Kawasaki NINJA ZX-10R Assembly & Preparation Manual

Brand: Kawasaki

Model: NINJA ZX-10R

Category: Motorcycles

Type: Assembly & Preparation Manual

This manual is also suitable for

Ninja ZX-10R ABS

Ninja ZX-10R

Ninja ZX-10R ABS

Motorcycle

Assembly & Preparation

Manual

Recharge the Battery First!

The 2011 Ninja ZX-10R comes with a

pre-filled, pre-charged sealed battery,

eliminating the need for dealers to prepare

the battery by filling it with electrolyte.

However, the battery must be charged

upon initial receipt of each unit since it may

have been warehoused for a significant

time period before being delivered to your

dealership.

After the initial charge at your dealership

the battery should be recharged every six

months. Because the battery will discharge

more rapidly at high ambient temperatures,

more frequent charging intervals may be

required for dealerships located in hot

climate zones.

When the battery is not charged

periodically during long term storage, its

internal resistance increases and could

prevent the battery from being recharged.

Refer to the "Battery Service" chapter for

details.

The battery is located within the crate at

the lower left corner indicated with a dotted

line. The battery can be removed from the

crate for charging by cutting off a portion of

the cardboard cover along the dotted line.

A. Dotted Line for Battery Location

B. Cardboard Cover

Foreword

In order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-

bled before crating. Since some of the most

commonly removed parts have a direct bear-

ing on a vehicle’s reliability and safety, consci-

entious pre-sale assembly and preparation be-

comes extremely important. Good setup pro-

cedures can prevent needless warranty claims

and give customers a greater sense of c onfi-

dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex-

plains step by step procedures of the following

items for all Kawasaki Ninja ZX-10R and Ninja

ZX-10R ABS.

1. Uncrating

2. Assembly

3. Preparation

The selling dealer assumes sole responsibil-

ity for any unauthorized modifications prior to

sale. Refer to your Service Binder for any Ser-

vice Bulletins specifying Factory Directed Mod-

ifications (Special Claims) which must be per-

formed before the vehicle is ready for sale.

Whenever you see the following symbols

heed their instructions! Always follow safe

operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WA RNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situa-

tion which, if not avoided, could result

in minor or moderate injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

NOTE

○This note symbol indicates points of particular

interest for m ore efficient and convenient op-

eration.

Kawasaki Heavy Industries, Ltd. accepts no

liability for any inaccuracies or omissions in this

publication, although every possible m easure

has been taken to make it as complete and ac-

curate as possible. All procedures and specifi-

cations subject to change without notice.

Table of Contents

crating ......................................................................................

Opening Crate ............................................................................. 3

Parts C heck ................................................................................. 5

sembly ......................................................................................

Windshield................................................................................... 6

Rider’s Seat Bolt.......................................................................... 6

rake Disc Cleaning ....................................................................

Preparation ................................................................................... 6

Battery Service ............................................................................ 6

ront Brake Fluid.........................................................................

Rear Brake Fluid ......................................................................... 12

Clutch Lever and Cable............................................................... 14

Drive Chain.................................................................................. 14

Steering Damper ......................................................................... 16

Front Fork.................................................................................... 16

Rear Shock Absorber .................................................................. 17

Tire Air Pressures........................................................................ 18

Fuel ............................................................................................. 18

Coolant ........................................................................................ 18

Engine Oil (4-stroke) ................................................................... 20

Throttle Grip and Cable ............................................................... 21

Rear Brake Light Switch.............................................................. 21

Headlight Aim .............................................................................. 22

Digital Meter ................................................................................ 23

Fastener Check ........................................................................... 26

Standard Torque Table ................................................................ 28

Test Ride the Motorcycle ............................................................. 28

A & P Check List ......................................................................... 28

UNCRATI

NG 3

Uncrating

Opening Crate

WARNING

Crates

have sharp edges and may have

nails or screws that can cause cuts and

injury. Always wear protective gloves,

boots

and eye protection when u ncrat-

ing to prevent injury.

WARNING

The

steel crate panel plates and fasten-

ers have sharp edges. Always wear pro-

tective gloves, boo ts and eye protection

en uncrating to prevent injury.

•

Clear a space about 6 m (20 ft) square to give

yourself plenty of space to work.

•

Place the crate upright on its base.

•

Remove the cardboard cover.

•

Remove the battery cardboard box first. Cut

the strap and remove the battery cardboard

box from the crate base.

Straps

Battery Cardboard Box

•

At the left side, cut the strap and remove the

parts cardboard box from the crate base.

A. Straps

B. Parts Cardboard Box

NOTICE

When removing the crate bracket from

the motorcycle, be careful not to drop

any parts or the bracket onto the fuel

tank and other components, and not to

scratch the fuel tank or other compo-

nents with the crate bracket.

•

Take out all the bolts and screws and remove

the top and sides of the crate.

•

Loosen the front axle holding nut (D = 14).

•

Remove the left support bracket bolt (D = 8,

L = 12) and discard it.

•

Remove the front axle holding nut (D = 14),

left support bracket, and rubber washers (D =

14.5) (2), and discard them.

4 UNCRAT

ING

A. Front Axle Holding Nut (D = 14)

B. Front Support Bracket (Left)

C. Bolt (D = 8, L = 12)

D. Rubber Washers (D = 14.5)

•

Remove the right support bracket bolt (D = 8,

L = 14) and discard it.

•

Remove the front axle holding bolt (D = 14,

L = 320), right support bracket, and rubber

washers (D = 14.5) (2), and discard them.

A. Front Axle Holding Bolt (D = 14, L = 320)

B. Front Support Bracket (Right)

C. Bolt (D = 8, L = 12)

Rubber Washers (D = 14.5)

•

Lift the vehicle upward about 10 cm (4 in.) and

remove the two lower support brackets and

rubber washers (D = 11.5 × 30) on the left and

right sides. Roll the vehicle off the crate base.

Lower Support Bracket

Rubber Washer (D = 11.5 × 30)

UNCRATI

NG 5

Parts Check

•

Open the parts cardboard box, and check the parts against the illustrations. There may be minor

differences between these illustrations and the actual vehicle parts. In the following charts under

Remarks, D = diameter in millimeters, and L = length in millimeters.

No. Part Name Qty Remarks

1 Plastic Washer 6 D=5.3×11.5

Socket Bolt, Windshield 6 D = 5, L = 16

Well

nut

6 D=5

Windshield 1

2 Flange Bolt, Rider’s Seat 2 D = 6, L = 22

Coll

2 24 × 10 × 11.5

Damper 2 20 × 10 × 12

3 Battery, YTZ7S (F) 1 12 V 6 Ah

Bat

tery, YTZ10S

1 12 V 8.6 Ah

(For models equipped with KIBS)

Band, (For YTZ7S (F)) 1 L=146

Band, (YTZ10S) 1 L=16

(For models equipped with KIBS)

4 Owner’s Manual 1

6PREPAR

ATION

Assembly

Windshield

•

Fit the six wellnuts (D = 5) into the upper fair-

ing hol

es from the outside with their flanges

out.

A. Wellnuts (D = 5)

B. Up

per Fairing

•

Install the windshield using the six plastic

washers and bolts (D = 5, L = 16) on the

upper fairing.

A. Bolts (D = 5, L = 16)

B. Plastic Washers

C. Windshield

•

Tighten the six bolts to the specified torque.

Torque: 1.2 N·m (0.12 kgf·m, 11 in·lb)

Rider’s Seat Bolt

•

Install the rider’s seat bolts. See “Battery Ser-

vice” section.

Brake Disc Cleaning

•

Clean the front and rear brake discs using

oilless solvent.

WARNING

An anticorrosive treatment applied to

the brake discs will increase braking

distan

ce and can cause an accident

resulting in serious injury or death. Re-

move the anticorrosive treatment using

an oil

less solvent.

Preparation

Battery Service

Charged Battery Service

The 2011 Ninja ZX-10R comes with a pre

-fi

lled, pre-charged sealed battery, eliminating

the need for dealers to prepare the battery by

filling it with electrolyte. However, the battery

mus

t be charged upon initial receipt of each unit

since it may have been warehoused for a signif-

icant time period before being delivered to your

alership.

After the initial charge at your dealership the

battery should be recharged every six months.

cause the battery will discharge more rapidly

at high ambient temperatures, more frequent

charging intervals m ay be required for dealer-

hips located in hot climate zones.

NOTICE

This battery is a pre-filled, pre-charged

sealed battery. It is not necessary to fill

the battery with electrolyte. Do not try to

remove the strip of caps.

CAUTION

The model equipped with KIBS (ABS)

and the model without KIBS (ABS) have

ifferent batteries. The battery positive

(+) and negative (–) terminals are re-

versed. Be sure the correct battery is

installed in each model.

•

Make sure the battery type before service.

PREPARA

TION 7

Models Battery Type

(+) Ter

minal

Without KIBS

(ABS)

YTZ7S (F)

12V 6Ah

Right

With KI

(ABS)

YTZ10S

12V 8.6Ah

Left

Battery (YTZ7S)

Battery (YTZ10S)

C. Positive (+) Terminal

D. Battery Recharging Record Label

Battery Recharging

DANGER

Batteries produce an explosive gas mix-

ture of hydrogen and oxygen that can

cause serious injury and burns if ignited.

Keep the battery away from sparks and

open flames during charging. When

using a battery charger, connect the

battery to the charger before turning on

the charger. This procedure prevents

sparks at the battery terminals which

could ignite any battery gases.

NOTICE

Always remove the battery from the

vehicle for charging. If the battery is

charged while still installed, battery

electrolyte may spill and corrode the

frame or other parts of the motorcycle.

Charging the battery at a rate higher than

specified may ruin the battery. Charging

at a high rate causes excess heat which

can warp the plates and cause internal

shorting.

Higher-than-normal charging rates also

cause the plates to shed active material.

Deposits will accumulate, and can cause

internal shorting.

If the temperature of the electrolyte

rises above 45°C (113°F) during charg-

ing, reduce the charging rate to lower

the temperature, and increase charging

time p roportionately.

NOTE

○Nev

er attempt to charge a frozen battery.

○Allow it to warm up to room temperature be-

fore charging.

○Nev

er leave a battery on a trickle c harger

longer than 48 hours. Serious damage to the

battery will occur.

○Al

ways install the red insulating cap to the

battery positive (+) terminal while the battery

is stored.

•

Charge the battery with the standard charging

rates indicated on the battery.

Models Without KIBS With KIBS

Battery types YTZ7S (F) YTZ10S

Standard Charge

0.6 A × 5 ∼

0 hours

0.9 A × 5 ∼

0 hours

•

Use a recommended battery charger, follow-

ing the manufacturer’s instructions.

Kawasaki-recommended chargers:

Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO 2

Yuasa MB-2040/2060

Christie C10122S

•

If the recommended chargers are not avail-

able, use equivalent one.

NOTE

○Charging rates will vary depending on how

long the battery has been stored, tempera-

ture, and the type of charger used.

•

Determine battery condition after charging.

8PREPAR

ATION

NOTE

○Determine the condition of the battery 30 min-

utes af

ter completion of the charge by mea-

suring the terminal voltage according to the

table below.

Criteria

Judgement

12.8 V or higher Good

12.0 ∼ 12.8 V

Charge insufficient

→ Recharge

12.0 V or lower

Unserviceable

→ Replace

NOTE

○If it is less than 12.8 volts, repeat charging

cycle.

○If the minimum voltage specification cannot

be reached after three consecutive charging

attempts, the battery should be replaced.

•

After recharging, record the charging date

and the name of person in charge of this job

to the label attached on the battery.

A. Recharging Record Label

B. Record the Charging Date and the

Name of Person Here.

○The battery recharging record label is at-

tached on the battery side as shown.

A. Battery Recharging Record Label

○The battery manufacturing date is printed on

battery top.

Example) 01 09 10 XX

Day M onth Year Mfg. location

A. Battery

B. Manufacturing Date

Battery Installation

•

Inspect the battery voltage using a voltmeter,

and recharge the battery if the voltage read-

ing is below 12.8 volts just before delivering to

your customer to ensure the maximum perfor-

mance and customer satisfaction. (Refer to

the "Battery Recharging" section.)

•

Insert the ignition key into the seat lock, and

turning it clockwise to remove the passen-

ger’s seat.

A. Ignition Key

Passenger’s Seat

•

Remove the four socket bolts (D = 5, L = 16)

and pull off the seat cover toward the rear.

PREPARA

TION 9

Socket Bolts (D = 5, L = 16)

Seat Cover

•

Remove the rider ’s seat.

NOTICE

Be sure the correct battery is installed in

the model equipped with KIBS and the

model without KIBS.

•

Make sure the ignition switch is turned OFF.

•

Place the battery into the battery case.

•

Hook the battery band with its tab facing up-

ward.

•

Remove the red insulating cap from the bat-

tery.

•

First connect the protective capped (+) cable

to the positive terminal, and then connect the

(–) cable to the negative terminal.

•

Apply a light coat of grease to the battery ter-

minals to prevent corrosion.

•

Cover the positive terminal with red protective

cover.

For models without KIBS:

Battery (YTZ7S (F))

B. Band (L = 146)

C. (+) Cable

D. (–) Cable

Protective Cover

For models equipped with KIBS:

Batt

ery (YTZ10S)

Band (L = 164)

C. (+) Cable

D. (–) Cable

E. Protective Cover

•

Install the mounting dampers (20 × 10 × 12)

and collars (24 × 10 × 11.5) into the holes of

the rider ’s seat stay.

Dampers (20 × 10 × 12)

B. Collars (24 × 10 × 11.5)

C. Rider’s Seat

•

Insert the tabs on the front of the rider ’s seat

into the slots in the frame.

10 PREPA

RATION

Rider’s Seat

B. Tabs

C. Slot

•

Secure the rider’s seat with two flange bolts

(D=6,L=22).

Rider’s Seat

Flange bolts (D = 6, L = 22)

•

Pull up the front end of the rider’s seat to make

sure the seat is securely installed.

•

Install the seat cover aligning the tabs on the

seat cover with the slots on the lower cover.

A. Tabs

B. Slots

•

Make sure the seat cover is properly installed,

then install and tighten the four socket bolts

(D=5,L=16).

Socket Bolts (D = 5, L = 16)

Seat Cover

•

Insert the tab on the rear of the passenger’s

seat into the slot in the frame.

•

Insert the projections at the front of the pas-

senger’s seat into the holes on the frame.

•

Push down the front part of the passenger’s

seat until the lock clicks.

Passenger’s Seat

B. Projections

Holes

D. Tab

Slot

•

Pull up the rear ends of the passenger’s seat

to make sure the seat is securely locked.

Front Brake Fluid

Front Brake Fluid Level Inspec tion

•

With the front brake fluid reservoir held hor-

izontal, check that the fluid level is between

the upper and lower level lines.

PREPARA

TION 11

A. Front Brake Fluid Reservoir

B. Upper Level Line

C. Lower Level Line

D. Cap Stopper Screw

•

If the fluid level in the reservoir is lower than

the lower level line, check for fluid leaks in the

front brake lines and fill the reservoir.

•

Loosen the cap stopper screw to remove the

front brake fluid reservoir cap and diaphragm.

•

Fill the reservoir to the upper level line with

DOT4 brake fluid.

WARNING

Brake fluid that is contaminated by

moisture or dirt, mixed or contains air

has a lower boiling point and can cause

the brake to be ineffective or fail, and it

may cause rubber parts to deterioate,

resulting in an accident causing injury

or death. Never reuse old brake fluid.

Do not use fluid from a container that

has been left unsealed or that has been

open for a long time. Do not mix two

types and brands of fluid for use in the

brake. Don’t leave the reservoir cap off

for any length of time to avoid moisture

contamination of the fluid. Don’t add or

change the fluid in the rain or when a

strong wind is blowing.

NOTE

○First, tighten the front brake fluid reservoir cap

clockwise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 turn while holding the brake fluid reservoir

body.

A. Reservoir

B. Cap

C. Clockwise

D. 1/6 turn

NOTICE

Brake fluid quickly ruins painted sur-

faces. Wipe up any spilled fluid immedi-

ately.

•

Operate the brake lever several times.

•

If it feels spongy, there might be air in the

brake line.

•

If necessary, bleed the air in the front brake

line.

•

Also check for fluid leakage around the fit-

tings.

Front Brake Line Air Bleeding

•

Loosen the cap stopper screw to remove the

reservoir cap and diaphragm, and check that

there is plenty of fluid in the reservoir.

NOTE

○The fluid level must be checked several times,

during the bleeding operation and replenished

as necessary. If the fluid in the reservoir runs

completely out any time during bleeding, the

bleeding operation must be repeated from the

beginning since air will have entered the line.

•

Attach a clear plastic hose to the bleed valve

on front master cylinder and run the other end

of the hose into a container.

•

With the reservoir cap off, slowly pump the

brake lever several times until no air bubbles

can be seen rising up through the fluid from

the holes at the bottom of the reservoir. This

bleeds the air from the brake master cylinder

end of the line.

12 PREPA

RATION

•

Pump the brake lever a few times until it

becomes hard and then, holding the lever

squeezed, quickly open (turn counterclock-

wise) and close the bleed valve. Then release

the lever. Repeat this operation until no more

air can be seen coming out into the plastic

hose.

A. Hold the brake lever applied.

B. Quickly open and close the bleed valve.

C. Release the brake lever.

•

Tighten the bleed valve to the specified

torque.

Torque: 5.4 N·m (0.55 kgf·m, 48 in·lb)

•

Attach a c lear plastic hose to the bleed valve

on each front brake caliper and run the other

end of the hose into a container.

•

Pump the brake lever a few times until it

becomes hard and then, holding the lever

squeezed, quickly open (turn counterclock-

wise) and close the bleed valve. Then release

the lever. Repeat this operation until no more

air can be seen coming out into the plastic

hose.

A. Hold the brake lever applied.

B. Quickly open and close the bleed valve.

Release the brake lever.

•

Repeat the previous step one more time for

the other front disc brake.

•

When air bleeding is finished, check that the

fluid level is between the upper and lower

level lines.

•

Install the diaphragm and reservoir cap.

•

Tighten the bleed valve(s) to the specified

torque.

Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

NOTE

○First, tighten the front brake fluid reservoir cap

clockwise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 turn while holding the brake fluid reservoir

body.

•

Install the cap stopper screw and tighten it.

•

Apply the brake forcefully for a few seconds,

and check for fluid leakage around the fittings.

Rear Brake Fluid

Rear Brake Fluid Level Inspection

•

With the rear brake fluid reservoir held hor-

izontal, check that the fluid level is between

the upper and lower level lines.

A. Rear Brake Fluid Reservoir

B. Upper Level Line

C. Lower Level Line

D. Cap Stopper Screw

•

If the fluid level in the reservoir is l ower than

the lower level line, check for fluid leaks in the

brake line, and fill the reservoir.

•

Remove the reservoir cap by loosing the stop-

per screw and remove the diaphragm, and fill

the reservoir to the upper level line with DOT4

brake fluid.

PREPARA

TION 13

NOTICE

Brake fluid quickly ruins painted sur-

faces. Wipe up any spilled fluid immedi-

ately.

NOTE

○First, tighten the rear brake fluid reservoir cap

clock

wise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 tu

rn while holding the brake fluid reservoir

body.

A. Reservoir

B. C

C. Clockwise

D. 1/6 turn

•

Reinstall the reservoir with the bolt.

•

Operate the brake pedal several times.

•

If it feels spongy, there might be air in the

brake line.

•

If necessary, bleed the air in the rear brake

line.

•

Also check for fluid leakage around the fit-

tings.

Rear Brake Line Air Bleeding

•

Loosen the reservoir cap stopper screw to

remove the rear brake reservoir cap and di-

aphragm, and check that there is plenty of

fluid in t he reservoir.

NOTE

○The fluid l evel must be checked several times,

during the bleeding operation and replenished

as necessary. If the fluid in the reservoir runs

completely out any time during bleeding, the

bleeding operation must be repeated from the

beginning since air will have entered the line.

•

Attach a clear plastic hose to the bleed valve

on the rear brake caliper and run the other

end of the hose into a container.

•

With the reservoir cap off, slowly pump the

brake pedal several times until no air bub-

bles can be seen rising up through the fluid

from the holes at the bottom of the reservoir.

This bleeds the air from the rear brake master

cylinder end of the line.

•

Pump the brake pedal a few times until it

becomes hard and then, holding the pedal

pushed down, quickly open (turn counter-

clockwise) and close the bleed valve. Then

release the pedal. Repeat this operation until

no more air can be seen coming out into the

plastic hose.

A. Hold the brake pedal applied.

Quickly open and close the bleed valve.

C. R

elease the brake pedal.

•

When air bleeding is finished, check that the

fluid level is between the upper and lower

level lines.

•

Tighten the bleed valve to the specified

torque.

Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

Install the diaphragm and reservoir cap.

•

Tighten the reservoir cap stopper screw.

NOTE

○First, tighten the rear brake fluid reservoir cap

clockwise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 turn while holding the brake fluid reservoir

body.

•

Apply the brake forcefully for a few seconds,

and check for fluid leakage around the fittings.

14 PREPA

RATION

Clutch Lever and Cable

Clutch

Lever Free Play Inspection

•

Check that the clutch lever has the specified

amount of free play as shown in the figure.

Clutch Lever Free Play:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

A. Adjuster

B. Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•

If the free play is incorrect, adjust the free

play.

Clutch Lever Free Play Adjustment

•

Turn the adjuster so that the clutch lever will

have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play.

•

If it cannot be done, use the adjusting nuts at

the lower end of the clutch cable.

A. Adjusting Nuts

B. Clutch Cable

NOTE

○After the adjustment is made, start the engine

and check that the clutch does not slip and

that it releases properly.

○For minor corrections, use the adjuster at the

clutch lever.

Drive Chain

Drive C

hain Slack and Wheel Alignment

Inspection

•

Set the motorcycle up on its side stand.

•

Make su

re that the drive chain has the speci-

fied amount of play, and that the left and right

notches are on the same marks or points on

the le

ft and right of the swingarm.

WARNING

Misal

ignment of the wheel will result in

abnormal tire wear and can cause an un-

safe riding condition. Be sure the wheel

is pro

perly aligned.

•

Rotate the rear wheel to find the position

where the chain is tightest, and measure

the maximum chain slack by pulling up and

pushing down the chain midway between the

engine sprocket and rear sprocket.

Drive Chain Slack:

25 ∼ 35 mm (1.0 ∼ 1.4 in.)

A. 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

•

If the drive chain is too tight or too loose, ad-

just it so that the chain slack will be within the

standard value.

WARNING

A chain that breaks or jumps off the

sprockets could snag on the engine

sprocket or lock the rear wheel, severely

damaging the motorcycle and causing

it to go out of control. Inspect the chain

for damage and proper adjustment.

Drive Chain Slack Adjustment

•

Remove the cotter pin, and loosen the rear

axle nut.

•

Loosen the left and right chain adjuster lock-

nuts.

PREPARA

TION 15

A. Rear Axle Nut

B. Cotter Pin

C. Ch

ain Adjuster

D. Chain Adjuster Locknut

•

If the chain is too loose, turn out the left and

right chain adjusters evenly.

•

If the chain is too tight, turn in the left and right

chain adjusters evenly.

•

Turn both chain adjusters evenly until the

drive chain has the correct amount of slack.

To keep the chain and wheel properly aligned,

the wheel alignment indicator notches should

align with the same marks on each side of

the swingarm.

A. Marks

B. Notch

C. Indicator

D. Chain Adjuster

E. Chain Adjuster Locknut

NOTE

○Wheel alignment can also be checked using

the straightedge or string method.

•

Tighten both chain adjuster locknuts.

•

Tighten the rear axle nut to the specified

torque.

Torque: 127 N·m (13.0 kgf·m, 94 ft·lb)

•

Rotate the wheel, measure the chain slack

again at the tightest position, and readjust i f

necessary.

•

Install a new cotter pin.

NOTE

○When inserting the cotter pin, if the slots in the

nut do

not align with the cotter pin hole in the

axle, tighten the nut clockwise up to the next

alignment.

○It sh

ould be within 30 degrees.

○Loosen once and tighten again when the slot

goes past the nearest hole.

A. Cotter Pin

B. Turning Clockwise

•

Bend the cotter pin over the nut.

A. Cotter Pin

B. Nut

WA RNING

A loose axle nut can lead to an acci-

dent resulting in serious injury or death.

Tighten the axle nut to the proper torque

and be sure the cotter pin is installed

correctly.

•

Check the rear brake effectiveness.

16 PREPA

RATION

Steering Damper

Dampin

g Adjustm ent

This motorcycle is equipped with the steer-

ing damper unit. Kawasaki recommends that

this st

eering damping adjuster is at the standard

setting during everyday riding.

•

Check the position of the damping adjuster of

the ste

ering damper.

•

Turn the damping adjuster clockwise all the

way, then turn it counterclockwise to the stan-

dard s

etting position.

Standard Setting Position:

18 clicks (Counterclockwise position

from t

he fully seated position)

A. Steering Damper

B. D

amping Adjuster

C. Softer (Counterclockwise)

D. Harder (Clockwise)

Front Fork

Spring Preload Adjustment

•

Check the position of the spring preload ad-

justers on the lower portion of each fork leg.

A. Spring Preload Adjuster

B. Wrench

•

Turn the spring preload adjuster counter-

clockwise all the way, then turn it clockwise

to the standard setting position.

Standard Setting Position:

6 turns in from the fully seated position

(turned fully counterclockwise)

NOTICE

The right and left fork legs must be ad-

justed evenly.

WARNING

If both spring preload adjusters and

both rebound and compression damp-

ing force adjusters are not adjusted

equally, handling may be impaired and

a hazardous condition may result. Set

all suspension adjusters equally to the

recommended settings.

Rebound D amping Adjustment and

Compression Damping Adjustment

•

Check the position of the rebound damping

adjusters and compression damping ad-

justers on the left and right fork legs.

A. Compression Damping Adjuster

B. Rebound Damping Adjuster

Compression Damping Adjuster:

•

Turn the compression damping adjuster

clockwise all the way, then turn it counter-

clockwise to the standard setting position.

Standard Setting Position:

4 1/2 turns out from the fully seated

position (turned fully clockwise)

PREPARA

TION 17

Rebound Damping Adjuster:

•

Turn the rebound damping adjuster clockwise

all the way, then turn it counterclockwise to

the standard setting position.

Standard Setting Position:

3 3/4 turns out from the fully seated

position (turned fully clockwise)

NOTICE

The right and left fork legs must be ad-

justed evenly.

NOTICE

Do not force to turn the rebound / com-

pression damping adjuster from the fully

seated position or the adjusting mecha-

nism may be damaged.

Rear Shock Absorber

Rebound Damping Adjustment

•

Check the position of the rebound damping

adjuster at the upper end of the rear shock

absorber.

A. Rebound Damping Adjuster

•

Turn the rebound damping adjuster clockwise

all the way, then turn it counterclockwise to

the standard setting position.

Standard Setting Position:

1 3/4 turns out from the fully seated

position (turned fully clockwise)

NOTICE

Do not force to turn the rebound damp-

ing adjuster from the fully seated posi-

tion or the adjusting mechanism may be

damaged.

Compression Damping Adjustment

•

Check the position of the compression damp-

ing adjuster on the gas reservoir at the left

side of the rear shock absorber. The com-

pression damping adjuster has both high and

low speed compression damping adjusters.

A. High Speed Compression Damping

Adjuster

Low Speed Compression Damping

Adjuster

NOTE

○Turning the high speed adjuster also turns the

low speed adjuster. Although the low speed

adjuster turns along with the high speed ad-

juster, the low speed adjuster setting position

does not change.

•

Turn the high s peed compression damping

adjuster clockwise all the way, then turn it

counterclockwise to the standard setting po-

sition.

Standard Setting Position:

1 3/4 turns out from the fully seated

position (turned fully clockwise)

•

Turn the low speed compression damping ad-

juster clockwise all the way, then turn it coun-

terclockwise to the standard setting position.

Standard Setting Position:

1 3/4 turns out from the fully seated

position (turned fully clockwise)

NOTICE

Do not force to turn the high speed / low

speed compression damping adjuster

from the fully seated position or the ad-

justing mechanism may be damaged.

18 PREPA

RATION

Tire Air Pressures

•

To prevent flat-spotting during shipment, the

tires are over-inflated before crating. Adjust

the pressures to the specified values in the

front and rear, and make sure to tighten the

caps securely.

Tire Air Pressure [when cold]:

Front: 250 kPa (2.50 kgf/cm², 36 psi)

Rear:

290 kP

a (2.90 kgf/cm², 42 psi)

A. Tire Air Pressure Gauge

Fuel

WARNING

Gasoline is extremely flammable and

can be explosive under certain condi-

tions, creating the potential for serious

burns. Turn the ignition switch “OFF”.

Do not smoke. Make sure the area is

well ventilated and free from any source

of flame or sparks; this includes any

appliance with a pilot light.

Never fill the tank completely to the top.

If the tank is filled completely to the top,

heat may cause the fuel to expand and

overflow through the vents in the tank

cap. After refueling, make sure the tank

cap is closed securely. If gasoline is

spilled on the fuel tank, wipe it off imme-

diately.

•

Open the fuel tank cap, and check for debris

in the fuel tank.

•

Fill the fuel tank with one gallon or four liters

of unleaded gasoline. Use a gasoline with a

minimum octane rating shown below.

For US, Canada and Brazil Models

Fuel Type Unleaded Gasoline

(RON + M

ON)

Antiknock

Index

Minimum

Octane

Rating

For Other than US, Canada and Brazil

Models

Fuel Type

Unleaded Gasoline

Research Octane Number (RON)

Minimum

Octane

Rating

•

Close the fuel tank cap, and check for any

leaks.

Coolant

Coolant Level Inspection

•

Situate the motorcycle s o that it is perpendic-

ular to the ground.

•

Check the coolant level with the coolant level

lines on the reserve tank located to the right

of the engine. The coolant level should be

between the F (Full) and L (Low) level lines.

NOTE

○Check the level when the engine is cold (room

or atmospheric temperature).

A. Reserve Tank

B. F (Full) Level Line

C. L (Low) Level Line

•

If the amount of coolant is insufficient, remove

the cap from the reserve tank and add coolant

through the filler opening to the F (Full) level

line.

Coolant Filling

•

Remove the mounting bolts, plastic washers

and collar from the right fairing and cover.

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Kawasaki NINJA ZX-10R Assembly & Preparation Manual

Brand: Kawasaki

Model: NINJA ZX-10R

Category: Motorcycles

Type: Assembly & Preparation Manual

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Ninja ZX-10R ABS

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Kawasaki NINJA ZX-10R Assembly & Preparation Manual

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Kawasaki NINJA ZX-10R Assembly & Preparation Manual

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