Ninja ZX-10R
2005 Ninja ZX-10R
Racing Kit Manual
This manual contains only the information of the racing kit parts. Refer to the base manual listed below for information of the original model.
Base Manual |
Part Number |
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Ninja ZX-10R |
99924-1322-02 |
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Motorcycle Service Manual |
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© 2005 Kawasaki Heavy Industries, Ltd. |
First Edition (1): Feb. 7, 2005 |
Congratulation on your purchase of racing kit parts for the 2005 Ninja ZX-10R.
IMPORTANT
This manual provides how to install racing kit parts for the 2005 Ninja ZX-10R and how to tune up basically.
As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-10R (P/No. 99924-1322-02).
When you participate in a race, it is necessary to modify the machine for the regulation. So we want you to ask for the tuning up shop.
WARNING
AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE.
CAUTION
When operating the engine, be careful not to trouble persons with noise. Do not turn the engine with loud engine and exhaust noise.
DISCLAIMER OF WARRANTY
ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED.
BASIC WORKS IN INSTALLING KIT PARTS
We are going to make up the original Ninja ZX-10R for the racing machine. We recommend that the rider himself should do the basic works, removing parts or installing parts etc., given advices by the tuning shop. In a race, although trouble will be apt to happen, if you participate in basic works, you can discriminate cause of trouble, so you can return the race soon.
But concerning difficult technical works, you should ask to tuning shop.
1
Table of Contents |
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General Specifications......................................................................................................... |
3 |
Racing Kit Service Data....................................................................................................... |
5 |
Periodic Maintenance Chart................................................................................................. |
5 |
Engine Parts Installation ...................................................................................................... |
7 |
Air Intake Parts ................................................................................................................. |
7 |
Camshaft Chain Tensioner ............................................................................................... |
8 |
Camshafts, Sprockets....................................................................................................... |
9 |
Cylinder Head................................................................................................................. |
11 |
Cylinder Compression .................................................................................................... |
12 |
Piston.............................................................................................................................. |
13 |
Crankshaft Main Journal Bushings ................................................................................. |
13 |
Connecting Rod Bolts..................................................................................................... |
14 |
Connecting Rod Big End Bushings................................................................................. |
16 |
Clutch Adjustment (Back-Torque Limiter Setting) ........................................................... |
17 |
Transmission .................................................................................................................. |
21 |
Alternator ........................................................................................................................ |
23 |
Water Temperature Sensor............................................................................................. |
27 |
Radiator.......................................................................................................................... |
27 |
Oil Catch Tank (Kit)......................................................................................................... |
30 |
Cover Gaskets................................................................................................................ |
32 |
ECU (Kit) ........................................................................................................................ |
32 |
Frame Parts Installation..................................................................................................... |
33 |
Throttle Parts (Kit Parts) ................................................................................................. |
33 |
Final Drive Parts (Kit Parts) ............................................................................................ |
34 |
Brake Pads (Kit Parts) .................................................................................................... |
34 |
Steering Damper (Kit Parts)............................................................................................ |
35 |
Seat Height Adjustment.................................................................................................. |
38 |
Front Fork Springs (Kit Parts) ......................................................................................... |
40 |
Electrical System ............................................................................................................... |
42 |
Battery ............................................................................................................................ |
42 |
Main Harness and Sub Harness (Kit Part)...................................................................... |
42 |
Left Switch Housing Wiring Change ............................................................................... |
52 |
Auto Shifter Installation................................................................................................... |
53 |
Wiring Diagram (with Original Meter).............................................................................. |
54 |
Wiring Diagram (with Kit Meter)...................................................................................... |
56 |
2
General Specifications
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Item |
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2005 Ninja ZX-10R Racing |
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Engine: |
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Ignition timing |
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10°BTDC @1 100 r/min (rpm) |
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Fuel (Recommended) |
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Racing gasoline |
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Engine oil (Recommended): |
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Racing oil |
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Level |
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Between upper and lower levels of oil level gauge. |
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Drive Train: |
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Primary drive reduction ratio |
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1.611 (87/54) |
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Transmission Gear Table |
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STD Type A |
Type B |
Type C |
Type D |
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In |
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13127-0020 |
13127-0030 |
13127-0031 |
13127-0032 |
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1st |
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Out |
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13262-0170 |
13262-0267 |
13262-0275 |
13262-0281 |
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Teeth (Out/In) |
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38/15 |
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31/13 |
34/14 |
37/16 |
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Gear Ratio |
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2.533 |
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2.385 |
2.429 |
2.313 |
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In |
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13262-0185 |
- |
- |
13262-0279 |
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2nd |
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Out |
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13262-0152 |
- |
- |
13262-0282 |
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Teeth (Out/In) |
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39/19 |
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- |
- |
36/18 |
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Gear Ratio |
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2.053 |
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- |
- |
2.000 |
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In |
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See Gear |
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See Gear |
See Gear |
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Selection |
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Selection |
Selection |
- |
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Out |
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3rd |
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13262-0182 |
13262-0268 |
13262-0276 |
- |
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Teeth (Out/In) |
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33/19 |
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34/13 |
28/16 |
- |
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Gear Ratio |
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1.737 |
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1.789 |
1.750 |
- |
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In |
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See Gear |
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See Gear |
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Selection |
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Selection |
- |
- |
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Out |
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4th |
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13262-0166 |
13262-0269 |
- |
- |
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Teeth (Out/In) |
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32/21 |
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31/20 |
- |
- |
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Gear Ratio |
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1.525 |
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1.550 |
- |
- |
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In |
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13262-0135 |
13262-0265 |
13262-0273 |
- |
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5th |
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Out |
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13262-0183 |
13262-0270 |
13262-0277 |
- |
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Teeth (Out/In) |
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29/21 |
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29/20 |
28/20 |
- |
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Gear Ratio |
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1.381 |
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1.450 |
1.400 |
- |
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In |
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13262-0136 |
13262-0266 |
13262-0274 |
13262-0280 |
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6th |
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Out |
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13262-0171 |
13262-0271 |
13262-0278 |
13262-0283 |
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Teeth (Out/In) |
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30/23 |
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29/21 |
28/21 |
28/22 |
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Gear Ratio |
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1.304 |
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1.381 |
1.333 |
1.273 |
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3
Input 3rd/4th Gear Selection Table
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4th Gear |
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A (=C) |
B |
3rd Gear |
A |
13262-0134 (19/21) |
13262-0286 (19/20) |
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B |
13262-0284 (19/21) |
13262-0264 (19/20) |
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C |
13262-0272 (16/21) |
13262-0285 (16/20) |
Gear Identification Slit Number Table
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Standard (Type A) |
Type B |
Type C |
Type D |
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1st |
Input |
0 |
2 |
3 |
4 |
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Output |
1 |
2 |
3 |
4 |
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2nd |
Input |
1 |
- |
- |
2 |
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Output |
1 |
- |
- |
2 |
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3rd |
Input |
1 |
2 |
0 |
- |
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Output |
0 |
2 |
3 |
- |
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4th |
Input |
0 |
1 |
- |
- |
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Output |
2 |
1 |
- |
- |
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5th |
Input |
2 |
0 |
3 |
- |
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Output |
1 |
0 |
3 |
- |
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6th |
Input |
1 |
2 |
3 |
4 |
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Output |
0 |
2 |
3 |
4 |
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Engine Sprocket
13144-0021 #520-16T
13144-0022 #520-17T
4
Racing Kit Service Data
Item |
Standard |
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Cylinder Head, Valves: |
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Valve timing: |
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Duration: |
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Intake |
300° |
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Exhaust |
292° |
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Camshaft timing (cam lift center): |
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Intake |
104° (ATDC) |
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Exhaust |
102° (BTDC) |
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Valve clearance: |
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Intake |
0.22 mm |
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Exhaust |
0.20 mm |
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Squish |
0.85 mm |
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Valve to piston clearance: |
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Intake |
1.45 mm @10°ATDC |
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Exhaust |
1.80 mm @10°BTDC |
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Ignition System: |
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Spark plugs |
NGK CR9EIA-9 (STD), R0045Q-10 or |
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R0373A-10 |
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Spark plug tightening torque |
13 N·m (1.3 kgf·m, 113 in·lb) |
These values show the specifications when standard cylinder head and gasket are used.
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
FREQENCY |
Each |
Every |
Every |
Every |
As |
OPERATION |
Race |
3 races |
5 races |
10 races |
Required |
Engine |
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Clutch plate - - check* |
● |
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Throttle grip play - - check* |
● |
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Spark plug - - clean/gap* |
● |
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Engine oil - - change |
● |
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Oil filter - - replace |
● |
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Valve lapping |
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● |
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Cylinder head/valve - - decarbonization |
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● |
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Cylinder - - check* |
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● |
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Piston/cylinder clearance - - check* |
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● |
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Piston ring, piston, and piston pin - - replace |
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● |
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Crankshaft main bearing - - check* |
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● |
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Connecting rod big end bearing - - check* |
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● |
Transmission gear, bearing - - check* |
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● |
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Engine sprocket - - check* |
● |
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5
FREQENCY |
Each |
Every |
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Every |
Every |
As |
OPERATION |
Race |
3 races |
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5 races |
10 races |
Required |
Coolant - - change |
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Radiator hoses, connections - - check* |
● |
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Frame |
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Brake operation - - check* |
● |
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Brake pad wear - - check* |
● |
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Brake fluid level - - check* |
● |
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Brake fluid - - change* |
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year |
Brake master cylinder cup and dust seal - - replace |
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year |
Brake caliper piston seal and dust seal - - replace |
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year |
Brake hose - - replace |
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2 years |
Drive chain - - adjust |
● |
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Drive chain - - lubricate |
● |
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Drive chain wear - - check* |
● |
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Drive chain guide - - replace |
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If damaged |
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Front fork - - clean/check* |
● |
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Front fork oil - - change |
First change after 2 races, then every 5 races |
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Nut, bolt, and fastener tightness - - check* |
● |
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Fuel system - - clean |
● |
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Fuel hose, fuel filter - - replace |
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Steering play - - check* |
● |
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Steering stem bearing - - grease |
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● |
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Rear sprocket - - replace |
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General lubrication of chassis - - perform |
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Wheel bearing (rear) - - grease |
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Swingarm pivot, uni-track linkage - - grease |
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● |
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Swingarm pivot, uni-track linkage - - check* |
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*: Replace, add, adjust, clean, or torque if necessary.
6
Engine Parts Installation
Air Intake Parts
Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance.
○When removing the air cleaner element, remove the element and relational parts as shown below.
1.Relational Parts of Secondary Air: Remove the Parts.
2.Remove the parts or cut the cleaner element off remaining the wire net.
3.Secondary Air Passages on Cylinder Head: Plug the holes, or press-fit the plugs (92066-1005) instead of the original pins.
Output of Secondary Air on Air Cleaner: Plug the hole
4.Air Cleaner Drain Tube: Use it cutting it in suitable length.
7
Camshaft Chain Tensioner
Replace the cam chain tensioner with the kit to decrease the flutter of tensioner.
Apply the engine oil to the tensioner rod, O-ring and tensioner body, insert them into the tensioner body.
○Check to see that the tensioner rod turns freely in the body, if not, polish the tensioner rod or fine the female threads in the body with a tap (Diameter × Pitch = 6 mm × 1.0 mm).
Install the tensioner on the cylinder block with the tensioner rod is fully pushed back. Turn the tensioner rod in with a screwdriver until it becomes hard to turn.
Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to
take up any gap and tighten the locknut.
After adjusting the tensioner rod if the tensioner rod does not stick out from the tensioner body, use the kit long tensioner rod (13116-1166).
NOTE
○Never forward the tensioner rod forcibly, this will increase mechanical loss of the tensioner and may damage to the chain guide.
○The cam chain tensioner must be adjusted at every race.
1. |
Tensioner Body |
4. |
O-ring |
2. |
Tensioner Rod: 13116-1166 (Kit) |
5. |
Locknut |
3. |
O-ring |
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8 |
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Camshafts, Sprockets
Camshafts, Sprockets:
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Camshaft |
Duration |
Lift |
49118-0008 |
(STD) (Intake) |
300° |
9.1 mm |
49118-0023 |
(STD) (Exhaust) |
292° |
8.5 mm |
49118-0034 |
(Kit) (Intake) |
310° |
9.7 mm |
Adjust the valve clearance within the specified value. Intake: 0.15 ~ 0.24 mm, Exhaust: 0.17 ~ 0.22 mm
More performance is expected when adjusted from middle value to upper limit between adjustable range.
If you can not adjust the valve timing for racing, install the camshaft sprocket to the camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-10R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range of the long bolt holes.
Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11 ft·lb) of torque.
Valve Timing
Timing (cam lift center) |
Intake |
Exhaust |
Original (when the round bolt holes are used) |
104° |
100° ~ 102° |
Race use (when the long bolt holes are used) |
108° |
102° |
(Recommended) |
(Recommended) |
○When grinding the cylinder head bottom surface, grinding the cylinder top surface or using thinner gaskets, be sure the valve to piston clearance especially.
○When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing, check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly.
Valve to Piston Clearance (Min.)
Intake |
0.7 mm |
Exhaust |
1.2 mm |
If the valve to piston clearance is less than the minimum value, do not start the engine because the valves will touch the piston and the engine may be damaged.
Adjust the valve timing again to keep the valve to piston clearance more than the minimum value.
Method of measuring clearance of valve and piston –1.
○Holding the crankshaft at 10° ATDC (intake) and 10° BTDC (exhaust) of crankshaft timing, measure the amount of the tappet movement until the valve comes in contact with the piston pushing the tappet.
9
Method of measuring clearance of valve and piston –2.
○Adjust the valve clearance and valve timing.
○Remove the cylinder head, and put a small piece of modeling clay on the hollow of piston to prevent valve from coming in contact.
○Install the cylinder head and adjust the camshaft chain timing.
○Turn the crankshaft by two rotations or more.
○Remove the cylinder head and measure the thickness of the clay. The thickness of the collapsed clay is a clearance of the valve and the piston.
10
Cylinder Head
Before reassemble the cylinder head grind off the stepped portions of the port and smooth the inside of ports to make intake/exhaust gas flow smooth.
○Grind off the stepped portions only at the mating surface between the carburetor holder and the intake port.
○When using the kit camshaft (12044-0043), grind off the inside of the intake port to extent 1mm from the original port diameter for improve the performance.
○Mark the carburetor holders so that they can be installed in their original positions.
○Grind off and smooth the stepped portions at the mating surface between the valve seat and the port.
○Smooth the inside of the intake port and exhaust port.
Chamfer the machining edge of the cylinder head where the valve seat installed, also smooth the dome of the combustion chamber with the valves installed. Excessive smoothing may reduce the cylinder compression.
Use the hand grinder.
○Use #200 oil stone for eliminating any stepped portion and #300 oil stone for finishing.
NOTE
○These procedures make air resistance less and intake/exhaust gas flow more smooth. However, much more effect can not be expected by excessive grinding and smoothing. It may be done to the extent of getting rid of uneven surfaces.
A: Stepped Portions
: Grind Area ( All around port )
11
The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners.
NOTE
○When grinding the cylinder head surface or using thinner gasket, adjust the valve timing to keep that the valve to piston clearance is not less than the minimum value (IN: 0.7 mm, EX: 1.2 mm).
Cylinder Compression
To adjust the cylinder compression, adjust the thickness of the cylinder head gasket or smooth the cylinder head under surface or cylinder top surface to make the piston squish
0.65 mm. Keep the piston squish more than 0.65 mm.
○Grind off the cylinder head under surface to 0.4 mm. Do not grind the cylinder upper surface. This can raise the compression ratio while keeping the clearance of the piston and valve, and one of the squish. Although, as the engine machining is uneven, determine the cutting dimension after keeping the recess and the squish before machining.
○Position the piston at Top Dead Center, and put a small piece of modeling clay on the shoulder of the piston. Install the cylinder head gasket and cylinder head, and tighten the head bolts to the specified torque.
○Remove the cylinder head and measure the thickness of the clay. The thickness of the collapsed clay is the size of the squish.
○The most preferable squish measurement is 0.65 mm.
○Select proper cylinder head gasket.
Cylinder Head Gasket
Part No. |
Tightening thickness |
Remarks |
11004-0026 |
0.65 mm Original |
KIT |
11004-0022 |
0.55 mm |
KIT |
11004-0023 |
0.45 mm |
KIT |
11004-0034 |
0.40 mm |
KIT |
12
Piston
1.Kit Piston (13001-0061): SB Method
Kit piston are exclusive the two piston ring for reduce the compression height (dimension between the center of piston pin hole to shoulder of the piston) and the mechanical friction loss.
Kit piston has more reduced the weight compared the original piston.
Establish the cylinder compression in 14.3 to use the this piston and grind off the cylinder head under surface to 0.4 mm
○Always use the higher octane rating gasoline for prevent the knocking. Use the kit piston rings and the kit pistons.
Change the kit pistons from the original pistons inspect the squish (refer to the Cylinder Compression section).
Use the kit pistons (13001-0061) following below.
○Use the kit connecting rod assemblies (13251-0015)
○Use the kit piston rings (13008-0019).
○Use the kit piston pins and snap rings.
○There are the machining edge for the valve relief portions of the piston heads. Must be hand finished for smooth corners. (Round the corner to R1)
Crankshaft Main Journal Bushings
Crankshaft Main Journal Bushings: Use original bushings.
13
Connecting Rod Bolts
1. Original Connecting Rod
Use the original connecting bolts and nuts.
Make recesses at both ends of the original connecting rod bolt to measure its length and
determine the bolt stretch. |
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Connecting Rod : |
13251 |
– 0005 |
Bolt : |
92153 |
– 0491 |
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92153 |
– 0809 (Kit Part : Attached Recess) |
Nut : |
92015 |
- 1311 |
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Install the original bolts into the connecting rod.
Before every tightening, use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch.
Apply a small amount of molybdenum disulfide grease to the threads and seating surfaces of nuts and bolts.
Tighten the big end nuts at the torque (reference torque) of 20 N·m (2.0 kgf·m, 14.5 ft·lb). Check the length of the bolts and find the bolt stretch.
Bolt Length after tightening – Bolt Length before tightening = Stretch
Bolt Stretch
Usable Range: 0. 32 mm (0.0126 in.) target
Turn the big end nuts more until the bolt stretch reaches the usable range.
NOTE
○Replace the original bolts with new ones if they have already been tightened up to usable range 2 times.
○Replace the bolts with new ones if they are used for the engine with a not clear feature.
14
2. Kit Connecting Rod Connecting Rod Bolt
Use the kit connecting rod bolts (with the original connecting rod bolts) and nuts. The kit connecting rod can use the original connecting rod bolt (92153-0491).
When using the original connecting rod bolts, make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch.
Connecting rod : |
13251 |
– 0035 |
Bolt : |
92153 |
– 0809 (Attached Recess) |
Nut: |
92015 |
- 1311 |
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Installation of the kit connecting rod bolt is same as installation of the original connecting rod bolt in the 1. original connecting rod section. Refer to the 1. original connecting rod section.
15
Connecting Rod Big End Bushings
The connecting rod bushing in the kit has improved its anti-seizure feature than standard one.
Connecting Rod Big End Bushing/Crankpin Clearance
When adjust the clearance by measurement in case aiming the clearance 0.050 mm.
Crankpin Diameter Marks ○: 34.493~34.500 mm
None: 34.484~34.492 mm
Connecting Rod Big End Bore Diameter Marks ○: 37.509~37.516 mm
None: 37.50037.508 mm
[A].Diameter Mark (○ or no mark)
[B].Weight Mark (Alphabet, E, F et)
Connecting Rod Big End Bushings
Color |
Kit Bushing Part |
Thickness |
|
Number |
|||
|
|
||
Blue |
92139-0109 |
1.488 ~ 1.493 mm |
|
Black |
92139-0110 |
1.483 ~ 1.488 mm |
|
Brown |
92139-0111 |
1.478 ~ 1.483 mm |
[A]. Color Mark
Big End Bearing Bushing Selection
Crankshaft |
○ |
○ |
|
None |
None |
Connecting Rod |
None |
○ |
|
None |
○ |
Bushing |
Brown |
|
Black |
Blue |
|
Clearance (recommend) |
34 ~ 60 μm |
|
32 ~ 58μm |
30 ~ 56μm |
NOTE
○Make the clearances between the crankshaft main Journals and the connecting rod big ends within the prescribed allowances. Excessive clearances will cause the oil pressure at the connecting rod big end to drop and lead to the damage of the bearing.
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Clutch Adjustment (Back-Torque Limiter Setting)
The Ninja ZX-10R engine is equipped with the Kawasaki back-torque limiter mechanism in the clutch. The back-torque limiter works to reduce the chance of rear wheel hop caused by engine braking during hard braking and down shifting. The back-torque limiter operating condition can be changed by changing the total thickness of clutch plates and changing the number of leaf springs. Try different settings and select the best.
The standard setting of length [A], total thickness of clutch plates shown below, becomes about 53.6 mm (Supposed combination of steel plates is the plate with spring × 1 pcs. + t 2.6 × 8 pcs.). For this setting the effective stroke of clutch spring plate during the back-torque limiter operation is adjusted between 0.45 and 0.75 mm.
By increasing the effective stroke the back-torque limiter causes more slip. The effective stroke increases by decreasing the length [A]. The length [A] between 52.8 and 53.6 mm is available by changing the combination of the steel plates. Replace one steel plate with a thinner one and try the setting. If the operation of the back-torque limiter is not enough replace other steel plates one by one.
Thickness (mm) |
Part Number |
2.3 |
13089-1084 |
1.6 |
13089-1115 |
2.9 |
13089-1093 |
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When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers (provided as optional production parts) to keep the preload of clutch springs according to the table below.
Length [A] |
Part Number |
Height [B] |
53.1 ~ 53.6 mm |
13092-1041 |
6 mm (standard) |
52.6 ~ 53.0 mm |
39108-0004 |
5 mm |
52.0 ~ 52.5 mm |
39108-0006 |
4.5 mm |
If you have clutch slip during acceleration use shorter spring retainers by one size to increase preload of clutch springs.
The original springs and retainers can be used if the length [A] is between 52.8 ~ 53.6 mm.
For precise setting the measurement of the effective stroke of clutch spring plate is recommended.
•Remove oil from clutch plates.
•Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.
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[A] |
Spacers |
[G] |
Friction Plates |
[B] |
Needle Bearing |
[H] |
Spring Plate Assembly |
[C] |
Bushing |
[I] |
Steel Plates |
[D] |
Clutch Housing |
[J] |
Spring Plate |
[E] |
Clutch Hub |
[K] |
Spring Retainer |
[F] |
Sub Clutch Hub |
|
|
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•Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub).
•To measure the effective stroke of clutch spring plate, set a dial gauge [A] against the raised center [B] of the clutch spring plate.
•Move the clutch housing gear back and forth [C]. The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate.
[D]Drive Shaft
After installing the clutch to the engine, measure and record the depth [B] shown below, the length from the clutch spring plate to the top surface of the sub clutch hub, using a caliper or a depth gauge. Manage the depth [B] to adjust the effective stroke after that, because the friction disks would be worn and the length [A] would change. The decrease of the depth [B] from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured.
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Spring Plate Assembly
The ZX-10R engine is used with the leaf sprig built in type steel plate assembly (spring plate assembly) in the clutch. The spring plate assembly are available for increase the spring constant. When outbreak the starting judder, use the spring plate assembly of the kit parts. Whenever the plate thickness is difference for adjusting the clutch plate, take care the length [A].
Part Number |
Spring Constant |
ID Color |
13089-0003 |
Standard |
None |
13089-0011 |
40 % up comparison standard |
White |
13089-0012 |
60 % up comparison standard |
Blue |
Identification Color: The ID marks are on the springs between the steel plates.
Transmission
Type B ~ D of the kit gears are available of the 2005 model ZX-10R. To change the gear ratios with combination the gears.
Remove the three steel balls (600A0500) from the output shaft assembly. This is done to start easily the engine with the second gear.
Replace the circlips with new ones if they were removed.
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Transmission Shimming
By using washers with various thickness, keep the axial clearance between 0.3 mm and 0.4 mm, to prevent the inclination of gears and to keep smooth gear-shifting.
|
Thickness (mm) |
Part No. |
Remarks |
Spline washer |
1.2 |
92200-0229 |
Kit |
|
1.4 |
92200-0230 |
Kit |
|
1.6 |
92200-0050 |
Original |
|
1.8 |
92200-0231 |
Kit |
|
2.0 |
92200-0232 |
Kit |
Plane washer A |
0.8 |
92200-0225 |
Kit |
|
1.0 |
92200-0226 |
Kit |
|
1.2 |
92200-0051 |
Original |
|
1.4 |
92200-0227 |
Kit |
|
1.6 |
92200-0228 |
Kit |
Plane washer B |
1.4 |
92200-0138 |
Kit |
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Use the type B ~ D input shafts with the shim adjustment since their sizes are, different from the standard shaft, designed taking the shim adjustment into account in order to make the dog lengths of the 3rd – 5th & 2nd – 6th gear dogs equal. Adjust the dog length of each gears to smooth gear-shifting.
Standard Adjusting
-2 Use the standard spline washer t1.6 mm (92200-0050)-2 Use the standard spline washer t1.2 mm (92200-0051)
When thin the washer of -1 ( -1) from the standard washer and thickly the washer of -2 ( -2) from the standard washer to increase the dog length of gears also reverse the combination to reduced the dog length of gear.
Alternator
Racing kit of the 2005 model ZX-10R are available the alternator to install the left end of the crankshaft. To quicken response by reducing the flywheel mass and to reduce the weight, use the kit alternator. Also use the kit alternator improve the engine ability
Kit Alternator Rated Output
10 A @ 8 000 rpm (original: 30 A @ 5 000 rpm)
Effective current 7~8 A for running the race method vehicle.
Select and use the kit alternator or original alternator for racing conditions.
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