Kawasaki ZX1200 (2002-2004) User Manual [ru]
Ninja ZX-12R
Motorcycle
Service Manual
Quick R eference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Troubleshooting 17 j
Ninja ZX-12R
Motorcycle
Service Manual
All r ights 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 Assurance Department/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.
© 2002 Kawasaki Heavy Industries, Ltd. Fourth Edition (1) : Mar. 5, 2004 (K)
LIST OF ABBREVIATIONS
A
ABDC after bottom dead center
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
ampere(s)
lb
m
pound(s)
meter(s)
Read OWNER’S MANUAL before operating.
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 cranckcase vapors into the atmosphere. Instead, the
vapors are routed through an oil separator to the inlet side of the engine. W hile 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 in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, 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 referred to as the Act’s " tampering provisions."
"Sec. 203(a) The following 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 f leet of m otor 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 a s follows :
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in o rder to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
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 stan-
dards.
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,
THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING
$10,000 PER VIOLATION.
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.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful t o the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic M aintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki Mo-
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divited into its
major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive
Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution sym bol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This m anual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......................... 1-9
Technical Information – Monocoque Frame . .......................................................................... 1-12
Technical Information – Spark Plug ........................................................................................ 1-13
Technical Information – Immobilizer System (ZX1200-B3)..................................................... 1-14
Torque and Locking Agent...................................................................................................... 1-17
Special Tools and Sealant ...................................................................................................... 1-22
Cable, W ire, and Hose Routing (ZX1200-B1/B2) ................................................................... 1-29
Cable, W ire, and Hose Routing (ZX1200-B3) ........................................................................ 1-46
Unit Conversion Table ............................................................................................................ 1-60
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations,
a certain amount of basic knowledge is also required for successful work.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Cables
Disconnect the ground (–) cable f rom the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the leads from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery.
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. But if this Service
Manual has installation or assembly procedures, follow them. Note parts locations and cable,
lead, and hose routing during removal or disassembly so they can be installed or assembled in
the same way. It is preferable to mark and record the locations and routing as much as possible.
(4) 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 evenly in a cross pattern. This is to avoid
distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. Where
there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must
be tightened in the order and method indicated.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what m ay be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in order
to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.
(10)Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of non-permanent locking agent commonly available in North America
is Loctite Lock’n Seal (Blue).
(11) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.
GENERAL INFORMATION 1-3
Before Servicing
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace
any ball or needle bearings that were removed with new ones, as removal generally damages
bearings. Install bearings with the marked side facing out applying pressure evenly with a suitable
driver. Only press on the race that forms the press fit with the base component to avoid damaging
the bearings. This prevents severe stress on the balls or needles and races, and prevent races
and balls or needles from being dented. Press a ball bearing until it stops at the stopper in the
hole or on the shaft.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks
facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with
the side of seal, until the face of the seal is even w ith the end of the hole. Before a shaft passes
through a seal, apply little high temperature grease on the lips to reduce rubber to metal friction.
(14)Circlip, Retaining Ring, and Cotter Pin
Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as
removal weakens and deforms them. When installing circlips and retaining rings, take care to
compress or expand them only enough to install them and no more.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever
is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don’t use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS
oil in the assembly of certain engine and chassis parts. The molybdenum disulfide oil is a mixture
of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1), which can be made in
your work shop. Always check manufacturer recommendations before using such special lubricants.
(16)Electrical Leads
All the electrical leads are either single-color or two-color and, with only a few exceptions, must
be connected to leads of the same color. On any of the two-color leads there is a greater amount
of one color and a lesser amount of a second color, so a two-color lead is identified by first the
primary color and then the secondary color. For example, a yellow lead with thin red stripes is
referred to as a "yellow/red" lead; it would be a "red/yellow" lead if the colors were reversed to
make red the main color .
2) and molybdenum disulfide
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.
1-4 GENERAL INFORMATION
Before Servicing
(18)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19)Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
(20)Instrument
Use a meter that has enough accuracy for an accurate measurement.
Read the manufacturer’s instructions thoroughly before using the meter.
Incorrect values may lead to improper adjustments.
Model Identification
ZX1200-B1 Left Side View
GENERAL INFORMATION 1-5
ZX1200-B1 Right Side View
1-6 GENERAL INFORMATION
General Specifications
Items ZX1200-B1 ∼ B3
Dimensions
Overall Length 2 085 mm (82.09 in.)
Overall Width 740 mm (29.13 in.)
Overall Height 1 200 mm (47.24 in.)
Wheelbase 1 450 mm (57.09 in.)
Road Clearance 120 mm (4.72 in.)
Seat Height 820 mm (32.28 in.)
Dry Mass 210 kg (463 lb)
Curb Mass:
Front 125 kg (276 lb)
Rear 121 kg (267 lb)
Fuel Tank Capacity 19.0 L (5.0 US gal)
Performance
Minimum Turning Radius 3.0 m (9.8 ft)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Liquid-cooled
Bore and Stroke 83.0 × 55.4 mm (3.27 × 2.18 in.)
Displacement 1 199 mL (73.16 cu in.)
Compression Ratio 12.2
Maximum Horsepower (H) 131 kW (178 PS) @9 500 r/min (rpm),
(AU) ZX1200-B1/B2: 130 kW (177 PS) @10 500 r/min (rpm),
(AU) ZX1200-B3: 131 kW (178 PS) @10 500 r/min (rpm),
(HR) 78.2 kW (106.4 PS) @8 500 r/min (rpm),
(MY) ZX1200-B1/B2: 131 kW (178 PS) @ 9 500 r/min ( rpm),
(MY) ZX1200-B3: 128 kW (174 PS) @9 500 r/min (rpm)
(US), (CA) – – –
Maximum Torque (H, AU) 134 N·m (13.7 kgf·m, 99 ft·lb) @7 500 r/min (rpm),
(MY) ZX1200-B1/B2: 134 N·m (13.7 kgf·m, 99 ft·lb) @7 500
r/min (rpm),
(MY) ZX1200-B3: 130 N·m ( 13.3 kgf·m, 96 ft·lb) @7 500 r/min
(rpm),
(HR) 111 N·m (11.3 kgf·m, 82 ft·lb) @5 000 r/min (rpm),
(US), (CA) – – –
Carburetion System FI (Fuel Injection), ZX1200-B1/B2: MIKUNI 46 EIS × 4
ZX1200-B3: KEIHIN ( 46 × 4)
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU)
Ignition Timing 10° BTDC @1 000 r/min (rpm)
Spark Plugs NGK CR9EKPA
Cylinder Numbering Method Left to right, 1-2-3-4
Firing Order 1-2-4-3
GENERAL INFORMATION 1-7
General Specifications
Items ZX1200-B1 ∼ B3
Valve Timing:
Inlet:
Open 46° BTDC
Close 74° ABDC
Duration 300°
Exhaust:
Open 69° BBDC
Close 45° ATDC
Duration 294°
Lubrication System Forced lubrication (wet sump with cooler)
Engine Oil:
Grade API SE, SF or SG
API SH or SJ with JASO MA
Viscosity
Capacity 3.6 L (3.8 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 1.596 (83/52)
Clutch Type Wet, multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.429 (34/14)
2nd
3rd
4th
5th 1.130 (26/23)
6th 1.033 (31/30)
Final Drive System:
Type Chain drive
Reduction Ratio 2.556 (46/18)
Overall Drive Ratio 4.215 @Top gear
Frame
Type Press backbone
Caster (Rake Angle) 23.5°
Trail
Front Tire:
Type Tubeless
Size 120/70 ZR17 M/C (58W)
Rear Tire:
Type Tubeless
Size 200/50 ZR17 M/C (75W)
SAE 10W-40
1.824 (31/17)
1.440 (36/25)
1.250 (30/24)
98 mm (3.86 in.)
1-8 GENERAL INFORMATION
General Specifications
Items ZX1200-B1 ∼ B3
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 140 mm (5.51 in.)
Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen) × 2
Tail/Brake Light 12 V 5/21 W × 2
Alternator:
Type Three-phase AC
Rated Output 31 A/14 V @ 5 000 r/min (rpm)
Telescopic fork (upside-down)
120 mm (4.72 in.)
Specifications are subject to change without notice, and may not apply to every country.
AU: Australian Model
US: U.S.A. Model
CA: Canadian Model
MY: Malaysian Model
HR: WVTA Approval Model, Honeycomb Catalytic Converter (Restricted Power)
H: WVTA Approval Model, Honeycomb Catalytic Converter
GENERAL INFORMATION 1-9
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYS TEM
Since the emission regulations become more severe, Kawasaki has adopted a type of simplified
KAWASAKI LOW EX HAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection system, according to each regulation of different countries.
The muffler with built-in catalyst has the same durability as the conventional muffler, however, do
not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without
ignition damages catalyst.
Refer to the ZX900E Service Manual (Part No. 99924-1255) for more information about the KLEEN
(theory, maintenance, and handling precautions), including the secondary air injection system.
Honeycomb Type Catalytic Converter
The converter is a three-way catalytic converter, and its surface is covered with alumina upon which
○
platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-
ing a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter. The
honeycomb structure is convenient for the catalytic converter because it has a large surface area
but small size to react effectively and has low exhaust resistance. In addition, its inherent strength
helps resist vibration, and has simple structure welded directly on the silencer.
Generally, the temperature of t he exhaust gas must be higher than activation temperature, so the
○
converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is
still high. And, the converters will be activated even under low load conditions.
After the exhaust gas is diluted with the secondary air injection, the catalytic converter works well
○
because of rich oxygen to reduce CO, HC, and NO
emission within regulation.
This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,
○
and NO
x than the pipe type catalytic converter because of its more and denser catalysts.
x. Accordingly, we can keep the exhaust gas
1. Manifold
2. Silencer
3. Honeycomb Type Catalyst
4. Non-Catalyst
5. Mark for Manifold
6. Mark for Silencer
1-10 GENERAL INFORMATION
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM
Exhaust System (ZX1200-B1/B2)
78.2: Horsepower 78.2 kW (106.3 ps)
Full: Full Power
H: Honeycomb Type Catalyst
UK: United Kingdom Model
GENERAL INFORMATION 1-11
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYS TEM
Exhaust System (ZX1200-B3)
78.2: Horsepower 78.2 kW (106.3 ps)
Full: Full Power
H: Honeycomb Type Catalyst
UK: United Kingdom Model
1-12 GENERAL INFORMATION
Technical Information – Monocoque Frame
Why a monocoque? Like all breakthrough innovations, the choice appears quite obvious after the
fact. When large-section aluminium spars are wrapped around an already wide, large-displacement
in-line Four engine, the resulting package must of necessity be wide. The ZX-12R’s all-aluminium box
-section monocoque chassis eliminates these perimeter spars in favor of a large box section running
over the top of the engine.
This frame design surpasses the levels of chassis stiffness and strength associated with conventional aluminium twin-beam frames, but with considerably less breadth. Without the twin beams or
other frame elements running around the side of the engine, the fairing can be much narrower, resulting in a much slimmer overall package and significantly better aerodynamics. Further, in a radical
departure, the hollow structure also doubles as an airbox for the Ram Air system, eliminating the need
for a space-consuming, conventional airbox.
And ultimately, it is the synergy of combining a compact, massively powerful engine with this super
stiff and slim chassis structure that explains much of the ZX-12R’s superlative high-speed performance.
All-new frame-integrated Ram Air system adds consider-
•
able horsepower in the higher speed ranges.
Monocoque frame allows for the use of perfectly straight,
•
highly efficient inlet ports.
Using the frame backbone as an airbox saves space and
•
creates a very efficient airbox.
Battery mounts inside the frame and the battery cover is
•
a structural element.
Revolutionary new all-aluminum monocoque frame for
•
high rigidity and lightweight.
Huge box section and heat-freated cast steering
•
head/swingarm pivot areas realize an extremely
stiff structure and contribute to the ZX-12R’s superb
high-speed stability and nimble, s uper sport handling
performance.
By eliminating the dual large-section beams of conven-
•
tional aluminum frames, this frame design makes possi-
ble a much narrower and more compact overall package
and greatly improves aerodynamics.
Technical Information – Spark Plug
ZX1200-B1 is equipped with the Kawasaki recommended
spark plug (NGK CR9EKPA). By using the Kawasaki recommended spark plug, the i dling stability, the fuel consumption improvement, and the maintenance free spark plug is
planed.
This spark plug is calculated 3 or 4 times as durable as
the usual one (NGK CR9EK).
Feature
1. This spark plug is more superior t o the usual one with
the ignition for the ignition point protruding.
2. Further, this spark plug is superior to the usual one with
the endurance for the Pt alloy [A] covering around the
center electrode and for the opposed area improvement
of the side electrodes.
Specification
1. Standard Spark Plug CR9EKPA, two side electrodes,
M10 threads
2. Hotter Spark Plug CR8EKPA, two side electrodes, M10
threads
GENERAL INFORMATION 1-13
CAUTION
Use only the recommender spark plug. Do not use
other spark plug, even though it may fit, because it
could cause the engine failure of the idling stability,
etc.
1-14 GENERAL INFORMATION
Technical Information – Immobilizer System (ZX1200-B3)
Overview
This system provides a theft proof device by means of matching a code between the inbuilt key
transponder and the ECU (Electronic Control Unit). If t his code does not match, the fuel pump, injectors, ignition system and sub-throttle valve actuator will not operate and the engine will not start.
Related Parts and Function
1. Transponder (Inside Keys)
2. Master Key
3. User Keys
4. FI Indicator Light
5. Immobilizer Antenna
6. Ignition Switch
7. Immobilizer Amplifier
Master Key (1 piece)
The master key (colored red) has an inbuilt transponder, containing a master key code. These
codes are unique to each key. This code and an additional two user key codes must be registered
in the ECU for the system to operate. The master key is necessary when registering user keys and
should not be used as the main key to start the motorcycle except in emergencies (loss or damage of
user keys). It should be kept in a safe place.
8. Starter Relay
9. Battery
10. Electronic Control Unit (ECU)
11. J unction Box
12. Fuse Box
13. Immobilizer/Kawasaki Diagnostic System
Connector
GENERAL INFORMATION 1-15
Technical Information – Immobilizer System (ZX1200-B3)
Transponder (in Keys)
The transponder (made by Texas Instruments, Inc.) has an integrated circuit with a unique code
that also calculates data sent by the ECU. When the ignition switch is turned ON, the transponder
is excited by the radio wave transmitted from the antenna and then transmits a unique code to the
antenna.
User Key (2 pieces)
The user keys (colored black) should be used when riding the motorcycle. These keys have unique
codes which differ from the master key. Up to a maximum of five user key codes can be stored by
the ECU at any one time. These codes can not be registered to the ECU without firstly registering the
master key c ode.
Antenna
The antenna transmits a radio wave to excite the transponder, receives the code from the t ransponder and then transmits the code to the ECU through the amplifier.
Ignition Switch
The ignition switch turns the main circuit ON and OFF.
Amplifier
The amplifier (which is approximately the same size as a match box), amplifies signals from the
antenna and the ECU.
ECU
The ECU has the capacity to store a maximum of six key code memories (one master and five user
keys). The owner can have a total of five user keys at any one time. The master key memory can not
be rewritten after initial registration, whereas the user key memories can be rewritten as necessary.
When the ECU communicates with the transponder, a cipher generator changes the code every time
it is used to avoid cloning.
FI Indicator Light
The condition or the failure of the immobilizer system is indicated by various patterns of the FI indicator light blinking.
1. Immobilizer Amplifier
2. Immobilizer Antenna
3. Ignition Switch
4. Meter Unit
5. FI Indicator Light
6. Ignition Fuse 10 A
7. ECU Fuse 15 A
8. Junction Box
9. ECU Main Relay
10. Starter Relay
11. Main Fuse 30 A
12. Battery 12 V 12 Ah
13. Immobilizer/Kawasaki Diagnostic System
Connector
14. Electronic Control Unit (ECU)
1-16 GENERAL INFORMATION
Technical Information – Immobilizer System (ZX1200-B3)
Sequence of Operation
1. Turn ON the ignition switch, the ECU, amplifier and antenna start working, and the meter assembly
FI indicator lights up.
2. The transponder excited by radio waves transmitted from the antenna receives the ciphered code
from the ECU.
3. The transponder transmits the calculated result from the key’s unique code to the ECU.
4. The ECU com pares this with its memorized code, and if they match the engine can start. At this
time, the FI indicator in the meter assembly is switched off.
GENERAL INFORMATION 1-17
Torque and Lo cking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
O: Apply oil to the threads and seating surface.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant.
St: Stake the fasteners to prevent loosening.
R: Replacement Parts
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Tor qu e
dia.(mm)
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11. 5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
N·m
kgf·m ft·lb
Fastener
N·m kgf·m ft·lb
Fuel System (DFI)
Fuel Level Sensor Bolts 6.9 0.70 61 in·lb L
Fuel Pump Bolts 6.9 0.70 61 in·lb L, S
Fuel Hose Clamp Bolts 1.5 0.15 13 in·lb
Inlet Air Pressure Sensor Bolt 12 1.2 106 in·lb
Inlet Air Pressure Sensor Bracket Nut 12 1.2 106 in·lb
Inlet Air Temperature Sensor 7.8 0.80 69 in·lb
Atmospheric Pressure Sensor Bolts 12 1.2 106 in·lb
Gear Position Switch Screws 4.0 0.40 35 in·lb L
Crankshaft Sensor Bolts 6.0 0.60 53 in·lb
Camshaft Position Sensor Bolt 12 1.2 106 in·lb
Crankshaft Position Sensor Rotor Bolt 12 1.2 106 in·lb L
Delivery Pipe Screws (ZX1200-B1/B2) 5.0 0.50 44 in·lb
Delivery Pipe Screws (ZX1200-B3) 3.4 0.35 30 in·lb
Nipple Assy Screws 3.5 0.35 31 in·lb
Cooling System
Coolant Hose Clamp Screws 2.0 0.20 18 in·lb
Torque
Remarks
1-18 GENERAL INFORMATION
Torque and Locki ng Agent
Fastener
Coolant Fitting Nozzle (ZX1200-B1/B2)
Coolant Drain Plug (Water Pump)
Coolant Drain Plug (Cylinder) 10 1.0 89 in·lb
Radiator Fan Switch 18 1.8 13
Water Temperature Sensor 25 2.5 18 SS
Water Pum p Impeller Bolt 10 1.0 89 in·lb
Water Pum p Cover Bolts 12 1.2 106 in·lb
Coolant Pipe Bolt 12 1.2 106 in·lb
Thermostat Housing Cover Bolts 8.0 0.80 71 in·lb L
Fitting Bolts 12 1.2 106 in·lb
Engine Top End
Spark Plugs 13 1.3 115 in·lb
Air Suction Valve Cover Bolts 12 1.2 106 in·lb
Baffle Plate Bolts 10 1.0 89 in·lb
Cylinder Head Cover Bolts 10 1.0 89 in·lb
Crankshaft Sensor Cover Bolts 15 1.5 11 L
Camshaft Chain Tensioner Mounting Bolts 10 1.0 89 in·lb L
Camshaft Cap Bolts 12 1.2 106 in·lb
Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb
Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18
Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 in·lb
Rear Camshaft Chain Guide Bolt 25 2.5 18
Camshaft Position Sensor Bolt 12 1.2 106 in·lb
Camshaft Position Sensor Rotor Bolt 12 1.2 106 in·lb L
Cylinder Head Bolts: M11 First Tighten 23 2.3 17 MO, S
Cylinder Head Bolts: M11 Final Tighten 59 6.0 44 MO, S
Cylinder Head Bolts: M7 20 2.0 15 S
Cylinder Head Jacket Plugs 22 2.2 16 L
Throttle Body Holder Bolts 12 1.2 106 in·lb
Muffler Body Connection Nuts 34 3.5 25
Guard Mounting Bolts 12 1.2 106 in·lb
Exhaust Pipe Holder Studs – – – (Stopped)
Clutch
Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S
Clutch Cover Bolts 15 1.5 11 L(2)
Clutch Cover Damper Plate Bolts 7.0 0.70 62 in·lb L
Clutch Spring Bolts 8.8 0.90 78 in·lb
Clutch Hub Nut 135 14 100 R
Engine Lubrication System
Oil Level Gauge Bolts
N·m
12 1.2 106 in·lb L
12 1.2 106 in·lb
12 1.2 106 in·lb
Torque
Remarks
kgf·m ft·lb
(Washer)
(Washer)
Torque and Lo cking Agent
GENERAL INFORMATION 1-19
Fastener
Oil Filler Plug 1.5 or
Engine Oil Drain Plug 20 2.0 15
Oil Filter (Cartridge Type) 31 3.2 23 EO, R
Oil Cooler Passage Bolt 78 7.8 58 EO
Oil Cooler Mounting Bolts 25 2.5 18 L
Oil Pan Bolts 15 1.5 11 L(1)
Oil Pipe Holder Bolts 12 1.2 106 in·lb L
Oil Pressure Relief Valve 15 1.5 11 L
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Screw 1.5 0.15 13 in·lb
Water Pump Impeller Bolt 10 1.0 89 in·lb
Engine Removal/Installation
Engine Mounting Bolts and Nuts: M12 59 6.0 44
Engine Mounting Bolts and Nuts: M8 25 2.5 18
Upper Engine Mounting Bracket Bolt: M12 59 6.0 44
Lower Engine Mounting Bracket Bolt: M10 44 4.5 32
Adjusting Collars 25 2.5 18
Crankshaft/Transmission
Breather Plate Bolts 10 1.0 89 in·lb L
Breather Tube Bracket Bolts 12 1.2 106 in·lb
Crankcase Bolts: M10 50 5.0 37 MO, S
Upper Crankcase Bolts: M8, L85
Upper Crankcase Bolts: M7
Lower Crankcase Bolts: M8, L99
Lower Crankcase Bolts: M7 20 2.0 15 S
Oil Passage Plugs (Each Side) 20 2.0 15 L
Connecting Rod Big End Nuts in the text ← ← ←
Timing Rotor Bolt 39 4.0 29
Starter Torque Limiter Cover Bolts 12 1.2 106 in·lb L
Oil Pressure Switch 15 1.5 11 SS
Gear Positioning Lever Bolt 10 1.0 89 in·lb L
Shift Shaft Return Spring Pin (Bolt) 30 3.0 22 L
Speed Sensor Bolt 12 1.2 106 in·lb L
Shift Drum Bearing Holder Bolt 12 1.2 106 in·lb L
Shift Drum Bearing Holder Screw 5.4 0.55 48 in·lb L
Shift Drum Cam Bolt 12 1.2 106 in·lb L
Balancer Shaft Clamp Lever Bolt 25 2.5 18 L
Balancer Shaft Clamp Bolt 12 1.2 106 in·lb
Oil Pipe Holder Bolts (Crankshaft Pipe) 12 1.2 106 in·lb L
Oil Pipe Holder Bolt (Transmission Pipe)
Oil Nozzle
N·m kgf·m ft·lb
Hand
-Tight
28 2.8 21
25 2.5 18
23 2.3 17
12 1.2 106 in·lb
2.5 0.25 22 in·lb
Torque
0.15 or
Hand
-Tight
Remarks
13 in·lb
or Hand
-Tight
S
S
S
St
1-20 GENERAL INFORMATION
Torque and Locki ng Agent
Fastener
Starter Clutch Shaft Bolt
Starter Clutch Shaft Plate Bolt
Wheels/Tires
Front Axle Clamp Bolts 20 2.0 15 AL
Front Axle Nut 125 13 92
Rear Axle Nut 125 13 92
Rear Sprocket Nuts 59 6.0 44
Air Valve Cap 0.15 0.015 1.3 in·lb
Final Drive
Engine Sprocket Nut 127 13 94 MO
Engine Sprocket Cover Bolts 12 1.2 106 in·lb
Chain Guide Bolt 12 1.2 106 in·lb L
Rear Sprocket Nuts 59 6.0 44
Rear Axle Nut 125 13 92
Brakes
Bleed Valves 7.8 0.80 69 in·lb
Brake Hose Banjo Bolts 25 2.5 18
Brake Lever Pivot Bolt 1.2 0.12 11 in·lb Si
Brake Lever Pivot Bolt Locknut 6.0 0.60 52 in·lb
Front Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Brake Light Switch Screw s 1.2 0.12 11 in·lb
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Front Brake Pad Spring Bolts (ZX1200-B1/B2) 3.0 0.30 27 in·lb
Front Caliper Mounting Bolts
Front Caliper Assembly Bolts
Brake Disc Mounting Bolts 27 2.8 20 L
Front Brake Pad Pins (ZX1200-B3) 15 1.5 11
Rear Caliper Mounting Bolts 25 2.5 18
Rear Caliper Assembly Bolts 30 3.0 22
Brake Pedal Mounting Bolt 8.8 0.90 78 in·lb
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Master Cylinder Push Rod Locknut 18 1.8 13
Suspension
Front Fork Clamp Bolts (Upper) 20 2.0 15
Front Fork Clamp Bolts (Lower) 20 2.0 15 AL
Front Fork Top Plugs 23 2.3 17
Piston Rod Nut 28 2.8 21
Front Fork Bottom Allen Bolts 40 4.0 30 L
Front Axle Clamp Bolts 20 2.0 15 AL
Rear Shock Absorber Bracket Nut 59 6.0 44
Rear Shock Absorber Nuts (Upper and Lower) 34 3.5 25
Swingarm Pivot Shaft Nut
Swingarm Pivot Shaft Lock Nut
N·m
25 2.5 18 L
12 1.2 106 in·lb L
34 3.5 25
21 2.1 15
125 13 92
98 10 72
Torque
Remarks
kgf·m ft·lb
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