Complete service repair manual with Electrical Wiring Diagrams for Kawasaki Motorcycles ZX-6R, ZX-6RR, ZX-7R(R), ZX-9R, ZX-10, ZX-10R, ZX-12R, ZX-14, ZX600, ZX750, ZX900, ZX1000, ZX1100, ZZ-R250, ZZ-R1200, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Kawasaki Motorcycles ZX-6R, ZX-6RR, ZX-7R(R), ZX-9R, ZX-10, ZX-10R, ZX-12R, ZX-14, ZX600, ZX750, ZX900, ZX1000, ZX1100, ZZ-R250, ZZ-R1200 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Kawasaki Motorcycle Service Repair Manual ’00 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’00 ZX-12R (DE).pdf
Kawasaki Motorcycle Service Repair Manual ’00 ZX-12R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’02-’04 ZX-12R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’02-’05 ZZ-R1200.pdf
Kawasaki Motorcycle Service Repair Manual ’03 ZX-6R(R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’03 ZX-6R(R) (IT).pdf
Kawasaki Motorcycle Service Repair Manual ’04-’05 ZZ-R250.pdf
Kawasaki Motorcycle Service Repair Manual ’04 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’05-’06 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’05-’06 ZX-6RR (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’05 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’06-’07 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’06 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’06 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’07-’08 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’07 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’08-’11 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’09 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’11 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’83-’97 ZX900-1000-1100 Ninja (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’84-’90 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’84 ZX-9R (DE).pdf
Kawasaki Motorcycle Service Repair Manual ’85-’97 ZX600 & 750 Fours (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’88-’90 ZX-10 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’90-’00 ZX600 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’90 ZXR400 (DE).pdf
Kawasaki Motorcycle Service Repair Manual ’93-’01 ZX-11 (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’94-’97 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’95-’02 ZX600 & 636 (ZX-6R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’96-’99 ZX-7R(R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’96 ZX-7R(R) (DE).pdf
Kawasaki Motorcycle Service Repair Manual ’98-’99 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual ’98 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual Assembly & Preparation ZX-6R.pdf
Kawasaki Motorcycle Service Repair Manual ZXR400 (ZX400H2).pdf
Kawasaki Motorcycle ZZR250 1990 – 1996 Repair Manual Supplement.pdf
Kawasaki Motorcycle Racing Kit Manual ’05 ZX-6RR.pdf
Kawasaki Motorcycle Service Parts Catalog ’05 ZX-6R.pdf
Kawasaki Motorcycle Service Parts Catalog ’91 GPX600R (ZX600-C4).pdf
PRODUCT DETAILS:
Total Pages: 2,122 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Kawasaki Motorcycle Racing Kit Manual '05 ZX-6RR…3
Kawasaki Motorcycle Service Parts Catalog '05 ZX-6R…66
AIR CLEANER…67
AIR DUCT…68
BRAKE PEDAL/TORQUE LINK…69
CABLES…70
CAMSHAFT(S)/TENSIONER…71
CHAIN COVER…72
CHASSIS ELECTRICAL EQUIPMENT…73
CLUTCH…74
COWLING…75
COWLING LOWERS…76
CRANKCASE…77
CRANKCASE BOLT PATTERN…78
CRANKSHAFT…79
CYLINDER HEAD…80
CYLINDER HEAD COVER…81
CYLINDER/PISTON(S)…82
DECALS (BLUE)…83
DECALS (GREEN)…84
DECALS (RED)…85
DECALS (TITANIUM)…86
ENGINE COVER(S)…87
ENGINE MOUNT…88
FOOTRESTS…89
FRAME…90
FRAME FITTINGS (FRONT)…91
FRAME FITTINGS (REAR)…92
FRONT BRAKE…93
FRONT FENDER(S)…94
FRONT FORK…95
FRONT MASTER CYLINDER…96
FRONT WHEEL…97
FUEL EVAPORATIVE SYSTEM (CA)…98
FUEL INJECTION…99
FUEL PUMP…100
FUEL TANK…101
GEAR CHANGE DRUM/SHIFT FORK(S)…102
GEAR CHANGE MECHANISM…103
GENERATOR…104
HANDLEBAR…105
HEADLIGHT(S)…106
IGNITION SWITCH/LOCKS/REFLECTORS…107
IGNITION SYSTEM…108
LABELS…109
METER(S)…110
MUFFLER(S)…111
OIL COOLER…112
OIL PAN…113
OIL PUMP/OIL FILTER…114
OWNER'S TOOLS…115
PUBLICATIONS…116
RADIATOR…117
REAR BRAKE…118
REAR FENDER(S)…119
REAR MASTER CYLINDER…120
REAR SUSPENSION…121
REAR WHEEL/CHAIN…122
SEAT…123
SHOCK ABSORBER(S)…124
SIDE COVERS…125
STAND(S)…126
STARTER MOTOR…127
SWINGARM…128
TAILLIGHT(S)…129
THROTTLE…130
TIRES…131
TOP FEED INJECTER…132
TRANSMISSION…133
TURN SIGNALS…134
VALVE(S)…135
WATER PIPE…136
…
Kawasaki Motorcycle Service Repair Manual '00 ZX-12R (EN)…689
Forward Ch-0…689
General Info Ch-1…697
Fuel Injection Ch-2…735
Cooling System Ch-3…830
Engine Top End Ch-4…850
Clutch Ch-5…885
Engine Lube System Ch-6…899
Engine Removal Ch-7…913
Crankshaft/Tranny Ch-8…919
Wheels/Tires Ch-9…950
Final Drive Ch-10…964
Brakes Ch-11…975
Suspension Ch12…996
Steering Ch13…1017
Electrical System Ch15…1041
Appendix Ch16…1112
Kawasaki Motorcycle Service Repair Manual '00 ZX-6R (EN)…1123
Cover…1123
Table of Contents…1124
Foreward…1129
1- General Info…1131
2- Fuel System…1171
3- Cooling System…1195
4- Engine Top End…1211
5- Clutch…1245
6- Engine Lube System…1255
7- Engine Removal/ Installation…1267
8- Crankshaft/ Transmission…1273
9- Wheels/ Tires…1295
10- Final Drive…1307
11- Brakes…1317
12- Suspension…1337
13- Steering…1356
14- Frame…1366
15- Electrical System…1376
16- Appendix…1444
Kawasaki Motorcycle Service Repair Manual '02-'04 ZX-12R (EN)…1455
SM_ZX1200-B1B2B3_English_eBook…0
SM_ZX1200-B1B2B3_English_eBook…0
tables…1455
LIST OF ABBREVIATIONS…1460
Basic Torque for General Fasteners…1481
Units of Mass:…1524
Units of Volume:…1524
Units of Force:…1524
Units of Length:…1524
Units of Torque:…1524
Units of Pressure:…1524
Units of Speed:…1524
Units of Power:…1524
Throttle Grip Free Play…1531
Idle Speed…1532
Engine Vacuum…1533
Engine Vacuum…1535
Main Throttle Sensor Output Voltage…1536
Water and Coolant Mixture Ratio (Recommended)…1541
Valve Clearance…1542
Clutch Lever Free Play…1546
Engine Oil…1547
Tread Depth…1548
Chain Slack…1549
Rollers Distance…1551
Drive Chain 20-link Length…1551
Recommended Disc Brake Fluid…1553
Pad Lining Thickness…1554
Pad Lining Thickness…1555
Brake Light Timing…1555
Fork Oil…1558
Oil Level (fully compressed, without spring)…1559
Fork Oil…1563
Oil Level (fully compressed, without spring)…1564
Choke Cable Free Play…1588
Sample Diagnosis Sheet…1619
Engine Doesn't Start, Starting Difficulty…1621
Poor Running at Low Speed…1623
Poor Running or No Power at High Speed…1627
Throttle Sensor Input Voltage…1639
Throttle Sensor Input Voltage…1640
Idle Speed…1640
Throttle Sensor Output Voltage…1640
Throttle Sensor Output Voltage…1641
Throttle Sensor Resistance…1642
Main Throttle Sensor Input Voltage…1644
Wiring Connection…1644
Idle Speed…1645
Main Throttle Sensor Output Voltage…1645
Wiring Connection…1645
Main Throttle Sensor Resistance…1646
Inlet Air Pressure Sensor Input Voltage…1648
Inlet Air Pressure Sensor Input Voltage…1649
Inlet Air Pressure Sensor Output Voltage…1649
Inlet Air Pressure Sensor Output Voltage…1650
Digital Volt Meter Connections…1651
Inlet Air Temperature Sensor Output Voltage…1653
Inlet Air Temperature Sensor Resistance…1654
Water Temperature Sensor Output Voltage…1657
Atmospheric Pressure Sensor Input Voltage…1659
Atmospheric Pressure Sensor Input Voltage…1660
Atmospheric Pressure Sensor Output Voltage…1661
Atmospheric Pressure Sensor Output Voltage…1661
Gear Position Switch Input Voltage Connections to ECU ZX1200-B1/…1671
ZX1200-B3:…1671
Input Voltage at ECU (Except gear position)…1671
Input Voltage at ECU (Respective Gear Position)…1671
Gear Position Switch Input Voltage Connection to ECU…1672
Input Voltage at Gear Position Switch Connector (Except Gear Pos…1672
Input Voltage at Gear Position Switch Connector (Respective Gear…1672
Vehicle-down Sensor Power Source Voltage…1677
Vehicle-down Sensor Output Voltage…1677
Subthrottle Sensor Input Voltage…1680
Wiring Connection…1680
Main Throttle Sensor Output Voltage…1681
Wiring Connection…1681
Throttle Sensor Resistance…1682
Antenna Resistance…1683
Amplifier Input Voltage…1683
Input Voltage…1683
Injector Power Source Voltage at ECU…1685
Injector Power Source Voltage at Injector…1686
Injector Output Voltage at ECU…1687
Injector Output Voltage at Injector…1688
Injector Resistance…1690
Fuel Line Maximum Pressure…1691
Fuel Pump Relay Operating Voltage at ECU…1694
Fuel Pump Relay Operating Voltage at Relay Connector…1695
Relay Power Source Voltage…1696
Fuel Pump Relay Power Source Voltage…1696
Stick Coil Input Voltage at ECU…1700
Subthrottle Valve Actuator Resistance…1703
Subthrottle Valve Actuator Input Voltage…1704
Input Voltage at Actuator…1704
ECU Grounding Inspection…1706
ECU Power Source Inspection…1707
Testing Relay…1709
FI Indicator LED Light Check…1711
Fuel Pressure…1713
Amount of Fuel Flow…1715
Pump Operating Voltage at Pump…1718
Radiator Cap Relief Pressure…1736
Thermostat Valve Opening Temperature…1738
Vacuum Switch Valve Closing Pressure (Open → Close)…1749
Camshaft Journal, Camshaft Cap Clearance…1756
Camshaft Journal Diameter…1756
Camshaft Runout…1757
Cam Height…1757
Cylinder Compression…1758
Cylinder Head Warp…1761
Valve/Valve Guide Clearance (Wobble Method)…1763
Valve Seating Surface Outside Diameter…1764
Valve Seating Surface Width…1764
Cylinder Inside Diameter…1772
Piston Diameter…1772
Piston Ring/Groove Clearance…1772
Piston Ring Groove Width…1772
Piston Ring Thickness…1773
Piston Ring End Gap…1773
Clutch Plate Assembly Length…1787
Friction Plate Thickness…1788
Friction and Steel Plate Warp…1788
Clutch Spring Free Length…1788
Oil Pressure…1800
Connecting Rod Bend…1821
Connecting Rod Twist…1822
Connecting Rod Big End Side Clearance…1822
Connecting Rod Big End Bearing Insert/Crankpin Clearance…1822
Crankpin Diameter…1822
Crankpin Diameter Marks…1823
Connecting Rod Big End Bore Diameter Marks…1823
Crankshaft Main Bearing Insert/Journal Clearance…1824
Crankshaft Main Journal Diameter…1824
Crankshaft Main Journal Diameter Marks…1824
Crankcase Main Bearing Bore Diameter Marks…1825
Crankshaft Side Clearance…1825
Crankshaft Runout…1826
Shift Fork Ear Thickness…1840
Gear Groove Width…1840
Shift Fork Guide Pin Diameter…1840
Shift Drum Groove Width…1840
Rim Runout…1850
Axle Runout/100 mm (3.94 in.)…1851
Balance Weight…1851
Air Pressure (when cold)…1854
Rear Sprocket Warp…1865
Pedal Position [C]…1875
Length [A]…1875
Front Disc Thickness…1891
Rear Disc Thickness…1891
Disc Runout…1891
Rebound Damping Force Adjustment ZX1200-B1/B2…1901
ZX1200-B3…1901
Compression Damping Force Adjustment ZX1200-B1/B2…1902
ZX1200-B3…1902
Adjuster Protrusion (from top)…1902
Spring Action…1902
Spring Free Length…1906
Rebound Damping Force Adjustment…1907
Compression Damping Force Adjustment…1907
Spring Free Length…1908
Spring Preload Setting…1908
Spring Adjustment…1908
Battery Terminal Voltage…1963
Terminal Voltage: 11.5 ∼ less than 12.6 V…1963
Terminal Voltage: less than 11.5 V…1963
Table 1 Alternator Output Voltage…1969
Table 2 Stator Coil Resistance…1969
Rectifier Circuit Inspection…1970
Regulator/Rectifier Output Voltage…1972
Regulator/Rectifier Output Voltage…1973
Connections…1976
Crankshaft Sensor Peak Voltage…1977
Connections…1978
Camshaft Position Sensor Peak Voltage…1978
Stick Coil Winding Resistance…1979
Primary Lead Connection…1980
Stick Coil Primary Peak Voltage…1980
Connection…1981
Condition…1981
Interlock Operation Voltage…1981
Condition…1982
Condition…1982
Starter Motor Brush Length…1988
Commutator Diameter…1988
Testing Relay…1990
Testing Relay…1996
Testing Turn Signal Relay…1999
Air Switching Valve Resistance…2001
Testing Relay…2003
B1 Model…2009
B2/B3 Model…2009
Oil Pressure Warning Indicator Light (LED) [A]:…2011
FI Indicator Light (LED) [B]:…2011
User Key Indicator Flashes…2018
Fan Switch Resistance…2034
Water Temperature Sensor…2035
Fuel Level Sensor Resistance…2037
Fuse Circuit Inspection…2039
Relay Circuit Inspection (with the battery disconnected)…2040
Relay Circuit Inspection (with the battery connected)…2040
Diode Circuit Inspection…2040
toc…1455
Read OWNER'S MANUAL before operating…1460
EMISSION CONTROL INFORMATION…1461
1…1461
2…1461
3…1461
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…1462
Foreword…1463
General Information…1465
Before starting to service a motorcycle, careful reading of the …1466
Especially note the following:…1466
ZX1200-B1 Left Side View…1469
ZX1200-B1 Right Side View…1469
Since the emission regulations become more severe, Kawasaki has …1473
Honeycomb Type Catalytic Converter…1473
Exhaust System (ZX1200-B1/B2)…1474
Exhaust System (ZX1200-B3)…1475
Why a monocoque? Like all breakthrough innovations, the choice a…1476
ZX1200-B1 is equipped with the Kawasaki recommended spark plug (…1477
Overview…1478
Related Parts and Function…1478
Sequence of Operation…1480
The following tables list the tightening torque for the major fa…1481
Oil Pressure Gauge, 5 kgf/cm :…1486
Prefixes for Units:…1524
Units of Temperature:…1524
Periodic Maintenance…1525
The scheduled maintenance must be done in accordance with this c…1526
Special Tools -…1529
Fuel System (DFI)…1530
Fuel Hose and Connection Inspection…1530
Throttle Control System Inspection…1531
Idle Speed Inspection…1532
Engine Vacuum Synchronization Inspection…1533
Special Tool -…1534
Special Tool -…1535
Air Cleaner Element Cleaning (ZX1200-B1/B2)/ Element Replacement…1537
Evaporative Emission Control System Inspection (CAL)…1538
Cooling System…1539
Cooling Hose and Connection Inspection…1539
Torque -…1539
Coolant Change…1539
Torque -…1540
Engine Top End…1541
Air Suction Valve Inspection…1541
Valve Clearance Inspection…1542
INLET VALVE CLEARANCE ADJUSTMENT CHART…1544
Example:…1544
EXHAUST VALVE CLEARANCE ADJUSTMENT CHART…1545
Example:…1545
Clutch…1546
Clutch Adjust Inspection…1546
Engine Lubrication System…1547
Engine Oil Change…1547
Torque -…1547
Oil Filter Replace…1547
Special Tool -…1547
Torque -…1547
Wheels/Tires…1548
Tire Wear Inspection…1548
Final Drive…1549
Drive Chain Slack Inspection…1549
Torque -…1549
Drive Chain Wear Inspection…1550
Drive Chain Lubrication…1552
Brakes…1552
Brake Hose, Connection Inspection…1552
Brake Fluid Level Inspection…1553
Brake Fluid Change…1553
Torque -…1554
Torque -…1554
Front Brake Pad Wear Inspection…1554
Rear Brake Pad Wear Inspection…1555
Brake/Master Cylinder Cup and Dust Seal Replace…1555
Caliper Piston/Dust Seal Replace…1555
Front Brake Light Switch Inspection…1555
Rear Brake Light Switch Inspection/Adjustment…1555
Suspension…1556
Front Fork Oil Change…1556
Special Tool -…1556
Special Tool -…1558
Special Tool -…1559
Special Tool -…1559
Special Tool -…1560
Torque -…1560
Special Tool -…1561
Special Tool -…1563
Special Tool -…1564
Special Tool -…1564
Special Tool -…1565
Torque -…1566
Front Fork Oil Leak Inspection…1566
Rear Shock Absorber Oil Leak Inspection…1566
Swingarm Pivot Lubrication…1566
Unit-trak Linkage Lubrication…1567
Steering…1567
Steering Inspection…1567
Special Tool -…1567
Special Tool -…1568
Torque -…1568
Special Tool -…1568
Torque -…1568
Torque -…1568
Steering Stem Bearing Lubrication…1569
Electrical System…1569
Spark Plug Cleaning and Inspection…1569
Torque -…1569
General Lubrication…1569
Lubrication Perform…1569
Points: Lubricate with Grease…1570
Cables: Lubricate with Cable Lubricant…1570
Nut, Bolt, and Fastener Tightness…1571
Tightness Inspection…1571
Nut, Bolt and Fastener to be checked…1571
Fuel System (DFI)…1573
Special Tools -…1586
Sealant -…1586
Free Play Inspection…1587
Free Play Adjustment…1587
Cable Installation…1587
Cable Lubrication…1587
Free Play Inspection…1588
Free Play Adjustment…1588
Choke Cable Installation…1588
Cable Lubrication…1588
Idle Speed Inspection…1589
Throttle Bore Cleaning…1589
Synchronization Inspection…1589
Synchronization Adjustment…1589
Throttle Body Assy Removal…1589
Special Tool -…1590
Special Tool -…1591
Throttle Body Assy Installation…1592
Special Tool -…1592
Special Tool -…1593
Throttle Body Assy Disassembly…1594
ZX1200-B1/B2…1594
Throttle Body Assy Assembly…1596
Torque -…1596
Torque -…1596
Torque -…1597
Element Removal…1598
Element Installation…1598
Air Cleaner Element Cleaning and Inspection…1598
Oil Draining…1598
Air Inlet Duct Removal…1599
Air Inlet Duct Installation…1599
Front Duct Removal/Installation…1599
Fuel Tank Removal…1600
Fuel Tank Installation…1602
Torque -…1602
Fuel Tank Inspection…1602
Fuel Tank Cleaning…1603
DFI System Wiring Diagram (ZX1200-B1/B2)…1604
Terminal Numbers of ECU Connectors…1606
DFI System Wiring Diagram (ZX1200-B3)…1608
Terminal Numbers of ECU Connectors…1610
There are a number of important precautions that should be follo…1612
Torque -…1613
Torque -…1613
Outline…1614
Special Tool -…1614
Special Tool -…1615
DFI Diagnosis Flow Chart…1618
Inquiries to Rider…1618
DFI System Troubleshooting Guide…1621
Self-diagnosis Outline…1630
Self-diagnosis Function…1630
Self-diagnosis Procedures…1631
How to Read Service Codes…1633
How to Erase Service Codes…1634
Footnotes…1635
Backups…1636
The throttle sensor is a rotating variable resistor that change …1639
Throttle Sensor Removal/Adjustment…1639
Input Voltage Inspection…1639
Special Tool -…1639
Special Tool -…1640
Output Voltage Inspection…1640
Special Tool -…1640
Special Tool -…1641
Resistance Inspection…1642
Main Throttle Sensor Removal/Adjustment…1644
Input Voltage Inspection…1644
Special Tool -…1644
Output Voltage Inspection…1645
Special Tool -…1645
Resistance Inspection…1646
CAUTION…1647
Removal…1647
Installation…1648
Torque -…1648
Input Voltage Inspection…1648
Special Tool -…1648
Special Tool -…1649
Output Voltage Inspection…1649
Special Tool -…1650
ZX1200-B1/B2…1650
ZX1200-B3…1651
Special Tool -…1651
Removal/Installation…1653
Torque -…1653
Output Voltage Inspection…1653
Special Tool -…1653
Sensor Resistance Inspection…1654
ZX1200-B1/B2…1655
ZX1200-B3…1655
Removal/Installation…1656
Torque -…1656
Output Voltage Inspection…1656
Special Tool -…1656
ZX1200-B1/B2…1657
ZX1200-B3…1658
Sensor Resistance Inspection…1658
CAUTION…1659
Removal…1659
Installation…1659
Torque -…1659
Input Voltage Inspection…1659
Special Tool -…1659
Special Tool -…1660
Output Voltage Inspection…1660
Special Tool -…1661
ZX1200-B1/B2…1662
ZX1200-B3…1662
Atmospheric Pressure/Altitude Relationship…1663
Start the engine and switch the diagnosis mode to Dealer 1 mode …1664
Crankshaft Sensor Removal/Installation…1664
Crankshaft Sensor Inspection…1664
ZX1200-B1/B2…1664
ZX1200-B3…1665
Start the engine and switch the diagnosis mode to Dealer 1 mode …1666
Camshaft Position Sensor Removal/Installation…1666
Camshaft Position Sensor Inspection…1666
ZX1200-B1/B2…1666
ZX1200-B3…1667
Speed Sensor Removal/Installation…1668
Speed Sensor Inspection…1668
Torque -…1668
Special Tool -…1668
ZX1200-B1/B2…1669
ZX1200-B3…1669
The gear position switch detects the gear position of the neutra…1670
Gear Position Switch Removal…1670
Gear Position Switch Installation…1670
Torque -…1670
Gear Position Switch Input Voltage Inspection…1671
Special Tool -…1671
Special Tool -…1672
Gear Position Switch Inspection…1672
ZX1200-B1/B2…1673
ZX1200-B3…1674
This sensor has a weight [A] with two magnets inside, and sends …1675
Removal…1675
Installation…1676
Inspection…1676
Special Tool -…1677
ZX1200-B1/B2…1678
ZX1200-B3…1679
Subthrottle Sensor Removal/Adjustment…1680
Input Voltage Inspection…1680
Special Tool -…1680
Output Voltage Inspection…1681
Special Tool -…1681
Resistance Inspection…1682
Antenna Resistance Inspection…1683
Amplifier Input Voltage Inspection…1683
Special Tool -…1683
This code appears in the following conditions. …1684
User Key Inspection…1684
Fuel Injector ##1: (Service Code 41)…1685
Power Source Voltage Inspection…1685
Special Tool -…1685
Output Voltage Inspection…1687
Audible Inspection…1688
Injector Signal Test…1689
Special Tool -…1689
Injector Resistance Inspection…1690
Special Tool -…1690
Injector Unit Test…1690
Injector Fuel Line Inspection…1691
Torque -…1691
Torque -…1691
ZX1200-B1/B2…1692
ZX1200-B3…1693
Service code 45 is short or open to the fuel pump relay system…1694
Fuel Pump Relay Removal…1694
Operating Voltage Inspection…1694
Special Tools -…1694
Power Source Voltage Inspection…1696
Special Tools -…1696
Relay Inspection…1697
ZX1200-B1/B2…1697
ZX1200-B3…1698
Stick Coil ##1: Ignition Coil (Service Code 51)…1699
Removal/Installation…1699
Input Voltage Inspection…1699
ZX1200-B1/B2…1701
ZX1200-B3…1702
Subthrottle Valve Actuator Removal…1703
Audible Inspection…1703
Visual Inspection…1703
Resistance Inspection…1703
Special Tool -…1703
Input Voltage Inspection…1704
Recommended Tool -…1704
Special Tool -…1704
CAUTION…1705
ECU Removal…1705
ECU Installation…1705
ECU Power Supply Inspection…1705
Special Tools -…1706
ZX1200-B1/B2…1706
ZX1200-B3…1706
ECU Power Source Circuit ZX1200-B1/B2…1708
ZX1200-B3…1708
ECU Fuse Removal…1709
ECU Fuse Installation…1709
ECU Fuse Inspection…1709
ECU Main Relay Removal…1709
ECU Main Relay Inspection…1709
Special Tool -…1709
Inspection Flow Chart…1710
LED Light Inspection…1711
ZX1200-B1/B2…1711
ZX1200-B3…1712
Fuel Pressure Inspection…1713
Special Tools -…1713
Torque -…1714
Fuel Flow Rate Inspection…1714
Special Tool -…1715
Fuel Pump Removal…1716
Pump Screen Cleaning…1717
Fuel Pump Installation…1717
Torque -…1717
Operation Inspection…1718
Operating Voltage Inspection…1718
Special Tools -…1718
ZX1200-B1/B2…1719
ZX1200-B3…1720
The Evaporative Emission Control System routes fuel vapors from …1721
Parts Removal/Installation…1721
Hose Inspection…1721
Separator Inspection…1721
Separator Operation Test…1722
Canister Inspection (California Model Only)…1722
Cooling System…1723
Special Tools -…1725
Sealant -…1725
Permanent type antifreeze is used as a coolant to protect the co…1726
Coolant Deterioration Inspection…1728
Coolant Level Inspection…1728
Coolant Draining…1728
Coolant Filling…1728
Pressure Testing…1729
Cooling System Flushing…1729
Water Pump Removal…1730
Water Pump Installation…1731
Torque -…1731
Torque -…1731
Water Pump Impeller Disassembly/Assembly…1731
Torque -…1731
Water Pump Inspection…1731
Water Pump Impeller Inspection…1732
Water Pump Housing Disassembly…1732
Water Pump Housing Assembly…1732
Special Tool -…1732
Special Tool -…1732
Mechanical Seal Inspection…1733
Radiator and Radiator Fan Removal…1734
Radiator and Radiator Fan Installation…1735
Radiator Inspection…1735
Radiator Cap Inspection…1736
Thermostat Removal…1737
Thermostat Installation…1737
Torque -…1737
Thermostat Inspection…1737
Hose Installation…1739
Torque -…1739
Hose Inspection…1739
Radiator Fan Switch, Water Temperature Sensor Removal…1740
Radiator Fan Switch, Water Temperature Sensor Installation…1740
Sealant -…1740
Torque -…1740
Radiator Fan Switch, Water Temperature Sensor Inspection…1740
Engine Top End…1741
ZX1200-B1/B2…1742
ZX1200-B3…1743
Special Tools -…1747
Sealant -…1747
Air Suction Valve Removal…1748
Air Suction Valve Installation…1748
Torque -…1748
Torque -…1748
Air Suction Valve Check…1748
Vacuum Switch Valve Removal (ZX1200-B1/B2)…1749
Vacuum Switch Valve Installation (ZX1200-B1/B2)…1749
Vacuum Switch Valve Test (ZX1200-B1/B2)…1749
Special Tool -…1749
Air Switching Valve Removal (ZX1200-B3)…1750
Air Switching Valve Installation (ZX1200-B3)…1750
Air Switching Valve Operation Test (ZX1200-B3)…1750
Air Switching Valve Unit Test (ZX1200-B3)…1750
Clean Air System Hose Inspection…1750
Cylinder Head Cover Removal…1751
Cylinder Head Cover Installation…1751
Sealant -…1752
Torque -…1752
Camshaft Chain Tensioner Removal…1753
Camshaft Chain Tensioner Installation…1753
Torque -…1753
Camshaft Removal…1754
Camshaft Installation…1754
Torque -…1755
Torque -…1756
Camshaft, Camshaft Cap Wear…1756
Torque -…1756
Camshaft Runout…1757
Cam Wear…1757
Camshaft Chain Removal…1757
Cylinder Compression Measurement…1758
Special Tools -…1758
Torque -…1758
Cylinder Head Removal…1759
Cylinder Head Installation…1760…
Brake Hose Inspection…1895
Suspension…1897
Special Tools -…1900
Rebound Damping Force Adjustment…1901
Compression Damping Force Adjustment…1901
Spring Preload Adjustment…1902
Front Fork Removal (each fork leg)…1903
Front Fork Installation…1903
Torque -…1903
Torque -…1903
Fork Oil Change…1903
Front Fork Disassembly…1904
Special Tool -…1904
Front Fork Assembly…1904
Special Tool -…1904
Torque -…1904
Special Tool -…1905
Inner Tube Inspection…1905
Dust Seal Inspection…1906
Spring Tension…1906
Rebound Damping Force Adjustment…1907
Compression Damping Force Adjustment…1907
Spring Preload Adjustment…1908
Special Tool -…1908
Special Tool -…1908
Rear Shock Absorber Removal…1908
Special Tool -…1908
Rear Shock Absorber Installation…1909
Torque -…1909
Rear Shock Absorber Scrapping…1909
Swingarm Removal…1910
Special Tool -…1910
Special Tool -…1910
Swingarm Installation…1911
Torque -…1911
Torque -…1911
Torque -…1911
Swingarm Bearing Removal…1911
Special Tool -…1911
Special Tool -…1911
Swingarm Bearing Installation…1912
Special Tool -…1912
Swingarm Bearing, Sleeve Inspection…1912
Swingarm Pivot Lubrication…1912
Chain Slider Inspection…1912
Tie-Rod Removal…1913
Special Tool -…1913
Tie-Rod Installation…1913
Torque -…1913
Rocker Arm Removal…1913
Special Tool -…1913
Rocker Arm Installation…1913
Torque -…1913
Needle Bearing Inspection…1914
Tie-Rod, Rocker Arm Sleeve Inspection…1914
Uni-track Linkage Lubrication…1914
Steering…1915
Special Tools -…1917
Steering Inspection…1918
Steering Adjustment…1918
Stem, Stem Bearing Removal…1919
Special Tool -…1919
Special Tool -…1919
Special Tool -…1920
Special Tool -…1920
Stem, Stem Bearing Installation…1920
Special Tools -…1920
Special Tools -…1921
Special Tool -…1921
Torque -…1921
Torque -…1922
Torque -…1923
Steering Bearing Lubrication and Inspection…1923
Steering Stem Warp…1923
Handlebar Removal…1924
Handlebar Installation…1924
Torque -…1924
Torque -…1924
Frame…1925
Rear Seat Removal…1929
Rear Seat Installation…1929
Rear Seat Cover Removal…1929
Rear Seat Cover Installation…1930
Front Seat Removal…1930
Front Seat Installation…1930
Seat Cover Removal…1931
Seat Cover Installation…1931
Lower Fairings (Left and Right) Removal…1932
Lower Fairings (Left and Right) Installation…1932
Lower Inner Fairing Removal…1933
Lower Inner Fairing Installation…1933
Upper Inner Fairings (Left and Right) Removal…1933
Upper Inner Fairings (Left and Right) Installation…1933
Wind Shield Removal…1934
Wind Shield Installation…1934
Torque -…1934
Upper Inner Covers (Left and Right) Removal…1934
Upper Inner Covers (Left and Right) Installation…1934
Lower Inner Covers (Left and Right) Removal…1934
Lower Inner Covers (Left and Right) Installation…1935
Upper Fairing Removal…1935
Upper Fairing Disassembly…1936
Upper Fairing Assembly…1937
Hot Wind Cover Installation…1938
Front Fender Removal…1939
Front Fender Installation…1939
Rear Fender Rear Removal…1939
Rear Fender Rear Installation…1939
Rear Fender Front Removal…1940
Rear Fender Front Installation…1940
Rear Frame Removal…1941
Rear Frame Installation…1941
Torque -…1941
Frame Inspection…1941
Storage Box Removal…1942
Storage Box Installation…1942
Side Stand Removal…1943
Side Stand Installation…1943
Torque -…1943
Torque -…1943
Electrical System…1945
Special Tools -…1953
Sealant -…1953
Starter Lockout Switch [A]…1954
There are a number of important precautions that should be follo…1955
Wiring Inspection…1957
Special Tool -…1957
Battery Removal…1958
Battery Installation…1959
Electrolyte Filling…1960
Initial Charge…1962
Precautions…1962
1)…1962
2)…1962
3)…1962
4)…1962
Interchange…1963
Charging Condition Inspection…1963
Refreshing Charge…1963
Alternator Cover Removal…1965
Alternator Cover Installation…1965
Sealant -…1965
Torque -…1965
Stator Coil Removal…1965
Stator Coil Installation…1966
Torque -…1966
Sealant -…1966
Torque -…1966
Torque -…1966
Alternator Rotor Removal…1967
Special Tool -…1967
Special Tools -…1967
Special Tool -…1967
Alternator Rotor Installation…1967
Special Tool -…1968
Special Tool -…1968
Torque -…1968
Alternator Inspection…1968
Special Tool -…1969
Regulator/Rectifier Inspection…1969
Regulator/Rectifier Output Voltage Inspection…1972
Special Tools -…1972
Special Tool -…1973
Charging System Circuit…1974
WARNING…1975
Crankshaft Sensor Removal…1975
Crankshaft Sensor Installation…1976
Torque -…1976
Sealant -…1976
Torque -…1976
Crankshaft Sensor Inspection…1976
Special Tool -…1976
Crankshaft Sensor Peak Voltage Inspection…1976
Special Tool -…1976
Recommended Tool -…1976
Camshaft Position Sensor Removal…1977
Camshaft Position Sensor Installation…1977
Torque -…1977
Camshaft Position Sensor Inspection…1978
Special Tool -…1978
Camshaft Position Sensor Peak Voltage Inspection…1978
Special Tool -…1978
Recommended Tool -…1978
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…1979
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…1979
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…1979
Stick Coil Primary Peak Voltage Inspection…1980
Recommended Tool -…1980
Special Tools -…1980
Spark Plug Removal…1980
Owner's Tool -…1980
Spark Plug Installation…1981
Owner's Tool -…1981
Torque -…1981
Spark Plug Cleaning and Inspection…1981
Spark Plug Gap Inspection…1981
Interlock Operation Inspection…1981
IC Igniter Inspection…1982
Ignition System Inspection…1983
Ignition System Circuit ZX1200-B1/B2…1984
ZX1200-B3…1985
Starter Motor Removal…1986
Starter Motor Installation…1986
Torque -…1986
Starter Motor Disassembly…1987
Starter Motor Assembly…1987
Brush Inspection…1988
Commutator Cleaning and Inspection…1988
Armature Inspection…1989
Brush Lead Inspection…1989
Brush Plate and Terminal Bolt Inspection…1989
Starter Relay Inspection…1989
Electric Starter Circuit ZX1200-B1/B2…1991
ZX1200-B3…1992
The U.S.A., Canadian, Australian, and Malaysian models adopt the…1993
Headlight Beam Horizontal/Vertical Adjustment…1993
Headlight Bulbs (Left and Right) Replacement…1994
City Light Bulb Replacement…1994
Tail/Brake Light Bulbs Replacement…1995
Tail/Brake Light Lens Assembly Replacement…1995
Torque -…1995
Headlight Relays (High/Low) Inspection…1996
Headlight/Tail Light Circuit ZX1200-B1/B2…1997
ZX1200-B3…1998
Turn Signal Relay Inspection…1998
Turn Signal Light Circuit…2000
Air Switching Valve Operation Test…2001
Air Switching Valve Unit Test…2001
Special Tool -…2001
Fan System Circuit Inspection…2002
Fan Motors Inspection…2002
Fan Relay Removal…2002
Fan Relay Inspection…2003
Special Tool -…2003
Radiator Fan Circuit…2003
Meter Unit Removal…2004
Meter Unit Disassembly…2004
Bulbs Replacement…2004
Meter Unit Inspection…2005
Meter Circuit ZX1200-B1/B2…2012
ZX1200-B3…2013
This motorcycle is equipped with an immobilizer system to protec…2014
Operational Cautions…2014
Key Registration…2014
Special Tool -…2015
Spare User Key Registration Flow Chart…2019
Special Tool -…2020
All Keys Initial Registration Flow Chart…2029
Immobilizer System Parts Replacement…2030
Immobilizer System Inspection…2032
Immobilizer System Circuit…2032
Front Brake Light Switch Inspection…2033
Rear Brake Light Switch Check/Adjustment…2033
Switch Inspection…2033
Special Tool -…2033
Rear Brake Light Switch Connections…2033
Side Stand Switch Connections…2033
Gear Position Switch Connections…2033
Engine Oil Pressure Switch Connections*…2033
Radiator Fan Switch Inspection…2034
Water Temperature Sensor Inspection…2035
Speed Sensor Removal…2035
Speed Sensor Installation…2036
Torque -…2036
Speed Sensor Inspection…2036
Special Tool -…2036
Fuel Level Sensor Inspection…2036
Special Tool -…2037
Torque -…2037
Fuel Reserve Switch Inspection (1)…2037
Special Tool -…2037
Fuel Reserve Switch Inspection (2)…2038
The junction box [A] has fuses [B], relays, and diodes. The rela…2039
Junction Box Fuse Circuit Inspection…2039
Starter Circuit/Headlight Relay Inspection…2039
Diode Circuit Inspection…2040
Junction Box Internal Circuit (U.S.A., Canadian, Australian, and…2041
Junction Box Internal Circuit (Other than U.S.A., Canadian, Aust…2041
30 A Main Fuse Removal…2042
30 A Headlight/Fan Fuse Removal…2042
Junction Box Fuse Removal…2042
15 A ECU Fuse Removal…2043
Fuse Installation…2043
Fuse Inspection…2043
Troubleshooting…2061
NOTE…2062
Engine Doesn't Start, Starting Difficulty:…2062
Starter motor not rotating:…2062
Starter motor rotating but engine doesn't turn over:…2062
Engine won't turn over:…2062
No fuel flow:…2062
Engine flooded:…2062
No spark; spark weak:…2062
Fuel/air mixture incorrect:…2062
Compression Low:…2062
Poor Running at Low Speed:…2062
Spark weak:…2062
Fuel/air mixture incorrect:…2062
Compression low:…2063
Other:…2063
Poor Running or No Power at High Speed:…2063
Firing incorrect:…2063
Fuel/air mixture incorrect:…2063
Compression low:…2063
Knocking:…2063
Miscellaneous:…2063
Overheating:…2063
Firing incorrect:…2063
Muffler overheating:…2063
Fuel/air mixture incorrect:…2063
Compression high:…2064
Engine load faulty:…2064
Lubrication inadequate:…2064
Gauge incorrect:…2064
Coolant incorrect:…2064
Cooling system component incorrect:…2064
Over Cooling:…2064
Gauge incorrect:…2064
Cooling system component incorrect:…2064
Clutch Operation Faulty:…2064
Clutch slipping:…2064
Clutch not disengaging properly:…2064
Gear Shifting Faulty:…2064
Doesn't go into gear; shift pedal doesn't return:…2064
Jumps out of gear:…2064
Overshifts:…2064
Abnormal Engine Noise:…2064
Knocking:…2064
Piston slap:…2064
Valve noise:…2064
Other noise:…2064
Abnormal Drive Train Noise:…2065
Clutch noise:…2065
Transmission noise:…2065
Drive line noise:…2065
Abnormal Frame Noise:…2065
Front fork noise:…2065
Rear shock absorber noise:…2065
Disc brake noise:…2065
Other noise:…2065
Oil Pressure Warning Light Goes On:…2065
Exhaust Smokes Excessively:…2065
White smoke:…2065
Black smoke:…2065
Brown smoke:…2065
Handling and/or Stability Unsatisfactory:…2065
Handlebar hard to turn:…2065
Handlebar shakes or excessively vibrates:…2065
Handlebar pulls to one side:…2065
Shock absorption unsatisfactory:…2066
Brake Doesn't Hold:…2066
Battery Trouble:…2066
Battery discharged:…2066
Battery overcharged:…2066
Kawasaki Motorcycle Service Repair Manual '02-'05 ZZ-R1200…2068
Index…2068
Section 1 – General Information…2069
Section 2 – Periodic Maintenance…2079
Section 3 – Fuel System…2125
Section 4 – Cooling System…2162
Section 5 – Engine Top End…2180
Section 6 – Clutch…2219
Section 7 – Engine Lubrication System…2234
Section 8 – Engine Removal / Installation…2256
Section 9 – Crankshaft/Transmission…2267
Section 10 – Wheels / Tires…2305
Section 11 – Final Drive…2325
Section 12 – Brakes…2338
Section 13 – Suspension…2365
Section 14 – Steering…2386
Section 15 – Frame…2397
Section 16 – Electrical System…2417
Section 17 – Appendix…2518
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (EN)…2560
General Information…2563
Periodic Maintenance…2586
Fuel System…2632
Cooling System…2748
Engine Top…2770
Clutch…2806
Engine Lubrication System…2822
Engine Removal / Installation…2837
Crankshaft / Transmission…2846
Wheels / Tires…2876
Final Drive…2893
Brakes…2904
Suspension…2926
Steering…2952
Frame…2962
Electrical System…2978
Appendix…3058
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (IT)…3074
Kawasaki Motorcycle Service Repair Manual '04 ZX-10R (EN)…3630
Kawasaki Motorcycle Service Repair Manual '04-'05 ZZ-R250…4225
Kawasaki Motorcycle Service Repair Manual '05 ZX-6R (EN)…4573
KAWASAKI ZX636-C1 SERVICE MANUAL…0
Tables…4573
LIST OF ABBREVIATIONS…4578
Units of Mass…4594
Units of Volume…4594
Units of Force…4594
Units of Length…4594
Units of Torque…4594
Units of Pressure…4594
Units of Speed…4594
Units of Power…4594
Periodic Inspection…4597
Periodic Replacement Parts…4599
Periodic Inspection…4600
Periodic Replacement Parts…4602
Basic Torque for General Fasteners…4608
Throttle Grip Free Play…4612
Engine Vacuum…4613
Main Throttle Sensor Output Voltage…4615
Idle Speed…4616
Valve Clearance…4619
Clutch Lever Free Play…4623
Air Pressure (when Cold)…4624
Tread Depth…4625
Chain Slack…4626
Drive Chain 20-link Length…4628
Standard Chain…4628
Recommended Disc Brake Fluid…4630
Pad Lining Thickness…4630
Side Stand Switch Operation…4639
Water and Coolant Mixture Ratio (Recommended)…4647
Recommended Engine Oil…4649
Terminal Names…4676
Sample Diagnosis Sheet…4684
Engine Doesn't Start, Starting Difficulty…4686
Poor Running at Low Speed…4688
Poor Running or No Power at High Speed:…4691
Service Code Table…4697
Main Throttle Sensor Input Voltage…4701
Input Voltage at ECU Connector…4701
Main Throttle Sensor Input Voltage…4702
Input Voltage at Sensor…4702
Main Throttle Sensor Output Voltage…4702
Idle Speed…4702
Output Voltage at ECU…4702
Throttle Sensor Output Voltage…4703
Output Voltage at Sensor…4703
Main Throttle Sensor Resistance…4704
Inlet Air Pressure Sensor Input Voltage…4705
Input Voltage at ECU…4705
Inlet Air Pressure Sensor Input Voltage…4706
Input Voltage at Sensor Connector…4706
Inlet Air Pressure Sensor Output Voltage…4706
Output Voltage at ECU…4706
Inlet Air Pressure Sensor Output Voltage…4707
Output Voltage at Sensor Connector…4707
Inlet Air Pressure Sensor Output Voltage Connection to Sensor…4708
Inlet Air Temperature Sensor Output Voltage…4710
Output Voltage at ECU…4710
Inlet Air Temperature Sensor Resistance…4711
Water Temperature Sensor Output Voltage…4713
Output Voltage at ECU…4713
Atmospheric Pressure Sensor Input Voltage…4715
Input Voltage at ECU…4715
Atmospheric Pressure Sensor Input Voltage…4716
Input Voltage at Sensor Connector…4716
Atmospheric Pressure Sensor Output Voltage…4716
Output Voltage…4716
Atmospheric Pressure Sensor Output Voltage…4717
Output Voltage at Sensor…4717
Speed Sensor Input Voltage…4721
Input Voltage at Sensor…4721
Speed Sensor Output Voltage…4722
Output Voltage at Sensor …4722
Vehicle-down Sensor Power Source Voltage…4724
Power Source Voltage at Sensor…4724
Vehicle-down Sensor Output Voltage…4724
Output Voltage at Sensor…4724
Subthrottle Sensor Input Voltage…4726
Input Voltage at ECU Connector…4726
Subthrottle Sensor Input Voltage…4727
Input Voltage at Sensor…4727
Subthrottle Sensor Output Voltage…4727
Output Voltage at ECU…4727
Subthrottle Sensor Output Voltage…4728
Output Voltage at Sensor…4728
Subthrottle Sensor Resistance…4729
Exhaust Butterfly Valve Actuator Sensor Resistance…4730
Antenna Resistance…4731
Amplifier Input Voltage…4731
Input Voltage…4731
Stick Coil Input Voltage at ECU…4734
Input Voltage at ECU…4734
Subthrottle Valve Actuator Resistance…4736
Subthrottle Valve Actuator Input Voltage…4737
Input Voltage at Sensor…4737
Connections…4740
Actuator Output Voltage (Pulley Original Position)…4740
ECU Identification…4741
ECU Grounding Inspection…4742
ECU Power Source Inspection…4743
FI Indicator Light (LED) Check…4745
Fuel Pressure…4746
Fuel Pressure (Idling)…4747
Amount of Fuel Flow…4748
Pump Operating Voltage at Pump…4750
Operating Voltage at Pump Connector…4750
Primary Fuel Injector Resistance…4753
Secondary Fuel Injector Resistance…4754
Primary Fuel Injector Power Source Voltage…4755
Secondary Fuel Injector Power Source Voltage…4755
Power Source Voltage at Injector Connector…4755
Primary Fuel Injector Output Voltage…4755
Secondary Fuel Injector Output Voltage…4756
Output Voltage at Injector Connector…4756
Fuel Line Maximum Pressure…4757
Radiator Cap Relief Pressure…4793
Thermostat Valve Opening Temperature…4797
Vacuum Switch Valve Closing Pressure (Open → Close)…4812
Camshaft Journal, Camshaft Cap Clearance…4818
Camshaft Journal Diameter…4818
Camshaft Runout…4818
Cam Height…4819
Cylinder Compression…4820
Cylinder Head Warp…4822
Valve/Valve Guide Clearance (Wobble Method)…4825
Valve Seating Surface Outside Diameter…4825
Valve Seating Surface Width…4825
Cylinder Inside Diameter…4832
Piston Diameter…4832
Piston Ring/Groove Clearance…4833
Piston Ring Groove Width…4833
Piston Ring Thickness…4833
Piston Ring End Gap…4834
Clutch Housing Gear Selection when Replacing Clutch Housing Gear…4855
Spring Plate Free Play …4858
Clutch Plate Assembly Length…4859
Friction Plate Thickness…4859
Friction and Steel Plate Warp…4859
Clutch Spring Free Length…4860
Oil Pressure…4875
Connecting Rod Big End Bearing Insert Selection…4893
Crankshaft Main Bearing Insert Selection…4893
Crankshaft Selection when Replacing Crankshaft…4899
Connecting Rod Bend…4904
Connecting Rod Twist…4904
Connecting Rod Big End Side Clearance…4904
Connecting Rod Big End Bearing Insert/Crankpin Clearance…4905
Crankpin Diameter…4905
Crankpin Diameter Marks…4905
Connecting Rod Big End Inside Diameter Marks…4906
Crankshaft Side Clearance…4906
Crankshaft Runout…4907
Crankshaft Main Bearing Insert/Journal Clearance…4907
Crankshaft Main Journal Diameter…4907
Crankshaft Main Journal Diameter Marks…4907
Crankcase Main Bearing Inside Diameter Marks…4908
Shift Fork Ear Thickness…4916
Gear Groove Width…4916
Shift Fork Guide Pin Diameter…4916
Shift Drum Groove Width…4916
Rim Runout…4926
Axle Runout/100 mm (3.94 in.)…4926
Balance Weight…4928
Link Pin Outside Diameter…4943
Link Plates Outside Width…4943
Rear Sprocket Warp…4948
Pedal Position…4956
Brake Discs Thickness…4966
Disc Runout…4966
Rebound Damping Force Adjustment…4981
Compression Damping Force Adjustment…4981
Adjuster Protrusion (from top)…4982
Spring Action…4982
Fork Oil…4985
Oil Level (fully compressed, without spring)…4986
Spring Free Length…4989
Rebound Damping Force Adjustment…4990
Rebound Damping Force Adjustment…4990
Spring Preload Setting…4991
Spring Adjustment…4991
Kawasaki-recommended chargers…5059
Battery Terminal Voltage…5061
Terminal Voltage: 11.5 ∼ less than 12.8 V…5062
Terminal Voltage: less than 11.5 V…5062
Table 1 Alternator Output Voltage…5066
Table 2 Stator Coil Resistance…5066
Charging Voltage…5069
Crankshaft Sensor Peak Voltage…5075
Ignition Coil Winding Resistance…5076
Primary Lead Connection…5077
Stick Coil Primary Peak Voltage…5077
Connections:…5079
Camshaft Position Sensor Peak Voltage…5079
Condition…5080
Condition…5080
Condition…5080
Starter Motor Brush Length…5084
Commutator Diameter…5085
Testing Relay…5086
Testing Turn Signal Relay…5093
Testing Turn Signal Relay…5094
User Key Indicator Flashes…5112
Water Temperature Sensor…5129
Connections…5130
Relay Circuit Inspection (with the battery disconnected)…5131
Relay Circuit Inspection (with the battery connected)…5132
Diode Circuit Inspection…5132
Table Of Contents…4573
Read OWNER'S MANUAL before operating…4578
EMISSION CONTROL INFORMATION…4579
1…4579
2…4579
3…4579
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…4580
Foreword…4581
General Information…4583
Before starting to perform an inspection service or carry out a …4584
Battery Ground…4584
Edges of Parts…4584
Solvent…4584
Cleaning vehicle before disassembly…4584
Arrangement and Cleaning of Removed Parts…4585
Storage of Removed Parts…4585
Inspection…4585
Replacement Parts…4585
Assembly Order…4585
Tightening Sequence…4586
Tightening Torque…4586
Force…4586
Gasket, O-ring…4586
Liquid Gasket, Non-permanent Locking Agent…4586
Press…4587
Ball Bearing and Needle Bearing…4587
Oil Seal, Grease Seal…4587
Circlips, Cotter Pins…4587
Lubrication…4588
Direction of Engine Rotation…4588
Electrical Wires…4588
ZX636-C1 (Europe) Left Side View…4589
ZX636-C1 (Europe) Right Side View…4589
ZX636-C1 (US and Canada) Left Side View…4590
ZX636-C1 (US and Canada) Right Side View…4590
Prefixes for Units…4594
Units of Temperature…4594
Periodic Maintenance…4595
The scheduled maintenance must be done in accordance with this c…4597
The scheduled maintenance must be done in accordance with this c…4600
The following tables list the tightening torque for the major fa…4603
Inside Circlip Pliers:…4611
Fuel System (DFI)…4612
Throttle Control System Inspection…4612
Engine Vacuum Synchronization Inspection…4612
Special Tool -…4613
Special Tool -…4614
Idle Speed Inspection…4616
Idle Speed Adjustment…4616
Fuel Hose Damage and Installation Condition Inspection…4616
Evaporative Emission Control System (California Model)…4617
Evaporative Emission Control System Inspection…4617
Cooling System…4618
Coolant Level Inspection…4618
Radiator Hose Damage and Installation Condition Inspection…4618
Torque -…4618
Engine Top End…4619
Valve Clearance Inspection…4619
Valve Clearance Adjustment…4620
VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE…4621
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE…4622
Air Suction System…4623
Air Suction System Damage Inspection…4623
Clutch…4623
Clutch Operation Inspection …4623
Wheels/Tires…4624
Air Pressure Inspection…4624
Wheel/Tire Damage Inspection…4624
Tire Tread Wear Inspection …4624
Wheel Bearing Damage Inspection…4625
Drive Train…4626
Drive Chain Lubrication Condition Inspection…4626
Drive Chain Slack Inspection…4626
Drive Chain Slack Adjustment…4627
Torque -…4627
Wheel Alignment Inspection…4628
Drive Chain Wear Inspection…4628
Chain Guide Wear Inspection…4629
Brake System…4629
Brake Fluid Leak (Brake Hose and Pipe) Inspection…4629
Brake Hose Damage and Installation Condition Inspection…4629
Torque -…4629
Brake Operation Inspection…4629
Brake Fluid Level Inspection…4630
Brake Pad Wear Inspection…4630
Brake Light Switch Operation Inspection…4630
Suspensions…4631
Front Forks/Rear Shock Absorber Operation Inspection…4631
Front Fork Oil Leak Inspection…4632
Rear Shock Absorber Oil Leak Inspection…4632
Rocker Arm Operation Inspection…4632
Tie-Rod Operation Inspection…4632
Steering System…4633
Steering Play Inspection…4633
Special Tools -…4633
Steering Play Adjustment…4633
Special Tool -…4633
Torque -…4634
Steering Stem Bearing Lubrication…4634
Electrical System…4634
Spark Plug Clean and Gap Inspection…4634
Lights and Switches Operation Inspection…4636
Headlight Aiming Inspection…4638
Side Stand Switch Operation Inspection…4639
Engine Stop Switch Operation Inspection…4640
Others…4641
Chassis Parts Lubrication …4641
Pivots: Lubricate with Grease…4641
Points: Lubricate with Grease…4641
Cables: Lubricate with Rust Inhibitor…4641
Bolts, Nuts and Fasteners Tightness Inspection…4642
Bolt, Nut and Fastener to be checked…4643
Replacement Parts…4644
Air Cleaner Element Replacement…4644
Fuel Hose Replacement…4644
Coolant Change…4646
Torque -…4646
Radiator Hose and O-ring Replacement…4648
Engine Oil Change…4649
Torque -…4649
Oil Filter Replacement…4649
Special Tool -…4649
Torque -…4649
Brake Hose and Pipe Replacement…4650
Torque -…4650
Brake Fluid Change…4650
Torque -…4651
Torque -…4651
Master Cylinder Rubber Parts Replacement…4652
Special Tool -…4652
Special Tool -…4652
Silicone Grease -…4653
Torque -…4653
Caliper Rubber Parts Replacement…4653
Torque -…4654
Torque -…4654
Torque -…4655
Spark Plug Replacement…4656
Owner's Tool -…4656
Torque -…4656
Fuel System (DFI)…4657
Dummy Page…4659
Oil Pressure Gauge, 5 kgf/cm :…4668
Subthrottle Sensor [A]…4670
DFI System…4672
DFI System Wiring Diagram…4674
Terminal Numbers of ECU Connectors…4676
There are a number of important precautions that should be follo…4677
Torque -…4678
Outline…4679
Special Tool -…4679
Sealant -…4680
Special Tool -…4680
DFI Diagnosis Flow Chart…4683
Inquiries to Rider…4683
NOTE…4686
Self-diagnosis Outline…4694
Self-diagnosis Procedures…4694
Service Code Clearing Procedures…4695
Service Code Reading…4697
Service Code Erasing…4697
Backups…4699
The main throttle sensor is a rotating variable resistor that ch…4701
Main Throttle Sensor Removal/Adjustment…4701
Input Voltage Inspection…4701
Special Tool -…4701
Special Tool -…4702
Output Voltage Inspection…4702
Special Tool -…4702
Special Tool -…4703
Resistance Inspection…4704
CAUTION…4705
Removal…4705
Installation…4705
Input Voltage Inspection…4705
Special Tool -…4705
Special Tool -…4706
Output Voltage Inspection…4706
Special Tool -…4707
Special Tools -…4708
Removal/Installation…4710
Output Voltage Inspection…4710
Special Tool -…4710
Sealant -…4711
Sensor Resistance Inspection…4711
Removal/Installation…4713
Sealant -…4713
Torque -…4713
Output Voltage Inspection…4713
Special Tool -…4713
Sealant -…4714
Sensor Resistance Inspection…4714
CAUTION…4715
Removal…4715
Installation…4715
Input Voltage Inspection…4715
Special Tool -…4715
Special Tool -…4716
Output Voltage Inspection…4716
Special Tool -…4717
Atmospheric Pressure/Altitude Relationship…4718
Crankshaft Sensor Removal/Installation…4719
Crankshaft Sensor Inspection…4719
Camshaft Position Sensor Removal/Installation…4720
Camshaft Position Sensor Inspection…4720
Speed Sensor Removal/Installation…4721
Speed Sensor Inspection…4721
Input Voltage Inspection…4721
Special Tool -…4721
Output Voltage Inspection…4721
Special Tool -…4722
This sensor has a weight [A] with two magnets inside, and sends …4723
Removal…4723
Installation…4723
Inspection…4723
Special Tool -…4724
Sealant -…4725
Subthrottle Sensor Removal/Adjustment…4726
Input Voltage Inspection…4726
Special Tool -…4726
Special Tool -…4727
Output Voltage Inspection…4727
Special Tool -…4727
Special Tool -…4728
Resistance Inspection…4729
Exhaust Butterfly Valve Actuator Sensor Inspection…4730
Antenna Resistance Inspection…4731
Amplifier Input Voltage Inspection…4731
Special Tool -…4731
This code appears in the following conditions. …4732
User Key Inspection…4732
Stick Coil ##1: Service Code 51…4734
Removal/Installation…4734
Input Voltage Inspection…4734
Subthrottle Valve Actuator Removal…4736
Subthrottle Valve Actuator Inspection…4736
Resistance Inspection…4736
Input Voltage Inspection…4737
Special Tools -…4737
Exhaust Butterfly Valve Actuator Removal…4738
Exhaust Butterfly Valve Actuator Installation…4738
Torque -…4738
Torque -…4739
Exhaust Butterfly Valve Actuator Inspection…4739
Output Voltage Inspection…4740
Special Tool -…4740
CAUTION…4741
ECU Identification…4741
ECU Removal…4741
ECU Installation…4742
ECU Power Supply Inspection…4742
Special Tool -…4742
ECU Power Source Circuit…4743
ECU Fuse Removal…4744
ECU Fuse Installation…4744
ECU Fuse Inspection…4744
Light (LED) Inspection…4745
Fuel Pressure Inspection…4746
Special Tools -…4746
Fuel Flow Rate Inspection…4747
Fuel Pump Removal…4749
Fuel Pump Installation…4749
Torque -…4750
Operation Inspection…4750
Operating Voltage Inspection…4750
Special Tools -…4750
CAUTION…4752
Audible Inspection…4752
Injector Signal Test…4752
Special Tool -…4753
Injector Resistance Inspection…4753
Special Tool -…4753
Special Tool -…4754
Injector Unit Test…4754
Injector Voltage Inspection…4755
Special Tool -…4755
Special Tool -…4755
Injector Fuel Line Inspection…4757
Free Play Inspection…4759
Free Play Adjustment…4759
Cable Installation…4759
Cable Lubrication…4759
Idle Speed Inspection…4760
Throttle Bore Cleaning…4760
Synchronization Inspection…4760
Synchronization Adjustment…4760
Throttle Body Assy Removal…4760
Throttle Body Assy Installation…4762
Torque -…4762
Throttle Body Assy Disassembly…4762
Throttle Body Assy Assembly…4763
Torque -…4763
Nozzle Assy Removal…4764
Nozzle Assy Installation…4764
Torque -…4764
Nozzle Assy Disassembly…4764
Nozzle Assy Assembly…4765
Torque -…4766
Torque -…4766
Element Removal…4767
Element Installation…4767
Air Cleaner Element Inspection…4767
Air Cleaner Housing Removal…4767
Air Cleaner Housing Installation…4768
Torque -…4768
Air Cleaner Housing Disassembly…4769
Air Cleaner Housing Assembly…4769
Oil Draining…4769
Air Inlet Duct Removal…4769
Air Inlet Duct Installation…4769
Fuel Tank Removal…4770
Fuel Tank Installation…4772
Fuel Tank and Cap Inspection…4773
Fuel Tank Cleaning…4773
The Evaporative Emission Control System routes fuel vapors from …4774
Parts Removal/Installation…4774
Hose Inspection…4774
Separator Inspection…4774
Separator Operation Test…4775
Canister Inspection …4775
Cooling System…4777
Bearing Driver, 32:…4781
Coolant Deterioration Inspection…4784
Coolant Level Inspection…4784
Coolant Draining…4784
Coolant Filling…4784
Pressure Testing…4784
Cooling System Flushing…4785
Coolant Reserve Tank Removal…4785
Coolant Reserve Tank Installation…4785
Torque -…4785
Water Pump Removal…4786
Water Pump Installation…4786
Water Pump Impeller Disassembly/Assembly…4786
Torque -…4786
Water Pump Impeller Inspection…4786
Water Pump Housing Disassembly…4786
Water Pump Housing Assembly…4787
Special Tool -…4787
Special Tool -…4787
Mechanical Seal Inspection…4787
Radiator and Radiator Fan Removal…4788
Radiator and Radiator Fan Installation…4789
Torque -…4792
Torque -…4792
Radiator Inspection…4793
Radiator Cap Inspection…4793
Radiator Filler Neck Inspection…4794
Thermostat Removal…4795
Thermostat Installation…4795
Torque -…4796
Thermostat Inspection…4796
Hose Installation…4798
Torque -…4798
Hose Inspection…4798
CAUTION…4799
Water Temperature Sensor Removal…4799
Water Temperature Sensor Inspection…4799
Engine Top End…4801
Exhaust System…4805
Compression Gauge, 20 kgf/cm :…4809
Air Suction Valve Removal…4811
Air Suction Valve Installation…4811
Torque -…4811
Air Suction Valve Inspection…4811
Vacuum Switch Valve Removal…4811
Vacuum Switch Valve Installation…4812
Vacuum Switch Valve Test…4812
Special Tool -…4812
Clean Air System Hose Inspection…4812
Cylinder Head Cover Removal…4813
Cylinder Head Cover Installation…4813
Sealant -…4813
Torque -…4814
Camshaft Chain Tensioner Removal…4815
Camshaft Chain Tensioner Installation…4815
Torque -…4815
Torque -…4815
Camshaft Removal…4816
Camshaft Installation…4816
Torque -…4817
Torque -…4817
Camshaft, Camshaft Cap Wear…4818
Torque -…4818
Camshaft Runout…4818
Cam Wear…4819
Camshaft Chain Removal…4819
Cylinder Compression Measurement…4820
Special Tools -…4820
Torque -…4820
Cylinder Head Removal…4821
Cylinder Head Installation…4821
Torque -…4822
Torque -…4822
Torque -…4822
Cylinder Head Warp…4822
Valve Clearance Inspection…4823
Valve Clearance Adjustment…4823
Valve Removal…4823
Special Tools -…4823
Valve Installation…4823
Valve Guide Removal…4823
Special Tool -…4823
Valve Guide Installation…4824
Special Tools -…4824
Special Tool -…4824
Valve-to-Guide Clearance Measurement (Wobble Method)…4824
Valve Seat Inspection…4825
Valve Seat Repair…4825
Special Tools -…4825
Cylinder Removal…4830
Cylinder Installation…4830
Piston Removal…4831
Special Tool -…4831
Piston Installation…4831
Cylinder Wear…4832
Piston Wear…4832
Piston Ring, Piston Ring Groove Wear…4833
Piston Ring Groove Width…4833
Piston Ring Thickness…4833
Piston Ring End Gap…4834
Throttle Body Holder Installation…4835
Torque -…4835
WARNING…4836
Muffler Body Removal…4836
Muffler Body Installation…4838
Torque -…4838
Exhaust Pipe Removal…4839
Exhaust Pipe Installation…4840
Torque -…4840
Exhaust Butterfly Valve Cable Removal…4841
Exhaust Butterfly Valve Cable Installation…4841
Torque -…4842
Torque -…4842
Torque -…4842
Clutch…4845
Clutch Holder:…4849
Clutch Lever Free Play Inspection…4850
Clutch Lever Free Play Adjustment…4850
Cable Removal…4850
Cable Installation…4850
Cable Lubrication…4850
Clutch Lever Installation…4850
Torque -…4850
Clutch Cover Removal…4851
Clutch Cover Installation…4851
Sealant -…4851
Torque -…4851
Release Shaft Removal…4851
Release Shaft Installation…4852
Clutch Cover Disassembly…4852
Clutch Cover Assembly…4852
Clutch Removal…4853
Special Tool -…4853
Clutch Installation…4854
Special Tool -…4857
Torque -…4857
Torque -…4857
Spring Plate Free Play Measurement…4858
Spring Plate Play Adjustment…4859
Torque -…4859
Clutch Plate, Wear, Damage Inspection…4859
Clutch Plate Warp Inspection…4859
Clutch Spring Free Length Measurement…4860
Damper Cam Inspection…4860
Engine Lubrication System…4861
Outside Circlip Pliers:…4865
WARNING…4868
Oil Level Inspection…4868
Engine Oil Change…4868
Oil Filter Replacement…4868
Oil Pan Removal…4869
Oil Pan Installation…4869
Torque -…4869
Torque -…4869
Oil Pressure Relief Valve Removal…4870
Oil Pressure Relief Valve Installation…4870
Oil Pressure Relief Valve Inspection…4870
Oil Pump Removal…4871
Oil Pump Installation…4871
Torque -…4872
Torque -…4872
Torque -…4872
Oil Pump Drive Gear Removal…4872
Special Tool -…4872
Oil Pump Drive Gear Installation…4873
Special Tool -…4873
Oil Cooler Removal…4874
Oil Cooler Installation…4874
Torque -…4874
Torque -…4874
Oil Pressure Measurement…4875
Special Tools -…4875
Torque -…4875
Oil Pressure Switch Removal…4876
Oil Pressure Switch Installation…4876
Sealant -…4876
Torque -…4876
Torque -…4876
Engine Removal/Installation…4877
Engine Mount Nut Wrench:…4880
Engine Removal…4881
Special Tool -…4882
Engine Installation…4883
Torque -…4884
Special Tool -…4884
Torque -…4884
Crankshaft/Transmission…4887
Bearing Puller:…4894
Crankcase Splitting…4895
Crankcase Assembly…4896
Sealant -…4896
Torque -…4896
Torque -…4896
Sealant -…4897
Torque -…4898
Torque -…4898
Torque -…4898
Torque -…4898
Torque -…4898
Crankshaft Removal…4899
Crankshaft Installation…4899
Connecting Rod Removal…4900
Connecting Rod Installation…4900
Crankshaft/Connecting Rod Cleaning…4904
Connecting Rod Bend…4904
Connecting Rod Twist…4904
Connecting Rod Big End Side Clearance…4904
Connecting Rod Big End Bearing Insert/Crankpin Wear…4905
Crankshaft Side Clearance…4906
Crankshaft Runout…4907
Crankshaft Main Bearing Insert/Journal Wear…4907
Shift Pedal Removal…4909
Shift Pedal Installation…4909
Torque -…4909
Torque -…4909
Torque -…4909
External Shift Mechanism Removal…4910
External Shift Mechanism Installation…4910
Torque -…4910
External Shift Mechanism Inspection…4910
Torque -…4910
Transmission Shaft Removal…4911
Transmission Shaft Installation…4911
Transmission Shaft Disassembly…4911
Special Tool -…4911
Special Tools -…4912
Transmission Shaft Assembly…4912
Special Tool -…4912
Shift Drum and Fork Removal…4915
Shift Drum and Fork Installation…4915
Torque -…4915
Shift Drum Disassembly…4915
Shift Drum Assembly…4915
Torque -…4915
Shift Fork Bending…4915
Shift Fork/Gear Groove Wear…4916
Shift Fork Guide Pin/Drum Groove Wear…4916
Gear Dog and Gear Dog Hole Damage…4916
Wheels/Tires…4917
Bearing Driver Set:…4921
Front Wheel Removal…4922
Special Tools -…4922
Front Wheel Installation…4922
Torque -…4923
Torque -…4923
Rear Wheel Removal…4923
Rear Wheel Installation…4924
Torque -…4925
Wheel Inspection…4926
Special Tools -…4926
Axle Inspection…4926
Balance Inspection…4927
Balance Adjustment…4927
Balance Weight Removal…4927
Balance Weight Installation…4927
Air Pressure Inspection/Adjustment…4929
Tire Inspection…4929
Tire Removal…4929
Tire Installation…4929
Tire Repair…4931
Hub Bearing Removal…4932
Special Tools -…4932
Hub Bearing Installation…4932
Special Tool -…4932
Special Tool -…4932
Hub Bearing Inspection…4932
Hub Bearing Lubrication…4933
Final Drive…4935
Inside Circlip Pliers:…4939
Drive Chain Slack Inspection…4940
Drive Chain Slack Adjustment…4940
Wheel Alignment Inspection/Adjustment…4940
Drive Chain Wear Inspection…4940
Drive Chain Lubrication…4940
Drive Chain Removal…4940
Drive Chain Installation…4941
Engine Sprocket Removal…4944
Engine Sprocket Installation…4944
Torque -…4944
Torque -…4945
Rear Sprocket Removal…4945
Rear Sprocket Installation…4945
Torque -…4945
Coupling Installation…4945
Coupling Bearing Removal…4946
Special Tool -…4946
Special Tool -…4946
Coupling Bearing Installation…4946
Special Tool -…4946
Special Tool -…4946
Special Tool -…4946
Coupling Bearing Inspection…4947
Coupling Bearing Lubrication…4947
Coupling Damper Inspection…4947
Sprocket Wear Inspection…4947
Rear Sprocket Warp Inspection…4948
Brakes…4949
Inside Circlip Pliers:…4955
Brake Lever Position Adjustment…4956
Brake Pedal Position Inspection …4956
Brake Pedal Position Adjustment …4956
Torque -…4956
Brake Pedal Removal…4956
Brake Pedal Installation…4957
Torque -…4957
Torque -…4957
Torque -…4957
Front Caliper Removal…4958
Rear Caliper Removal…4958
Caliper Installation…4958
Torque -…4958
Front Caliper Disassembly…4959
Front Caliper Assembly…4959
Rear Caliper Disassembly…4959
Rear Caliper Assembly…4959
Caliper Fluid Seal Damage…4959
Rear Caliper Dust Boot and Friction Boot Damage…4960
Caliper Piston and Cylinder Damage…4960
Rear Caliper Holder Shaft Wear…4960
Front Brake Pad Removal…4961
Front Brake Pad Installation…4961
Torque -…4961
Rear Brake Pad Removal …4962
Rear Brake Pad Installation…4962
Brake Pad Wear Inspection…4962
Front Master Cylinder Removal…4963
Front Master Cylinder Installation…4963
Torque -…4963
Torque -…4963
Rear Master Cylinder Removal…4964
Rear Master Cylinder Installation…4964
Torque -…4964
Front Master Cylinder Disassembly…4964
Rear Master Cylinder Disassembly…4964
Master Cylinder Assembly…4964
Master Cylinder Inspection (Visual Inspection)…4964
Brake Disc Removal…4966
Brake Disc Installation…4966
Torque -…4966
Brake Disc Wear…4966
Brake Disc Warp…4966
Special Tools -…4966
Brake Fluid Level Inspection…4967
Brake Fluid Change…4967
Brake Line Bleeding…4967
Torque -…4968
Torque -…4969
Brake Hose Removal/Installation…4971
Brake Hose Inspection…4971
Suspension…4973
Inside Circlip Pliers:…4979
Rebound Damping Force Adjustment…4981
Compression Damping Force Adjustment…4981
Spring Preload Adjustment…4982
Front Fork Removal (Each Fork Leg)…4982
Front Fork Installation…4983
Torque -…4983
Torque -…4983
Front Fork Oil Change…4983
Special Tools -…4983
Special Tool -…4985
Special Tool -…4985
Special Tool -…4986
Special Tool -…4986
Special Tools -…4986
Torque -…4987
Front Fork Disassembly…4987
Special Tool -…4987
Front Fork Assembly…4988
Special Tool -…4988
Torque -…4988
Special Tool -…4988
Inner Tube Inspection…4988
Dust Seal Inspection…4989
Spring Tension…4989
Rebound Damping Force Adjustment…4990
Compression Damping Force Adjustment…4990
Spring Preload Adjustment…4990
Special Tools -…4990
Special Tools -…4991
Rear Shock Absorber Removal…4991
Special Tools -…4991
Rear Shock Absorber Installation…4992
Torque -…4992
Rear Shock Absorber Inspection…4992
Rear Shock Absorber Scrapping…4992
Swingarm Removal…4993
Special Tool -…4994
Swingarm Installation…4994
Torque -…4994
Special Tool -…4995
Torque -…4995
Torque -…4995
Swingarm Bearing Removal…4995
Special Tool -…4995
Special Tool -…4995
Swingarm Bearing Installation…4996
Special Tools -…4996
Swingarm Bearing, Sleeve Inspection…4996
Chain Guide Inspection…4997
Tie-Rod Removal…4998
Special Tools -…4998
Tie-Rod Installation…4998
Torque -…4998
Rocker Arm Removal…4998
Special Tools -…4998
Rocker Arm Installation…4999
Torque -…4999
Tie-Rod and Rocker Arm Bearing Removal…4999
Special Tools -…4999
Tie-Rod and Rocker Arm Bearing Installation…4999
Special Tools -…5000
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…5001
Rocker Arm/Tie-Rod Bearing Lubrication…5001
Steering…5003
Bearing Puller Adapter:…5006
Steering Inspection…5007
Steering Adjustment…5007
Stem, Stem Bearing Removal…5008
Special Tool -…5008
Special Tool -…5008
Special Tools -…5009
Stem, Stem Bearing Installation…5009
Special Tools -…5009
Special Tools -…5009
Special Tool -…5010
Torque -…5010
Torque -…5011
Steering Stem Bearing Lubrication…5011
Steering Stem Warp…5011
Stem Cap Deterioration, Damage…5011
Handlebar Removal…5012
Handlebar Installation…5012
Torque -…5012
Torque -…5013
Frame…5015
Rear Seat Removal…5022
Rear Seat Installation…5022
Front Seat Removal…5022
Front Seat Installation…5022
Lower Fairing Removal…5023
Lower Fairing Installation…5023
Center Fairing Removal…5023
Center Fairing Installation…5024
Windshield Removal…5024
Windshield Installation…5024
Torque -…5024
Upper Fairing Removal…5024
Upper Fairing Disassembly…5025
Upper Fairing Assembly…5025
Upper Fairing Installation…5026
Torque -…5026
Upper Inner Fairing Removal…5026
Upper Inner Fairing Installation…5026
Center Inner Fairing Removal…5026
Center Inner Fairing Installation…5026
Right and Left Inner Fairing Removal…5027
Right and Left Inner Fairing Installation…5027
Left Side Cover Removal…5028
Left Side Cover Installation…5028
Right Side Cover Removal…5028
Right Side Cover Installation…5028
Seat Cover Removal…5029
Seat Cover Installation…5029
Front Fender Removal…5030
Front Fender Installation…5030
Torque -…5030
Flap and Rear Fender Rear Removal…5030
Flap and Rear Fender Rear Installation…5031
Rear Fender Front Removal…5032
Rear Fender Front Installation…5032
Rear Frame Removal…5033
Rear Frame Installation…5033
Torque -…5033
Frame Inspection…5033
Side Stand Removal…5034
Side Stand Installation…5034
Torque -…5034
Torque -…5034
Electrical System…5035
Flywheel Holder:…5053
There are a number of important precautions that are musts when …5054
Wiring Inspection…5056
Special Tool -…5056
Battery Removal…5057
Battery Installation…5057
Battery Activation…5057
Precautions…5060
1)…5060
2)…5060
3)…5060
4)…5060
Interchange…5060
Charging Condition Inspection…5061
Refreshing Charge…5061
Alternator Cover Removal…5063
Alternator Cover Installation…5063
Sealant -…5063
Torque -…5063
Stator Coil Removal…5063
Stator Coil Installation…5064
Torque -…5064
Sealant -…5064
Torque -…5064
Alternator Rotor Removal…5064
Special Tool -…5064
Special Tool -…5064
Alternator Rotor Installation…5064
Special Tool -…5065
Torque -…5065
Alternator Inspection…5066
Special Tool -…5066
Regulator/Rectifier Removal…5067
Regulator/Rectifier Inspection…5067
Charging Voltage Inspection…5069
Special Tool -…5069
Charging System Circuit…5070
Starter Motor Clutch Removal/Inspection…5071
Starter Motor Clutch Inspection…5071
Starter Motor Clutch Disassembly…5071
Starter Motor Clutch Assembly…5071
Torque -…5071
Crankshaft Sensor Removal…5073
Crankshaft Sensor Installation…5074
Torque -…5074
Sealant -…5074
Torque -…5074
Crankshaft Sensor Inspection…5074
Special Tool -…5074
Crankshaft Sensor Peak Voltage…5074
Special Tools -…5075
Timing Rotor Removal…5075
Special Tool -…5075
Timing Rotor Installation…5075
Torque -…5075
Special Tool -…5075
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…5075
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…5076
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…5076
Stick Coil Primary Peak Voltage…5077
Special Tools -…5077
Spark Plug Removal…5077
Spark Plug Installation…5078
Spark Plug Clean and Inspection…5078
Spark Plug Gap Inspection…5078
Camshaft Position Sensor Removal…5078
Camshaft Position Sensor Installation…5078
Torque -…5078
Camshaft Position Sensor Inspection…5078
Special Tool -…5079
Camshaft Position Sensor Peak Voltage Inspection…5079
Special Tool -…5079
Interlock Operation Inspection…5080
IC Igniter Inspection…5081
Ignition System Circuit…5082
Starter Motor Removal…5083
Starter Motor Installation…5083
Torque -…5083
Starter Motor Disassembly…5083
Starter Motor Assembly…5083
Brush Inspection…5084
Commutator Cleaning and Inspection…5085
Armature Inspection…5085
Special Tool -…5085
Brush Lead Inspection…5085
Special Tool -…5085
Right-hand End Cover Assembly Inspection…5086
Special Tool -…5086
Starter Relay Inspection…5086
Special Tool -…5086
Electric Starter Circuit…5087
This motorcycle adopt the daylight system and have a headlight r…5088
Headlight Beam Horizontal Adjustment…5088
Headlight Beam Vertical Adjustment…5088
Headlight Bulb Replacement…5088
City Light Bulb Replacement…5089
Headlight Removal/Installation…5089
Tail/Brake Light (LED) Removal…5090
Tail/Brake Light (LED) Installation…5090
License Plate Light Bulb Replacement…5090
Headlight/Tail Light Circuit…5091
Turn Signal Light Bulb Replacement…5092
Turn Signal Relay Inspection…5093
Turn Signal Light Circuit…5095
Fan Motor Inspection…5096
Radiator Fan Circuit…5097
Meter Unit Removal…5098
Meter Unit Disassembly…5098
Electronic Combination Meter Assembly Inspection…5099
Special Tool -…5099
Special Tool -…5104
Meter Circuit…5107
This motorcycle is equipped with an immobilizer system to protec…5108
Operational Cautions…5108
Key Registration…5108
Special Tool -…5109
Spare User Key Registration Flow Chart…5113
Special Tool -…5114
All Keys Initial Registration Flow Chart…5123
Immobilizer System Parts Replacement…5124
Immobilizer System Inspection…5126
Immobilizer System Circuit…5126
Brake Light Timing Inspection…5127
Brake Light Timing Adjustment…5127
Neutral Switch Replacement…5127
Torque -…5127
Switch Inspection…5128
Special Tool -…5128
Rear Brake Light Switch Connections…5128
Side Stand Switch Connections…5128
Neutral Switch Connections…5128
Oil Pressure Switch Connections *…5128
Water Temperature Sensor Inspection…5129
Speed Sensor Removal…5129
Speed Sensor Installation…5129
Torque -…5129
Speed Sensor Inspection…5130
Special Tool -…5130
Fuel Reserve Switch Inspection…5130
Special Tool -…5130
The relay box [A] has relays and diodes. The relays and diodes c…5131
Relay Box Removal…5131
Relay Circuit Inspection…5131
Diode Circuit Inspection…5132
Relay Box Internal Circuit…5133
30 A Main Fuse Removal…5134
Fuse Box Fuse Removal…5134
15 A ECU Fuse Removal…5134
Fuse Installation…5135
Fuse Inspection…5135
Appendix…5137
California Model…5162
NOTE…5164
Engine Doesn't Start, Starting Difficulty:…5164
Starter motor not rotating:…5164
Starter motor rotating but engine doesn't turn over:…5164
Engine won't turn over:…5164
No fuel flow:…5164
No spark; spark weak:…5164
Fuel/air mixture incorrect:…5164
Compression Low:…5164
Poor Running at Low Speed:…5164
Spark weak:…5164
Fuel/air mixture incorrect:…5164
Compression low:…5164
Other:…5165
Poor Running or No Power at High Speed:…5165
Firing incorrect:…5165
Fuel/air mixture incorrect:…5165
Compression low:…5165
Knocking:…5165
Miscellaneous:…5165
Overheating:…5165
Firing incorrect:…5165
Muffler overheating:…5165
Fuel/air mixture incorrect:…5165
Compression high:…5165
Engine load faulty:…5165
Lubrication inadequate:…5166
Oil cooler incorrect:…5166
Gauge incorrect:…5166
Coolant incorrect:…5166
Cooling system component incorrect:…5166
Over Cooling:…5166
Gauge incorrect:…5166
Cooling system component incorrect:…5166
Clutch Operation Faulty:…5166
Clutch slipping:…5166
Clutch not disengaging properly:…5166
Gear Shifting Faulty:…5166
Doesn't go into gear; shift pedal doesn't return:…5166
Jumps out of gear:…5166
Overshifts:…5166
Abnormal Engine Noise:…5166
Knocking:…5166
Piston slap:…5166
Valve noise:…5166
Other noise:…5166
Abnormal Drive Train Noise:…5167
Clutch noise:…5167
Transmission noise:…5167
Drive line noise:…5167
Abnormal Frame Noise:…5167
Front fork noise:…5167
Rear shock absorber noise:…5167
Disc brake noise:…5167
Other noise:…5167
Oil Pressure Warning Light Goes On:…5167
Exhaust Smokes Excessively:…5167
White smoke:…5167
Black smoke:…5167
Brown smoke:…5167
Handling and/or Stability Unsatisfactory:…5167
Handlebar hard to turn:…5167
Handlebar shakes or excessively vibrates:…5167
Handlebar pulls to one side:…5167
Shock absorption unsatisfactory:…5167
Brake Doesn't Hold:…5168
Battery Trouble:…5168
Battery discharged:…5168
Battery overcharged:…5168
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6R (EN)…5170
tables…0
LIST OF ABBREVIATIONS…5173
Units of Mass…5190
Units of Volume…5190
Units of Force…5190
Units of Length…5190
Units of Torque…5190
Units of Pressure…5190
Units of Speed…5190
Units of Power…5190
Periodic Inspection…5194
Periodic Replacement Parts…5196
Periodic Inspection…5197
Periodic Replacement Parts…5199
Basic Torque for General Fasteners…5205
Throttle Grip Free Play…5209
Engine Vacuum…5210
Main Throttle Sensor Output Voltage…5212
Idle Speed…5213
Valve Clearance…5216
Clutch Lever Free Play…5220
Air Pressure (when Cold)…5221
Tread Depth…5222
Chain Slack…5223
Drive Chain 20-link Length…5225
Standard Chain…5225
Recommended Disc Brake Fluid…5227
Pad Lining Thickness…5227
Side Stand Switch Operation…5236
Water and Coolant Mixture Ratio (Recommended)…5244
Recommended Engine Oil…5246
Terminal Names…5273
Sample Diagnosis Sheet…5281
Engine Doesn't Start, Starting Difficulty…5283
Poor Running at Low Speed…5285
Poor Running or No Power at High Speed:…5288
Service Code Table…5294
Main Throttle Sensor Input Voltage…5298
Input Voltage at ECU Connector…5298
Main Throttle Sensor Input Voltage…5299
Input Voltage at Sensor…5299
Main Throttle Sensor Output Voltage…5299
Idle Speed…5299
Output Voltage at ECU…5299
Throttle Sensor Output Voltage…5300
Output Voltage at Sensor…5300
Main Throttle Sensor Resistance…5301
Inlet Air Pressure Sensor Input Voltage…5302
Input Voltage at ECU…5302
Inlet Air Pressure Sensor Input Voltage…5303
Input Voltage at Sensor Connector…5303
Inlet Air Pressure Sensor Output Voltage…5303
Output Voltage at ECU…5303
Inlet Air Pressure Sensor Output Voltage…5304
Output Voltage at Sensor Connector…5304
Inlet Air Pressure Sensor Output Voltage Connection to Sensor…5305
Inlet Air Temperature Sensor Output Voltage…5307
Output Voltage at ECU…5307
Inlet Air Temperature Sensor Resistance…5308
Water Temperature Sensor Output Voltage…5310
Output Voltage at ECU…5310
Atmospheric Pressure Sensor Input Voltage…5312
Input Voltage at ECU…5312
Atmospheric Pressure Sensor Input Voltage…5313
Input Voltage at Sensor Connector…5313
Atmospheric Pressure Sensor Output Voltage…5313
Output Voltage…5313
Atmospheric Pressure Sensor Output Voltage…5314
Output Voltage at Sensor…5314
Speed Sensor Input Voltage…5318
Input Voltage at Sensor…5318
Speed Sensor Output Voltage…5319
Output Voltage at Sensor …5319
Vehicle-down Sensor Power Source Voltage…5321
Power Source Voltage at Sensor…5321
Vehicle-down Sensor Output Voltage…5321
Output Voltage at Sensor…5321
Subthrottle Sensor Input Voltage…5323
Input Voltage at ECU Connector…5323
Subthrottle Sensor Input Voltage…5324
Input Voltage at Sensor…5324
Subthrottle Sensor Output Voltage…5324
Output Voltage at ECU…5324
Subthrottle Sensor Output Voltage…5325
Output Voltage at Sensor…5325
Subthrottle Sensor Resistance…5326
Exhaust Butterfly Valve Actuator Sensor Resistance…5327
Antenna Resistance…5328
Amplifier Input Voltage…5328
Input Voltage…5328
Stick Coil Input Voltage at ECU…5331
Input Voltage at ECU…5331
Subthrottle Valve Actuator Resistance…5333
Subthrottle Valve Actuator Input Voltage…5334
Input Voltage at Sensor…5334
Connections…5337
Actuator Output Voltage (Pulley Original Position)…5337
ECU Identification…5338
ECU Grounding Inspection…5339
ECU Power Source Inspection…5340
FI Indicator Light (LED) Check…5342
Fuel Pressure…5343
Fuel Pressure (Idling)…5344
Amount of Fuel Flow…5345
Pump Operating Voltage at Pump…5347
Operating Voltage at Pump Connector…5347
Primary Fuel Injector Resistance…5350
Secondary Fuel Injector Resistance…5351
Primary Fuel Injector Power Source Voltage…5352
Secondary Fuel Injector Power Source Voltage…5352
Power Source Voltage at Injector Connector…5352
Primary Fuel Injector Output Voltage…5352
Secondary Fuel Injector Output Voltage…5353
Output Voltage at Injector Connector…5353
Fuel Line Maximum Pressure…5354
Radiator Cap Relief Pressure…5390
Thermostat Valve Opening Temperature…5394
Vacuum Switch Valve Closing Pressure (Open → Close)…5409
Camshaft Journal, Camshaft Cap Clearance…5416
Camshaft Journal Diameter…5416
Camshaft Runout…5416
Cam Height…5417
Cylinder Compression…5418
Cylinder Head Warp…5420
Valve/Valve Guide Clearance (Wobble Method)…5423
Valve Seating Surface Outside Diameter…5423
Valve Seating Surface Width…5423
Cylinder Inside Diameter…5430
Piston Diameter…5430
Piston Ring/Groove Clearance…5431
Piston Ring Groove Width…5431
Piston Ring Thickness…5431
Piston Ring End Gap…5432
Clutch Housing Gear Selection when Replacing Clutch Housing Gear…5452
Spring Plate Free Play …5455
Clutch Plate Assembly Length…5456
Friction Plate Thickness…5456
Friction and Steel Plate Warp…5456
Clutch Spring Free Length…5457
Oil Pressure…5472
Connecting Rod Big End Bearing Insert Selection…5490
Crankshaft Main Bearing Insert Selection…5490
Crankshaft Selection when Replacing Crankshaft…5496
Connecting Rod Bend…5501
Connecting Rod Twist…5501
Connecting Rod Big End Side Clearance…5501
Connecting Rod Big End Bearing Insert/Crankpin Clearance…5502
Crankpin Diameter…5502
Crankpin Diameter Marks…5502
Connecting Rod Big End Inside Diameter Marks…5503
Crankshaft Side Clearance…5503
Crankshaft Runout…5504
Crankshaft Main Bearing Insert/Journal Clearance…5504
Crankshaft Main Journal Diameter…5504
Crankshaft Main Journal Diameter Marks…5504
Crankcase Main Bearing Inside Diameter Marks…5505
Shift Fork Ear Thickness…5513
Gear Groove Width…5513
Shift Fork Guide Pin Diameter…5513
Shift Drum Groove Width…5513
Rim Runout (with tire installed)…5523
Axle Runout/100 mm (3.94 in.)…5523
Balance Weight…5525
Link Pin Outside Diameter…5540
Link Plates Outside Width…5540
Rear Sprocket Warp…5545
Pedal Position…5553
Brake Discs Thickness…5563
Disc Runout…5563
Rebound Damping Force Adjustment…5578
Compression Damping Force Adjustment…5578
Adjuster Protrusion (from top)…5579
Spring Action…5579
Fork Oil…5582
Oil Level (fully compressed, without spring)…5583
Spring Free Length…5587
Rebound Damping Force Adjustment…5588
Rebound Damping Force Adjustment…5588
Spring Preload Setting…5589
Spring Adjustment…5589
Kawasaki-recommended chargers…5656
Battery Terminal Voltage…5658
Terminal Voltage: 11.5 ∼ less than 12.8 V…5659
Terminal Voltage: less than 11.5 V…5659
Table 1 Alternator Output Voltage…5663
Table 2 Stator Coil Resistance…5663
Charging Voltage…5666
Crankshaft Sensor Peak Voltage…5672
Ignition Coil Winding Resistance…5673
Primary Lead Connection…5674
Stick Coil Primary Peak Voltage…5674
Connections:…5676
Camshaft Position Sensor Peak Voltage…5676
Condition…5677
Condition…5677
Condition…5677
Starter Motor Brush Length…5681
Commutator Diameter…5682
Testing Relay…5683
Testing Turn Signal Relay…5690
Testing Turn Signal Relay…5691
User Key Indicator Flashes…5709
Water Temperature Sensor…5726
Connections…5727
Relay Circuit Inspection (with the battery disconnected)…5728
Relay Circuit Inspection (with the battery connected)…5729
Relay Circuit Inspection (with the battery disconnected)…5729
Relay Circuit Inspection (with the battery connected)…5729
Diode Circuit Inspection…5730
Diode Circuit Inspection…5730
toc…0
Read OWNER'S MANUAL before operating…5173
EMISSION CONTROL INFORMATION…5174
1…5174
2…5174
3…5174
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…5175
Foreword…5176
General Information…5178
Before starting to perform an inspection service or carry out a …5179
Battery Ground…5179
Edges of Parts…5179
Solvent…5179
Cleaning vehicle before disassembly…5179
Arrangement and Cleaning of Removed Parts…5180
Storage of Removed Parts…5180
Inspection…5180
Replacement Parts…5180
Assembly Order…5180
Tightening Sequence…5181
Tightening Torque…5181
Force…5181
Gasket, O-ring…5181
Liquid Gasket, Non-permanent Locking Agent…5181
Press…5182
Ball Bearing and Needle Bearing…5182
Oil Seal, Grease Seal…5182
Circlips, Cotter Pins…5182
Lubrication…5183
Direction of Engine Rotation…5183
Electrical Wires…5183
Instrument…5183
ZX636-C1 ∼ (Europe) Left Side View…5184
ZX636-C1 ∼ (Europe) Right Side View…5184
ZX636-C1 ∼ (US and Canada) Left Side View…5185
ZX636-C1 ∼ (US and Canada) Right Side View…5185
ZX636D6F (US and Canada) Left Side View…5186
ZX636D6F (US and Canada) Right Side View…5186
Prefixes for Units…5190
Units of Temperature…5190
Periodic Maintenance…5192
The scheduled maintenance must be done in accordance with this c…5194
The scheduled maintenance must be done in accordance with this c…5197
The following tables list the tightening torque for the major fa…5200
Inside Circlip Pliers:…5208
Fuel System (DFI)…5209
Throttle Control System Inspection…5209
Engine Vacuum Synchronization Inspection…5209
Special Tool -…5210
Special Tool -…5211
Idle Speed Inspection…5213
Idle Speed Adjustment…5213
Fuel Hose Damage and Installation Condition Inspection…5213
Evaporative Emission Control System (California Model)…5214
Evaporative Emission Control System Inspection…5214
Cooling System…5215
Coolant Level Inspection…5215
Radiator Hose Damage and Installation Condition Inspection…5215
Torque -…5215
Engine Top End…5216
Valve Clearance Inspection…5216
Valve Clearance Adjustment…5217
VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE…5218
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE…5219
Air Suction System…5220
Air Suction System Damage Inspection…5220
Clutch…5220
Clutch Operation Inspection …5220
Wheels/Tires…5221
Air Pressure Inspection…5221
Wheel/Tire Damage Inspection…5221
Tire Tread Wear Inspection …5221
Wheel Bearing Damage Inspection…5222
Drive Train…5223
Drive Chain Lubrication Condition Inspection…5223
Drive Chain Slack Inspection…5223
Drive Chain Slack Adjustment…5224
Torque -…5224
Wheel Alignment Inspection…5225
Drive Chain Wear Inspection…5225
Chain Guide Wear Inspection…5226
Brake System…5226
Brake Fluid Leak (Brake Hose and Pipe) Inspection…5226
Brake Hose Damage and Installation Condition Inspection…5226
Torque -…5226
Brake Operation Inspection…5226
Brake Fluid Level Inspection…5227
Brake Pad Wear Inspection…5227
Brake Light Switch Operation Inspection…5227
Suspensions…5228
Front Forks/Rear Shock Absorber Operation Inspection…5228
Front Fork Oil Leak Inspection…5229
Rear Shock Absorber Oil Leak Inspection…5229
Rocker Arm Operation Inspection…5229
Tie-Rod Operation Inspection…5229
Steering System…5230
Steering Play Inspection…5230
Special Tools -…5230
Steering Play Adjustment…5230
Special Tool -…5230
Torque -…5231
Steering Stem Bearing Lubrication…5231
Electrical System…5231
Spark Plug Clean and Gap Inspection…5231
Lights and Switches Operation Inspection…5233
Headlight Aiming Inspection…5235
Side Stand Switch Operation Inspection…5236
Engine Stop Switch Operation Inspection…5237
Others…5238
Chassis Parts Lubrication …5238
Pivots: Lubricate with Grease…5238
Points: Lubricate with Grease…5238
Cables: Lubricate with Rust Inhibitor…5238
Bolts, Nuts and Fasteners Tightness Inspection…5239
Bolt, Nut and Fastener to be checked…5240
Replacement Parts…5241
Air Cleaner Element Replacement…5241
Fuel Hose Replacement…5241
Coolant Change…5243
Torque -…5243
Radiator Hose and O-ring Replacement…5245
Engine Oil Change…5246
Torque -…5246
Oil Filter Replacement…5246
Special Tool -…5246
Torque -…5246
Brake Hose and Pipe Replacement…5247
Torque -…5247
Brake Fluid Change…5247
Torque -…5248
Torque -…5248
Master Cylinder Rubber Parts Replacement…5249
Special Tool -…5249
Special Tool -…5249
Silicone Grease -…5250
Torque -…5250
Caliper Rubber Parts Replacement…5250
Torque -…5251
Torque -…5251
Torque -…5252
Spark Plug Replacement…5253
Owner's Tool -…5253
Torque -…5253
Fuel System (DFI)…5254
Dummy Page…5256
Oil Pressure Gauge, 5 kgf/cm :…5265
Subthrottle Sensor [A]…5267
DFI System…5269
DFI System Wiring Diagram…5271
Terminal Numbers of ECU Connectors…5273
There are a number of important precautions that should be follo…5274
Torque -…5275
Outline…5276
Special Tool -…5276
Sealant -…5277
Special Tool -…5277
DFI Diagnosis Flow Chart…5280
Inquiries to Rider…5280
NOTE…5283
Self-diagnosis Outline…5291
Self-diagnosis Procedures…5291
Service Code Clearing Procedures…5292
Service Code Reading…5294
Service Code Erasing…5294
Backups…5296
The main throttle sensor is a rotating variable resistor that ch…5298
Main Throttle Sensor Removal/Adjustment…5298
Input Voltage Inspection…5298
Special Tool -…5298
Special Tool -…5299
Output Voltage Inspection…5299
Special Tool -…5299
Special Tool -…5300
Resistance Inspection…5301
CAUTION…5302
Removal…5302
Installation…5302
Input Voltage Inspection…5302
Special Tool -…5302
Special Tool -…5303
Output Voltage Inspection…5303
Special Tool -…5304
Special Tools -…5305
Removal/Installation…5307
Output Voltage Inspection…5307
Special Tool -…5307
Sealant -…5308
Sensor Resistance Inspection…5308
Removal/Installation…5310
Sealant -…5310
Torque -…5310
Output Voltage Inspection…5310
Special Tool -…5310
Sealant -…5311
Sensor Resistance Inspection…5311
CAUTION…5312
Removal…5312
Installation…5312
Input Voltage Inspection…5312
Special Tool -…5312
Special Tool -…5313
Output Voltage Inspection…5313
Special Tool -…5314
Atmospheric Pressure/Altitude Relationship…5315
Crankshaft Sensor Removal/Installation…5316
Crankshaft Sensor Inspection…5316
Camshaft Position Sensor Removal/Installation…5317
Camshaft Position Sensor Inspection…5317
Speed Sensor Removal/Installation…5318
Speed Sensor Inspection…5318
Input Voltage Inspection…5318
Special Tool -…5318
Output Voltage Inspection…5318
Special Tool -…5319
This sensor has a weight [A] with two magnets inside, and sends …5320
Removal…5320
Installation…5320
Inspection…5320
Special Tool -…5321
Sealant -…5322
Subthrottle Sensor Removal/Adjustment…5323
Input Voltage Inspection…5323
Special Tool -…5323
Special Tool -…5324
Output Voltage Inspection…5324
Special Tool -…5324
Special Tool -…5325
Resistance Inspection…5326
Exhaust Butterfly Valve Actuator Sensor Inspection…5327
Antenna Resistance Inspection…5328
Amplifier Input Voltage Inspection…5328
Special Tool -…5328
This code appears in the following conditions. …5329
User Key Inspection…5329
Stick Coil ##1: Service Code 51…5331
Removal/Installation…5331
Input Voltage Inspection…5331
Subthrottle Valve Actuator Removal…5333
Subthrottle Valve Actuator Inspection…5333
Resistance Inspection…5333
Input Voltage Inspection…5334
Special Tools -…5334
Exhaust Butterfly Valve Actuator Removal…5335
Exhaust Butterfly Valve Actuator Installation…5335
Torque -…5335
Torque -…5336
Exhaust Butterfly Valve Actuator Inspection…5336
Output Voltage Inspection…5337
Special Tool -…5337
CAUTION…5338
ECU Identification…5338
ECU Removal…5338
ECU Installation…5339
ECU Power Supply Inspection…5339
Special Tool -…5339
ECU Power Source Circuit…5340
ECU Fuse Removal…5341
ECU Fuse Installation…5341
ECU Fuse Inspection…5341
Light (LED) Inspection…5342
Fuel Pressure Inspection…5343
Special Tools -…5343
Fuel Flow Rate Inspection…5344
Fuel Pump Removal…5346
Fuel Pump Installation…5346
Torque -…5347
Operation Inspection…5347
Operating Voltage Inspection…5347
Special Tools -…5347
CAUTION…5349
Audible Inspection…5349
Injector Signal Test…5349
Special Tool -…5350
Injector Resistance Inspection…5350
Special Tool -…5350
Special Tool -…5351
Injector Unit Test…5351
Injector Voltage Inspection…5352
Special Tool -…5352
Special Tool -…5352
Injector Fuel Line Inspection…5354
Free Play Inspection…5356
Free Play Adjustment…5356
Cable Installation…5356
Cable Lubrication…5356
Idle Speed Inspection…5357
Throttle Bore Cleaning…5357
Synchronization Inspection…5357
Synchronization Adjustment…5357
Throttle Body Assy Removal…5357
Throttle Body Assy Installation…5359
Torque -…5359
Throttle Body Assy Disassembly…5359
Throttle Body Assy Assembly…5360
Torque -…5360
Nozzle Assy Removal…5361
Nozzle Assy Installation…5361
Torque -…5361
Nozzle Assy Disassembly…5361
Nozzle Assy Assembly…5362
Torque -…5363
Torque -…5363
Element Removal…5364
Element Installation…5364
Air Cleaner Element Inspection…5364
Air Cleaner Housing Removal…5364
Air Cleaner Housing Installation…5365
Torque -…5365
Air Cleaner Housing Disassembly…5366
Air Cleaner Housing Assembly…5366
Oil Draining…5366
Air Inlet Duct Removal…5366
Air Inlet Duct Installation…5366
Fuel Tank Removal…5367
Fuel Tank Installation…5369
Fuel Tank and Cap Inspection…5370
Fuel Tank Cleaning…5370
The Evaporative Emission Control System routes fuel vapors from …5371
Parts Removal/Installation…5371
Hose Inspection…5371
Separator Inspection…5371
Separator Operation Test…5372
Canister Inspection …5372
Cooling System…5374
Bearing Driver, 32:…5378
Coolant Deterioration Inspection…5381
Coolant Level Inspection…5381
Coolant Draining…5381
Coolant Filling…5381
Pressure Testing…5381
Cooling System Flushing…5382
Coolant Reserve Tank Removal…5382
Coolant Reserve Tank Installation…5382
Torque -…5382
Water Pump Removal…5383
Water Pump Installation…5383
Water Pump Impeller Disassembly/Assembly…5383
Torque -…5383
Water Pump Impeller Inspection…5383
Water Pump Housing Disassembly…5383
Water Pump Housing Assembly…5384
Special Tool -…5384
Special Tool -…5384
Mechanical Seal Inspection…5384
Radiator and Radiator Fan Removal…5385
Radiator and Radiator Fan Installation…5386
Torque -…5389
Torque -…5389
Radiator Inspection…5390
Radiator Cap Inspection…5390
Radiator Filler Neck Inspection…5391
Thermostat Removal…5392
Thermostat Installation…5392
Torque -…5393
Thermostat Inspection…5393
Hose Installation…5395
Torque -…5395
Hose Inspection…5395
CAUTION…5396
Water Temperature Sensor Removal…5396
Water Temperature Sensor Inspection…5396
Engine Top End…5398
Exhaust System…5402
Compression Gauge, 20 kgf/cm :…5406
Air Suction Valve Removal…5408
Air Suction Valve Installation…5408
Torque -…5408
Air Suction Valve Inspection…5408
Vacuum Switch Valve Removal…5409
Vacuum Switch Valve Installation…5409
Vacuum Switch Valve Test…5409
Special Tool -…5409
Clean Air System Hose Inspection…5410
Cylinder Head Cover Removal…5411
Cylinder Head Cover Installation…5411
Sealant -…5411
Torque -…5412
Camshaft Chain Tensioner Removal…5413
Camshaft Chain Tensioner Installation…5413
Torque -…5413
Torque -…5413
Camshaft Removal…5414
Camshaft Installation…5414
Torque -…5415
Torque -…5415
Camshaft, Camshaft Cap Wear…5416
Torque -…5416
Camshaft Runout…5416
Cam Wear…5417
Camshaft Chain Removal…5417
Cylinder Compression Measurement…5418
Special Tools -…5418
Torque -…5418
Cylinder Head Removal…5419
Cylinder Head Installation…5419
Torque -…5420
Torque -…5420
Torque -…5420
Cylinder Head Warp…5420
Valve Clearance Inspection…5421
Valve Clearance Adjustment…5421
Valve Removal…5421
Special Tools -…5421
Valve Installation…5421
Valve Guide Removal…5421
Special Tool -…5421
Valve Guide Installation…5422
Special Tools -…5422
Special Tool -…5422
Valve-to-Guide Clearance Measurement (Wobble Method)…5422
Valve Seat Inspection…5423
Valve Seat Repair…5423
Special Tools -…5423
Cylinder Removal…5428
Cylinder Installation…5428
Piston Removal…5429
Special Tool -…5429
Piston Installation…5429
Cylinder Wear…5430
Piston Wear…5430
Piston Ring, Piston Ring Groove Wear…5431
Piston Ring Groove Width…5431
Piston Ring Thickness…5431
Piston Ring End Gap…5432
Throttle Body Holder Installation…5433
Torque -…5433
WARNING…5434
Muffler Body Removal…5434
Muffler Body Installation…5436
Torque -…5436
Exhaust Pipe Removal…5437
Exhaust Pipe Installation…5438
Torque -…5438
Exhaust Butterfly Valve Cable Removal…5439
Exhaust Butterfly Valve Cable Installation…5439
Torque -…5440
Torque -…5440
Torque -…5440
Clutch…5442
Clutch Holder:…5446
Clutch Lever Free Play Inspection…5447
Clutch Lever Free Play Adjustment…5447
Cable Removal…5447
Cable Installation…5447
Cable Lubrication…5447
Clutch Lever Installation…5447
Torque -…5447
Clutch Cover Removal…5448
Clutch Cover Installation…5448
Sealant -…5448
Torque -…5448
Release Shaft Removal…5448
Release Shaft Installation…5449
Clutch Cover Disassembly…5449
Clutch Cover Assembly…5449
Clutch Removal…5450
Special Tool -…5450
Clutch Installation…5451
Special Tool -…5454
Torque -…5454
Torque -…5454
Spring Plate Free Play Measurement…5455
Spring Plate Play Adjustment…5456
Torque -…5456
Clutch Plate, Wear, Damage Inspection…5456
Clutch Plate Warp Inspection…5456
Clutch Spring Free Length Measurement…5457
Damper Cam Inspection…5457
Engine Lubrication System…5458
Outside Circlip Pliers:…5462
WARNING…5465
Oil Level Inspection…5465
Engine Oil Change…5465
Oil Filter Replacement…5465
Oil Pan Removal…5466
Oil Pan Installation…5466
Torque -…5466
Torque -…5466
Oil Pressure Relief Valve Removal…5467
Oil Pressure Relief Valve Installation…5467
Oil Pressure Relief Valve Inspection…5467
Oil Pump Removal…5468
Oil Pump Installation…5468
Torque -…5469
Torque -…5469
Torque -…5469
Oil Pump Drive Gear Removal…5469
Special Tool -…5469
Oil Pump Drive Gear Installation…5470
Special Tool -…5470
Oil Cooler Removal…5471
Oil Cooler Installation…5471
Torque -…5471
Torque -…5471
Oil Pressure Measurement…5472
Special Tools -…5472
Torque -…5472
Oil Pressure Switch Removal…5473
Oil Pressure Switch Installation…5473
Sealant -…5473
Torque -…5473
Torque -…5473
Engine Removal/Installation…5474
Engine Mount Nut Wrench:…5477
Engine Removal…5478
Special Tool -…5479
Engine Installation…5480
Torque -…5481
Special Tool -…5481
Torque -…5481
Crankshaft/Transmission…5484
Bearing Puller:…5491
Crankcase Splitting…5492
Crankcase Assembly…5493
Sealant -…5493
Torque -…5493
Torque -…5493
Sealant -…5494
Torque -…5495
Torque -…5495
Torque -…5495
Torque -…5495
Torque -…5495
Crankshaft Removal…5496
Crankshaft Installation…5496
Connecting Rod Removal…5497
Connecting Rod Installation…5497
Crankshaft/Connecting Rod Cleaning…5501
Connecting Rod Bend…5501
Connecting Rod Twist…5501
Connecting Rod Big End Side Clearance…5501
Connecting Rod Big End Bearing Insert/Crankpin Wear…5502
Crankshaft Side Clearance…5503
Crankshaft Runout…5504
Crankshaft Main Bearing Insert/Journal Wear…5504
Shift Pedal Removal…5506
Shift Pedal Installation…5506
Torque -…5506
Torque -…5506
Torque -…5506
External Shift Mechanism Removal…5507
External Shift Mechanism Installation…5507
Torque -…5507
External Shift Mechanism Inspection…5507
Torque -…5507
Transmission Shaft Removal…5508
Transmission Shaft Installation…5508
Transmission Shaft Disassembly…5508
Special Tool -…5508
Special Tools -…5509
Transmission Shaft Assembly…5509
Special Tool -…5509
Shift Drum and Fork Removal…5512
Shift Drum and Fork Installation…5512
Torque -…5512
Shift Drum Disassembly…5512
Shift Drum Assembly…5512
Torque -…5512
Shift Fork Bending…5512
Shift Fork/Gear Groove Wear…5513
Shift Fork Guide Pin/Drum Groove Wear…5513
Gear Dog and Gear Dog Hole Damage…5513
Wheels/Tires…5514
Bearing Driver Set:…5518
Front Wheel Removal…5519
Special Tools -…5519
Front Wheel Installation…5519
Torque -…5520
Torque -…5520
Rear Wheel Removal…5520
Rear Wheel Installation…5521
Torque -…5522
Wheel Inspection…5523
Special Tools -…5523
Axle Inspection…5523
Balance Inspection…5524
Balance Adjustment…5524
Balance Weight Removal…5524
Balance Weight Installation…5524
Air Pressure Inspection/Adjustment…5526
Tire Inspection…5526
Tire Removal…5526
Tire Installation…5526
Tire Repair…5528
Hub Bearing Removal…5529
Special Tools -…5529
Hub Bearing Installation…5529
Special Tool -…5529
Special Tool -…5529
Hub Bearing Inspection…5529
Hub Bearing Lubrication…5530
Final Drive…5532
Inside Circlip Pliers:…5536
Drive Chain Slack Inspection…5537
Drive Chain Slack Adjustment…5537
Wheel Alignment Inspection/Adjustment…5537
Drive Chain Wear Inspection…5537
Drive Chain Lubrication…5537
Drive Chain Removal…5537
Drive Chain Installation…5538
Engine Sprocket Removal…5541
Engine Sprocket Installation…5541
Torque -…5541
Torque -…5542
Rear Sprocket Removal…5542
Rear Sprocket Installation…5542
Torque -…5542
Coupling Installation…5542
Coupling Bearing Removal…5543
Special Tool -…5543
Special Tool -…5543
Coupling Bearing Installation…5543
Special Tool -…5543
Special Tool -…5543
Special Tool -…5543
Coupling Bearing Inspection…5544
Coupling Bearing Lubrication…5544
Coupling Damper Inspection…5544
Sprocket Wear Inspection…5544
Rear Sprocket Warp Inspection…5545
Brakes…5546
Inside Circlip Pliers:…5552
Brake Lever Position Adjustment…5553
Brake Pedal Position Inspection …5553
Brake Pedal Position Adjustment …5553
Torque -…5553
Brake Pedal Removal…5553
Brake Pedal Installation…5554
Torque -…5554
Torque -…5554
Torque -…5554
Front Caliper Removal…5555
Rear Caliper Removal…5555
Caliper Installation…5555
Torque -…5555
Front Caliper Disassembly…5556
Front Caliper Assembly…5556
Rear Caliper Disassembly…5556
Rear Caliper Assembly…5556
Caliper Fluid Seal Damage…5556
Rear Caliper Dust Boot and Friction Boot Damage…5557
Caliper Piston and Cylinder Damage…5557
Rear Caliper Holder Shaft Wear…5557
Front Brake Pad Removal…5558
Front Brake Pad Installation…5558
Torque -…5558
Rear Brake Pad Removal …5559
Rear Brake Pad Installation…5559
Brake Pad Wear Inspection…5559
Front Master Cylinder Removal…5560
Front Master Cylinder Installation…5560
Torque -…5560
Torque -…5560
Rear Master Cylinder Removal…5561
Rear Master Cylinder Installation…5561
Torque -…5561
Front Master Cylinder Disassembly…5561
Rear Master Cylinder Disassembly…5561
Master Cylinder Assembly…5561
Master Cylinder Inspection (Visual Inspection)…5561
Brake Disc Removal…5563
Brake Disc Installation…5563
Torque -…5563
Brake Disc Wear…5563
Brake Disc Warp…5563
Special Tools -…5563
Brake Fluid Level Inspection…5564
Brake Fluid Change…5564
Brake Line Bleeding…5564
Torque -…5565
Torque -…5566
Brake Hose Removal/Installation…5568
Brake Hose Inspection…5568
Suspension…5570
Inside Circlip Pliers:…5576
Rebound Damping Force Adjustment…5578
Compression Damping Force Adjustment…5578
Spring Preload Adjustment…5579
Front Fork Removal (Each Fork Leg)…5579
Front Fork Installation…5580
Torque -…5580
Torque -…5580
Front Fork Oil Change…5580
Special Tools -…5580
Special Tool -…5582
Special Tool -…5583
Special Tool -…5583
Special Tool -…5583
Special Tools -…5584
Torque -…5584
Front Fork Disassembly…5584
Special Tool -…5584
Front Fork Assembly…5585
Special Tool -…5585
Torque -…5585
Special Tool -…5586
Inner Tube Inspection…5586
Dust Seal Inspection…5586
Spring Tension…5587
Rebound Damping Force Adjustment…5588
Compression Damping Force Adjustment…5588
Spring Preload Adjustment…5588
Special Tools -…5588
Special Tools -…5589
Rear Shock Absorber Removal…5589
Special Tools -…5589
Rear Shock Absorber Installation…5590
Torque -…5590
Rear Shock Absorber Inspection…5590
Rear Shock Absorber Scrapping…5590
Swingarm Removal…5591
Special Tool -…5592
Swingarm Installation…5592
Torque -…5592
Special Tool -…5593
Torque -…5593
Torque -…5593
Swingarm Bearing Removal…5593
Special Tool -…5593
Special Tool -…5593
Swingarm Bearing Installation…5594
Special Tools -…5594
Swingarm Bearing, Sleeve Inspection…5594
Chain Guide Inspection…5595
Tie-Rod Removal…5596
Special Tools -…5596
Tie-Rod Installation…5596
Torque -…5596
Rocker Arm Removal…5596
Special Tools -…5596
Rocker Arm Installation…5597
Torque -…5597
Tie-Rod and Rocker Arm Bearing Removal…5597
Special Tools -…5597
Tie-Rod and Rocker Arm Bearing Installation…5597
Special Tools -…5598
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…5599
Rocker Arm/Tie-Rod Bearing Lubrication…5599
Steering…5600
Bearing Puller Adapter:…5603
Steering Inspection…5604
Steering Adjustment…5604
Stem, Stem Bearing Removal…5605
Special Tool -…5605
Special Tool -…5605
Special Tools -…5606
Stem, Stem Bearing Installation…5606
Special Tools -…5606
Special Tools -…5606
Special Tool -…5607
Torque -…5607
Torque -…5608
Steering Stem Bearing Lubrication…5608
Steering Stem Warp…5608
Stem Cap Deterioration, Damage…5608
Handlebar Removal…5609
Handlebar Installation…5609
Torque -…5609
Torque -…5610
Frame…5612
Rear Seat Removal…5619
Rear Seat Installation…5619
Front Seat Removal…5619
Front Seat Installation…5619
Lower Fairing Removal…5620
Lower Fairing Installation…5620
Center Fairing Removal…5620
Center Fairing Installation…5621
Windshield Removal…5621
Windshield Installation…5621
Torque -…5621
Upper Fairing Removal…5621
Upper Fairing Disassembly…5622
Upper Fairing Assembly…5622
Upper Fairing Installation…5623
Torque -…5623
Upper Inner Fairing Removal…5623
Upper Inner Fairing Installation…5623
Center Inner Fairing Removal…5623
Center Inner Fairing Installation…5623
Right and Left Inner Fairing Removal…5624
Right and Left Inner Fairing Installation…5624
Left Side Cover Removal…5625
Left Side Cover Installation…5625
Right Side Cover Removal…5625
Right Side Cover Installation…5625
Seat Cover Removal…5626
Seat Cover Installation…5626
Front Fender Removal…5627
Front Fender Installation…5627
Torque -…5627
Flap and Rear Fender Rear Removal…5627
Flap and Rear Fender Rear Installation…5628
Rear Fender Front Removal…5629
Rear Fender Front Installation…5629
Rear Frame Removal…5630
Rear Frame Installation…5630
Torque -…5630
Frame Inspection…5630
Side Stand Removal…5631
Side Stand Installation…5631
Torque -…5631
Torque -…5631
Electrical System…5632
Flywheel Holder:…5650
There are a number of important precautions that are musts when …5651
Wiring Inspection…5653
Special Tool -…5653
Battery Removal…5654
Battery Installation…5654
Battery Activation…5654
Precautions…5657
1)…5657
2)…5657
3)…5657
4)…5657
Interchange…5657
Charging Condition Inspection…5658
Refreshing Charge…5658
Alternator Cover Removal…5660
Alternator Cover Installation…5660
Sealant -…5660
Torque -…5660
Stator Coil Removal…5660
Stator Coil Installation…5661
Torque -…5661
Sealant -…5661
Torque -…5661
Alternator Rotor Removal…5661
Special Tool -…5661
Special Tool -…5661
Alternator Rotor Installation…5661
Special Tool -…5662
Torque -…5662
Alternator Inspection…5663
Special Tool -…5663
Regulator/Rectifier Removal…5664
Regulator/Rectifier Inspection…5664
Charging Voltage Inspection…5666
Special Tool -…5666
Charging System Circuit…5667
Starter Motor Clutch Removal/Installation…5668
Starter Motor Clutch Inspection…5668
Starter Motor Clutch Disassembly…5668
Starter Motor Clutch Assembly…5668
Torque -…5668
Crankshaft Sensor Removal…5670
Crankshaft Sensor Installation…5671
Torque -…5671
Sealant -…5671
Torque -…5671
Crankshaft Sensor Inspection…5671
Special Tool -…5671
Crankshaft Sensor Peak Voltage…5671
Special Tools -…5672
Timing Rotor Removal…5672
Special Tool -…5672
Timing Rotor Installation…5672
Torque -…5672
Special Tool -…5672
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…5672
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…5673
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…5673
Stick Coil Primary Peak Voltage…5674
Special Tools -…5674
Spark Plug Removal…5674
Spark Plug Installation…5675
Spark Plug Clean and Inspection…5675
Spark Plug Gap Inspection…5675
Camshaft Position Sensor Removal…5675
Camshaft Position Sensor Installation…5675
Torque -…5675
Camshaft Position Sensor Inspection…5675
Special Tool -…5676
Camshaft Position Sensor Peak Voltage Inspection…5676
Special Tools -…5676
Interlock Operation Inspection…5677
IC Igniter Inspection…5678
Ignition System Circuit…5679
Starter Motor Removal…5680
Starter Motor Installation…5680
Torque -…5680
Starter Motor Disassembly…5680
Starter Motor Assembly…5680
Brush Inspection…5681
Commutator Cleaning and Inspection…5682
Armature Inspection…5682
Special Tool -…5682
Brush Lead Inspection…5682
Special Tool -…5682
Right-hand End Cover Assembly Inspection…5683
Special Tool -…5683
Starter Relay Inspection…5683
Special Tool -…5683
Electric Starter Circuit…5684
This motorcycle adopt the daylight system and have a headlight r…5685
Headlight Beam Horizontal Adjustment…5685
Headlight Beam Vertical Adjustment…5685
Headlight Bulb Replacement…5685
City Light Bulb Replacement…5686
Headlight Removal/Installation…5686
Tail/Brake Light (LED) Removal…5687
Tail/Brake Light (LED) Installation…5687
License Plate Light Bulb Replacement…5687
Headlight/Tail Light Circuit…5688
Turn Signal Light Bulb Replacement…5689
Turn Signal Relay Inspection…5690
Turn Signal Light Circuit…5692
Fan Motor Inspection…5693
Radiator Fan Circuit…5694
Meter Unit Removal…5695
Meter Unit Disassembly…5695
Electronic Combination Meter Assembly Inspection…5696
Special Tool -…5696
Special Tool -…5701
Meter Circuit…5704
This motorcycle is equipped with an immobilizer system to protec…5705
Operational Cautions…5705
Key Registration…5705
Special Tool -…5706
Spare User Key Registration Flow Chart…5710
Special Tool -…5711
All Keys Initial Registration Flow Chart…5720
Immobilizer System Parts Replacement…5721
Immobilizer System Inspection…5723
Immobilizer System Circuit…5723
Brake Light Timing Inspection…5724
Brake Light Timing Adjustment…5724
Neutral Switch Replacement…5724
Torque -…5724
Switch Inspection…5725
Special Tool -…5725
Rear Brake Light Switch Connections…5725
Side Stand Switch Connections…5725
Neutral Switch Connections…5725
Oil Pressure Switch Connections *…5725
Water Temperature Sensor Inspection…5726
Speed Sensor Removal…5726
Speed Sensor Installation…5726
Torque -…5726
Speed Sensor Inspection…5727
Special Tool -…5727
Fuel Reserve Switch Inspection…5727
Special Tool -…5727
The relay box [A] has relays and diodes. The relays and diodes c…5728
Relay Box Removal…5728
Relay Circuit Inspection…5728
Diode Circuit Inspection…5730
Relay Box Internal Circuit (ZX636-C1 Models of ZX636CE000001 thr…5730
Relay Box Internal Circuit (After ZX636CE013061 of ZX636C Models…5731
30 A Main Fuse Removal…5732
Fuse Box Fuse Removal…5732
15 A ECU Fuse Removal…5732
Fuse Installation…5733
Fuse Inspection…5733
Appendix…5734
California Model…5759
NOTE…5761
Engine Doesn't Start, Starting Difficulty:…5761
Starter motor not rotating:…5761
Starter motor rotating but engine doesn't turn over:…5761
Engine won't turn over:…5761
No fuel flow:…5761
No spark; spark weak:…5761
Fuel/air mixture incorrect:…5761
Compression Low:…5761
Poor Running at Low Speed:…5761
Spark weak:…5761
Fuel/air mixture incorrect:…5761
Compression low:…5761
Other:…5762
Poor Running or No Power at High Speed:…5762
Firing incorrect:…5762
Fuel/air mixture incorrect:…5762
Compression low:…5762
Knocking:…5762
Miscellaneous:…5762
Overheating:…5762
Firing incorrect:…5762
Muffler overheating:…5762
Fuel/air mixture incorrect:…5762
Compression high:…5762
Engine load faulty:…5762
Lubrication inadequate:…5763
Oil cooler incorrect:…5763
Gauge incorrect:…5763
Coolant incorrect:…5763
Cooling system component incorrect:…5763
Over Cooling:…5763
Gauge incorrect:…5763
Cooling system component incorrect:…5763
Clutch Operation Faulty:…5763
Clutch slipping:…5763
Clutch not disengaging properly:…5763
Gear Shifting Faulty:…5763
Doesn't go into gear; shift pedal doesn't return:…5763
Jumps out of gear:…5763
Overshifts:…5763
Abnormal Engine Noise:…5763
Knocking:…5763
Piston slap:…5763
Valve noise:…5763
Other noise:…5763
Abnormal Drive Train Noise:…5764
Clutch noise:…5764
Transmission noise:…5764
Drive line noise:…5764
Abnormal Frame Noise:…5764
Front fork noise:…5764
Rear shock absorber noise:…5764
Disc brake noise:…5764
Other noise:…5764
Oil Pressure Warning Light Goes On:…5764
Exhaust Smokes Excessively:…5764
White smoke:…5764
Black smoke:…5764
Brown smoke:…5764
Handling and/or Stability Unsatisfactory:…5764
Handlebar hard to turn:…5764
Handlebar shakes or excessively vibrates:…5764
Handlebar pulls to one side:…5764
Shock absorption unsatisfactory:…5764
Brake Doesn't Hold:…5765
Battery Trouble:…5765
Battery discharged:…5765
Battery overcharged:…5765
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6RR (EN)…5767
tables…0
LIST OF ABBREVIATIONS…5770
Units of Mass…5786
Units of Volume…5786
Units of Force…5786
Units of Length…5786
Units of Torque…5786
Units of Pressure…5786
Units of Speed…5786
Units of Power…5786
Periodic Inspection…5789
Periodic Replacement Parts…5791
Periodic Inspection…5792
Periodic Replacement Parts…5794
Basic Torque for General Fasteners…5800
Throttle Grip Free Play…5804
Engine Vacuum…5805
Example:…5805
Main Throttle Sensor Output Voltage…5807
Idle Speed…5807
Valve Clearance…5810
Example:…5812
Adjustment Shims…5813
Clutch Lever Free Play…5814
Air Pressure (when Cold)…5815
Tread Depth…5816
Chain Slack…5818
Drive Chain 20-link Length…5820
Standard Chain…5820
Recommended Disc Brake Fluid…5822
Pad Lining Thickness…5822
Side Stand Switch Operation…5830
Water and Coolant Mixture Ratio (Recommended)…5837
Recommended Engine Oil…5839
Terminal Names…5866
Sample Diagnosis Sheet…5873
Engine Doesn't Start, Starting Difficulty…5875
Poor Running at Low Speed…5877
Poor Running or No Power at High Speed:…5880
Service Code Table…5886
Main Throttle Sensor Input Voltage…5890
Input Voltage at ECU Connector…5890
Main Throttle Sensor Input Voltage…5891
Input Voltage at Sensor…5891
Main Throttle Sensor Output Voltage…5891
Idle Speed…5891
Output Voltage at ECU…5891
Main Throttle Sensor Output Voltage…5892
Output Voltage at Sensor…5892
Main Throttle Sensor Resistance…5893
Inlet Air Pressure Sensor Input Voltage…5894
Input Voltage at ECU…5894
Inlet Air Pressure Sensor Input Voltage…5895
Input Voltage at Sensor Connector…5895
Inlet Air Pressure Sensor Output Voltage…5895
Output Voltage at ECU…5895
Inlet Air Pressure Sensor Output Voltage…5896
Output Voltage at Sensor Connector…5896
Inlet Air Pressure Sensor Output Voltage Connection to Sensor…5897
Inlet Air Temperature Sensor Output Voltage…5899
Output Voltage at ECU…5899
Inlet Air Temperature Sensor Resistance…5900
Water Temperature Sensor Output Voltage…5902
Output Voltage at ECU…5902
Atmospheric Pressure Sensor Input Voltage…5904
Input Voltage at ECU…5904
Atmospheric Pressure Sensor Input Voltage…5905
Input Voltage at Sensor Connector…5905
Atmospheric Pressure Sensor Output Voltage…5905
Output Voltage…5905
Atmospheric Pressure Sensor Output Voltage…5906
Output Voltage at Sensor…5906
Speed Sensor Input Voltage…5910
Input Voltage at Sensor…5910
Speed Sensor Output Voltage…5911
Output Voltage at Sensor …5911
Vehicle-down Sensor Input Voltage…5913
Power Source Voltage at Sensor…5913
Vehicle-down Sensor Output Voltage…5913
Output Voltage at Sensor…5913
Subthrottle Sensor Input Voltage…5915
Input Voltage at ECU Connector…5915
Subthrottle Sensor Input Voltage…5916
Input Voltage at Sensor…5916
Subthrottle Sensor Output Voltage…5916
Output Voltage at ECU…5916
Subthrottle Sensor Output Voltage…5917
Output Voltage at Sensor…5917
Subthrottle Sensor Resistance…5918
Exhaust Butterfly Valve Actuator Sensor Resistance…5919
Stick Coil Input Voltage at ECU…5920
Input Voltage at ECU…5920
Subthrottle Valve Actuator Resistance…5922
Subthrottle Valve Actuator Input Voltage…5923
Input Voltage at Sensor…5923
Connections…5926
Actuator Output Voltage (Pulley Original Position)…5926
ECU Grounding Inspection…5928
ECU Power Source Inspection…5928
FI Indicator Light (LED) Check…5931
Fuel Pressure…5932
Fuel Pressure (Idling)…5933
Amount of Fuel Flow…5934
Pump Operating Voltage at Pump…5936
Operating Voltage at Pump Connector…5936
Primary Fuel Injector Resistance…5939
Secondary Fuel Injector Resistance…5940
Primary Fuel Injector Power Source Voltage…5940
Secondary Fuel Injector Power Source Voltage…5940
Power Source Voltage at Fuel Injector Connector…5940
Primary Fuel Injector Output Voltage…5941
Secondary Fuel Injector Output Voltage…5941
Output Voltage at Fuel Injector Connector…5941
Fuel Line Maximum Pressure…5942
Radiator Cap Relief Pressure…5977
Thermostat Valve Opening Temperature…5979
Vacuum Switch Valve Closing Pressure (Open → Close)…5994
Camshaft Journal, Camshaft Cap Clearance…6001
Camshaft Journal Diameter…6001
Camshaft Runout…6001
Cam Height…6002
Cylinder Compression…6003
Cylinder Head Warp…6005
Valve/Valve Guide Clearance (Wobble Method)…6008
Valve Seating Surface Outside Diameter…6008
Valve Seating Surface Width…6008
Cylinder Inside Diameter…6015
Piston Diameter…6015
Piston Ring/Groove Clearance…6016
Piston Ring Groove Width…6016
Piston Ring Thickness…6016
Piston Ring End Gap…6017
Spring Plate Free Play …6039
Clutch Plate Assembly Length…6039
Friction Plate Thickness…6040
Friction and Steel Plate Warp…6040
Clutch Spring Free Length…6040
Oil Pressure…6056
Connecting Rod Big End Bearing Insert Selection…6073
Crankshaft Main Bearing Insert Selection…6073
Connecting Rod Bend…6083
Connecting Rod Twist…6083
Connecting Rod Big End Side Clearance…6083
Connecting Rod Big End Bearing Insert/Crankpin Clearance…6084
Crankpin Diameter…6084
Crankpin Diameter Marks…6084
Connecting Rod Big End Inside Diameter Marks…6085
Crankshaft Side Clearance…6085
Crankshaft Runout…6086
Crankshaft Main Bearing Insert/Journal Clearance…6086
Crankshaft Main Journal Diameter…6086
Crankshaft Main Journal Diameter Marks…6086
Crankcase Main Bearing Inside Diameter Marks…6087
Shift Fork Ear Thickness…6095
Gear Groove Width…6095
Shift Fork Guide Pin Diameter…6095
Shift Drum Groove Width…6095
Rim Runout (with tire installed)…6106
Axle Runout/100 mm (3.94 in.)…6106
Balance Weight…6107
Link Pin Outside Diameter…6123
Link Plates Outside Width…6123
Rear Sprocket Warp…6128
Pedal Position…6136
Brake Discs Thickness…6146
Disc Runout…6146
Rebound Damping Force Adjustment…6161
Compression Damping Force Adjustment…6161
Adjuster Protrusion (from top)…6162
Spring Action…6162
Fork Oil…6165
Oil Level (fully compressed, without spring)…6166
Spring Free Length…6169
Rebound Damping Force Adjustment…6170
Compression Damping Force Adjustment…6170
Compression Damping Force Adjustment…6171
Spring Preload Setting…6172
Spring Adjustment…6172
Kawasaki-recommended chargers…6237
Battery Terminal Voltage…6239
Terminal Voltage: 11.5 ∼ less than 12.8 V…6239
Terminal Voltage: less than 11.5 V…6239
Table 1 Alternator Output Voltage…6244
Table 2 Stator Coil Resistance…6244
Charging Voltage…6247
Crankshaft Sensor Peak Voltage…6253
Ignition Coil Winding Resistance…6254
Primary Lead Connection…6255
Stick Coil Primary Peak Voltage…6255
Connections:…6257
Camshaft Position Sensor Peak Voltage…6257
Condition…6258
Condition…6258
Condition…6258
Starter Motor Brush Length…6262
Commutator Diameter…6263
Testing Relay…6264
Testing Turn Signal Relay…6271
Testing Turn Signal Relay…6272
Water Temperature Sensor…6286
Connections…6287
Relay Circuit Inspection (with the battery disconnected)…6288
Relay Circuit Inspection (with the battery connected)…6289
Diode Circuit Inspection…6289
toc…0
Read OWNER'S MANUAL before operating…5770
EMISSION CONTROL INFORMATION…5771
1…5771
2…5771
3…5771
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…5772
Foreword…5773
General Information…5775
Before starting to perform an inspection service or carry out a …5776
Battery Ground…5776
Edges of Parts…5776
Solvent…5776
Cleaning vehicle before disassembly…5776
Arrangement and Cleaning of Removed Parts…5777
Storage of Removed Parts…5777
Inspection…5777
Replacement Parts…5777
Assembly Order…5777
Tightening Sequence…5778
Tightening Torque…5778
Force…5778
Gasket, O-ring…5778
Liquid Gasket, Non-permanent Locking Agent…5778
Press…5779
Ball Bearing and Needle Bearing…5779
Oil Seal, Grease Seal…5779
Circlips, Cotter Pins…5779
Lubrication…5780
Direction of Engine Rotation…5780
Electrical Leads…5780
Instrument…5780
ZX600-N1 (Europe) Left Side View…5781
ZX600-N1 (Europe) Right Side View…5781
ZX600-N1 (US and Canada) Left Side View…5782
ZX600-N1 (US and Canada) Right Side View…5782
Prefixes for Units…5786
Units of Temperature…5786
Periodic Maintenance…5787
The scheduled maintenance must be done in accordance with this c…5789
The scheduled maintenance must be done in accordance with this c…5792
The following tables list the tightening torque for the major fa…5795
Inside Circlip Pliers:…5803
Fuel System (DFI)…5804
Throttle Control System Inspection…5804
Engine Vacuum Synchronization Inspection…5804
Special Tool -…5805
Special Tool -…5805
Idle Speed Inspection…5807
Idle Speed Adjustment…5808
Fuel Hose Damage and Installation Condition Inspection…5808
Evaporative Emission Control System Inspection (California Model…5808
Cooling System…5809
Coolant Level Inspection…5809
Water Hose Damage and Installation Condition Inspection…5810
Torque -…5810
Engine Top End…5810
Valve Clearance Inspection…5810
Valve Clearance Adjustment…5811
Air Suction System Damage Inspection…5814
Clutch…5814
Clutch Operation Inspection …5814
Wheels/Tires…5815
Air Pressure Inspection…5815
Wheel/Tire Damage Inspection…5816
Tire Tread Wear Inspection …5816
Wheel Bearing Damage Inspection…5817
Final Drive…5817
Drive Chain Lubrication Condition Inspection…5817
Drive Chain Slack Inspection…5818
Drive Chain Slack Adjustment…5819
Torque -…5819
Wheel Alignment Inspection…5820
Drive Chain Wear Inspection…5820
Chain Guide Wear Inspection…5821
Brakes…5821
Brake Fluid Leak (Brake Hose and Pipe) Inspection…5821
Brake Hose Damage and Installation Condition Inspection…5821
Torque -…5821
Brake Operation Inspection…5821
Brake Fluid Level Inspection…5822
Brake Pad Wear Inspection…5822
Brake Light Switch Operation Inspection…5823
Suspension…5823
Front Forks/Rear Shock Absorber Operation Inspection…5823
Front Fork Oil Leak Inspection…5824
Rear Shock Absorber Oil Leak Inspection…5824
Rocker Arm Operation Inspection…5824
Tie-Rod Operation Inspection…5824
Steering…5825
Steering Play Inspection…5825
Special Tools -…5825
Steering Play Adjustment…5825
Special Tool -…5825
Torque -…5826
Steering Stem Bearing Lubrication…5826
Electrical System…5826
Spark Plug Clean and Gap Inspection…5826
Lights and Switches Operation Inspection…5827
Headlight Aiming Inspection…5829
Side Stand Switch Operation Inspection…5830
Engine Stop Switch Operation Inspection…5831
Others…5832
Chassis Parts Lubrication …5832
Pivots: Lubricate with Grease…5832
Points: Lubricate with Grease…5832
Cables: Lubricate with Rust Inhibitor…5832
Bolts, Nuts and Fasteners Tightness Inspection…5833
Bolt, Nut and Fastener to be checked…5833
Replacement Parts…5834
Air Cleaner Element Replacement…5834
Fuel Hose Replacement…5834
Coolant Change…5836
Torque -…5836
Radiator Hose and O-ring Replacement…5838
Engine Oil Change…5839
Torque -…5839
Oil Filter Replacement…5839
Special Tool -…5839
Torque -…5839
Brake Hose and Pipe Replacement…5840
Torque -…5840
Brake Fluid Change…5840
Torque -…5841
Torque -…5841
Master Cylinder Rubber Parts Replacement…5842
Special Tool -…5842
Special Tool -…5842
Torque -…5843
Caliper Rubber Parts Replacement…5843
Torque -…5844
Spark Plug Replacement…5846
Owner's Tool -…5846
Torque -…5846
Fuel System (DFI)…5847
Dummy Page…5849
Oil Pressure Gauge, 5 kgf/cm 2:…5858
Subthrottle Sensor [A]…5860
DFI System…5862
DFI System Wiring Diagram…5864
Terminal Numbers of ECU Connectors…5866
There are a number of important precautions that should be follo…5867
Torque -…5867
Outline…5868
Special Tool -…5868
Sealant -…5869
Special Tool -…5869
DFI Diagnosis Flow Chart…5872
Inquiries to Rider…5872
NOTE…5875
Self-diagnosis Outline…5883
Self-diagnosis Procedures…5883
Service Code Clearing Procedures…5884
Service Code Reading…5886
Service Code Erasing…5886
Backups…5888
The main throttle sensor is a rotating variable resistor that ch…5890
Main Throttle Sensor Removal/Adjustment…5890
Main Throttle Sensor Input Voltage Inspection…5890
Special Tool -…5890
Special Tool -…5891
Main Throttle Sensor Output Voltage Inspection…5891
Special Tool -…5891
Special Tool -…5892
Main Throttle Sensor Resistance Inspection…5893
CAUTION…5894
Inlet Air Pressure Sensor Removal…5894
Inlet Air Pressure Sensor Installation…5894
Inlet Air Pressure Sensor Input Voltage Inspection…5894
Special Tool -…5894
Special Tool -…5895
Inlet Air Temperature Sensor Output Voltage Inspection…5895
Special Tool -…5896
Special Tools -…5897
Inlet Air Temperature Sensor Removal/Installation…5899
Inlet Air Temperature Sensor Output Voltage Inspection…5899
Special Tool -…5899
Sealant -…5900
Inlet Air Temperature Sensor Resistance Inspection…5900
Water Temperature Sensor Removal/Installation…5902
Sealant -…5902
Torque -…5902
Water Temperature Sensor Output Voltage Inspection…5902
Special Tool -…5902
Sealant -…5903
Water Temperature Sensor Resistance Inspection…5903
CAUTION…5904
Atmospheric Pressure Sensor Removal…5904
Atmospheric Pressure Sensor Installation…5904
Atmospheric Pressure Sensor Input Voltage Inspection…5904
Special Tool -…5904
Special Tool -…5905
Atmospheric Pressure Sensor Output Voltage Inspection…5905
Special Tool -…5906
Atmospheric Pressure/Altitude Relationship…5907
Crankshaft Sensor Removal/Installation…5908
Crankshaft Sensor Inspection…5908
Camshaft Position Sensor Removal/Installation…5909
Camshaft Position Sensor Inspection…5909
Speed Sensor Removal/Installation…5910
Speed Sensor Inspection…5910
Speed Sensor Input Voltage Inspection…5910
Special Tool -…5910
Speed Sensor Output Voltage Inspection…5910
Special Tool -…5911
This sensor has a weight [A] with two magnets inside, and sends …5912
Vehicle-down Sensor Removal…5912
Vehicle-down Sensor Installation…5912
Vehicle-down Sensor Inspection…5912
Special Tool -…5913
Sealant -…5914
Subthrottle Sensor Removal/Adjustment…5915
Subthrottle Sensor Input Voltage Inspection…5915
Special Tool -…5915
Special Tool -…5916
Subthrottle Sensor Output Voltage Inspection…5916
Special Tool -…5916
Special Tool -…5917
Subthrottle Sensor Resistance Inspection…5918
Exhaust Butterfly Valve Actuator Sensor Inspection…5919
Stick Coil ##1: Service Code 51…5920
Stick Coils Removal/Installation…5920
Stick Coils Input Voltage Inspection…5920
Subthrottle Valve Actuator Removal…5922
Subthrottle Valve Actuator Inspection…5922
Subthrottle Valve Actuator Resistance Inspection…5922
Subthrottle Valve Actuator Input Voltage Inspection…5923
Special Tools -…5923
Exhaust Butterfly Valve Actuator Removal…5924
Exhaust Butterfly Valve Actuator Installation…5924
Torque -…5924
Torque -…5925
Exhaust Butterfly Valve Actuator Inspection…5925
Exhaust Butterfly Valve Actuator Output Voltage Inspection…5926
Special Tool -…5926
CAUTION…5927
ECU Removal…5927
ECU Installation…5927
ECU Power Supply Inspection…5928
Special Tool -…5928
ECU Power Source Circuit…5929
ECU Fuse Removal…5930
ECU Fuse Installation…5930
ECU Fuse Inspection…5930
Light (LED) Inspection…5931
Fuel Pressure Inspection…5932
Special Tools -…5932
Fuel Flow Rate Inspection…5933
Fuel Pump Removal…5935
Fuel Pump Installation…5935
Torque -…5936
Fuel Pump Operation Inspection…5936
Fuel Pump Operating Voltage Inspection…5936
Special Tools -…5936
CAUTION…5938
Fuel Injector Audible Inspection…5938
Fuel Injector Signal Test…5938
Special Tool -…5939
Fuel Injector Resistance Inspection…5939
Special Tool -…5939
Special Tool -…5939
Fuel Injector Unit Test…5940
Fuel Injector Voltage Inspection…5940
Special Tool -…5940
Special Tool -…5941
Fuel Injector Fuel Line Inspection…5942
Throttle Grip Free Play Inspection…5944
Throttle Grip Free Play Adjustment…5944
Cable Installation…5944
Cable Lubrication…5944
Idle Speed Inspection…5945
Throttle Bore Cleaning…5945
Synchronization Inspection…5945
Synchronization Adjustment…5945
Throttle Body Assy Removal…5945
Throttle Body Assy Installation…5946
Torque -…5947
Throttle Body Assy Disassembly…5947
Throttle Body Assy Assembly…5948
Torque -…5948
Nozzle Assy Removal…5949
Nozzle Assy Installation…5949
Torque -…5949
Nozzle Assy Disassembly…5949
Nozzle Assy Assembly…5950
Torque -…5951
Torque -…5951
Air Cleaner Element Removal…5952
Air Cleaner Element Installation…5952
Air Cleaner Element Inspection…5952
Air Cleaner Housing Removal…5952
Air Cleaner Housing Installation…5953
Torque -…5953
Air Cleaner Housing Disassembly…5954
Air Cleaner Housing Assembly…5954
Adhesive -…5954
Adhesive -…5954
Oil Draining…5954
Air Inlet Duct Removal…5954
Air Inlet Duct Installation…5954
Fuel Tank Removal…5955
Fuel Tank Installation…5957
Fuel Tank and Cap Inspection…5958
Fuel Tank Cleaning…5958
The Evaporative Emission Control System routes fuel vapors from …5959
Parts Removal/Installation…5959
Hose Inspection…5959
Separator Inspection…5959
Separator Operation Test…5960
Canister Inspection …5960
Cooling System…5961
Bearing Driver, 32:…5965
Coolant Deterioration Inspection…5968
Coolant Level Inspection…5968
Coolant Draining…5968
Coolant Filling…5968
Pressure Testing…5968
Cooling System Flushing…5969
Coolant Reserve Tank Removal…5969
Coolant Reserve Tank Installation…5969
Torque -…5969
Water Pump Removal…5970
Water Pump Installation…5970
Water Pump Impeller Disassembly/Assembly…5970
Torque -…5970
Water Pump Impeller Inspection…5970
Water Pump Housing Disassembly…5970
Water Pump Housing Assembly…5971
Special Tool -…5971
Special Tool -…5971
Mechanical Seal Inspection…5971
Radiator and Radiator Fan Removal…5972
Radiator and Radiator Fan Installation…5973
Torque -…5976
Torque -…5976
Radiator Inspection…5976
Radiator Cap Inspection…5977
Radiator Filler Neck Inspection…5977
Thermostat Removal…5978
Thermostat Installation…5978
Torque -…5978
Thermostat Inspection…5979
Hose Installation…5980
Torque -…5980
Hose Inspection…5980
CAUTION…5981
Water Temperature Sensor Removal…5981
Torque -…5981
Water Temperature Sensor Inspection…5981
Engine Top End…5983
Exhaust System…5987
Compression Gauge, 20 kgf/cm 2:…5991
Air Suction Valve Removal…5993
Air Suction Valve Installation…5993
Torque -…5993
Air Suction Valve Inspection…5993
Vacuum Switch Valve Removal…5994
Vacuum Switch Valve Installation…5994
Vacuum Switch Valve Test…5994
Special Tool -…5994
Clean Air System Hose Inspection…5995
Cylinder Head Cover Removal…5996
Cylinder Head Cover Installation…5996
Sealant -…5996
Torque -…5997
Camshaft Chain Tensioner Removal…5998
Camshaft Chain Tensioner Installation…5998
Torque -…5998
Torque -…5998
Camshaft Removal…5999
Camshaft Installation…5999
Torque -…6000
Torque -…6000
Camshaft, Camshaft Cap Wear Inspection…6001
Torque -…6001
Camshaft Runout Inspection…6001
Cam Wear Inspection…6002
Camshaft Chain Removal…6002
Cylinder Compression Measurement…6003
Special Tools -…6003
Torque -…6003
Cylinder Head Removal…6004
Cylinder Head Installation…6004
Torque -…6005
Torque -…6005
Torque -…6005
Cylinder Head Warp Inspection…6005
Valve Clearance Inspection…6006
Valve Clearance Adjustment…6006
Valve Removal…6006
Special Tools -…6006
Valve Installation…6006
Valve Guide Removal…6006
Special Tool -…6006
Valve Guide Installation…6007
Special Tools -…6007
Special Tool -…6007
Valve/Valve Guide Clearance Measurement (Wobble Method)…6007
Valve Seat Inspection…6008
Valve Seat Repair…6008
Special Tools -…6008
Cylinder Removal…6013
Cylinder Installation…6013
Piston Removal…6014
Special Tool -…6014
Piston Installation…6014
Cylinder Wear Inspection…6015
Piston Wear Inspection…6015
Piston Ring, Piston Ring Groove Wear Inspection…6016
Piston Ring Groove Width Inspection…6016
Piston Ring Thickness Inspection…6016
Piston Ring End Gap Inspection…6017
Throttle Body Holder Installation…6018
Torque -…6018
Muffler Body Removal…6019
Muffler Body Installation…6020
Torque -…6020
Exhaust Pipe Manifold Removal…6021
Exhaust Pipe Manifold Installation…6022
Torque -…6022
Exhaust Butterfly Valve Cable Removal…6023
Exhaust Butterfly Valve Cable Installation…6023
Torque -…6024
Torque -…6024
Torque -…6024
Clutch…6027
Clutch Holder:…6031
Clutch Lever Free Play Inspection…6032
Clutch Lever Free Play Adjustment…6032
Cable Removal…6032
Cable Installation…6032
Cable Lubrication…6032
Clutch Lever Installation…6032
Torque -…6032
Clutch Cover Removal…6033
Clutch Cover Installation…6033
Sealant -…6033
Torque -…6033
Release Shaft Removal…6033
Release Shaft Installation…6034
Clutch Cover Disassembly…6034
Clutch Cover Assembly…6034
Clutch Removal…6035
Special Tool -…6035
Clutch Installation…6035
Special Tool -…6037
Torque -…6037
Torque -…6038
Spring Plate Free Play Measurement…6038
Spring Plate Play Adjustment…6039
Torque -…6039
Clutch Plate, Wear, Damage Inspection…6040
Clutch Plate Warp Inspection…6040
Clutch Spring Free Length Measurement…6040
Damper Cam Inspection…6040
Engine Lubrication System…6041
Outside Circlip Pliers:…6045
WARNING…6048
Oil Level Inspection…6048
Engine Oil Change…6048
Oil Filter Replacement…6048
Oil Pan Removal…6049
Oil Pan Installation…6049
Torque -…6049
Torque -…6050
Oil Pressure Relief Valve Removal…6051
Oil Pressure Relief Valve Installation…6051
Oil Pressure Relief Valve Inspection…6051
Oil Pump Removal…6052
Oil Pump Installation…6052
Torque -…6053
Torque -…6053
Torque -…6053
Oil Pump Drive Gear Removal…6053
Special Tool -…6053
Oil Pump Drive Gear Installation…6054
Special Tool -…6054
Oil Cooler Removal…6055
Oil Cooler Installation…6055
Torque -…6055
Torque -…6055
Oil Pressure Measurement…6056
Special Tools -…6056
Torque -…6056
Oil Pressure Switch Removal…6057
Oil Pressure Switch Installation…6057
Sealant -…6057
Torque -…6057
Torque -…6057
Engine Removal/Installation…6059
Engine Mount Nut Wrench:…6062
Engine Removal…6063
Special Tool -…6064
Engine Installation…6065
Torque -…6065
Torque -…6065
Torque -…6065
Torque -…6065
Special Tool -…6065
Torque -…6065
Crankshaft/Transmission…6067
Bearing Puller:…6074
Crankcase Splitting…6075
Crankcase Assembly…6076
Sealant -…6076
Torque -…6076
Torque -…6076
Sealant -…6077
Torque -…6078
Torque -…6078
Torque -…6078
Torque -…6078
Torque -…6078
Crankshaft Removal…6079
Crankshaft Installation…6079
Connecting Rod Removal…6079
Connecting Rod Installation…6079
Crankshaft/Connecting Rod Cleaning…6083
Connecting Rod Bend Inspection…6083
Connecting Rod Twist Inspection…6083
Connecting Rod Big End Side Clearance Inspection…6083
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection…6084
Crankshaft Side Clearance Inspection…6085
Crankshaft Runout Inspection…6086
Crankshaft Main Bearing Insert/Journal Wear Inspection…6086
Shift Pedal Removal…6088
Shift Pedal Installation…6088
Torque -…6088
Torque -…6088
Torque -…6088
External Shift Mechanism Removal…6089
External Shift Mechanism Installation…6089
Torque -…6089
External Shift Mechanism Inspection…6089
Torque -…6089
Transmission Shaft Removal…6090
Transmission Shaft Installation…6090
Transmission Shaft Disassembly…6090
Special Tool -…6090
Special Tools -…6091
Transmission Shaft Assembly…6091
Special Tool -…6091
Shift Drum and Fork Removal…6094
Shift Drum and Fork Installation…6094
Torque -…6094
Shift Drum Disassembly…6094
Shift Drum Assembly…6094
Torque -…6094
Shift Fork Bending…6094
Shift Fork/Gear Groove Wear Inspection…6095
Shift Fork Guide Pin/Drum Groove Wear Inspection…6095
Gear Dog and Gear Dog Hole Damage Inspection…6095
Wheels/Tires…6097
Bearing Driver Set:…6101
Front Wheel Removal…6102
Special Tools -…6102
Front Wheel Installation…6102
Torque -…6103
Torque -…6103
Rear Wheel Removal…6103
Rear Wheel Installation…6104
Torque -…6105
Wheel Inspection…6105
Special Tools -…6105
Axle Inspection…6106
Balance Inspection…6106
Balance Adjustment…6107
Balance Weight Removal…6107
Balance Weight Installation…6107
Air Pressure Inspection/Adjustment…6109
Tire Inspection…6109
Tire Removal…6109
Tire Installation…6109
Tire Repair…6111
Hub Bearing Removal…6112
Special Tools -…6112
Hub Bearing Installation…6112
Special Tool -…6112
Special Tool -…6112
Hub Bearing Inspection…6112
Hub Bearing Lubrication…6113
Final Drive…6115
Inside Circlip Pliers:…6119
Drive Chain Slack Inspection…6120
Drive Chain Slack Adjustment…6120
Wheel Alignment Inspection/Adjustment…6120
Drive Chain Wear Inspection…6120
Drive Chain Lubrication…6120
Drive Chain Removal…6120
Drive Chain Installation…6121
Engine Sprocket Removal…6124
Engine Sprocket Installation…6124
Torque -…6124
Torque -…6125
Rear Sprocket Removal…6125
Rear Sprocket Installation…6125
Torque -…6125
Torque -…6125
Coupling Installation…6125
Coupling Bearing Removal…6126
Special Tool -…6126
Special Tool -…6126
Coupling Bearing Installation…6126
Special Tool -…6126
Special Tool -…6126
Special Tool -…6126
Coupling Bearing Inspection…6127
Coupling Bearing Lubrication…6127
Coupling Damper Inspection…6127
Sprocket Wear Inspection…6127
Rear Sprocket Warp Inspection…6128
Brakes…6129
Inside Circlip Pliers:…6135
Brake Lever Position Adjustment…6136
Brake Pedal Position Inspection …6136
Brake Pedal Position Adjustment …6136
Torque -…6136
Brake Pedal Removal…6136
Brake Pedal Installation…6137
Torque -…6137
Torque -…6137
Torque -…6137
Front Caliper Removal…6138
Rear Caliper Removal…6138
Caliper Installation…6138
Torque -…6138
Front Caliper Disassembly …6139
Front Caliper Assembly…6139
Rear Caliper Disassembly…6139
Rear Caliper Assembly…6139
Caliper Fluid Seal Damage Inspection…6139
Rear Caliper Dust Boot and Rubber Boot Damage Inspection…6140
Caliper Piston and Cylinder Damage Inspection…6140
Rear Caliper Holder Shaft Wear Inspection…6140
Front Brake Pad Removal…6141
Front Brake Pad Installation…6141
Torque -…6141
Rear Brake Pad Removal …6142
Rear Brake Pad Installation…6142
Brake Pad Wear Inspection…6142
Front Master Cylinder Removal…6143
Front Master Cylinder Installation…6143
Torque -…6143
Torque -…6143
Rear Master Cylinder Removal…6144
Rear Master Cylinder Installation…6144
Torque -…6144
Front Master Cylinder Disassembly…6144
Rear Master Cylinder Disassembly…6144
Master Cylinder Assembly…6144
Master Cylinder Inspection (Visual Inspection)…6144
Brake Disc Removal…6146
Brake Disc Installation…6146
Torque -…6146
Brake Disc Wear Inspection…6146
Brake Disc Warp Inspection…6146
Special Tools -…6146
Brake Fluid Level Inspection…6147
Brake Fluid Change…6147
Brake Line Bleeding…6147
Torque -…6148
Torque -…6149
Brake Hose Removal/Installation…6151
Brake Hose Inspection…6151
Suspension…6153
Inside Circlip Pliers:…6159
Rebound Damping Force Adjustment…6161
Compression Damping Force Adjustment…6161
Spring Preload Adjustment…6162
Front Fork Removal (Each Fork Leg)…6162
Front Fork Installation…6163
Torque -…6163
Torque -…6163
Front Fork Oil Change…6163
Special Tools -…6163
Special Tool -…6165
Special Tool -…6165
Special Tool -…6166
Special Tool -…6166
Special Tools -…6166
Torque -…6167
Front Fork Disassembly…6167
Special Tool -…6167
Front Fork Assembly…6168
Special Tool -…6168
Torque -…6168
Special Tool -…6168
Inner Tube Inspection…6168
Dust Seal Inspection…6169
Spring Tension Inspection…6169
Rebound Damping Force Adjustment…6170
Compression Damping Force Adjustment…6170
Spring Preload Adjustment…6171
Special Tools -…6171
Rear Shock Absorber Removal…6172
Special Tools -…6172
Rear Shock Absorber Installation…6172
Torque -…6172
Rear Shock Absorber Inspection…6173
Rear Shock Absorber Scrapping…6173
Swingarm Removal…6174
Special Tool -…6175
Swingarm Installation…6175
Torque -…6175
Special Tool -…6176
Torque -…6176
Torque -…6176
Swingarm Bearing Removal…6176
Special Tool -…6176
Special Tool -…6176
Swingarm Bearing Installation…6177
Special Tools -…6177
Swingarm Bearing, Sleeve Inspection…6177
Chain Guide Inspection…6178
Tie-Rod Removal…6179
Special Tools -…6179
Tie-Rod Installation…6179
Torque -…6179
Rocker Arm Removal…6179
Special Tools -…6179
Rocker Arm Installation…6180
Torque -…6180
Tie-Rod and Rocker Arm Bearing Removal…6180
Special Tools -…6180
Tie-Rod and Rocker Arm Bearing Installation…6180
Special Tools -…6181
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…6182
Rocker Arm/Tie-Rod Bearing Lubrication…6182
Steering…6183
Bearing Puller Adapter:…6186
Steering Inspection…6187
Steering Adjustment…6187
Steering Stem, Steering Stem Bearing Removal…6188
Special Tool -…6188
Special Tool -…6188
Special Tools -…6189
Steering Stem, Steering Stem Bearing Installation…6189
Special Tools -…6189
Special Tools -…6189
Special Tool -…6190
Torque -…6190
Torque -…6191
Steering Stem Bearing Lubrication…6191
Steering Stem Warp Inspection…6191
Steering Stem Cap Deterioration, Damage Inspection…6191
Handlebar Removal…6192
Handlebar Installation…6192
Torque -…6192
Torque -…6193
Frame…6195
Rear Seat Removal…6202
Rear Seat Installation…6202
Front Seat Removal…6202
Front Seat Installation…6202
Lower Fairing Removal…6203
Lower Fairing Installation…6203
Center Fairing Removal…6203
Center Fairing Installation…6204
Windshield Removal…6204
Windshield Installation…6204
Torque -…6204
Upper Fairing Removal…6204
Upper Fairing Disassembly…6205
Upper Fairing Assembly…6205
Upper Fairing Installation…6206
Torque -…6206
Upper Inner Fairing Removal…6206
Upper Inner Fairing Installation…6206
Center Inner Fairing Removal…6206
Center Inner Fairing Installation…6206
Right and Left Inner Fairing Removal…6207
Right and Left Inner Fairing Installation…6207
Left Side Cover Removal…6208
Left Side Cover Installation…6208
Right Side Cover Removal…6208
Right Side Cover Installation…6208
Seat Cover Removal…6209
Seat Cover Installation…6209
Front Fender Removal…6210
Front Fender Installation…6210
Torque -…6210
Flap and Rear Fender Rear Removal…6210
Flap and Rear Fender Rear Installation…6211
Rear Fender Front Removal…6212
Rear Fender Front Installation…6212
Rear Frame Removal…6213
Rear Frame Installation…6213
Torque -…6213
Frame Inspection…6213
Side Stand Removal…6214
Side Stand Installation…6214
Torque -…6214
Torque -…6214
Electrical System…6215
Flywheel Holder:…6231
There are a number of important precautions that are musts when …6232
Wiring Inspection…6234
Special Tool -…6234
Battery Removal…6235
Battery Installation…6235
Battery Activation…6235
Precautions…6238
1)…6238
2)…6238
3)…6238
4)…6238
Interchange…6238
Charging Condition Inspection…6239
Refreshing Charge…6239
Alternator Cover Removal…6241
Alternator Cover Installation…6241
Sealant -…6241
Torque -…6241
Stator Coil Removal…6241
Stator Coil Installation…6241
Torque -…6241
Sealant -…6241
Torque -…6242
Alternator Rotor Removal…6242
Special Tool -…6242
Special Tool -…6242
Alternator Rotor Installation…6242
Special Tool -…6243
Torque -…6243
Alternator Inspection…6243
Special Tool -…6244
Regulator/Rectifier Removal…6245
Regulator/Rectifier Inspection…6245
Charging Voltage Inspection…6247
Special Tool -…6247
Charging System Circuit…6248
Starter Motor Clutch Removal/Installation…6249
Starter Motor Clutch Inspection…6249
Starter Motor Clutch Disassembly…6249
Starter Motor Clutch Assembly…6249
Torque -…6249
Crankshaft Sensor Removal…6251
Crankshaft Sensor Installation…6252
Torque -…6252
Sealant -…6252
Torque -…6252
Crankshaft Sensor Inspection…6252
Special Tool -…6252
Crankshaft Sensor Peak Voltage Inspection…6252
Special Tools -…6253
Timing Rotor Removal…6253
Special Tool -…6253
Timing Rotor Installation…6253
Torque -…6253
Special Tool -…6253
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…6253
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…6254
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…6254
Stick Coil Primary Peak Voltage Inspection…6255
Special Tools -…6255
Spark Plug Removal…6255
Spark Plug Installation…6255
Spark Plug Clean and Inspection…6256
Spark Plug Gap Inspection…6256
Camshaft Position Sensor Removal…6256
Camshaft Position Sensor Installation…6256
Torque -…6256
Camshaft Position Sensor Inspection…6256
Special Tool -…6257
Camshaft Position Sensor Peak Voltage Inspection…6257
Special Tools -…6257
Interlock Operation Inspection…6258
IC Igniter Inspection…6259
Ignition System Circuit…6260
Starter Motor Removal…6261
Starter Motor Installation…6261
Torque -…6261
Starter Motor Disassembly…6261
Starter Motor Assembly…6261
Brush Inspection…6262
Commutator Cleaning and Inspection…6263
Armature Inspection…6263
Special Tool -…6263
Brush Lead Inspection…6263
Special Tool -…6263
Right-hand End Cover Assembly Inspection…6264
Special Tool -…6264
Starter Relay Inspection…6264
Special Tool -…6264
Electric Starter Circuit…6265
This motorcycle adopt the daylight system and have a headlight r…6266
Headlight Beam Horizontal Adjustment…6266
Headlight Beam Vertical Adjustment…6266
Headlight Bulb Replacement…6266
City Light Bulb Replacement (Europe Models)…6267
Headlight Removal/Installation…6267
Tail/Brake Light (LED) Removal…6268
Tail/Brake Light (LED) Installation…6268
License Plate Light Bulb Replacement…6268
Headlight/Tail Light Circuit…6269
Turn Signal Light Bulb Replacement…6269
Turn Signal Relay Inspection…6271
Turn Signal Light Circuit…6273
Fan Motor Inspection…6274
Radiator Fan Circuit…6274
Meter Unit Removal…6275
Meter Unit Disassembly…6275
Electronic Combination Meter Unit Inspection…6276
Special Tool -…6276
Special Tool -…6281
Meter Circuit…6283
Brake Light Timing Inspection…6284
Brake Light Timing Adjustment…6284
Neutral Switch Replacement…6284
Torque -…6284
Switch Inspection…6285
Special Tool -…6285
Rear Brake Light Switch Connections…6285
Side Stand Switch Connections…6285
Neutral Switch Connections…6285
Oil Pressure Switch Connections *…6285
Water Temperature Sensor Inspection…6286
Speed Sensor Removal…6286
Speed Sensor Installation…6286
Torque -…6286
Speed Sensor Inspection…6287
Special Tool -…6287
Fuel Reserve Switch Inspection…6287
Special Tool -…6287
The relay box [A] has relays and diodes. The relays and diodes c…6288
Relay Box Removal…6288
Relay Circuit Inspection…6288
Diode Circuit Inspection…6289
Relay Box Internal Circuit…6289
30 A Main Fuse Removal…6291
Fuse Box Fuse Removal…6291
15 A ECU Fuse Removal…6291
Fuse Installation…6292
Fuse Inspection…6292
Appendix…6293
California Model Only…6320
NOTE…6322
Engine Doesn't Start, Starting Difficulty:…6322
Starter motor not rotating:…6322
Starter motor rotating but engine doesn't turn over:…6322
Engine won't turn over:…6322
No fuel flow:…6322
No spark; spark weak:…6322
Fuel/air mixture incorrect:…6322
Compression Low:…6322
Poor Running at Low Speed:…6322
Spark weak:…6322
Fuel/air mixture incorrect:…6322
Compression low:…6322
Other:…6323
Poor Running or No Power at High Speed:…6323
Firing incorrect:…6323
Fuel/air mixture incorrect:…6323
Compression low:…6323
Knocking:…6323
Miscellaneous:…6323
Overheating:…6323
Firing incorrect:…6323
Muffler overheating:…6323
Fuel/air mixture incorrect:…6323
Compression high:…6323
Engine load faulty:…6323
Lubrication inadequate:…6323
Oil cooler incorrect:…6324
Gauge incorrect:…6324
Coolant incorrect:…6324
Cooling system component incorrect:…6324
Over Cooling:…6324
Gauge incorrect:…6324
Cooling system component incorrect:…6324
Clutch Operation Faulty:…6324
Clutch slipping:…6324
Clutch not disengaging properly:…6324
Gear Shifting Faulty:…6324
Doesn't go into gear; shift pedal doesn't return:…6324
Jumps out of gear:…6324
Overshifts:…6324
Abnormal Engine Noise:…6324
Knocking:…6324
Piston slap:…6324
Valve noise:…6324
Other noise:…6324
Abnormal Drive Train Noise:…6325
Clutch noise:…6325
Transmission noise:…6325
Drive line noise:…6325
Abnormal Frame Noise:…6325
Front fork noise:…6325
Rear shock absorber noise:…6325
Disc brake noise:…6325
Other noise:…6325
Oil Pressure Warning Light Goes On:…6325
Exhaust Smokes Excessively:…6325
White smoke:…6325
Black smoke:…6325
Brown smoke:…6325
Handling and/or Stability Unsatisfactory:…6325
Handlebar hard to turn:…6325
Handlebar shakes or excessively vibrates:…6325
Handlebar pulls to one side:…6325
Shock absorption unsatisfactory:…6325
Brake Doesn't Hold:…6325
Battery Trouble:…6326
Battery discharged:…6326
Battery overcharged:…6326
Kawasaki Motorcycle Service Repair Manual '06 ZX-10R (EN)…6328
tables…6328
LIST OF ABBREVIATIONS…6333
COUNTRY AND AREA CODES…6333
Units of Mass…6349
Units of Volume…6349
Units of Force…6349
Units of Length…6349
Units of Torque…6349
Units of Pressure…6349
Units of Speed…6349
Units of Power…6349
Periodic Inspection…6352
Periodic Replacement Parts…6354
Basic Torque for General Fasteners…6361
Throttle Grip Free Play…6365
Throttle Body Vacuum…6366
Main Throttle Sensor Output Voltage…6368
Idle Speed…6368
Valve Clearance…6372
Example:…6373
Adjustment Shims…6374
Clutch Lever Free Play…6376
Air Pressure (when Cold)…6377
Tread Depth…6378
Chain Slack…6379
Drive Chain 20-link Length…6381
Standard Chain…6381
Recommended Disc Brake Fluid…6383
Pad Lining Thickness…6383
Sidestand Switch Operation…6391
Water and Coolant Mixture Ratio (Recommended)…6399
Recommended Engine Oil…6402
Standard Spark Plug…6409
Sample Diagnosis Sheet…6440
Engine Doesn't Start, Starting Difficulty…6442
Poor Running at Low Speed…6444
Poor Running or No Power at High Speed:…6447
Main Throttle Sensor Input Voltage…6459
Input Voltage at ECU Connector…6459
Main Throttle Sensor Input Voltage…6460
Input Voltage at Sensor…6460
Main Throttle Sensor Output Voltage…6461
Idle Speed…6461
Output Voltage at ECU…6461
Throttle Sensor Output Voltage…6463
Output Voltage at Sensor…6463
Main Throttle Sensor Resistance…6464
Inlet Air Pressure Sensor Input Voltage…6465
Input Voltage at ECU…6465
Inlet Air Pressure Sensor Input Voltage…6466
Input Voltage at Sensor Connector…6466
Inlet Air Pressure Sensor Output Voltage…6466
Output Voltage at ECU…6466
Inlet Air Pressure Sensor Output Voltage…6467
Output Voltage at Sensor Connector…6467
Inlet Air Pressure Sensor Output Voltage Connection to Adapter…6468
Inlet Air Temperature Sensor Output Voltage…6470
Output Voltage at ECU…6470
Inlet Air Temperature Sensor Resistance…6471
Water Temperature Sensor Output Voltage…6473
Output Voltage at ECU…6473
Atmospheric Pressure Sensor Input Voltage…6475
Input Voltage at ECU…6475
Atmospheric Pressure Sensor Input Voltage…6476
Input Voltage at Sensor Connector…6476
Atmospheric Pressure Sensor Output Voltage…6476
Output Voltage…6476
Atmospheric Pressure Sensor Output Voltage…6477
Output Voltage at Sensor…6477
Speed Sensor Input Voltage…6481
Input Voltage at ECU Connector…6481
Speed Sensor Input Voltage…6482
Input Voltage at Sensor…6482
Speed Sensor Output Voltage…6483
Output Voltage at Sensor …6483
Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions…6484
Input Voltage at 1 ∼ 6 Gear Positions…6484
Vehicle-down sensor Power Source Voltage…6487
Power Source Voltage at Sensor…6487
Vehicle-down sensor Output Voltage…6487
Output Voltage at Sensor…6487
Subthrottle Sensor Input Voltage…6489
Input Voltage at ECU Connector…6489
Subthrottle Sensor Input Voltage…6490
Input Voltage at Sensor…6490
Subthrottle Sensor Output Voltage…6490
Output Voltage at ECU…6490
Subthrottle Sensor Output Voltage…6491
Output Voltage at Sensor…6491
Subthrottle Sensor Resistance…6492
Oxygen Sensor ##1 Output Voltage…6493
Oxygen Sensor ##1 Output Voltage (with Plugs)…6494
Oxygen Sensor ##1 Output Voltage (without Plugs)…6494
Exhaust Butterfly Valve Actuator Sensor Resistance…6496
Antenna Resistance…6497
Amplifier Input Voltage…6497
Input Voltage…6497
Testing Relay…6499
Stick Coil Input Voltage at ECU…6500
Input Voltage at ECU…6500
Subthrottle Valve Actuator Resistance…6502
Subthrottle Valve Actuator Input Voltage…6503
Input Voltage…6503
Connections to Adapter…6507
Actuator Output Voltage (Pulley Original Position)…6507
Oxygen Sensor Heaters Resistance…6508
Oxygen Sensor Heaters Power Source Voltage…6509
Power Source Voltage at Sensor Connector…6509
Oxygen Sensor ##2 Output Voltage…6512
Oxygen Sensor Output Voltage (with Plugs)…6513
Oxygen Sensor ##2 Output Voltage (without Plugs)…6513
ECU Identification…6515
ECU Grounding Inspection…6516
ECU Power Source Inspection…6517
Fuel Pressure…6521
Fuel Pressure (idling)…6522
Amount of Fuel Flow…6523
Pump Operating Voltage at Pump…6525
Operating Voltage at Pump Connector…6525
Injector Power Source Voltage at ECU Connector…6527
Power Source Voltage at ECU…6527
Injector Power Source Voltage at Injector…6528
Power Source Voltage at Injector Connector…6528
Injector Output Voltage at ECU…6528
Output Voltage at ECU…6528
Injector Output Voltage at Injector…6529
Output Voltage at Injector Connector…6529
Injector Resistance…6530
Fuel Line Maximum Pressure…6531
Radiator Cap Relief Pressure…6565
Thermostat Valve Opening Temperature…6569
Camshaft Journal, Camshaft Cap Clearance…6596
Camshaft Journal Diameter…6596
Camshaft Runout…6596
Cam Height…6597
Cylinder Compression…6598
Cylinder Head Warp…6601
Valve/Valve Guide Clearance (Wobble Method)…6604
Valve Seating Surface Outside Diameter…6604
Valve Seating Surface Width…6604
Spring Plate Free Play …6634
Spring Plate Free Play…6635
Clutch Plate Assembly Length (Reference)…6635
Friction Plate Thickness…6635
Friction and Steel Plate Warp…6636
Clutch Spring Free Length…6636
Oil Pressure…6654
Connecting Rod Big End Bearing Insert Selection…6677
Crankshaft Main Bearing Insert Selection…6677
Connecting Rod Bend…6689
Connecting Rod Twist…6690
Connecting Rod Big End Side Clearance…6690
Connecting Rod Big End Bearing Insert/Crankpin Clearance…6690
Crankpin Diameter…6691
Crankpin Diameter Marks…6691
Connecting Rod Big End Inside Diameter Marks…6692
Crankshaft Side Clearance…6692
Crankshaft Runout…6692
Crankshaft Main Bearing Insert/Journal Clearance…6693
Crankshaft Main Journal Diameter…6693
Crankshaft Main Journal Diameter Marks…6693
Crankcase Main Bearing Inside Diameter Marks…6694
Cylinder Inside Diameter…6697
Piston Diameter…6697
Piston Ring/Groove Clearance…6697
Piston Ring Groove Width…6698
Piston Ring Thickness…6698
Piston Ring End Gap…6698
Shift Fork Ear Thickness…6707
Gear Groove Width…6707
Shift Fork Guide Pin Diameter…6707
Shift Drum Groove Width…6707
Rim Runout (with tire installed)…6717
Axle Runout/100 mm (3.94 in.)…6717
Balance Weight…6719
Link Pin Outside Diameter…6735
Link Plates Outside Width…6735
Rear Sprocket Warp…6740
Pedal Position…6749
Brake Discs Thickness…6759
Disc Runout…6759
Rebound Damping Force Adjustment…6774
Compression Damping Force Adjustment…6774
Adjuster Protrusion (from the top plug nut surface)…6775
Spring Action…6775
Fork Oil…6779
Oil Level (fully compressed, without spring)…6779
Spring Free Length…6784
Rebound Damping Force Adjustment…6785
Rebound Damping Force Adjustment…6785
Spring Preload Setting…6786
Spring Adjustment…6786
Damping Force Adjustment…6802
Kawasaki-recommended chargers:…6858
Battery Terminal Voltage…6860
Terminal Voltage: 11.5 ∼ less than 12.8 V…6861
Terminal Voltage: less than 11.5 V…6861
Table 1 Alternator Output Voltage…6865
Table 2 Stator Coil Resistance…6865
Regulator/Rectifier Resistance (Unit: kΩ)…6866
Charging Voltage…6867
Crankshaft Sensor Peak Voltage…6871
Ignition Coil Winding Resistance…6874
Primary Lead Connection…6874
Stick Coil Primary Peak Voltage…6875
Connections:…6877
Camshaft Position Sensor Peak Voltage…6877
Condition:…6877
Condition:…6878
Condition:…6878
Starter Motor Brush Length…6888
Commutator Diameter…6888
Testing Relay…6889
Testing Turn Signal Relay…6896
Air Switching Valve Resistance…6898
User Key Indicator Light and Symbol Flashes…6915
Water Temperature Sensor…6932
Connections…6933
Gear Position Switch Resistance kΩ…6937
Relay Circuit Inspection (with the battery disconnected)…6938
Relay Circuit Inspection (with the battery connected)…6939
Diode Circuit Inspection…6939
toc…6328
EMISSION CONTROL INFORMATION…6334
1…6334
2…6334
3…6334
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…6335
Foreword…6336
General Information…6338
Before starting to perform an inspection service or carry out a …6339
Battery Ground…6339
Edges of Parts…6339
Solvent…6339
Cleaning vehicle before disassembly…6339
Arrangement and Cleaning of Removed Parts…6340
Storage of Removed Parts…6340
Inspection…6340
Replacement Parts…6340
Assembly Order…6340
Tightening Sequence…6341
Tightening Torque…6341
Force…6341
Gasket, O-ring…6341
Liquid Gasket, Non-permanent Locking Agent…6341
Press…6342
Ball Bearing and Needle Bearing…6342
Oil Seal, Grease Seal…6342
Circlips, Cotter Pins…6342
Lubrication…6343
Direction of Engine Rotation…6343
Electrical Wires…6343
Instrument…6343
ZX1000D6F (Europe) Left Side View…6344
ZX1000D6F (Europe) Right Side View…6344
ZX1000D6F (United States and Canada) Left Side View…6345
ZX1000D6F (United States and Canada) Right Side View…6345
Frame Number…6345
Engine Number…6345
Prefixes for Units…6349
Units of Temperature…6349
Periodic Maintenance…6350
The scheduled maintenance must be done in accordance with this c…6352
Inside Circlip Pliers:…6364
Fuel System (DFI)…6365
Throttle Control System Inspection…6365
Engine Vacuum Synchronization Inspection…6365
Special Tool -…6366
Special Tool -…6366
Special Tool -…6367
Torque -…6367
Torque -…6367
Idle Speed Inspection…6368
Idle Speed Adjustment…6369
Fuel Hose Inspection (fuel leak, damage, installation condition)…6369
Evaporative Emission Control System (California Model)…6370
Evaporative Emission Control System Inspection…6370
Cooling System…6371
Coolant Level Inspection…6371
Radiator Hose and Pipe Inspection (coolant leak, damage, install…6371
Torque -…6371
Engine Top End…6371
Valve Clearance Inspection…6371
Valve Clearance Adjustment…6373
Air Suction System…6375
Air Suction System Damage Inspection…6375
Special Tool -…6375
Clutch…6376
Clutch Operation Inspection …6376
Wheels/Tires…6377
Air Pressure Inspection…6377
Wheel/Tire Damage Inspection…6377
Tire Tread Wear Inspection …6377
Wheel Bearing Damage Inspection…6378
Drive Train…6379
Drive Chain Lubrication Condition Inspection…6379
Drive Chain Slack Inspection…6379
Drive Chain Slack Adjustment…6380
Torque -…6380
Wheel Alignment Inspection…6381
Drive Chain Wear Inspection…6381
Chain Guide Wear Inspection…6382
Brake System…6382
Brake Fluid Leak (Brake Hose and Pipe) Inspection…6382
Brake Hose Damage and Installation Condition Inspection…6382
Torque -…6382
Brake Operation Inspection…6382
Brake Fluid Level Inspection…6383
Brake Pad Wear Inspection…6383
Brake Light Switch Operation Inspection…6383
Suspensions…6384
Front Forks/Rear Shock Absorber Operation Inspection…6384
Front Fork Oil Leak Inspection…6385
Rear Shock Absorber Oil Leak Inspection…6385
Rocker Arm Operation Inspection…6385
Tie-Rod Operation Inspection…6385
Steering System…6386
Steering Play Inspection…6386
Special Tools -…6386
Steering Play Adjustment…6386
Special Tool -…6386
Torque -…6387
Steering Stem Bearing Lubrication…6387
Steering Damper Oil Leak Inspection…6387
Electrical System…6388
Lights and Switches Operation Inspection…6388
Headlight Aiming Inspection…6390
Sidestand Switch Operation Inspection…6391
Engine Stop Switch Operation Inspection…6392
Others…6393
Chassis Parts Lubrication …6393
Pivots: Lubricate with Grease…6393
Points: Lubricate with Grease…6393
Cables: Lubricate with Rust Inhibitor…6393
Bolts, Nuts and Fasteners Tightness Inspection…6394
Bolt, Nut and Fastener to be checked…6395
Replacement Parts…6396
Air Cleaner Element Replacement…6396
Torque -…6397
Fuel Hose Replacement…6397
Coolant Change…6398
Torque -…6399
Torque -…6399
Radiator Hose and O-ring Replacement…6401
Torque -…6401
Engine Oil Change…6402
Torque -…6402
Torque -…6402
Oil Filter Replacement…6402
Special Tool -…6402
Torque -…6403
Brake Hose and Pipe Replacement…6403
Torque -…6403
Brake Fluid Change…6403
Torque -…6404
Torque -…6404
Master Cylinder Rubber Parts Replacement…6405
Special Tool -…6405
Special Tool -…6405
Torque -…6406
Caliper Rubber Parts Replacement…6406
Torque -…6407
Torque -…6407
Torque -…6408
Spark Plug Replacement…6409
Owner's Tool -…6409
Torque -…6409
Fuel System (DFI)…6410
DFI System…6419
Oil Pressure Gauge, 5 kgf/cm :…6423
Main Throttle Sensor [A]…6425
DFI System Wiring Diagram…6427
Terminal Numbers of ECU Connectors…6429
DFI Servicing Precautions…6431
Torque -…6432
The warning indicator light (LED) [A] is used for the FI indicat…6433
Outline…6433
Special Tool -…6435
Sealant -…6435
Special Tool -…6436
DFI Diagnosis Flow Chart…6439
Inquiries to Rider…6439
NOTE…6442
The warning indicator light (LED) [A] is used for the FI indicat…6450
Self-diagnosis Outline…6450
Self-diagnosis Procedures…6451
Self-Diagnosis Flow Chart…6453
Service Code Reading…6454
Service Code Erasing…6454
Backups…6456
The main throttle sensor is a rotating variable resistor that ch…6459
Main Throttle Sensor Removal/Adjustment…6459
Input Voltage Inspection…6459
Special Tool -…6459
Special Tool -…6460
Output Voltage Inspection…6461
Special Tool -…6461
Special Tool -…6463
Resistance Inspection…6464
Main Throttle Sensor Circuit…6464
CAUTION…6465
Removal…6465
Installation…6465
Input Voltage Inspection…6465
Special Tool -…6465
Special Tool -…6466
Output Voltage Inspection…6466
Special Tool -…6466
Special Tool -…6467
Inlet Air Pressure Sensor Circuit…6467
Special Tools -…6468
Removal/Installation…6470
Output Voltage Inspection…6470
Special Tool -…6470
Sealant -…6471
Sensor Resistance Inspection…6471
Inlet Air Temperature Sensor Circuit…6472
Removal/Installation…6473
Sealant -…6473
Torque -…6473
Output Voltage Inspection…6473
Special Tool -…6473
Sealant -…6474
Sensor Resistance Inspection…6474
Water Temperature Sensor Circuit…6474
CAUTION…6475
Removal…6475
Installation…6475
Input Voltage Inspection…6475
Special Tool -…6475
Special Tool -…6476
Output Voltage Inspection…6476
Special Tool -…6476
Special Tool -…6477
Atmospheric Pressure Sensor Circuit…6477
Atmospheric Pressure/Altitude Relationship…6478
Crankshaft Sensor Removal/Installation…6479
Crankshaft Sensor Inspection…6479
Crankshaft Sensor Circuit…6479
Camshaft Position Sensor Removal/Installation…6480
Camshaft Position Sensor Inspection…6480
Camshaft Position Sensor Circuit…6480
Speed Sensor Removal/Installation…6481
Input Voltage Inspection…6481
Special Tool -…6481
Special Tool -…6482
Output Voltage Inspection…6482
Special Tool -…6482
Speed Sensor Circuit…6483
Gear Position Switch Removal/Installation…6484
Gear Position Switch Inspection…6484
Input Voltage Inspection…6484
Special Tool -…6484
Gear Position Switch Circuit…6485
This sensor has a weight [A] with two magnets inside, and sends …6486
Removal…6486
Installation…6486
Torque -…6486
Inspection…6486
Special Tool -…6487
Special Tool -…6487
Sealant -…6488
Vehicle-down Sensor Circuit…6488
The subthrottle sensor is a rotating variable resistor that chan…6489
Subthrottle Sensor Removal/Adjustment…6489
Input Voltage Inspection…6489
Special Tool -…6489
Special Tool -…6490
Output Voltage Inspection…6490
Special Tool -…6490
Special Tool -…6491
Resistance Inspection…6492
Subthrottle Sensor Circuit…6492
Oxygen Sensor ##1 Removal/Installation…6493
Oxygen Sensor ##1 Inspection…6493
Special Tool -…6493
Special Tool -…6494
Sealant -…6494
Oxygen Sensor Circuit…6495
Exhaust Butterfly Valve Actuator Sensor Inspection…6496
Exhaust Butterfly Valve Actuator Sensor Circuit…6496
Antenna Resistance Inspection…6497
Amplifier Input Voltage Inspection…6497
Special Tool -…6497
User Key Inspection…6498
Immobilizer System Circuit…6498
Fuel Pump Relay Removal…6499
Fuel Pump Relay Inspection…6499
Special Tool -…6499
Fuel Pump Relay Circuit…6499
Stick Coil ##1: Service Code 51…6500
Removal/Installation…6500
Input Voltage Inspection…6500
Special Tool -…6500
Stick Coil Circuit…6501
Subthrottle Valve Actuator Removal…6502
Subthrottle Valve Actuator Inspection…6502
Resistance Inspection…6502
Input Voltage Inspection…6503
Special Tools -…6503
Subthrottle Valve Actuator Circuit…6504
Exhaust Butterfly Valve Actuator Removal…6505
Exhaust Butterfly Valve Actuator Installation…6505
Torque -…6505
Torque -…6506
Exhaust Butterfly Valve Actuator Inspection…6506
Output Voltage Inspection…6507
Special Tool -…6507
Exhaust Butterfly Valve Actuator Circuit…6507
Oxygen Sensor Heaters Removal/Installation…6508
Oxygen Sensor Heaters Inspection …6508
Special Tool -…6508
Special Tool -…6509
Sealant -…6509
Oxygen Sensor Circuit…6510
ECU Main Relay Inspection…6511
Oxygen Sensor ##2 Removal/Installation…6512
Oxygen Sensor ##2 Inspection…6512
Special Tool -…6512
Special Tool -…6513
Sealant -…6513
Oxygen Sensor Circuit…6514
CAUTION…6515
ECU Identification…6515
ECU Removal…6515
ECU Installation…6516
ECU Power Supply Inspection…6516
Special Tool -…6516
ECU Power Source Circuit…6518
ECU Fuse Removal…6519
ECU Fuse Installation…6519
ECU Fuse Inspection…6519
Light (LED) Inspection…6520
Warning Indicator Light (LED) (FI/Immobilizer) Circuit…6520
Fuel Pressure Inspection…6521
Special Tools -…6521
Fuel Flow Rate Inspection…6522
Special Tool -…6522
Fuel Pump Removal…6524
Fuel Pump Installation…6524
Torque -…6525
Operation Inspection…6525
Operating Voltage Inspection…6525
Special Tools -…6525
Fuel Pump Circuit…6526
Removal/Installation…6527
Power Source Voltage Inspection…6527
Special Tool -…6527
Special Tool -…6528
Output Voltage Inspection…6528
Special Tool -…6528
Special Tool -…6529
Audible Inspection…6529
Special Tool -…6529
Injector Signal Test…6530
Special Tool -…6530
Injector Resistance Inspection…6530
Injector Unit Test…6531
Injector Fuel Line Inspection…6531
Fuel Injector Circuit…6532
Free Play Inspection…6533
Free Play Adjustment…6533
Cable Installation…6533
Cable Lubrication…6533
Idle Speed Inspection…6534
Throttle Bore Cleaning…6534
Synchronization Inspection…6534
Synchronization Adjustment…6534
Throttle Body Assy Removal…6534
Throttle Body Assy Installation…6536
Torque -…6536
Torque -…6536
Throttle Body Assy Disassembly…6537
Throttle Body Assy Assembly…6538
Torque -…6539
Element Removal…6540
Element Installation…6540
Air Cleaner Element Inspection…6540
Air Cleaner Housing Removal…6540
Air Cleaner Housing Installation…6541
Torque -…6542
Air Cleaner Housing Disassembly…6542
Air Cleaner Housing Assembly…6542
Sealant -…6542
Oil Draining…6542
Air Inlet Duct Removal…6543
Air Inlet Duct Installation…6543
Torque -…6543
Fuel Tank Removal…6544
Fuel Tank Installation…6546
Fuel Tank and Cap Inspection…6547
Fuel Tank Cleaning…6547
The Evaporative Emission Control System routes fuel vapors from …6548
Parts Removal/Installation…6548
Hose Inspection…6548
Separator Inspection…6548
Separator Operation Test…6549
Canister Inspection…6549
Cooling System…6550
Coolant Deterioration Inspection…6556
Coolant Level Inspection…6556
Coolant Draining…6556
Coolant Filling…6556
Pressure Testing…6556
Cooling System Flushing…6557
Coolant Reserve Tank Removal…6557
Coolant Reserve Tank Installation…6558
Torque -…6558
Water Pump Removal…6559
Water Pump Installation…6559
Torque -…6560
Torque -…6560
Torque -…6560
Water Pump Impeller Inspection…6560
Radiator and Radiator Fan Removal…6561
Radiator and Radiator Fan Installation…6562
Torque -…6563
Torque -…6563
Torque -…6563
Torque -…6563
Radiator Inspection…6565
Radiator Cap Inspection…6565
Radiator Filler Neck Inspection…6566
Thermostat Removal…6567
Thermostat Installation…6567
Torque -…6568
Torque -…6568
Torque -…6568
Torque -…6568
Thermostat Inspection…6568
Hose Installation…6570
Torque -…6570
Hose Inspection…6570
CAUTION…6571
Water Temperature Sensor Removal…6571
Water Temperature Sensor Inspection…6571
Engine Top End…6572
Dummy Page…6574
Exhaust System ZX1000D6F…6579
Compression Gauge, 20 kgf/cm :…6583
Air Suction Valve Removal…6585
Air Suction Valve Installation…6585
Torque -…6585
Air Suction Valve Inspection…6585
Air Switching Valve Removal…6586
Air Switching Valve Installation…6586
Air Switching Valve Operation Test…6586
Air Switching Valve Unit Test…6586
Clean Air System Hose Inspection…6586
Cylinder Head Cover Removal…6587
Cylinder Head Cover Installation…6587
Sealant -…6587
Torque -…6588
Camshaft Chain Tensioner Removal…6589
Camshaft Chain Tensioner Installation…6590
Torque -…6590
Torque -…6590
Torque -…6590
Camshaft Removal…6591
Camshaft Installation…6592
Torque -…6593
Torque -…6595
Torque -…6595
Camshaft, Camshaft Cap Wear…6596
Camshaft Runout…6596
Cam Wear…6597
Camshaft Chain Removal…6597
Cylinder Compression Measurement…6598
Special Tools -…6598
Torque -…6598
Cylinder Head Removal…6599
Cylinder Head Installation…6600
Torque -…6600
Torque -…6600
Torque -…6600
Cylinder Head Warp…6601
Valve Clearance Inspection…6602
Valve Removal…6602
Special Tools -…6602
Valve Installation…6602
Valve Guide Removal…6602
Special Tool -…6602
Valve Guide Installation…6603
Special Tools -…6603
Special Tool -…6603
Valve-to-Guide Clearance Measurement (Wobble Method)…6603
Valve Seat Inspection…6604
Valve Seat Repair…6604
Special Tools -…6604
Throttle Body Assy Holder Removal…6609
Throttle Body Assy Holder Installation…6609
Torque -…6609
WARNING…6610
Muffler Body Removal…6610
Muffler Body Installation…6611
Torque -…6611
Torque -…6611
Middle and Rear Exhaust Pipe Removal…6612
Middle and Rear Exhaust Pipe Installation…6613
Torque -…6613
Torque -…6613
Torque -…6613
Front Exhaust Pipe Removal…6614
Front Exhaust Pipe Installation…6615
Torque -…6615
Exhaust Butterfly Valve Cable Removal…6616
Exhaust Butterfly Valve Cable Installation…6617
Torque -…6617
Torque -…6618
Torque -…6618
Clutch…6620
Clutch Holder:…6624
Clutch Lever Free Play Inspection…6625
Clutch Lever Free Play Adjustment…6625
Cable Removal…6625
Cable Installation…6625
Cable Lubrication…6625
Clutch Lever Installation…6625
Torque -…6625
Clutch Cover Removal…6626
Clutch Cover Installation…6626
Sealant -…6626
Torque -…6626
Release Shaft Removal…6626
Release Shaft Installation…6627
Clutch Cover Disassembly…6627
Clutch Cover Assembly…6628
Torque -…6628
Clutch Removal…6629
Special Tool -…6629
Special Tool -…6629
Clutch Installation…6631
Torque -…6631
Special Tool -…6632
Torque -…6632
Torque -…6633
Spring Plate Free Play Measurement…6634
Spring Plate Free Play Adjustment…6635
Torque -…6635
Clutch Plate, Wear, Damage Inspection…6635
Clutch Plate Warp Inspection…6636
Clutch Spring Free Length Measurement…6636
Damper Cam Inspection…6636
Engine Lubrication System…6638
Oil Pressure Gauge, 10 kgf/cm :…6644
WARNING…6645
Oil Level Inspection…6645
Engine Oil Change…6645
Oil Filter Replacement…6645
Oil Pan Removal…6646
Oil Pan Installation…6646
Torque -…6646
Oil Pressure Relief Valve Removal…6647
Oil Pressure Relief Valve Installation…6647
Torque -…6647
Oil Pressure Relief Valve Inspection…6648
Oil Pump Removal…6649
Oil Pump Installation…6649
Torque -…6650
Oil Pump Gear Removal…6650
Special Tool -…6650
Oil Pump Gear Installation…6650
Special Tool -…6651
Torque -…6651
Oil Cooler Removal…6652
Oil Cooler Installation…6652
Torque -…6652
Torque -…6652
Oil Cooler/Oil Filter Case Removal…6652
Oil Cooler/Oil Filter Case Installation…6653
Torque -…6653
Torque -…6653
Oil Pressure Measurement…6654
Special Tools -…6654
Torque -…6654
Oil Pressure Switch Removal…6655
Oil Pressure Switch Installation…6655
Sealant -…6655
Torque -…6655
Torque -…6655
Engine Removal/Installation…6656
Engine Mount Nut Wrench:…6659
Engine Removal…6660
Special Tool -…6663
Engine Installation…6663
Torque -…6665
Torque -…6665
Torque -…6666
Special Tool -…6666
Torque -…6666
Torque -…6666
Torque -…6667
Torque -…6667
Torque -…6667
Torque -…6667
Crankshaft/Transmission…6670
Bearing Puller:…6678
Crankcase Splitting…6679
Crankcase Assembly…6680
Sealant -…6680
Torque -…6681
Sealant -…6682
Torque -…6683
Torque -…6683
Torque -…6683
Torque -…6684
Torque -…6684
Torque -…6684
Crankshaft Removal…6685
Crankshaft Installation…6685
Connecting Rod Removal…6685
Connecting Rod Installation…6686
Crankshaft/Connecting Rod Cleaning…6689
Connecting Rod Bend…6689
Connecting Rod Twist…6690
Connecting Rod Big End Side Clearance…6690
Connecting Rod Big End Bearing Insert/Crankpin Wear…6690
Crankshaft Side Clearance…6692
Crankshaft Runout…6692
Crankshaft Main Bearing Insert/Journal Wear…6693
Piston Removal…6695
Special Tool -…6695
Piston Installation…6696
Special Tools -…6697
Cylinder Wear (Upper Crankcase)…6697
Piston Wear…6697
Piston Ring, Piston Ring Groove Wear…6697
Piston Ring Groove Width…6698
Piston Ring Thickness…6698
Piston Ring End Gap…6698
Shift Pedal Removal…6699
Shift Pedal Installation…6699
Torque -…6699
Torque -…6699
Torque -…6699
External Shift Mechanism Removal…6699
Special Tool -…6699
External Shift Mechanism Installation…6700
Torque -…6700
External Shift Mechanism Inspection…6700
Torque -…6700
Transmission Shaft Removal…6701
Transmission Shaft Installation…6701
Torque -…6701
Transmission Shaft Disassembly…6702
Special Tool -…6702
Special Tools -…6702
Transmission Shaft Assembly…6702
Spacial Tool -…6702
Shift Drum and Fork Removal…6706
Shift Drum and Fork Installation…6706
Torque -…6706
Shift Drum Disassembly…6706
Shift Drum Assembly…6706
Torque -…6706
Shift Fork Bending…6707
Shift Fork/Gear Groove Wear…6707
Shift Fork Guide Pin/Drum Groove Wear…6707
Gear Dog and Gear Dog Hole Damage…6707
Wheels/Tires…6708
Bearing Driver Set:…6712
Front Wheel Removal…6713
Special Tools -…6713
Front Wheel Installation…6713
Torque -…6714
Torque -…6714
Rear Wheel Removal…6715
Rear Wheel Installation…6715
Torque -…6716
Wheel Inspection…6717
Special Tools -…6717
Axle Inspection…6717
Balance Inspection…6718
Balance Adjustment…6718
Balance Weight Removal…6718
Balance Weight Installation…6718
Air Pressure Inspection/Adjustment…6720
Tire Inspection…6720
Tire Removal…6720
Tire Installation…6720
Tire Repair…6722
Hub Bearing Removal…6723
Special Tools -…6723
Hub Bearing Installation…6723
Special Tool -…6723
Special Tool -…6723
Hub Bearing Inspection…6723
Hub Bearing Lubrication…6724
Final Drive…6726
Inside Circlip Pliers:…6730
Drive Chain Slack Inspection…6731
Drive Chain Slack Adjustment…6731
Wheel Alignment Inspection/Adjustment…6731
Drive Chain Wear Inspection…6731
Drive Chain Lubrication…6731
Drive Chain Removal…6731
Drive Chain Installation…6733
Engine Sprocket Removal…6736
Engine Sprocket Installation…6736
Torque -…6736
Torque -…6737
Rear Sprocket Removal…6737
Rear Sprocket Installation…6737
Torque -…6737
Coupling Installation…6738
Coupling Bearing Removal…6738
Special Tool -…6738
Special Tool -…6738
Coupling Bearing Installation…6738
Special Tool -…6738
Special Tool -…6738
Special Tool -…6739
Coupling Bearing Inspection…6739
Coupling Bearing Lubrication…6739
Coupling Damper Inspection…6739
Sprocket Wear Inspection…6739
Rear Sprocket Warp Inspection…6740
Brakes…6742
Inside Circlip Pliers:…6748
Brake Lever Position Adjustment…6749
Brake Pedal Position Inspection …6749
Brake Pedal Position Adjustment …6749
Torque -…6749
Brake Pedal Removal…6749
Brake Pedal Installation…6750
Torque -…6750
Torque -…6750
Torque -…6750
Front Caliper Removal…6751
Rear Caliper Removal…6751
Caliper Installation…6751
Torque -…6751
Front Caliper Disassembly…6752
Front Caliper Assembly…6752
Rear Caliper Disassembly…6752
Rear Caliper Assembly…6752
Caliper Fluid Seal Damage…6752
Rear Caliper Dust Boot and Friction Boot Damage…6753
Caliper Piston and Cylinder Damage…6753
Rear Caliper Holder Shaft Wear…6753
Front Brake Pad Removal…6754
Front Brake Pad Installation…6754
Torque -…6754
Rear Brake Pad Removal …6755
Rear Brake Pad Installation…6755
Brake Pad Wear Inspection…6755
Front Master Cylinder Removal…6756
Front Master Cylinder Installation…6756
Torque -…6756
Torque -…6756
Rear Master Cylinder Removal…6757
Rear Master Cylinder Installation…6757
Torque -…6757
Front Master Cylinder Disassembly…6757
Rear Master Cylinder Disassembly…6757
Master Cylinder Assembly…6757
Master Cylinder Inspection (Visual Inspection)…6758
Brake Disc Removal…6759
Brake Disc Installation…6759
Torque -…6759
Brake Disc Wear…6759
Brake Disc Warp…6759
Special Tools -…6759
Brake Fluid Level Inspection…6760
Brake Fluid Change…6760
Brake Line Bleeding…6760
Torque -…6761
Torque -…6762
Torque -…6762
Brake Hose Removal/Installation…6764
Brake Hose Inspection…6764
Suspension…6766
Inside Circlip Pliers:…6772
Rebound Damping Force Adjustment…6774
Compression Damping Force Adjustment…6774
Spring Preload Adjustment…6775
Front Fork Removal (each fork leg)…6775
Front Fork Installation…6776
Torque -…6776
Torque -…6776
Front Fork Oil Change…6776
Special Tools -…6777
Special Tool -…6778
Special Tool -…6779
Special Tool -…6779
Special Tool -…6780
Special Tools -…6780
Torque -…6781
Front Fork Disassembly…6782
Special Tool -…6782
Front Fork Assembly…6782
Special Tool -…6782
Torque -…6782
Special Tool -…6783
Inner Tube Inspection…6783
Dust Seal Inspection…6784
Spring Tension…6784
Rebound Damping Force Adjustment…6785
Compression Damping Force Adjustment…6785
Spring Preload Adjustment…6785
Special Tool -…6785
Special Tool -…6786
Rear Shock Absorber Removal…6786
Special Tools -…6786
Rear Shock Absorber Installation…6787
Torque -…6787
Rear Shock Absorber Inspection…6787
Rear Shock Absorber Scrapping…6787
Swingarm Removal…6788
Special Tool -…6788
Swingarm Installation…6789
Torque -…6789
Special Tool -…6789
Torque -…6789
Torque -…6789
Swingarm Bearing Removal…6790
Special Tool -…6790
Special Tools -…6790
Swingarm Bearing Installation…6790
Special Tool -…6790
Swingarm Bearing, Sleeve Inspection…6791
Swingarm Pivot Lubrication…6791
Chain Guide Inspection…6791
Tie-Rod Removal…6792
Special Tools -…6792
Tie-Rod Installation…6792
Torque -…6792
Rocker Arm Removal…6792
Special Tools -…6792
Rocker Arm Installation…6793
Torque -…6793
Tie-Rod and Rocker Arm Bearing Removal…6793
Special Tools -…6793
Tie-Rod and Rocker Arm Bearing Installation…6793
Special Tools -…6794
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…6795
Rocker Arm/Tie-Rod Bearing Lubrication…6795
Steering…6796
Bearing Puller Adapter:…6800
Steering Inspection…6801
Steering Adjustment…6801
Steering Damper Removal…6802
Steering Damper Installation…6802
Damping Force Adjustment…6802
Steering Damper Oil Leak Inspection…6802
Stem, Stem Bearing Removal…6803
Special Tool -…6803
Special Tool -…6804
Special Tools -…6804
Stem, Stem Bearing Installation…6804
Special Tools -…6804
Special Tools -…6805
Special Tool -…6805
Torque -…6805
Torque -…6806
Steering Stem Bearing Lubrication…6807
Steering Stem Warp…6807
Stem Cap Deterioration, Damage…6807
Handlebar Removal…6808
Handlebar Installation…6808
Torque -…6808
Torque -…6809
Frame…6810
Rear Seat Removal…6817
Rear Seat Installation…6817
Front Seat Removal…6817
Front Seat Installation…6817
Lower Fairing Removal…6818
Lower Fairing Installation…6818
Middle Fairing Removal…6818
Middle Fairing Installation…6819
Windshield Removal…6819
Windshield Installation…6820
Torque -…6820
Upper Fairing Removal…6820
Upper Fairing Disassembly…6820
Upper Fairing Assembly…6820
Upper Fairing Installation…6820
Upper Inner Fairing Removal…6821
Upper Inner Fairing Installation…6821
Center Inner Fairing Removal…6821
Center Inner Fairing Installation…6821
Right and Left Inner Fairing Removal…6822
Right and Left Inner Fairing Installation…6822
Side Cover Removal…6823
Side Cover Installation…6823
Seat Cover Removal…6824
Seat Cover Installation…6825
Front Fender Removal…6826
Front Fender Installation…6826
Torque -…6826
Rear Fender Rear Removal…6826
Rear Fender Rear Installation…6827
Rear Fender Front Removal…6827
Rear Fender Front Installation…6828
Rear Frame Removal…6829
Rear Frame Installation…6829
Torque -…6829
Frame Inspection…6829
Sidestand Removal…6830
Sidestand Installation…6830
Torque -…6830
Torque -…6830
Electrical System…6832
Dummy Page…6842
Hand Tester:…6852
There are a number of important precautions that are musts when …6853
Wiring Inspection…6855
Special Tool -…6855
Battery Removal…6856
Battery Installation…6856
Battery Activation…6857
Precautions…6859
1)…6859
2)…6859
3)…6859
4)…6859
Interchange…6860
Charging Condition Inspection…6860
Refreshing Charge…6860
Alternator Cover Removal…6862
Alternator Cover Installation…6862
Sealant -…6862
Torque -…6862
Stator Coil Removal…6862
Stator Coil Installation…6863
Torque -…6863
Sealant -…6863
Torque -…6863
Alternator Rotor Removal…6863
Special Tools -…6863
Special Tool -…6863
Alternator Rotor Installation…6863
Special Tools -…6864
Torque -…6864
Alternator Inspection…6864
Special Tool -…6865
Regulator/Rectifier Inspection…6866
Special Tool -…6866
Torque -…6866
Charging Voltage Inspection…6867
Special Tool -…6867
Charging System Circuit…6868
Crankshaft Sensor Removal…6870
Crankshaft Sensor Installation…6870
Torque -…6870
Sealant -…6870
Crankshaft Sensor Inspection…6871
Special Tool -…6871
Crankshaft Sensor Peak Voltage Inspection…6871
Special Tools -…6871
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…6871
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…6873
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…6874
Stick Coil Primary Peak Voltage…6874
Special Tools -…6874
Spark Plug Removal…6875
Spark Plug Installation…6875
Spark Plug Condition Inspection…6875
Camshaft Position Sensor Removal…6876
Camshaft Position Sensor Installation…6876
Torque -…6876
Camshaft Position Sensor Inspection…6876
Special Tool -…6876
Camshaft Position Sensor Peak Voltage Inspection…6877
Special Tool -…6877
Interlock Operation Inspection…6877
IC Igniter Inspection…6878
Ignition System Circuit…6879
Starter Idle Gear Removal…6880
Starter Idle Gear Installation…6880
Sealant -…6881
Torque -…6881
Torque -…6881
Starter Clutch Removal…6882
Special Tools -…6882
Starter Clutch Installation …6882
Special Tools -…6883
Torque -…6883
Starter Clutch Disassembly…6883
Starter Clutch Assembly…6883
Starter Clutch Inspection…6883
Starter Motor Removal…6884
Starter Motor Installation…6885
Torque -…6885
Torque -…6885
Starter Motor Disassembly…6885
Starter Motor Assembly…6886
Torque -…6886
Torque -…6887
Brush Inspection…6888
Commutator Cleaning and Inspection…6888
Armature Inspection…6888
Special Tool -…6888
Brush Lead Inspection…6889
Special Tool -…6889
Right-hand End Cover Assembly Inspection…6889
Special Tool -…6889
Starter Relay Inspection…6889
Special Tool -…6889
Torque -…6889
Electric Starter Circuit…6890
This motorcycle adopt the daylight system and have a headlight r…6891
Headlight Beam Horizontal Vertical Adjustment…6891
Headlight Beam Vertical Adjustment…6891
Headlight Bulb Replacement…6891
City Light Bulb Replacement…6892
Headlight Removal/Installation…6892
Torque -…6892
Tail/Brake Light (LED) Removal…6893
Tail/Brake Light (LED) Installation…6893
License Plate Light Bulb Replacement…6893
Torque -…6893
Headlight/Tail Light Circuit…6894
Turn Signal Light Bulb Replacement…6894
Torque -…6896
Turn Signal Relay Inspection…6896
Turn Signal Light Circuit…6897
Air Switching Valve Operation Test…6898
Air Switching Valve Unit Test…6898
Special Tool -…6898
Fan Motor Inspection…6899
Radiator Fan Circuit…6899
Meter Unit Removal/Installation…6900
Torque -…6900
Meter Unit Disassembly…6900
Electronic Combination Meter Unit Inspection…6901
Meter Unit Circuit…6910
This motorcycle is equipped with an immobilizer system to protec…6911
Operational Cautions…6911
Key Registration…6911
Special Tool -…6912
Spare User Key Registration Flow Chart…6916
Special Tool -…6917
All Keys Initial Registration Flow Chart…6926
Immobilizer System Parts Replacement…6927
Immobilizer System Inspection…6929
Immobilizer System Circuit…6930
Brake Light Timing Inspection…6931
Brake Light Timing Adjustment…6931
Switch Inspection…6931
Special Tool -…6931
Rear Brake Light Switch Connections…6931
Sidestand Switch Connections…6931
Oil Pressure Switch Connections *…6931
Water Temperature Sensor Inspection…6932
Speed Sensor Removal…6932
Speed Sensor Installation…6933
Torque -…6933
Speed Sensor Inspection…6933
Fuel Reserve Switch Inspection…6933
Special Tool -…6933
Oxygen Sensor Removal (Europe Models)…6934
Oxygen Sensor Installation (Europe Models)…6935
Torque -…6935
Oxygen Sensor Inspection (Europe Models)…6935
Oxygen Sensor Heater Inspection (Europe Models)…6935
Gear Position Switch Removal…6935
Gear Position Switch Installation…6936
Torque -…6936
Gear Position Switch Inspection…6937
Special Tool -…6937
The relay box [A] has relays and diodes. The relays and diodes c…6938
Relay Box Removal…6938
Relay Circuit Inspection…6938
Diode Circuit Inspection…6939
Relay Box Internal Circuit…6940
30 A Main Fuse Removal…6941
Fuse Box Fuse Removal…6941
15 A ECU Fuse Removal…6941
Fuse Installation…6942
Fuse Inspection…6942
Appendix…6944
California Model…6969
California Model…6971
NOTE…6973
Engine Doesn't Start, Starting Difficulty:…6973
Starter motor not rotating:…6973
Starter motor rotating but engine doesn't turn over:…6973
Engine won't turn over:…6973
No fuel flow:…6973
No spark; spark weak:…6973
Fuel/air mixture incorrect:…6973
Compression Low:…6973
Poor Running at Low Speed:…6973
Spark weak:…6973
Fuel/air mixture incorrect:…6973
Compression low:…6973
Other:…6974
Poor Running or No Power at High Speed:…6974
Firing incorrect:…6974
Fuel/air mixture incorrect:…6974
Compression low:…6974
Knocking:…6974
Miscellaneous:…6974
Overheating:…6974
Firing incorrect:…6974
Muffler overheating:…6974
Fuel/air mixture incorrect:…6974
Compression high:…6974
Engine load faulty:…6974
Lubrication inadequate:…6975
Oil cooler incorrect:…6975
Gauge incorrect:…6975
Coolant incorrect:…6975
Cooling system component incorrect:…6975
Over Cooling:…6975
Gauge incorrect:…6975
Cooling system component incorrect:…6975
Clutch Operation Faulty:…6975
Clutch slipping:…6975
Clutch not disengaging properly:…6975
Gear Shifting Faulty:…6975
Doesn't go into gear; shift pedal doesn't return:…6975
Jumps out of gear:…6975
Overshifts:…6975
Abnormal Engine Noise:…6975
Knocking:…6975
Piston slap:…6975
Valve noise:…6975
Other noise:…6975
Abnormal Drive Train Noise:…6976
Clutch noise:…6976
Transmission noise:…6976
Drive line noise:…6976
Abnormal Frame Noise:…6976
Front fork noise:…6976
Rear shock absorber noise:…6976
Disc brake noise:…6976
Other noise:…6976
Oil Pressure Warning Light Goes On:…6976
Exhaust Smokes Excessively:…6976
White smoke:…6976
Black smoke:…6976
Brown smoke:…6976
Handling and/or Stability Unsatisfactory:…6976
Handlebar hard to turn:…6976
Handlebar shakes or excessively vibrates:…6976
Handlebar pulls to one side:…6976
Shock absorption unsatisfactory:…6976
Brake Doesn't Hold:…6977
Battery Trouble:…6977
Battery discharged:…6977
Battery overcharged:…6977
EDDŠp2-6.pdf…0
toc…6355
Kawasaki Motorcycle Service Repair Manual '06 ZX-14 (EN)…6979
ZZR1400_'ABS'_&_ZX-14_(ZX1400-A6F_&_B6F)_SM_2006_.pdf…0
ZZR1400_'ABS'_&_ZX-14_(ZX1400-A6F_&_B6F)_SM_2006_.pdf…0
Cover…6979
Quick Reference Guide…6981
1.General Information…6989
Before starting to perform an inspection service or carry out a …6990
Battery Ground…6990
Edges of Parts…6990
Solvent…6990
Cleaning vehicle before disassembly…6990
Arrangement and Cleaning of Removed Parts…6991
Storage of Removed Parts…6991
Inspection…6991
Replacement Parts…6991
Assembly Order…6991
Tightening Sequence…6992
Tightening Torque…6992
Force…6992
Gasket, O-ring…6992
Liquid Gasket, Non-permanent Locking Agent…6992
Press…6993
Ball Bearing and Needle Bearing…6993
Oil Seal, Grease Seal…6993
Circlips, Cotter Pins…6993
Lubrication…6994
Direction of Engine Rotation…6994
Electrical Wires…6994
Instrument…6994
ZX1400A6F (Europe) Left Side View…6995
ZX1400A6F (Europe) Right Side View…6995
Frame Number…6995
Engine Number…6995
ZX1400A6F (United States and Canada) Left Side View…6996
ZX1400A6F (United States and Canada) Right Side View…6996
ZX1400A6F (Malaysia) Left Side View…6997
ZX1400A6F (Malaysia) Right Side View…6997
ZX1400B6F (Europe) Left Side View…6998
ZX1400B6F (Europe) Right Side View…6998
ZX1400B6F (Malaysia) Left Side View…6999
ZX1400B6F (Malaysia) Right Side View…6999
Overview…7003
Structure and Function…7004
System failure and maintenance…7005
Prefixes for Units…7006
Units of Temperature…7006
2.Periodic Maintenance…7007
The scheduled maintenance must be done in accordance with this c…7009
The following tables list the tightening torque for the major fa…7012
Inside Circlip Pliers:…7020
Fuel System (DFI)…7021
Throttle Control System Inspection…7021
Engine Vacuum Synchronization Inspection…7021
Special Tool -…7022
Special Tool -…7023
Special Tool -…7023
Torque -…7024
Torque -…7024
Idle Speed Inspection…7025
Idle Speed Adjustment…7025
Fuel Hose Inspection (fuel leak, damage, installation condition)…7025
Cooling System…7026
Coolant Level Inspection…7026
Radiator Hose and Pipe Inspection…7026
Torque -…7026
Evaporative Emission Control System (California Model)…7027
Evaporative Emission Control System Inspection…7027
Air Suction System…7027
Air Suction System Damage Inspection…7027
Engine Top End…7028
Valve Clearance Inspection…7028
EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART…7031
INLET- VALVE CLEARANCE ADJUSTMENT CHART…7032
Clutch and Drive Train…7033
Clutch Operation Inspection …7033
Clutch Fluid Level Inspection…7033
Clutch Fluid Leak Inspection…7034
Clutch Hose and Pipe Damage and Installation Condition Inspectio…7034
Torque -…7034
Wheels/Tires…7035
Air Pressure Inspection…7035
Wheel/Tire Damage Inspection…7035
Tire Tread Wear Inspection …7035
Wheel Bearing Damage Inspection…7036
Drive Train…7036
Drive Chain Lubrication Condition Inspection…7036
Drive Chain Slack Inspection…7037
Drive Chain Slack Adjustment…7037
Torque -…7037
Wheel Alignment Inspection…7038
Drive Chain Wear Inspection…7038
Chain Guide Wear Inspection…7039
Brake System…7040
Brake Fluid Leak (Brake Hose and Pipe) Inspection…7040
Brake Hose and Pipe Damage and Installation Condition Inspection…7041
Torque -…7041
Brake Operation Inspection…7041
Brake Fluid Level Inspection…7041
Brake Pad Wear Inspection…7042
Brake Light Switch Operation Inspection…7043
Suspensions…7043
Front Forks/Rear Shock Absorber Operation Inspection…7043
Front Fork Oil Leak Inspection…7044
Rear Shock Absorber Oil Leak Inspection…7044
Rocker Arm Operation Inspection…7044
Tie-Rod Operation Inspection…7044
Steering System…7045
Steering Play Inspection…7045
Special Tools -…7045
Steering Play Adjustment…7045
Special Tool -…7046
Torque -…7046
Steering Stem Bearing Lubrication…7046
Electrical System…7047
Lights and Switches Operation Inspection…7047
Headlight Aiming Inspection…7050
Sidestand Switch Operation Inspection…7051
Engine Stop Switch Operation Inspection…7052
Others…7052
Chassis Parts Lubrication …7052
Pivots: Lubricate with Grease…7052
Points: Lubricate with Grease…7052
Cables: Lubricate with Rust Inhibitor…7053
Bolts, Nuts and Fasteners Tightness Inspection…7053
Bolt, Nut and Fastener to be checked…7054
Replacement Parts…7054
Air Cleaner Element Replacement…7054
Torque -…7055
Fuel Hose Replacement…7055
Coolant Change…7057
Torque -…7057
Radiator Hose and O-ring Replacement…7059
Engine Oil Change…7059
Torque -…7059
Oil Filter Replacement…7060
Special Tool -…7060
Torque -…7060
Brake Hose and Pipe Replacement…7061
Torque -…7062
Brake Fluid Change…7063
Torque -…7064
Torque -…7064
Master Cylinder Rubber Parts Replacement…7064
Special Tool -…7064
Special Tool -…7064
Torque -…7065
Caliper Rubber Parts Replacement…7065
Torque -…7066
Torque -…7066
Rear Caliper Assembly…7068
Torque -…7068
Torque -…7069
Clutch Hose and Pipe Replacement…7069
Torque -…7069
Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacemen…7070
Special Tool -…7070
Torque -…7070
Clutch Fluid Change…7072
Torque -…7072
Spark Plug Replacement…7072
Torque -…7073
3.Fuel System (DFI)…7075
DFI System…7084
Terminal Numbers of ECU Connectors…7088
Main Throttle Sensor [A]…7090
Oil Pressure Gauge, 5 kgf/cm :…7094
DFI Servicing Precautions…7096
Torque -…7097
Outline…7098
Special Tool -…7100
Sealant -…7100
Special Tool -…7101
DFI Diagnosis Flow Chart…7103
Inquiries to Rider…7103
NOTE…7106
Self-diagnosis Outline…7111
Self-diagnosis Procedures…7112
Self-Diagnosis Flow Chart…7114
Service Code Reading…7115
Service Code Erasing…7115
Backups…7117
The main throttle sensor is a rotating variable resistor that ch…7119
Main Throttle Sensor Removal/Adjustment…7119
Input Voltage Inspection…7119
Special Tool -…7119
Special Tool -…7120
Output Voltage Inspection…7121
Special Tool -…7121
Special Tool -…7123
Resistance Inspection…7124
Main Throttle Sensor Circuit…7124
CAUTION…7125
Removal…7125
Installation…7125
Input Voltage Inspection…7126
Special Tool -…7126
Special Tool -…7126
Output Voltage Inspection…7127
Special Tool -…7127
Special Tool -…7127
Inlet Air Pressure Sensor Circuit…7128
Special Tools -…7129
Removal/Installation…7131
Output Voltage Inspection…7131
Special Tool -…7131
Sensor Resistance Inspection…7132
Inlet Air Temperature Sensor Circuit…7133
Removal/Installation…7134
Torque -…7134
Output Voltage Inspection…7134
Special Tool -…7134
Sensor Resistance Inspection…7135
Water Temperature Sensor Circuit…7135
CAUTION…7136
Removal…7136
Installation…7136
Input Voltage Inspection…7136
Special Tool -…7136
Special Tool -…7137
Output Voltage Inspection…7137
Special Tool -…7137
Special Tool -…7138
Atmospheric Pressure Sensor Circuit…7138
Atmospheric Pressure/Altitude Relationship…7139
Crankshaft Sensor Removal/Installation…7140
Crankshaft Sensor Inspection…7140
Crankshaft Sensor Circuit…7140
Camshaft Position Sensor Removal/Installation…7141
Camshaft Position Sensor Inspection…7141
Camshaft Position Sensor Circuit…7141
Speed Sensor Removal/Installation…7142
Speed Sensor Inspection…7142
Input Voltage Inspection…7142
Special Tool -…7142
Output Voltage Inspection…7143
Special Tool -…7143
Gear Position Switch Removal/Installation…7145
Gear Position Switch Inspection…7145
Input Voltage Inspection…7145
Special Tool -…7145
Gear Position Switch Circuit…7146
This sensor has a weight [A] with two magnets inside, and sends …7147
Removal…7147
Installation…7147
Torque -…7147
Inspection…7148
Special Tool -…7148
Special Tool -…7149
Vehicle-down Sensor Circuit…7149
The subthrottle sensor is a rotating variable resistor that chan…7150
Subthrottle Sensor Removal/Adjustment…7150
Input Voltage Inspection…7150
Special Tool -…7150
Special Tool -…7151
Output Voltage Inspection…7152
Special Tool -…7152
Special Tool -…7153
Resistance Inspection…7154
Subthrottle Sensor Circuit…7154
Antenna Resistance Inspection…7155
Amplifier Input Voltage Inspection…7155
Special Tool -…7155
User Key Inspection…7156
Immobilizer System Circuit…7156
Fuel Pump Relay Removal…7157
Fuel Pump Relay Inspection…7157
Special Tool -…7157
Fuel Pump Relay Circuit…7158
Stick Coil ##1: Service Code 51…7159
Removal/Installation…7159
Input Voltage Inspection…7159
Special Tool -…7159
Stick Coil Circuit…7160
Subthrottle Valve Actuator Removal…7161
Subthrottle Valve Actuator Inspection…7161
Resistance Inspection…7161
Input Voltage Inspection…7162
Special Tools -…7162
Subthrottle Valve Actuator Circuit…7163
ECU Main Relay Inspection…7164
CAUTION…7165
ECU Identification…7165
ECU Removal…7165
ECU Installation…7166
ECU Power Supply Inspection…7167
Special Tool -…7167
ECU Power Source Circuit…7169
CAN Communication Line Resistance Inspection…7169
CAN Communication Line Circuit…7170
ECU Fuse Removal…7171
ECU Fuse Installation…7171
ECU Fuse Inspection…7171
Light (LED) Inspection…7172
Warning Indicator Light (LED) Circuit…7172
Fuel Pressure Inspection…7173
Special Tools -…7173
Fuel Flow Rate Inspection…7174
Special Tool -…7174
Fuel Pump Removal…7177
Fuel Pump Installation…7177
Torque -…7178
Operation Inspection…7178
Operating Voltage Inspection…7178
Special Tools -…7178
Fuel Pump Circuit…7179
Removal/Installation…7180
Power Source Voltage Inspection…7180
Special Tool -…7180
Special Tool -…7181
Output Voltage Inspection…7181
Special Tool -…7181
Special Tool -…7182
Audible Inspection…7182
Injector Signal Test…7183
Special Tool -…7183
Injector Resistance Inspection…7183
Injector Unit Test…7184
Injector Fuel Line Inspection…7184
Fuel Injector Circuit…7185
Free Play Inspection…7186
Free Play Adjustment…7186
Cable Installation…7186
Cable Lubrication…7186
Idle Speed Inspection…7187
Throttle Bore Cleaning…7187
Synchronization Inspection…7187
Synchronization Adjustment…7187
Throttle Body Assy Removal…7187
Throttle Body Assy Installation…7190
Torque -…7190
Torque -…7191
Torque -…7191
Throttle Body Assy Disassembly…7192
Throttle Body Assy Assembly…7193
Torque -…7194
Element Removal…7195
Element Installation…7195
Air Cleaner Element Inspection…7195
Air Cleaner Element Holder Removal…7195
Air Cleaner Element Holder Installation…7195
Torque -…7195
Oil Draining…7196
Rear Air Inlet Duct Removal…7196
Rear Air Inlet Duct Installation…7196
Torque -…7196
Torque -…7197
Front and Middle Air Inlet Duct Removal…7197
Front and Middle Air Inlet Duct Installation…7197
Torque -…7198
Torque -…7198
Torque -…7198
Fuel Tank Removal…7199
Fuel Tank Installation…7201
Fuel Tank and Cap Inspection…7203
Fuel Tank Cleaning…7203
The Evaporative Emission Control System routes fuel vapors from …7204
Parts Removal/Installation…7204
Hose Inspection…7204
Separator Inspection…7204
Separator Operation Test…7205
Canister Inspection…7205
4.Cooling System…7207
Coolant Deterioration Inspection…7213
Coolant Level Inspection…7213
Coolant Draining…7213
Coolant Filling…7213
Pressure Testing…7213
Cooling System Flushing…7214
Coolant Reserve Tank Removal/Installation…7214
Water Pump Removal…7215
Water Pump Installation…7215
Torque -…7216
Water Pump Impeller Inspection…7216
Radiator and Radiator Fan Removal…7217
Radiator and Radiator Fan Installation…7218
Radiator Inspection…7218
Radiator Cap Inspection…7219
Radiator Filler Neck Inspection…7219
Thermostat Removal…7220
Thermostat Installation…7220
Torque -…7220
Thermostat Inspection…7220
Hose Installation…7222
Torque -…7222
Hose Inspection…7222
CAUTION…7223
Water Temperature Sensor Removal…7223
Water Temperature Sensor Inspection…7223
5.Engine Top End…7225
Compression Gauge, 20 kgf/cm :…7233
Air Suction Valve Removal…7235
Air Suction Valve Installation…7235
Torque -…7235
Air Suction Valve Inspection…7236
Air Switching Valve Removal…7236
Air Switching Valve Installation…7236
Air Switching Valve Operation Test…7236
Air Switching Valve Unit Test…7236
Clean Air System Hose Inspection…7236
Cylinder Head Cover Removal…7237
Cylinder Head Cover Installation…7237
Sealant -…7237
Torque -…7238
Camshaft Chain Tensioner Removal…7239
Camshaft Chain Tensioner Installation…7239
Torque -…7239
Camshaft Removal…7241
Camshaft Installation…7241
Torque -…7241
Torque -…7244
Camshaft, Camshaft Cap Wear…7244
Torque -…7244
Camshaft Runout…7245
Cam Wear…7245
Camshaft Chain Removal…7245
Camshaft Chain Installation…7246
Torque -…7246
Cylinder Compression Measurement…7247
Owner's Tool -…7247
Special Tools -…7247
Torque -…7247
Cylinder Head Removal…7248
Cylinder Head Installation…7248
Torque -…7249
Torque -…7249
Torque -…7249
Torque -…7249
Cylinder Head Warp…7249
Valve Clearance Inspection…7250
Valve Removal…7250
Special Tools -…7250
Valve Installation…7250
Valve Guide Removal…7250
Special Tool -…7250
Valve Guide Installation…7251
Special Tools -…7251
Special Tool -…7251
Valve-to-Guide Clearance Measurement (Wobble Method)…7252
Valve Seat Inspection…7253
Valve Seat Repair…7253
Special Tools -…7253
Throttle Body Holder Installation…7258
Torque -…7258
WARNING…7259
Muffler Body Removal/Installation…7259
Torque -…7260
Exhaust Pipe Removal…7260
Exhaust Pipe Installation…7260
Torque -…7260
6.Clutch…7261
Inside Circlip Pliers:…7265
Clutch Lever Adjustment…7266
Clutch Master Cylinder Removal…7266
Clutch Master Cylinder Installation …7266
Torque -…7267
Torque -…7267
Clutch Master Cylinder Disassembly …7267
Clutch Master Cylinder Assembly…7267
Clutch Master Cylinder Inspection…7267
Special Tool -…7267
Clutch Slave Cylinder Removal…7268
Clutch Slave Cylinder Installation…7269
Torque -…7269
Clutch Slave Cylinder Disassembly …7269
Clutch Slave Cylinder Assembly…7269
Clutch Fluid Level Inspection…7270
Clutch Fluid Change…7270
Bleeding the Clutch Line…7270
Torque -…7271
Torque -…7271
Clutch Hose Removal/Installation…7271
Clutch Hose and Connection Inspection…7271
Clutch Cover Removal…7272
Clutch Cover Installation…7272
Sealant -…7272
Torque -…7272
Clutch Removal…7273
Special Tool -…7273
Special Tool -…7273
Clutch Installation…7274
Special Tool -…7274
Special Tool -…7274
Torque -…7274
Torque -…7275
Clutch Plate Assembly Inspection…7276
Torque -…7276
Clutch Plate Assembly Adjustment…7276
Torque -…7276
Clutch Plate, Wear, Damage Inspection…7277
Clutch Plate Warp Inspection…7277
Clutch Spring Free Length Measurement…7277
7.Engine Lubrication System…7279
Oil Pressure Gauge, 10 kgf/cm :…7285
WARNING…7286
Oil Level Inspection…7286
Engine Oil Change…7286
Oil Filter Replacement…7286
Oil Pan Removal…7287
Oil Pan Installation…7287
Torque -…7287
Torque -…7288
Oil Pressure Relief Valve Removal…7289
Oil Pressure Relief Valve Installation…7289
Oil Pressure Relief Valve Inspection…7289
Oil Pump Removal…7290
Oil Pump Installation…7290
Torque -…7291
Oil Cooler Removal…7292
Oil Cooler Installation…7292
Torque -…7292
Torque -…7292
Oil Pressure Measurement…7293
Special Tools -…7293
Torque -…7293
Oil Pressure Switch Removal…7294
Oil Pressure Switch Installation…7294
Sealant -…7294
Torque -…7294
Torque -…7294
8.Engine Removal/Installation…7295
Engine Removal…7298
Engine Installation…7300
Torque -…7303
Torque -…7304
Torque -…7304
9.Crankshaft/Transmission…7307
Bearing Puller:…7315
Crankcase Splitting…7316
Crankcase Assembly…7317
Torque -…7317
Sealant -…7318
Torque -…7319
Torque -…7319
Torque -…7320
Crankshaft Removal…7321
Crankshaft Installation…7321
Connecting Rod Removal…7322
Connecting Rod Installation…7322
Crankshaft/Connecting Rod Cleaning…7325
Connecting Rod Bend…7325
Connecting Rod Twist…7326
Connecting Rod Big End Side Clearance…7326
Connecting Rod Big End Bearing Insert/Crankpin Wear…7326
Crankshaft Side Clearance…7328
Crankshaft Runout…7329
Crankshaft Main Bearing Insert/Journal Wear…7329
Piston Removal…7332
Special Tool -…7332
Piston Installation…7333
Special Tools -…7334
Cylinder Wear (Upper Crankcase)…7334
Piston Wear…7334
Piston Ring, Piston Ring Groove Wear…7334
Piston Ring Groove Width…7335
Piston Ring Thickness…7335
Piston Ring End Gap…7335
Front Balancer Removal…7336
Front Balancer Installation…7336
Torque -…7337
Torque -…7337
Rear Balancer Removal…7337
Rear Balancer Installation…7338
Torque -…7339
Torque -…7339
Balancer Adjustment…7340
Torque -…7340
Balancer Damper Inspection…7340
Starter Motor Clutch Removal…7341
Starter Motor Clutch Installation…7341
Torque -…7341
Torque -…7341
Starter Motor Clutch Disassembly…7341
Starter Motor Clutch Assembly…7342
Starter Clutch Inspection…7342
Torque Limiter Removal…7342
Torque Limiter Installation…7343
Torque -…7343
Shift Pedal Removal…7344
Shift Pedal Installation…7344
External Shift Mechanism Removal…7344
External Shift Mechanism Installation…7345
Torque -…7345
External Shift Mechanism Inspection…7345
Torque -…7345
Transmission Shaft Removal…7345
Transmission Shaft Installation…7346
Torque -…7346
Transmission Shaft Disassembly…7346
Special Tools -…7347
Transmission Shaft Assembly…7347
Shift Drum and Fork Removal…7350
Shift Drum and Fork Installation…7350
Torque -…7350
Shift Drum Disassembly…7350
Shift Drum Assembly…7350
Torque -…7350
Shift Fork Bending…7351
Shift Fork/Gear Groove Wear…7351
Shift Fork Guide Pin/Drum Groove Wear…7351
Gear Dog and Gear Dog Hole Damage…7351
10.Wheels/Tires…7353
Bearing Driver Set:…7357
Front Wheel Removal…7358
Special Tools -…7358
Front Wheel Installation…7358
Torque -…7359
Torque -…7359
Rear Wheel Removal…7359
Rear Wheel Installation…7360
Torque -…7360
Wheel Inspection…7362
Special Tools -…7362
Axle Inspection…7362
Balance Inspection…7363
Balance Adjustment…7363
Balance Weight Removal…7363
Balance Weight Installation…7364
Air Pressure Inspection/Adjustment…7366
Tire Inspection…7366
Tire Removal…7366
Tire Installation…7366
Tire Repair…7368
Hub Bearing Removal…7369
Special Tools -…7369
Hub Bearing Installation…7369
Special Tool -…7369
Special Tool -…7369
Hub Bearing Inspection…7369
Hub Bearing Lubrication…7370
11.Final Drive…7371
Inside Circlip Pliers:…7375
Drive Chain Slack Inspection…7376
Drive Chain Slack Adjustment…7376
Wheel Alignment Inspection/Adjustment…7376
Drive Chain Wear Inspection…7376
Drive Chain Lubrication…7376
Drive Chain Removal…7376
Drive Chain Installation…7376
Engine Sprocket Removal…7377
Engine Sprocket Installation…7377
Torque -…7377
Torque -…7377
Torque -…7378
Rear Sprocket Removal…7378
Rear Sprocket Installation…7378
Torque -…7378
Coupling Installation…7378
Coupling Bearing Removal…7379
Special Tool -…7379
Special Tool -…7379
Coupling Bearing Installation…7379
Special Tool -…7379
Special Tool -…7379
Special Tool -…7379
Coupling Bearing Inspection…7380
Coupling Bearing Lubrication…7380
Coupling Damper Inspection…7380
Sprocket Wear Inspection…7380
Rear Sprocket Warp Inspection…7381
12.Brakes…7383
Dummy Page…7385
ZX1400A Models…7386
ZX1400B Models…7390
Inside Circlip Pliers:…7395
Brake Lever Position Adjustment…7396
Brake Pedal Position Inspection …7396
Brake Pedal Position Adjustment …7396
Torque -…7396
Brake Pedal Removal…7396
Brake Pedal Installation…7397
Torque -…7397
Torque -…7397
Torque -…7397
Front Caliper Removal…7398
Rear Caliper Removal…7398
Caliper Installation…7399
Torque -…7399
Front Caliper Disassembly…7399
Front Caliper Assembly…7399
Rear Caliper Disassembly…7399
Rear Caliper Assembly…7399
Caliper Fluid Seal Damage…7400
Caliper Dust Seal Damage…7400
Caliper Piston and Cylinder Damage…7401
Front Brake Pad Removal…7402
Front Brake Pad Installation…7402
Torque -…7402
Rear Brake Pad Removal …7403
Rear Brake Pad Installation…7403
Torque -…7403
Brake Pad Wear Inspection…7403
Front Master Cylinder Removal…7404
Front Master Cylinder Installation…7404
Torque -…7404
Torque -…7404
Rear Master Cylinder Removal…7404
Rear Master Cylinder Installation…7405
Torque -…7405
Front Master Cylinder Disassembly…7405
Rear Master Cylinder Disassembly…7405
Master Cylinder Assembly…7405
Master Cylinder Inspection (Visual Inspection)…7405
Brake Disc Removal…7407
Brake Disc Installation…7407
Torque -…7407
Brake Disc Wear…7407
Brake Disc Warp…7407
Special Tools -…7407
Brake Fluid Level Inspection…7408
Brake Fluid Change…7408
Brake Line Bleeding…7408
Torque -…7409
Torque -…7410
Torque -…7410
Brake Hose and Pipe Removal/Installation…7412
Brake Hose and Pipe Inspection…7412
Parts Location…7413
ABS System Wiring Diagram…7414
Terminal Names…7415
ABS Servicing Precautions…7416
ABS Troubleshooting Outline…7418
Special Tool -…7418
Special Tool -…7419
ABS Diagnosis Flow Chart…7420
Inquiries to Rider…7421
Pre-Diagnosis Inspection 1…7422
Pre-Diagnosis Inspection 2…7423
Self-diagnosis Outline…7423
Self-diagnosis Procedures…7423
Service Code Clearing Procedures…7424
Self-diagnosis Flow Chart…7426
How to Read Service Codes…7427
How to Erase Service Codes…7427
ABS Indicator Light (LED) Inspection…7429
ABS Indicator Light (LED) is Unlit (When the Ignition Switch tur…7429
Special Tool -…7429
ABS Indicator Light (LED) Lights (When the Motorcycle is Running…7430
Special Tool -…7430
Solenoid Valve Inspection (Service Code 13,14,17,18)…7430
ABS Solenoid Valve Relay Inspection (Service Code 19)…7430
Special Tool -…7431
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)…7432
ABS Pump Motor Relay Inspection (Service Code 35)…7432
Special Tool -…7433
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)…7433
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)…7434
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)…7435
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)…7436
Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)…7436
Special Tool -…7437
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)…7437
Special Tool -…7438
ECU Inspection (Service Code 55)…7438
ABS Hydraulic Unit Removal…7438
ABS Hydraulic Unit Installation…7440
Torque -…7440
ABS Hydraulic Unit Inspection…7441
Front Wheel Rotation Sensor Removal…7441
Front Wheel Rotation Sensor Installation…7441
Rear Wheel Rotation Sensor Removal…7442
Rear Wheel Rotation Sensor Installation…7442
Wheel Rotation Sensor Inspection…7443
Wheel Rotation Sensor Air Gap Inspection…7443
Wheel Rotation Sensor Rotor Inspection…7444
ABS Solenoid Valve Relay Fuse (20 A) Removal…7444
ABS Motor Relay Fuse (30 A) Removal…7444
ABS ECU Fuse (10 A) Removal…7444
Fuse Installation…7445
Fuse Inspection…7445
13.Suspension…7447
Inside Circlip Pliers:…7453
Rebound Damping Force Adjustment…7455
Compression Damping Force Adjustment…7455
Spring Preload Adjustment…7456
Front Fork Removal (Each Fork Leg)…7456
Front Fork Installation…7457
Torque -…7457
Torque -…7457
Front Fork Oil Change…7457
Special Tools -…7457
Special Tool -…7459
Special Tool -…7460
Special Tool -…7460
Special Tool -…7460
Special Tools -…7461
Torque -…7461
Front Fork Disassembly…7462
Special Tool -…7462
Front Fork Assembly…7462
Special Tool -…7462
Torque -…7462
Special Tool -…7463
Inner Tube Inspection…7463
Dust Seal Inspection…7464
Spring Tension…7464
Rebound Damping Force Adjustment…7465
Compression Damping Force Adjustment…7465
Spring Preload Adjustment…7465
Special Tool -…7465
Special Tool -…7466
Rear Shock Absorber Removal…7466
Special Tools -…7466
Rear Shock Absorber Installation…7467
Torque -…7467
Rear Shock Absorber Inspection…7467
Rear Shock Absorber Scrapping…7468
Swingarm Removal…7469
Special Tool -…7469
Swingarm Installation…7470
Torque -…7470
Special Tool -…7470
Torque -…7470
Torque -…7470
Swingarm Bearing Removal…7471
Special Tool -…7471
Special Tool -…7471
Swingarm Bearing Installation…7471
Special Tools -…7471
Swingarm Bearing, Sleeve Inspection…7472
Chain Guide Inspection…7473
Tie-Rod Removal…7474
Special Tools -…7474
Tie-Rod Installation…7474
Torque -…7474
Rocker Arm Removal…7474
Special Tools -…7474
Rocker Arm Installation…7475
Torque -…7475
Tie-Rod and Rocker Arm Bearing Removal…7475
Special Tools -…7475
Tie-Rod and Rocker Arm Bearing Installation…7475
Special Tools -…7476
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…7477
Rocker Arm/Tie-Rod Bearing Lubrication…7477
14.Steering…7479
Head Pipe Outer Race Press Shaft:…7482
Steering Inspection…7483
Steering Adjustment…7483
Stem, Stem Bearing Removal…7484
Special Tool -…7484
Special Tool -…7484
Stem, Stem Bearing Installation…7485
Special Tools -…7485
Special Tools -…7485
Special Tool -…7486
Torque -…7486
Torque -…7487
Steering Stem Bearing Lubrication…7487
Steering Stem Warp…7487
Stem Cap Deterioration, Damage…7487
Handlebar Removal…7488
Handlebar Installation…7488
Torque -…7488
Torque -…7489
Torque -…7489
15.Frame…7491
Seat Removal…7500
Seat Installation…7500
Lower Fairing Removal…7501
Lower Fairing Installation…7501
Fairing Cover Removal…7501
Middle Fairing Removal…7501
Middle Fairing Installation…7502
Windshield Removal…7502
Windshield Installation…7503
Torque -…7503
Upper Fairing Removal…7503
Upper Fairing Disassembly…7503
Upper Fairing Assembly…7503
Upper Fairing Installation…7504
Inner Cover Removal…7504
Inner Cover Installation…7504
Upper Inner Fairing Removal…7504
Upper Inner Fairing Installation…7505
Upper Fairing Bracket Removal…7505
Upper Fairing Bracket Installation…7505
Inner Fairing Removal…7505
Inner Fairing Installation…7505
Rear Fairing Removal…7505
Rear Fairing Installation…7505
Seat Cover Removal…7506
Seat Cover Installation…7506
Torque -…7507
Front Fender Removal…7508
Front Fender Installation…7508
Flap and Rear Fender Removal…7508
Flap and Rear Fender Installation…7509
Torque -…7509
Rear Frame Removal…7510
Rear Frame Installation…7510
Torque -…7510
Frame Inspection…7510
Center Stand Removal (Equipped Models)…7511
Center Stand Installation (Equipped Models)…7511
Torque -…7511
Sidestand Removal…7511
Sidestand Installation…7511
Torque -…7511
Torque -…7511
16.Electrical System…7513
Hand Tester:…7531
There are a number of important precautions that are musts when …7533
Wiring Inspection…7534
Special Tool -…7534
Battery Removal…7535
Battery Installation…7536
Battery Activation…7536
Precautions…7539
1)…7539
2)…7539
3)…7539
4)…7539
Interchange…7539
Charging Condition Inspection…7539
Refreshing Charge…7540
Alternator Cover Removal…7541
Alternator Cover Installation…7541
Sealant -…7541
Torque -…7541
Stator Coil Removal…7541
Stator Coil Installation…7542
Torque -…7542
Sealant -…7542
Torque -…7542
Alternator Rotor Removal…7542
Special Tools -…7542
Special Tool -…7542
Alternator Rotor Installation…7542
Special Tools -…7543
Torque -…7543
Alternator Inspection…7543
Special Tool -…7544
Regulator/Rectifier Inspection…7545
Special Tool -…7545
Torque -…7545
Charging Voltage Inspection…7546
Special Tool -…7546
Charging System Circuit…7547
Crankshaft Sensor Removal…7549
Crankshaft Sensor Installation…7550
Torque -…7550
Sealant -…7550
Torque -…7550
Crankshaft Sensor Inspection…7550
Special Tool -…7550
Crankshaft Sensor Peak Voltage Inspection…7550
Special Tools -…7551
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…7551
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…7551
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…7552
Stick Coil Primary Peak Voltage…7552
Special Tools -…7552
Spark Plug Removal…7553
Spark Plug Installation…7553
Spark Plug Condition Inspection…7553
Camshaft Position Sensor Removal…7554
Camshaft Position Sensor Installation…7554
Torque -…7554
Camshaft Position Sensor Inspection…7554
Special Tool -…7554
Camshaft Position Sensor Peak Voltage Inspection…7555
Special Tools -…7555
Interlock Operation Inspection…7555
IC Igniter Inspection…7556
Ignition System Circuit…7557
Starter Motor Removal…7558
Starter Motor Installation…7558
Torque -…7558
Torque -…7558
Starter Motor Disassembly…7559
Starter Motor Assembly…7559
Torque -…7559
Torque -…7560
Brush Inspection…7560
Commutator Cleaning and Inspection…7561
Armature Inspection…7561
Special Tool -…7561
Brush Lead Inspection…7561
Special Tool -…7561
Right-hand End Cover Assembly Inspection…7562
Special Tool -…7562
Starter Relay Inspection…7562
Special Tool -…7562
Torque -…7562
Electric Starter Circuit…7563
This motorcycle adopt the daylight system and have a headlight r…7564
Headlight Beam Horizontal Vertical Adjustment…7564
Headlight Beam Vertical Adjustment…7564
Headlight Bulb Replacement…7564
City Light Bulb Replacement…7565
Headlight Removal/Installation…7565
Torque -…7565
Headlight Relay Inspection…7566
Special Tool -…7566
Tail/Brake Light (LED) Removal…7566
Tail/Brake Light (LED) Installation…7567
Torque -…7567
License Plate Light Bulb Replacement…7567
Torque -…7567
Headlight/Tail Light Circuit…7568
Turn Signal Light Bulb Replacement…7568
Turn Signal Relay Inspection…7570
Turn Signal Light Circuit…7571
Air Switching Valve Operation Test…7572
Air Switching Valve Unit Test…7572
Special Tool -…7572
Fan Motor Inspection…7573
Radiator Fan Circuit…7573
Meter Unit Removal…7574
Meter Unit Installation…7574
Meter Unit Disassembly…7575
Meter Unit Inspection…7575
Special Tool -…7576
Special Tool -…7586
Special Tool -…7587
Meter Unit Circuit…7591
This motorcycle is equipped with an immobilizer system to protec…7592
Operational Cautions…7592
Key Registration…7592
Special Tool -…7592
Spare User Key Registration Flow Chart…7597
Special Tool -…7598
All Keys Initial Registration Flow Chart…7607
Immobilizer System Parts Replacement…7608
ECU (Electric Control Unit) Replacement (for Immobilizer Models)…7609
Immobilizer System Inspection…7610
Immobilizer System Circuit…7611
Brake Light Timing Inspection…7612
Brake Light Timing Adjustment…7612
Switch Inspection…7612
Special Tool -…7612
Rear Brake Light Switch Connections…7612
Sidestand Switch Connections…7612
Oil Pressure Switch Connections *…7612
Water Temperature Sensor Inspection…7613
Speed Sensor Removal…7613
Speed Sensor Installation…7613
Torque -…7613
Speed Sensor Inspection…7614
Special Tool -…7614
Fuel Level Sensor Inspection…7614
Special Tools -…7614
Torque -…7615
Fuel Reserve Switch Inspection…7615
Special Tool -…7615
Gear Position Switch Removal…7616
Gear Position Switch Installation…7617
Torque -…7617
Gear Position Switch Inspection…7617
Special Tool -…7617
The relay box [A] has relays and diodes. The relays and diodes c…7618
Relay Box Removal…7618
Relay Circuit Inspection…7618
Diode Circuit Inspection…7619
Relay Box Internal Circuit…7620
30 A Main Fuse Removal…7621
Fuse Box Fuse Removal…7621
15 A ECU Fuse Removal…7622
Fuse Installation…7622
Fuse Inspection…7623
17.Appendix…7625
ZX1400B Models…7650
ZX1400B Models…7660
ZX1400B Models…7662
ZX1400B Models…7664
ZX1400B Models…7666
ZX1400B Models…7668
ZX1400B Models…7670
ZX1400B Models…7672
California Model…7674
NOTE…7676
Engine Doesn't Start, Starting Difficulty:…7676
Starter motor not rotating:…7676
Starter motor rotating but engine doesn't turn over:…7676
Engine won't turn over:…7676
No fuel flow:…7676
No spark; spark weak:…7676
Fuel/air mixture incorrect:…7676
Compression Low:…7676
Poor Running at Low Speed:…7676
Spark weak:…7676
Fuel/air mixture incorrect:…7676
Compression low:…7677
Run-on (dieseling):…7677
Other:…7677
Poor Running or No Power at High Speed:…7677
Firing incorrect:…7677
Fuel/air mixture incorrect:…7677
Compression low:…7677
Knocking:…7677
Miscellaneous:…7677
Overheating:…7677
Firing incorrect:…7677
Muffler overheating:…7677
Fuel/air mixture incorrect:…7677
Compression high:…7678
Engine load faulty:…7678
Lubrication inadequate:…7678
Oil cooler incorrect:…7678
Gauge incorrect:…7678
Coolant incorrect:…7678
Cooling system component incorrect:…7678
Over Cooling:…7678
Gauge incorrect:…7678
Cooling system component incorrect:…7678
Clutch Operation Faulty:…7678
Clutch slipping:…7678
Clutch not disengaging properly:…7678
Gear Shifting Faulty:…7678
Doesn't go into gear; shift pedal doesn't return:…7678
Jumps out of gear:…7678
Overshifts:…7678
Abnormal Engine Noise:…7678
Knocking:…7678
Piston slap:…7678
Valve noise:…7678
Other noise:…7678
Abnormal Drive Train Noise:…7679
Clutch noise:…7679
Transmission noise:…7679
Drive line noise:…7679
Abnormal Frame Noise:…7679
Front fork noise:…7679
Rear shock absorber noise:…7679
Disc brake noise:…7679
Other noise:…7679
Oil Pressure Warning Light Goes On:…7679
Exhaust Smokes Excessively:…7679
White smoke:…7679
Black smoke:…7679
Brown smoke:…7679
Handling and/or Stability Unsatisfactory:…7679
Handlebar hard to turn:…7679
Handlebar shakes or excessively vibrates:…7679
Handlebar pulls to one side:…7679
Shock absorption unsatisfactory:…7679
Brake Doesn't Hold:…7680
Battery Trouble:…7680
Battery discharged:…7680
Battery overcharged:…7680
Kawasaki Motorcycle Service Repair Manual '06-'07 ZX-14 (EN)…7682
tables…0
LIST OF ABBREVIATIONS…7685
COUNTRY AND AREA CODES…7685
Units of Mass…7707
Units of Volume…7707
Units of Force…7707
Units of Length…7707
Units of Torque…7707
Units of Pressure…7707
Units of Speed…7707
Units of Power…7707
Periodic Inspection…7710
Periodic Replacement Parts…7712
Basic Torque for General Fasteners…7718
Throttle Grip Free Play…7722
Throttle Body Vacuum…7723
Main Throttle Sensor Output Voltage…7725
Idle Speed…7726
Valve Clearance…7729
Adjustment Shims…7731
Air Pressure (when Cold)…7736
Tread Depth…7736
Chain Slack…7738
Drive Chain 20-link Length…7739
Standard Chain…7740
Recommended Disc Brake Fluid…7743
Pad Lining Thickness…7743
Sidestand Switch Operation…7752
Water and Coolant Mixture Ratio (Recommended)…7759
Recommended Engine Oil…7761
Standard Spark Plug…7774
Sample Diagnosis Sheet…7805
Engine Won't Turn Over…7807
Poor Running at Low Speed…7807
Poor Running or No Power at High Speed:…7810
Main Throttle Sensor Input Voltage…7820
Input Voltage at ECU Connector…7820
Main Throttle Sensor Input Voltage…7821
Input Voltage at Sensor…7821
Main Throttle Sensor Output Voltage…7822
Idle Speed…7822
Output Voltage at ECU…7822
Throttle Sensor Output Voltage…7824
Output Voltage at Sensor…7824
Main Throttle Sensor Resistance…7825
Inlet Air Pressure Sensor Input Voltage…7827
Input Voltage at ECU…7827
Inlet Air Pressure Sensor Input Voltage…7827
Input Voltage at Sensor Connector…7827
Inlet Air Pressure Sensor Output Voltage…7828
Output Voltage at ECU…7828
Inlet Air Pressure Sensor Output Voltage…7828
Output Voltage at Sensor Connector…7828
Inlet Air Pressure Sensor Output Voltage Connection to Adapter…7830
Inlet Air Temperature Sensor Output Voltage…7832
Output Voltage at ECU…7832
Inlet Air Temperature Sensor Resistance…7833
Water Temperature Sensor Output Voltage…7835
Output Voltage at ECU…7835
Atmospheric Pressure Sensor Input Voltage…7837
Input Voltage at ECU…7837
Atmospheric Pressure Sensor Input Voltage…7838
Input Voltage at Sensor Connector…7838
Atmospheric Pressure Sensor Output Voltage…7838
Output Voltage…7838
Atmospheric Pressure Sensor Output Voltage…7839
Output Voltage at Sensor…7839
Speed Sensor Input Voltage…7843
Input Voltage…7843
Speed Sensor Output Voltage…7844
Output Voltage at Sensor …7844
Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions…7846
Input Voltage at 1 ∼ 6 Gear Positions…7846
Vehicle-down sensor Power Source Voltage…7849
Power Source Voltage at Sensor…7849
Vehicle-down sensor Output Voltage…7850
Output Voltage at Sensor…7850
Subthrottle Sensor Input Voltage…7851
Input Voltage at ECU Connector…7851
Subthrottle Sensor Input Voltage…7852
Input Voltage at Sensor…7852
Subthrottle Sensor Output Voltage…7853
Output Voltage at ECU…7853
Subthrottle Sensor Output Voltage…7854
Output Voltage at Sensor…7854
Subthrottle Sensor Resistance…7855
Antenna Resistance…7856
Amplifier Input Voltage…7856
Input Voltage…7856
Testing Relay…7858
Stick Coil Input Voltage at ECU…7860
Input Voltage at ECU…7860
Subthrottle Valve Actuator Resistance…7862
Subthrottle Valve Actuator Input Voltage…7863
Input Voltage…7863
ECU Identification…7866
ECU Grounding Inspection…7868
ECU Power Source Inspection…7869
Fuel Pressure…7873
Fuel Pressure (idling)…7874
Amount of Fuel Flow…7876
Pump Operating Voltage at Pump…7878
Operating Voltage at Pump Connector…7878
Injector Power Source Voltage at ECU Connector…7880
Power Source Voltage at ECU…7880
Injector Power Source Voltage at Injector…7881
Power Source Voltage at Injector Connector…7881
Injector Output Voltage at ECU…7881
Output Voltage at ECU…7881
Injector Output Voltage at Injector…7882
Output Voltage at Injector Connector…7882
Injector Resistance…7883
Fuel Line Maximum Pressure…7884
Radiator Cap Relief Pressure…7920
Thermostat Valve Opening Temperature…7922
Camshaft Journal, Camshaft Cap Clearance…7945
Camshaft Journal Diameter…7946
Camshaft Runout…7946
Cam Height…7946
Cylinder Compression…7948
Cylinder Head Warp…7950
Valve/Valve Guide Clearance (Wobble Method)…7953
Valve Seating Surface Outside Diameter…7954
Valve Seating Surface Width…7954
Clutch Plate Assembly Length…7978
Friction Plate Thickness (13088-0030, 13088-0031)…7979
Friction Plate Thickness (13088-0032)…7979
Friction and Steel Plate Warp…7979
Friction Plate Warp (only 13088-0030)…7979
Clutch Spring Free Length…7979
Oil Pressure…7994
Connecting Rod Big End Bearing Insert Selection…8015
Crankshaft Main Bearing Insert Selection…8015
Connecting Rod Bend…8026
Connecting Rod Twist…8027
Connecting Rod Big End Side Clearance…8027
Connecting Rod Big End Bearing Insert/Crankpin Clearance…8027
Crankpin Diameter…8028
Crankpin Diameter Marks…8028
Connecting Rod Big End Inside Diameter Marks…8028
Crankshaft Side Clearance…8029
Crankshaft ##3 Main Journal Width…8030
Crankshaft Runout…8030
Crankshaft Main Bearing Insert/Journal Clearance…8031
Crankshaft Main Journal Diameter…8031
Crankshaft Main Journal Diameter Marks…8031
Crankcase Main Bearing Inside Diameter Marks…8031
Cylinder Inside Diameter…8035
Piston Diameter…8035
Piston Ring/Groove Clearance…8035
Piston Ring Groove Width…8036
Piston Ring Thickness…8036
Piston Ring End Gap…8036
Shift Fork Ear Thickness…8052
Gear Groove Width…8052
Shift Fork Guide Pin Diameter…8052
Shift Drum Groove Width…8052
Rim Runout (with tire installed)…8063
Axle Runout/100 mm (3.94 in.)…8063
Balance Weight…8065
Rear Sprocket Warp (Runout)…8082
Pedal Position…8097
Brake Discs Thickness…8108
Disc Runout…8108
Sample Diagnosis Sheet…8122
Service Code Table…8129
Terminal Voltage…8130
Battery Terminal Voltage…8132
Battery Terminal Voltage…8134
Air Gap…8135
Air Gap…8136
Battery Terminal Voltage…8138
Battery Terminal Voltage…8139
Air Gap…8145
Rebound Damping Force Adjustment…8156
Compression Damping Force Adjustment…8156
Adjuster Protrusion (from top)…8157
Spring Action…8157
Fork Oil…8160
Oil Level (fully compressed, without spring)…8161
Spring Free Length…8165
Rebound Damping Force Adjustment…8166
Rebound Damping Force Adjustment…8166
Spring Preload Setting…8167
Spring Adjustment…8167
Kawasaki-recommended chargers:…8245
Battery Terminal Voltage…8247
Terminal Voltage: 11.5 ∼ less than 12.6 V…8247
Terminal Voltage: less than 11.5 V…8247
Table 1 Alternator Output Voltage…8251
Table 2 Stator Coil Resistance at 20°C (68°F)…8251
Regulator/Rectifier Resistance (Unit: kΩ)…8252
Charging Voltage…8253
Connections:…8258
Crankshaft Sensor Peak Voltage…8258
Stick Coil Winding Resistance…8259
Primary Lead Connection…8259
Stick Coil Primary Peak Voltage…8260
Connections:…8262
Camshaft Position Sensor Peak Voltage…8262
Condition:…8262
Condition:…8263
Condition:…8263
Starter Motor Brush Length…8267
Commutator Diameter…8268
Testing Relay…8269
Testing Relay…8273
Testing Turn Signal Relay…8277
Air Switching Valve Resistance…8279
CAN Communication Line Resistance (at Meter Unit)…8283
Connections:…8293
Speed Sensor Supply Voltage…8293
Connections:…8294
User Key Indicator Light Flashes…8302
Water Temperature Sensor…8320
Fuel Level Sensor Resistance…8321
Connections…8322
Gear Position Switch Resistance kΩ…8324
Relay Circuit Inspection (with the battery disconnected)…8325
Relay Circuit Inspection (with the battery connected)…8326
Diode Circuit Inspection…8326
toc…0
EMISSION CONTROL INFORMATION…7686
1…7686
2…7686
3…7686
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…7687
Foreword…7688
General Information…7690
Before starting to perform an inspection service or carry out a …7691
Battery Ground…7691
Edges of Parts…7691
Solvent…7691
Cleaning vehicle before disassembly…7691
Arrangement and Cleaning of Removed Parts…7692
Storage of Removed Parts…7692
Inspection…7692
Replacement Parts…7692
Assembly Order…7692
Tightening Sequence…7693
Tightening Torque…7693
Force…7693
Gasket, O-ring…7693
Liquid Gasket, Non-permanent Locking Agent…7693
Press…7694
Ball Bearing and Needle Bearing…7694
Oil Seal, Grease Seal…7694
Circlips, Cotter Pins…7694
Lubrication…7695
Direction of Engine Rotation…7695
Electrical Leads…7695
Instrument…7695
ZX1400A6F (Europe) Left Side View…7696
ZX1400A6F (Europe) Right Side View…7696
Frame Number…7696
Engine Number…7696
ZX1400A6F (United States and Canada) Left Side View…7697
ZX1400A6F (United States and Canada) Right Side View…7697
ZX1400A6F (Malaysia) Left Side View…7698
ZX1400A6F (Malaysia) Right Side View…7698
ZX1400B6F (Europe) Left Side View…7699
ZX1400B6F (Europe) Right Side View…7699
ZX1400B6F (Malaysia) Left Side View…7700
ZX1400B6F (Malaysia) Right Side View…7700
Overview…7704
Structure and Function…7705
System maintenance…7706
Prefixes for Units…7707
Units of Temperature…7707
Periodic Maintenance…7708
The scheduled maintenance must be done in accordance with this c…7710
The following tables list the tightening torque for the major fa…7713
Inside Circlip Pliers:…7721
Fuel System (DFI)…7722
Throttle Control System Inspection…7722
Engine Vacuum Synchronization Inspection…7722
Special Tool -…7723
Special Tool -…7724
Special Tool -…7724
Torque -…7725
Torque -…7725
Idle Speed Inspection…7726
Idle Speed Adjustment…7726
Fuel Hose Inspection (fuel leak, damage, installation condition)…7726
Evaporative Emission Control System (CAL) Inspection…7727
Cooling System…7728
Coolant Level Inspection…7728
Water Hose and Pipe Inspection…7728
Torque -…7728
Engine Top End…7729
Valve Clearance Inspection…7729
EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART…7732
INLET- VALVE CLEARANCE ADJUSTMENT CHART…7733
Air Suction System Damage Inspection…7734
Clutch…7734
Clutch Operation Inspection …7734
Clutch Fluid Level Inspection…7735
Clutch Fluid Leak Inspection…7735
Clutch Hose and Pipe Damage and Installation Condition Inspectio…7735
Torque -…7735
Wheels/Tires…7736
Air Pressure Inspection…7736
Wheel/Tire Damage Inspection…7736
Tire Tread Wear Inspection …7736
Wheel Bearing Damage Inspection…7737
Final Drive…7737
Drive Chain Lubrication Condition Inspection…7737
Drive Chain Slack Inspection…7738
Drive Chain Slack Adjustment…7738
Torque -…7738
Wheel Alignment Inspection…7739
Drive Chain Wear Inspection…7739
Drive Chain Guide Wear Inspection…7740
Brakes…7741
Brake Fluid Leak (Brake Hose and Pipe) Inspection…7741
Brake Hose and Pipe Damage and Installation Condition Inspection…7742
Torque -…7742
Brake Operation Inspection…7742
Brake Fluid Level Inspection…7742
Brake Pad Wear Inspection…7743
Brake Light Switch Operation Inspection…7744
Suspension…7744
Front Forks/Rear Shock Absorber Operation Inspection…7744
Front Fork Oil Leak Inspection…7745
Rear Shock Absorber Oil Leak Inspection…7745
Rocker Arm Operation Inspection…7745
Tie-Rod Operation Inspection…7745
Steering…7746
Steering Play Inspection…7746
Special Tools -…7746
Steering Play Adjustment…7746
Special Tool -…7747
Torque -…7747
Steering Stem Bearing Lubrication…7747
Electrical System…7748
Lights and Switches Operation Inspection…7748
Headlight Aiming Inspection…7751
Sidestand Switch Operation Inspection…7752
Engine Stop Switch Operation Inspection…7753
Others…7753
Chassis Parts Lubrication and Cable Inspection…7753
Pivots: Lubricate with Grease…7753
Points: Lubricate with Grease…7753
Points: Lubricate with Engine Oil…7753
Cables: Lubricate with Rust Inhibitor…7754
Bolts, Nuts and Fasteners Tightness Inspection…7754
Bolt, Nut and Fastener to be checked…7755
Replacement Parts…7755
Air Cleaner Element Replacement…7755
Torque -…7756
Fuel Hose Replacement…7756
Coolant Change…7758
Torque -…7758
Radiator Hose and O-ring Replacement…7760
Engine Oil Change…7760
Torque -…7760
Oil Filter Replacement…7761
Special Tool -…7761
Torque -…7761
Brake Hose and Pipe Replacement…7762
Torque -…7763
Brake Fluid Change…7764
Torque -…7765
Torque -…7765
Master Cylinder Rubber Parts Replacement…7765
Special Tool -…7765
Special Tool -…7765
Torque -…7766
Caliper Rubber Parts Replacement…7766
Torque -…7767
Torque -…7767
Rear Caliper Assembly…7769
Torque -…7769
Torque -…7770
Clutch Hose and Pipe Replacement…7770
Torque -…7770
Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacemen…7771
Special Tool -…7771
Torque -…7771
Clutch Fluid Change…7773
Torque -…7773
Spark Plug Replacement…7773
Torque -…7774
Fuel System (DFI)…7776
DFI System…7785
Terminal Numbers of ECU Connectors…7789
Main Throttle Sensor [A]…7791
Oil Pressure Gauge, 5 kgf/cm :…7795
DFI Servicing Precautions…7797
Torque -…7798
Outline…7799
Special Tool -…7801
Sealant -…7801
Special Tool -…7802
DFI Diagnosis Flow Chart…7804
Inquiries to Rider…7804
NOTE…7807
Self-diagnosis Outline…7812
Self-diagnosis Procedures…7813
Self-Diagnosis Flow Chart…7815
Service Code Reading…7816
Service Code Erasing…7816
Backups…7818
The main throttle sensor is a rotating variable resistor that ch…7820
Main Throttle Sensor Removal/Adjustment…7820
Input Voltage Inspection…7820
Special Tool -…7820
Special Tool -…7821
Output Voltage Inspection…7822
Special Tool -…7822
Special Tool -…7824
Resistance Inspection…7825
Main Throttle Sensor Circuit…7825
CAUTION…7826
Removal…7826
Installation…7826
Input Voltage Inspection…7827
Special Tool -…7827
Special Tool -…7827
Output Voltage Inspection…7828
Special Tool -…7828
Special Tool -…7828
Inlet Air Pressure Sensor Circuit…7829
Special Tools -…7830
Removal/Installation…7832
Output Voltage Inspection…7832
Special Tool -…7832
Sensor Resistance Inspection…7833
Inlet Air Temperature Sensor Circuit…7834
Removal/Installation…7835
Torque -…7835
Output Voltage Inspection…7835
Special Tool -…7835
Sensor Resistance Inspection…7836
Water Temperature Sensor Circuit…7836
CAUTION…7837
Removal…7837
Installation…7837
Input Voltage Inspection…7837
Special Tool -…7837
Special Tool -…7838
Output Voltage Inspection…7838
Special Tool -…7838
Special Tool -…7839
Atmospheric Pressure Sensor Circuit…7839
Atmospheric Pressure/Altitude Relationship…7840
Crankshaft Sensor Removal/Installation…7841
Crankshaft Sensor Inspection…7841
Crankshaft Sensor Circuit…7841
Camshaft Position Sensor Removal/Installation…7842
Camshaft Position Sensor Inspection…7842
Camshaft Position Sensor Circuit…7842
Speed Sensor Removal/Installation…7843
Speed Sensor Inspection…7843
Input Voltage Inspection…7843
Special Tool -…7843
Output Voltage Inspection…7844
Special Tool -…7844
Gear Position Switch Removal/Installation…7846
Gear Position Switch Inspection…7846
Input Voltage Inspection…7846
Special Tool -…7846
Gear Position Switch Circuit…7847
This sensor has a weight [A] with two magnets inside, and sends …7848
Removal…7848
Installation…7848
Torque -…7848
Inspection…7849
Special Tool -…7849
Special Tool -…7850
Vehicle-down Sensor Circuit…7850
The subthrottle sensor is a rotating variable resistor that chan…7851
Subthrottle Sensor Removal/Adjustment…7851
Input Voltage Inspection…7851
Special Tool -…7851
Special Tool -…7852
Output Voltage Inspection…7853
Special Tool -…7853
Special Tool -…7854
Resistance Inspection…7855
Subthrottle Sensor Circuit…7855
Antenna Resistance Inspection…7856
Amplifier Input Voltage Inspection…7856
Special Tool -…7856
User Key Inspection…7857
Immobilizer System Circuit…7857
Fuel Pump Relay Removal…7858
Fuel Pump Relay Inspection…7858
Special Tool -…7858
Fuel Pump Relay Circuit…7859
Stick Coil ##1: Service Code 51…7860
Removal/Installation…7860
Input Voltage Inspection…7860
Special Tool -…7860
Stick Coil Circuit…7861
Subthrottle Valve Actuator Removal…7862
Subthrottle Valve Actuator Inspection…7862
Resistance Inspection…7862
Input Voltage Inspection…7863
Special Tools -…7863
Subthrottle Valve Actuator Circuit…7864
ECU Main Relay Inspection…7865
CAUTION…7866
ECU Identification…7866
ECU Removal…7866
ECU Installation…7867
ECU Power Supply Inspection…7868
Special Tool -…7868
ECU Power Source Circuit…7870
CAN Communication Line Resistance Inspection…7870
CAN Communication Line Circuit…7871
Light (LED) Inspection…7872
Warning Indicator Light (LED) Circuit…7872
Fuel Pressure Inspection…7873
Special Tools -…7873
Fuel Flow Rate Inspection…7874
Special Tool -…7874
Fuel Pump Removal…7877
Fuel Pump Installation…7877
Torque -…7878
Operation Inspection…7878
Operating Voltage Inspection…7878
Special Tools -…7878
Fuel Pump Circuit…7879
Removal/Installation…7880
Power Source Voltage Inspection…7880
Special Tool -…7880
Special Tool -…7881
Output Voltage Inspection…7881
Special Tool -…7881
Special Tool -…7882
Audible Inspection…7882
Injector Signal Test…7883
Special Tool -…7883
Injector Resistance Inspection…7883
Injector Unit Test…7884
Injector Fuel Line Inspection…7884
Fuel Injector Circuit…7885
Free Play Inspection…7886
Free Play Adjustment…7886
Cable Installation…7886
Cable Lubrication…7886
Idle Speed Inspection…7887
Throttle Bore Cleaning…7887
Synchronization Inspection…7887
Synchronization Adjustment…7887
Throttle Body Assy Removal…7887
Throttle Body Assy Installation…7890
Torque -…7890
Torque -…7891
Torque -…7891
Throttle Body Assy Disassembly…7892
Throttle Body Assy Assembly…7893
Torque -…7894
Element Removal…7895
Element Installation…7895
Air Cleaner Element Inspection…7895
Air Cleaner Element Holder Removal…7895
Air Cleaner Element Holder Installation…7895
Torque -…7895
Oil Draining…7896
Rear Air Inlet Duct Removal…7896
Rear Air Inlet Duct Installation…7896
Torque -…7896
Torque -…7897
Front and Middle Air Inlet Duct Removal…7897
Front and Middle Air Inlet Duct Installation…7897
Torque -…7898
Torque -…7898
Torque -…7898
Fuel Tank Removal…7899
Fuel Tank Installation…7901
Fuel Tank and Cap Inspection…7903
Fuel Tank Cleaning…7903
The Evaporative Emission Control System routes fuel vapors from …7904
Parts Removal/Installation…7904
Hose Inspection…7904
Separator Inspection…7904
Separator Operation Test…7905
Canister Inspection…7905
Cooling System…7908
Coolant Deterioration Inspection…7914
Coolant Level Inspection…7914
Coolant Draining…7914
Coolant Filling…7914
Pressure Testing…7914
Cooling System Flushing…7915
Coolant Reserve Tank Removal/Installation…7915
Water Pump Removal…7916
Water Pump Installation…7916
Torque -…7917
Water Pump Impeller Inspection…7917
Radiator and Radiator Fan Removal…7918
Radiator and Radiator Fan Installation…7919
Torque -…7919
Radiator Inspection…7919
Radiator Cap Inspection…7920
Radiator Filler Neck Inspection…7920
Thermostat Removal…7921
Thermostat Installation…7921
Torque -…7921
Thermostat Inspection…7921
Hose Installation…7923
Torque -…7923
Hose Inspection…7923
CAUTION…7924
Water Temperature Sensor Removal…7924
Water Temperature Sensor Inspection…7924
Engine Top End…7926
Compression Gauge, 20 kgf/cm :…7934
Air Suction Valve Removal…7936
Air Suction Valve Installation…7936
Torque -…7936
Air Suction Valve Inspection…7937
Air Switching Valve Removal…7937
Air Switching Valve Installation…7937
Air Switching Valve Operation Test…7937
Air Switching Valve Unit Test…7937
Clean Air System Hose Inspection…7937
Cylinder Head Cover Removal…7938
Cylinder Head Cover Installation…7938
Sealant -…7938
Torque -…7939
Camshaft Chain Tensioner Removal…7940
Camshaft Chain Tensioner Installation…7940
Torque -…7940
Camshaft Removal…7942
Camshaft Installation…7942
Torque -…7942
Torque -…7945
Camshaft, Camshaft Cap Wear…7945
Torque -…7945
Camshaft Runout…7946
Cam Wear…7946
Camshaft Chain Removal…7946
Camshaft Chain Installation…7947
Torque -…7947
Cylinder Compression Measurement…7948
Owner's Tool -…7948
Special Tools -…7948
Torque -…7948
Cylinder Head Removal…7949
Cylinder Head Installation…7949
Torque -…7950
Torque -…7950
Torque -…7950
Torque -…7950
Cylinder Head Warp Inspection…7950
Valve Clearance Inspection…7951
Valve Removal…7951
Special Tools -…7951
Valve Installation…7951
Valve Guide Removal…7951
Special Tool -…7951
Valve Guide Installation…7952
Special Tools -…7952
Special Tool -…7952
Valve-to-Guide Clearance Measurement (Wobble Method)…7953
Valve Seat Inspection…7954
Valve Seat Repair…7954
Special Tools -…7954
Throttle Body Holder Installation…7959
Torque -…7959
WARNING…7960
Muffler Body Removal/Installation…7960
Torque -…7961
Exhaust Pipe Removal…7961
Exhaust Pipe Installation…7961
Torque -…7961
Clutch…7962
Inside Circlip Pliers:…7966
Clutch Lever Adjustment…7967
Clutch Master Cylinder Removal…7967
Clutch Master Cylinder Installation …7967
Torque -…7968
Torque -…7968
Clutch Master Cylinder Disassembly …7968
Clutch Master Cylinder Assembly…7968
Clutch Master Cylinder Inspection…7968
Special Tool -…7968
Clutch Slave Cylinder Removal…7969
Clutch Slave Cylinder Installation…7970
Torque -…7970
Torque -…7970
Clutch Slave Cylinder Disassembly …7970
Clutch Slave Cylinder Assembly…7970
Clutch Fluid Level Inspection…7971
Clutch Fluid Change…7971
Bleeding the Clutch Line…7971
Torque -…7972
Torque -…7972
Torque -…7973
Clutch Hose Removal/Installation…7973
Clutch Hose and Connection Inspection…7973
Clutch Cover Removal…7974
Clutch Cover Installation…7974
Sealant -…7974
Torque -…7974
Clutch Removal…7975
Special Tool -…7975
Special Tool -…7975
Clutch Installation…7976
Special Tool -…7976
Special Tool -…7976
Torque -…7976
Torque -…7977
Clutch Plate Assembly Inspection…7978
Torque -…7978
Clutch Plate Assembly Adjustment…7978
Torque -…7978
Clutch Plate, Wear, Damage Inspection…7979
Clutch Plate Warp Inspection…7979
Clutch Spring Free Length Measurement…7979
Engine Lubrication System…7980
Oil Pressure Gauge, 10 kgf/cm :…7986
WARNING…7987
Oil Level Inspection…7987
Engine Oil Change…7987
Oil Filter Replacement…7987
Oil Pan Removal…7988
Special Tool -…7988
Oil Pan Installation…7988
Torque -…7988
Torque -…7989
Oil Pressure Relief Valve Removal…7990
Oil Pressure Relief Valve Installation…7990
Oil Pressure Relief Valve Inspection…7990
Oil Pump Removal…7991
Oil Pump Installation…7991
Torque -…7992
Oil Cooler Removal…7993
Oil Cooler Installation…7993
Torque -…7993
Torque -…7993
Oil Pressure Measurement…7994
Special Tools -…7994
Torque -…7994
Oil Pressure Switch Removal…7995
Oil Pressure Switch Installation…7995
Sealant -…7995
Torque -…7995
Torque -…7995
Engine Removal/Installation…7996
Engine Removal…7999
Engine Installation…8001
Torque -…8004
Torque -…8005
Torque -…8005
Crankshaft/Transmission…8008
Bearing Puller:…8016
Crankcase Splitting…8017
Crankcase Assembly…8018
Torque -…8018
Sealant -…8019
Torque -…8020
Torque -…8020
Torque -…8021
Crankshaft Removal…8022
Crankshaft Installation…8022
Connecting Rod Removal…8023
Connecting Rod Installation…8023
Crankshaft/Connecting Rod Cleaning…8026
Connecting Rod Bend Inspection…8026
Connecting Rod Twist Inspection…8027
Connecting Rod Big End Side Clearance Inspection…8027
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection…8027
Crankshaft Side Clearance Inspection…8029
Crankshaft Runout Inspection…8030
Crankshaft Main Bearing Insert/Journal Wear Inspection…8030
Piston Removal…8033
Special Tool -…8033
Piston Installation…8034
Special Tools -…8035
Cylinder Wear (Upper Crankcase) Inspection…8035
Piston Wear Inspection…8035
Piston Ring, Piston Ring Groove Wear Inspection…8035
Piston Ring Groove Width Inspection…8036
Piston Ring Thickness Inspection…8036
Piston Ring End Gap Inspection…8036
Front Balancer Removal…8037
Front Balancer Installation…8037
Torque -…8038
Torque -…8038
Rear Balancer Removal…8038
Rear Balancer Installation…8039
Torque -…8040
Torque -…8040
Balancer Adjustment…8041
Torque -…8041
Balancer Damper Inspection…8041
Starter Motor Clutch Removal…8042
Starter Motor Clutch Installation…8042
Torque -…8042
Torque -…8042
Starter Motor Clutch Disassembly…8042
Starter Motor Clutch Assembly…8043
Starter Clutch Inspection…8043
Torque Limiter Removal…8043
Torque Limiter Installation…8044
Torque -…8044
Shift Pedal Removal…8045
Shift Pedal Installation…8045
Torque -…8045
External Shift Mechanism Removal…8045
External Shift Mechanism Installation…8046
Torque -…8046
External Shift Mechanism Inspection…8046
Torque -…8046
Transmission Shaft Removal…8046
Transmission Shaft Installation…8047
Torque -…8047
Transmission Shaft Disassembly…8048
Special Tools -…8048
Transmission Shaft Assembly…8048
Shift Drum and Fork Removal…8051
Shift Drum and Fork Installation…8051
Torque -…8051
Shift Drum Disassembly…8051
Shift Drum Assembly…8051
Torque -…8051
Shift Fork Bending Inspection…8052
Shift Fork/Gear Groove Wear Inspection…8052
Shift Fork Guide Pin/Drum Groove Wear Inspection…8052
Gear Dog and Gear Dog Hole Damage Inspection…8052
Wheels/Tires…8054
Bearing Driver Set:…8058
Front Wheel Removal…8059
Special Tools -…8059
Front Wheel Installation…8059
Torque -…8060
Torque -…8060
Rear Wheel Removal…8060
Rear Wheel Installation…8061
Torque -…8061
Wheel Inspection…8063
Special Tools -…8063
Axle Inspection…8063
Balance Inspection…8064
Balance Adjustment…8064
Balance Weight Removal…8064
Balance Weight Installation…8065
Air Pressure Inspection/Adjustment…8067
Tire Inspection…8067
Tire Removal…8067
Tire Installation…8067
Tire Repair…8069
Hub Bearing Removal…8070
Special Tools -…8070
Hub Bearing Installation…8070
Special Tool -…8070
Special Tool -…8070
Hub Bearing Inspection…8070
Hub Bearing Lubrication…8071
Final Drive…8072
Inside Circlip Pliers:…8076
Drive Chain Slack Inspection…8077
Drive Chain Slack Adjustment…8077
Wheel Alignment Inspection/Adjustment…8077
Drive Chain Wear Inspection…8077
Drive Chain Lubrication…8077
Drive Chain Removal…8077
Drive Chain Installation…8077
Engine Sprocket Removal…8078
Engine Sprocket Installation…8078
Torque -…8078
Torque -…8078
Torque -…8079
Rear Sprocket Removal…8079
Rear Sprocket Installation…8079
Torque -…8079
Torque -…8079
Coupling Installation…8079
Coupling Bearing Removal…8080
Special Tool -…8080
Special Tool -…8080
Coupling Bearing Installation…8080
Special Tool -…8080
Special Tool -…8080
Special Tool -…8080
Coupling Bearing Inspection…8081
Coupling Bearing Lubrication…8081
Coupling Damper Inspection…8081
Sprocket Wear Inspection…8081
Rear Sprocket Warp (Runout) Inspection…8082
Brakes…8084
Dummy Page…8086
ZX1400A Models…8087
ZX1400A Models…8089
ZX1400B Models…8091
ZX1400B Models…8093
Inside Circlip Pliers:…8096
Brake Lever Position Adjustment…8097
Brake Pedal Position Inspection …8097
Brake Pedal Position Adjustment …8097
Torque -…8097
Brake Pedal Removal…8097
Brake Pedal Installation…8098
Torque -…8098
Torque -…8098
Torque -…8098
Front Caliper Removal…8099
Rear Caliper Removal…8099
Caliper Installation…8100
Torque -…8100
Front Caliper Disassembly…8100
Front Caliper Assembly…8100
Rear Caliper Disassembly…8100
Rear Caliper Assembly…8100
Caliper Fluid Seal Damage Inspection…8101
Caliper Dust Seal Damage Inspection…8101
Caliper Piston and Cylinder Damage Inspection…8102
Front Brake Pad Removal…8103
Front Brake Pad Installation…8103
Torque -…8103
Rear Brake Pad Removal …8104
Rear Brake Pad Installation…8104
Torque -…8104
Brake Pad Wear Inspection…8104
Front Master Cylinder Removal…8105
Front Master Cylinder Installation…8105
Torque -…8105
Torque -…8105
Rear Master Cylinder Removal…8105
Rear Master Cylinder Installation…8106
Torque -…8106
Front Master Cylinder Disassembly…8106
Rear Master Cylinder Disassembly…8106
Master Cylinder Assembly…8106
Master Cylinder Inspection (Visual Inspection)…8106
Brake Disc Removal…8108
Brake Disc Installation…8108
Torque -…8108
Brake Disc Wear Inspection…8108
Brake Disc Warp Inspection…8108
Special Tools -…8108
Brake Fluid Level Inspection…8109
Brake Fluid Change…8109
Brake Line Bleeding…8109
Torque -…8110
Torque -…8111
Torque -…8111
Brake Hose and Pipe Removal/Installation…8113
Brake Hose and Pipe Inspection…8113
Parts Location…8114
ABS System Wiring Diagram…8115
Terminal Names…8116
ABS Servicing Precautions…8117
ABS Troubleshooting Outline…8119
Special Tool -…8119
Special Tool -…8120
ABS Diagnosis Flow Chart…8121
Inquiries to Rider…8122
Pre-Diagnosis Inspection 1…8123
Pre-Diagnosis Inspection 2…8124
Self-diagnosis Outline…8124
Self-diagnosis Procedures…8124
Service Code Clearing Procedures…8125
Self-diagnosis Flow Chart…8127
How to Read Service Codes…8128
How to Erase Service Codes…8128
ABS Indicator Light (LED) Inspection…8130
ABS Indicator Light (LED) is Unlit (When the Ignition Switch tur…8130
Special Tool -…8130
ABS Indicator Light (LED) Lights (When the Motorcycle is Running…8131
Special Tool -…8131
Solenoid Valve Inspection (Service Code 13,14,17,18)…8131
ABS Solenoid Valve Relay Inspection (Service Code 19)…8131
Special Tool -…8132
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)…8133
ABS Pump Motor Relay Inspection (Service Code 35)…8133
Special Tool -…8134
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)…8135
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)…8135
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)…8136
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)…8137
Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)…8138
Special Tool -…8138
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)…8139
Special Tool -…8139
ECU Inspection (Service Code 55)…8140
ABS Hydraulic Unit Removal…8140
ABS Hydraulic Unit Installation…8141
Torque -…8142
ABS Hydraulic Unit Inspection…8142
Front Wheel Rotation Sensor Removal…8142
Front Wheel Rotation Sensor Installation…8143
Rear Wheel Rotation Sensor Removal…8143
Rear Wheel Rotation Sensor Installation…8144
Wheel Rotation Sensor Inspection…8144
Wheel Rotation Sensor Air Gap Inspection…8145
Wheel Rotation Sensor Rotor Inspection…8145
ABS Solenoid Valve Relay Fuse (20 A) Removal…8146
ABS Motor Relay Fuse (30 A) Removal…8146
ABS ECU Fuse (10 A) Removal…8146
Fuse Installation…8146
Fuse Inspection…8146
Suspension…8148
Inside Circlip Pliers:…8154
Rebound Damping Force Adjustment…8156
Compression Damping Force Adjustment…8156
Spring Preload Adjustment…8157
Front Fork Removal (Each Fork Leg)…8157
Front Fork Installation…8158
Torque -…8158
Torque -…8158
Front Fork Oil Change…8158
Special Tools -…8158
Special Tool -…8160
Special Tool -…8161
Special Tool -…8161
Special Tool -…8161
Special Tools -…8162
Torque -…8162
Front Fork Disassembly…8163
Special Tool -…8163
Front Fork Assembly…8163
Special Tool -…8163
Torque -…8163
Special Tool -…8164
Inner Tube Inspection…8164
Dust Seal Inspection…8165
Spring Tension…8165
Rebound Damping Force Adjustment…8166
Compression Damping Force Adjustment…8166
Spring Preload Adjustment…8166
Special Tool -…8166
Special Tool -…8167
Rear Shock Absorber Removal…8167
Special Tools -…8167
Rear Shock Absorber Installation…8168
Torque -…8168
Rear Shock Absorber Inspection…8168
Rear Shock Absorber Scrapping…8169
Swingarm Removal…8170
Special Tool -…8170
Swingarm Installation…8171
Torque -…8171
Special Tool -…8171
Torque -…8171
Torque -…8171
Swingarm Bearing Removal…8172
Special Tool -…8172
Special Tool -…8172
Swingarm Bearing Installation…8172
Special Tools -…8172
Swingarm Bearing, Sleeve Inspection…8173
Chain Guide Inspection…8174
Tie-Rod Removal…8175
Special Tools -…8175
Tie-Rod Installation…8175
Torque -…8175
Rocker Arm Removal…8175
Special Tools -…8175
Rocker Arm Installation…8176
Torque -…8176
Tie-Rod and Rocker Arm Bearing Removal…8176
Special Tools -…8176
Tie-Rod and Rocker Arm Bearing Installation…8176
Special Tools -…8177
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…8178
Rocker Arm/Tie-Rod Bearing Lubrication…8178
Steering…8180
Head Pipe Outer Race Press Shaft:…8183
Steering Inspection…8184
Steering Adjustment…8184
Stem, Stem Bearing Removal…8185
Special Tool -…8185
Special Tool -…8185
Stem, Stem Bearing Installation…8186
Special Tools -…8186
Special Tools -…8186
Special Tool -…8187
Torque -…8187
Torque -…8188
Steering Stem Bearing Lubrication…8188
Steering Stem Warp Inspection…8188
Stem Cap Deterioration, Damage Inspection…8188
Handlebar Removal…8189
Handlebar Installation…8189
Torque -…8189
Torque -…8190
Torque -…8190
Frame…8192
Seat Removal…8201
Seat Installation…8201
Lower Fairing Removal…8202
Lower Fairing Installation…8202
Fairing Cover Removal…8202
Middle Fairing Removal…8202
Middle Fairing Installation…8203
Windshield Removal…8203
Windshield Installation…8204
Torque -…8204
Upper Fairing Removal…8204
Upper Fairing Disassembly…8204
Upper Fairing Assembly…8204
Upper Fairing Installation…8205
Inner Cover Removal…8205
Inner Cover Installation…8205
Upper Inner Fairing Removal…8205
Upper Inner Fairing Installation…8206
Upper Fairing Bracket Removal…8206
Upper Fairing Bracket Installation…8206
Inner Fairing Removal…8206
Inner Fairing Installation…8206
Rear Fairing Removal…8206
Rear Fairing Installation…8206
Seat Cover Removal…8207
Seat Cover Installation…8207
Torque -…8208
Front Fender Removal…8209
Front Fender Installation…8209
Flap and Rear Fender Removal…8209
Flap and Rear Fender Installation…8210
Torque -…8210
Rear Frame Removal…8211
Rear Frame Installation…8211
Torque -…8211
Frame Inspection…8211
Center Stand Removal (Equipped Models)…8212
Center Stand Installation (Equipped Models)…8212
Torque -…8212
Sidestand Removal…8212
Sidestand Installation…8212
Torque -…8212
Torque -…8212
Electrical System…8214
Hand Tester:…8238
There are a number of important precautions that are musts when …8240
Wiring Inspection…8241
Special Tool -…8241
Battery Removal…8242
Battery Installation…8243
Battery Activation…8243
Precautions…8246
1)…8246
2)…8246
3)…8246
4)…8246
Interchange…8246
Charging Condition Inspection…8246
Refreshing Charge…8247
Alternator Cover Removal…8248
Alternator Cover Installation…8248
Sealant -…8248
Torque -…8248
Stator Coil Removal…8248
Stator Coil Installation…8249
Torque -…8249
Sealant -…8249
Torque -…8249
Alternator Rotor Removal…8249
Special Tools -…8249
Special Tool -…8249
Alternator Rotor Installation…8249
Special Tools -…8250
Torque -…8250
Alternator Inspection…8250
Special Tool -…8251
Regulator/Rectifier Inspection…8252
Special Tool -…8252
Torque -…8252
Charging Voltage Inspection…8253
Special Tool -…8253
Charging System Circuit…8254
Crankshaft Sensor Removal…8256
Crankshaft Sensor Installation…8257
Torque -…8257
Sealant -…8257
Torque -…8257
Crankshaft Sensor Inspection…8257
Special Tool -…8257
Crankshaft Sensor Peak Voltage Inspection…8257
Special Tools -…8258
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal…8258
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa…8258
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti…8259
Stick Coil Primary Peak Voltage…8259
Special Tools -…8259
Spark Plug Removal…8260
Spark Plug Installation…8260
Spark Plug Condition Inspection…8260
Camshaft Position Sensor Removal…8260
Camshaft Position Sensor Installation…8261
Torque -…8261
Camshaft Position Sensor Inspection…8261
Special Tool -…8261
Camshaft Position Sensor Peak Voltage Inspection…8262
Special Tools -…8262
Interlock Operation Inspection…8262
IC Igniter Inspection…8263
Ignition System Circuit…8264
Starter Motor Removal…8265
Starter Motor Installation…8265
Torque -…8265
Torque -…8265
Starter Motor Disassembly…8266
Starter Motor Assembly…8266
Torque -…8266
Torque -…8267
Brush Inspection…8267
Commutator Cleaning and Inspection…8268
Armature Inspection…8268
Special Tool -…8268
Brush Lead Inspection…8268
Special Tool -…8268
Right-hand End Cover Assembly Inspection…8269
Special Tool -…8269
Starter Relay Inspection…8269
Special Tool -…8269
Torque -…8269
Electric Starter Circuit…8270
This motorcycle adopt the daylight system and have a headlight r…8271
Headlight Beam Horizontal Vertical Adjustment…8271
Headlight Beam Vertical Adjustment…8271
Headlight Bulb Replacement…8271
City Light Bulb Replacement…8272
Headlight Removal/Installation…8272
Torque -…8272
Headlight Relay Inspection…8273
Special Tool -…8273
Tail/Brake Light (LED) Removal…8273
Tail/Brake Light (LED) Installation…8274
Torque -…8274
License Plate Light Bulb Replacement…8274
Torque -…8274
Headlight/Tail Light Circuit…8275
Turn Signal Light Bulb Replacement…8275
Turn Signal Relay Inspection…8277
Turn Signal Light Circuit…8278
Air Switching Valve Operation Test…8279
Air Switching Valve Unit Test…8279
Special Tool -…8279
Fan Motor Inspection…8280
Radiator Fan Circuit…8280
Meter Unit Removal…8281
Meter Unit Installation…8281
Meter Unit Disassembly…8282
Meter Unit Inspection…8282
Special Tool -…8283
Special Tool -…8293
Special Tool -…8294
Meter Unit Circuit…8298
This motorcycle is equipped with an immobilizer system to protec…8299
Operational Cautions…8299
Key Registration…8299
Special Tool -…8299
Spare User Key Registration Flow Chart…8304
Special Tool -…8305
All Keys Initial Registration Flow Chart…8314
Immobilizer System Parts Replacement…8315
ECU (Electric Control Unit) Replacement (for Immobilizer Models)…8316
Immobilizer System Inspection…8317
Immobilizer System Circuit…8318
Brake Light Timing Inspection…8319
Brake Light Timing Adjustment…8319
Switch Inspection…8319
Special Tool -…8319
Rear Brake Light Switch Connections…8319
Sidestand Switch Connections…8319
Oil Pressure Switch Connections *…8319
Water Temperature Sensor Inspection…8320
Speed Sensor Removal…8320
Speed Sensor Installation…8320
Torque -…8320
Speed Sensor Inspection…8321
Special Tool -…8321
Fuel Level Sensor Inspection…8321
Special Tools -…8321
Torque -…8322
Fuel Reserve Switch Inspection…8322
Special Tool -…8322
Gear Position Switch Removal…8323
Gear Position Switch Installation…8324
Torque -…8324
Gear Position Switch Inspection…8324
Special Tool -…8324
The relay box [A] has relays and diodes. The relays and diodes c…8325
Relay Box Removal…8325
Relay Circuit Inspection…8325
Diode Circuit Inspection…8326
Relay Box Internal Circuit…8327
30 A Main Fuse Removal…8328
Fuse Box Fuse Removal…8328
15 A ECU Fuse Removal…8329
Fuse Installation…8329
Fuse Inspection…8330
Appendix…8332
ZX1400B Models…8357
ZX1400B Models…8367
ZX1400B Models…8369
ZX1400B Models…8371
ZX1400B Models…8373
ZX1400B Models…8375
ZX1400B Models…8377
ZX1400B Models…8379
California Model…8381
NOTE…8383
Engine Doesn't Start, Starting Difficulty:…8383
Starter motor not rotating:…8383
Starter motor rotating but engine doesn't turn over:…8383
Engine won't turn over:…8383
No fuel flow:…8383
No spark; spark weak:…8383
Fuel/air mixture incorrect:…8383
Compression Low:…8383
Poor Running at Low Speed:…8383
Spark weak:…8383
Fuel/air mixture incorrect:…8383
Compression low:…8384
Run-on (dieseling):…8384
Other:…8384
Poor Running or No Power at High Speed:…8384
Firing incorrect:…8384
Fuel/air mixture incorrect:…8384
Compression low:…8384
Knocking:…8384
Miscellaneous:…8384
Overheating:…8384
Firing incorrect:…8384
Muffler overheating:…8384
Fuel/air mixture incorrect:…8384
Compression high:…8385
Engine load faulty:…8385
Lubrication inadequate:…8385
Oil cooler incorrect:…8385
Gauge incorrect:…8385
Coolant incorrect:…8385
Cooling system component incorrect:…8385
Over Cooling:…8385
Gauge incorrect:…8385
Cooling system component incorrect:…8385
Clutch Operation Faulty:…8385
Clutch slipping:…8385
Clutch not disengaging properly:…8385
Gear Shifting Faulty:…8385
Doesn't go into gear; shift pedal doesn't return:…8385
Jumps out of gear:…8385
Overshifts:…8385
Abnormal Engine Noise:…8385
Knocking:…8385
Piston slap:…8385
Valve noise:…8385
Other noise:…8385
Abnormal Drive Train Noise:…8386
Clutch noise:…8386
Transmission noise:…8386
Drive line noise:…8386
Abnormal Frame Noise:…8386
Front fork noise:…8386
Rear shock absorber noise:…8386
Disc brake noise:…8386
Other noise:…8386
Oil Pressure Warning Light Goes On:…8386
Exhaust Smokes Excessively:…8386
White smoke:…8386
Black smoke:…8386
Brown smoke:…8386
Handling and/or Stability Unsatisfactory:…8386
Handlebar hard to turn:…8386
Handlebar shakes or excessively vibrates:…8386
Handlebar pulls to one side:…8386
Shock absorption unsatisfactory:…8386
Brake Doesn't Hold:…8387
Battery Trouble:…8387
Battery discharged:…8387
Battery overcharged:…8387
Kawasaki Motorcycle Service Repair Manual '07 ZX-6R (EN)…8389
tables…0
LIST OF ABBREVIATIONS…8392
COUNTRY AND AREA CODES…8392
Units of Mass…8408
Units of Volume…8408
Units of Force…8408
Units of Length…8408
Units of Torque…8408
Units of Pressure…8408
Units of Speed…8408
Units of Power…8408
Periodic Inspection…8411
Periodic Replacement Parts…8413
Basic Torque for General Fasteners…8419
Throttle Grip Free Play…8423
Idle Speed…8424
Engine Vacuum…8424
Main Throttle Sensor Output Voltage…8426
Idle Speed…8426
Valve Clearance…8429
Example:…8430
Adjustment Shims…8431
Clutch Lever Free Play…8434
Air Pressure (when Cold)…8435
Tread Depth…8435
Chain Slack…8437
Drive Chain 20-link Length…8439
Standard Chain…8439
Recommended Disc Brake Fluid…8441
Pad Lining Thickness…8442
Side Stand Switch Operation…8449
Water and Coolant Mixture Ratio (Recommended)…8459
Recommended Engine Oil…8461
Standard Spark Plug…8468
Terminal Names…8488
Sample Diagnosis Sheet…8496
Engine Won't Turn Over…8498
Poor Running at Low Speed…8498
Poor Running or No Power at High Speed:…8501
Main Throttle Sensor Input Voltage…8511
Input Voltage at ECU Connector…8511
Main Throttle Sensor Input Voltage…8512
Input Voltage at Sensor…8512
Main Throttle Sensor Output Voltage…8512
Idle Speed…8512
Output Voltage at ECU…8512
Main Throttle Sensor Output Voltage…8513
Output Voltage at Sensor…8513
Main Throttle Sensor Resistance…8513
Inlet Air Pressure Sensor Input Voltage…8515
Input Voltage at ECU…8515
Inlet Air Pressure Sensor Input Voltage…8516
Input Voltage at Sensor Connector…8516
Inlet Air Pressure Sensor Output Voltage…8516
Output Voltage at ECU…8516
Inlet Air Pressure Sensor Output Voltage…8517
Output Voltage at Sensor Connector…8517
Inlet Air Pressure Sensor Output Voltage Connection to Sensor…8518
Inlet Air Temperature Sensor Output Voltage…8520
Output Voltage at ECU…8520
Inlet Air Temperature Sensor Resistance…8521
Water Temperature Sensor Output Voltage…8522
Output Voltage at ECU…8522
Atmospheric Pressure Sensor Input Voltage…8524
Input Voltage at ECU…8524
Atmospheric Pressure Sensor Input Voltage…8525
Input Voltage at Sensor Connector…8525
Atmospheric Pressure Sensor Output Voltage…8525
Output Voltage…8525
Atmospheric Pressure Sensor Output Voltage…8526
Output Voltage at Sensor…8526
Speed Sensor Input Voltage…8530
Input Voltage at Sensor…8530
Speed Sensor Output Voltage…8531
Output Voltage at Sensor …8531
Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions…8532
Input Voltage at 1 ∼ 6 Gear Positions…8532
Vehicle-down Sensor Power Source Voltage…8535
Power Source Voltage at Sensor…8535
Vehicle-down Sensor Output Voltage…8536
Output Voltage at Sensor…8536
Subthrottle Sensor Input Voltage…8538
Input Voltage at ECU Connector…8538
Subthrottle Sensor Input Voltage…8539
Input Voltage at Sensor…8539
Subthrottle Sensor Output Voltage…8539
Output Voltage at ECU…8539
Subthrottle Sensor Output Voltage…8540
Output Voltage at Sensor…8540
Subthrottle Sensor Resistance…8541
Oxygen Sensor Output Voltage…8542
Oxygen Sensor Output Voltage (with Plugs)…8542
Oxygen Sensor Output Voltage (without Plugs)…8543
Exhaust Butterfly Valve Actuator Sensor Input Voltage…8544
Input Voltage at Actuator…8544
Wiring Connections…8544
Exhaust Butterfly Valve Actuator Sensor Output Voltage…8545
Output Voltage at Actuator…8545
Wiring Connections…8545
Exhaust Butterfly Valve Actuator Sensor Resistance…8546
Antenna Resistance…8547
Amplifier Input Voltage…8547
Input Voltage…8547
Wiring Connections…8550
Stick Coil Input Voltage at ECU…8551
Input Voltage at ECU…8551
Subthrottle Valve Actuator Resistance…8555
Subthrottle Valve Actuator Input Voltage…8556
Input Voltage at Sensor…8556
Connections…8559
Actuator Output Voltage (Pulley Original Position)…8559
Oxygen Sensor Resistance…8562
Oxygen Sensor Heaters Power Source Voltage…8562
Power Source Voltage at Sensor Connector…8562
Oxygen Sensor Output Voltage…8564
Oxygen Sensor Output Voltage (with Plugs)…8564
Oxygen Sensor Output Voltage (without Plugs)…8565
ECU Identification…8566
ECU Grounding Inspection…8567
ECU Power Source Inspection…8568
Fuel Pressure…8571
Fuel Pressure (Idling)…8572
Amount of Fuel Flow…8573
Pump Operating Voltage at Pump…8575
Operating Voltage at Pump Connector…8575
Testing Relay…8577
Secondary Fuel Injector Resistance…8579
Primary Injector Resistance…8579
Secondary Fuel Injector Power Source Voltage…8580
Primary Fuel Injector Power Source Voltage…8580
Power Source Voltage at Injector Connector…8580
Secondary Fuel Injector Output Voltage…8581
Primary Fuel Injector Output Voltage…8581
Output Voltage at Injector Connector…8581
Fuel Line Maximum Pressure…8582
Radiator Cap Relief Pressure…8618
Thermostat Valve Opening Temperature…8621
Camshaft Journal, Camshaft Cap Clearance…8645
Camshaft Journal Diameter…8646
Camshaft Runout…8646
Cam Height…8646
Cylinder Compression…8647
Cylinder Head Warp…8649
Valve/Valve Guide Clearance (Wobble Method)…8652
Valve Seating Surface Outside Diameter…8653
Valve Seating Surface Width…8653
Spring Plate Free Play …8682
Spring Plate Free Play…8682
Clutch Plate Assembly Length (Reference)…8683
Friction Plate Thickness…8683
Friction and Steel Plate Warp…8683
Clutch Spring Free Length…8684
Oil Pressure…8704
Connecting Rod Big End Bearing Insert Selection…8726
Crankshaft Main Bearing Insert Selection (Engine No. ∼ ZX600PE…8726
Crankshaft Main Bearing Insert Selection (Engine No. ZX600PE0085…8726
Connecting Rod Bend…8740
Connecting Rod Twist…8740
Connecting Rod Big End Side Clearance…8740
Connecting Rod Big End Bearing Insert/Crankpin Clearance…8741
Crankpin Diameter…8741
Crankpin Diameter Marks…8741
Connecting Rod Big End Inside Diameter Marks…8742
Crankshaft Side Clearance…8742
Crankshaft ##3 Main Journal Width…8742
Crankshaft Runout…8743
Crankshaft Main Bearing Insert/Journal Clearance…8743
Crankshaft Main Journal Diameter…8743
Crankshaft Main Journal Diameter Marks…8743
Crankcase Main Bearing Inside Diameter Marks…8744
(Engine No. ∼ ZX600PE008560)…8744
(Engine No. ZX600PE008561 ∼)…8744
Cylinder Inside Diameter…8747
Piston Diameter…8747
Piston Ring/Groove Clearance…8747
Piston Ring Groove Width…8748
Piston Ring Thickness…8748
Piston Ring End Gap…8748
Shift Fork Ear Thickness…8764
Gear Groove Width…8764
Shift Fork Guide Pin Diameter…8764
Shift Drum Groove Width…8764
Rim Runout (with tire installed)…8774
Axle Runout/100 mm (3.94 in.)…8774
Balance Weight…8776
Link Pin Outside Diameter…8791
Link Plates Outside Width…8791
Rear Sprocket Warp…8796
Pedal Position…8804
Brake Discs Thickness…8814
Disc Runout…8814
Rebound Damping Force Adjustment…8829
Spring Action…8829
Compression Damping Force Adjustment…8830
Fork Oil…8832
Oil Level (fully compressed, without spring)…8833
Spring Free Length…8838
Rebound Damping Force Adjustment…8839
Spring Preload Setting…8840
Spring Adjustment…8840
Kawasaki-recommended chargers…8912
Battery Terminal Voltage…8914
Terminal Voltage: 11.5 ∼ less than 12.8 V…8915
Terminal Voltage: less than 11.5 V…8915
Table 1 Alternator Output Voltage…8918
Table 2 Stator Coil Resistance…8919
Regulator/Rectifier Resistance (Unit: kΩ)…8920
Charging Voltage…8921
Crankshaft Sensor Peak Voltage…8926
Ignition Coil Winding Resistance…8927
Primary Lead Connection…8927
Stick Coil Primary Peak Voltage…8928
Connections:…8930
Camshaft Position Sensor Peak Voltage…8930
Condition…8931
Condition…8931
Condition…8931
Starter Motor Brush Length…8936
Commutator Diameter…8936
Testing Relay…8938
Testing Turn Signal Relay…8947
Testing Turn Signal Relay…8947
Air Switching Valve Resistance…8949
LCD segment actions for 1.5 seconds…8953
Electric Source Voltage…8958
User Key Indicator Flashes…8973
Immobilizer Relational Parts Replacement Chart…8988
Gear Position Switch Resistance kΩ…8992
Water Temperature Sensor…8994
Connections…8996
Relay Circuit Inspection (with the battery disconnected)…8999
Relay Circuit Inspection (with the battery connected)…8999
Diode Circuit Inspection…8999
toc…0
EMISSION CONTROL INFORMATION…8393
1…8393
2…8393
3…8393
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…8394
Foreword…8395
General Information…8397
Before starting to perform an inspection service or carry out a …8398
Battery Ground…8398
Edges of Parts…8398
Solvent…8398
Cleaning vehicle before disassembly…8398
Arrangement and Cleaning of Removed Parts…8399
Storage of Removed Parts…8399
Inspection…8399
Replacement Parts…8399
Assembly Order…8399
Tightening Sequence…8400
Tightening Torque…8400
Force…8400
Gasket, O-ring…8400
Liquid Gasket, Non-permanent Locking Agent…8400
Press…8401
Ball Bearing and Needle Bearing…8401
Oil Seal, Grease Seal…8401
Circlips, Cotter Pins…8401
Lubrication…8402
Direction of Engine Rotation…8402
Electrical Wires…8402
Instrument…8402
ZX600P7F (Europe) Left Side View…8403
ZX600P7F (Europe) Right Side View…8403
ZX600P7F (US and Canada) Left Side View…8404
ZX600P7F (US and Canada) Right Side View…8404
Prefixes for Units…8408
Units of Temperature…8408
Periodic Maintenance…8409
The scheduled maintenance must be done in accordance with this c…8411
The following tables list the tightening torque for the major fa…8414
Inside Circlip Pliers:…8422
Fuel System (DFI)…8423
Throttle Control System Inspection…8423
Engine Vacuum Synchronization Inspection…8423
Special Tool -…8424
Special Tool -…8424
Special Tool -…8425
Special Tool -…8426
Idle Speed Inspection…8426
Idle Speed Adjustment…8427
Fuel Hose Inspection (fuel leak, damage, installation condition)…8427
Evaporative Emission Control System (California Model)…8427
Evaporative Emission Control System Inspection…8427
Engine Top End…8428
Valve Clearance Inspection…8428
Valve Clearance Adjustment…8430
Air Suction System…8432
Air Suction System Damage Inspection…8432
Cooling System…8433
Coolant Level Inspection…8433
Radiator Hose Damage and Installation Condition Inspection…8433
Torque -…8433
Clutch…8434
Clutch Operation Inspection …8434
Wheels/Tires…8435
Air Pressure Inspection…8435
Wheel/Tire Damage Inspection…8435
Tire Tread Wear Inspection …8435
Wheel Bearing Damage Inspection…8436
Drive Train…8437
Drive Chain Lubrication Condition Inspection…8437
Drive Chain Slack Inspection…8437
Drive Chain Slack Adjustment…8438
Torque -…8438
Wheel Alignment Inspection…8439
Drive Chain Wear Inspection…8439
Chain Guide Wear Inspection…8440
Brake System…8440
Brake Fluid Leak (Brake Hose and Pipe) Inspection…8440
Brake Hose Damage and Installation Condition Inspection…8440
Torque -…8440
Brake Operation Inspection…8441
Brake Fluid Level Inspection…8441
Brake Pad Wear Inspection…8442
Brake Light Switch Operation Inspection…8442
Suspensions…8443
Front Forks/Rear Shock Absorber Operation Inspection…8443
Front Fork Oil Leak Inspection…8443
Rear Shock Absorber Oil Leak Inspection…8444
Rocker Arm Operation Inspection…8444
Tie-Rod Operation Inspection…8444
Steering System…8444
Steering Play Inspection…8444
Special Tools -…8444
Steering Play Adjustment…8445
Special Tool -…8445
Torque -…8445
Steering Stem Bearing Lubrication…8446
Lights and Switches Operation Inspection…8446
Headlight Aiming Inspection…8448
Side Stand Switch Operation Inspection…8449
Engine Stop Switch Operation Inspection…8450
Others…8451
Chassis Parts Lubrication …8451
Pivots: Lubricate with Grease…8451
Points: Lubricate with Grease…8451
Cables: Lubricate with Rust Inhibitor…8451
Bolts, Nuts and Fasteners Tightness Inspection…8452
Bolt, Nut and Fastener to be checked…8453
Replacement Parts…8454
Air Cleaner Element Replacement…8454
Torque -…8455
Fuel Hose Replacement…8455
Torque -…8457
Coolant Change…8458
Torque -…8458
Radiator Hose and O-ring Replacement…8460
Torque -…8460
Engine Oil Change…8461
Torque -…8461
Oil Filter Replacement…8461
Special Tool -…8461
Torque -…8461
Brake Hose and Pipe Replacement…8462
Torque -…8462
Brake Fluid Change…8462
Torque -…8463
Torque -…8463
Master Cylinder Rubber Parts Replacement…8464
Special Tool -…8464
Special Tool -…8464
Silicone Grease -…8465
Torque -…8465
Caliper Rubber Parts Replacement…8465
Torque -…8466
Torque -…8466
Torque -…8467
Spark Plug Replacement…8468
Owner's Tool -…8468
Torque -…8468
Fuel System (DFI)…8469
Oil Pressure Gauge, 5 kgf/cm :…8480
Inlet Air Pressure Sensor [A]…8482
DFI System…8484
DFI System Wiring Diagram…8486
Terminal Numbers of ECU Connectors…8488
There are a number of important precautions that should be follo…8489
Torque -…8490
The warning indicator light (LED) [A] is used for the FI indicat…8491
Outline…8491
Special Tool -…8493
Sealant -…8493
DFI Diagnosis Flow Chart…8495
Inquiries to Rider…8495
NOTE…8498
The warning indicator light (LED) [A] is used for the FI indicat…8503
Self-diagnosis Outline…8503
Self-diagnosis Procedures…8504
Self-Diagnosis Flow Chart…8505
Service Code Reading…8506
Service Code Erasing…8506
Backups…8508
The main throttle sensor is a rotating variable resistor that ch…8511
Main Throttle Sensor Removal/Adjustment…8511
Main Throttle Sensor Input Voltage Inspection…8511
Special Tool -…8511
Special Tool -…8512
Main Throttle Sensor Output Voltage Inspection…8512
Special Tool -…8512
Special Tool -…8513
Main Throttle Sensor Resistance Inspection…8513
Main Throttle Sensor Circuit…8514
CAUTION…8515
Inlet Air Pressure Sensor Removal…8515
Inlet Air Pressure Sensor Installation…8515
Inlet Air Pressure Sensor Input Voltage Inspection…8515
Special Tool -…8515
Special Tool -…8516
Inlet Air Pressure Sensor Output Voltage Inspection…8516
Special Tool -…8517
Inlet Air Pressure Sensor Circuit…8517
Special Tools -…8518
Inlet Air Temperature Sensor Removal/Installation…8520
Inlet Air Temperature Sensor Output Voltage Inspection…8520
Special Tool -…8520
Sealant -…8521
Inlet Air Temperature Sensor Resistance Inspection…8521
Inlet Air Temperature Sensor Circuit…8521
Water Temperature Sensor Removal/Installation…8522
Sealant -…8522
Torque -…8522
Water Temperature Sensor Output Voltage Inspection…8522
Special Tool -…8522
Sealant -…8523
Water Temperature Sensor Circuit…8523
Water Temperature Sensor Resistance Inspection…8523
CAUTION…8524
Atmospheric Pressure Sensor Removal…8524
Atmospheric Pressure Sensor Installation…8524
Atmospheric Pressure Sensor Input Voltage Inspection…8524
Special Tool -…8524
Special Tool -…8525
Atmospheric Pressure Sensor Output Voltage Inspection…8525
Special Tool -…8526
Atmospheric Pressure Sensor Circuit…8526
Atmospheric Pressure/Altitude Relationship…8527
Crankshaft Sensor Removal/Installation…8528
Crankshaft Sensor Inspection…8528
Crankshaft Sensor Circuit…8528
Camshaft Position Sensor Removal/Installation…8529
Camshaft Position Sensor Inspection…8529
Camshaft Position Sensor Circuit…8529
Speed Sensor Removal/Installation…8530
Speed Sensor Inspection…8530
Speed Sensor Input Voltage Inspection…8530
Special Tool -…8530
Speed Sensor Output Voltage Inspection…8530
Special Tool -…8531
Speed Sensor Circuit…8531
Gear Position Switch Removal/Installation…8532
Gear Position Switch Inspection…8532
Gear Position Switch Input Voltage Inspection…8532
Special Tool -…8532
Gear Position Switch Circuit…8533
This sensor has a weight [A] with two magnets inside, and sends …8534
Vehicle-down Sensor Removal…8534
Vehicle-down Sensor Installation…8534
Torque -…8534
Vehicle-down Sensor Inspection…8535
Special Tool -…8535
Special Tool -…8536
Sealant -…8536
Vehicle-down Sensor Circuit…8537
Subthrottle Sensor Removal/Adjustment…8538
Subthrottle Sensor Input Voltage Inspection…8538
Special Tool -…8538
Special Tool -…8539
Subthrottle Sensor Output Voltage Inspection…8539
Special Tool -…8539
Special Tool -…8540
Resistance Inspection…8541
Subthrottle Sensor Circuit…8541
Oxygen Sensor ##1: Service Code 33…8542
Oxygen Sensor Removal/Installation…8542
Oxygen Sensor Inspection…8542
Special Tool -…8542
Sealant -…8543
Oxygen Sensor Circuit…8543
Exhaust Butterfly Valve Actuator Sensor Removal/Installation…8544
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection…8544
Special Tool -…8544
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio…8545
Special Tool -…8545
Exhaust Butterfly Valve Actuator Sensor Inspection…8546
Exhaust Butterfly Valve Actuator Sensor Circuit…8546
Antenna Resistance Inspection…8547
Amplifier Input Voltage Inspection…8547
Special Tool -…8547
This code appears in the following conditions. …8548
User Key Inspection…8548
Immobilizer System Circuit…8549
ECU Communication Line Inspection…8550
ECU Communication Line Circuit…8550
Stick Coil ##1: Service Code 51…8551
Stick Coil Removal/Installation…8551
Stick Coil Input Voltage Inspection…8551
Special Tool -…8551
Stick Coil Circuit…8552
Radiator Fan Relay Removal/Installation…8553
Radiator Fan Relay Inspection…8553
Radiator Fan Relay Circuit…8554
Subthrottle Valve Actuator Removal…8555
Subthrottle Valve Actuator Inspection…8555
Subthrottle Valve Actuator Resistance Inspection…8555
Subthrottle Valve Actuator Input Voltage Inspection…8556
Special Tools -…8556
Subthrottle Valve Actuator Circuit…8556
Exhaust Butterfly Valve Actuator Removal…8557
Exhaust Butterfly Valve Actuator Installation…8557
Torque -…8558
Torque -…8558
Exhaust Butterfly Valve Actuator Inspection…8559
Exhaust Butterfly Valve Actuator Output Voltage Inspection…8559
Special Tool -…8559
Exhaust Butterfly Valve Actuator Circuit…8560
Air Switching Valve Removal/Installation…8561
Air Switching Valve Inspection…8561
Air Switching Valve Circuit (Other than Europe Models)…8561
Oxygen Sensor Heater Removal/Installation…8562
Oxygen Sensor Heater Inspection …8562
Special Tool -…8562
Special Tool -…8562
Sealant -…8563
Oxygen Sensor Circuit…8563
Oxygen Sensor ##1: Service Code 94…8564
Oxygen Sensor Removal/Installation…8564
Oxygen Sensor Inspection…8564
Special Tool -…8564
Sealant -…8565
Oxygen Sensor Circuit…8565
CAUTION…8566
ECU Identification…8566
ECU Removal…8566
ECU Installation…8567
ECU Power Supply Inspection…8567
Special Tool -…8567
ECU Power Source Circuit…8568
ECU Fuse Removal…8569
ECU Fuse Installation…8569
ECU Fuse Inspection…8569
Warning Indicator Light (LED) Inspection…8570
Warning Indicator Light (LED) (FI/Immobilizer) Circuit…8570
Fuel Pressure Inspection…8571
Special Tools -…8571
Fuel Flow Rate Inspection…8572
Special Tool -…8573
Fuel Pump Removal…8574
Fuel Pump Installation…8574
Torque -…8575
Fuel Pump Operation Inspection…8575
Fuel Pump Operating Voltage Inspection…8575
Special Tools -…8575
Fuel Pump Circuit…8576
Fuel Pump Relay Removal…8577
Fuel Pump Relay Inspection…8577
Special Tool -…8577
CAUTION…8578
Audible Inspection…8578
Injector Signal Test…8578
Special Tool -…8579
Injector Resistance Inspection…8579
Special Tool -…8579
Injector Unit Test…8580
Injector Voltage Inspection…8580
Special Tool -…8580
Special Tool -…8580
Injector Fuel Line Inspection…8582
Fuel Injector Circuit…8583
Free Play Inspection…8584
Free Play Adjustment…8584
Cable Installation…8584
Cable Lubrication…8584
Idle Speed Inspection…8585
Synchronization Inspection…8585
Synchronization Adjustment…8585
Throttle Body Assy Removal…8585
Special Tool -…8585
Throttle Body Assy Installation…8586
Torque -…8586
Torque -…8586
Throttle Body Assy Disassembly…8587
Throttle Body Assy Assembly…8588
Torque -…8588
Nozzle Assy Removal…8589
Nozzle Assy Installation…8589
Torque -…8589
Nozzle Assy Disassembly…8590
Nozzle Assy Assembly…8590
Torque -…8591
Torque -…8591
Air Cleaner Element Removal…8592
Air Cleaner Element Installation…8592
Air Cleaner Element Inspection…8592
Air Cleaner Housing Removal…8592
Air Cleaner Housing Installation…8593
Torque -…8593
Air Cleaner Housing Disassembly…8594
Air Cleaner Housing Assembly…8594
Torque -…8594
Oil Draining…8595
Fuel Tank Removal…8596
Fuel Tank Installation…8598
Fuel Tank and Cap Inspection…8598
Fuel Tank Cleaning…8599
The Evaporative Emission Control System routes fuel vapors from …8600
Parts Removal/Installation…8600
Hose Inspection…8600
Separator Inspection…8600
Separator Operation Test…8601
Canister Inspection …8601
Cooling System…8603
Bearing Driver, 32:…8607
Coolant Deterioration Inspection…8610
Coolant Level Inspection…8610
Coolant Draining…8610
Coolant Filling…8610
Pressure Testing…8610
Cooling System Flushing…8611
Coolant Reserve Tank Removal…8611
Coolant Reserve Tank Installation…8612
Torque -…8612
Water Pump Removal…8613
Water Pump Installation…8613
Water Pump Impeller Disassembly/Assembly…8613
Torque -…8613
Water Pump Impeller Inspection…8613
Water Pump Housing Disassembly…8613
Water Pump Housing Assembly…8614
Special Tool -…8614
Special Tool -…8614
Mechanical Seal Inspection…8614
Radiator and Radiator Fan Removal…8615
Radiator and Radiator Fan Installation…8616
Torque -…8617
Torque -…8617
Torque -…8617
Torque -…8617
Radiator Inspection…8618
Radiator Cap Inspection…8618
Radiator Filler Neck Inspection…8619
Thermostat Removal…8620
Thermostat Installation…8620
Torque -…8620
Torque -…8621
Thermostat Inspection…8621
Hose Installation…8622
Torque -…8622
Hose Inspection…8622
Water Temperature Sensor Removal…8623
Water Temperature Sensor Inspection…8623
Engine Top End…8625
Compression Gauge, 20 kgf/cm :…8633
Air Suction Valve Removal…8635
Air Suction Valve Installation…8635
Torque -…8635
Air Suction Valve Inspection…8635
Air Switching Valve Removal…8636
Air Switching Valve Installation…8636
Air Switching Valve Operation Test…8636
Air Switching Valve Unit Test…8636
Clean Air System Hose Inspection…8636
Cylinder Head Cover Removal…8637
Cylinder Head Cover Installation…8637
Sealant -…8637
Torque -…8638
Torque -…8638
Camshaft Chain Tensioner Removal…8639
Camshaft Chain Tensioner Installation…8639
Torque -…8639
Torque -…8639
Camshaft Removal…8640
Camshaft Installation…8642
Torque -…8642
Torque -…8645
Camshaft, Camshaft Cap Wear…8645
Torque -…8645
Camshaft Runout…8646
Cam Wear…8646
Camshaft Chain Removal…8646
Cylinder Compression Measurement…8647
Special Tools -…8647
Torque -…8647
Cylinder Head Removal…8648
Cylinder Head Installation…8648
Torque -…8649
Torque -…8649
Torque -…8649
Cylinder Head Warp…8649
Valve Clearance Inspection…8650
Valve Clearance Adjustment…8650
Valve Removal…8650
Special Tools -…8650
Valve Installation…8650
Valve Guide Removal…8651
Special Tool -…8651
Valve Guide Installation…8651
Special Tools -…8651
Special Tool -…8651
Valve-to-Guide Clearance Measurement (Wobble Method)…8652
Valve Seat Inspection…8653
Valve Seat Repair…8653
Special Tools -…8653
Throttle Body Assy Holder Removal…8658
Throttle Body Assy Holder Installation…8658
Torque -…8658
WARNING…8659
Muffler Body Removal…8659
Muffler Body Installation…8660
Torque -…8660
Torque -…8660
Rear Exhaust Pipe Removal…8661
Rear Exhaust Pipe Installation…8662
Torque -…8662
Front Exhaust Pipe Removal…8663
Front Exhaust Pipe Installation…8664
Torque -…8664
Exhaust Butterfly Valve Cable Removal…8665
Exhaust Butterfly Valve Cable Installation…8666
Torque -…8666
Torque -…8666
Torque -…8667
Torque -…8668
Clutch…8669
Clutch Holder:…8673
Clutch Lever Free Play Inspection…8674
Clutch Lever Free Play Adjustment…8674
Cable Removal…8674
Cable Installation…8674
Cable Lubrication…8674
Clutch Lever Installation…8674
Torque -…8674
Clutch Cover Removal…8675
Clutch Cover Installation…8675
Sealant -…8675
Torque -…8675
Release Shaft Removal…8675
Release Shaft Installation…8676
Clutch Cover Disassembly…8676
Clutch Cover Assembly…8677
Torque -…8677
Clutch Removal…8678
Special Tool -…8678
Clutch Installation…8678
Special Tool -…8680
Torque -…8680
Torque -…8681
Spring Plate Free Play Measurement…8681
Spring Plate Free Play Adjustment…8682
Torque -…8683
Clutch Plate, Wear, Damage Inspection…8683
Clutch Plate Warp Inspection…8683
Clutch Spring Free Length Measurement…8684
Damper Cam Inspection…8684
Engine Lubrication System…8685
Outside Circlip Pliers:…8689
WARNING…8692
Oil Level Inspection…8692
Engine Oil Change…8692
Oil Filter Replacement…8692
Oil Pan Removal…8693
Oil Pan Installation…8693
Torque -…8694
Oil Pressure Relief Valve Removal…8695
Oil Pressure Relief Valve Installation…8695
Torque -…8695
Oil Pressure Relief Valve Inspection…8696
Oil Pump Removal…8697
Oil Pump Installation…8698
Torque -…8698
Torque -…8698
Torque -…8698
Torque -…8699
Oil Pump Gear Removal…8699
Oil Pump Gear Installation…8699
Torque -…8699
Oil Pump Gear Shaft Removal…8700
Special Tool -…8700
Oil Pump Gear Shaft Installation…8700
Special Tool -…8700
Oil Cooler Removal…8701
Oil Cooler Installation…8701
Torque -…8701
Torque -…8701
Oil Cooler/Oil Filter Case Removal…8702
Oil Cooler/Oil Filter Case Installation…8703
Torque -…8703
Torque -…8703
Torque -…8703
Oil Pressure Measurement…8704
Special Tools -…8704
Torque -…8704
Oil Pressure Switch Removal…8705
Oil Pressure Switch Installation…8705
Sealant -…8705
Torque -…8705
Torque -…8705
Engine Removal/Installation…8707
Engine Mount Nut Wrench:…8710
Engine Removal…8711
Special Tool -…8713
Engine Installation…8714
Torque -…8715
Torque -…8716
Torque -…8716
Torque -…8716
Special Tool -…8716
Torque -…8716
Torque -…8716
Crankshaft/Transmission…8719
Outside Circlip Pliers:…8727
Crankcase Splitting…8728
Crankcase Assembly…8729
Torque -…8729
Special Tool -…8730
Torque -…8730
Torque -…8730
Torque -…8730
Torque -…8731
Sealant -…8732
Torque -…8733
Torque -…8733
Torque -…8733
Crankshaft Removal…8734
Crankshaft Installation…8734
Connecting Rod Removal…8736
Connecting Rod Installation…8736
Crankshaft/Connecting Rod Cleaning…8740
Connecting Rod Bend…8740
Connecting Rod Twist…8740
Connecting Rod Big End Side Clearance…8740
Connecting Rod Big End Bearing Insert/Crankpin Wear…8741
Crankshaft Side Clearance…8742
Crankshaft Runout…8743
Crankshaft Main Bearing Insert/Journal Wear…8743
Piston Removal…8745
Special Tool -…8745
Piston Installation…8746
Special Tools -…8747
Cylinder Wear (Upper Crankcase)…8747
Piston Wear…8747
Piston Ring, Piston Ring Groove Wear…8747
Piston Ring Groove Width…8748
Piston Ring Thickness…8748
Piston Ring End Gap…8748
Starter Idle Gear Removal…8749
Starter Idle Gear Installation…8749
Sealant -…8750
Torque -…8750
Torque -…8750
Starter Clutch Removal…8751
Special Tools -…8751
Starter Clutch Installation …8751
Special Tools -…8751
Torque -…8751
Starter Clutch Disassembly…8751
Starter Clutch Assembly…8752
Starter Clutch Inspection…8752
Shift Pedal Removal…8754
Shift Pedal Installation…8754
Torque -…8754
Torque -…8754
Torque -…8754
External Shift Mechanism Removal…8754
Special Tool -…8754
External Shift Mechanism Installation…8755
Torque -…8755
Special Tool -…8755
External Shift Mechanism Inspection…8755
Torque -…8756
Transmission Assy Removal…8756
Transmission Assy Disassembly…8756
Transmission Assy Assembly…8757
Special Tool -…8757
Torque -…8757
Torque -…8757
Torque -…8757
Transmission Assy Installation…8758
Torque -…8758
Transmission Shaft Removal…8759
Transmission Shaft Installation…8759
Transmission Shaft Disassembly…8760
Special Tool -…8760
Transmission Shaft Assembly…8760
Shift Drum and Fork Removal…8763
Shift Drum and Fork Installation…8763
Shift Drum Disassembly…8763
Shift Drum Assembly…8763
Torque -…8763
Shift Fork Bending…8763
Shift Fork/Gear Groove Wear…8764
Shift Fork Guide Pin/Drum Groove Wear…8764
Gear Dog and Gear Dog Hole Damage…8764
Wheels/Tires…8765
Bearing Driver Set:…8769
Front Wheel Removal…8770
Special Tools -…8770
Front Wheel Installation…8770
Torque -…8771
Torque -…8771
Rear Wheel Removal…8771
Rear Wheel Installation…8772
Torque -…8773
Wheel Inspection…8774
Special Tools -…8774
Axle Inspection…8774
Balance Inspection…8775
Balance Adjustment…8775
Balance Weight Removal…8775
Balance Weight Installation…8775
Air Pressure Inspection/Adjustment…8777
Tire Inspection…8777
Tire Removal…8777
Tire Installation…8777
Tire Repair…8779
Hub Bearing Removal…8780
Special Tools -…8780
Hub Bearing Installation…8780
Special Tool -…8780
Special Tool -…8780
Hub Bearing Inspection…8780
Hub Bearing Lubrication…8781
Final Drive…8783
Inside Circlip Pliers:…8787
Drive Chain Slack Inspection…8788
Drive Chain Slack Adjustment…8788
Wheel Alignment Inspection/Adjustment…8788
Drive Chain Wear Inspection…8788
Drive Chain Lubrication…8788
Drive Chain Removal…8788
Drive Chain Installation…8789
Engine Sprocket Removal…8792
Engine Sprocket Installation…8792
Torque -…8792
Torque -…8793
Rear Sprocket Removal…8793
Rear Sprocket Installation…8793
Torque -…8793
Coupling Installation…8794
Coupling Bearing Removal…8794
Special Tool -…8794
Special Tool -…8794
Coupling Bearing Installation…8794
Special Tool -…8794
Special Tool -…8794
Special Tool -…8795
Coupling Bearing Inspection…8795
Coupling Bearing Lubrication…8795
Coupling Damper Inspection…8795
Sprocket Wear Inspection…8795
Rear Sprocket Warp Inspection…8796
Brakes…8797
Inside Circlip Pliers:…8803
Brake Lever Position Adjustment…8804
Brake Pedal Position Inspection …8804
Brake Pedal Position Adjustment …8804
Torque -…8804
Brake Pedal Removal…8804
Brake Pedal Installation…8805
Torque -…8805
Torque -…8805
Torque -…8805
Front Caliper Removal…8806
Rear Caliper Removal…8806
Caliper Installation…8806
Torque -…8806
Front Caliper Disassembly…8807
Front Caliper Assembly…8807
Rear Caliper Disassembly…8807
Rear Caliper Assembly…8807
Caliper Fluid Seal Damage…8807
Rear Caliper Dust Boot and Friction Boot Damage…8808
Caliper Piston and Cylinder Damage…8808
Rear Caliper Holder Shaft Wear…8808
Front Brake Pad Removal…8809
Front Brake Pad Installation…8809
Torque -…8809
Rear Brake Pad Removal …8809
Rear Brake Pad Installation…8810
Brake Pad Wear Inspection…8810
Front Master Cylinder Removal…8811
Front Master Cylinder Installation…8811
Torque -…8811
Torque -…8811
Rear Master Cylinder Removal…8812
Rear Master Cylinder Installation…8812
Torque -…8812
Front Master Cylinder Disassembly…8812
Rear Master Cylinder Disassembly…8812
Master Cylinder Inspection (Visual Inspection)…8812
Master Cylinder Assembly…8813
Brake Disc Removal…8814
Brake Disc Installation…8814
Torque -…8814
Brake Disc Wear…8814
Brake Disc Warp…8814
Special Tools -…8814
Brake Fluid Level Inspection…8815
Brake Fluid Change…8815
Brake Line Bleeding…8815
Torque -…8816
Torque -…8817
Torque -…8817
Brake Hose Removal/Installation…8819
Brake Hose Inspection…8819
Suspension…8821
Inside Circlip Pliers:…8827
Rebound Damping Force Adjustment…8829
Spring Preload Adjustment…8829
Compression Damping Force Adjustment…8830
Front Fork Removal (Each Fork Leg)…8830
Front Fork Installation…8831
Torque -…8831
Torque -…8831
Front Fork Oil Change…8831
Special Tool -…8831
Special Tool -…8832
Special Tool -…8832
Special Tool -…8833
Special Tool -…8833
Special Tool -…8834
Special Tool -…8834
Special Tool -…8834
Torque -…8835
Front Fork Disassembly…8835
Front Fork Assembly…8836
Special Tool -…8837
Special Tool -…8837
Torque -…8837
Inner Tube Inspection…8837
Dust Seal Inspection…8838
Spring Tension…8838
Rebound Damping Force Adjustment…8839
Compression Damping Force Adjustment…8839
Spring Preload Adjustment…8840
Special Tool -…8840
Special Tools -…8840
Rear Shock Absorber Removal…8841
Special Tools -…8841
Rear Shock Absorber Installation…8841
Torque -…8841
Rear Shock Absorber Inspection…8841
Rear Shock Absorber Scrapping…8842
Swingarm Removal…8843
Special Tool -…8843
Swingarm Installation…8844
Torque -…8844
Special Tool -…8844
Torque -…8844
Torque -…8845
Swingarm Bearing Removal…8845
Special Tool -…8845
Special Tool -…8845
Swingarm Bearing Installation…8845
Special Tools -…8845
Swingarm Bearing, Sleeve Inspection…8846
Chain Guide Inspection…8846
Tie-Rod Removal…8847
Special Tools -…8847
Tie-Rod Installation…8847
Torque -…8847
Rocker Arm Removal…8847
Special Tools -…8848
Rocker Arm Installation…8848
Torque -…8848
Tie-Rod and Rocker Arm Bearing Removal…8849
Special Tool -…8849
Tie-Rod and Rocker Arm Bearing Installation…8849
Special Tools -…8850
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…8851
Rocker Arm/Tie-Rod Bearing Lubrication…8851
Steering…8853
Bearing Puller:…8856
Steering Inspection…8857
Steering Adjustment…8857
Stem, Stem Bearing Removal…8858
Special Tool -…8858
Special Tool -…8858
Special Tools -…8859
Stem, Stem Bearing Installation…8859
Special Tools -…8859
Special Tools -…8859
Special Tool -…8860
Torque -…8860
Torque -…8861
Steering Stem Bearing Lubrication…8861
Steering Stem Warp…8861
Stem Cap Deterioration, Damage…8861
Handlebar Removal…8862
Handlebar Installation…8863
Torque -…8863
Torque -…8863
Frame…8865
Rear Seat Removal…8872
Rear Seat Installation…8872
Front Seat Removal…8872
Front Seat Installation…8872
Lower Fairing Removal…8873
Lower Fairing Installation…8873
Middle Fairing Removal…8873
Windshield Removal…8875
Windshield Installation…8875
Torque -…8875
Upper Fairing Disassembly…8876
Upper Fairing Assembly…8876
Upper Fairing Installation…8876
Inner Cover Removal…8876
Inner Cover Installation…8877
Center Inner Fairing Removal…8877
Center Inner Fairing Installation…8877
Lower Inner Fairing Removal…8877
Lower Inner Fairing Installation…8878
Left Side Cover Removal…8879
Left Side Cover Installation…8879
Right Side Cover Removal…8879
Right Side Cover Installation…8879
Seat Cover Removal…8880
Seat Cover Installation…8880
Heat Insulation Plate Removal…8881
Heat Insulation Plate Installation…8881
Heat Insulation Rubber Plate Pemoval…8881
Heat Insulation Rubber Plate Installation…8882
Front Fender Removal…8883
Front Fender Installation…8883
Torque -…8883
Flap and Rear Fender Removal…8883
Flap and Rear Fender Installation…8886
Rear Frame Removal…8887
Rear Frame Installation…8887
Torque -…8887
Frame Inspection…8887
Sidestand Removal…8888
Sidestand Installation…8888
Torque -…8888
Torque -…8888
Electrical System…8889
Hand Tester:…8907
There are a number of important precautions that are musts when …8908
Wiring Inspection…8909
Special Tool -…8909
Battery Removal…8910
Battery Installation…8910
Battery Activation…8910
Precautions…8913
1)…8913
2)…8913
3)…8913
4)…8913
Interchange…8913
Charging Condition Inspection…8914
Refreshing Charge…8914
Alternator Cover Removal…8916
Alternator Cover Installation…8916
Sealant -…8916
Torque -…8916
Stator Coil Removal…8916
Stator Coil Installation…8917
Torque -…8917
Sealant -…8917
Torque -…8917
Alternator Rotor Removal…8917
Special Tools -…8917
Special Tool -…8917
Alternator Rotor Installation…8917
Special Tools -…8917
Special Tool -…8918
Special Tools -…8918
Torque -…8918
Alternator Inspection…8918
Special Tool -…8919
Regulator/Rectifier Removal…8919
Regulator/Rectifier Inspection…8920
Special Tool -…8920
Torque -…8920
Charging Voltage Inspection…8921
Special Tool -…8921
Charging System Circuit…8922
Crankshaft Sensor Removal…8924
Crankshaft Sensor Installation…8924
Torque -…8924
Sealant -…8924
Crankshaft Sensor Inspection…8925
Special Tool -…8925
Crankshaft Sensor Peak Voltage…8925
Special Tools -…8926
Stick Coil Removal…8926
Stick Coil Installation…8926
Stick Coil Inspection…8927
Stick Coil Primary Peak Voltage…8927
Special Tools -…8927
Spark Plug Removal…8928
Spark Plug Installation…8928
Spark Plug Clean and Inspection…8928
Camshaft Position Sensor Removal…8929
Camshaft Position Sensor Installation…8929
Torque -…8929
Camshaft Position Sensor Inspection…8929
Special Tool -…8930
Camshaft Position Sensor Peak Voltage Inspection…8930
Special Tools -…8930
Interlock Operation Inspection…8931
IC Igniter Inspection…8932
Ignition System Circuit…8933
Starter Motor Removal…8934
Starter Motor Installation…8934
Torque -…8934
Starter Motor Disassembly…8935
Starter Motor Assembly…8935
Brush Inspection…8936
Commutator Cleaning and Inspection…8936
Armature Inspection…8937
Special Tool -…8937
Brush Lead Inspection…8937
Special Tool -…8937
Right-hand End Cover Assembly Inspection…8937
Special Tool -…8937
Starter Relay Inspection…8937
Special Tool -…8938
Electric Starter Circuit…8939
This motorcycle adopt the daylight system and have a headlight r…8940
Headlight Beam Horizontal Adjustment…8940
Headlight Beam Vertical Adjustment…8940
Headlight Bulb Replacement…8940
City Light Bulb Replacement…8941
Headlight Removal/Installation…8941
Tail/Brake Light (LED) Removal…8941
Tail/Brake Light (LED) Installation…8942
License Plate Light Bulb Replacement…8942
Headlight/Tail Light Circuit…8943
Turn Signal Light Bulb Replacement…8943
Turn Signal Light Removal…8945
Turn Signal Relay Inspection…8946
Turn Signal Light Circuit…8948
Air Switching Valve Operation Test…8949
Air Switching Valve Unit Test…8949
Special Tool -…8949
Fan Motor Inspection…8950
Radiator Fan Circuit…8950
Meter Unit Removal…8951
Meter Unit Disassembly…8951
Electronic Combination Meter Unit Inspection…8952
Fuel Level Sensor Line Self-Diagnosis Mode Inspection…8968
Meter Circuit…8969
This motorcycle is equipped with an immobilizer system to protec…8970
Operational Cautions…8970
Key Registration…8970
Special Tool -…8970
Spare User Key Registration Flow Chart…8975
Special Tool -…8976
All Keys Initial Registration Flow Chart…8985
Immobilizer System Parts Replacement…8986
Immobilizer System Inspection…8988
Immobilizer System Circuit…8989
Brake Light Timing Inspection…8990
Brake Light Timing Adjustment…8990
Gear Position Switch Removal…8990
Gear Position Switch Installation…8991
Torque -…8991
Gear Position Switch Inspection…8992
Special Tool -…8992
Switch Inspection…8993
Special Tool -…8993
Rear Brake Light Switch Connections…8993
Side Stand Switch Connections…8993
Oil Pressure Switch Connections *…8993
Water Temperature Sensor Inspection…8994
Speed Sensor Removal…8994
Speed Sensor Installation…8995
Torque -…8995
Speed Sensor Inspection…8995
Special Tool -…8995
Fuel Reserve Switch Inspection…8996
Oxygen Sensor Removal (Equipped Models)…8996
Oxygen Sensor Installation (Equipped Models)…8997
Torque -…8997
Oxygen Sensor Inspection (Equipped Models)…8997
The relay box [A] has relays and diodes. The relays and diodes c…8998
Relay Box Removal…8998
Relay Circuit Inspection…8998
Diode Circuit Inspection…8999
Relay Box Internal Circuit…9000
30 A Main Fuse Removal…9001
Fuse Box Fuse Removal…9001
10 A ECU Fuse Removal…9001
Fuse Installation…9002
Fuse Inspection…9002
Appendix…9003
California Model…9029
California Model…9030
NOTE…9032
Engine Doesn't Start, Starting Difficulty:…9032
Starter motor not rotating:…9032
Starter motor rotating but engine doesn't turn over:…9032
Engine won't turn over:…9032
No fuel flow:…9032
No spark; spark weak:…9032
Fuel/air mixture incorrect:…9032
Compression Low:…9032
Poor Running at Low Speed:…9032
Spark weak:…9032
Fuel/air mixture incorrect:…9032
Compression low:…9033
Run-on (dieseling):…9033
Other:…9033
Poor Running or No Power at High Speed:…9033
Firing incorrect:…9033
Fuel/air mixture incorrect:…9033
Compression low:…9033
Knocking:…9033
Miscellaneous:…9033
Overheating:…9033
Firing incorrect:…9033
Muffler overheating:…9033
Fuel/air mixture incorrect:…9033
Compression high:…9034
Engine load faulty:…9034
Lubrication inadequate:…9034
Oil cooler incorrect:…9034
Water temperature meter incorrect:…9034
Coolant incorrect:…9034
Cooling system component incorrect:…9034
Over Cooling:…9034
Water temperature meter incorrect:…9034
Cooling system component incorrect:…9034
Clutch Operation Faulty:…9034
Clutch slipping:…9034
Clutch not disengaging properly:…9034
Gear Shifting Faulty:…9034
Doesn't go into gear; shift pedal doesn't return:…9034
Jumps out of gear:…9034
Overshifts:…9034
Abnormal Engine Noise:…9034
Knocking:…9034
Piston slap:…9034
Valve noise:…9034
Other noise:…9034
Abnormal Drive Train Noise:…9035
Clutch noise:…9035
Transmission noise:…9035
Drive line noise:…9035
Abnormal Frame Noise:…9035
Front fork noise:…9035
Rear shock absorber noise:…9035
Disc brake noise:…9035
Other noise:…9035
Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:…9035
Exhaust Smokes Excessively:…9035
White smoke:…9035
Black smoke:…9035
Brown smoke:…9035
Handling and/or Stability Unsatisfactory:…9035
Handlebar hard to turn:…9035
Handlebar shakes or excessively vibrates:…9035
Handlebar pulls to one side:…9035
Shock absorption unsatisfactory:…9035
Brake Doesn't Hold:…9036
Battery Trouble:…9036
Battery discharged:…9036
Battery overcharged:…9036
Kawasaki Motorcycle Service Repair Manual '07-'08 ZX-6R (EN)…9038
tables…0
LIST OF ABBREVIATIONS…9041
COUNTRY AND AREA CODES…9041
Units of Mass…9057
Units of Volume…9057
Units of Force…9057
Units of Length…9057
Units of Torque…9057
Units of Pressure…9057
Units of Speed…9057
Units of Power…9057
Periodic Inspection…9060
Periodic Replacement Parts…9062
Basic Torque for General Fasteners…9068
Throttle Grip Free Play…9072
Idle Speed…9073
Engine Vacuum…9073
Main Throttle Sensor Output Voltage…9075
Idle Speed…9075
Valve Clearance…9078
Example:…9079
Adjustment Shims…9080
Clutch Lever Free Play…9083
Air Pressure (when Cold)…9084
Tread Depth…9084
Chain Slack…9086
Drive Chain 20-link Length…9088
Standard Chain…9088
Recommended Disc Brake Fluid…9090
Pad Lining Thickness…9091
Side Stand Switch Operation…9098
Water and Coolant Mixture Ratio (Recommended)…9107
Recommended Engine Oil…9109
Standard Spark Plug…9116
Terminal Names…9137
Sample Diagnosis Sheet…9145
Engine Won't Turn Over…9147
Poor Running at Low Speed…9147
Poor Running or No Power at High Speed:…9150
Main Throttle Sensor Input Voltage…9160
Input Voltage at ECU Connector…9160
Main Throttle Sensor Input Voltage…9161
Input Voltage at Sensor…9161
Main Throttle Sensor Output Voltage…9161
Idle Speed…9161
Output Voltage at ECU…9161
Main Throttle Sensor Output Voltage…9162
Output Voltage at Sensor…9162
Main Throttle Sensor Resistance…9162
Inlet Air Pressure Sensor Input Voltage…9164
Input Voltage at ECU…9164
Inlet Air Pressure Sensor Input Voltage…9165
Input Voltage at Sensor Connector…9165
Inlet Air Pressure Sensor Output Voltage…9165
Output Voltage at ECU…9165
Inlet Air Pressure Sensor Output Voltage…9166
Output Voltage at Sensor Connector…9166
Inlet Air Pressure Sensor Output Voltage Connection to Sensor…9167
Inlet Air Temperature Sensor Output Voltage…9169
Output Voltage at ECU…9169
Inlet Air Temperature Sensor Resistance…9170
Water Temperature Sensor Output Voltage…9171
Output Voltage at ECU…9171
Atmospheric Pressure Sensor Input Voltage…9173
Input Voltage at ECU…9173
Atmospheric Pressure Sensor Input Voltage…9174
Input Voltage at Sensor Connector…9174
Atmospheric Pressure Sensor Output Voltage…9174
Output Voltage…9174
Atmospheric Pressure Sensor Output Voltage…9175
Output Voltage at Sensor…9175
Speed Sensor Input Voltage…9179
Input Voltage at Sensor…9179
Speed Sensor Output Voltage…9180
Output Voltage at Sensor …9180
Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions…9181
Input Voltage at 1 ∼ 6 Gear Positions…9181
Vehicle-down Sensor Power Source Voltage…9184
Power Source Voltage at Sensor…9184
Vehicle-down Sensor Output Voltage…9185
Output Voltage at Sensor…9185
Subthrottle Sensor Input Voltage…9187
Input Voltage at ECU Connector…9187
Subthrottle Sensor Input Voltage…9188
Input Voltage at Sensor…9188
Subthrottle Sensor Output Voltage…9188
Output Voltage at ECU…9188
Subthrottle Sensor Output Voltage…9189
Output Voltage at Sensor…9189
Subthrottle Sensor Resistance…9190
Oxygen Sensor Output Voltage…9191
Oxygen Sensor Output Voltage (with Plugs)…9191
Oxygen Sensor Output Voltage (without Plugs)…9192
Exhaust Butterfly Valve Actuator Sensor Input Voltage…9193
Input Voltage at Actuator…9193
Wiring Connections…9193
Exhaust Butterfly Valve Actuator Sensor Output Voltage…9194
Output Voltage at Actuator…9194
Wiring Connections…9194
Exhaust Butterfly Valve Actuator Sensor Resistance…9195
Antenna Resistance…9196
Amplifier Input Voltage…9196
Input Voltage…9196
Wiring Connections…9199
Stick Coil Input Voltage at ECU…9200
Input Voltage at ECU…9200
Subthrottle Valve Actuator Resistance…9204
Subthrottle Valve Actuator Input Voltage…9205
Input Voltage at Sensor…9205
Connections…9208
Actuator Output Voltage (Pulley Original Position)…9208
Oxygen Sensor Resistance…9211
Oxygen Sensor Heaters Power Source Voltage…9211
Power Source Voltage at Sensor Connector…9211
Oxygen Sensor Output Voltage…9213
Oxygen Sensor Output Voltage (with Plugs)…9213
Oxygen Sensor Output Voltage (without Plugs)…9214
ECU Identification…9215
ECU Grounding Inspection…9216
ECU Power Source Inspection…9217
Fuel Pressure (Idling)…9221
Amount of Fuel Flow…9222
Pump Operating Voltage at Pump…9224
Operating Voltage at Pump Connector…9224
Testing Relay…9226
Secondary Fuel Injector Resistance…9228
Primary Injector Resistance…9228
Secondary Fuel Injector Power Source Voltage…9229
Primary Fuel Injector Power Source Voltage…9229
Power Source Voltage at Injector Connector…9229
Secondary Fuel Injector Output Voltage…9230
Primary Fuel Injector Output Voltage…9230
Output Voltage at Injector Connector…9230
Fuel Line Maximum Pressure…9231
Radiator Cap Relief Pressure…9267
Thermostat Valve Opening Temperature…9270
Camshaft Journal, Camshaft Cap Clearance…9294
Camshaft Journal Diameter…9295
Camshaft Runout…9295
Cam Height…9295
Cylinder Compression…9296
Cylinder Head Warp…9298
Valve/Valve Guide Clearance (Wobble Method)…9301
Valve Seating Surface Outside Diameter…9302
Valve Seating Surface Width…9302
Spring Plate Free Play …9331
Spring Plate Free Play…9331
Clutch Plate Assembly Length (Reference)…9332
Friction Plate Thickness…9332
Friction and Steel Plate Warp…9332
Clutch Spring Free Length…9333
Oil Pressure…9353
Connecting Rod Big End Bearing Insert Selection…9375
Crankshaft Main Bearing Insert Selection (Engine No. ∼ ZX600PE…9375
Crankshaft Main Bearing Insert Selection (Engine No. ZX600PE0085…9375
Connecting Rod Bend…9389
Connecting Rod Twist…9389
Connecting Rod Big End Side Clearance…9389
Connecting Rod Big End Bearing Insert/Crankpin Clearance…9390
Crankpin Diameter…9390
Crankpin Diameter Marks…9390
Connecting Rod Big End Inside Diameter Marks…9391
Crankshaft Side Clearance…9391
Crankshaft ##3 Main Journal Width…9391
Crankshaft Runout…9392
Crankshaft Main Bearing Insert/Journal Clearance…9392
Crankshaft Main Journal Diameter…9392
Crankshaft Main Journal Diameter Marks…9392
Crankcase Main Bearing Inside Diameter Marks…9393
(Engine No. ∼ ZX600PE008560)…9393
(Engine No. ZX600PE008561 ∼)…9393
Cylinder Inside Diameter…9396
Piston Diameter…9396
Piston Ring/Groove Clearance…9396
Piston Ring Groove Width…9397
Piston Ring Thickness…9397
Piston Ring End Gap…9397
Shift Fork Ear Thickness…9413
Gear Groove Width…9413
Shift Fork Guide Pin Diameter…9413
Shift Drum Groove Width…9413
Rim Runout (with tire installed)…9423
Axle Runout/100 mm (3.94 in.)…9423
Balance Weight…9425
Link Pin Outside Diameter…9440
Link Plates Outside Width…9440
Rear Sprocket Warp…9445
Pedal Position…9453
Brake Discs Thickness…9463
Disc Runout…9463
Rebound Damping Force Adjustment…9478
Spring Action…9478
Compression Damping Force Adjustment…9479
Fork Oil…9481
Oil Level (fully compressed, without spring)…9482
Spring Free Length…9487
Rebound Damping Force Adjustment…9488
Spring Preload Setting…9489
Spring Adjustment…9489
Kawasaki-recommended chargers…9571
Battery Terminal Voltage…9573
Terminal Voltage: 11.5 ∼ less than 12.8 V…9574
Terminal Voltage: less than 11.5 V…9574
Table 1 Alternator Output Voltage…9577
Table 2 Stator Coil Resistance…9578
Regulator/Rectifier Resistance (Unit: kΩ)…9579
Charging Voltage…9580
Crankshaft Sensor Peak Voltage…9585
Ignition Coil Winding Resistance…9586
Primary Lead Connection…9586
Stick Coil Primary Peak Voltage…9587
Connections:…9589
Camshaft Position Sensor Peak Voltage…9589
Condition…9590
Condition…9590
Condition…9590
Starter Motor Brush Length…9595
Commutator Diameter…9595
Testing Relay…9597
Testing Turn Signal Relay…9606
Testing Turn Signal Relay…9606
Air Switching Valve Resistance…9608
LCD segment actions for 1.5 seconds…9613
Electric Source Voltage…9618
User Key Indicator Flashes…9633
Immobilizer Relational Parts Replacement Chart…9648
Gear Position Switch Resistance kΩ…9652
Water Temperature Sensor…9654
Connections…9656
Relay Circuit Inspection (with the battery disconnected)…9659
Relay Circuit Inspection (with the battery connected)…9659
Diode Circuit Inspection…9659
toc…0
EMISSION CONTROL INFORMATION…9042
1…9042
2…9042
3…9042
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED…9043
Foreword…9044
General Information…9046
Before starting to perform an inspection service or carry out a …9047
Battery Ground…9047
Edges of Parts…9047
Solvent…9047
Cleaning vehicle before disassembly…9047
Arrangement and Cleaning of Removed Parts…9048
Storage of Removed Parts…9048
Inspection…9048
Replacement Parts…9048
Assembly Order…9048
Tightening Sequence…9049
Tightening Torque…9049
Force…9049
Gasket, O-ring…9049
Liquid Gasket, Non-permanent Locking Agent…9049
Press…9050
Ball Bearing and Needle Bearing…9050
Oil Seal, Grease Seal…9050
Circlips, Cotter Pins…9050
Lubrication…9051
Direction of Engine Rotation…9051
Electrical Wires…9051
Instrument…9051
ZX600P7F (Europe) Left Side View…9052
ZX600P7F (Europe) Right Side View…9052
Frame Number…9052
Engine Number…9052
ZX600P7F (US and Canada) Left Side View…9053
ZX600P7F (US and Canada) Right Side View…9053
Prefixes for Units…9057
Units of Temperature…9057
Periodic Maintenance…9058
The scheduled maintenance must be done in accordance with this c…9060
The following tables list the tightening torque for the major fa…9063
Inside Circlip Pliers:…9071
Fuel System (DFI)…9072
Throttle Control System Inspection…9072
Engine Vacuum Synchronization Inspection…9072
Special Tool -…9073
Special Tool -…9073
Special Tool -…9074
Special Tool -…9075
Idle Speed Inspection…9075
Idle Speed Adjustment…9076
Fuel Hose Inspection (fuel leak, damage, installation condition)…9076
Evaporative Emission Control System Inspection (California Mode…9076
Engine Top End…9077
Valve Clearance Inspection…9077
Valve Clearance Adjustment…9079
Air Suction System Damage Inspection…9081
Cooling System…9082
Coolant Level Inspection…9082
Radiator Hose Damage and Installation Condition Inspection…9082
Torque -…9082
Clutch…9083
Clutch Operation Inspection …9083
Wheels/Tires…9084
Air Pressure Inspection…9084
Wheel/Tire Damage Inspection…9084
Tire Tread Wear Inspection …9084
Wheel Bearing Damage Inspection…9085
Final Drive…9086
Drive Chain Lubrication Condition Inspection…9086
Drive Chain Slack Inspection…9086
Drive Chain Slack Adjustment…9087
Torque -…9087
Wheel Alignment Inspection…9088
Drive Chain Wear Inspection…9088
Chain Guide Wear Inspection…9089
Brakes…9089
Brake Fluid Leak (Brake Hose and Pipe) Inspection…9089
Brake Hose Damage and Installation Condition Inspection…9089
Torque -…9089
Brake Operation Inspection…9090
Brake Fluid Level Inspection…9090
Brake Pad Wear Inspection…9091
Brake Light Switch Operation Inspection…9091
Suspensions…9092
Front Forks/Rear Shock Absorber Operation Inspection…9092
Front Fork Oil Leak Inspection…9092
Rear Shock Absorber Oil Leak Inspection…9093
Rocker Arm Operation Inspection…9093
Tie-Rod Operation Inspection…9093
Steering System…9093
Steering Play Inspection…9093
Special Tools -…9093
Steering Play Adjustment…9094
Special Tool -…9094
Torque -…9094
Steering Stem Bearing Lubrication…9095
Lights and Switches Operation Inspection…9095
Headlight Aiming Inspection…9097
Side Stand Switch Operation Inspection…9098
Engine Stop Switch Operation Inspection…9099
Others…9100
Chassis Parts Lubrication …9100
Pivots: Lubricate with Grease…9100
Points: Lubricate with Grease…9100
Cables: Lubricate with Rust Inhibitor…9100
Bolts, Nuts and Fasteners Tightness Inspection…9101
Bolt, Nut and Fastener to be checked…9101
Replacement Parts…9102
Air Cleaner Element Replacement…9102
Torque -…9103
Fuel Hose Replacement…9103
Torque -…9105
Coolant Change…9106
Torque -…9106
Radiator Hose and O-ring Replacement…9108
Torque -…9108
Engine Oil Change…9109
Torque -…9109
Oil Filter Replacement…9109
Special Tool -…9109
Torque -…9109
Brake Hose and Pipe Replacement…9110
Torque -…9110
Brake Fluid Change…9110
Torque -…9111
Torque -…9111
Master Cylinder Rubber Parts Replacement…9112
Special Tool -…9112
Special Tool -…9112
Silicone Grease -…9113
Torque -…9113
Caliper Rubber Parts Replacement…9113
Torque -…9114
Torque -…9114
Torque -…9115
Spark Plug Replacement…9116
Owner's Tool -…9116
Torque -…9116
Fuel System (DFI)…9118
Oil Pressure Gauge, 5 kgf/cm :…9129
Inlet Air Pressure Sensor [A]…9131
DFI System…9133
DFI System Wiring Diagram…9135
Terminal Numbers of ECU Connectors…9137
There are a number of important precautions that should be follo…9138
Torque -…9139
The warning indicator light (LED) [A] is used for the FI indicat…9140
Outline…9140
Special Tool -…9142
Sealant -…9142
DFI Diagnosis Flow Chart…9144
Inquiries to Rider…9144
NOTE…9147
The warning indicator light (LED) [A] is used for the FI indicat…9152
Self-diagnosis Outline…9152
Self-diagnosis Procedures…9153
Self-Diagnosis Flow Chart…9154
Service Code Reading…9155
Service Code Erasing…9155
Backups…9157
The main throttle sensor is a rotating variable resistor that ch…9160
Main Throttle Sensor Removal/Adjustment…9160
Main Throttle Sensor Input Voltage Inspection…9160
Special Tool -…9160
Special Tool -…9161
Main Throttle Sensor Output Voltage Inspection…9161
Special Tool -…9161
Special Tool -…9162
Main Throttle Sensor Resistance Inspection…9162
Main Throttle Sensor Circuit…9163
CAUTION…9164
Inlet Air Pressure Sensor Removal…9164
Inlet Air Pressure Sensor Installation…9164
Inlet Air Pressure Sensor Input Voltage Inspection…9164
Special Tool -…9164
Special Tool -…9165
Inlet Air Pressure Sensor Output Voltage Inspection…9165
Special Tool -…9166
Inlet Air Pressure Sensor Circuit…9166
Special Tools -…9167
Inlet Air Temperature Sensor Removal/Installation…9169
Inlet Air Temperature Sensor Output Voltage Inspection…9169
Special Tool -…9169
Sealant -…9170
Inlet Air Temperature Sensor Resistance Inspection…9170
Inlet Air Temperature Sensor Circuit…9170
Water Temperature Sensor Removal/Installation…9171
Sealant -…9171
Torque -…9171
Water Temperature Sensor Output Voltage Inspection…9171
Special Tool -…9171
Sealant -…9172
Water Temperature Sensor Circuit…9172
Water Temperature Sensor Resistance Inspection…9172
CAUTION…9173
Atmospheric Pressure Sensor Removal…9173
Atmospheric Pressure Sensor Installation…9173
Atmospheric Pressure Sensor Input Voltage Inspection…9173
Special Tool -…9173
Special Tool -…9174
Atmospheric Pressure Sensor Output Voltage Inspection…9174
Special Tool -…9175
Atmospheric Pressure Sensor Circuit…9175
Atmospheric Pressure/Altitude Relationship…9176
Crankshaft Sensor Removal/Installation…9177
Crankshaft Sensor Inspection…9177
Crankshaft Sensor Circuit…9177
Camshaft Position Sensor Removal/Installation…9178
Camshaft Position Sensor Inspection…9178
Camshaft Position Sensor Circuit…9178
Speed Sensor Removal/Installation…9179
Speed Sensor Inspection…9179
Speed Sensor Input Voltage Inspection…9179
Special Tool -…9179
Speed Sensor Output Voltage Inspection…9179
Special Tool -…9180
Speed Sensor Circuit…9180
Gear Position Switch Removal/Installation…9181
Gear Position Switch Inspection…9181
Gear Position Switch Input Voltage Inspection…9181
Special Tool -…9181
Gear Position Switch Circuit…9182
This sensor has a weight [A] with two magnets inside, and sends …9183
Vehicle-down Sensor Removal…9183
Vehicle-down Sensor Installation…9183
Torque -…9183
Vehicle-down Sensor Inspection…9184
Special Tool -…9184
Special Tool -…9185
Sealant -…9185
Vehicle-down Sensor Circuit…9186
Subthrottle Sensor Removal/Adjustment…9187
Subthrottle Sensor Input Voltage Inspection…9187
Special Tool -…9187
Special Tool -…9188
Subthrottle Sensor Output Voltage Inspection…9188
Special Tool -…9188
Special Tool -…9189
Resistance Inspection…9190
Subthrottle Sensor Circuit…9190
Oxygen Sensor ##1: Service Code 33…9191
Oxygen Sensor Removal/Installation…9191
Oxygen Sensor Inspection…9191
Special Tool -…9191
Sealant -…9192
Oxygen Sensor Circuit…9192
Exhaust Butterfly Valve Actuator Sensor Removal/Installation…9193
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection…9193
Special Tool -…9193
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio…9194
Special Tool -…9194
Exhaust Butterfly Valve Actuator Sensor Inspection…9195
Exhaust Butterfly Valve Actuator Sensor Circuit…9195
Antenna Resistance Inspection…9196
Amplifier Input Voltage Inspection…9196
Special Tool -…9196
This code appears in the following conditions. …9197
User Key Inspection…9197
Immobilizer System Circuit…9198
ECU Communication Line Inspection…9199
ECU Communication Line Circuit…9199
Stick Coil ##1: Service Code 51…9200
Stick Coil Removal/Installation…9200
Stick Coil Input Voltage Inspection…9200
Special Tool -…9200
Stick Coil Circuit…9201
Radiator Fan Relay Removal/Installation…9202
Radiator Fan Relay Inspection…9202
Radiator Fan Relay Circuit…9203
Subthrottle Valve Actuator Removal…9204
Subthrottle Valve Actuator Inspection…9204
Subthrottle Valve Actuator Resistance Inspection…9204
Subthrottle Valve Actuator Input Voltage Inspection…9205
Special Tools -…9205
Subthrottle Valve Actuator Circuit…9205
Exhaust Butterfly Valve Actuator Removal…9206
Exhaust Butterfly Valve Actuator Installation…9206
Torque -…9206
Torque -…9207
Exhaust Butterfly Valve Actuator Inspection…9208
Exhaust Butterfly Valve Actuator Output Voltage Inspection…9208
Special Tool -…9208
Exhaust Butterfly Valve Actuator Circuit…9209
Air Switching Valve Removal/Installation…9210
Air Switching Valve Inspection…9210
Air Switching Valve Circuit (Other than Europe Models)…9210
Oxygen Sensor Heater Removal/Installation…9211
Oxygen Sensor Heater Inspection …9211
Special Tool -…9211
Special Tool -…9211
Sealant -…9212
Oxygen Sensor Circuit…9212
Oxygen Sensor ##1: Service Code 94…9213
Oxygen Sensor Removal/Installation…9213
Oxygen Sensor Inspection…9213
Special Tool -…9213
Sealant -…9214
Oxygen Sensor Circuit…9214
CAUTION…9215
ECU Identification…9215
ECU Removal…9215
ECU Installation…9216
ECU Power Supply Inspection…9216
Special Tool -…9216
ECU Power Source Circuit…9217
ECU Fuse Removal…9218
ECU Fuse Installation…9218
ECU Fuse Inspection…9218
Warning Indicator Light (LED) Inspection…9219
Warning Indicator Light (LED) (FI/Immobilizer) Circuit…9219
Fuel Pressure Inspection…9220
Special Tools -…9220
Fuel Flow Rate Inspection…9221
Special Tool -…9222
Fuel Pump Removal…9223
Fuel Pump Installation…9223
Torque -…9224
Fuel Pump Operation Inspection…9224
Fuel Pump Operating Voltage Inspection…9224
Special Tools -…9224
Fuel Pump Circuit…9225
Fuel Pump Relay Removal…9226
Fuel Pump Relay Inspection…9226
Special Tool -…9226
CAUTION…9227
Audible Inspection…9227
Injector Signal Test…9227
Special Tool -…9228
Injector Resistance Inspection…9228
Special Tool -…9228
Injector Unit Test…9229
Injector Voltage Inspection…9229
Special Tool -…9229
Special Tool -…9229
Injector Fuel Line Inspection…9231
Fuel Injector Circuit…9232
Free Play Inspection…9233
Free Play Adjustment…9233
Cable Installation…9233
Cable Lubrication…9233
Idle Speed Inspection…9234
Synchronization Inspection…9234
Synchronization Adjustment…9234
Throttle Body Assy Removal…9234
Special Tool -…9234
Throttle Body Assy Installation…9235
Torque -…9235
Torque -…9235
Throttle Body Assy Disassembly…9236
Throttle Body Assy Assembly…9237
Torque -…9237
Nozzle Assy Removal…9238
Nozzle Assy Installation…9238
Torque -…9238
Nozzle Assy Disassembly…9239
Nozzle Assy Assembly…9239
Torque -…9240
Torque -…9240
Air Cleaner Element Removal…9241
Air Cleaner Element Installation…9241
Air Cleaner Element Inspection…9241
Air Cleaner Housing Removal…9241
Air Cleaner Housing Installation…9242
Torque -…9242
Air Cleaner Housing Disassembly…9243
Air Cleaner Housing Assembly…9243
Torque -…9243
Oil Draining…9244
Fuel Tank Removal…9245
Fuel Tank Installation…9247
Fuel Tank and Cap Inspection…9247
Fuel Tank Cleaning…9248
The Evaporative Emission Control System routes fuel vapors from …9249
Parts Removal/Installation…9249
Hose Inspection…9249
Separator Inspection…9249
Separator Operation Test…9250
Canister Inspection …9250
Cooling System…9252
Bearing Driver, 32:…9256
Coolant Deterioration Inspection…9259
Coolant Level Inspection…9259
Coolant Draining…9259
Coolant Filling…9259
Pressure Testing…9259
Cooling System Flushing…9260
Coolant Reserve Tank Removal…9260
Coolant Reserve Tank Installation…9261
Torque -…9261
Water Pump Removal…9262
Water Pump Installation…9262
Water Pump Impeller Disassembly/Assembly…9262
Torque -…9262
Water Pump Impeller Inspection…9262
Water Pump Housing Disassembly…9262
Water Pump Housing Assembly…9263
Special Tool -…9263
Special Tool -…9263
Mechanical Seal Inspection…9263
Radiator and Radiator Fan Removal…9264
Radiator and Radiator Fan Installation…9265
Torque -…9266
Torque -…9266
Torque -…9266
Torque -…9266
Radiator Inspection…9267
Radiator Cap Inspection…9267
Radiator Filler Neck Inspection…9268
Thermostat Removal…9269
Thermostat Installation…9269
Torque -…9269
Torque -…9270
Thermostat Inspection…9270
Hose Installation…9271
Torque -…9271
Hose Inspection…9271
Water Temperature Sensor Removal…9272
Water Temperature Sensor Inspection…9272
Engine Top End…9274
Compression Gauge, 20 kgf/cm :…9282
Air Suction Valve Removal…9284
Air Suction Valve Installation…9284
Torque -…9284
Air Suction Valve Inspection…9284
Air Switching Valve Removal…9285
Air Switching Valve Installation…9285
Air Switching Valve Operation Test…9285
Air Switching Valve Unit Test…9285
Clean Air System Hose Inspection…9285
Cylinder Head Cover Removal…9286
Cylinder Head Cover Installation…9286
Sealant -…9286
Torque -…9287
Torque -…9287
Camshaft Chain Tensioner Removal…9288
Camshaft Chain Tensioner Installation…9288
Torque -…9288
Torque -…9288
Camshaft Removal…9289
Camshaft Installation…9291
Torque -…9291
Torque -…9294
Camshaft, Camshaft Cap Wear…9294
Torque -…9294
Camshaft Runout…9295
Cam Wear…9295
Camshaft Chain Removal…9295
Cylinder Compression Measurement…9296
Special Tools -…9296
Torque -…9296
Cylinder Head Removal…9297
Cylinder Head Installation…9297
Torque -…9298
Torque -…9298
Torque -…9298
Cylinder Head Warp…9298
Valve Clearance Inspection…9299
Valve Clearance Adjustment…9299
Valve Removal…9299
Special Tools -…9299
Valve Installation…9299
Valve Guide Removal…9300
Special Tool -…9300
Valve Guide Installation…9300
Special Tools -…9300
Special Tool -…9300
Valve-to-Guide Clearance Measurement (Wobble Method)…9301
Valve Seat Inspection…9302
Valve Seat Repair…9302
Special Tools -…9302
Throttle Body Assy Holder Removal…9307
Throttle Body Assy Holder Installation…9307
Torque -…9307
WARNING…9308
Muffler Body Removal…9308
Muffler Body Installation…9309
Torque -…9309
Torque -…9309
Rear Exhaust Pipe Removal…9310
Rear Exhaust Pipe Installation…9311
Torque -…9311
Front Exhaust Pipe Removal…9312
Front Exhaust Pipe Installation…9313
Torque -…9313
Exhaust Butterfly Valve Cable Removal…9314
Exhaust Butterfly Valve Cable Installation…9315
Torque -…9315
Torque -…9315
Torque -…9316
Torque -…9317
Clutch…9318
Clutch Holder:…9322
Clutch Lever Free Play Inspection…9323
Clutch Lever Free Play Adjustment…9323
Cable Removal…9323
Cable Installation…9323
Cable Lubrication…9323
Clutch Lever Installation…9323
Torque -…9323
Clutch Cover Removal…9324
Clutch Cover Installation…9324
Sealant -…9324
Torque -…9324
Release Shaft Removal…9324
Release Shaft Installation…9325
Clutch Cover Disassembly…9325
Clutch Cover Assembly…9326
Torque -…9326
Clutch Removal…9327
Special Tool -…9327
Clutch Installation…9327
Special Tool -…9329
Torque -…9329
Torque -…9330
Spring Plate Free Play Measurement…9330
Spring Plate Free Play Adjustment…9331
Torque -…9332
Clutch Plate, Wear, Damage Inspection…9332
Clutch Plate Warp Inspection…9332
Clutch Spring Free Length Measurement…9333
Damper Cam Inspection…9333
Engine Lubrication System…9334
Outside Circlip Pliers:…9338
WARNING…9341
Oil Level Inspection…9341
Engine Oil Change…9341
Oil Filter Replacement…9341
Oil Pan Removal…9342
Oil Pan Installation…9342
Torque -…9343
Oil Pressure Relief Valve Removal…9344
Oil Pressure Relief Valve Installation…9344
Torque -…9344
Oil Pressure Relief Valve Inspection…9345
Oil Pump Removal…9346
Oil Pump Installation…9347
Torque -…9347
Torque -…9347
Torque -…9347
Torque -…9348
Oil Pump Gear Removal…9348
Oil Pump Gear Installation…9348
Torque -…9348
Oil Pump Gear Shaft Removal…9349
Special Tool -…9349
Oil Pump Gear Shaft Installation…9349
Special Tool -…9349
Oil Cooler Removal…9350
Oil Cooler Installation…9350
Torque -…9350
Torque -…9350
Oil Cooler/Oil Filter Case Removal…9351
Oil Cooler/Oil Filter Case Installation…9352
Torque -…9352
Torque -…9352
Torque -…9352
Oil Pressure Measurement…9353
Special Tools -…9353
Torque -…9353
Oil Pressure Switch Removal…9354
Oil Pressure Switch Installation…9354
Sealant -…9354
Torque -…9354
Torque -…9354
Engine Removal/Installation…9356
Engine Mount Nut Wrench:…9359
Engine Removal…9360
Special Tool -…9362
Engine Installation…9363
Torque -…9364
Torque -…9365
Torque -…9365
Torque -…9365
Special Tool -…9365
Torque -…9365
Torque -…9365
Crankshaft/Transmission…9368
Outside Circlip Pliers:…9376
Crankcase Splitting…9377
Crankcase Assembly…9378
Torque -…9378
Special Tool -…9379
Torque -…9379
Torque -…9379
Torque -…9379
Torque -…9380
Sealant -…9381
Torque -…9382
Torque -…9382
Torque -…9382
Crankshaft Removal…9383
Crankshaft Installation…9383
Connecting Rod Removal…9385
Connecting Rod Installation…9385
Crankshaft/Connecting Rod Cleaning…9389
Connecting Rod Bend…9389
Connecting Rod Twist…9389
Connecting Rod Big End Side Clearance…9389
Connecting Rod Big End Bearing Insert/Crankpin Wear…9390
Crankshaft Side Clearance…9391
Crankshaft Runout…9392
Crankshaft Main Bearing Insert/Journal Wear…9392
Piston Removal…9394
Special Tool -…9394
Piston Installation…9395
Special Tools -…9396
Cylinder Wear (Upper Crankcase)…9396
Piston Wear…9396
Piston Ring, Piston Ring Groove Wear…9396
Piston Ring Groove Width…9397
Piston Ring Thickness…9397
Piston Ring End Gap…9397
Starter Idle Gear Removal…9398
Starter Idle Gear Installation…9398
Sealant -…9399
Torque -…9399
Torque -…9399
Starter Clutch Removal…9400
Special Tools -…9400
Starter Clutch Installation …9400
Special Tools -…9400
Torque -…9400
Starter Clutch Disassembly…9400
Starter Clutch Assembly…9401
Starter Clutch Inspection…9401
Shift Pedal Removal…9403
Shift Pedal Installation…9403
Torque -…9403
Torque -…9403
Torque -…9403
External Shift Mechanism Removal…9403
Special Tool -…9403
External Shift Mechanism Installation…9404
Torque -…9404
Special Tool -…9404
External Shift Mechanism Inspection…9404
Torque -…9405
Transmission Assy Removal…9405
Transmission Assy Disassembly…9405
Transmission Assy Assembly…9406
Special Tool -…9406
Torque -…9406
Torque -…9406
Torque -…9406
Transmission Assy Installation…9407
Torque -…9407
Transmission Shaft Removal…9408
Transmission Shaft Installation…9408
Transmission Shaft Disassembly…9409
Special Tool -…9409
Transmission Shaft Assembly…9409
Shift Drum and Fork Removal…9412
Shift Drum and Fork Installation…9412
Shift Drum Disassembly…9412
Shift Drum Assembly…9412
Torque -…9412
Shift Fork Bending…9412
Shift Fork/Gear Groove Wear…9413
Shift Fork Guide Pin/Drum Groove Wear…9413
Gear Dog and Gear Dog Hole Damage…9413
Wheels/Tires…9414
Bearing Driver Set:…9418
Front Wheel Removal…9419
Special Tools -…9419
Front Wheel Installation…9419
Torque -…9420
Torque -…9420
Rear Wheel Removal…9420
Rear Wheel Installation…9421
Torque -…9422
Wheel Inspection…9423
Special Tools -…9423
Axle Inspection…9423
Balance Inspection…9424
Balance Adjustment…9424
Balance Weight Removal…9424
Balance Weight Installation…9424
Air Pressure Inspection/Adjustment…9426
Tire Inspection…9426
Tire Removal…9426
Tire Installation…9426
Tire Repair…9428
Hub Bearing Removal…9429
Special Tools -…9429
Hub Bearing Installation…9429
Special Tool -…9429
Special Tool -…9429
Hub Bearing Inspection…9429
Hub Bearing Lubrication…9430
Final Drive…9432
Inside Circlip Pliers:…9436
Drive Chain Slack Inspection…9437
Drive Chain Slack Adjustment…9437
Wheel Alignment Inspection/Adjustment…9437
Drive Chain Wear Inspection…9437
Drive Chain Lubrication…9437
Drive Chain Removal…9437
Drive Chain Installation…9438
Engine Sprocket Removal…9441
Engine Sprocket Installation…9441
Torque -…9441
Torque -…9442
Rear Sprocket Removal…9442
Rear Sprocket Installation…9442
Torque -…9442
Coupling Installation…9443
Coupling Bearing Removal…9443
Special Tool -…9443
Special Tool -…9443
Coupling Bearing Installation…9443
Special Tool -…9443
Special Tool -…9443
Special Tool -…9444
Coupling Bearing Inspection…9444
Coupling Bearing Lubrication…9444
Coupling Damper Inspection…9444
Sprocket Wear Inspection…9444
Rear Sprocket Warp Inspection…9445
Brakes…9446
Inside Circlip Pliers:…9452
Brake Lever Position Adjustment…9453
Brake Pedal Position Inspection …9453
Brake Pedal Position Adjustment …9453
Torque -…9453
Brake Pedal Removal…9453
Brake Pedal Installation…9454
Torque -…9454
Torque -…9454
Torque -…9454
Front Caliper Removal…9455
Rear Caliper Removal…9455
Caliper Installation…9455
Torque -…9455
Front Caliper Disassembly…9456
Front Caliper Assembly…9456
Rear Caliper Disassembly…9456
Rear Caliper Assembly…9456
Caliper Fluid Seal Damage…9456
Rear Caliper Dust Boot and Friction Boot Damage…9457
Caliper Piston and Cylinder Damage…9457
Rear Caliper Holder Shaft Wear…9457
Front Brake Pad Removal…9458
Front Brake Pad Installation…9458
Torque -…9458
Rear Brake Pad Removal …9458
Rear Brake Pad Installation…9459
Brake Pad Wear Inspection…9459
Front Master Cylinder Removal…9460
Front Master Cylinder Installation…9460
Torque -…9460
Torque -…9460
Rear Master Cylinder Removal…9461
Rear Master Cylinder Installation…9461
Torque -…9461
Front Master Cylinder Disassembly…9461
Rear Master Cylinder Disassembly…9461
Master Cylinder Inspection (Visual Inspection)…9461
Master Cylinder Assembly…9462
Brake Disc Removal…9463
Brake Disc Installation…9463
Torque -…9463
Brake Disc Wear…9463
Brake Disc Warp…9463
Special Tools -…9463
Brake Fluid Level Inspection…9464
Brake Fluid Change…9464
Brake Line Bleeding…9464
Torque -…9465
Torque -…9466
Torque -…9466
Brake Hose Removal/Installation…9468
Brake Hose Inspection…9468
Suspension…9470
Inside Circlip Pliers:…9476
Rebound Damping Force Adjustment…9478
Spring Preload Adjustment…9478
Compression Damping Force Adjustment…9479
Front Fork Removal (Each Fork Leg)…9479
Front Fork Installation…9480
Torque -…9480
Torque -…9480
Front Fork Oil Change…9480
Special Tool -…9480
Special Tool -…9481
Special Tool -…9481
Special Tool -…9482
Special Tool -…9482
Special Tool -…9483
Special Tool -…9483
Special Tool -…9483
Torque -…9484
Front Fork Disassembly…9484
Front Fork Assembly…9485
Special Tool -…9486
Special Tool -…9486
Torque -…9486
Inner Tube Inspection…9486
Dust Seal Inspection…9487
Spring Tension…9487
Rebound Damping Force Adjustment…9488
Compression Damping Force Adjustment…9488
Spring Preload Adjustment…9489
Special Tool -…9489
Special Tools -…9489
Rear Shock Absorber Removal…9490
Special Tools -…9490
Rear Shock Absorber Installation…9490
Torque -…9490
Rear Shock Absorber Inspection…9490
Rear Shock Absorber Scrapping…9491
Swingarm Removal…9492
Special Tool -…9492
Swingarm Installation…9493
Torque -…9493
Special Tool -…9493
Torque -…9493
Torque -…9494
Swingarm Bearing Removal…9494
Special Tool -…9494
Special Tool -…9494
Swingarm Bearing Installation…9494
Special Tools -…9494
Swingarm Bearing, Sleeve Inspection…9495
Chain Guide Inspection…9495
Tie-Rod Removal…9496
Special Tools -…9496
Tie-Rod Installation…9496
Torque -…9496
Rocker Arm Removal…9496
Special Tools -…9497
Rocker Arm Installation…9497
Torque -…9497
Tie-Rod and Rocker Arm Bearing Removal…9498
Special Tool -…9498
Tie-Rod and Rocker Arm Bearing Installation…9498
Special Tools -…9499
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…9500
Rocker Arm/Tie-Rod Bearing Lubrication…9500
Steering…9502
Bearing Puller:…9505
Steering Inspection…9506
Steering Adjustment…9506
Stem, Stem Bearing Removal…9507
Special Tool -…9507
Special Tool -…9507
Special Tools -…9508
Stem, Stem Bearing Installation…9508
Special Tools -…9508
Special Tools -…9508
Special Tool -…9509
Torque -…9509
Torque -…9510
Steering Stem Bearing Lubrication…9510
Steering Stem Warp…9510
Stem Cap Deterioration, Damage…9510
Handlebar Removal…9511
Handlebar Installation…9512
Torque -…9512
Torque -…9512
Frame…9514
Rear Seat Removal…9521
Rear Seat Installation…9521
Front Seat Removal…9521
Front Seat Installation…9521
Lower Fairing Removal…9522
Lower Fairing Installation…9522
Middle Fairing Removal…9522
Windshield Removal…9524
Windshield Installation…9524
Torque -…9524
Upper Fairing Disassembly…9525
Upper Fairing Assembly…9525
Upper Fairing Installation…9525
Inner Cover Removal…9525
Inner Cover Installation…9526
Center Inner Fairing Removal…9526
Center Inner Fairing Installation…9526
Lower Inner Fairing Removal…9526
Lower Inner Fairing Installation…9527
Left Side Cover Removal…9528
Left Side Cover Installation…9528
Right Side Cover Removal…9528
Right Side Cover Installation…9528
Seat Cover Removal…9529
Seat Cover Installation…9529
Heat Insulation Plate Removal…9530
Heat Insulation Plate Installation…9530
Heat Insulation Rubber Plate Pemoval…9530
Heat Insulation Rubber Plate Installation…9531
Front Fender Removal…9532
Front Fender Installation…9532
Torque -…9532
Flap and Rear Fender Removal…9532
Flap and Rear Fender Installation…9536
Torque -…9536
Torque -…9536
Rear Frame Removal…9537
Rear Frame Installation…9537
Torque -…9537
Frame Inspection…9537
Sidestand Removal…9538
Sidestand Installation…9538
Torque -…9538
Torque -…9538
Electrical System…9540
Hand Tester:…9566
There are a number of important precautions that are musts when …9567
Wiring Inspection…9568
Special Tool -…9568
Battery Removal…9569
Battery Installation…9569
Battery Activation…9569
Precautions…9572
1)…9572
2)…9572
3)…9572
4)…9572
Interchange…9572
Charging Condition Inspection…9573
Refreshing Charge…9573
Alternator Cover Removal…9575
Alternator Cover Installation…9575
Sealant -…9575
Torque -…9575
Stator Coil Removal…9575
Stator Coil Installation…9576
Torque -…9576
Sealant -…9576
Torque -…9576
Alternator Rotor Removal…9576
Special Tools -…9576
Special Tool -…9576
Alternator Rotor Installation…9576
Special Tools -…9576
Special Tool -…9577
Special Tools -…9577
Torque -…9577
Alternator Inspection…9577
Special Tool -…9578
Regulator/Rectifier Removal…9578
Regulator/Rectifier Inspection…9579
Special Tool -…9579
Torque -…9579
Charging Voltage Inspection…9580
Special Tool -…9580
Charging System Circuit…9581
Crankshaft Sensor Removal…9583
Crankshaft Sensor Installation…9583
Torque -…9583
Sealant -…9583
Crankshaft Sensor Inspection…9584
Special Tool -…9584
Crankshaft Sensor Peak Voltage…9584
Special Tools -…9585
Stick Coil Removal…9585
Stick Coil Installation…9585
Stick Coil Inspection…9586
Stick Coil Primary Peak Voltage…9586
Special Tools -…9586
Spark Plug Removal…9587
Spark Plug Installation…9587
Spark Plug Clean and Inspection…9587
Camshaft Position Sensor Removal…9588
Camshaft Position Sensor Installation…9588
Torque -…9588
Camshaft Position Sensor Inspection…9588
Special Tool -…9589
Camshaft Position Sensor Peak Voltage Inspection…9589
Special Tools -…9589
Interlock Operation Inspection…9590
IC Igniter Inspection…9591
Ignition System Circuit…9592
Starter Motor Removal…9593
Starter Motor Installation…9593
Torque -…9593
Starter Motor Disassembly…9594
Starter Motor Assembly…9594
Brush Inspection…9595
Commutator Cleaning and Inspection…9595
Armature Inspection…9596
Special Tool -…9596
Brush Lead Inspection…9596
Special Tool -…9596
Right-hand End Cover Assembly Inspection…9596
Special Tool -…9596
Starter Relay Inspection…9596
Special Tool -…9597
Electric Starter Circuit…9598
This motorcycle adopt the daylight system and have a headlight r…9599
Headlight Beam Horizontal Adjustment…9599
Headlight Beam Vertical Adjustment…9599
Headlight Bulb Replacement…9599
City Light Bulb Replacement…9600
Headlight Removal/Installation…9600
Tail/Brake Light (LED) Removal…9600
Tail/Brake Light (LED) Installation…9601
License Plate Light Bulb Replacement…9601
Headlight/Tail Light Circuit…9602
Turn Signal Light Bulb Replacement…9602
Turn Signal Light Removal…9604
Turn Signal Relay Inspection…9605
Turn Signal Light Circuit…9607
Air Switching Valve Operation Test…9608
Air Switching Valve Unit Test…9608
Special Tool -…9608
Fan Motor Inspection…9609
Radiator Fan Circuit ZX600P7F…9609
Radiator Fan Circuit ZX600P8F…9610
Meter Unit Removal…9611
Meter Unit Disassembly…9611
Electronic Unit (Combination Meter) Inspection…9612
Fuel Level Sensor Line Self-Diagnosis Mode Inspection…9628
Meter Circuit…9629
This motorcycle is equipped with an immobilizer system to protec…9630
Operational Cautions…9630
Key Registration…9630
Special Tool -…9630
Spare User Key Registration Flow Chart…9635
Special Tool -…9636
All Keys Initial Registration Flow Chart…9645
Immobilizer System Parts Replacement…9646
Immobilizer System Inspection…9648
Immobilizer System Circuit…9649
Brake Light Timing Inspection…9650
Brake Light Timing Adjustment…9650
Gear Position Switch Removal…9650
Gear Position Switch Installation…9651
Torque -…9651
Gear Position Switch Inspection…9652
Special Tool -…9652
Switch Inspection…9653
Special Tool -…9653
Rear Brake Light Switch Connections…9653
Side Stand Switch Connections…9653
Oil Pressure Switch Connections *…9653
Water Temperature Sensor Inspection…9654
Speed Sensor Removal…9654
Speed Sensor Installation…9655
Torque -…9655
Speed Sensor Inspection…9655
Special Tool -…9655
Fuel Reserve Switch Inspection…9656
Oxygen Sensor Removal (Equipped Models)…9656
Oxygen Sensor Installation (Equipped Models)…9657
Torque -…9657
Oxygen Sensor Inspection (Equipped Models)…9657
The relay box [A] has relays and diodes. The relays and diodes c…9658
Relay Box Removal…9658
Relay Circuit Inspection…9658
Diode Circuit Inspection…9659
Relay Box Internal Circuit…9660
30 A Main Fuse Removal…9661
Fuse Box Fuse Removal…9661
10 A ECU Fuse Removal…9661
Fuse Installation…9662
Fuse Inspection…9662
Appendix…9664
California Model…9690
California Model…9691
NOTE…9693
Engine Doesn't Start, Starting Difficulty:…9693
Starter motor not rotating:…9693
Starter motor rotating but engine doesn't turn over:…9693
Engine won't turn over:…9693
No fuel flow:…9693
No spark; spark weak:…9693
Fuel/air mixture incorrect:…9693
Compression Low:…9693
Poor Running at Low Speed:…9693
Spark weak:…9693
Fuel/air mixture incorrect:…9693
Compression low:…9694
Run-on (dieseling):…9694
Other:…9694
Poor Running or No Power at High Speed:…9694
Firing incorrect:…9694
Fuel/air mixture incorrect:…9694
Compression low:…9694
Knocking:…9694
Miscellaneous:…9694
Overheating:…9694
Firing incorrect:…9694
Muffler overheating:…9694
Fuel/air mixture incorrect:…9694
Compression high:…9695
Engine load faulty:…9695
Lubrication inadequate:…9695
Oil cooler incorrect:…9695
Water temperature meter incorrect:…9695
Coolant incorrect:…9695
Cooling system component incorrect:…9695
Over Cooling:…9695
Water temperature meter incorrect:…9695
Cooling system component incorrect:…9695
Clutch Operation Faulty:…9695
Clutch slipping:…9695
Clutch not disengaging properly:…9695
Gear Shifting Faulty:…9695
Doesn't go into gear; shift pedal doesn't return:…9695
Jumps out of gear:…9695
Overshifts:…9695
Abnormal Engine Noise:…9695
Knocking:…9695
Piston slap:…9695
Valve noise:…9695
Other noise:…9695
Abnormal Drive Train Noise:…9696
Clutch noise:…9696
Transmission noise:…9696
Drive line noise:…9696
Abnormal Frame Noise:…9696
Front fork noise:…9696
Rear shock absorber noise:…9696
Disc brake noise:…9696
Other noise:…9696
Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:…9696
Exhaust Smokes Excessively:…9696
White smoke:…9696
Black smoke:…9696
Brown smoke:…9696
Handling and/or Stability Unsatisfactory:…9696
Handlebar hard to turn:…9696
Handlebar shakes or excessively vibrates:…9696
Handlebar pulls to one side:…9696
Shock absorption unsatisfactory:…9696
Brake Doesn't Hold:…9697
Battery Trouble:…9697
Battery discharged:…9697
Battery overcharged:…9697
Kawasaki Motorcycle Service Repair Manual '08-'11 ZX-14 (EN)…9699
General Information…9707
Before Servicing…9708
Model Identification…9713
General Specifications…9716
Unit Conversion Table…9719
Periodic Maintenance…9721
Periodic Maintenance Chart…9723
Torque and Locking Agent…9727
Specifications…9734
Special Tools and Sealant…9736
Periodic Maintenance Procedures…9737
Fuel System (DFI)…9737
Throttle Control System Inspection…9737
Engine Vacuum Synchronization Inspection…9737
Idle Speed Inspection…9741
Idle Speed Adjustment…9741
Fuel Hose Inspection (fuel leak, damage, installation condition)…9741
Evaporative Emission Control System Inspection (CAL, SEA and TH Models) …9742
Cooling System…9743
Coolant Level Inspection…9743
Radiator Hose and Pipe Inspection…9744
Engine Top End…9744
Valve Clearance Inspection…9744
Valve Clearance Adjustment…9746
Air Suction System Damage Inspection…9749
Clutch…9749
Clutch Operation Inspection …9749
Clutch Fluid Level Inspection…9750
Clutch Fluid Leak Inspection…9750
Clutch Hose and Pipe Damage and Installation Condition Inspection…9750
Wheels/Tires…9751
Air Pressure Inspection…9751
Wheel/Tire Damage Inspection…9751
Tire Tread Wear Inspection …9751
Wheel Bearing Damage Inspection…9752
Final Drive…9753
Drive Chain Lubrication Condition Inspection…9753
Drive Chain Slack Inspection…9753
Drive Chain Slack Adjustment…9754
Wheel Alignment Inspection…9755
Drive Chain Wear Inspection…9755
Drive Chain Guide Wear Inspection…9756
Brakes…9756
Brake Fluid Leak (Brake Hose and Pipe) Inspection…9756
Brake Hose and Pipe Damage and Installation Condition Inspection…9757
Brake Operation Inspection…9757
Brake Fluid Level Inspection…9757
Brake Pad Wear Inspection…9758
Brake Light Switch Operation Inspection…9759
Suspension…9759
Front Forks/Rear Shock Absorber Operation Inspection…9759
Front Fork Oil Leak Inspection…9760
Rear Shock Absorber Oil Leak Inspection…9760
Rocker Arm Operation Inspection…9760
Tie-Rod Operation Inspection…9760
Steering…9761
Steering Play Inspection…9761
Steering Play Adjustment…9761
Steering Stem Bearing Lubrication…9762
Electrical System…9763
Lights and Switches Operation Inspection…9763
Headlight Aiming Inspection…9766
Sidestand Switch Operation Inspection…9767
Engine Stop Switch Operation Inspection…9768
Others…9768
Chassis Parts Lubrication …9768
Bolts, Nuts and Fasteners Tightness Inspection…9769
Replacement Parts…9770
Air Cleaner Element Replacement…9770
Fuel Hose Replacement…9772
Coolant Change…9773
Radiator Hose and O-ring Replacement…9775
Clutch Hose Replacement…9776
Clutch Fluid Change…9777
Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement…9778
Engine Oil Change…9779
Oil Filter Replacement…9780
Brake Hose Replacement…9781
Brake Fluid Change…9783
Master Cylinder Rubber Parts Replacement…9784
Caliper Rubber Parts Replacement…9785
Spark Plug Replacement…9789
Fuel System (DFI)…9791
Exploded View…9794
DFI System…9800
DFI Parts Location…9806
Specifications…9808
Special Tools and Sealant…9810
DFI Servicing Precautions…9812
DFI Servicing Precautions…9812
Troubleshooting the DFI System…9814
Outline…9814
Inquiries to Rider…9819
DFI System Troubleshooting Guide…9822
Self-Diagnosis…9827
Self-diagnosis Outline…9827
Self-diagnosis Procedures…9828
Service Code Reading…9831
Service Code Erasing…9831
Backups…9833
Main Throttle Sensor (Service Code 11)…9835
Main Throttle Sensor Removal/Adjustment…9835
Main Throttle Sensor Input Voltage Inspection…9835
Main Throttle Sensor Output Voltage Inspection…9837
Main Throttle Sensor Resistance Inspection…9840
Inlet Air Pressure Sensor (Service Code 12)…9841
Inlet Air Pressure Sensor Removal…9841
Inlet Air Pressure Sensor Installation…9841
Inlet Air Pressure Sensor Input Voltage Inspection…9842
Inlet Air Pressure Sensor Output Voltage Inspection…9843
Inlet Air Temperature Sensor (Service Code 13)…9847
Inlet Air Temperature Sensor Removal/Installation…9847
Inlet Air Temperature Sensor Output Voltage Inspection…9847
Inlet Air Temperature Sensor Resistance Inspection…9848
Water Temperature Sensor (Service Code 14)…9850
Water Temperature Sensor Removal/Installation…9850
Water Temperature Sensor Output Voltage Inspection…9850
Water Temperature Sensor Resistance Inspection…9851
Atmospheric Pressure Sensor (Service Code 15)…9852
Atmospheric Pressure Sensor Removal…9852
Atmospheric Pressure Sensor Installation…9852
Atmospheric Pressure Sensor Input Voltage Inspection…9852
Atmospheric Pressure Sensor Output Voltage Inspection…9853
Crankshaft Sensor (Service Code 21)…9856
Crankshaft Sensor Removal/Installation…9856
Crankshaft Sensor Inspection…9856
Camshaft Position Sensor (Service Code 23)…9857
Camshaft Position Sensor Removal/Installation…9857
Camshaft Position Sensor Inspection…9857
Speed Sensor (Service Code 24)…9858
Speed Sensor Removal/Installation…9858
Speed Sensor Inspection…9858
Speed Sensor Input Voltage Inspection…9858
Speed Sensor Output Voltage Inspection…9859
Gear Position Switch (Service Code 25)…9861
Gear Position Switch Removal/Installation…9861
Gear Position Switch Inspection…9861
Gear Position Switch Input Voltage Inspection…9861
Vehicle-down Sensor (Service Code 31)…9863
Vehicle-down Sensor Removal…9863
Vehicle-down Sensor Installation…9863
Vehicle-down Sensor Inspection…9864
Subthrottle Sensor (Service Code 32)…9866
Subthrottle Sensor Removal/Adjustment…9866
Subthrottle Sensor Input Voltage Inspection…9866
Subthrottle Sensor Output Voltage Inspection…9868
Subthrottle Sensor Resistance Inspection…9870
Oxygen Sensor – not activated (Service Code 33) (Equipped Models)…9871
Oxygen Sensor Removal/Installation…9871
Oxygen Sensor Inspection…9871
Immobilizer Amplifier (Service Code 35) (Equipped Models)…9873
Antenna Resistance Inspection…9873
Amplifier Input Voltage Inspection…9873
Blank Key Detection (Service Code 36) (Equipped Models)…9874
User Key Inspection…9874
Fuel Pump Relay (Service Code 46)…9875
Fuel Pump Relay Removal…9875
Fuel Pump Relay Inspection…9875
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)…9877
Stick Coil Removal/Installation…9877
Stick Coil Input Voltage Inspection…9877
Subthrottle Valve Actuator (Service Code 62)…9879
Subthrottle Valve Actuator Removal…9879
Subthrottle Valve Actuator Inspection…9879
Subthrottle Valve Actuator Resistance Inspection…9879
Subthrottle Valve Actuator Input Voltage Inspection…9880
Oxygen Sensor Heater (Service Code 67) (Equipped Models)…9882
Oxygen Sensor Heater Removal/Installation…9882
Oxygen Sensor Heater Inspection …9882
ECU Main Relay (Service Code 75)…9885
ECU Main Relay Inspection…9885
ECU…9886
ECU Identification…9886
ECU Removal…9886
ECU Installation…9888
ECU Power Supply Inspection…9889
CAN Communication Line Resistance Inspection…9890
Warning Indicator Light (LED)…9892
Light (LED) Inspection…9892
Fuel Line…9893
Fuel Pressure Inspection…9893
Fuel Flow Rate Inspection…9894
Fuel Pump…9897
Fuel Pump Removal…9897
Fuel Pump Installation…9897
Fuel Pump Operation Inspection…9898
Fuel Pump Operating Voltage Inspection…9898
Fuel Injectors…9900
Fuel Injectors Removal/Installation…9900
Fuel Injectors Power Source Voltage Inspection…9900
Fuel Injector Output Voltage Inspection…9901
Fuel Injector Audible Inspection…9902
Fuel Injector Signal Test…9903
Fuel Injector Resistance Inspection…9904
Fuel Injector Unit Test…9904
Fuel Injector Fuel Line Inspection…9905
Throttle Grip and Cables…9907
Free Play Inspection…9907
Free Play Adjustment…9907
Cable Installation…9907
Cable Lubrication…9907
Throttle Body Assy…9908
Idle Speed Inspection/Adjustment…9908
Throttle Bore Cleaning…9908
Synchronization Inspection/Adjustment…9908
Throttle Body Assy Removal…9908
Throttle Body Assy Installation…9911
Throttle Body Assy Disassembly…9913
Throttle Body Assy Assembly…9914
Air Line…9916
Air Cleaner Element Removal…9916
Air Cleaner Element Installation…9916
Air Cleaner Element Inspection…9916
Air Cleaner Element Holder Removal…9916
Air Cleaner Element Holder Installation…9916
Air Cleaner Oil Draining…9917
Rear Air Inlet Duct Removal…9917
Rear Air Inlet Duct Installation…9917
Front and Middle Air Inlet Duct Removal…9918
Front and Middle Air Inlet Duct Installation…9918
Fuel Tank…9920
Fuel Tank Removal…9920
Fuel Tank Installation…9923
Fuel Tank Inspection…9924
Fuel Tank Cleaning…9925
Evaporative Emission Control System (CAL, SEA and TH Models)…9926
Parts Removal/Installation…9926
Hose Inspection…9926
Separator Inspection…9926
Separator Operation Test…9927
Canister Inspection…9927
Cooling System…9929
Exploded View…9930
Coolant Flow Chart…9932
Specifications…9934
Coolant…9935
Coolant Deterioration Inspection…9935
Coolant Level Inspection…9935
Coolant Draining…9935
Coolant Filling…9935
Pressure Testing…9935
Cooling System Flushing…9936
Coolant Reserve Tank Removal/Installation…9936
Water Pump…9937
Water Pump Removal…9937
Water Pump Installation…9937
Water Pump Impeller Inspection…9938
Radiator…9939
Radiator and Radiator Fan Removal…9939
Radiator and Radiator Fan Installation…9940
Radiator Inspection…9940
Radiator Cap Inspection…9941
Radiator Filler Neck Inspection…9941
Thermostat…9942
Thermostat Removal…9942
Thermostat Installation…9942
Thermostat Inspection…9942
Hoses and Pipes…9944
Hose Installation…9944
Hose Inspection…9944
Water Temperature Sensor…9945
Water Temperature Sensor Removal…9945
Water Temperature Sensor Inspection…9945
Engine Top End…9947
Exploded View…9948
Exhaust System…9952
Specifications…9954
Special Tools and Sealant…9955
Clean Air System…9957
Air Suction Valve Removal…9957
Air Suction Valve Installation…9957
Air Suction Valve Inspection…9958
Air Switching Valve Removal…9958
Air Switching Valve Installation…9958
Air Switching Valve Operation Test…9958
Air Switching Valve Unit Test…9958
Clean Air System Hose Inspection…9959
Cylinder Head Cover…9960
Cylinder Head Cover Removal…9960
Cylinder Head Cover Installation…9960
Camshaft Chain Tensioner…9962
Camshaft Chain Tensioner Removal…9962
Camshaft Chain Tensioner Installation…9962
Camshaft, Camshaft Chain…9963
Camshaft Removal…9963
Camshaft Installation…9963
Camshaft, Camshaft Cap Wear…9966
Camshaft Runout…9967
Cam Wear…9967
Camshaft Chain Removal…9967
Camshaft Chain Installation…9968
Cylinder Head…9969
Cylinder Compression Measurement…9969
Cylinder Head Removal…9970
Cylinder Head Installation…9970
Cylinder Head Warp Inspection…9971
Valves…9972
Valve Clearance Inspection…9972
Valve Clearance Adjustment…9972
Valve Removal…9972
Valve Installation…9972
Valve Guide Removal…9972
Valve Guide Installation…9973
Valve-to-Guide Clearance Measurement (Wobble Method)…9974
Valve Seat Inspection…9975
Valve Seat Repair…9975
Throttle Body Holder…9980
Throttle Body Holder Installation…9980
Muffler…9981
Muffler Body Removal/Installation…9981
Exhaust Pipe Removal…9982
Exhaust Pipe Installation…9982
Clutch…9983
Exploded View…9984
Specifications…9986
Special Tools and Sealant…9987
Clutch Master Cylinder…9988
Clutch Lever Position Adjustment…9988
Clutch Master Cylinder Removal…9988
Clutch Master Cylinder Installation …9988
Clutch Master Cylinder Disassembly …9989
Clutch Master Cylinder Assembly…9989
Clutch Master Cylinder Inspection…9989
Clutch Slave Cylinder…9990
Clutch Slave Cylinder Removal…9990
Clutch Slave Cylinder Installation…9991
Clutch Slave Cylinder Disassembly …9991
Clutch Slave Cylinder Assembly…9991
Clutch Fluid…9992
Clutch Fluid Level Inspection…9992
Clutch Fluid Change…9992
Bleeding the Clutch Line…9992
Clutch Hose Removal/Installation…9994
Clutch Hose Inspection…9994
Clutch Cover…9995
Clutch Cover Removal…9995
Clutch Cover Installation…9995
Clutch…9996
Clutch Removal…9996
Clutch Installation…9996
Clutch Plate Assembly Inspection…9998
Clutch Plate Assembly Adjustment…9999
Clutch Plate, Wear, Damage Inspection…9999
Clutch Plate Warp Inspection…9999
Clutch Spring Free Length Measurement…10000
Engine Lubrication System…10001
Exploded View…10002
Engine Oil Flow Chart…10004
Specifications…10006
Special Tools and Sealant…10007
Engine Oil and Oil Filter…10008
Oil Level Inspection…10008
Engine Oil Change…10008
Oil Filter Replacement…10008
Oil Pan…10009
Oil Pan Removal…10009
Oil Pan Installation…10009
Oil Pressure Relief Valve…10011
Oil Pressure Relief Valve Removal…10011
Oil Pressure Relief Valve Installation…10011
Oil Pressure Relief Valve Inspection…10011
Oil Pump…10012
Oil Pump Removal…10012
Oil Pump Installation…10012
Oil Cooler…10014
Oil Cooler Removal…10014
Oil Cooler Installation…10014
Oil Pressure Measurement…10015
Oil Pressure Measurement…10015
Oil Pressure Switch…10016
Oil Pressure Switch Removal…10016
Oil Pressure Switch Installation…10016
Engine Removal/Installation…10017
Exploded View…10018
Engine Removal/Installation…10020
Engine Removal…10020
Engine Installation…10022
Crankshaft/Transmission…10029
Exploded View…10030
Specifications…10034
Special Tools and Sealants…10037
Crankcase Splitting…10038
Crankcase Splitting…10038
Crankcase Assembly…10039
Crankshaft and Connecting Rods…10043
Crankshaft Removal…10043
Crankshaft Installation…10043
Connecting Rod Removal…10044
Connecting Rod Installation…10044
Crankshaft/Connecting Rod Cleaning…10047
Connecting Rod Bend Inspection…10048
Connecting Rod Twist Inspection…10048
Connecting Rod Big End Side Clearance Inspection…10048
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection…10049
Crankshaft Side Clearance Inspection…10050
Crankshaft Runout Inspection…10051
Crankshaft Main Bearing Insert/Journal Wear Inspection…10051
Pistons…10054
Piston Removal…10054
Piston Installation…10055
Cylinder Wear (Upper Crankcase) Inspection…10056
Piston Wear Inspection…10056
Piston Ring, Piston Ring Groove Wear Inspection…10056
Piston Ring Groove Width Inspection…10057
Piston Ring Thickness Inspection…10057
Piston Ring End Gap Inspection…10057
Balancer…10058
Front Balancer Removal…10058
Front Balancer Installation…10058
Rear Balancer Removal…10059
Rear Balancer Installation…10060
Balancer Adjustment…10062
Balancer Damper Inspection…10062
Starter Motor Clutch and Torque Limiter…10063
Starter Motor Clutch Removal…10063
Starter Motor Clutch Installation…10063
Starter Motor Clutch Disassembly…10063
Starter Motor Clutch Assembly…10064
Starter Clutch Inspection…10064
Torque Limiter Removal…10064
Torque Limiter Installation…10065
Transmission…10066
Shift Pedal Removal…10066
Shift Pedal Installation…10066
External Shift Mechanism Removal…10066
External Shift Mechanism Installation…10067
External Shift Mechanism Inspection…10067
Transmission Shaft Removal…10067
Transmission Shaft Installation…10068
Transmission Shaft Disassembly…10069
Transmission Shaft Assembly…10069
Shift Drum and Fork Removal…10072
Shift Drum and Fork Installation…10072
Shift Drum Disassembly…10072
Shift Drum Assembly…10072
Shift Fork Bending Inspection…10073
Shift Fork/Gear Groove Wear Inspection…10073
Shift Fork Guide Pin/Drum Groove Wear Inspection…10073
Gear Dog and Gear Dog Hole Damage Inspection…10073
Wheels/Tires…10075
Exploded View…10076
Specifications…10078
Special Tools…10079
Wheels (Rims)…10080
Front Wheel Removal…10080
Front Wheel Installation…10080
Rear Wheel Removal…10081
Rear Wheel Installation…10082
Wheel Inspection…10084
Axle Inspection…10084
Balance Inspection…10085
Balance Adjustment…10085
Balance Weight Removal…10085
Balance Weight Installation…10086
Tires…10088
Air Pressure Inspection/Adjustment…10088
Tire Inspection…10088
Tire Removal…10088
Tire Installation…10088
Tire Repair…10090
Hub Bearing…10091
Hub Bearing Removal…10091
Hub Bearing Installation…10091
Hub Bearing Inspection…10091
Hub Bearing Lubrication…10092
Final Drive…10093
Exploded View …10094
Specifications …10096
Special Tools…10097
Drive Chain…10098
Drive Chain Slack Inspection…10098
Drive Chain Slack Adjustment…10098
Wheel Alignment Inspection/Adjustment…10098
Drive Chain Wear Inspection…10098
Drive Chain Lubrication…10098
Drive Chain Removal…10098
Drive Chain Installation…10098
Sprocket, Coupling…10099
Engine Sprocket Removal…10099
Engine Sprocket Installation…10099
Rear Sprocket Removal…10100
Rear Sprocket Installation…10100
Coupling Installation…10100
Coupling Bearing Removal…10101
Coupling Bearing Installation…10101
Coupling Bearing Inspection…10102
Coupling Bearing Lubrication…10102
Coupling Damper Inspection…10102
Sprocket Wear Inspection…10102
Rear Sprocket Warp Inspection…10102
Brakes…10103
Exploded View …10106
Specifications …10114
Special Tools…10115
Brake Lever, Brake Pedal…10116
Brake Lever Position Adjustment…10116
Brake Pedal Position Inspection …10116
Brake Pedal Position Adjustment …10116
Brake Pedal Removal…10116
Brake Pedal Installation…10117
Calipers…10118
Front Caliper Removal…10118
Rear Caliper Removal…10118
Caliper Installation…10119
Front Caliper Disassembly…10119
Front Caliper Assembly…10119
Rear Caliper Disassembly…10119
Rear Caliper Assembly…10119
Caliper Fluid Seal Damage Inspection…10120
Caliper Dust Seal Damage Inspection…10120
Caliper Piston and Cylinder Damage Inspection…10121
Brake Pads…10122
Front Brake Pad Removal…10122
Front Brake Pad Installation…10122
Rear Brake Pad Removal …10123
Rear Brake Pad Installation…10123
Brake Pad Wear Inspection…10123
Master Cylinder…10124
Front Master Cylinder Removal…10124
Front Master Cylinder Installation…10124
Rear Master Cylinder Removal…10124
Rear Master Cylinder Installation…10125
Front Master Cylinder Disassembly…10125
Rear Master Cylinder Disassembly…10125
Master Cylinder Assembly…10125
Master Cylinder Inspection (Visual Inspection)…10125
Brake Disc…10126
Brake Disc Removal…10126
Brake Disc Installation…10126
Brake Disc Wear Inspection…10126
Brake Disc Warp Inspection…10126
Brake Fluid…10127
Brake Fluid Level Inspection…10127
Brake Fluid Change…10127
Brake Line Bleeding…10127
Brake Hose…10131
Brake Hose and Pipe Removal/Installation…10131
Brake Hose and Pipe Inspection…10131
Anti-Lock Brake System (Equipped Models)…10132
ABS Servicing Precautions…10136
ABS Troubleshooting Outline…10138
Inquiries to Rider…10141
Self-diagnosis Outline…10143
Self-diagnosis Procedures…10143
Service Code Clearing Procedures…10144
How to Read Service Codes…10147
How to Erase Service Codes…10147
ABS Indicator Light (LED) Inspection…10149
ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)…10149
ABS Indicator Light (LED) Lights (When the Motorcycle is Running, – No Service Code)…10150
Solenoid Valve Inspection (Service Code 13,14,17,18)…10150
ABS Solenoid Valve Relay Inspection (Service Code 19)…10150
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)…10152
ABS Pump Motor Relay Inspection (Service Code 35)…10152
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)…10154
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)…10154
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)…10155
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)…10156
Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)…10157
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)…10158
ECU Inspection (Service Code 55)…10159
ABS Hydraulic Unit Removal…10159
ABS Hydraulic Unit Installation…10160
ABS Hydraulic Unit Inspection…10161
Front Wheel Rotation Sensor Removal…10161
Front Wheel Rotation Sensor Installation…10162
Rear Wheel Rotation Sensor Removal…10162
Rear Wheel Rotation Sensor Installation…10163
Wheel Rotation Sensor Inspection…10163
Wheel Rotation Sensor Air Gap Inspection…10164
Wheel Rotation Sensor Rotor Inspection…10164
ABS Solenoid Valve Relay Fuse (20 A) Removal…10165
ABS Motor Relay Fuse (30 A) Removal…10165
ABS ECU Fuse (10 A) Removal…10165
Fuse Installation…10165
Fuse Inspection…10165
Suspension…10167
Exploded View…10168
Specifications…10172
Special Tools…10173
Front Fork…10175
Rebound Damping Force Adjustment…10175
Compression Damping Force Adjustment…10175
Spring Preload Adjustment…10176
Front Fork Removal (Each Fork Leg)…10176
Front Fork Installation…10177
Front Fork Oil Change…10177
Front Fork Disassembly…10182
Front Fork Assembly…10183
Inner Tube, Outer Tube Inspection…10184
Dust Seal Inspection…10184
Spring Tension Inspection…10184
Rear Shock Absorber…10185
Rebound Damping Force Adjustment…10185
Compression Damping Force Adjustment…10185
Spring Preload Adjustment…10185
Rear Shock Absorber Removal…10186
Rear Shock Absorber Installation…10187
Rear Shock Absorber Inspection…10187
Rear Shock Absorber Scrapping…10188
Swingarm…10189
Swingarm Removal…10189
Swingarm Installation…10190
Swingarm Bearing Removal…10191
Swingarm Bearing Installation…10191
Swingarm Bearing, Sleeve Inspection…10192
Swingarm Bearing Lubrication…10193
Chain Guide Inspection…10193
Tie-Rod, Rocker Arm…10194
Tie-Rod Removal…10194
Tie-Rod Installation…10194
Rocker Arm Removal…10194
Rocker Arm Installation…10195
Tie-Rod and Rocker Arm Bearing Removal…10195
Tie-Rod and Rocker Arm Bearing Installation…10195
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…10197
Rocker Arm/Tie-Rod Bearing Lubrication…10197
Steering…10199
Exploded View…10200
Special Tools…10202
Steering…10203
Steering Inspection…10203
Steering Adjustment…10203
Steering Stem…10204
Stem, Stem Bearing Removal…10204
Stem, Stem Bearing Installation…10205
Steering Stem Bearing Lubrication…10207
Steering Stem Warp Inspection…10207
Stem Cap Deterioration, Damage Inspection…10207
Handlebar…10208
Handlebar Removal…10208
Handlebar Installation…10208
Frame…10211
Exploded View…10212
Seat…10220
Seat Removal…10220
Seat Installation…10220
Fairings…10221
Lower Fairing Removal…10221
Lower Fairing Installation…10221
Fairing Cover Removal…10221
Fairing Cover Installation…10221
Middle Fairing Removal…10221
Middle Fairing Installation…10222
Windshield Removal…10222
Windshield Installation…10223
Upper Fairing Removal…10223
Upper Fairing Disassembly…10223
Upper Fairing Assembly…10223
Upper Fairing Installation…10224
Inner Cover Removal…10224
Inner Cover Installation…10224
Upper Inner Fairing Removal…10224
Upper Inner Fairing Installation…10225
Upper Fairing Bracket Removal…10225
Upper Fairing Bracket Installation…10225
Inner Fairing Removal…10225
Inner Fairing Installation…10225
Rear Fairing Removal…10225
Rear Fairing Installation…10225
Seat Cover…10226
Seat Cover Removal…10226
Seat Cover Installation…10226
Fenders…10228
Front Fender Removal…10228
Front Fender Installation…10228
Flap and Rear Fender Removal…10228
Flap and Rear Fender Installation…10229
Frame…10230
Rear Frame Removal…10230
Rear Frame Installation…10230
Frame Inspection…10230
Center Stand, Sidestand…10231
Center Stand Removal (Equipped Models)…10231
Center Stand Installation (Equipped Models)…10231
Sidestand Removal…10231
Sidestand Installation…10231
Electrical System…10233
Exploded View…10236
Specifications…10242
Special Tools and Sealant…10243
Parts Location…10245
Wiring Diagram (ZX1400C8F ∼ C9F CA, CAL and US Models)…10248
Wiring Diagram (ZX1400C8F ∼ C9F AU and MY Models)…10250
Wiring Diagram (ZX1400C8F ∼ C9F Other than CA, CAL, US, AU and MY Models)…10252
Wiring Diagram (ZX1400D8F ∼ D9F ABS Equipped Models: MY Model)…10254
Wiring Diagram (ZX1400D8F ∼ D9F ABS Equipped Models: Other than MY Model)…10256
Wiring Diagram (ZX1400CAF ∼ CBF CA, CAL and US Models)…10258
Wiring Diagram (ZX1400CAF ∼ CBF AU and MY Models)…10260
Wiring Diagram (ZX1400CAF ∼ CBF Other than CA, CAL, US, AU and MY Models)…10262
Wiring Diagram (ZX1400DAF ∼ DBF ABS Equipped Models: MY Model)…10264
Wiring Diagram (ZX1400DAF ∼ DBF ABS Equipped Models: Other than MY Model)…10266
Precautions…10268
Electrical Wiring…10269
Wiring Inspection…10269
Battery…10270
Battery Removal…10270
Battery Installation…10271
Battery Activation…10271
Precautions…10274
Interchange…10274
Charging Condition Inspection…10274
Refreshing Charge…10275
Charging System…10276
Alternator Cover Removal…10276
Alternator Cover Installation…10276
Stator Coil Removal…10276
Stator Coil Installation…10277
Alternator Rotor Removal…10277
Alternator Rotor Installation…10277
Alternator Inspection…10278
Regulator/Rectifier Inspection…10280
Charging Voltage Inspection…10281
Ignition System…10283
Crankshaft Sensor Removal…10283
Crankshaft Sensor Installation…10284
Crankshaft Sensor Inspection…10284
Crankshaft Sensor Peak Voltage Inspection…10284
Timing Rotor Removal…10285
Timing Rotor Installation…10285
Camshaft Position Sensor Removal…10285
Camshaft Position Sensor Installation…10286
Camshaft Position Sensor Inspection…10286
Camshaft Position Sensor Peak Voltage Inspection…10287
Stick Coil Removal…10287
Stick Coil Installation…10288
Stick Coil Inspection…10288
Stick Coil Primary Peak Voltage…10289
Spark Plug Removal…10289
Spark Plug Installation…10289
Spark Plug Condition Inspection…10290
Interlock Operation Inspection…10290
IC Igniter Inspection…10291
Electric Starter System…10294
Starter Motor Removal…10294
Starter Motor Installation…10294
Starter Motor Disassembly…10295
Starter Motor Assembly…10295
Brush Inspection…10297
Commutator Cleaning and Inspection…10297
Armature Inspection…10297
Brush Lead Inspection…10298
Right-hand End Cover Assembly Inspection…10298
Starter Relay Inspection…10298
Lighting System…10300
Headlight Beam Horizontal Adjustment…10300
Headlight Beam Vertical Adjustment…10300
Headlight Bulb Replacement…10300
City Light Bulb Replacement…10301
Headlight Removal/Installation…10301
Headlight Relay Inspection…10302
Tail/Brake Light (LED) Removal…10302
Tail/Brake Light (LED) Installation…10303
License Plate Light Bulb Replacement…10303
Turn Signal Light Bulb Replacement…10304
Turn Signal Relay Inspection…10306
Air Switching Valve…10308
Air Switching Valve Operation Test…10308
Air Switching Valve Unit Test…10308
Radiator Fan System…10310
Fan Motor Inspection…10310
Meter, Gauge, Indicator Unit…10311
Meter Unit Removal…10311
Meter Unit Installation…10311
Meter Unit Disassembly…10312
Meter Unit Inspection…10312
Immobilizer System (Equipped Models), ZX1400C8F ∼ CAF/D8F ∼ DAF Models…10329
Operational Cautions…10329
Key Registration…10329
Immobilizer System Parts Replacement…10345
ECU Replacement…10345
Immobilizer System (Equipped Models), ZX1400CBF/DBF Models…10347
Operational Cautions…10347
Key Registration…10347
Immobilizer System Parts Replacement…10365
ECU Replacement…10365
Immobilizer System (Equipped Models)…10367
Immobilizer System Inspection…10367
Switches and Sensors…10368
Brake Light Timing Inspection…10368
Brake Light Timing Adjustment…10368
Switch Inspection…10368
Water Temperature Sensor Inspection…10369
Speed Sensor Removal…10369
Speed Sensor Installation…10369
Speed Sensor Inspection…10370
Oxygen Sensor Removal (Equipped Models)…10370
Oxygen Sensor Installation (Equipped Models)…10370
Oxygen Sensor Inspection (Equipped Models)…10370
Fuel Level Sensor Inspection…10371
Fuel Reserve Switch Inspection…10372
Gear Position Switch Removal…10373
Gear Position Switch Installation…10374
Gear Position Switch Inspection…10374
Relay Box…10375
Relay Box Removal…10375
Relay Circuit Inspection…10375
Diode Circuit Inspection…10376
Fuse…10378
30 A Main Fuse Removal…10378
Fuse Box Fuse Removal…10378
15 A ECU Fuse Removal…10379
Fuse Installation…10379
Fuse Inspection…10380
Appendix…10381
Cable, Wire, and Hose Routing…10382
Troubleshooting Guide…10440
Kawasaki Motorcycle Service Repair Manual '09 ZX-6R (EN)…10446
General Information…10456
Before Servicing…10457
Model Identification…10462
General Specifications…10464
Unit Conversion Table…10467
Periodic Maintenance…10468
Periodic Maintenance Chart…10470
Torque and Locking Agent…10473
Specifications…10480
Special Tools…10482
Periodic Maintenance Procedures…10483
Fuel System (DFI)…10483
Throttle Control System Inspection…10483
Engine Vacuum Synchronization Inspection…10483
Idle Speed Inspection…10487
Idle Speed Adjustment…10487
Fuel Hose Inspection (fuel leak, damage, installation condition)…10487
Evaporative Emission Control System Inspection (CAL, SEA and TH Models)…10488
Cooling System…10489
Coolant Level Inspection…10489
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)…10490
Engine Top End…10490
Valve Clearance Inspection…10490
Valve Clearance Adjustment…10491
Air Suction System Damage Inspection…10494
Clutch…10495
Clutch Operation Inspection …10495
Wheels/Tires…10496
Air Pressure Inspection…10496
Wheel/Tire Damage Inspection…10496
Tire Tread Wear Inspection …10496
Wheel Bearing Damage Inspection…10497
Final Drive…10498
Drive Chain Lubrication Condition Inspection…10498
Drive Chain Slack Inspection…10498
Drive Chain Slack Adjustment…10499
Wheel Alignment Inspection…10500
Drive Chain Wear Inspection…10500
Chain Guide Wear Inspection…10501
Brakes…10501
Brake Fluid Leak (Brake Hose and Pipe) Inspection…10501
Brake Hose and Pipe Damage and Installation Condition Inspection…10501
Brake Fluid Level Inspection…10502
Brake Pad Wear Inspection…10503
Brake Operation Inspection…10503
Brake Light Switch Operation Inspection…10503
Suspension…10504
Front Forks/Rear Shock Absorber Operation Inspection…10504
Front Fork Oil Leak Inspection…10504
Rear Shock Absorber Oil Leak Inspection…10505
Rocker Arm Operation Inspection…10505
Tie-Rod Operation Inspection…10505
Steering…10505
Steering Play Inspection…10505
Steering Play Adjustment…10506
Steering Stem Bearing Lubrication…10507
Steering Damper Oil Leak Inspection…10507
Electrical System…10508
Lights and Switches Operation Inspection…10508
Headlight Aiming Inspection…10510
Sidestand Switch Operation Inspection…10511
Engine Stop Switch Operation Inspection…10512
Others…10513
Chassis Parts Lubrication …10513
Bolts, Nuts and Fasteners Tightness Inspection…10514
Replacement Parts…10515
Air Cleaner Element Replacement…10515
Fuel Hose Replacement…10515
Coolant Change…10518
Radiator Hose and O-ring Replacement…10521
Engine Oil Change…10522
Oil Filter Replacement…10523
Brake Hose and Pipe Replacement…10524
Brake Fluid Change…10524
Master Cylinder Rubber Parts Replacement…10526
Caliper Rubber Parts Replacement…10527
Spark Plug Replacement…10530
Fuel System (DFI)…10532
Exploded View…10535
DFI System…10541
DFI Parts Location…10547
Specifications…10550
Special Tools and Sealant…10552
DFI Servicing Precautions…10554
DFI Servicing Precautions…10554
Troubleshooting the DFI System…10556
Outline…10556
Inquiries to Rider…10560
DFI System Troubleshooting Guide…10563
Self-Diagnosis…10568
Self-diagnosis Outline…10568
Self-diagnosis Procedures…10569
Service Code Reading…10572
Service Code Erasing…10572
Backups…10574
Main Throttle Sensor (Service Code 11)…10577
Main Throttle Sensor Removal/Adjustment…10577
Main Throttle Sensor Input Voltage Inspection…10577
Main Throttle Sensor Output Voltage Inspection…10578
Main Throttle Sensor Resistance Inspection…10579
Inlet Air Pressure Sensor #1 (Service Code 12)…10580
Inlet Air Pressure Sensor #1 Removal…10580
Inlet Air Pressure Sensor #1 Installation…10580
Inlet Air Pressure Sensor #1 Input Voltage Inspection…10580
Inlet Air Pressure Sensor #1 Output Voltage Inspection…10581
Inlet Air Temperature Sensor (Service Code 13)…10586
Inlet Air Temperature Sensor Removal/Installation…10586
Inlet Air Temperature Sensor Output Voltage Inspection…10586
Inlet Air Temperature Sensor Resistance Inspection…10587
Water Temperature Sensor (Service Code 14)…10589
Water Temperature Sensor Removal/Installation…10589
Water Temperature Sensor Output Voltage Inspection…10589
Water Temperature Sensor Resistance Inspection…10590
Inlet Air Pressure Sensor #2 (Service Code 16)…10591
Inlet Air Pressure Sensor #2 Removal…10591
Inlet Air Pressure Sensor #2 Installation…10591
Inlet Air Pressure Sensor #2 Input Voltage Inspection…10591
Inlet Air Pressure Sensor #2 Output Voltage Inspection…10592
Crankshaft Sensor (Service Code 21)…10596
Crankshaft Sensor Removal/Installation…10596
Crankshaft Sensor Resistance Inspection…10596
Crankshaft Sensor Peak Voltage Inspection…10596
Speed Sensor (Service Code 24)…10598
Speed Sensor Removal/Installation…10598
Speed Sensor Inspection…10598
Speed Sensor Input Voltage Inspection…10598
Speed Sensor Output Voltage Inspection…10599
Gear Position Switch (Service Code 25)…10601
Gear Position Switch Removal/Installation…10601
Gear Position Switch Resistance Inspection…10601
Gear Position Switch Output Voltage Inspection…10601
Vehicle-down Sensor (Service Code 31)…10603
Vehicle-down Sensor Removal…10603
Vehicle-down Sensor Installation…10603
Vehicle-down Sensor Input Voltage Inspection…10604
Vehicle-down Sensor Output Voltage Inspection…10605
Subthrottle Sensor (Service Code 32)…10607
Subthrottle Sensor Removal/Adjustment…10607
Subthrottle Sensor Input Voltage Inspection…10607
Subthrottle Sensor Output Voltage Inspection…10608
Subthrottle Sensor Resistance Inspection…10609
Oxygen Sensor – not activated (Service Code 33 (Equipped Models))…10610
Oxygen Sensor Removal/Installation…10610
Oxygen Sensor Inspection…10610
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)…10613
Exhaust Butterfly Valve Actuator Sensor Removal/Installation…10613
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection…10613
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection…10614
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection…10615
Immobilizer Amplifier (Service Code 35 (Equipped Models))…10616
Antenna Resistance Inspection…10616
Amplifier Input Voltage Inspection…10616
Blank Key Detection (Service Code 36 (Equipped Models))…10617
User Key Inspection…10617
ECU Communication Error (Service Code 39)…10619
ECU Communication Line Inspection…10619
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)…10620
Stick Coil Removal/Installation…10620
Stick Coil Primary Winding Resistance Inspection…10620
Stick Coil Input Voltage Inspection…10620
Radiator Fan Relay (Service Code 56)…10622
Radiator Fan Relay Removal/Installation…10622
Radiator Fan Relay Inspection…10622
Subthrottle Valve Actuator (Service Code 62)…10624
Subthrottle Valve Actuator Removal…10624
Subthrottle Valve Actuator Inspection…10624
Subthrottle Valve Actuator Resistance Inspection…10624
Subthrottle Valve Actuator Input Voltage Inspection…10625
Exhaust Butterfly Valve Actuator (Service Code 63)…10627
Exhaust Butterfly Valve Actuator Removal…10627
Exhaust Butterfly Valve Actuator Installation…10627
Exhaust Butterfly Valve Actuator Inspection…10629
Exhaust Butterfly Valve Actuator Resistance Inspection…10629
Air Switching Valve (Service Code 64)…10631
Air Switching Valve Removal/Installation…10631
Air Switching Valve Inspection…10631
Oxygen Sensor Heater (Service Code 67 (Equipped Models))…10632
Oxygen Sensor Heater Removal/Installation…10632
Oxygen Sensor Heater Resistance Inspection…10632
Oxygen Sensor Heater Power Source Voltage Inspection…10633
Oxygen Sensor – Incorrect Output Voltage (Service Code 94 (Equipped Models))…10635
Oxygen Sensor Removal/Installation…10635
Oxygen Sensor Inspection…10635
Warning Indicator Light (LED)…10638
Light (LED) Inspection…10638
ECU…10639
ECU Identification…10639
ECU Removal…10639
ECU Installation…10640
ECU Power Supply Inspection…10640
DFI Power Source…10643
ECU Fuse Removal…10643
ECU Fuse Installation…10643
ECU Fuse Inspection…10643
ECU Main Relay Removal/Installation…10643
ECU Main Relay Inspection…10643
Fuel Line…10644
Fuel Pressure Inspection…10644
Fuel Flow Rate Inspection…10645
Fuel Pump…10647
Fuel Pump Removal…10647
Fuel Pump Installation…10648
Fuel Pump Operation Inspection…10648
Fuel Pump Operating Voltage Inspection…10649
Pressure Regulator Removal…10650
Fuel Filter Cleaning…10650
Fuel Injectors…10651
Primary Fuel Injector Removal/Installation…10651
Secondary Fuel Injector Removal/Installation…10651
Fuel Injector Audible Inspection…10651
Fuel Injector Resistance Inspection…10652
Fuel Injector Power Source Voltage Inspection…10653
Fuel Injector Output Voltage Inspection…10655
Fuel Injector Fuel Line Inspection…10657
Throttle Grip and Cables…10659
Free Play Inspection…10659
Free Play Adjustment…10659
Cable Installation…10659
Cable Lubrication…10659
Throttle Body Assy…10660
Idle Speed Inspection/Adjustment…10660
Synchronization Inspection/Adjustment…10660
Throttle Body Assy Removal…10660
Throttle Body Assy Installation…10661
Throttle Body Assy Disassembly…10662
Throttle Body Assy Assembly…10663
Nozzle Assy…10664
Nozzle Assy Removal…10664
Nozzle Assy Installation…10664
Nozzle Assy Disassembly…10665
Nozzle Assy Assembly…10665
Air Cleaner…10667
Air Cleaner Element Removal/Installation…10667
Air Cleaner Element Inspection…10667
Air Cleaner Oil Draining…10667
Air Cleaner Housing Removal…10667
Air Cleaner Housing Installation…10669
Air Cleaner Housing Disassembly…10669
Air Cleaner Housing Assembly…10670
Air Line…10671
Air Inlet Duct Removal…10671
Air Inlet Duct Installation…10671
Fuel Tank…10672
Fuel Tank Removal…10672
Fuel Tank Installation…10674
Fuel Tank Inspection…10676
Fuel Tank Cleaning…10676
Evaporative Emission Control System (CAL, SEA and TH Models)…10677
Parts Removal/Installation…10677
Hose Inspection…10677
Separator Inspection…10677
Separator Operation Test…10678
Canister Inspection …10678
Cooling System…10680
Exploded View…10681
Coolant Flow Chart…10683
Specifications…10685
Special Tools…10686
Coolant…10687
Coolant Deterioration Inspection…10687
Coolant Level Inspection…10687
Coolant Draining…10687
Coolant Filling…10687
Pressure Testing…10687
Cooling System Flushing…10688
Coolant Reserve Tank Removal…10688
Coolant Reserve Tank Installation…10688
Water Pump…10689
Water Pump Removal…10689
Water Pump Installation…10689
Water Pump Inspection…10689
Water Pump Impeller Disassembly/Assembly…10689
Water Pump Impeller Inspection…10689
Water Pump Housing Disassembly…10689
Water Pump Housing Assembly…10690
Mechanical Seal Inspection…10690
Radiator…10691
Radiator and Radiator Fan Removal…10691
Radiator and Radiator Fan Installation…10692
Radiator Inspection…10692
Radiator Cap Inspection…10693
Radiator Filler Neck Inspection…10693
Thermostat…10694
Thermostat Removal…10694
Thermostat Installation…10694
Thermostat Inspection…10694
Hoses and Pipes…10696
Hose Installation…10696
Hose Inspection…10696
Water Temperature Sensor…10697
Water Temperature Sensor Removal/Installation…10697
Water Temperature Sensor Inspection…10697
Engine Top End…10698
Exploded View…10699
Exhaust System Identification…10703
Specifications…10705
Special Tools and Sealant…10706
Clean Air System…10708
Air Suction Valve Removal…10708
Air Suction Valve Installation…10708
Air Suction Valve Inspection…10709
Air Switching Valve Removal…10709
Air Switching Valve Installation…10709
Air Switching Valve Operation Test…10710
Air Switching Valve Unit Test…10710
Clean Air System Hose Inspection…10710
Cylinder Head Cover…10711
Cylinder Head Cover Removal…10711
Cylinder Head Cover Installation…10711
Camshaft Chain Tensioner…10713
Camshaft Chain Tensioner Removal…10713
Camshaft Chain Tensioner Installation…10714
Camshaft, Camshaft Chain…10715
Camshaft Removal…10715
Camshaft Installation…10716
Camshaft, Camshaft Cap Wear Inspection…10720
Camshaft Runout Inspection…10721
Cam Wear Inspection…10721
Camshaft Chain Removal…10721
Cylinder Head…10722
Cylinder Compression Measurement…10722
Cylinder Head Removal…10723
Cylinder Head Installation…10724
Cylinder Head Warp Inspection…10725
Valves…10726
Valve Clearance Inspection…10726
Valve Removal…10726
Valve Installation…10726
Valve Guide Removal…10726
Valve Guide Installation…10726
Valve-to-Guide Clearance Measurement (Wobble Method)…10727
Valve Seat Inspection…10728
Valve Seat Repair…10728
Throttle Body Assy Holder…10733
Throttle Body Assy Holder Removal…10733
Throttle Body Assy Holder Installation…10733
Muffler…10734
Muffler Body Removal…10734
Muffler Body Installation…10735
Premuffler Chamber Removal…10736
Premuffler Chamber Installation…10737
Exhaust Pipe Removal…10738
Exhaust Pipe Installation…10739
Exhaust Butterfly Valve Cable Removal…10740
Exhaust Butterfly Valve Cable Installation…10741
Clutch…10744
Exploded View…10745
Specifications…10747
Special Tool and Sealant…10748
Clutch Lever and Cable…10749
Clutch Lever Free Play Inspection…10749
Clutch Lever Free Play Adjustment…10749
Cable Removal…10749
Cable Installation…10749
Cable Lubrication…10749
Clutch Lever Installation…10749
Clutch Cover…10750
Clutch Cover Removal…10750
Clutch Cover Installation…10750
Release Shaft Removal…10751
Release Shaft Installation…10751
Clutch Cover Disassembly…10751
Clutch Cover Assembly…10752
Clutch…10754
Clutch Removal…10754
Clutch Installation…10755
Spring Plate Free Play Measurement…10758
Spring Plate Free Play Adjustment…10759
Clutch Plate, Wear, Damage Inspection…10760
Clutch Plate Warp Inspection…10760
Clutch Spring Free Length Measurement…10761
Clutch Housing Finger Inspection…10761
Clutch Housing Spline Inspection…10761
Damper Cam Inspection…10761
Engine Lubrication System…10762
Exploded View…10763
Engine Oil Flow Chart…10765
Specifications…10767
Special Tools and Sealant…10768
Engine Oil and Oil Filter…10769
Oil Level Inspection…10769
Engine Oil Change…10769
Oil Filter Replacement…10769
Oil Pan…10770
Oil Pan Removal…10770
Oil Pan Installation…10770
Oil Pressure Relief Valve…10771
Oil Pressure Relief Valve Removal…10771
Oil Pressure Relief Valve Installation…10771
Oil Pressure Relief Valve Inspection…10772
Oil Pump…10773
Oil Pump Removal…10773
Oil Pump Installation…10774
Oil Pump Drive Gear Removal…10775
Oil Pump Drive Gear Installation…10775
Oil Pump Drive Gear Shaft Removal…10775
Oil Pump Drive Gear Shaft Installation…10776
Oil Cooler…10777
Oil Cooler Removal…10777
Oil Cooler Installation…10777
Oil Cooler/Oil Filter Case Removal…10777
Oil Cooler/Oil Filter Case Installation…10778
Oil Pressure Measurement…10780
Oil Pressure Measurement…10780
Oil Pressure Switch…10781
Oil Pressure Switch Removal…10781
Oil Pressure Switch Installation…10781
Engine Removal/Installation…10782
Exploded View…10783
Special Tool…10785
Engine Removal/Installation…10786
Engine Removal…10786
Engine Installation…10789
Crankshaft/Transmission…10792
Exploded View…10793
Specifications…10797
Special Tools and Sealants…10800
Crankcase…10802
Crankcase Splitting…10802
Crankcase Assembly…10803
Crankshaft and Connecting Rods…10808
Crankshaft Removal…10808
Crankshaft Installation…10808
Connecting Rod Removal…10809
Connecting Rod Installation…10810
Crankshaft/Connecting Rod Cleaning…10813
Connecting Rod Bend Inspection…10813
Connecting Rod Twist Inspection…10814
Connecting Rod Big End Side Clearance Inspection…10814
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection…10814
Crankshaft Side Clearance Inspection…10816
Crankshaft Runout Inspection…10816
Crankshaft Main Bearing Insert/Journal Wear Inspection…10817
Pistons…10819
Piston Removal…10819
Piston Installation…10820
Cylinder (Upper Crankcase) Wear Inspection…10821
Piston Wear Inspection…10821
Piston Ring, Piston Ring Groove Wear Inspection…10821
Piston Ring Groove Width Inspection…10822
Piston Ring Thickness Inspection…10822
Piston Ring End Gap Inspection…10822
Starter Idle Gear and Starter Clutch…10823
Starter Idle Gear Removal…10823
Starter Idle Gear Installation…10823
Starter Clutch Removal…10825
Starter Clutch Installation …10825
Starter Clutch Disassembly…10825
Starter Clutch Assembly…10826
Starter Clutch Inspection…10826
Transmission…10828
Transmission Assy Removal…10828
Transmission Assy Disassembly…10828
Transmission Assy Assembly…10828
Transmission Assy Installation…10830
Transmission Shaft Removal…10831
Transmission Shaft Installation…10831
Transmission Shaft Disassembly…10831
Transmission Shaft Assembly…10831
Shift Drum and Fork Removal…10835
Shift Drum and Fork Installation…10835
Shift Drum Disassembly…10835
Shift Drum Assembly…10835
Shift Fork Bending Inspection…10835
Shift Fork/Gear Groove Wear Inspection…10835
Shift Fork Guide Pin/Drum Groove Wear Inspection…10836
Gear Dog and Gear Dog Hole Damage Inspection…10836
External Shift Mechanism…10837
Shift Pedal Removal…10837
Shift Pedal Installation…10837
External Shift Mechanism Removal…10838
External Shift Mechanism Installation…10838
External Shift Mechanism Inspection…10839
Wheels/Tires…10840
Exploded View…10841
Specifications…10843
Special Tools…10844
Wheels (Rims)…10845
Front Wheel Removal…10845
Front Wheel Installation…10846
Rear Wheel Removal…10847
Rear Wheel Installation…10847
Wheel Inspection…10849
Axle Inspection…10849
Balance Inspection…10850
Balance Adjustment…10850
Balance Weight Removal…10850
Balance Weight Installation…10850
Tires…10852
Air Pressure Inspection/Adjustment…10852
Tire Inspection…10852
Tire Removal…10852
Tire Installation…10852
Tire Repair…10854
Hub Bearing…10855
Hub Bearing Removal…10855
Hub Bearing Installation…10855
Hub Bearing Inspection…10855
Hub Bearing Lubrication…10856
Final Drive…10858
Exploded View …10859
Specifications …10861
Special Tools…10862
Drive Chain…10863
Drive Chain Slack Inspection…10863
Drive Chain Slack Adjustment…10863
Wheel Alignment Inspection/Adjustment…10863
Drive Chain Wear Inspection…10863
Drive Chain Lubrication…10863
Drive Chain Guide Wear Inspection…10863
Drive Chain Removal…10863
Sprocket, Coupling…10867
Engine Sprocket Removal…10867
Engine Sprocket Installation…10867
Rear Sprocket Removal…10868
Rear Sprocket Installation…10869
Coupling Installation…10869
Coupling Bearing Removal…10869
Coupling Bearing Installation…10870
Coupling Bearing Inspection…10870
Coupling Bearing Lubrication…10870
Coupling Damper Inspection…10870
Sprocket Wear Inspection…10871
Rear Sprocket Warp Inspection…10871
Brakes…10872
Exploded View …10873
Specifications …10877
Special Tools…10878
Brake Lever, Brake Pedal…10879
Brake Lever Position Adjustment…10879
Brake Pedal Position Inspection …10879
Brake Pedal Position Adjustment …10879
Brake Pedal Removal…10879
Brake Pedal Installation…10880
Calipers…10882
Front Caliper Removal…10882
Rear Caliper Removal…10882
Caliper Installation…10883
Front Caliper Disassembly…10883
Front Caliper Assembly…10883
Rear Caliper Disassembly…10883
Rear Caliper Assembly…10883
Caliper Fluid Seal Damage Inspection…10884
Caliper Dust Seal Damage Inspection…10884
Rear Caliper Dust Boot and Friction Boot Damage Inspection…10884
Caliper Piston and Cylinder Damage Inspection…10885
Rear Caliper Holder Shaft Wear Inspection…10885
Brake Pads…10886
Front Brake Pad Removal…10886
Front Brake Pad Installation…10886
Rear Brake Pad Removal …10887
Rear Brake Pad Installation…10887
Brake Pad Wear Inspection…10887
Master Cylinder…10888
Front Master Cylinder Removal…10888
Front Master Cylinder Installation…10888
Rear Master Cylinder Removal…10889
Rear Master Cylinder Installation…10890
Front Master Cylinder Disassembly…10890
Rear Master Cylinder Disassembly…10891
Master Cylinder Assembly…10891
Master Cylinder Inspection (Visual Inspection)…10891
Brake Disc…10892
Brake Disc Removal…10892
Brake Disc Installation…10892
Brake Disc Wear Inspection…10892
Brake Disc Warp Inspection…10893
Brake Fluid…10894
Brake Fluid Level Inspection…10894
Brake Fluid Change…10894
Brake Line Bleeding…10894
Brake Hose…10899
Brake Hose Removal/Installation…10899
Brake Hose Inspection…10899
Suspension…10900
Exploded View…10901
Specifications…10905
Special Tools…10906
Front Fork…10908
Rebound Damping Force Adjustment…10908
Compression Damping Force Adjustment…10908
Spring Preload Adjustment…10909
Front Fork Removal (Each Fork Leg)…10909
Front Fork Installation (Each Fork Leg)…10910
Front Fork Oil Change…10910
Front Fork Disassembly…10913
Front Fork Assembly…10914
Inner Tube Inspection…10915
Dust Seal Inspection…10915
Spring Tension Inspection…10915
Rear Shock Absorber…10916
Rebound Damping Force Adjustment…10916
Compression Damping Force Adjustment…10916
Spring Preload Adjustment…10917
Rear Shock Absorber Removal…10918
Rear Shock Absorber Installation…10919
Rear Shock Absorber Inspection…10919
Rear Shock Absorber Scrapping…10919
Swingarm…10920
Swingarm Removal…10920
Swingarm Installation…10920
Swingarm Bearing Removal…10921
Swingarm Bearing Installation…10922
Swingarm Bearing, Sleeve Inspection…10923
Swingarm Bearing Lubrication…10923
Tie-Rod, Rocker Arm…10924
Tie-Rod Removal…10924
Tie-Rod Installation…10924
Rocker Arm Removal…10924
Rocker Arm Installation…10925
Tie-Rod and Rocker Arm Bearing Removal…10925
Tie-Rod and Rocker Arm Bearing Installation…10926
Tie-Rod/Rocker Arm Bearing, Sleeve Inspection…10927
Tie-Rod/Rocker Arm Bearing Lubrication…10927
Steering…10928
Exploded View…10929
Specifications…10931
Special Tools…10932
Steering…10933
Steering Inspection…10933
Steering Adjustment…10933
Steering Damper…10934
Damping Force Adjustment…10934
Steering Damper Removal…10934
Steering Damper Installation…10934
Steering Damper Oil Leak Inspection…10934
Steering Stem…10935
Stem, Stem Bearing Removal…10935
Stem, Stem Bearing Installation…10936
Steering Stem Bearing Lubrication…10938
Steering Stem Warp Inspection…10938
Stem Cap Deterioration, Damage Inspection…10938
Handlebar…10939
Handlebar Removal…10939
Handlebar Installation…10940
Frame…10942
Exploded View…10943
Seats…10949
Front Seat Removal…10949
Front Seat Installation…10949
Rear Seat Removal…10949
Rear Seat Installation…10949
Fairings…10950
Lower Fairing Removal…10950
Lower Fairing Installation…10950
Lower Inner Fairing Removal…10950
Lower Inner Fairing Installation…10951
Upper Fairing Assembly Removal…10951
Upper Fairing Assembly Installation…10952
Center Fairing Removal…10952
Center Fairing Installation…10953
Upper Fairing Removal…10953
Upper Fairing Installation…10953
Upper Center Fairing Removal…10953
Upper Center Fairing Installation…10954
Upper Inner Fairing Removal…10954
Upper Inner Fairing Installation…10954
Center Inner Fairing Removal…10955
Center Inner Fairing Installation…10955
Inner Fairing Removal…10955
Inner Fairing Installation…10955
Fairing Cover Removal…10956
Fairing Cover Installation…10956
Side Covers…10957
Side Cover Removal…10957
Side Cover Installation…10957
Seat Covers…10958
Seat Cover Removal…10958
Seat Cover Installation…10959
Upper Seat Cover Removal (Only on Ninja ZX-6R MONSTER ENERGY® Model)…10960
Upper Seat Cover Installation (Only on Ninja ZX-6R MONSTER ENERGY® Model)…10960
Fenders…10961
Front Fender Removal…10961
Front Fender Installation…10961
Flap and Rear Fender Removal…10961
Flap and Rear Fender Installation…10962
Frame…10963
Rear Frame Rear Removal…10963
Rear Frame Rear Installation…10963
Rear Frame Front Removal…10963
Rear Frame Front Installation…10963
Frame Inspection…10963
Windshield…10964
Windshield Removal…10964
Windshield Installation…10964
Guard…10965
Mud Guard Removal…10965
Mud Guard Installation…10965
Sidestand…10966
Sidestand Removal…10966
Sidestand Installation…10966
Electrical System…10968
Exploded View…10971
Specifications…10977
Special Tools and Sealant…10978
Parts Location…10979
Wiring Diagram (US, CAL and CA Models)…10981
Wiring Diagram (Other than US, CAL and CA Models)…10983
Precautions…10985
Electrical Wiring…10986
Wiring Inspection…10986
Battery…10987
Battery Removal…10987
Battery Installation…10987
Battery Activation…10987
Precautions…10991
Interchange…10991
Charging Condition Inspection…10991
Refreshing Charge…10992
Charging System…10993
Alternator Cover Removal…10993
Alternator Cover Installation…10993
Stator Coil Removal…10993
Stator Coil Installation…10994
Alternator Rotor Removal…10994
Alternator Rotor Installation…10994
Charging Voltage Inspection…10996
Alternator Inspection…10996
Regulator/Rectifier Inspection…10998
Ignition System…11000
Crankshaft Sensor Removal…11000
Crankshaft Sensor Installation…11000
Crankshaft Sensor Inspection…11001
Crankshaft Sensor Peak Voltage Inspection…11001
Stick Coil Removal…11002
Stick Coil Installation…11002
Stick Coil Inspection…11002
Stick Coil Primary Peak Voltage Inspection…11003
Spark Plug Removal…11003
Spark Plug Installation…11003
Spark Plug Condition Inspection…11004
Interlock Operation Inspection…11004
IC Igniter Inspection…11005
Electric Starter System…11008
Starter Motor Removal…11008
Starter Motor Installation…11008
Starter Motor Disassembly…11009
Starter Motor Assembly…11009
Brush Inspection…11010
Commutator Cleaning and Inspection…11011
Armature Inspection…11011
Brush Lead Inspection…11011
Right-hand End Cover Assembly Inspection…11012
Starter Relay Inspection…11012
Lighting System…11014
Headlight Beam Horizontal Adjustment…11014
Headlight Beam Vertical Adjustment…11014
Headlight Bulb Replacement…11014
City Light Bulb Replacement…11015
Headlight Removal/Installation…11015
Tail/Brake Light (LED) Removal/Installation…11016
License Plate Light Bulb Replacement…11016
Turn Signal Light Bulb Replacement…11018
Turn Signal Relay Inspection…11019
Air Switching Valve…11022
Air Switching Valve Operation Test…11022
Air Switching Valve Unit Test…11022
Radiator Fan System…11024
Fan Motor Inspection…11024
Meter, Gauge, Indicator Unit…11025
Meter Unit Removal/Installation…11025
Meter Unit Disassembly…11025
Electronic Unit (Combination Meter) Inspection…11026
Immobilizer System (Equipped Models)…11037
Operational Cautions…11037
Key Registration…11037
Immobilizer System Parts Replacement…11053
Immobilizer System Inspection…11054
Switches and Sensors…11056
Brake Light Timing Inspection…11056
Brake Light Timing Adjustment…11056
Switch Inspection…11056
Water Temperature Sensor Inspection…11057
Speed Sensor Removal…11057
Speed Sensor Installation…11058
Speed Sensor Inspection…11058
Fuel Reserve Switch Inspection…11058
Oxygen Sensor Removal (Equipped Models)…11059
Oxygen Sensor Installation (Equipped Models)…11060
Oxygen Sensor Inspection (Equipped Models)…11060
Oxygen Sensor Heater Inspection (Equipped Models)…11060
Gear Position Switch Removal…11060
Gear Position Switch Installation…11061
Gear Position Switch Inspection…11061
Relay Box…11063
Relay Box Removal…11063
Relay Circuit Inspection…11063
Diode Circuit Inspection…11064
Fuse…11065
30 A Main Fuse Removal…11065
Fuse Box Fuse Removal…11065
10 A ECU Fuse Removal…11065
Fuse Installation…11066
Fuse Inspection…11066
Appendix…11068
Cable, Wire, and Hose Routing…11069
Troubleshooting Guide…11115
Kawasaki Motorcycle Service Repair Manual '11 ZX-10R (EN)…11121
General Information…11129
Before Servicing…11130
Model Identification…11135
General Specifications…11139
Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC)…11142
Technical Information-Power Mode…11145
Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)…11147
Unit Conversion Table…11151
Periodic Maintenance…11153
Periodic Maintenance Chart…11155
Torque and Locking Agent…11158
Specifications…11164
Special Tools…11166
Periodic Maintenance Procedures…11167
Fuel System (DFI)…11167
Throttle Control System Inspection…11167
Engine Vacuum Synchronization Inspection…11167
Idle Speed Inspection…11171
Idle Speed Adjustment…11172
Fuel Hose Inspection (fuel leak, damage, installation condition)…11172
Evaporative Emission Control System Inspection (CAL and SEA Models)…11173
Cooling System…11174
Coolant Level Inspection…11174
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)…11174
Engine Top End…11175
Valve Clearance Inspection…11175
Valve Clearance Adjustment…11176
Air Suction System Damage Inspection…11178
Clutch…11179
Clutch Operation Inspection …11179
Wheels/Tires…11180
Tire Air Pressure Inspection…11180
Wheel/Tire Damage Inspection…11180
Tire Tread Wear Inspection …11181
Wheel Bearing Damage Inspection…11181
Final Drive…11182
Drive Chain Lubrication Condition Inspection…11182
Drive Chain Slack Inspection…11183
Drive Chain Slack Adjustment…11183
Wheel Alignment Inspection…11184
Drive Chain Wear Inspection…11184
Chain Guide Wear Inspection…11185
Brakes…11185
Brake Fluid Leak (Brake Hose and Pipe) Inspection…11185
Brake Hose and Pipe Damage and Installation Condition Inspection…11186
Brake Fluid Level Inspection…11186
Brake Pad Wear Inspection…11187
Brake Operation Inspection…11187
Brake Light Switch Operation Inspection…11187
Suspension…11188
Front Forks/Rear Shock Absorber Operation Inspection…11188
Front Fork Oil Leak Inspection…11189
Rear Shock Absorber Oil Leak Inspection…11189
Rocker Arm Operation Inspection…11189
Tie-Rod Operation Inspection…11189
Steering…11190
Steering Play Inspection…11190
Steering Play Adjustment…11190
Steering Stem Bearing Lubrication…11191
Steering Damper Oil Leak Inspection…11192
Electrical System…11193
Lights and Switches Operation Inspection…11193
Headlight Aiming Inspection…11195
Headlight Aiming Adjustment…11195
Sidestand Switch Operation Inspection…11196
Engine Stop Switch Operation Inspection…11197
Others…11198
Chassis Parts Lubrication …11198
Bolts, Nuts and Fasteners Tightness Inspection…11199
Replacement Parts…11201
Air Cleaner Element Replacement…11201
Fuel Hose Replacement…11201
Coolant Change…11204
Radiator Hose and O-ring Replacement…11206
Engine Oil Change…11207
Oil Filter Replacement…11208
Brake Hose and Pipe Replacement…11209
Brake Fluid Change…11212
Master Cylinder Rubber Parts Replacement…11213
Caliper Rubber Parts Replacement…11215
Spark Plug Replacement…11219
Fuel System (DFI)…11221
Exploded View…11223
DFI System…11230
DFI Parts Location…11240
Specifications…11243
Special Tools and Sealant…11244
DFI Servicing Precautions…11245
DFI Servicing Precautions…11245
Troubleshooting the DFI System…11247
Outline…11247
Inquiries to Rider…11251
DFI System Troubleshooting Guide…11254
Warning Indicator Light (LED)…11259
Light (LED) Inspection…11259
ECU…11260
ECU Identification…11260
ECU Removal…11260
ECU Installation…11260
ECU Power Supply Inspection…11261
CAN Communication Line…11264
CAN Communication Line Resistance Inspection…11264
DFI Power Source…11266
ECU Fuse Removal…11266
ECU Fuse Installation…11266
ECU Fuse Inspection…11266
ECU Main Relay Removal/Installation…11266
ECU Main Relay Inspection…11266
Fuel Line…11267
Fuel Pressure Inspection…11267
Fuel Flow Rate Inspection…11268
Fuel Pump…11270
Fuel Pump Removal…11270
Fuel Pump Installation…11271
Fuel Pump Operation Inspection…11271
Fuel Pump Operating Voltage Inspection…11271
Pressure Regulator Removal…11272
Fuel Filter Cleaning…11273
Fuel Injectors…11274
Primary Fuel Injector Removal/Installation…11274
Secondary Fuel Injector Removal/Installation…11274
Fuel Injector Audible Inspection…11274
Fuel Injector Resistance Inspection…11275
Fuel Injector Power Source Voltage Inspection…11276
Fuel Injector Output Voltage Inspection…11278
Fuel Injector Fuel Line Inspection…11280
Throttle Grip and Cables…11282
Free Play Inspection…11282
Free Play Adjustment…11282
Cable Installation…11282
Cable Lubrication…11282
Throttle Body Assy…11283
Idle Speed Inspection…11283
Synchronization Inspection/Adjustment…11283
Throttle Body Assy Removal…11283
Throttle Body Assy Installation…11284
Throttle Body Assy Disassembly…11285
Throttle Body Assy Assembly…11286
Nozzle Assy…11288
Nozzle Assy Removal…11288
Nozzle Assy Installation…11288
Nozzle Assy Disassembly…11288
Nozzle Assy Assembly…11289
Air Cleaner…11290
Air Cleaner Element Removal/Installation…11290
Air Cleaner Element Inspection…11290
Air Cleaner Oil Draining…11290
Air Cleaner Housing Removal…11290
Air Cleaner Housing Installation…11291
Air Cleaner Housing Disassembly…11292
Air Cleaner Housing Assembly…11292
Air Line…11294
Air Intake Duct Removal…11294
Air Intake Duct Installation…11294
Air Intake Duct Disassembly…11294
Air Intake Duct Assembly…11295
Air Intake Duct Disassembly (Other than US, CA and CAL Models)…11295
Air Intake Duct Assembly (Other than US, CA and CAL Models)…11296
Air Intake Solenoid Valve Removal (Other than US, CA and CAL Models)…11297
Air Intake Solenoid Valve Installation (Other than US, CA and CAL Models)…11297
Air Intake Solenoid Valve Unit Test (Other than US, CA and CAL Models)…11297
Vacuum Chamber Removal (Other than US, CA and CAL Models)…11298
Vacuum Chamber Installation (Other than US, CA and CAL Models)…11298
Fuel Tank…11299
Fuel Tank Removal…11299
Fuel Tank Installation…11302
Fuel Tank and Cap Inspection…11304
Fuel Tank Cleaning…11304
Evaporative Emission Control System (CAL and SEA Models)…11305
Parts Removal/Installation…11305
Hose Inspection…11305
Separator Inspection…11305
Separator Operation Test…11306
Canister Inspection …11307
Cooling System…11309
Exploded View…11310
Coolant Flow Chart…11312
Specifications…11314
Special Tools…11315
Coolant…11316
Coolant Deterioration Inspection…11316
Coolant Level Inspection…11316
Coolant Draining…11316
Coolant Filling…11316
Pressure Testing…11316
Cooling System Flushing…11317
Coolant Reserve Tank Removal…11317
Coolant Reserve Tank Installation…11317
Water Pump…11318
Water Pump Removal…11318
Water Pump Installation…11318
Water Pump Inspection…11318
Water Pump Impeller Disassembly/Assembly…11318
Water Pump Impeller Inspection…11318
Water Pump Housing Disassembly…11318
Water Pump Housing Assembly…11319
Mechanical Seal Inspection…11319
Radiator…11320
Radiator and Radiator Fan Removal…11320
Radiator and Radiator Fan Installation…11321
Radiator Inspection…11321
Radiator Cap Inspection…11322
Radiator Filler Neck Inspection…11322
Thermostat…11323
Thermostat Removal…11323
Thermostat Installation…11323
Thermostat Inspection…11324
Hoses and Pipes…11325
Hose Installation…11325
Hose Inspection…11325
Water Temperature Sensor…11326
Water Temperature Sensor Removal/Installation…11326
Water Temperature Sensor Inspection…11326
Engine Top End…11327
Exploded View…11328
Exhaust System Identification…11332
Specifications…11334
Special Tools and Sealant…11335
Clean Air System…11337
Air Suction Valve Removal…11337
Air Suction Valve Installation…11337
Air Suction Valve Inspection…11338
Air Switching Valve Removal…11338
Air Switching Valve Installation…11338
Air Switching Valve Operation Test…11339
Air Switching Valve Unit Test…11339
Clean Air System Hose Inspection…11339
Cylinder Head Cover…11340
Cylinder Head Cover Removal…11340
Cylinder Head Cover Installation…11340
Camshaft Chain Tensioner…11342
Camshaft Chain Tensioner Removal…11342
Camshaft Chain Tensioner Installation…11343
Camshaft, Camshaft Chain…11344
Camshaft Removal…11344
Camshaft Installation…11345
Camshaft, Camshaft Cap Wear Inspection…11347
Camshaft Runout Inspection…11348
Cam Wear Inspection…11348
Camshaft Chain Removal…11348
Camshaft Chain Installation…11349
Cylinder Head…11350
Cylinder Compression Measurement…11350
Cylinder Head Removal…11350
Cylinder Head Installation…11351
Cylinder Head Warp Inspection…11352
Valves…11353
Valve Clearance Inspection…11353
Valve Removal…11353
Valve Installation…11353
Valve Guide Removal…11353
Valve Guide Installation…11354
Valve-to-Guide Clearance Measurement (Wobble Method)…11354
Valve Seat Inspection…11355
Valve Seat Repair…11355
Throttle Body Assy Holder…11360
Throttle Body Assy Holder Removal…11360
Throttle Body Assy Holder Installation…11360
Muffler…11361
Muffler Body Removal…11361
Muffler Body Installation…11361
Premuffler Chamber Removal…11362
Premuffler Chamber Installation…11363
Exhaust Pipe Removal…11364
Exhaust Pipe Installation…11364
Exhaust Butterfly Valve Cable Removal…11365
Exhaust Butterfly Valve Cable Installation…11367
Clutch…11369
Exploded View…11370
Specifications…11372
Special Tool and Sealant…11373
Clutch Lever and Cable…11374
Clutch Lever Free Play Inspection…11374
Clutch Lever Free Play Adjustment…11374
Cable Removal…11374
Cable Installation…11374
Cable Lubrication…11374
Clutch Lever Installation…11374
Clutch Cover…11375
Clutch Cover Removal…11375
Clutch Cover Installation…11375
Release Shaft Removal…11376
Release Shaft Installation…11376
Clutch Cover Disassembly…11376
Clutch Cover Assembly…11377
Clutch…11378
Clutch Removal…11378
Clutch Installation…11379
Spring Plate Free Play Measurement…11382
Spring Plate Free Play Adjustment…11383
Clutch Plate, Wear, Damage Inspection…11384
Clutch Plate Warp Inspection…11384
Clutch Spring Free Length Measurement…11385
Clutch Housing Finger Inspection…11385
Clutch Housing Spline Inspection…11385
Damper Cam Inspection…11385
Engine Lubrication System…11387
Exploded View…11388
Engine Oil Flow Chart…11390
Specifications…11391
Special Tools and Sealant…11392
Engine Oil and Oil Filter…11393
Oil Level Inspection…11393
Engine Oil Change…11393
Oil Filter Replacement…11393
Oil Pan…11394
Oil Pan Removal…11394
Oil Pan Installation…11394
Oil Pressure Relief Valve…11396
Oil Pressure Relief Valve Removal…11396
Oil Pressure Relief Valve Installation…11396
Oil Pressure Relief Valve Inspection…11396
Oil Pump…11397
Oil Pump Removal…11397
Oil Pump Installation…11397
Oil Pump Drive Gear Removal/Installation…11398
Oil Pump Drive Gear Installation…11399
Oil Pump Drive Gear Shaft Removal…11399
Oil Pump Drive Gear Shaft Installation…11399
Oil Cooler…11400
Oil Cooler Removal…11400
Oil Cooler Installation…11400
Oil Pressure Measurement…11401
Oil Pressure Measurement…11401
Oil Pressure Switch…11402
Oil Pressure Switch Removal…11402
Oil Pressure Switch Installation…11402
Engine Removal/Installation…11403
Exploded View…11404
Special Tool…11406
Engine Removal/Installation…11407
Engine Removal…11407
Engine Installation…11410
Crankshaft/Transmission…11413
Exploded View…11414
Specifications…11418
Special Tools and Sealants…11421
Crankcase…11422
Crankcase Splitting…11422
Crankcase Assembly…11423
Crankshaft and Connecting Rods…11429
Crankshaft Removal…11429
Crankshaft Installation…11429
Connecting Rod Removal…11430
Connecting Rod Installation…11430
Crankshaft/Connecting Rod Cleaning…11433
Connecting Rod Bend Inspection…11434
Connecting Rod Twist Inspection…11434
Connecting Rod Big End Side Clearance Inspection…11434
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection…11435
Crankshaft Side Clearance Inspection…11436
Crankshaft Runout Inspection…11437
Crankshaft Main Bearing Insert/Journal Wear Inspection…11437
Pistons…11439
Piston Removal…11439
Piston Installation…11440
Cylinder (Upper Crankcase) Wear Inspection…11441
Piston Wear Inspection…11441
Piston Ring, Piston Ring Groove Wear Inspection…11442
Piston Ring Groove Width Inspection…11442
Piston Ring Thickness Inspection…11442
Piston Ring End Gap Inspection…11443
Balancer…11444
Balancer Removal…11444
Balancer Assemble…11444
Balancer Installation…11445
Balancer Adjustment…11445
Balancer Damper Inspection…11445
Torque Limiter…11446
Torque Limiter Removal…11446
Torque Limiter Installation…11446
Starter Clutch…11448
Starter Clutch Removal…11448
Starter Clutch Installation…11448
Starter Clutch Disassembly…11448
Starter Clutch Assembly…11449
Starter Clutch Inspection…11449
Transmission…11450
Transmission Assy Removal…11450
Transmission Assy Disassembly…11450
Transmission Assy Assembly…11451
Transmission Assy Installation…11452
Transmission Shaft Removal…11453
Transmission Shaft Installation…11453
Transmission Shaft Disassembly…11453
Transmission Shaft Assembly…11453
Shift Drum and Fork Removal…11456
Shift Drum and Fork Installation…11456
Shift Drum Disassembly…11456
Shift Drum Assembly…11456
Shift Fork Bending Inspection…11456
Shift Fork/Gear Groove Wear Inspection…11456
Shift Fork Guide Pin/Drum Groove Wear Inspection…11457
Gear Dog and Gear Dog Hole Damage Inspection…11457
External Shift Mechanism…11458
Shift Pedal Removal…11458
Shift Pedal Installation…11458
External Shift Mechanism Removal…11459
External Shift Mechanism Installation…11459
External Shift Mechanism Inspection…11461
Wheels/Tires…11463
Exploded View…11464
Specifications…11466
Special Tools…11467
Wheels (Rims)…11468
Front Wheel Removal…11468
Front Wheel Installation…11469
Rear Wheel Removal…11470
Rear Wheel Installation…11470
Wheel Inspection…11472
Axle Inspection…11472
Balance Inspection…11473
Balance Adjustment…11473
Balance Weight Removal…11473
Balance Weight Installation…11474
Tires…11475
Air Pressure Inspection/Adjustment…11475
Tire Inspection…11475
Tire Removal…11475
Tire Installation…11475
Tire Repair…11477
Hub Bearing…11478
Hub Bearing Removal…11478
Hub Bearing Installation…11478
Hub Bearing Inspection…11478
Hub Bearing Lubrication…11479
Final Drive…11481
Exploded View …11482
Specifications …11484
Special Tools…11485
Drive Chain…11486
Drive Chain Slack Inspection…11486
Drive Chain Slack Adjustment…11486
Wheel Alignment Inspection/Adjustment…11486
Drive Chain Wear Inspection…11486
Drive Chain Lubrication…11486
Drive Chain Guide Wear Inspection…11486
Drive Chain Removal…11486
Sprocket, Coupling…11490
Engine Sprocket Removal…11490
Engine Sprocket Installation…11490
Rear Sprocket Removal…11491
Rear Sprocket Installation…11491
Coupling Installation…11491
Coupling Bearing Removal…11492
Coupling Bearing Installation…11492
Coupling Bearing Inspection…11493
Coupling Bearing Lubrication…11493
Coupling Damper Inspection…11493
Sprocket Wear Inspection…11493
Rear Sprocket Warp Inspection…11493
Brakes…11495
Exploded View …11496
Specifications …11504
Special Tools…11505
Brake Lever, Brake Pedal…11506
Brake Lever Position Adjustment…11506
Brake Pedal Position Inspection …11506
Brake Pedal Position Adjustment …11506
Brake Pedal Removal…11506
Brake Pedal Installation…11507
Calipers…11509
Front Caliper Removal…11509
Rear Caliper Removal…11509
Caliper Installation…11510
Front Caliper Disassembly…11510
Front Caliper Assembly…11510
Rear Caliper Disassembly…11510
Rear Caliper Assembly…11510
Caliper Fluid Seal Damage…11511
Rear Caliper Dust Boot and Friction Boot Damage…11511
Caliper Piston and Cylinder Damage…11511
Rear Caliper Holder Shaft Wear…11512
Brake Pads…11513
Front Brake Pad Removal…11513
Front Brake Pad Installation…11513
Rear Brake Pad Removal …11513
Rear Brake Pad Installation…11514
Brake Pad Wear Inspection…11514
Master Cylinder…11515
Front Master Cylinder Removal…11515
Front Master Cylinder Installation…11515
Rear Master Cylinder Removal…11516
Rear Master Cylinder Installation…11517
Front Master Cylinder Disassembly…11517
Rear Master Cylinder Disassembly…11517
Master Cylinder Assembly…11517
Master Cylinder Inspection (Visual Inspection)…11518
Brake Disc…11519
Brake Disc Removal…11519
Brake Disc Installation…11519
Brake Disc Wear Inspection…11519
Brake Disc Warp Inspection…11520
Brake Fluid…11521
Brake Fluid Level Inspection…11521
Brake Fluid Change…11521
Brake Line Bleeding…11521
Brake Hose…11525
Brake Hose Removal/Installation…11525
Brake Hose Inspection…11525
KIBS (Equipped Models)…11526
Parts Location…11526
KIBS Servicing Precautions…11529
KIBS Troubleshooting Outline…11531
Inquiries to Rider…11534
Self-diagnosis Outline…11536
ABS and KIBS Indicator Lights (LED) Inspection…11537
KIBS Hydraulic Unit Removal…11537
KIBS Hydraulic Unit Installation…11539
KIBS Hydraulic Unit Inspection…11539
Front Wheel Rotation Sensor Removal…11540
Front Wheel Rotation Sensor Installation…11540
Rear Wheel Rotation Sensor Removal…11541
Rear Wheel Rotation Sensor Installation…11541
Wheel Rotation Sensor Inspection…11542
Wheel Rotation Sensor Air Gap Inspection…11542
Wheel Rotation Sensor Rotor Inspection…11542
KIBS Solenoid Valve Relay Fuse (20 A) Removal…11543
KIBS Motor Relay Fuse (30 A) Removal…11543
Fuse Installation…11543
Fuse Inspection…11543
Suspension…11545
Exploded View…11546
Specifications…11550
Special Tools…11551
Front Fork…11553
Rebound Damping Force Adjustment…11553
Compression Damping Force Adjustment…11553
Spring Preload Adjustment…11554
Front Fork Removal (Each Fork Leg)…11554
Front Fork Installation (Each Fork Leg)…11555
Front Fork Oil Change…11556
Front Fork Disassembly…11560
Front Fork Assembly…11560
Inner Tube Inspection…11561
Dust Seal Inspection…11562
Spring Tension Inspection…11562
Rear Shock Absorber…11563
Rebound Damping Force Adjustment…11563
Compression Damping Force Adjustment…11563
Spring Preload Adjustment…11564
Rear Shock Absorber Removal…11565
Rear Shock Absorber Installation…11566
Rear Shock Absorber Inspection…11566
Rear Shock Absorber Scrapping…11566
Swingarm…11567
Swingarm Removal…11567
Swingarm Installation…11568
Swingarm Bearing Removal…11569
Swingarm Bearing Installation…11569
Swingarm Bearing, Sleeve Inspection…11570
Swingarm Bearing Lubrication…11571
Tie-Rod, Rocker Arm…11572
Tie-Rod Removal…11572
Tie-Rod Installation…11572
Rocker Arm Removal…11572
Rocker Arm Installation…11573
Tie-Rod and Rocker Arm Bearing Removal…11573
Tie-Rod and Rocker Arm Bearing Installation…11574
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection…11575
Rocker Arm/Tie-Rod Bearing Lubrication…11575
Steering…11577
Exploded View…11578
Specifications…11580
Special Tools…11581
Steering…11582
Steering Inspection…11582
Steering Adjustment…11582
Steering Damper…11583
Damping Force Adjustment…11583
Steering Damper Removal…11583
Steering Damper Installation…11583
Steering Damper Oil Leak Inspection…11583
Steering Stem…11584
Stem, Stem Bearing Removal…11584
Stem, Stem Bearing Installation…11585
Steering Stem Bearing Lubrication…11587
Steering Stem Warp Inspection…11587
Stem Cap Deterioration, Damage Inspection…11587
Handlebar…11588
Handlebar Removal…11588
Handlebar Installation…11589
Frame…11591
Exploded View…11592
Seats…11598
Front Seat Removal…11598
Front Seat Installation…11598
Rear Seat Removal…11598
Rear Seat Installation…11598
Fairings…11599
Lower Fairing Removal…11599
Lower Fairing Installation…11599
Upper Fairing Assembly Removal…11599
Upper Fairing Assembly Installation…11600
Upper Fairing Assembly Disassembly…11601
Upper Inner Fairing Removal…11601
Upper Inner Fairing Installation…11601
Center Inner Fairing Removal…11601
Center Inner Fairing Installation…11602
Seat Covers…11603
Seat Cover Removal…11603
Seat Cover Installation…11603
Fenders…11604
Front Fender Removal…11604
Front Fender Installation…11604
Flap and Rear Fender Rear Removal…11604
Flap and Rear Fender Rear Installation…11605
Rear Fender Front Removal…11606
Rear Fender Front Installation…11606
Frame…11607
Rear Frame Rear Removal…11607
Rear Frame Rear Installation…11607
Rear Frame Front Removal…11607
Rear Frame Front Installation…11607
Frame Inspection…11607
Windshield…11608
Windshield Removal…11608
Windshield Installation…11608
Guard…11609
Mud Guard Removal…11609
Mud Guard Installation…11609
Sidestand…11610
Sidestand Removal…11610
Sidestand Installation…11610
Footpeg…11611
Footpeg Height Adjustment…11611
Electrical System…11613
Exploded View…11616
Specifications…11622
Special Tools and Sealant…11623
Parts Location…11624
Wiring Diagram (US, CA and CAL without KIBS Models)…11627
Wiring Diagram (US, CA and CAL with KIBS Models)…11630
Wiring Diagram (Other than US, CA and CAL without KIBS Models)…11632
Wiring Diagram (Other than US, CA and CAL with KIBS Models)…11634
Precautions…11636
Electrical Wiring…11637
Wiring Inspection…11637
Battery…11638
Battery Removal…11638
Battery Installation…11638
Precautions…11638
Interchange…11639
Charging Condition Inspection…11639
Refreshing Charge…11640
Charging System…11642
Alternator Cover Removal…11642
Alternator Cover Installation…11642
Stator Coil Removal…11642
Stator Coil Installation…11643
Alternator Rotor Removal…11643
Alternator Rotor Installation…11643
Charging Voltage Inspection…11645
Alternator Inspection…11645
Regulator/Rectifier Inspection…11647
Ignition System…11649
Crankshaft Sensor Removal…11649
Crankshaft Sensor Installation…11650
Crankshaft Sensor Inspection…11650
Crankshaft Sensor Peak Voltage Inspection…11651
Stick Coil Removal…11651
Stick Coil Installation…11652
Stick Coil Inspection…11652
Stick Coil Primary Peak Voltage Inspection…11653
Spark Plug Removal…11653
Spark Plug Installation…11653
Spark Plug Condition Inspection…11654
Interlock Operation Inspection…11654
IC Igniter Inspection…11655
Electric Starter System…11658
Starter Motor Removal…11658
Starter Motor Installation…11658
Starter Motor Disassembly…11659
Starter Motor Assembly…11659
Brush Inspection…11661
Commutator Cleaning and Inspection…11661
Armature Inspection…11661
Brush Lead Inspection…11662
Right-hand End Cover Inspection…11662
Starter Relay Inspection…11662
Lighting System…11664
Headlight Beam Horizontal Adjustment…11664
Headlight Beam Vertical Adjustment…11664
Headlight Bulb Replacement…11664
Headlight Removal/Installation…11665
City Light (LED) Removal/Installation…11665
Tail/Brake Light (LED) Removal/Installation…11665
License Plate Light Bulb Replacement…11666
Rear Turn Signal Light Bulb Replacement…11668
Turn Signal Relay Inspection…11669
Air Switching Valve…11672
Air Switching Valve Operation Test…11672
Air Switching Valve Unit Test…11672
Air Intake Solenoid Valve…11674
Air Intake Solenoid Valve Operation Test…11674
Air Intake Solenoid Valve Unit Test…11674
Radiator Fan System…11676
Fan Motor Inspection…11676
Meter, Gauge, Indicator Unit…11677
Meter Unit Removal/Installation…11677
Meter Unit Disassembly…11677
Meter Operation Inspection…11678
Meter System Inspection…11681
Meter Unit Inspection…11683
Immobilizer System (Equipped Models)…11689
Operational Cautions…11689
Key Registration…11689
Immobilizer System Parts Replacement…11707
Immobilizer System Inspection…11708
Switches and Sensors…11710
Brake Light Timing Inspection…11710
Brake Light Timing Adjustment…11710
Switch Inspection…11710
Water Temperature Sensor Inspection…11711
Fuel Reserve Switch Inspection…11711
Oxygen Sensor Removal (Equipped Models)…11712
Oxygen Sensor Installation (Equipped Models)…11712
Oxygen Sensor Inspection (Equipped Models)…11713
Oxygen Sensor Heater Inspection (Equipped Models)…11713
Gear Position Switch Removal…11713
Gear Position Switch Installation…11713
Gear Position Switch Inspection…11714
Relay Box…11715
Relay Box Removal…11715
Relay Circuit Inspection…11715
Diode Circuit Inspection…11716
Fuse…11717
30 A Main/15 A ECU Fuse Removal…11717
Fuse Box Fuse Removal…11717
Fuse Installation…11718
Fuse Inspection…11718
Self-Diagnosis System…11719
Specifications…11722
Special Tools…11724
Self-Diagnosis…11725
Self-Diagnosis Outline…11725
Self-Diagnosis Procedures…11726
Self-Diagnosis Flow Chart…11728
Service Code Reading…11729
Service Code Erasing…11729
Backups…11731
Main Throttle Sensor (Service Code 11)…11734
Main Throttle Sensor Removal/Adjustment…11734
Main Throttle Sensor Input Voltage Inspection…11734
Main Throttle Sensor Resistance Inspection…11735
Main Throttle Sensor Output Voltage Inspection…11736
Intake Air Pressure Sensor #1 (Service Code 12)…11739
Intake Air Pressure Sensor #1 Removal…11739
Intake Air Pressure Sensor #1 Installation…11739
Intake Air Pressure Sensor #1 Input Voltage Inspection…11740
Intake Air Pressure Sensor #1 Output Voltage Inspection…11741
Intake Air Temperature Sensor (Service Code 13)…11745
Intake Air Temperature Sensor Removal…11745
Intake Air Temperature Sensor Installation…11745
Intake Air Temperature Sensor Output Voltage Inspection…11746
Intake Air Temperature Sensor Resistance Inspection…11747
Water Temperature Sensor (Service Code 14)…11748
Water Temperature Sensor Removal/Installation…11748
Water Temperature Sensor Output Voltage Inspection…11748
Water Temperature Sensor Resistance Inspection…11749
Intake Air Pressure Sensor #2 (Service Code 16)…11750
Intake Air Pressure Sensor #2 Removal…11750
Intake Air Pressure Sensor #2 Installation…11750
Intake Air Pressure Sensor #2 Input Voltage Inspection…11751
Intake Air Pressure Sensor #2 Output Voltage Inspection…11752
Crankshaft Sensor (Service Code 21)…11754
Crankshaft Sensor Removal/Installation…11754
Crankshaft Sensor Resistance Inspection…11754
Crankshaft Sensor Peak Voltage Inspection…11754
Rear Wheel Rotation Sensor Signal (Service Code 24)…11756
Rear Wheel Rotation Sensor Signal Inspection…11756
Gear Position Switch (Service Code 25)…11759
Gear Position Switch Removal/Installation…11759
Gear Position Switch Resistance Inspection…11759
Gear Position Switch Output Voltage Inspection…11759
Front Wheel Rotation Sensor Signal (Service Code 27)…11761
Front Wheel Rotation Sensor Signal Inspection…11761
Vehicle-down Sensor (Service Code 31)…11764
Vehicle-down Sensor Removal…11764
Vehicle-down Sensor Installation…11764
Vehicle-down Sensor Input Voltage Inspection…11765
Vehicle-down Sensor Output Voltage Inspection…11766
Subthrottle Sensor (Service Code 32)…11768
Subthrottle Sensor Removal/Adjustment…11768
Subthrottle Sensor Input Voltage Inspection…11768
Subthrottle Sensor Output Voltage Inspection…11769
Subthrottle Sensor Resistance Inspection…11771
Oxygen Sensor – not activated (Service Code 33, Equipped Models)…11772
Oxygen Sensor Removal/Installation…11772
Oxygen Sensor Inspection…11772
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)…11776
Exhaust Butterfly Valve Actuator Sensor Removal/Installation…11776
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection…11776
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection…11777
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection…11778
Immobilizer Amplifier (Service Code 35, Equipped Models)…11779
Antenna Resistance Inspection…11779
Amplifier Input Voltage Inspection…11779
Blank Key Detection (Service Code 36, Equipped Models)…11780
User Key Inspection…11780
ECU Communication Error (Service Code 39)…11781
ECU Communication Line Inspection…11781
Fuel Pump Relay (Service Code 46)…11783
Fuel Pump Relay Removal/Installation…11783
Fuel Pump Relay Inspection…11783
Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54)…11784
Stick Coil Removal/Installation…11784
Stick Coil Primary Winding Resistance Inspection…11784
Stick Coil Input Voltage Inspection…11784
Radiator Fan Relay (Service Code 56)…11786
Radiator Fan Relay Removal/Installation…11786
Radiator Fan Relay Inspection…11786
Subthrottle Valve Actuator (Service Code 62)…11787
Subthrottle Valve Actuator Removal…11787
Subthrottle Valve Actuator Inspection…11787
Subthrottle Valve Actuator Resistance Inspection…11787
Subthrottle Valve Actuator Input Voltage Inspection…11788
Exhaust Butterfly Valve Actuator (Service Code 63)…11790
Exhaust Butterfly Valve Actuator Removal…11790
Exhaust Butterfly Valve Actuator Installation…11791
Exhaust Butterfly Valve Actuator Inspection…11792
Exhaust Butterfly Valve Actuator Resistance Inspection…11792
Air Switching Valve (Service Code 64)…11794
Air Switching Valve Removal/Installation…11794
Air Switching Valve Inspection…11794
Oxygen Sensor Heater (Service Code 67, Equipped Models)…11795
Oxygen Sensor Heater Removal/Installation…11795
Oxygen Sensor Heater Resistance Inspection…11795
Oxygen Sensor Heater Power Source Voltage Inspection…11796
KIBS Hydraulic Unit Communication Error (Service Code 1b, KIBS Equipped Models)…11798
KIBS Hydraulic Unit Communication Line Inspection…11798
Idle Speed Control Valve Actuator (Service Code 1C)…11800
Idle Speed Control Valve Actuator Removal…11800
Idle Speed Control Valve Actuator Installation…11800
Idle Speed Control Valve Actuator Resistance Inspection…11800
Idle Speed Control Valve Actuator Input Voltage Inspection…11801
Air Intake Solenoid Valve (Service Code 2d, Equipped Models)…11803
Air Intake Solenoid Valve Removal/Installation…11803
Air Intake Solenoid Valve Inspection…11803
KIBS Service Codes (KIBS Equipped Models)…11804
Solenoid Valve Inspection (Service Code b 13, b 14, b 17, b 18)…11804
KIBS Solenoid Valve Relay Inspection (Service Code b 19)…11804
Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code b 25)…11804
KIBS Motor Relay Inspection (Service Code b 35)…11804
Front Wheel Rotation Sensor Signal Abnormal (Service Code b 42)…11805
Front Wheel Rotation Sensor Wiring Inspection (Service Code b 43)…11806
Rear Wheel Rotation Sensor Signal Abnormal (Service Code b 44)…11806
Rear Wheel Rotation Sensor Wiring Inspection (Service Code b 45)…11807
Power Supply Voltage Inspection (Low-Voltage) (Service Code b 52)…11807
Power Supply Voltage Inspection (Over-Voltage) (Service Code b 53)…11808
ECU Inspection (Service Code b 55)…11808
CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code b 57) CAN Communication (Reception) Monitor Inspection (Service Code b 58)…11808
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code b 83)…11809
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code b 84)…11809
Fluid Pressure Sensor Supply Voltage Inspection (Service Code b 89)…11809
Appendix…11811
Cable, Wire, and Hose Routing…11812
Troubleshooting Guide…11852
Kawasaki Motorcycle Service Repair Manual '83-'97 ZX900-1000-1100 Ninja (EN)…11858
Kawasaki Motorcycle Service Repair Manual '84 ZX-9R (DE)…12097
Kawasaki Motorcycle Service Repair Manual '84-'90 ZX-9R (EN)…12339
Kawasaki Motorcycle Service Repair Manual '85-'97 ZX600 & 750 Fours (EN)…12633
Kawasaki Motorcycle Service Repair Manual '88-'90 ZX-10 (EN)…12898
ZX10 Front Cover '88-'90…12898
Model Application…12899
Quick Reference…12900
Title page…12901
Foreward…12905
1 General Information…12907
Model Identification…12910
Specifications…12911
Periodic Maintenance Chart…12914
Cable,Wire and Hose Routing…12920
2 Fuel System…12927
Carburetors…12932
Fuel pump and Filter…12937
3 Cooling System…12941
Water pump…12946
Thermostat…12949
4 Engine Top End…12951
Cylinder Head Cover…12958
Cylinder Head…12962
Valves…12964
Cylinder, Piston…12971
Carburetor Holder…12973
5 Clutch…12975
6 Engine Lubrication System…12987
Engine oil and filter…12992
7 Engine Removal/Installation…12999
8 Crankshaft/Transmission…13003
Crankcase splitting…13008
…
Kawasaki Motorcycle ZZR250 1990 – 1996 Repair Manual Supplement…16184
Front_Cover…16184
Model_Application…16185
Quick_Reference_Guide…16186
General_Information_1…16191
Fuel_System_2…16203
Cooling_System_3…16211
Engine_Top_End_4…16215
Clutch_5…16223
Engine_Lubrication_System_6…16227
Engine_Removal/Installation_7…16230
Crankshaft/Transmission_8…16233
Wheels/Tires_9…16239
Final_Drive_10…16247
Brakes_11…16253
Suspension_12…16258
Steering_13…16268
Frame_14…16271
Electrical_System_15…16279
Appendix_16…16306
Back_Cover…16308
Kawasaki Motorcycles ZX-6R, ZX-6RR, ZX-7R(R), ZX-9R, ZX-10, ZX-10R, ZX-12R, ZX-14, ZX600, ZX750, ZX900, ZX1000, ZX1100, ZZ-R250, ZZ-R1200 Repair Service Manuals