolt [D] Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) External Shift Mechanism Inspection the shift shaft [A] for any damage.
9-32www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Transmission Transmission Shaft Removal the crankcase (see Crankcase Splitting). • Split Remove the output shaft [A]. • Discard the oil seal [B] • • 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] Pull out the drive shaft [C].
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-33 www.zxforums.com Transmission the crankcase (see Crankcase Assembly). • Assemble Press in the oil seal [A] onto collar [B] so that the • surface of thenew oil seal is flush with the counterbore bottom surface [C] of the crankcase. ○Apply high-temperature grease to the oil seal lips. Transmission Shaft Disassembly the transmission shafts (see Transmission Shaft • Remove Removal). the circlips, disassemble the transmission • Remove shafts.
9-34www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Transmission engine oil to the bushings, ball bearings and shafts. • Apply Install the gear bushings [A] on the shaft with their holes • [B] aligned. any circlips removed with new ones. • Replace Install the [A] so that the opening [B] of it is aligned • with splinecirclips grooves [C]. the circlips so that the mark [D] on them faces to • Install each gear side.
CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-35 www.zxforums.com Transmission the steel balls into the 5th gear holes in the output • Fit 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.
9-36www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Transmission www.zxforums.com 1. Output Shaft 2. Collar 3. Ball Bearing 4. 2nd Gear 5. 6th (Top) Gear 6. 4th Gear 7. 3rd Gear 8. Steel Ball 9. 5th Gear 10. 1st Gear 11. Needle Bearing 12. Bearing Outer Race www.zxforums.com 13. Bushing 14. Thrust Washer, 34 mm (1.34 in.) 15. Snap Ring 16. Bushing 17. Toothed Washer, 34 mm (1.34 in.) 18. Thrust Washer, 32 mm (1.26 in.) 19. Bushing 20. Snap Ring 21. Bushing 22.
www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com 9-37 Transmission Shift Drum and Fork Removal the crankcase (see Crankcase Splitting). • Split Remove: • Gear Position Switch (see Gear Position Switch Removal in the Electrical System chapter) Bolt [A] Shift Fork Holder [B] Screws [C] Shift Drum Bearing Holder [D] out the shift rods [A], and take off the shift forks [B]. • Pull Pull • out the shift drum [C].
9-38www.zxforums.com CRANKSHAFT/TRANSMISSION www.zxforums.com www.zxforums.com Transmission Shift Fork Bending inspect the shift forks, and replace any fork that is • Visually 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 the thickness of the shift fork ears [A], and mea• Measure sure the width [B] of the gear grooves.
www.zxforums.com www.zxforums.com WHEELS/TIRES www.zxforums.com 10-1 Wheels/Tires Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools ..........................................................................................................................
10-2www.zxforums.com WHEELS/TIRES www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com WHEELS/TIRES www.zxforums.com 10-3 www.zxforums.com Exploded View No. 1 2 3 Fastener N·m 20 127 108 Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Torque kgf·m 2.0 13.0 11.0 ft·lb 15 94 80 Remarks AL 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.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
10-4www.zxforums.com WHEELS/TIRES www.zxforums.com www.zxforums.com Specifications Item Wheels (Rims) Rim Runout: Axial Radial Axle Runout/100 mm Wheel Balance Balance Weights Standard TIR 0.5 mm (0.02 in.) or less TIR 0.8 mm (0.03 in.) or less 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.) Rim Size: Front 17 × 3.50 Rear 17 × 6.00 Tires Air Pressure (When Cold): Front Up to 180 kg (397 lb) load: 250 kPa (2.
www.zxforums.com www.zxforums.com WHEELS/TIRES www.zxforums.com 10-5 Special Tools Bearing Driver Set: 57001-1129 Bearing Remover Shaft, 57001-1377 Jack: 57001-1238 Jack Attachment: 57001-1608 Bearing Remover Head, 57001-1293 20 × 13: 22: www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
10-6www.zxforums.com WHEELS/TIRES www.zxforums.com www.zxforums.com Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] (Left and Right) • Loosen: Left Side Axle Clamp Bolts [A] Axle Nut [B] Right Side Axle Clamp Bolts the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). • Raise the front wheel off the ground with the jack [A]. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 www.zxforums.
www.zxforums.com www.zxforums.com WHEELS/TIRES www.zxforums.com 10-7 Wheels (Rims) high-temperature grease to the grease seal lips. • Apply Fit the collars [A] on the both sides of the hub. •○The collars are identical. the axle. • Insert Tighten the axle nut [B]. • Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] 0.7 ∼ 4.1 mm (0.028 ∼ 0.161 in.) [E] Viewed from Rear [F] Torque - Front Axle Nut: 127 N·m (13.
10-8www.zxforums.com WHEELS/TIRES www.zxforums.com www.zxforums.com Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) www.zxforums.com the drive chain [A] from the rear sprocket toward • Remove the left. • Move the rear wheel back and remove it. CAUTION Do not lay the wheel on the ground with the disc facing down.
www.zxforums.com www.zxforums.com WHEELS/TIRES www.zxforums.com 10-9 Wheels (Rims) ○If the coupling [A] is removed from the rear wheel, apply the grease [B] as shown. Wheel Flange Portion [C] O-ring [D] the drive chain with the rear sprocket. • Engage Install the caliper bracket [A] onto the swingarm stop [B]. •○Insert the axle from the right side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut: 108 N·m (11.
10-10 WHEELS/TIRES www.zxforums.com www.zxforums.com www.zxforums.com Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 the wheel lightly, and check for roughness or binding. • Spin If roughness or binding is found, replace the hub bearings. the wheel for small cracks, dents, bending, or • Inspect warp. • • If there is any damage to the wheel, replace the wheel.
www.zxforums.com www.zxforums.com WHEELS/TIRES 10-11 www.zxforums.com Wheels (Rims) Balance Inspection the wheel (see wheels (Rims) section). • Remove Support the wheel so that it can be spun freely. • Spin the wheel and mark [A] the wheel at the top • when the wheellightly, stops. ○Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is well balanced. If the wheel always stops in one position, adjust the wheel balance.
10-12 WHEELS/TIRES www.zxforums.com 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 ○Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability. ○Do not use four or more balance weight (more than 90 gram).
www.zxforums.com www.zxforums.com WHEELS/TIRES 10-13 www.zxforums.com Tires Air Pressure Inspection/Adjustment to the Tires Air Pressure Inspection in the Periodic • Refer Maintenance chapter (see Tires Air Pressure Inspection in the Periodic Maintenance chapter). Tire Inspection to the Wheels/Tires Damage Inspection in the Pe• Refer riodic Maintenance chapter (see Wheels/Tires Damage Inspection in the Periodic Maintenance chapter).
10-14 WHEELS/TIRES www.zxforums.com www.zxforums.com www.zxforums.com Tires a new valve in the rim. •○Install Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. ○The air valve is shown in the figure.
www.zxforums.com www.zxforums.com WHEELS/TIRES 10-15 www.zxforums.com Tires to see that the rim lines [A] on both sides of the tire • Check sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again. After the tire beads seat in the rim flanges, check for air leakage. ○Inflate the tire slightly above standard inflation.
10-16 WHEELS/TIRES www.zxforums.com www.zxforums.com www.zxforums.com Hub Bearing Hub Bearing Removal the wheel, and take out the following. • Remove Collars Coupling (out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
www.zxforums.com www.zxforums.com WHEELS/TIRES 10-17 www.zxforums.com Hub Bearing Hub Bearing Lubrication NOTE ○Since the hub bearings are packed with grease and sealed, lubrication is not required. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
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www.zxforums.com www.zxforums.com FINAL DRIVE 11-1 www.zxforums.com Final Drive Table of Contents Exploded View ....................................................................................................................... Specifications ........................................................................................................................ Special Tools ..........................................................................................................................
11-2 www.zxforums.com FINAL DRIVE www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FINAL DRIVE 11-3 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 Fastener N·m 108 59 125 10 Rear Axle Nut Rear Sprocket Nuts Engine Sprocket Nut Engine Sprocket Cover Bolts Torque kgf·m 11.0 6.0 12.7 1.0 ft·lb 80 44 92 89 in·lb Remarks MO 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.
11-4 www.zxforums.com FINAL DRIVE www.zxforums.com www.zxforums.com Specifications Item Drive Chain Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain Make Type Link Sprockets Rear Sprocket Warp Standard Service Limit 30 ∼ 35 mm (1.2 ∼ 1.4 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) – – – 323 mm (12.7 in.) – – – – – – – – – RK EXCEL RK 525MFO, Endless 108 links 0.4 mm (0.016 in.) or less 0.5 mm (0.02 in.) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FINAL DRIVE 11-5 www.zxforums.com Special Tools Inside Circlip Pliers: 57001-143 Bearing Driver Set: 57001-1129 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
11-6 www.zxforums.com FINAL DRIVE www.zxforums.com www.zxforums.com Drive Chain Drive Chain Slack Inspection to the Drive Chain Slack Inspection in the Periodic • Refer Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). Drive Chain Slack Adjustment to the Drive Chain Slack Inspection in the Periodic • Refer Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter).
www.zxforums.com www.zxforums.com FINAL DRIVE 11-7 www.zxforums.com Drive Chain a suitable tool [A], cut the drive chain by removing • Using the link pins. Recommended Tool: RK EXCEL 70 Tool (RK-700) CAUTION Read the Tool Manual before removing.
11-8 www.zxforums.com FINAL DRIVE www.zxforums.com www.zxforums.com Drive Chain ○Screw in the pressure bolt assy [A] in the pressure bolt (A) [B]. ○Install the handle lever [C] to the pressure bolt assy. ○Turn in the handle lever until the link pin [D] removed at the link plate [E]. • Repeat the above steps for other link pin [A]. Drive Chain Installation new drive chain to the old drive chain and pull • Engage the end of the old drive chain until they are changing the • • • • • • position.
www.zxforums.com www.zxforums.com FINAL DRIVE 11-9 www.zxforums.com Drive Chain ○Install the link plate so that the gold painted [A] faces out. ○Fit the link plate [A] in the pressure holder [B]. ○Fit the link plates of the chain into the wedge holder and wedge pin [D]. ○Turn the pressure bolt (A) [C] by hand until link plate touches the link pins. ○Install the handle lever [A] onto the pressure bolt (A) [B]. ○Turn the handle lever, press in the link plate to the link pins. www.zxforums.
11-10 FINAL DRIVE www.zxforums.com www.zxforums.com www.zxforums.com Drive Chain staking, measure the outside diameter [A] of the link • After 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.) • • If the reading exceeds the specified length, cut and rejoin the chain again.
www.zxforums.com www.zxforums.com FINAL DRIVE 11-11 www.zxforums.com Sprocket, Coupling Engine Sprocket Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame • chapter) Shift Lever Bolt [A] Pull the shift lever [B]. • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] out the bended washer [A]. • Flatten Remove the engine sprocket nut [B] and washer. • NOTE ○When loosening the engine sprocket nut, hold the rear brake on. www.zxforums.
11-12 FINAL DRIVE www.zxforums.com www.zxforums.com www.zxforums.com Sprocket, Coupling the guide [A] into the sprocket cover [B] so that the • Install hook [C] of the guide fits into the receiver [D]. the engine sprocket cover [A] with the guide [B]. •○Install Install the pins [C] into the holes [D]. • Tighten the engine sprocket cover bolts. Torque - Engine Sprocket Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters).
www.zxforums.com www.zxforums.com FINAL DRIVE 11-13 www.zxforums.com Sprocket, Coupling Coupling Installation the following and install the coupling. • Grease Coupling Grease Seal Lips [A] Coupling Internal Surface [B] grease to the O-ring [A]. • Apply Install the collar [B]. • Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] www.zxforums.com Special Tool - Inside Circlip Pliers [B]: 57001-143 • Remove the bearing [A] by tapping from the wheel side.
11-14 FINAL DRIVE www.zxforums.com www.zxforums.com www.zxforums.com Sprocket, Coupling the grease seal with a new one. • Replace Press in the seal so that the seal surface is flush • with the end grease of the hole. ○Apply 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.
www.zxforums.com www.zxforums.com FINAL DRIVE 11-15 www.zxforums.com Sprocket, Coupling Rear Sprocket Warp Inspection the rear wheel off the ground (see Rear Wheel • Raise Removal in the Wheels/Tires chapter) so that it will turn • freely. Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp).
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www.zxforums.com www.zxforums.com BRAKES 12-1 www.zxforums.com Brakes Table of Contents Exploded View ....................................................................................................................... Specifications ........................................................................................................................ Special Tools ..........................................................................................................................
12-2www.zxforums.com BRAKES www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com BRAKES 12-3 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 Fastener Bleed Valves Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Nut Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Pad Pins Front Brake Reservoir Cap Stopper Screw Front Caliper Assembly Bolts Front Caliper Mounting Bolts Front Brake Master Cylinder Bleed Valve Front Master Cylinder Clamp Bolts N·m 7.8 25 1.0 5.9 27 1.2 15 1.2 22 34 5.4 8.
12-4www.zxforums.com BRAKES www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com BRAKES 12-5 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 Fastener Bleed Valve Brake Hose Banjo Bolts Brake Pedal Bolt Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut N·m 7.8 25 8.8 27 25 25 17 Torque kgf·m 0.80 2.5 0.90 2.8 2.5 2.5 1.7 ft·lb 69 in·lb 18 78 in·lb 20 18 18 13 Remarks L B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent.
12-6www.zxforums.com BRAKES www.zxforums.com www.zxforums.com Specifications Item Brake Lever, Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Discs Thickness: Front Rear Runout Standard Service Limit – – – – 6-way adjustable (to suit rider) Non-adjustable Non-adjustable About 90 mm (3.5 in.) below footpeg top 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.
www.zxforums.com www.zxforums.com BRAKES 12-7 www.zxforums.com Special Tools Inside Circlip Pliers: 57001-143 Jack Attachment: 57001-1608 Jack: 57001-1238 www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
12-8www.zxforums.com BRAKES 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. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. ○The distance from the grip to the lever is minimum at number 6 and maximum at number 1.
www.zxforums.com www.zxforums.com BRAKES 12-9 www.zxforums.com Brake Lever, Brake Pedal • Remove: Cotter Pin [A] • Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation grease to the pivot shaft [A] and install the washer • Apply [B]. • Install: Brake Pedal [C] Washer [D] Brake Pedal Bolt [E] Torque - Brake Pedal Bolt: 8.8 N·m (0.
12-10 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Calipers Front Caliper Removal the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. the caliper mounting bolts [B], and detach the • Unscrew caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage.
www.zxforums.com www.zxforums.com BRAKES 12-11 www.zxforums.com Calipers 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 application of the lever or pedal if this is not done.
12-12 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Calipers Rear Caliper Dust Boot and Friction Boot Damage that the dust boot [A] and friction boot [B] are not • Check cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage inspect the pistons [A] and cylinder surfaces [B]. • Visually Replace the caliper if the cylinder and piston are badly scores or rusty. www.zxforums.
www.zxforums.com www.zxforums.com BRAKES 12-13 www.zxforums.com Brake Pads Front Brake Pad Removal • Loosen: Pad Pins [A] • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation the caliper pistons in by hand as far as they will go. • Push Install • shown.the outside pad [A] and insert the pad pin [B] as www.zxforums.com • Set: Inside Pad [A] Pad Spring [B] ○Pushing the pin holder [C] to hole of the pad and insert the pad pin. Torque - Front Brake Pad Pins: 15 N·m (1.
12-14 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Brake Pads Rear Brake Pad Removal the caliper with the hose installed. • Remove Remove: • Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Installation the caliper piston in by hand as far as it will go. • Push Install the pad spring in place. • Install the piston side pad [A] first, and then another pad. •○Fit the projections [B] of the pad into the recesses [C] of • • the caliper holder. Install the pad pin and clip.
www.zxforums.com www.zxforums.com BRAKES 12-15 www.zxforums.com Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket nut [A]. the banjo bolt [A] to disconnect the brake hose • Remove from the master cylinder (see Brake Hose Removal/In- • • stallation). Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and brake switch installed. Disconnect the front brake light switch connector [D].
12-16 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Master Cylinder Rear Master Cylinder Removal the brake hose banjo bolt [A] and brake hose • Unscrew [B]. • Remove: Cotter Pin [C] • • Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder Slide out the clamp [G]. Pull off the reservoir hose lower end [H], and drain the brake fluid into a container. Rear Master Cylinder Installation the cotter pin with a new one.
www.zxforums.com www.zxforums.com BRAKES 12-17 www.zxforums.com Master Cylinder Master Cylinder Inspection (Visual Inspection) the master cylinders (see Front/Rear Master • Remove Cylinder Removal). the front and rear master cylinders (see • Disassemble Master Cylinder Rubber Parts Replacement in the Peri- • • odic Maintenance chapter). 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].
12-18 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Brake Disc Brake Disc Removal the wheel (see Wheels (Rims) section in the • Remove Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation the brake disc on the wheel so that the marked side • Install [B] faces out. a non-permanent locking agent to the threads of • Apply the rear brake disc mounting bolts [A]. • Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.
www.zxforums.com www.zxforums.com BRAKES 12-19 www.zxforums.com Brake Fluid Brake Fluid Level Inspection to the Brake Fluid Level Inspection in the Periodic • Refer Maintenance chapter (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). Brake Fluid Change to the Brake Fluid Change in the Periodic Mainte• Refer nance chapter (see Brake Fluid Change in the Periodic Maintenance chapter).
12-20 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Brake Fluid the rubber cap from the bleed valve on the front • Remove master cylinder. a clear plastic hose [A] to the bleed valve, and run • Attach the other end of the hose into a container. the brake line and the master cylinder. •○Bleed Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2.
www.zxforums.com www.zxforums.com BRAKES 12-21 www.zxforums.com Brake Fluid the brake line and the caliper. •○Bleed Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C].
12-22 BRAKES www.zxforums.com www.zxforums.com www.zxforums.com Brake Fluid WARNING When working with the disc brake, observe the precautions 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.
www.zxforums.com www.zxforums.com BRAKES 12-23 www.zxforums.com Brake Hose Brake Hose Removal/Installation to the Brake Hose and Pipe Replacement in the • Refer Periodic Maintenance chapter (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Brake Hose Inspection to the Brake Hose Damage and Installation Condi• Refer tion Inspection in the Periodic Maintenance chapter (see Brake Hose Damage and Installation Condition Inspection in the Periodic Maintenance chapter). www.
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www.zxforums.com www.zxforums.com SUSPENSION www.zxforums.com 13-1 Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools ..........................................................................................................................
13-2www.zxforums.com SUSPENSION www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com SUSPENSION www.zxforums.com 13-3 www.zxforums.com Exploded View No. 1 2 3 4 5 6 Fastener Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts N·m 20 23 30 20 23 15 Torque kgf·m 2.0 2.3 3.1 2.0 2.3 1.5 ft·lb 15 17 22 15 17 11 Remarks AL L AL AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent.
13-4www.zxforums.com SUSPENSION www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com SUSPENSION www.zxforums.com 13-5 www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 8 Fastener Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Uni-Trak Rocker Arm Nut Swingarm Pivot Adjusting Shaft Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts N·m 59 34 34 34 20 98 108 59 Torque kgf·m 6.0 3.5 3.5 3.5 2.0 10.0 11.0 6.0 ft·lb 44 25 25 25 15 72 80 44 Remarks G: Apply or add grease.
13-6www.zxforums.com SUSPENSION www.zxforums.com www.zxforums.com Specifications Item Front Fork (Per One Unit) Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Standard 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.
www.zxforums.com www.zxforums.com SUSPENSION www.zxforums.com 13-7 Special Tools Inside Circlip Pliers: 57001-143 Fork Cylinder Holder: 57001-1287 Oil Seal & Bearing Remover: 57001-1058 Fork Oil Level Gauge: 57001-1290 Hook Wrench R37.5, R42: 57001-1101 Bearing Remover Head, 57001-1293 20 × 22: www.zxforums.com Bearing Driver Set: 57001-1129 Fork Piston Rod Puller, M10 × 1.0: 57001-1298 Jack: 57001-1238 Bearing Remover Shaft, 57001-1377 www.zxforums.com www.zxforums.com 13: www.zxforums.
13-8www.zxforums.com SUSPENSION www.zxforums.com www.zxforums.com Special Tools Fork Oil Seal Driver, 57001-1530 43: Needle Bearing Driver, 57001-1609 Fork Spring Compressor: 57001-1587 Stem Bearing Driver, 57001-1610 Swingarm Pivot Nut Wrench: 57001-1597 Clamp: 57001-1626 17/ 18: 28: www.zxforums.com Jack Attachment: 57001-1608 www.zxforums.com Spacer, 18: 57001-1636 www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com SUSPENSION www.zxforums.com 13-9 Front Fork Rebound Damping Force Adjustment adjust the rebound damping force, turn the rebound • To damping adjuster [A] until you feel a click. ○The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position.
13-10 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Front Fork Spring Preload Adjustment the spring preload adjuster [A] to change spring • Turn preload setting. ○The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 17 mm (0.67 in.) [B] from the top plug nut surface as shown. Adjuster Protrusion (from the top plug nut surface) Standard: 17 mm (0.67 in.) Usable Range: 4 ∼ 19 mm (0.16 ∼ 0.75 in.
www.zxforums.com www.zxforums.com SUSPENSION 13-11 www.zxforums.com Front Fork the handlebar bolt [A], upper fork clamp bolt [B] • Loosen and lower fork clamp bolts [C]. • With a twisting motion, work the fork leg down and out. Front Fork Installation the fork so that the top end [A] of the outer tube is • Install flush with the upper surface [B] of the steering stem head • bracket. Tighten the upper fork clamp bolt and fork top plug. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.
13-12 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Front Fork • Install the clamps [A] as shown. NOTE ○Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D]. The outer tube is used as a guide. Special Tools - Fork Spring Compressor: 57001-1587 Clamp: 57001-1626 the holder bar [A] into the axle hole of the front fork • Insert [B]. www.zxforums.
www.zxforums.com www.zxforums.com SUSPENSION 13-13 www.zxforums.com Front Fork the adjust nut [A] onto the compression shaft as • Screw shown. • • 20 mm (0.79 in.) [B] Screw the locknut [C]. Set the other side compression shaft same process. • Screw in one side nut [A] come out the piston rod nut. the piston rod nut with a wrench [A], remove the • Holding top plug [B] from the piston rod. www.zxforums.
13-14 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Front Fork the fork tube upright, press the inner tube [A] and • Hold the piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Viscosity: KHL15-10 (KAYABA) or equivalent Amount (per side): When changing oil: Approx. 480 mL (16.2 US oz.) After disassembly and completely dry: 567 ±4 mL (19.2 ±0.14 US oz.) If necessary, measure the oil level as follows. ○Hold the inner tube vertically in a vise.
www.zxforums.com www.zxforums.com SUSPENSION 13-15 www.zxforums.com Front Fork the fork piston rod puller onto the end of the piston • Screw rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 the puller up above the outer tube top. • Pull Install • upward.the fork spring [A] with the smaller end facing [B] • Install: Spring Seat Collar the rod nut [B] onto the piston rod [A] as shown. • Screw 11 mm (0.43 in.
13-16 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Front Fork • Set the holder bar [B], and compression shafts [A]. the piston rod nut [A]. • Hold Remove the piston rod puller [B]. • • Install the rebound damping adjuster rod [A]. www.zxforums.com in the top plug [A] stopped onto the piston rod. • Screw Check [B] on the top plug and replace it with a • new onetheif O-ring damaged. the top plug with a wrench, tighten the piston rod • Holding nut [C] against the top plug.
www.zxforums.com www.zxforums.com SUSPENSION 13-17 www.zxforums.com Front Fork Front Fork Disassembly the front fork (see Front Fork Removal). • Remove Drain the fork oil (see Front Fork Oil Change). • Hold the front a vise [A]. • Stop the cylinderfork[B]infrom turning by using the fork cylinder • holder [C]. Special Tool - Fork Cylinder Holder: 57001-1287 the Allen bolt [D], then take the bolt and gasket • Unscrew out of the bottom of the inner tube. the cylinder unit [A].
13-18 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Front Fork the following parts into the inner tube [A]. • Install Dust Seal [B] Circlip [C] Oil Seal [D] Washer [E] the inner tube to the outer tube. • Insert After installing washer, install the oil seal [A] by using • the fork oil sealthedriver [B]. Special Tool - Fork Oil Seal Driver, 43: 57001-1530 the circlip and dust seal. • Install Pour in • Change).
www.zxforums.com www.zxforums.com SUSPENSION 13-19 www.zxforums.com Front Fork Dust Seal Inspection the dust seals [A] for any signs of deterioration or • Inspect damage. Replace it if necessary. Spring Tension a spring becomes shorter as it weakens, check its • Since free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
13-20 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Rear Shock Absorber Rebound Damping Force Adjustment adjust the rebound damping force, turn the lower • To damping adjuster [A] to the desired position, until you feel a click. ○The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 2 turns out from the fully clockwise position.
www.zxforums.com www.zxforums.com SUSPENSION 13-21 www.zxforums.com Rear Shock Absorber adjust the spring preload, turn in the adjusting nut [A] • To to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 179 mm (7.0 in.) Usable Range: Spring length 179 ∼ 191.5 mm (7.047 ∼ 7.539 in.) ○The standard adjusting nut setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is 180 mm (7.0 in.) spring length.
13-22 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Rear Shock Absorber • Squeeze the brake lever slowly and it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. • Remove: Lower Shock Absorber Nut and Bolt [A] • Upper Tie-Rod Nut and Bolt [B] Upper Shock Absorber Nut and Bolt [C] Remove the shock absorber downward.
www.zxforums.com www.zxforums.com SUSPENSION 13-23 www.zxforums.
13-24 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Swingarm Swingarm Installation plenty of grease to the lip [A] of the oil seals. • Apply Install the collar. • • Place the adjusting collar [A] into the frame [B] as shown. the pivot adjusting shaft [A] into the frame from the • Insert right side. the pivot shaft so that the clearance between the • Tighten adjusting collar [B] and the ball bearing [C] come to 0 mm (0 in.). www.zxforums.
www.zxforums.com www.zxforums.com SUSPENSION 13-25 www.zxforums.com Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip (Right Side) [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tools - Oil Seal & Bearing Remover [A]: 57001-1058 Bearing Remover Head: 57001-1293 Bearing Remover Shaft: 57001-1377 Swingarm Bearing Installation the ball and needle bearings with new ones.
13-26 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Removal may damage them. the needle bearings [A] and ball bearing installed • Inspect in the swingarm. ○The 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.
www.zxforums.com www.zxforums.com SUSPENSION 13-27 www.zxforums.com Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame • chapter) Middle Exhaust Pipe (see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter) Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground.
13-28 SUSPENSION www.zxforums.com www.zxforums.com www.zxforums.com Tie-Rod, Rocker Arm Rocker Arm Installation grease to the inside of the grease seals. • Apply Tighten: • Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Shock Absorber Nuts: 34 N·m (3.
www.zxforums.com www.zxforums.com SUSPENSION 13-29 www.zxforums.com Tie-Rod, Rocker Arm ○Screw the needle bearing driver [A] into the driver holder [B]. ○Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing’s Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.
13-30 SUSPENSION www.zxforums.com 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. Removal may damage them. inspect the rocker arm, or tie-rod sleeves [A] and • Visually needle bearings [B]. rollers in a needle bearing normally wear very little, • The and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.
www.zxforums.com www.zxforums.com STEERING 14-1 www.zxforums.com Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Steering ..................................................................................................................................
14-2www.zxforums.com STEERING www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com STEERING 14-3 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 8 Fastener Handlebar Switch Housing Screws Handlebar Bolts Handlebar Position Bolts Steering Stem Head Nut Front Fork Clamp Bolts (Upper) Steering Stem Locknut Steering Stem Nut Front Fork Clamp Bolts (Lower) N·m 3.5 25 9.8 78 20 – 20 30 Torque kgf·m 0.36 2.5 1.0 8.0 2.0 – 2.0 3.1 ft·lb 31 in·lb 18 87 in·lb 58 15 – 15 22 Remarks L Hand-tighten AL 9. Lock Washer 10.
14-4www.zxforums.com STEERING www.zxforums.com www.zxforums.com Exploded View Item Steering Damper Damper Set Standard 18 turns out from the fully clockwise position (Usable range: 0 ←→ 18 tuns out) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com STEERING 14-5 www.zxforums.com Special Tools Bearing Puller Adapter: 57001-136 Bearing Driver Set: 57001-1129 Bearing Puller: 57001-158 Steering Stem Bearing Driver, 57001-1344 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Bearing Driver Adapter, 57001-1345 42.5: 41.5: www.zxforums.com Steering Stem Nut Wrench: 57001-1100 www.zxforums.com Head Pipe Outer Race Driver, 57001-1446 www.zxforums.com 55: www.zxforums.
14-6www.zxforums.com STEERING www.zxforums.com www.zxforums.com Steering Steering Inspection to the Steering Play Inspection in the Periodic Main• Refer tenance chapter (see Steering Play Inspection in the Periodic Maintenance chapter). Steering Adjustment to the Steering Play Adjustment in the Periodic • Refer Maintenance chapter (see Steering Play Adjustment in the Periodic Maintenance chapter). www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com STEERING 14-7 www.zxforums.com Steering Damper Steering Damper Removal the TORX bolt [A] and washer [B]. • Remove Remove the bolt [C], washer, collar and steering damper • [D]. Steering Damper Installation the steering damper [F] and parts as shown. • Install Collar [A] • Washer [B] Fuel Tank Bracket [C] Bolt [D] Washer [E] Tighten a new TORX bolt [G].
14-8www.zxforums.com STEERING www.zxforums.com www.zxforums.com Steering Stem Stem, Stem Bearing Removal • Remove: Steering Damper (see Steering Damper Removal) Steering Stem Head Nut [A] and Washer [B] Steering Stem Head [C] Handlebars [D] • Remove: Brake Hose Clamp [A] Right Switch Housing Lead Clamp [B] the left switch housing lead and ignition switch • Remove lead clamp [A]. www.zxforums.
www.zxforums.com www.zxforums.com STEERING 14-9 www.zxforums.com Steering Stem • Remove the lock washer [A]. up the stem base, and remove the steering stem • Pushing nut with stem cap [A]. • Remove: Steering Stem [C] Upper Ball Bearing Inner Race Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 remove the bearing outer races [A] pressed into the • To 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.
14-10 STEERING www.zxforums.com www.zxforums.com www.zxforums.com Steering Stem the bearing inner races with new ones. • Replace Install the oil seal [D] on the steering stem, and drive the • lower ball bearing inner race [A] applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver [B]: 57001 -1344 Steering Stem Bearing Driver Adapter [C]: 57001-1345 the lower ball bearing [A] onto the stem.
www.zxforums.com www.zxforums.com STEERING 14-11 www.zxforums.com Steering Stem the lock washer [A] so that claw [B] of washer fit • Install the notch [C] of steering stem locknut [D]. tighten the steering stem locknut by hand until the • First 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. Check that there is no play and the steering stem turns smoothly without rattles.
14-12 STEERING www.zxforums.com www.zxforums.com www.zxforums.com Steering Stem Steering Stem Bearing Lubrication to the Steering Stem Bearing Lubrication in the Pe• Refer riodic Maintenance chapter (see Steering Stem Bearing Lubrication in the Periodic Maintenance chapter). Steering Stem Warp the steering stem is removed, or if the steering • Whenever can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem.
www.zxforums.com www.zxforums.com STEERING 14-13 www.zxforums.
14-14 STEERING www.zxforums.com www.zxforums.com www.zxforums.com Handlebar the left and right switch housings. •○Install Fit 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·lb) • Connect the front brake light switch connector. the clutch lever [A] so that the mating surface [B] • Install of the clutch lever clamps with punch mark [C] on the handlebar.
www.zxforums.com www.zxforums.com FRAME 15-1 www.zxforums.com Frame Table of Contents Exploded View........................................................................................................................ Seats ...................................................................................................................................... Rear Seat Removal........................................................................................................... Rear Seat Installation.
15-2www.zxforums.com FRAME www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FRAME 15-3 www.zxforums.com www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 Fastener Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts Rear Master Cylinder Mounting Bolts Sidestand Bolt Sidestand Switch Bolt Sidestand Bracket Bolts N·m 25 25 44 25 44 8.8 49 Torque kgf·m 2.5 2.5 4.5 2.5 4.5 0.90 5.0 ft·lb 18 18 32 18 32 78 in·lb 36 Remarks G L L 8. Immobilizer Models G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts www.zxforums.
15-4www.zxforums.com FRAME www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FRAME 15-5 www.zxforums.com www.zxforums.com Exploded View No. 1 Fastener N·m 3.9 Front Fender Mounting Bolts Torque kgf·m 0.40 ft·lb 35 in·lb Remarks 2. United States and Canada Models 3. Australian Models www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
15-6www.zxforums.com FRAME www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com FRAME 15-7 www.zxforums.com www.zxforums.com Exploded View No. 1 Fastener N·m 0.4 Windshield Mounting Bolts Torque kgf·m 0.04 ft·lb 4 in·lb Remarks www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
15-8www.zxforums.com FRAME www.zxforums.com www.zxforums.com Seats Rear Seat Removal the ignition switch key [A] into the seat lock, turning • Insert the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation the rear seat hook [A] on the rib [B]. • Put Insert the seat pin [C] into the latch hole [D].
www.zxforums.com www.zxforums.com FRAME 15-9 www.zxforums.com Fairings Lower Fairing Removal • Pull up the core [A] by the thin blade driver [B]. • Remove: Quick Rivets [A] • • • Bolts [B] with Washers Screws [C] Separate the right lower fairing [D] from the left lower fairing. Clear the hook portion and projection [E] from the slots. Remove the right lower fairing. Lower Fairing Installation the hook portion [A] into the slot [B], and put the • Insert projection [C] into the hole [D].
15-10 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Fairings For the California Model ○Remove: Band [A] Canister [B] ○Clear the right switch housing lead from the clamp [A]. ○Disconnect the right turn signal lead connector [B]. the left turn signal lead connector [A]. • Disconnect Clear the left housing lead and ignition switch lead • from the clampswitch [B]. www.zxforums.com Middle Fairing Installation the turn signal lead connectors.
www.zxforums.com www.zxforums.com FRAME 15-11 www.zxforums.com Fairings Windshield Installation • Put the front tongue [A] into the hollow [B]. Torque - Windshield Mounting Bolts: 0.4 N·m (0.
15-12 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Fairings Upper Inner Fairing Removal the bolts [A] with washers. • Remove Remove the upper inner fairing [B]. •○Remove the upper inner fairing by pulling the rear of it up and upward to clear the projection from the stopper [C]. ○Remove the upper inner fairing by sliding the front of it up and backward to clear the projection from the stopper [D].
www.zxforums.com www.zxforums.com FRAME 15-13 www.zxforums.com Fairings Right and Left Inner Fairing Removal • Remove: Right and Left Middle Fairings (see Middle Fairing Removal) Bolts [A] Inner Fairing [B] Right and Left Inner Fairing Installation • Tighten the bolts [A]. www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
15-14 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Side Covers Side Cover Removal • Remove: Bolt and Washer [A] • Pull out the side cover [B]. Side Cover Installation the projections [A] into the holes [B]. • Insert Tighten the bolt with washer. • www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com FRAME 15-15 www.zxforums.com Seat Cover Seat Cover Removal • Remove: Seats (see Seats section) • Bolts [A] Quick Rivets [B] Pull the seat cover backward, and clear the projections from the holes. • Disconnect: Tail/Brake Light Lead Connector [A] Turn Signal Light Lead Connectors [B] • Remove: Seat Lock Cable [A] Pull • the seat cover backward. www.zxforums.
15-16 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Seat Cover • Remove: Screws [A] Seat Lock Assy [B] Seat Cover Installation the seat lock assy with screws. • Install Connect tail/brake light lead connector. • Install thethetail/brake • the stoppers [C]. light [A] inserting the hooks [B] into • Connect the both turn signal light lead connectors. the seat cover. •○Install Insert the projections [A] into the holes [B]. • Install: Bolts Quick Rivets www.zxforums.com www.zxforums.com www.
www.zxforums.com www.zxforums.com FRAME 15-17 www.zxforums.com Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Left and Right) • Bolts [B] with Washers (Left and Right) Remove the front fender assy [C]. • Remove: Bolts [A] Separate the front fender cover [B] and front fender [C]. • Front Fender Installation the front fender assy to the front fork. • Install Tighten: • Torque - Front Fender Mounting Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) www.zxforums.
15-18 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Fenders out the rear fender rear [A] assembled turn signal • Pull lights and license plate light downward. Rear Fender Rear Installation the harness clamp in accordance with Harness • Install Routing section in Appendix chapter.
www.zxforums.com www.zxforums.com FRAME 15-19 www.zxforums.com Fenders • Remove: Bolts and Nuts [A] • • Collars [B] Dampers [C] Upper Heat Guard [D] Remove: Bolt [E] Bolts [F] Fender Bracket [G] Remove: Rivet [H] Nut [I] Bolt [J] Rear Fender Front [K] Front [L] Viewed from Upside [M] www.zxforums.com Rear Fender Front Installation the on the chassis. • Insert Install removed parts (see appropriate chapters).
15-20 FRAME www.zxforums.com www.zxforums.com www.zxforums.com Frame Rear Frame Removal • Remove: Vehicle-down Sensor (see Vehicle-down Sensor Removal 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 • Tighten: Torque - Rear Frame Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb) Frame Inspection inspect the frame for cracks, dents, bending, or • Visually warp.
www.zxforums.com www.zxforums.com FRAME 15-21 www.zxforums.com Sidestand Sidestand Removal the rear wheel off the ground with the stand. • Raise Remove: • Lower Fairings (see Lower Fairing Removal) the sidestand switch lead connector [A] and • Disconnect clear the lead from the clamps [B].
www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-1 www.zxforums.com Electrical System Table of Contents Exploded View........................................................................................................................ 16-4 Parts Location......................................................................................................................... 16-10 Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan)....................
16-2www.zxforums.com ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com Starter Idle Gear Installation ............................................................................................. 16-49 Starter Clutch Removal..................................................................................................... 16-51 Starter Clutch Installation ................................................................................................. 16-51 Starter Clutch Disassembly.................
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-3 www.zxforums.com Relay Box ............................................................................................................................... Relay Box Removal .......................................................................................................... Relay Circuit Inspection .................................................................................................... Diode Circuit Inspection .....................
16-4www.zxforums.com ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-5 www.zxforums.com Exploded View No. 1 2 3 4 5 6 7 Fastener Meter Unit Mounting Screws Headlight Mounting Screws Front Turn Signal Light Mounting Screws Rear Turn Signal Light Mounting Screws Rear Turn Signal Light Lens Screws License Plate Light Mounting Screws License Plate Light Cover Screws N·m 1.2 1.2 1.2 1.2 1.2 1.2 1.2 Torque kgf·m 0.12 0.12 0.12 0.12 0.12 0.12 0.
16-6www.zxforums.com ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com ELECTRICAL SYSTEM 16-7 www.zxforums.com www.zxforums.com Exploded View No.
16-8www.zxforums.com ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com Exploded View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-9 www.zxforums.com Exploded View No.
16-10 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Parts Location www.zxforums.com 1. Starter Lockout Switch 14. Sidestand Switch 2. Ignition Switch with Immobilizer Antenna (Im- 15. Gear Position Switch mobilizer Models) 16. Turn Signal Relay 3. Stick Coils 17. Regulator/Rectifier 4. Water Temperature Sensor 18. Air Switching Valve 5. Alternator 19. Front Brake Light Switch 6. Starter Relay with Main Fuse 20. Meter Unit 7. Battery 12 V 10 Ah 21. Rear Brake Light Switch 8.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-11 www.zxforums.com Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan) Dummy Page www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-12 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-13 www.zxforums.com Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-14 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Wiring Diagram (Other than United States, Canada, New Zealand, Colombia, Taiwan, Australia and Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-15 www.zxforums.com Wiring Diagram (Other than United States, Canada, New Zealand, Colombia, Taiwan, Australia and Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-16 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Wiring Diagram (Australia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-17 www.zxforums.com Wiring Diagram (Australia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-18 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Wiring Diagram (Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-19 www.zxforums.com Wiring Diagram (Malaysia) www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-20 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-21 www.zxforums.com Special Tools and Sealant Hand Tester: 57001-1394 Grip: 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405 Rotor Holder: 57001-1658 Peak Voltage Adapter: 57001-1415 Rotor Holder: 57001-1666 www.zxforums.com Lead Wire - Peak Voltage Adapter: 57001-1449 Kawasaki Bond (Silicone Sealant): 92104-0004 Key Registration Unit: 57001-1582 www.zxforums.com www.zxforums.com www.zxforums.
16-22 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-23 www.zxforums.com Precautions Male Connectors [B] www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-24 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-25 www.zxforums.com Battery Battery Removal • Remove: Front Seat (see Front Seat Removal in the Frame chapter) Relay Box [A] the black and red caps [A] out. • Slide Disconnect • (+) cable [C].the negative (–) cable [B] and then positive CAUTION Be sure to disconnect the negative (–) cable first. • Remove the band [D]. • Pull the battery [A] out of the case. www.zxforums.com Battery Installation inspect the surface of the battery container.
16-26 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Battery Battery Activation Electrolyte Filling Make sure that the model name [A] of the electrolyte container 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 electrolyte volume and specific gravity vary with the battery type.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-27 www.zxforums.com Battery the electrolyte flow. • Check If no air bubbles [A] are coming up from the filler ports, or • if the container cells have not emptied completely, tap the container [B] a few times. Keep the container in place for 20 minutes or more. Don’t remove the container from the battery until it’s empty, the battery requires all the electrolyte from the container for proper operation.
16-28 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Battery charging is completed, press down firmly with both • After 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.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-29 www.zxforums.com 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.
16-30 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) 5A×1h Quick Charge 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: 1.2 A × 20 h NOTE ○Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-31 www.zxforums.
16-32 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Charging System Stator Coil Installation • Tighten the stator coil bolts to the specified torque. Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) silicone sealant to the circumference of the alter• Apply nator lead grommet, and fit the grommet into the notch of the cover securely.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-33 www.zxforums.com Charging System a cleaning fluid, clean off any oil or dirt on the • Using washer [A] and dry if with a clean cloth. • Install the washer. NOTE ○Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. the rotor bolt [B] and tighten it with 70 N·m (7.0 • Install kgf·m, 52 ft·lb) of torque. the rotor bolt and washer. • Remove Check the torque with flywheel puller [A].
16-34 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Charging System check the alternator output voltage, do the following • To procedures. ○Turn off the ignition switch. ○Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). ○Disconnect the alternator lead connector [A]. ○Connect the hand tester as shown in the table 1. ○Start the engine. ○Run it at the rpm given in the table 1. ○Note the voltage readings (total 3 measurements).
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-35 www.zxforums.com Charging System Regulator/Rectifier Inspection • Remove the Bolts [A]. the connectors [A]. • Disconnect Remove the regulator/rectifier [B]. • the hand tester to the × 1 kΩ range and make the • Set measurements shown in the table. Special Tool - Hand Tester: 57001-1394 the hand tester to the regulator rectifier. • Connect If the tester readings are not as specified, replace the www.zxforums.com regulator/rectifier.
16-36 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Charging System Charging Voltage Inspection the battery condition (see Charging Condition In• Check spection). up the engine to obtain actual alternator operating • Warm conditions. the Front seat (see Front Seat Removal in the • Remove Frame chapter). that the ignition switch is turned off, and connect • Check the hand tester [A] to the battery terminals [B].
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-37 www.zxforums.com Charging System Charging System Circuit 1. Ignition Switch 2. Main Fuse 30 A 3. Starter Relay 4. Battery 12 V 10 Ah 5. Frame Ground 6. Load 7. Alternator 8. Regulator/Rectifier www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-38 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-39 www.zxforums.com Ignition System WARNING The ignition system produces extremely high voltage. 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.
16-40 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System Crankshaft Sensor Inspection the crankshaft sensor lead connector (see • Disconnect Crankshaft Sensor Removal). the hand tester [A] to the × 100 Ω range and connect • Set it to the crankshaft sensor lead connector [B]. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance: 380 ∼ 570 Ω If there is more resistance than the specified value, the coil has an open lead and must be replaced.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-41 www.zxforums.com Ignition System the stick coil connectors [A]. • Disconnect Pull the stick coils #2, #3 [B] off the spark plugs. • CAUTION Do not pry the connector part of the coil while removing the coil. remove the stick coil #1 as follows.
16-42 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System ○Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] ○Pull out the stick coil #4 [A] to forward. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation grease to the stick coils. • Apply the stick coils [A] as shown being careful of the coil • Insert heads directions. ○Align www.zxforums.com the lines [B] of the cylinder head cover and coil heads.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-43 www.zxforums.com Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection the stick coils (see Stick Coil (Ignition Coil to• Remove gether with Spark Plug Cap) Removal). the primary winding resistance [A] as follows. •○Measure Connect the hand tester between the coil terminals. ○Set the tester to the × 1 Ω range, and read the tester. the secondary winding resistance [B] as follows.
16-44 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. the ignition switch and engine stop switch ON. • Turn Pushing starter button, turn the engine 4 ∼ 5 seconds • with the the transmission in neutral to measure the primary • peak voltage. Repeat the measurements 5 times for one stick coil.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-45 www.zxforums.com Ignition System Camshaft Position Sensor Removal • 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) Disconnect the camshaft position sensor lead connector [A].
16-46 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System Camshaft Position Sensor Peak Voltage Inspection the camshaft position sensor connector (see • Disconnect Camshaft Position Sensor Removal). the hand tester [A] to the 10 V DC range. • Set Connect the peak voltage adapter [B] to the hand tester • and camshaft position sensor leads in the terminals.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-47 www.zxforums.com Ignition System 2nd Check Start the engine to the following conditions. • Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○Turn the ignition switch ON and push the starter button. ○Then the starter motor should turn when the starter sys- tem circuit is normality. If the starter motor is not turn, inspect the starter lockout switch, gear position switch, sidestand switch and relay box.
16-48 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Ignition System Ignition System Circuit www.zxforums.com 1. Ignition Switch 2. Joint Connector 1 3. Starter Lockout Switch 4. Fuse Box 5. ECU Fuse 15 A 6. Ignition Fuse 15 A 7. Relay Box 8. Fuel Pump Relay 9. Main Fuse 30 A 10. Starter Relay 11. Battery 12 V 10 Ah www.zxforums.com 12. Frame Ground 13. Fuel Pump 14. Vehicle-down Sensor 15. Joint Connector 2 16. ECU 17. Water-proof Joint 1 18. Gear Position Switch 19.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-49 www.zxforums.com Electric Starter System Starter Idle Gear Removal • Remove: Right Middle Fairing (see Right Middle Fairing Removal in the Frame chapter) Bolts [A] Idle Gear Cover [B] out the idle gear (starter motor side) [A] with the shaft • Pull [B]. • Remove: Clutch Cable Lower End (see Cable Removal in the Clutch chapter) Bolts [A] Clamp [B] Starter Clutch Cover [C] www.zxforums.
16-50 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electric Starter System the idle gear (starter clutch side) [A] on the shaft. • Install Engage the idle gear with the starter clutch gear. • Apply silicone sealant to the following portion. • Crankshaft Sensor Lead Grommet [B] Crankcase Halves Mating Surfaces [C] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the dowel pin [D] and new gasket. grease to the O-rings of starter motor.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-51 www.zxforums.com Electric Starter System Starter Clutch Removal • Remove: Starter Clutch Cover (see Idle Gear Removal) • Idle Gear (Starter Clutch Side, see Idle Gear Removal) Unscrew the starter clutch bot [A], while holding the alternator rotor steady with the rotor holder (see Alternator Rotor Removal). Special Tools - Grip: 57001-1591 Rotor Holder (Stopper, M38 × 1.5): 57001 -1658 Rotor Holder: 57001-1666 • Remove the washer [B].
16-52 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electric Starter System [A] the starter clutch gear [B] in and turn it counter• Push clockwise [C] and install it. the washer [A]. • Install Tighten starter clutch bot [B], while holding the alterna• tor rotorthe steady with the rotor holder (see Alternator Rotor Installation). Special Tools - Grip: 57001-1591 Rotor Holder (Stopper, M38 × 1.5): 57001 -1658 Rotor Holder: 57001-1666 Torque - Starter Clutch Bolt: 49 N·m (5.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-53 www.zxforums.com Electric Starter System the starter clutch (see Starter Clutch Disas• Disassemble sembly), and visually inspect the clutch parts. One-way Clutch [A] Starter Clutch Case [B] If there is any worn or damaged part, replace it. ○Examine the starter clutch gear [C] as well. Replace the clutch gear if it is worn or damaged.
16-54 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electric Starter System the starter motor mounting bolts [A]. • Remove 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. the starter motor legs [A] and crankcase [B] where • Clean the starter motor is ground. the O-rings [A] with new ones. • Replace Apply grease the new O-rings.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-55 www.zxforums.com Electric Starter System • Pull the armature [A] out of the yoke [B]. • Remove: Brush Plate Terminal Nut [A] Brush Plate Assembly [B] Starter Motor Assembly • Pry the spring end [A] and insert the brush [B]. www.zxforums.com the brush plate assembly [A] into the right-hand end • Install cover [B]. the O-ring [C] with a new one.
16-56 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electric Starter System the O-rings [A] with new ones. • Replace Put the armature [B] among the brushes [C]. • a thin coat of grease to the oil seal [A]. • Apply Fit the toothed washer [B] into the left-hand end cover. • the marks [A] to assembly the yoke and the end • Align covers. www.zxforums.com the O-rings [A] with new ones. • Replace Tighten: • Torque - Starter Motor Through Bolts [B]: 3.4 N·m (0.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-57 www.zxforums.com Electric Starter System Brush Inspection the length [A] of each brush [B]. • Measure 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 the commutator surface [A] if necessary with fine • Smooth emery cloth [B], and clean out the grooves. the diameter [A] of the commutator [B].
16-58 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Electric Starter System Brush Lead Inspection the × 1 Ω hand tester range, measure the resis• Using tance as shown. Terminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open. Replace the brush holder assembly.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-59 www.zxforums.com Electric Starter System Electric Starter Circuit www.zxforums.com 1. Ignition Switch 2. Joint Connector 1 3. Starter Lockout Switch 4. Fuse Box 5. Ignition Fuse 15 A 6. Relay Box 7. Starter Circuit Relay 8. Starter Motor 9. Main Fuse 30 A 10. Starter Relay 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 www.zxforums.
16-60 ELECTRICAL SYSTEM www.zxforums.com 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.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-61 www.zxforums.com Lighting System the headlight bulb [A] clockwise. • Turn Connect the headlight connector. • After installation, the headlight aim (see Headlight • Aiming Inspectionadjust in the Periodic Maintenance chapter). City Light Bulb Replacement the upper inner fairing (see Upper Inner Fairing • Remove Removal in the Frame chapter). • Pull out the socket [A] together with the bulb. • Pull the bulb [A] out of the socket [B].
16-62 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Lighting System Tail/Brake Light (LED) Removal to the Seat Cover Removal in the Frame chapter • Refer (see Seat Cover Removal in the Frame chapter). Tail/Brake Light (LED) Installation to the Seat Cover Installation in the Frame chapter • Refer (see Seat Cover Installation in the Frame chapter).
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-63 www.zxforums.com Lighting System Headlight/Tail Light Circuit www.zxforums.com 1. Ignition Switch 2. High Beam Indicator Light (LED) 3. Joint Connector 1 4. Right City Light 6. Headlight (High Beam) 5. Headlight (Low Beam) 7. Left City Light 8. Passing Button 9. Dimmer Switch 10. Headlight Fuse 10 A 11. Tail Light Fuse 10 A 12. Fuse Box 13. Relay Box 14. Headlight Relay 15. Starter Relay 16. Main Fuse 30 A 17. Battery 12 V 10 Ah 18.
16-64 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Lighting System and turn the front turn signal light bulb [A] counter• Push clockwise and remove it. • Replace the bulb with new ones. the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the soket, and turn the bulb clockwise. ○Turn the bulb about 15° degrees. the socket and turn it clockwise.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-65 www.zxforums.com Lighting System the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15° degrees. the projections [A] of the lens into the grooves [B] of • Fit the turn signal light. • Tighten: Torque - Rear Turn Signal Light Lens Screws: 1.2 N·m (0.
16-66 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Lighting System Turn Signal Light Circuit www.zxforums.com 1. Ignition Switch 2. Turn Signal Indicator Lights (Right and Left) 3. Joint Connector 1 4. Front Right Turn Signal Light 5. Front Left Turn Signal Light 6. Turn Signal Switch 7. Fuse Box 8. Turn Signal Relay Fuse 10 A 9. Main Fuse 30 A 10. Battery 12 V 10 Ah 11. Frame Ground 12. Joint Connector 2 13. Rear Left Turn Signal Light 14. Rear Right Turn Signal Light 15.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-67 www.zxforums.com Air Switching Valve Air Switching Valve Operation Test to the Air Suction System Damage Inspection in the • Refer Periodic Maintenance chapter (see Air Suction System Damage Inspection in the Periodic Maintenance chapter). Air Switching Valve Unit Test the air switching valve (see Air Switching Valve • Remove Removal in the Engine Top End chapter).
16-68 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Radiator Fan System Fan Motor Inspection the left upper inner fairing (see Upper Inner Fair• Remove ing Removal in the Frame chapter). the connector [A]. • Disconnect Using an auxiliary leads, supply battery power to the fan • motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit www.zxforums.com 1. Ignition Switch 2. Joint Connector 1 3. Fuse Box 4. Fan Fuse 10 A 5.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-69 www.zxforums.com Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • 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. • Tighten: Torque - Meter Unit Mounting Screws: 1.2 N·m (0.
16-70 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection the meter unit (see Meter Unit Removal) [A].
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-71 www.zxforums.com Meter, Gauge, Indicator Unit ○When the terminals are connected, all the LCD segments [A] appear for three seconds. If the LCD segments will not appear, replace the meter assembly. Disconnect the terminal [1]. ○All the LCD segments disappear. If the segments do not disappear, replace the meter assembly.
16-72 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Meter, Gauge, Indicator Unit setting mode, press the REST button to ef• InfectthetheHOUR MINUTE setting mode. ○The minute display flashes on the display. • Press the MODE button to set the minute. the MINUTE setting mode, press the REST button to • Inreturn to the HOUR/MINUTE setting mode. Press • process.the MODE button to complete the time setting ○The clock starts counting the seconds a soon as the MODE button is pressed.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-73 www.zxforums.com Meter, Gauge, Indicator Unit the oscillator is not available, the speedometer can be • Ifchecked as follows. ○Install the meter unit. ○Raise the rear wheel off the ground, using the jack. ○Turn on the ignition switch. ○Rotate the rear wheel by hand. ○Check that the speedometer shows the speed. If the speedometer does not work, check the speed sensor and wiring (see Speed Sensor section in the Fuel System (DFI) chapter).
16-74 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Meter, Gauge, Indicator Unit Tachometer Check Connect the 12 V battery and terminals in the same manner as specified in the "Liquid Crystal Display (LCD) Segments Check". ○When the terminals are connected, the tachometer needle momentary points to the last reading, and then return to the 0 position. If the needle function does not work, replace the meter assembly.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-75 www.zxforums.com Meter, Gauge, Indicator Unit Stop Watch Check Connect the 12 V battery and terminal in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”. Press the MODE button each time to set the stop watch mode. Connect the insulated auxiliary lead processed insulation to the terminal [3] as shown, then stop watch start to count.
16-76 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Meter, Gauge, Indicator Unit Neutral Indicator Light (LED) Inspection ○Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments check.” Using the insulated auxiliary lead, 12 V battery to the meter unit connector as follows. ○Connect the battery negative (–) terminal to the terminal [5]. ○When the terminals are connected, the neutral indicator light (LED) should go on.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-77 www.zxforums.com Meter, Gauge, Indicator Unit High Beam Indicator Light (LED) ○Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments check.” Using the insulated auxiliary lead, 12 V battery to the meter unit connector as follows. ○Connect the battery positive (+) terminal to the terminal [17]. • ○When the terminals are connected, the high beam indica- tor light (LED) should go on.
16-78 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Meter, Gauge, Indicator Unit Shift Up Indicator Light (LED) ○Connect the 12 V battery and terminal in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”. 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 terminal [7].
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-79 www.zxforums.com Meter, Gauge, Indicator Unit Meter Unit Circuit www.zxforums.com 1. Ignition Switch 2. Turn Signal Indicator Light (LED) 3. High Beam Indicator Light (LED) 4. Neutral Indicator Light (LED) 5. Fuel Level Warning Indicator Light (LED) 6. Warning Indicator Light (LED) (FI/Immobilizer/Oil Pressure Warning) 7. Odometer/Trip Meter/Clock/Stop Watch Indicator 8. Water Temperature Gauge 9. Tachometer 10. Speedmeter 11.
16-80 ELECTRICAL SYSTEM www.zxforums.com 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).
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-81 www.zxforums.com Immobilizer System (Equipped Models) • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 • Insert the master key to the ignition switch and turn it ON. Verified ○The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the registration mode (go to the next step).
16-82 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) • Insert the user key 1 to the ignition switch and turn it ON. NOTE ○Keep the other user key away from the immobilizer antenna. ○If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-83 www.zxforums.com Immobilizer System (Equipped Models) the user key 1 OFF and remove the user key 1. •○Turn The warning indicator light (LED) [A] blinks to display the registration mode. NOTE ○Turn 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. ○This procedure registered the master key and one user key.
16-84 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) user key 2 is registered in the ECU. •○The The warning indicator light (LED) and immobilizer warning symbol [A] blinks 3 times and stops for 1 second and then repeats this cycle. ○This procedure has registered the master key and 2 user keys. Continue with the procedure to register an additional 3 user keys. • NOTE ○The ECU can store up the six key codes (master key × 1 and user key × 5).
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-85 www.zxforums.com Immobilizer System (Equipped Models) Spare User Key Registration Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-86 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) Case 2: When the ignition switch is faulty and to be replaced. Prepare a new ignition switch [A] and two new user keys [B]. ○These parts are available as a set. Prepare the current master key [C].
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-87 www.zxforums.com Immobilizer System (Equipped Models) Not Verified ○The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure Master Key Collation Error OFF and remove the new user key 1. • Turn Temporarily • switch [B]. place the antenna [A] on the new ignition the user key 1 [C] again into the new ignition switch • Insert and turn it ON. www.zxforums.
16-88 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) ○If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error www.zxforums.com user key 1 is successfully registered in the ECU.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-89 www.zxforums.com Immobilizer System (Equipped Models) ○If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error www.zxforums.com user key 2 is successfully registered in the ECU.
16-90 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) the key registration unit and connect the immo• Remove bilizer/Kawasaki diagnostic system connector. NOTE ○Turn the ignition switch ON with the registered user key. ○Check that the engine can be started using all registered user keys. • Install the new ignition switch and antenna. Case 3: When the electric control unit (ECU) is faulty and has to be replaced.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-91 www.zxforums.com Immobilizer System (Equipped Models) master key is registered in the ECU. •○The The warning indicator light (LED) and immobilizer warning symbol [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. OFF the master key and remove it. •○Turn The warning indicator light (LED) [A] blinks to display the registration mode.
16-92 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) User Key Collation Error user key 1 is registered in the ECU. •○The The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key. OFF and remove the user key 1. •○Turn The warning indicator light (LED) [A] blinks to display the registration mode codes. NOTE www.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-93 www.zxforums.com Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error user key 2 is registered in the ECU. •○The The warning indicator light (LED) and immobilizer warn- • • ing symbol [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2. Turn OFF the ignition switch and wait for period more than 15 seconds.
16-94 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) a new ECU [A], new master key [B] and current • Prepare user keys [C]. NOTE ○The key registration unit is not required. ○The key registration process is same as the electric control unit replacement. Case 5: When replacing the antenna. Prepare a new antenna. Refer to the Immobilizer System Parts Replacement. • • NOTE ○No key registration is required. www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-95 www.zxforums.com Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-96 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna Remove the left middle fairing (see Middle Faring Removal in the Frame chapter). Disconnect the lead connectors [A]. • • • Remove: Steering Stem Head (see Stem, Stem Bearing Removal • • in the Steering chapter) Handlebar (see Handlebar Removal in the Steering chapter) Using a small chisel or punch, turn out the Torx bolts [A].
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-97 www.zxforums.com Immobilizer System (Equipped Models) ECU (Electric Control Unit) Replacement (for Immobilizer Models) Remove: Front Seat (see Front Seat Removal in the Frame chapter) Relay Box [A] • a small chisel or other suitable tool, cut off the • Using screws [A]. • Remove: Upper Guard Bracket [B] Lower Guard Bracket [C] • Take out the ECU [A] and disconnect the connectors [B]. www.zxforums.com the ECU connectors.
16-98 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Immobilizer System (Equipped Models) • Install: Lower Guard Bracket [A] Upper Guard Bracket [B] CAUTION Do not pinch the leads. new screws [C] use Kawasaki genuine screws of • Tighten which threads are coated with locking agent. Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Ignition Key Key Switch (Red) (Black) Master Key (Red) • * Ignition Switch ECU ○ • Antenna • Amplifier ○ www.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-99 www.zxforums.com Immobilizer System (Equipped Models) Immobilizer System Circuit 1. Ignition Switch 2. Immobilizer Antenna 3. Meter Unit 4. Immobilizer Amplifier 5. Joint Connector 1 6. Fuse Box 7. ECU Fuse 15 A 8. Ignition Fuse 15 A 9. Main Fuse 30 A 10. Starter Relay 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.
16-100 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Switches and Sensors Brake Light Timing Inspection to the Brake Light Switch Operation Inspection • Refer in the Periodic Maintenance chapter (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Light Timing Adjustment to the Brake Light Switch Operation Inspection • Refer in the Periodic Maintenance chapter (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter).
www.zxforums.com www.zxforums.com ELECTRICALwww.zxforums.com SYSTEM 16-101 Switches and Sensors Water Temperature Sensor Inspection the water temperature sensor (see Removal/In• Remove stallation in the Fuel System (DFI) chapter). the sensor [A] in a container of coolant so that • Suspend the temperature-sensing projection [E] and threaded por- • tion [E] are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE ○The sensor and thermometer must not touch the container side or bottom.
16-102 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Switches and Sensors • Disconnect the connector [A]. • Remove: Bolt [A] Speed Senor [B] Speed Sensor Installation grease to the new O-ring [A]. • Apply Set the • Tighten:speed sensor bolt [B]. • www.zxforums.com Torque - Speed Sensor Bolt: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters).
www.zxforums.com www.zxforums.com ELECTRICALwww.zxforums.com SYSTEM 16-103 Switches and Sensors the fuel pump (see Fuel Pump Removal in the • Remove Fuel System (DFI) chapter). the test light (12 V 3.4 W bulb in a socket with • Connect 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] If the test light doesn’t light, replace the fuel pump.
16-104 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Switches and Sensors • 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.
www.zxforums.com www.zxforums.com ELECTRICALwww.zxforums.
16-106 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Switches and Sensors Gear Position Switch Inspection NOTE ○Be sure the transmission mechanism is good condition. the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). • Disconnect the connector [A]. the hand tester [A] to the 1 kΩ or × 100 Ω range and • Set connect it to the terminals in the gear position switch lead connector [B] and ground.
www.zxforums.com www.zxforums.com ELECTRICALwww.zxforums.com SYSTEM 16-107 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal the front seat (see Front Seat Removal in the • Remove Frame chapter). out the relay box [A] and disconnect the connectors • Take [B]. Relay Circuit Inspection NOTE ○The ECU main relay function is included in the ECU. www.zxforums.com the relay box (see Relay Box Removal).
16-108 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Relay Box Relay Circuit Inspection (with the battery connected) Battery Connection (+) (–) Tester Connection Tester Reading (Ω) Fuel Pump Relay 6-7 4-5 0 Fan Relay 15-16 14-17 0 Battery Connection (+) (–) Starter Circuit Relay Tester Tester Connection DC 25 V Range Reading (V) 13-9 8-9 Battery Voltage (+): Apply positive lead. (–): Apply negative lead.
www.zxforums.com www.zxforums.com ELECTRICALwww.zxforums.com SYSTEM 16-109 Relay Box Relay Box Internal Circuit A. Headlight Relay B. Fuel Pump Relay C. Starter Circuit Relay D. Fan Relay www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
16-110 ELECTRICAL SYSTEM www.zxforums.com www.zxforums.com www.zxforums.com Fuse 30 A Main Fuse Removal • Remove: Front Seat (see Front Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) 30 A Main Fuse Connector [A] out the main fuse [A] from the starter relay with needle • Pull nose pliers. Fuse Box Fuse Removal the front seat (see Front Seat Removal in the • Remove Frame chapter). • Push the hook [A] to lift up the lid [B]. www.zxforums.
www.zxforums.com www.zxforums.com ELECTRICAL SYSTEM 16-111 www.zxforums.com Fuse the ECU fuse [A] straight out of the fuse box with • Pull needle nose pliers. Fuse Installation • If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. Install the junction box fuses on the original position as specified on the lid. Fuse Inspection the fuse (see Fuse Removal). • Remove Inspect the element.
www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-1 www.zxforums.com Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ........................................................................................................... 17-2 17-30 www.zxforums.com 17 www.zxforums.com www.zxforums.com www.zxforums.
17-2www.zxforums.com APPENDIX www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-3 www.zxforums.com Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clamp 3. Meter Connector 4. Clamp the right switch housing lead. 5. Right Switch Housing Lead 6. City Light Connector 7. Right Headlight Connector 8. Right Turn Signal Light Connector 9. 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.
17-4www.zxforums.com APPENDIX www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-5 www.zxforums.com Cable, Wire, and Hose Routing 1. Throttle Cable (Accelerator) 2. Throttle Cable (Decelerator) 3. Run the throttle cables above the harness and hose, and under the ignition switch lead. 4. Clutch Cable 5. Clamp 6. Throttle Cables 7. Viewed A 8. Through the clutch cable into the bracket. 9. Through the clutch cable into the engine bracket. 10. Evaporative Hoses (California Model only) 11.
17-6www.zxforums.com APPENDIX www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-7 www.zxforums.com Cable, Wire, and Hose Routing 1. Right Headlight Connector 2. Right City Light Connector 3. Right Turn Signal Light Connector 4. Right Switch Housing Lead 5. Clamp the right switch housing lead. 6. Horn 7. Engine Subharness Joint Connector (To the Throttle Assy) 8. Inlet Air Temperature Sensor (To the Air Cleaner Box) 9. Starter Relay 10. Frame Ground Lead 11. Regulator/Rectifier 12. Rear Brake Light Switch Lead 13.
17-8www.zxforums.com APPENDIX www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-9 www.zxforums.com Cable, Wire, and Hose Routing 1. Battery Positive (+) Terminal 2. Relay Box 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Fuse Box 5. Turn Signal Relay 6. Right Turn Signal Light Connector 7. Tail/Brake Light Connector 8. Clamp (The clamp attached on the main harness.) 9. License Plate Light Connector 10. Left Turn Signal Light Connector 11. Vehicle-down Sensor 12.
17-10 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-11 www.zxforums.com Cable, Wire, and Hose Routing 1. Left City Light Connector 2. Meter Connector 3. Clamp 4. Headlight Connector 5. Clamp 6. Run the fan motor lead connector above the main harness. 7. Immobilizer Amplifier 8. Joint Connector for the stick coil and air switching valve leads (Install it into the bracket). 9. Clamp (The clamp attached on the main harness.) 10. Fuel Pump Connector 11. Vehicle-down Sensor 12.
17-12 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-13 www.zxforums.com Cable, Wire, and Hose Routing 1. Insert the radiator coolant return hose to the corner portion of the radiator pipe. 2. Clamp 3. Radiator Overflow Hose 4. Clamp 5. Run the radiator coolant return hose inside the engine mount. 6. Clamp 7. Clamp 8. Clamp 9. Radiator Hose 10. Clamp 11. Install the clamp so that the clamp and the crankcase mating surface align parallel. 12. Clamp 13.
17-14 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-15 www.zxforums.com Cable, Wire, and Hose Routing 1. Clamp 2. Air Cleaner Drain Hose 3. Breather Hose 4. Joint Connector (Water Temperature Sensor Lead, Gear Position Sensor Lead, Speed Sensor Lead, and Oil Pressure Switch Lead) 5. Right Side 6. Front 7. Rear 8. Left Side 9. Clamp 10. Clamp 11. Radiator Hose 12. Clamp 13. Face the paint mark to the front. 14. Clamp 15. Water Hose (To the Oil Cooler) 16. Sidestand Switch Lead 17. Bracket 18.
17-16 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-17 www.zxforums.com Cable, Wire, and Hose Routing 1. Stick Coil #1 2. Stick Coil #2 3. Stick Coil #3 4. Stick Coil #4 5. Air Switching Valve 6. Evaporative Hose (White) 7. Evaporative Hose (Green) 8. Clamp 9. Through the crankshaft sensor lead into the clamp (attached on the air switching valve). 10. Crankshaft Sensor Lead Connector 11. Through the crankshaft sensor lead into the hole of the heat insulation rubber plate. 12. Heat Insulation Rubber Plate 13.
17-18 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-19 www.zxforums.com Cable, Wire, and Hose Routing 1. Install the air switching valve after installing the heat insulation rubber plate. 2. Throttle Body Assy 3. Hang down the shaded portions of the heat insultaion rubber plate. 4. For Left Engine Bracket Bolt 5. For Radiator 6. For Air Suction Valve Covers and Stick Coils 7. For Right Engine Bracket (Cylinder Head Side) 8. For Throttle Body Holders 9. Set the projection into the hole. 10.
17-20 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com 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.
www.zxforums.com www.zxforums.com APPENDIX 17-21 www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com 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 www.zxforums.
17-22 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com 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.
www.zxforums.com www.zxforums.com APPENDIX 17-23 www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com 1. Air Switching Valve 2. Face the paint mark upward. 3. Air Switching Valve Hose 4. To the fitting of the holder assy. 5. Holder Assy 6. Clamp 7. Throttle Body Assy 8. To the Radiator 9. Install the starter cover bolt with the clamp. www.zxforums.com 10. Run the water hose through the clamp. 11. Water Hose 12. Install the upper crankcase bolt with the clamp. 13. Oil Filter 14.
17-24 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-25 www.zxforums.com Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamps 4. Brake Hoses 5. Face the paint mark outside. 6. Viewed Right Side 7. Viewed Left Side 8. Brake Hose 9. Rubber Dumper 10. Clamps 11. Brake Hose 12. Face the paint mark outside. 13. Viewed A www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
17-26 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing California Model www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-27 www.zxforums.com Cable, Wire, and Hose Routing 1. Front 2. To the Fuel Tank 3. Hose (Blue) 4. Hose (Red) 5. Hose (White) 6. To the fitting of the Throttle Body #3 (Run the hose over the subthrottle valve actuator connector.) 7. Hose (Green) 8. To the fitting of the Throttle Body #4 (Run the hose under the harness.) 9. 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.
17-28 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Cable, Wire, and Hose Routing California Model www.zxforums.com 1. Fuel Tank 2. Clamps 3. Hose (Red) 4. Canister 5. Clamp 6. To the Fitting of the Throttle Body #3 7. To the Fitting of the Throttle Body #4 8. Clamps www.zxforums.com 9. Throttle Bodies 10. Hose (Blue) 11. Hose (Blue) 12. Separator 13. Hose (Green) 14. Hose (White) 15. Fitting 16. Hose (Green) www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-29 www.zxforums.com Cable, Wire, and Hose Routing www.zxforums.com 1. Adjusters 2. Closing Cable 3. Yellow 4. Dark Green 5. Rear Frame 6. Dust Covers 7. Opening Cable 8. Clamp 9. 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.
17-30 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.com Troubleshooting Guide NOTE ○Refer to the Fuel System chapter for most of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
www.zxforums.com www.zxforums.com APPENDIX 17-31 www.zxforums.
17-32 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com APPENDIX 17-33 www.zxforums.
17-34 APPENDIX www.zxforums.com www.zxforums.com www.zxforums.
www.zxforums.com www.zxforums.com www.zxforums.com MODEL APPLICATION Year Model 2006 ZX1000D6F Beginning Frame No. JKAZXCD1□6A000001 JKAZXT00DDA000001 ZXT00D-000001 □:This digit in the frame number changes from one machine to another. www.zxforums.com www.zxforums.com www.zxforums.com Part No.99924-1365-02 www.zxforums.
