Kawasaki NINJA ZX-10R User Manual

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

Ninja ZX-10R

Motorcycle Service Manual

99924-1322-02

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.

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.

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.

WARNING

CAUTION

Table of Contents

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

General Specifications

Item 2005 Ninja ZX-10R Racing

Engine:

Ignition timing 10°BTDC @1 100 r/min (rpm) Fuel (Recommended) Racing gasoline Engine oil (Recommended): Racing oil Level Between upper and lower levels of oil level gauge.

Drive Train:

Primary drive reduction ratio 1.611 (87/54)

Transmission Gear Table

STD（Type A） Type B Type C Type D

1st

2nd

3rd

4th

5th

6th

In Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio

In Out Teeth (Out/In) Gear Ratio

In Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio

13127-0020 13262-0170

38/15

2.533 13262-0185 13262-0152

39/19

2.053

See Gear

Selection

13262-0182

33/19

1.737

See Gear

Selection

13262-0166

32/21

1.525 13262-0135 13262-0183

29/21

1.381 13262-0136 13262-0171

30/23

1.304

13127-0030 13262-0267

31/13

2.385

See Gear

Selection

13262-0268

34/13

1.789

See Gear

Selection

13262-0269

31/20

1.550 13262-0265 13262-0270

29/20

1.450 13262-0266 13262-0271

29/21

1.381

13127-0031 13262-0275

34/14

2.429

See Gear

Selection

13262-0276

28/16

1.750

13262-0273 13262-0277

28/20

1.400 13262-0274 13262-0278

28/21

1.333

13127-0032 13262-0281

37/16

2.313 13262-0279 13262-0282

36/18

2.000

13262-0280 13262-0283

28/22

1.273

Input 3rd/4th Gear Selection Table

4th Gear

A (=C) B

3rd Gear

A 13262-0134 (19/21) 13262-0286 (19/20) B 13262-0284 (19/21) 13262-0264 (19/20) C 13262-0272 (16/21) 13262-0285 (16/20)

Gear Identification Slit Number Table

Standard (Type A) Type B Type C Type D

1st

Input 0 2 3 4

Output 1 2 3 4

2nd

Input 1 - - 2

Output 1 - - 2

3rd

Input 1 2 0 -

Output 0 2 3 -

4th

Input 0 1 - -

Output 2 1 - -

5th

Input 2 0 3 -

Output 1 0 3 -

6th

Input 1 2 3 4

Output 0 2 3 4

Engine Sprocket

13144-0021 #520-16T 13144-0022 #520-17T

Racing Kit Service Data

Item Standard

Cylinder Head, Valves:

Valve timing: Duration: Intake 300° Exhaust 292° Camshaft timing (cam lift center): Intake 104° (ATDC) Exhaust 102° (BTDC) Valve clearance: Intake 0.22 mm Exhaust 0.20 mm Squish 0.85 mm Valve to piston clearance: Intake 1.45 mm @10°ATDC Exhaust 1.80 mm @10°BTDC

Ignition System:

Spark plugs

NGK CR9EIA-9 (STD), R0045Q-10 or R0373A-10

Spark plug tightening torque 13 N·m (1.3 kgf·m, 113 in·lb)

These values show the specifications when standard cylinder head and gasket are used.

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the

motorcycle in good running condition.

FREQENCY

OPERATION

Engine

Clutch plate - - check* ●

Throttle grip play - - check* ●

Spark plug - - clean/gap* ●

Engine oil - - change ●

Oil filter - - replace ●

Valve lapping ●

Cylinder head/valve - - decarbonization ●

Cylinder - - check* ●

Piston/cylinder clearance - - check* ●

Piston ring, piston, and piston pin - - replace ●

Crankshaft main bearing - - check* ●

Connecting rod big end bearing - - check* ●

Transmission gear, bearing - - check* ●

Engine sprocket - - check* ●

Each

Race

Every

3 races

Every

5 races

Every

10 races

Required

FREQENCY

OPERATION

Coolant - - change ●

Radiator hoses, connections - - check* ●

Frame

Brake operation - - check* ●

Brake pad wear - - check* ●

Brake fluid level - - check* ●

Brake fluid - - change* year

Brake master cylinder cup and dust seal - - replace year

Brake caliper piston seal and dust seal - - replace year

Brake hose - - replace 2 years

Drive chain - - adjust ●

Drive chain - - lubricate ●

Drive chain wear - - check* ●

Drive chain guide - - replace If damaged

Front fork - - clean/check* ●

Front fork oil - - change First change after 2 races, then every 5 races

Nut, bolt, and fastener tightness - - check* ●

Fuel system - - clean ●

Fuel hose, fuel filter - - replace ●

Steering play - - check* ●

Steering stem bearing - - grease ●

Rear sprocket - - replace ●

General lubrication of chassis - - perform ●

Wheel bearing (rear) - - grease ●

Swingarm pivot, uni-track linkage - - grease ●

Swingarm pivot, uni-track linkage - - check* ●

Each

Race

Every

3 races

Every

5 races

Every

10 races

Required

*: Replace, add, adjust, clean, or torque if necessary.

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.

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

Camshafts, Sprockets

Camshafts, Sprockets:

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)

(Recommended)

108°

(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.

102°

 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.

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 )

 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 11004-0022 0.55 mm KIT 11004-0023 0.45 mm KIT 11004-0034 0.40 mm KIT

0.65 mm（Original）

KIT

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.

Connecting Rod Bolts

1. Original Connecting Rod Use the original connecting bolts and nuts. Make recesses at both ends of the original connecting rod bolt to measure its length and

determine the bolt stretch.

Connecting Rod : 13251 – 0005 Bolt : 92153 – 0491 92153 – 0809 (Kit Part : Attached Recess) Nut : 92015 - 1311

 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.

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

※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.

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 Connecting Rod None

○ ○

○

None None None

○

Bushing Brown Black Blue Clearance (recommend)

○ Make the clearances between the crankshaft main Journals and the connecting rod big

34 ~ 60 μm 32 ~ 58μm 30 ~ 56μm

NOTE

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.

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

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.

[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

• 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.

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.

Transmission Shimming

By using washers with various thickness, keep the axial clearance between 0.3 mm and

0.4 mm, to prevent the inclination of gears and to keep smooth gear-shifting.

Thickness (mm) Part No. Remarks ① Spline washer

1.2 92200-0229 Kit

1.4 92200-0230 Kit

1.6 92200-0050 Original

1.8 92200-0231 Kit

2.0 92200-0232 Kit

② 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

③ Plane washer B

1.4 92200-0138 Kit

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

①-2 Use the standard spline washer t1.6 mm (92200-0050) ②-2 Use the standard spline washer t1.2 mm (92200-0051)

When thin the washer of ①-1 (②-1) from the standard washer and thickly the washer of ①

-2 (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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