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Ninja ZX-10R
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Motorcycle
Service Manual
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Quick Reference Guide
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General Information |
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Periodic Maintenance |
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Fuel System (DFI) |
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Cooling System |
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Engine Top End |
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Clutch |
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Engine Lubrication System |
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Engine Removal/Installation |
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Crankshaft/Transmission |
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Wheels/Tires |
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Final Drive |
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Brakes |
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Suspension |
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Steering |
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Frame |
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Electrical System |
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Appendix |
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This quick reference guide will assist |
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you in locating a desired topic or pro- |
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cedure. |
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•Bend the pages back to match the |
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black tab of the desired chapter num- |
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ber with the black tab on the edge at |
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each table of contents page. |
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•Refer to the sectional table of contents |
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for the exact pages to locate the spe- |
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cific topic required. |
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Ninja ZX-10R
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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.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2005 Kawasaki Heavy Industries, Ltd. |
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Second Edition (1): Jan. 19, 2006 (K) |
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LIST OF ABBREVIATIONS |
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A |
ampere(s) |
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lb |
pound(s) |
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ABDC |
after bottom dead center |
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m |
meter(s) |
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AC |
alternating current |
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min |
minute(s) |
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ATDC |
after top dead center |
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N |
newton(s) |
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BBDC |
before bottom dead center |
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Pa |
pascal(s) |
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BDC |
bottom dead center |
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PS |
horsepower |
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BTDC |
before top dead center |
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psi |
pound(s) per square inch |
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°C |
degree(s) Celsius |
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r |
revolution |
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DC |
direct current |
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rpm |
revolution(s) per minute |
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F |
farad(s) |
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TDC |
top dead center |
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°F |
degree(s) Fahrenheit |
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TIR |
total indicator reading |
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ft |
foot, feet |
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V |
volt(s) |
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g |
gram(s) |
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W |
watt(s) |
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h |
hour(s) |
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Ω |
ohm(s) |
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L |
liter(s) |
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COUNTRY AND AREA CODES |
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AT |
Austria |
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FR |
France |
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AU |
Australia |
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GB |
United Kingdom |
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CA |
Canada |
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MY |
Malaysia |
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CAL |
California |
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US |
United States |
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CH |
Switzerland |
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WVTA |
Whole Vehicle Type Approval |
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DE |
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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. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referredwwwto as the Act’s.zxforums“tampering p ovisions”. .com
“Sec. 203(a) The follo ing acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”
NOTE
○The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.
1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2.Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
000 PER VIOLATION. |
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TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.
•Removal of the muffler(s) or any internal portion of the muffler(s).
•Removal of the air box or air box cover.
•Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.
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Foreword
This manual is designed primarily for use by |
Guide shows you all of the product’s system |
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trained mechanics in a properly equipped shop. |
and assists in locating their chapters. Each |
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However, it contains enough detail and basic in- |
chapter in turn has its own comprehensive Ta- |
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formation to make it useful to the owner who de- |
ble of Contents. |
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sires to perform his own basic maintenance and |
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For example, if you want ignition coil informa- |
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repair work. A basic knowledge of mechanics, |
tion, use the Quick Reference Guide to locate |
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the proper use of tools, and workshop proce- |
the Electrical System chapter. Then, use the |
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dures must be understood in order to carry out |
Table of Contents on the first page of the chap- |
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maintenance and repair satisfactorily. When- |
ter to find the Ignition Coil section. |
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ever the owner has insufficient experience or |
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Whenever you see these WARNING and |
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doubts his ability to do the work, all adjust- |
CAUTION symbols, heed their instructions! |
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ments, maintenance, and repair should be car- |
Always follow safe operating and maintenance |
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ried out only by qualified mechanics. |
practices. |
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In order to perform the work efficiently and |
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WARNING |
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to avoid costly mistakes, read the text, thor- |
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This warning symbol identifies special |
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oughly familiarize yourself with the procedures |
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before starting work, and then do the work care- |
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instructions or procedures which, if not |
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fully in a clean area. Whenever special tools or |
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correctly followed, could result in per- |
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equipment are specified, do not use makeshift |
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sonal injury, or loss of life. |
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tools or equipment. Precision measurements |
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can only be made if the proper instruments are |
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CAUTION |
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used, and the use of substitute tools may ad- |
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This caution sy bol identifies special |
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versely affect safe operation. |
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instructions or procedures which, if not |
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For the duration of the warranty period, |
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strictly observed, could result in dam- |
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we recommend that all repairs and scheduled |
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age to or destruction of equipment. |
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maintenance be performed in accordance with |
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this service manual. Any owner maintenance or |
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This manual contains four more symbols (in |
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repair procedure not performed in accordance |
addition to WARNING and CAUTION) which will |
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with this manual may void the warranty. |
help you distinguish different types of informa- |
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To get the longest life out of your vehicle. |
tion. |
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•Follow the Periodic Maintenance Chart in the |
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NOTE |
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Service Manual. |
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This note symbol indicates points of par- |
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•Be alert for problems and non-scheduled |
○ |
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maintenance. |
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ticular interest for more efficient and con- |
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•Use proper tools and genuine Kawasaki Mo- |
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venient operation. |
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•Indicates a procedural step or work to be |
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torcycle parts. Special tools, gauges, and |
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testers that are necessary when servicing |
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Kawasaki motorcycles are introduced by the |
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done. |
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Indicates a procedural sub-step or how to do |
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Service Manual. Genuine parts provided as |
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○ |
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spare parts are listed in the Parts Catalog. |
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the work of the procedural step it follows. It |
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also precedes the text of a NOTE. |
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•Follow the procedures in this manual care- |
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Indicates a conditional step or what action to |
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fully. Don’t take shortcuts. |
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take based on the results of the test or inspec- |
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•Remember to keep complete records of main- |
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tion in the procedural step or sub-step it fol- |
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tenance and repair with dates and any new |
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lows. |
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parts installed. |
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In most chapters an exploded view illustration |
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of the system components follows the Table of |
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How to Use This Manual |
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Contents. In these illustrations you will find the |
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In this manual, the product is divided into |
instructions indicating which parts require spec- |
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ified tightening torque, oil, grease or a locking |
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its major systems and these systems make up |
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agent during assembly. |
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the manual’s chapters. The Quick Reference |
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GENERAL INFORMATION 1-1 |
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General Information |
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Table of Contents |
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1 |
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-9 |
Unit Conversion Table ............................................................................................................ |
1-12 |
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1-2 GENERAL INFORMATION |
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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. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent www.zxforums.com
Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
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GENERAL INFORMATION 1-3 |
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Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual forwwwservice limits on.zxforumsindividual parts. Replace .com the parts if any damage has been found if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
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1-4 GENERAL INFORMATION |
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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. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agentwwwapplied using.zxforumsan impact d iver. .com Use a plastic-faced mallet henever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
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GENERAL INFORMATION 1-5 |
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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. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make surewwwthe seal is aligned.zxforumsproperly when installing. .com
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
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1-6 GENERAL INFORMATION |
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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. Rotate the crankshaft to positive direction (clockwise viewed from output side).
Electrical Wires
A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
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Instrument
Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
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GENERAL INFORMATION 1-7 |
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Model Identification
ZX1000D6F (Europe) Left Side View
ZX1000D6F (Europe) Right Side View
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1-8 GENERAL INFORMATION |
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Model Identification
ZX1000D6F (United States and Canada) Left Side View
ZX1000D6F (United States and Canada) Right Side View
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Engine Number |
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GENERAL INFORMATION 1-9 |
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General Specifications |
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Items |
ZX1000D6F (Ninja ZX-10R) |
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Dimensions |
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Overall Length |
2 065 mm (81.3 in.) |
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Overall Width |
(CA), (CAL), (US) 730 mm (28.7 in.) |
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705 mm (27.8 in.) |
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Overall Height |
1 130 mm (44.5 in.) |
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Wheelbase |
1 390 mm (54.7 in.) |
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Road Clearance |
120 mm (4.7 in.) |
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Seat Height |
825 mm (32.5 in.) |
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Dry Mass |
175 kg (386 lb) |
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Curb Mass: |
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Front |
102 kg (225 lb) |
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Rear |
100 kg (221 lb) |
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Fuel Tank Capacity |
17 L (4.5 US gal) |
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Performance |
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Minimum Turning Radius |
3.3 m (10.8 ft) |
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Engine |
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Type |
4-stroke, DOHC, 4-cylinder |
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Cooling System |
Liquid-cooled |
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Bore and Stroke |
76.0 × 55.0 mm (3.0 × 2.2 in.) |
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Displacement |
998 mL (60.9 cu in.) |
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Compression Ratio |
12.7 : 1 |
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Maximum Horsepower |
128.7 kW (175 PS) @11 700 r/min (rpm), |
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(FR) 78.2 kW (106 PS) @10 500 r/min (rpm), |
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(AU) 128.7 kW (175 PS) @11 500 r/min (rpm), |
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(MY) 120.5 kW (164 PS) @10 000 r/min (rpm), |
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(CA), (CAL), (US) – – – |
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Maximum Torque |
115 N·m (11.7 kgf·m, 85 ft·lb) @9 500 r/min (rpm), |
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(FR) 86 N·m (8.8 kgf·m, 63 ft·lb) @5 200 r/min (rpm), |
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(CA), (CAL), (US) – – – |
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Carburetion System |
FI (Fuel injection), MIKUNI 43EIDW × 4 |
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Starting System |
Electric starter |
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Ignition System |
Battery and coil (transistorized) |
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Timing Advance |
Electronically advanced (digital igniter in ECU) |
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Ignition Timing |
From 10° BTDC @1 100 r/min (rpm) |
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Spark Plug |
NGK CR9EIA-9 |
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Cylinder Numbering Method |
Left to right, 1-2-3-4 |
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Firing Order |
1-2-4-3 |
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Valve Timing: |
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Inlet: |
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Open |
46° BTDC |
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Close |
74° ABDC |
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Duration |
300° |
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Exhaust: |
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|
|
Open |
66° BBDC |
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Close |
46° ATDC |
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1-10 GENERAL INFORMATION |
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General Specifications |
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Items |
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ZX1000D6F (Ninja ZX-10R) |
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Duration |
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292° |
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Lubrication System |
Forced lubrication (wet sump with cooler) |
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Engine Oil: |
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Type |
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API SE, SF or SG |
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API SH, SJ or SL with JASO MA |
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Viscosity |
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SAE10W-40 |
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Capacity |
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4.0 L (4.2 US qt) |
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Drive Train |
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Primary Reduction System: |
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Type |
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Gear |
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Reduction Ratio |
1.611 (87/54) |
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Clutch Type |
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Wet multi disc |
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Transmission: |
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Type |
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6-speed, constant mesh, return shift |
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Gear Ratios: |
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1st |
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2.533 (38/15) |
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2nd |
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2.053 (39/19) |
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3rd |
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1.737 (33/19) |
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4th |
www. |
1.524 (32/21) |
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5th |
zxforums.com |
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1.381 (29/21) |
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6th |
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1.304 (30/23) |
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Final Drive System: |
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Type |
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Chain drive |
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Reduction Ratio |
2.353 (40/17) |
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Overall Drive Ratio |
4.945 @Top gear |
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Frame |
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Type |
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Tubular, diamond |
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Caster (Rake Angle) |
24.5° |
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Trail |
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102 mm (4.0 in.) |
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Front Tire: |
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Type |
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Tubeless |
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Size |
|
120/70 ZR17 M/C (58 W) |
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Rear Tire: |
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Type |
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Tubeless |
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Size |
|
190/55 ZR17 M/C (75 W) |
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Rim Size: |
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Front |
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17 × 3.50 |
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Rear |
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17 × 6.00 |
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Front Suspension: |
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Type |
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Telescopic fork (upside-down) |
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Wheel Travel |
|
120 mm (4.7 in.) |
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Rear Suspension: |
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Type |
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Swingarm (uni-trak) |
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Wheelwww.zxforumsTravel .com |
125 mmwww(4.zxforums9 in.) .com |
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GENERAL INFORMATION 1-11 |
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General Specifications |
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Items |
ZX1000D6F (Ninja ZX-10R) |
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Brake Type: |
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Front |
Dual discs |
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Rear |
Single disc |
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Electrical Equipment |
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Battery |
12 V 10 Ah |
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Headlight: |
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Type |
Semi-sealed beam |
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Bulb: |
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High |
12 V 55 W + 65 W (quartz-halogen) |
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Low |
12 V 55 W (quartz-halogen) |
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Tail/Brake Light |
12 V 0.5/4.1 W (LED) |
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Alternator: |
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Type |
Three-phase AC |
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Rated Output |
31 A/14 V @5 000 r/min (rpm) |
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|
Specifications subject to change without notice, and may not apply to every country.
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1-12 GENERAL INFORMATION |
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Unit Conversion Table |
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|
Prefixes for Units |
Units of Length |
|
Prefix |
Symbol |
|
Power |
|
mega |
M |
× 1 000 |
000 |
|
kilo |
k |
× |
1 000 |
|
centi |
c |
× |
0.01 |
|
milli |
m |
× |
0.001 |
|
micro |
µ |
× 0.000001 |
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Units of Mass
kg |
× |
2.205 |
= |
lb |
g |
× |
0.03527 |
= |
oz |
km |
× |
0.6214 |
= |
mile |
m |
× |
3.281 |
= |
ft |
mm |
× |
0.03937 |
= |
in |
Units of Torque
N·m |
× |
0.1020 |
= |
kgf·m |
N·m |
× |
0.7376 |
= |
ft·lb |
N·m |
× |
8.851 |
= |
in·lb |
kgf·m |
× |
9.807 |
= |
N·m |
kgf·m |
× |
7.233 |
= |
ft·lb |
kgf·m |
× |
86.80 |
= |
in·lb |
Units of Volume |
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Units of Pressure |
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L |
× |
0.2642 |
= |
gal (US) |
|
kPa |
× |
0.01020 |
= |
kgf/cm² |
L |
× |
0.2200 |
= |
gal (imp) |
|
kPa |
× |
0.1450 |
= |
psi |
L |
× |
1.057 |
= |
qt (US) |
|
kPa |
× |
0.7501 |
= |
cmHg |
L |
× |
0.8799 |
= |
qt (imp) |
|
kgf/cm² |
× |
98.07 |
= |
kPa |
L |
× |
2.113 |
= |
pint (US) |
|
kgf/cm² |
× |
14.22 |
= |
psi |
L |
× |
1.816 |
= |
pint (imp) |
|
cmHg |
× |
1.333 |
= |
kPa |
mL |
× |
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0.03381 |
= |
oz (US) |
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mL |
× |
0.02816 |
= |
oz (imp) |
|
Units of Speed |
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mL |
× |
0.06102 |
= |
cu in |
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|
km/h |
× |
0.6214 |
= |
mph |
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Units of Force |
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Units of Power |
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N |
× |
0.1020 |
= |
kg |
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|
kW |
× |
1.360 |
= |
PS |
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N |
× |
0.2248 |
= |
lb |
|
|||||
|
kW |
× |
1.341 |
= |
HP |
|||||
kg |
× |
9.807 |
= |
N |
|
|||||
|
PS |
× |
0.7355 |
= |
kW |
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kg |
× |
2.205 |
= |
lb |
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|
PS |
× |
0.9863 |
= |
HP |
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Units of Temperature
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PERIODIC MAINTENANCE 2-1 |
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Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... |
|
|
2-3 |
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Torque and Locking Agent...................................................................................................... |
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2-6 |
2 |
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Specifications |
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|
2-13 |
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Special Tools .......................................................................................................................... |
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2-15 |
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Maintenance Procedure ......................................................................................................... |
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2-16 |
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Fuel System (DFI)................................................................................................................ |
|
|
2-16 |
|
|
Throttle Control System Inspection................................................................................... |
|
2-16 |
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|
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Engine Vacuum Synchronization Inspection..................................................................... |
|
2-16 |
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|
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Idle Speed Inspection ....................................................................................................... |
|
|
2-19 |
|
|
Idle Speed Adjustment...................................................................................................... |
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|
2-20 |
|
|
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... |
2-20 |
|
|
||
Evaporative Emission Control System (California Model) ................................................... |
|
2-21 |
|
|
|
Evaporative Emission Control System Inspection ............................................................ |
|
2-21 |
|
|
|
Cooling System.................................................................................................................... |
|
|
2-22 |
|
|
Coolant Level Inspection................................................................................................... |
|
|
2-22 |
|
|
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... |
2-22 |
|
|
||
Engine Top End ................................................................................................................... |
|
|
2-22 |
|
|
Valve Clearance Inspection .............................................................................................. |
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|
2-22 |
|
|
Valve Clearance Adjustment ................................................ |
|
........................................ |
2-24 |
|
|
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2-26 |
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Air Suction System ................ |
................................................ ........................................ |
|
|
||
Air Suction System Damage Inspection................................. |
........................................ |
2-26 |
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|
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Clutch................................................................................................................................... |
|
|
2-27 |
|
|
Clutch Operation Inspection ............................................................................................. |
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|
2-27 |
|
|
Wheels/Tires........................................................................................................................ |
|
|
2-28 |
|
|
Air Pressure Inspection..................................................................................................... |
|
|
2-28 |
|
|
Wheel/Tire Damage Inspection......................................................................................... |
|
2-28 |
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|
|
Tire Tread Wear Inspection .............................................................................................. |
|
|
2-28 |
|
|
Wheel Bearing Damage Inspection .................................................................................. |
|
2-29 |
|
|
|
Drive Train ........................................................................................................................... |
|
|
2-30 |
|
|
Drive Chain Lubrication Condition Inspection ................................................................... |
|
2-30 |
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|
|
Drive Chain Slack Inspection ............................................................................................ |
|
|
2-30 |
|
|
Drive Chain Slack Adjustment .......................................................................................... |
|
2-31 |
|
|
|
Wheel Alignment Inspection ............................................................................................. |
|
|
2-32 |
|
|
Drive Chain Wear Inspection ............................................................................................ |
|
|
2-32 |
|
|
Chain Guide Wear Inspection ........................................................................................... |
|
|
2-33 |
|
|
Brake System ...................................................................................................................... |
|
|
2-33 |
|
|
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ |
|
2-33 |
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|
|
Brake Hose Damage and Installation Condition Inspection.............................................. |
|
2-33 |
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|
|
Brake Operation Inspection .............................................................................................. |
|
|
2-33 |
|
|
Brake Fluid Level Inspection............................................................................................. |
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|
2-34 |
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|
Brake Pad Wear Inspection .............................................................................................. |
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|
2-34 |
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|
Brake Light Switch Operation Inspection .......................................................................... |
|
2-34 |
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|
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Suspensions ........................................................................................................................ |
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|
2-35 |
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|
Front Forks/Rear Shock Absorber Operation Inspection .................................................. |
|
2-35 |
|
|
|
Front Fork Oil Leak Inspection.......................................................................................... |
|
2-36 |
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|
|
Rear Shock Absorber Oil Leak Inspection ........................................................................ |
|
2-36 |
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Rocker Arm Operation Inspection..................................................................................... |
|
2-36 |
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|
|
Tie-Rod Operation Inspection ........................................................................................... |
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|
2-36 |
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|
Steering System .................................................................................................................. |
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2-37 |
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|
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2-37 |
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||
Steering Play Inspection ................................................................................................... |
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|
|
2-2 PERIODIC MAINTENANCE |
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||
|
|
|
Steering Play Adjustment.................................................................................................. |
|
2-37 |
Steering Stem Bearing Lubrication ................................................................................... |
|
2-38 |
Steering Damper Oil Leak Inspection ............................................................................... |
|
2-38 |
Electrical System ................................................................................................................. |
|
2-39 |
Lights and Switches Operation Inspection........................................................................ |
2-39 |
|
Headlight Aiming Inspection ............................................................................................. |
|
2-41 |
Sidestand Switch Operation Inspection ............................................................................ |
|
2-42 |
Engine Stop Switch Operation Inspection......................................................................... |
2-43 |
|
Others.................................................................................................................................. |
|
2-44 |
Chassis Parts Lubrication ................................................................................................ |
|
2-44 |
Bolts, Nuts and Fasteners Tightness Inspection............................................................... |
2-45 |
|
Replacement Parts .............................................................................................................. |
|
2-47 |
Air Cleaner Element Replacement.................................................................................... |
|
2-47 |
Fuel Hose Replacement ................................................................................................... |
|
2-48 |
Coolant Change................................................................................................................ |
|
2-49 |
Radiator Hose and O-ring Replacement........................................................................... |
|
2-52 |
Engine Oil Change............................................................................................................ |
|
2-53 |
Oil Filter Replacement ...................................................................................................... |
|
2-53 |
Brake Hose and Pipe Replacement.................................................................................. |
|
2-54 |
Brake Fluid Change .......................................................................................................... |
|
2-54 |
Master Cylinder Rubber Parts Replacement .................................................................... |
2-56 |
|
Caliper Rubber Parts Replacement .................................................................................. |
|
2-57 |
Spark Plug Replacement .................................................................................................. |
|
2-60 |
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PERIODIC MAINTENANCE 2-3 |
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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 |
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* ODOMETER READING |
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comes |
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× 1 000 km |
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See |
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first |
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(× 1 000 mile) |
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Page |
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1 |
6 |
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12 |
18 |
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24 |
30 |
36 |
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INSPECTION |
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Every |
(0.6) |
(4) |
(7.5) |
(12) |
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(15) |
(20) |
(24) |
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Fuel System |
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Throttle control system (play, smooth |
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year |
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• |
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• |
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• |
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• |
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2-16 |
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return, no drag)-inspect |
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Engine vacuum synchronization-inspect |
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• |
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• |
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• |
|
2-16 |
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Idle speed-inspect |
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• |
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• |
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• |
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• |
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2-19 |
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Fuel leak (fuel hose and pipe)-inspect |
year |
|
• |
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• |
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|
• |
|
• |
|
2-20 |
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Fuel hose and pipe damage-inspect |
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year |
|
• |
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• |
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• |
|
• |
|
2-20 |
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Fuel hose and pipe installation |
|
year |
|
• |
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• |
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• |
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• |
|
2-20 |
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condition-inspect |
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Evaporative Emission Control System |
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(CAL) |
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Evaporative emission control system |
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|
• |
• |
|
• |
• |
• |
• |
• |
2-21 |
|||
function-inspect |
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www.zxforums |
• |
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.com• • |
|
• |
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Cooling System |
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Coolant level-inspect |
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|
2-22 |
Coolant leak (radiator hose and |
|
year |
|
• |
|
|
• |
|
|
• |
|
• |
|
2-22 |
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pipe)-inspect |
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|||||||||
Radiator hose damage-inspect |
|
year |
|
• |
|
|
• |
|
|
• |
|
• |
|
2-22 |
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Radiator hose installation condition |
|
year |
|
• |
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|
• |
|
|
• |
|
• |
|
2-22 |
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-inspect |
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Engine Top End |
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Valve clearance-inspect |
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• |
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2-22 |
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Air Suction System |
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|
|
|
|
|
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|
|
|
|
|
|
|
|
|
|
Air suction system damage-inspect |
|
|
|
|
|
|
|
|
|
• |
|
|
• |
|
• |
|
2-26 |
Clutch |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Clutch operation (play, disengagement, |
|
|
|
|
• |
|
|
• |
|
|
• |
|
• |
|
2-27 |
||
engagement)-inspect |
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Wheels and Tires |
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Tire air pressure-inspect |
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year |
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• |
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• |
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• |
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2-28 |
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Wheel/tire damage-inspect |
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• |
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2-28 |
Tire tread wear, abnormal wear-inspect |
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2-28 |
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Wheel bearing damage-inspect |
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year |
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2-29 |
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Drive Train |
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Drive chain lubrication condition-inspect # |
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Every 600 km (400 mile) |
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2-30 |
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Drive chain slack-inspect # |
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Every 1 000 km (600 mile) |
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2-30 |
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Drive chain wear-inspect # |
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• |
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• |
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2-32 |
Drive chain guide wear-inspect |
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• |
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• |
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2-33 |
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2-4 PERIODIC MAINTENANCE |
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www.zxforums.com |
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Periodic Maintenance Chart |
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FREQUENCY |
Whichever |
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* ODOMETER READING |
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comes |
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× 1 000 km |
See |
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first |
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(× 1 000 mile) |
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Page |
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1 |
6 |
12 |
18 |
24 |
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30 |
36 |
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INSPECTION |
Every |
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(0.6) |
(4) |
(7.5) |
(12) |
(15) |
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(20) |
(24) |
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Brake System |
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Brake fluid leak (brake hose and |
year |
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• |
• |
• |
• |
• |
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• |
• |
2-33 |
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pipe)-inspect |
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Brake hose and pipe damage-inspect |
year |
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• |
• |
• |
• |
• |
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• |
• |
2-33 |
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Brake pad wear-inspect # |
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• |
• |
• |
• |
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• |
• |
2-34 |
Brake hose installation condition-inspect |
year |
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• |
• |
• |
• |
• |
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• |
• |
2-33 |
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Brake fluid level-inspect |
6 months |
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• |
• |
• |
• |
• |
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• |
• |
2-34 |
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Brake operation (effectiveness, play, no |
year |
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• |
• |
• |
• |
• |
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• |
• |
2-33 |
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drag)-inspect |
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Brake light switch operation-inspect |
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• |
• |
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• |
• |
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2-34 |
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Suspensions |
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Front forks/rear shock absorber operation |
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• |
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• |
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• |
2-35 |
(damping and smooth stroke)-inspect |
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Front forks/rear shock absorber oil |
year |
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• |
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• |
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• |
2-36 |
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leak-inspect |
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Rocker arm operation-inspect |
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• |
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2-36 |
Steering System www |
.zxforums |
• |
.com |
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• |
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Tie-Rods operation-inspect |
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2-36 |
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Steering play-inspect |
year |
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• |
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• |
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• |
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• |
2-37 |
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Steering stem bearings-lubricate |
2 years |
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• |
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2-38 |
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Steering damper oil leak-inspect |
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• |
• |
• |
• |
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• |
• |
2-38 |
Electrical System |
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Lights and switches operation-inspect |
year |
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• |
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• |
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• |
2-39 |
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Headlight aiming-inspect |
year |
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• |
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• |
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• |
2-41 |
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Sidestand switch operation-inspect |
year |
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• |
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• |
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• |
2-42 |
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Engine stop switch operation-inspect |
year |
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• |
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• |
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• |
2-43 |
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Others |
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Chassis parts-lubricate |
year |
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• |
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• |
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• |
2-44 |
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Bolts and nuts tightness-inspect |
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• |
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• |
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• |
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• |
2-45 |
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*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
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PERIODIC MAINTENANCE 2-5 |
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www.zxforums.com |
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Periodic Maintenance Chart |
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Periodic Replacement Parts |
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FREQUENCY |
Whichever |
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* ODOMETER READING |
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come |
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× 1 000 km |
See |
|||
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first |
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(× 1 000 mile) |
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Page |
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1 |
12 |
24 |
36 |
48 |
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CHANGE/REPLACE ITEM |
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Every |
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(0.6) |
(7.5) |
(15) |
(24) |
(30) |
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Air cleaner element # |
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Every 18 000 km (12 000 mile) |
2-47 |
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Fuel hose |
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4 years |
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• |
2-48 |
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Coolant |
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3 years |
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• |
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2-49 |
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Radiator hose and O-ring |
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3 years |
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• |
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2-52 |
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Engine oil # |
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year |
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• |
• |
• |
• |
• |
2-53 |
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Oil filter |
|
year |
|
• |
• |
• |
• |
• |
2-53 |
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Brake hose and pipe |
|
4 years |
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• |
2-54 |
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Brake fluid |
|
2 years |
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• |
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• |
2-54 |
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Rubber parts of master cylinder and caliper |
4 years |
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• |
2-56 |
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Spark plug |
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• |
• |
• |
• |
2-60 |
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
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2-6 PERIODIC MAINTENANCE |
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Torque and Locking Agent
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.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1.)
R:Replacement Parts
S:Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).
SS:Apply silicone sealant.
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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Fuel System |
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Air Cleaner Element Cover Screws |
1.1 |
0.11 |
9.7 in·lb |
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Air Cleaner Housing Holder Clamp Screws |
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|
18 in·lb |
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2.0 |
0.20 |
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Air Cleaner Housing Mounting Bolts |
|
7.0 |
0.71 |
62 in·lb |
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Air Inlet Duct Mounting Bolts |
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|
7.0 |
0.71 |
62 in·lb |
L |
Bypass Screws |
|
|
0.2 |
0.02 |
17 in·lb |
|
Camshaft Position Sensor Bolt |
|
|
10 |
1.0 |
89 in·lb |
|
www.zxforums |
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Canister Bracket Mounting Bolt (M5) |
4.3 |
0 44 |
38 in·lb |
|
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Canister Bracket Mounting Scre |
s (M5) |
4.3 |
0 44 |
38 in·lb |
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|
Crankshaft Sensor Bolts |
|
|
6.0 |
0.61 |
53 in·lb |
L |
Delivery Pipe Mounting Screws |
|
|
5.0 |
0.51 |
44 in·lb |
|
Exhaust Butterfly Valve Actuator Mounting Bolts |
|
0.8 |
0.08 |
7 in·lb |
|
|
Exhaust Butterfly Valve Actuator Pulley Bolts |
|
5.0 |
0.51 |
44 in·lb |
|
|
Fuel Pump Bolts |
|
|
10 |
1.0 |
89 in·lb |
L, S |
Gear Position Switch Screws |
|
|
3.0 |
0.31 |
27 in·lb |
L |
Inlet Air Pressure Sensor Bracket Screws |
|
3.5 |
0.36 |
31 in·lb |
|
|
Separator Bracket Mounting Bolts |
|
7.0 |
0.71 |
62 in·lb |
|
|
Separator/Canister Hose Clamp Bolt |
|
7.0 |
0.71 |
62 in·lb |
|
|
Speed Sensor Bolt |
|
|
10 |
1.0 |
89 in·lb |
|
Throttle Body Assy Holder Bolts |
|
|
10 |
1.0 |
89 in·lb |
|
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
||
Vehicle-down Sensor Bolts |
|
|
6.0 |
0.61 |
53 in·lb |
|
Water Temperature Sensor |
|
|
25 |
2.5 |
18 |
SS |
Cooling System |
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|
Coolant By-pass Fitting Bolt |
|
|
9.0 |
0.92 |
80 in·lb |
L |
Coolant Drain Bolt (Cylinder) |
|
|
10 |
1.0 |
89 in·lb |
|
Coolant Drain Bolt (Water Pump) |
|
|
10 |
1.0 |
89 in·lb |
|
Coolant Reserve Tank Mounting Bolts |
|
7.0 |
0.71 |
62 in·lb |
|
|
Oil Cooler Mounting Bolts |
|
|
20 |
2.0 |
15 |
|
Thermostat Housing Cover Bolts |
|
|
6.0 |
0.61 |
53 in·lb |
|
Thermostat Housing Mounting Bolts |
|
10 |
1.0 |
89 in·lb |
|
|
Radiator Bracket Mounting Bolt |
|
|
7.0 |
0.71 |
62 in·lb |
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|||
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PERIODIC MAINTENANCE 2-7 |
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Torque and Locking Agent |
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Fastener |
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Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||
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|||
Radiator Lower Bolt |
|
7.0 |
0.71 |
62 in·lb |
|
Radiator Upper Bolt |
|
7.0 |
0.71 |
62 in·lb |
|
Water Hose Clamp Screws |
|
2.0 |
0.20 |
18 in·lb |
|
Water Hose Fitting Bolts |
|
10 |
1.0 |
89 in·lb |
|
Water Passage Plugs |
|
19.6 |
2.0 |
14 |
L |
Water Pump Cover Bolts |
|
10 |
1.0 |
89 in·lb |
|
Water Temperature Sensor |
|
25 |
2.5 |
18 |
SS |
Engine Top End |
|
|
|
|
|
Air Suction Valve Cover Bolts |
|
10 |
1.0 |
89 in·lb |
L |
Camshaft Cap Bolts |
|
12 |
1.2 |
106 in·lb |
S |
Camshaft Chain Tensioner Cap Bolt |
20 |
2.0 |
15 |
|
|
Camshaft Chain Tensioner Mounting Bolts |
10 |
1.0 |
89 in·lb |
|
|
Camshaft Position Sensor Bolt |
|
10 |
1.0 |
89 in·lb |
|
Cam Sprocket Mounting Bolts |
|
15 |
1.5 |
11 |
L |
Coolant Drain Plug (Cylinder) |
|
10 |
1.0 |
89 in·lb |
|
Cylinder Head Bolts (M6) |
|
12 |
1.2 |
106 in·lb |
|
Cylinder Head Bolts (M10 New Bolts) |
59 |
6.0 |
44 |
MO, S |
|
Cylinder Head Bolts (M10 Used Bolts) |
57 |
5.8 |
42 |
MO, S |
|
www.zxforums |
10 |
.com |
89 in·lb |
|
|
Cylinder Head Cover Bolts |
|
1.0 |
|
||
Exhaust Butterfly Valve Cable Adjuster L cknuts |
7.0 |
0.71 |
62 in·lb |
|
|
Exhaust Butterfly Valve Cable Locknuts |
7.0 |
0.71 |
62 in·lb |
|
|
Exhaust Pipe Manifold Mounting Bolts |
14 |
1.4 |
10 |
|
|
Front Camshaft Chain Guide Bolt (Upper) |
25 |
2.5 |
18 |
|
|
Front Camshaft Chain Guide Bolt (Lower) |
12 |
1.2 |
106 in·lb |
|
|
Front Exhaust Pipe Manifold Holder Nuts |
17 |
1.7 |
13 |
|
|
Idle Gear Cover Bolts |
|
10 |
1.0 |
89 in·lb |
|
Middle Exhaust Pipe Clamp Bolt |
|
17 |
1.7 |
13 |
|
Middle Exhaust Pipe Stay Bolt |
|
25 |
2.5 |
18 |
|
Muffler Body Assembly Nuts |
|
22 |
2.2 |
16 |
|
Muffler Body Cover Bolts |
|
7.0 |
0.71 |
62 in·lb |
|
Muffler Body Mounting Bolts |
|
25 |
2.5 |
18 |
|
Oxygen Sensors (Europe Models) |
|
25 |
2.5 |
18 |
|
Rear Exhaust Pipe Clamp Bolt |
|
17 |
1.7 |
13 |
|
Right Engine Bracket Bolts (Cylinder Head Side) |
10 |
1.0 |
89 in·lb |
L |
|
Spark Plugs |
|
13 |
1.3 |
115 in·lb |
|
Starter Clutch Bolt Cap |
|
– |
– |
– |
Hand-tighten |
Starter Clutch Cover Bolts (M6, L = 30 mm) |
10 |
1.0 |
89 in·lb |
|
|
Starter Clutch Cover Bolts (M6, L = 20 mm) |
10 |
1.0 |
89 in·lb |
|
|
Throttle Body Assy Holder Bolts |
|
10 |
1.0 |
89 in·lb |
S |
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
S |
|
Timing Inspection Cap |
|
– |
– |
– |
Hand-tighten |
Upper Camshaft Chain Guide Bolts |
|
12 |
1.2 |
106 in·lb |
S |
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19.6 |
2.0 |
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|
Water Passage Plugs |
|
14 |
L |
||
2-8 PERIODIC MAINTENANCE |
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|
||||
Torque and Locking Agent |
|
|
|
|
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Fastener |
|
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||
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|
|||
Clutch |
|
|
|
|
|
Clutch Cover Mounting Bolts |
|
10 |
1.0 |
89 in·lb |
S |
Clutch Hub Nut |
|
130 |
13.3 |
96 |
R |
Clutch Lever Clamp Bolts |
|
7.8 |
0.80 |
69 in·lb |
S |
Clutch Spring Bolts |
|
9.8 |
1.0 |
87 in·lb |
|
Oil Filler Plug |
|
– |
– |
– |
Hand-tighten |
Sub Clutch Hub Bolts |
|
25 |
2.5 |
18 |
L |
Engine Lubrication System |
|
|
|
|
|
Engine Oil Drain Bolt |
|
|
|
15 |
|
|
20 |
2.0 |
|
||
Oil Cooler Mounting Bolts |
|
20 |
2.0 |
15 |
L |
Oil Filter |
|
31 |
3.2 |
23 |
EO, R |
Oil Cooler/Oil Filter Case Mounting Bolts |
|
20 |
2.0 |
15 |
L |
Oil Filter Pipe |
|
35 |
3.6 |
26 |
L |
Oil Pan Bolts |
|
10 |
1.0 |
89 in·lb |
|
Oil Passage Plugs |
|
20 |
2.0 |
15 |
L |
Oil Pressure Relief Valve |
|
15 |
1.5 |
11 |
L |
Oil Pressure Switch |
|
15 |
1.5 |
11 |
SS |
Oil Pressure Switch Terminal Bolt |
|
1.5 |
0.15 |
13 in·lb |
G |
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10 |
.com |
|
||
Oil Pump Cover Bolts |
|
1.0 |
89 in·lb |
|
|
Oil Pump Gear Bolts |
|
10 |
1.0 |
89 in·lb |
L |
Engine Removal/Installation |
|
|
|
|
|
Adjusting Collar Locknut |
|
49 |
5.0 |
36 |
S |
Left Engine Bracket Bolts (M10, L = 30 mm) |
44 |
4.5 |
32 |
S |
|
Left Front Engine Mounting Bolt (M10, L = 42 mm) |
44 |
4.5 |
32 |
S |
|
Lower Engine Mounting Bolt |
|
9.8 |
1.0 |
87 in·lb |
S |
Lower Engine Mounting Nut |
|
44 |
4.5 |
32 |
S |
Middle Engine Mounting Bolt |
|
9.8 |
1.0 |
87 in·lb |
S |
Middle Engine Mounting Nut |
|
44 |
4.5 |
32 |
S |
Right Engine Bracket Bolt (M10, L = 35 mm) |
44 |
4.5 |
32 |
S |
|
Right Engine Bracket Bolts (M10, L = 30 mm) |
44 |
4.5 |
32 |
S |
|
Right Engine Bracket Bolts (Cylinder Head Side) |
10 |
1.0 |
89 in·lb |
L |
|
Right Front Engine Mounting Bolt (M10, L = 67 mm) |
44 |
4.5 |
32 |
S |
|
Crankshaft/Transmission |
|
|
|
|
|
Bearing Position Plate Screws |
|
5.0 |
0.51 |
44 in·lb |
L |
Breather Plate Bolts |
|
10 |
1.0 |
89 in·lb |
L |
Connecting Rod Bid End Bolts |
|
see Text |
← |
← |
MO |
Coolant Drain Plug (Cylinder) |
|
10 |
1.0 |
89 in·lb |
|
Crankcase Bolts (M9) |
|
39 |
4.0 |
29 |
MO, S |
Crankcase Bolts (M8) |
|
27 |
2.8 |
20 |
S |
Crankcase Bolts (M7, L = 85 mm) |
|
20 |
2.0 |
15 |
S |
Crankcase Bolts (M7, L = 50 mm) |
|
20 |
2.0 |
15 |
S |
Crankcase Bolts (M7, L = 32 mm) |
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20 |
2.0 |
15 |
S |
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12 |
1.2 |
www.zxforums.com |
||
Crankcase Bolts (M6, L = 45 mm) |
|
106 in·lb |
S |
||
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