Kawasaki ZX900 A GPZ900R 1987 Service and Repair Manual

Kawasaki
Brand
Kawasaki
Model
ZX900 A GPZ900R 1987
Category
Motorcycles
Type
Service and Repair Manual
Kawasaki
ZX900,
1000
&
1100
Liquid-cooled Fours
Service and Repair Manual
by Mark Coombs and Penny Cox
Models covered
ZX900 A
(G
PZ900R). 908cc.
UK
April 1984
to
1996
ZX900 A (Ninja). 90Bec. US
November
1983
to
1986
ZXl
000 A
(G
PZl
OOORX).
997cc.
UK
November
1985
to
September
1989
ZX1000 A (Ninja 1000R). 997cc.
US
September
1985
to
1987
ZX1000 B (ZX-10).
997cc.
UK
December
1987
to
April 1991
ZX1000 B (Ninja ZX-1 0). 997cc.
US
April 1988
to
1990
ZXl100
C
(ZZ-Rl100).
1052cc
.
UK
March
1990
to
December
1992
ZX1100 C (Ninja ZX-11C).
1052c
c.
US
1990
to
1993
ZX1100 0 (ZZ-R1100). 1052cc.
UK
December
1992
to
1997
ZX1100 0 (Ninja ZX-11
D).
1052cc.
US
1993
to
1997
o
Hayne.
Publishing
1999
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85960
355
6
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0. 4 Introduction
Kawasaki
The
Green
Meanies
by
Julian
Ryder
Kawasaki Heavy Industries
~
wasaki
is
a company
of
contradictions
It Is the smallest
of
the big
four
apanese manufacturel1l
but
the
biggest company, k
was
the
last of th9 four
to
make
and
market motorcycles yet k owns
the
oldest name in the Japanese industry. and it
was the first to set
up
a factory in the USA.
Kawasaki Heavy Industries,
01
which the
motorcycle operation is but a small
component, is a massive company with
its
heritage firmly In the
old
heavy Industries like
shipbuilding
and
railways: nowada)'ll It Is as
much Involved in aerospace
as
in
motorcycles
In
fac
t
it
may
be
because
of
t
his
t
hat
Kawasak
i's
motorcycl
es
have always been
quirky, you get the impression that they are
desigrJed
by
a small group of enthusiasts
who
are given
an
admirably free hand. More
realistically. it may
be
that Kawasaki's
designers have experience with tochniques
and materiats Irom other engineering
disciplines. Either way, Kawasaki have
managed
to
be
the factory who surprise us
more than the res
t.
Quite often. they
do
lIlis
by
totally
Ig
noring a market segment the
others are scrabbling over. but more often
they hit us with pure. undiluted performance
They bought their high-tochnology
experience to bear first on engines which
Wefe
sold on to a number of manufacturers
as
original equipment. Both two- and four-stroke
units were made. a 58
cc
and 148
cc
OHC
unit.
One
01
the
customer companies was
Meihatsu Heavy Industries. another company
w~hin
the Kawasaki group, which in 1
961
was
shaken
up
and renamed Kawasaki Auto
Sales. At the same time, the Akashi factory
which was to
be
Kawasaki's main production
facilrty until the Kobe earthquake of 1995,
was
opened. Shortly aflerwards, Kawasaki took
over the ailing Meguro company, Japan's
oldest motorcycle maker, thus Instanlly
obtaining a
range of bigger bikes which
were
marketed as Kawasaki-Meguroa. The
following year.
lhe
Ilrst bike 10
be
made ami
sold
as
a Kawasaki was produced, a 125 cc
single called lhe
B8
and
In
1963 a motocross
version, the B8M appeared.
The
origins of the company, and its name,
go back to 1818 when
&lozo
Kawasaki set up
a dockyard
In
Tokyo. By the late 19305, the
company
was
making its
OWn
steel
In
massive
steelworks and manufacturing railway locos
and rolling stock. In the run
up
to war. the
Kawasaki Aircraft Company was set
up
in
1931 and it was this arm of
the
now giant
operatiOO that would look to motorcycle
engine manufacture
in
post-war Japan.
The
thrflfl
cylinder
two-stroke
150
Model
develop
m
ent
~
wasakl"
lirSI appearance
on
a road-
I1IC8
CIrCUit
came
In 1965 with a
batch
01
i$C-valv. 125 twins. They were
no
match
lor
Ihe
opposition
trom Japan
in
the
shape
01
Suzutd
and
Yamaha
or
lor
the fading
Iorce
01
the
faciO<)'
MZs
from
Easl
Germany
.
Only
alter the Olher
Japanne
factories
had
puled
out
oItha
class did Kawasaki win, with
Brlti$l1
rider Oallil Simmonds becoming
WOOd
125
GP
Champion
In
1969 on a bike that
looked astonishingly similar to the original
meer.
Th
at same year Kawasaki reorganised
once again. tl"ll,
lime
merging tl"lree
companle'
10
torm Kawasaki Heavy
Industries. One
of
the new organisal
ion',
objectives was to lake
motorcycle
production
forward
and
~
marXeI$ outside
Japarl.
KHI
echie~
tl"lal
target
Immediately
and
set
oul
lhelr
,Iall
lor
the
luture
with
the
astonishing
alld
lrightenlng
HI.
This th,tIe-
cylinder pir-cooled 500
cc
two-slro
ke was
arguably the first modern pure performance
bike
to hit the
mar1<et.
II l"Iypnollsed a whole
generlltlon
of
motorcyclists
who'd
never
before encountered
such
a ferocious, whee/Ie
indIXing power band
or
such shaltering
stra
ight-line speecl allied to questionable
handling. And
as
for the 750
C(;
venion
..
Tile triplea perfectly
,uiled
Ihe
lale '60s.
fitting
In
wei
w"h
the
Stu<len
l demonstratlons
01
1968
and
the anti-establishment ethos
of
Ihe Summer
of
Love. Unfortunalely,
Ihe
oil
ai:sis
would
put an
end
to
the thirsty
strokenI
but Kawasald
had
another
high-performance
_ up their corponIte $leave. 0.. rather
It>ey
1hougI>11hey
did.
The 1968
Tokyo
$how
saw
probably
the
SIngle
most significant new molorCycle
&va<
made unveiled: the Honda CB750.
AI
Kawasaki
It
caused a
major
shock,
for
they
also
had a 750
cc
four.
code
-named New
Vorl<
Sleak, almost ready to
roH
and
~
was a
double. falher than
lingle.
overhead
cam
motor. Bravely. they
tOOk
the decision to go
ahead
- but
With
the
molor
taken 001 to
900
ce. The result
wit
the
Zt,
unveiled
al
the
t9n
Cologne
Show." was I bike straight
out
of
the same mould as the H
I.
scare storie$
spread
about
~
powยซ,
dubious
straight-llne,tabiIity
and
frightening nandIing.
none
of
which Slopped the sales graptl
rocketing
Upwardl
and
led
to the coining
of
tile
t&nTI
's
upertllke'. While rising fuel
prices
CUI
short development
01
the big two-strokes,
the
Zt
want on to found a dyrlasty,
Indeed
Its
genes can
'ti
ll
be
detec
led
In
Kawasak
i's
lalesl pr
oduCII
ilke the ZZ-Fll t 00 (Ninja
ZX-tt).
This
II
another characleri$lic
of
the way
Kawasaki operates.
Models
quite
olt..,
llallil
very
long
livu,
or
gradualty evolve. There
Is
no
major
difference between that
firsI
ZI
and
the .... -eooIed
GPz
range.
Add
water-cooling
and you heve the GPZ900,
w1"Iich
in
lum
metamorphosed
into
lhe
GPZ1000RX and
then
theZX-tO lind the
ZZ-All00.Indeed.
the
Introduction 0. 5
The
first
Superblk
e, Kawasald', 900
CC
ZI
One
o
ftha
two-
s
trok
e
tngI
ned
KH a
nd
KE range -
the
KE1008
0' 6 I
ntrod
uction
The
GT7
50 - a lavo
urit
e hack for despstch
riders
lasl three models share the same 58 mm
stroke. Tha bikes are
obviously
very dIfferent
but
11'&
diffi(;uil to put your
ronger
on
exactly
"",.
Other
model'
have remained effectively
untouched
lor
OYer
a
decade:
\fle
KH
8f>d
KE
single-cylinder air-cooled
two
-stroke learner
bikes,
t
he
GT550 and 750 shalt-drive hacks
favoured
by big
city
despatch
ridefs
and
the
GPz305
~
prime
examples.
It's
only
when
they
step
outside
the
perlormaoce
field Itwlt
Kawasaltis
seems
less
SU"e.
Their
IV$!
factory
The
h
ig
h-
perfo
rm
anc
e
ZXR7
50
customs
were dire,
you
$imply
got
the
impression
that
!he
leam
that designed
them
didn't
have
their
heart
In
the
job.
Only
when
the
Classic range appeared in 1995 did
they
get
~
right.
Racing
success
K
awasaki
atilO
have a more focused
approach
10
racing than the other
factories.
The
policy
kas
always been
to
I1I(:e
the
road
bikes
and
with
just
a
couple
of
exceptions
that's
what they've done. Even
Simmonds'
ehampionshlp
winner
bore
a
strong resemblance
to
the twins they were
selling
ill
the
tale
'60s
and
racing V9'Slons
of
t
he
500 and 750 cc triples were also sold as
ovlt.-the-counter racers, tho
HI
Rand
H2R.
The
500 was in the torafront
ot
the
two-Itroke
assautt
on
MY
Agusla but wasn't a
Grand
PnK
winner. It was
the
750 that made
the
impact
and
carried
the
factorys Imag& In
F750
racing
against
the
Suzuki
triples
and
Yamaha
fouO's..
The
factorys decltion to
"""
green.
l>SU3IIy
regarded
as
an
unlucl<y
colour
in
sport,
meant
It I bikes and
~onnel
stood
out and the
phrase ยทGreen Meanies' fitted them
perIec:1ly.
The
21 motor
soon
became a
11.11
11000
cc
and
powered Kawasaki'S assault in
Ft
racing,
notably in endurance which Kawasaki saw as
being
most
closely
related
to its
road
bikes.
That didn., stop them
dominating
250
and
350 cc
GPs
wtth a tandem twin two-stroke
in
the late '70s and early
'80s,
but
their
path-
breaking
monocoque
500
while
a race winner
never won a world tItle. When Superblke
arrived. Kawasakl"s road 750$
were<1'1
as
trackยทfriendly
as
tha
oppos~ion's
outยทand-out
race replicas. This makes Scott Russell'S
World
t~le
on the ZXR750
In
1993
even more
praiseworthy,
lor the
homologation
bike. the
ZlCR75ORR.
was much heavier and much
more
of
a road bike than th" Italian and
Japaf"l8SflcompeIrtion.
The company's
Supa-sport
600 contenders
have slmilarty been
more
sports-tourers than
race-replicas. yet they
100
have been
competiti\ra on the tracll. Indeed. the flagship
bike. the ZZ-Rt 100,
Is
mos
t definitely a sports
lourer capable
01
carrying two people and
their
luggage
at
high
speed
in
comfort
all
day
and
then
doing
it
again
the
noW
day.
TI)"
that
on one
01
the race replicas and
youยท1I
be
In
need
of
a
coorH
01
treatment from a
chiropractor.
Through doing II their way Kawasaki
developed
8.
brand loyaity for their
per/ormance bikes that kapt the
ZI's
d&rivatives
In
production unt
il
the
mid-'80s
and
lumad
the bike Into a classic in its model
life.
You
oould _ argue that the
Zl
lives
on
in
the
shape of the
1100
Zephyr's GP>:II(l()-
derived
motor.
And
thaI's another Kawasaki
invention,
the
retro
biq.
But
wtIen
you
look a\
what
many
commentators refer to
as
the
retro
boom, espeCially in Japan. you find lhat it Is
no
such thing. II Is
the
Zephyr boom. Just
another example
01
Japan'.
most surprising
motorcyc~
maoulaclurer getll
ng
it right again.
The
ZX900, 1000 and 1100
liquid-cooled fours
W
".
an tho
world's
motorcycla
press
turned up at Laguna
Seca
race track
m Oecemoor 1963 for the riding
taunch
of
tho GPZ9O(lR thera was an instant
run
on global reserves
of
supef1atives. Hefe
was
that rarest
of
things. a genuine quantum
leap forwards. a new design that instantly
ren<lered
most
of
its competitioo redurJdant -
ootably the
GPzl
100 and Z750 Turbo which
at the tima Wefa
top
of
Kawasak
i's
range.
Here
was a bike that packed the power
of
an
1100
into a 750-slze package with state-of-
the-art suspension and striking looks. The
Production TT proved the bike was track-
worthy and the road
tests
showed it was a
comfortable, practical roadstef. At the time, it
was
soon
as
an
out-and-out sportster but not
a race-replica. which made its TT victories
even!llOfe
notewOr1hy.
1\
didnยทt take Kawasaki long to
try
and
improve on tho first Ninja as the 900 was
cal
l
ed
everywhere except the UK, the
GPZ1000RX
(Ninja
1()(lQA
in the
US)
arrived in
1986
to mixed reviews because
most
joumalists could not
sao
how
~
was
in
any
way
an
improvement
on
the
900. The
AX
motor
was
basically a bored-out 900
motor
with
r
......
ised breathing arrangements.
bu
t the
chassis was completely new. Gone was the
spine frame that used the
motor
as a load-
bearing
membef
and in came a full cradle
frame
which
made
the bike bigger
and
heavier.
The
AX
was certainly one
of
the fastest -
~
oot
lhe fastest - bikes available
in
the mid-ยท60s
but
~
didn't take
long
for
it to be superSeded.
this time by the
ZX
-l0.
Although the bore
and
straka
di~ons
stayed the same. the motor
was
heavily modif;oo and lightened. Valve lash
adjustment changed from screw and tappet
to
shim, and the motor lost over
37
Ib of weight
Only
t
he
crankcases remained lhe same. The
chassis changed completely again, this t
ima
to
an
aluminium frame in the Dellabox
configuration that was
now
oocoming the
Industry standard. The steering was
Acknowledgements
O
ur thanks are due
to
CW Motorcycles
of
Dorchester and
TVM
Mot
orcy~es
of
Newton
Abbot
who
supplied the
machines featured
In
Ihe
photographs
throughout this manual. Thanks are also due
to Kawasaki Motors (UK) Ltd
for
supply
of
technical information and permission
to
use
some
of
the line drawings featured.
The
Avon
Rubber Company supplied intormation on tyre
fitting. and NGK Spark plugs (UK) Ltd
provided information on spark
plug
maintenance and electrode conditions
Thanks are also due \0 Kawasaki
Information
service
and Kel Edge for
supplying transparencies. and to Phil Flowers
who
carried
out
the front cover photography.
Introduction
0'7
The
ZZ-Al100
sports
tcurer
sharpened
up
and the styling made less
slabby. Everyone agreed, here was a maj
or
step
lorward compared \0 the
l000AX
- bot
was It really better than the ori9inal
9OO?
Probably not
The genuine leap forward came
in
1990
w~h
the ZZ-R
ll
00 (Ninja 2)(-" in the
US).
All
sporting pretensions
wOO!
abandoned and the
bike was presented as
an
unashamed sports
tourer. bot also as the fastest bike money
could
buy. These seemingly mutually
exclusi
ve
requirements were somehow
resolved in a packaga that
li
ke the first
Z1
and
the first Ninja. is
muct1
more than the
Sum
of
~s
parts.
Irs
fast,
~'s
comtortable. it
's
easy to
ride. it simply has no faults. The
motor
was
bored out again and heavily modified and
installed in a much better looking bike. It was
The int
rOd
uction
"Kawasaki - The Green
Meanies" was written
by
Julian Ryder.
About this Manual
n
aim
of
this manual is to help you get
the best
va.
lue from your motorcycle. It
can
do
so
In
several ways. It can help
you decide what work must be done. evan if
you choose
to
have it done by a dealer: it
provides information and procedures for
ro
utine maintenance and servicing: and it
offers diagnostic and rapai. procedures
to
follow when trouble occurs.
We
hope you use the manual to tackle the
work yourself. For many simpler jobs. doing it
yourself may be quicker than arranging
an
appointment to get the motorcycle into a
dealer and making the
trips
to leave It and
heavier than the
ZX-l0
but just worked better.
retinad is the best word to
descr
ibe il. It is
astonishingly fast yot very civilised to live with
Like all the great Kawasakis. the
ZZ-Rl100
enjoys a long model life.
The original GPZ900 went through six
model changes
(Alto
A8) bot the last one
lived
on
In
importers ranges t
or
years after it
first appeared
in
1991.
In
the UK, it was even
reintroduced as a bargain bike. The
AX
and
2)(-tO only went through three model
changes. A I to
A3
and B I to B3, res.peclively.
Seven years into its model
li
fe
the ZZยทAI
tOO
is still going strong. slill being
updated
annually and still winning comparison tests
with all its rivals - remarkably you can stili
detect
the heritaga
of
the original Kawasaki
sllperbike. the
ZI
, in the thing
pick it up. More Importantly, a lot
01
money
can be saved
by
avoiding the expen$(! the
shop must pass on to you to
COver
~s
labour
and ovamead costs.
An
added benefit is the
sense
of
satisfaction and accomplishment
that you feel after doing the job
yourseH.
References to the left
o.
right side
of
the
motorcycle assume you are sitting
on
the
seat, facing f{)(Ward.
We
take
great
prid
e
in
the
accuracy
of
in
f
ormation
given
in
thi$
manual,
but
motorcycle
manufacturers
make
alterations
and
design
changes
during
the
production
ron
of
a particular
motorcycle
01
wnich they
do
not
inform
us.
No
liability
can
be
accepted
by
the
authors
or
publi
$her5
lor
JO$s,
damage or injury caused by any etTOf"S
In,
Or
omissions from, the Infonnatlon given.
0. 8 Identification numbers
Frame
and
engine
numbers
The 'ram",
numoor
is
stamped
into
Ihe
ri
gh
t
-handsideofthesteeringhead
, The
eogine
number
is
slamped
into the
top
01
!he
crankcase,
on
the
right-hand
side,just
below
no
. 4
carburettor.
80th
of
these number.;
should
be
recorded
and
kepi
in a saf",plac:e
so
they
can
be
furnished
to
law
enforcement
officials in
the
event
of
a
lheft
. Ther9 is al
so
a
carburettor identificabon
number
on the side
of
ea<:h
carburett
or
bod
y.
n
ot
known. the model
code
can
be
established f
ro
m the engine and frame
numbe
rs
(see
fo
ll
owing
li
st). Note that the
d
at
es
giv
en
are
Kawasa
ki's
prod
ucllon yea
r,;
and
t
hese
will nol
nocassar
ily coincide wi
th
the
da
te
01
registration.
Machines In
thlsmanua
i are identili
ed
by
their model
code
rather than popularn.ame.
If
popul8r
.......
,v-
UK
GPDOOR:
"
..
""
1987
"sa
""
"90
199HI6
UKGPZ100(lRX:
i
:;
'
'''''
UKZX-10:
'
'''''
1990-91
UK
ZZ
ยท
Rt,oo:
ZX900A3
"'900""
=~ASA
ZX9OOA>
ZX9OO'"
ZXl000Al
ZXl000A2
ZXtOOOA31A3A
1990
ZX
l
l00C
t
1~
gii:g
1993 ZXl 1
00Dl
tWo!
ZXl 1
00D2
1995 ZX
l1
00D3
1996
ZXl
1
00D4
1997
ZXl
l
00D5
US
Nq.
(J
-
.....
InJ
IIPC'
n.
US
-
.....
In
US):
1984
ZX900Al
(J)
ZX900Al
(U
S)
ZX900f<2(J)
ZX900A2.(USl
ZX900A2(J)
ZX900A2(US}
US
Nlnjal000R
(J
-madain.n.p.n,
lIS
_
madain
US):
1986 ZX1(lOOAl
(J)
ZX1000A1
(US)
ZX1000f<2(J)
ZX1000f<2(US}
~::Inj
a
ZX-10:
ZX1000
B1
1989
ZX1000B2
1990
ZX1000B3
US
Ninja
ZXl1
(J _
madain
hpยฅI,
US
-madain
US):
1990
ZX1
1
00C1
(J)
1990
ZX
1
100C
1 (US)
1991
ZX
l
100C2(J)
1991 ZX1
100C2(US)
1
992
ZX1100C3(J)
1992
ZXl
1
00C3(US)
1993 ZX l 1
00C4(US)
1993
ZX1100Dl(J)
1993
ZX1
1
00D
l (US)
1994
ZX110002
(J)
1994
ZX1100D2(US)
1995
ZXll00D3(J)
1995
ZXl100D3(US)
1996
ZXl10004
(J)
1996
ZX1100 D4 (US)
1997
ZXl
100D5(J)
1997
ZX1100D5(US)
ZX9OOA-OOOOO1-015000
ZX
9OOA"()15004-015SOO
ZX9OOA-01SOO1-015003
ZX900A
-015501on
ZX9OOA-Q31001on
ZX900A-Q35101on
ZX
900A-Q38501
on
ZX900A-042001
on
g~~!'=:
i
:
ZXT
OOA-OOOOOlon
ZXTOOA-014801on
ZXTOOA
-
022401on
ZXTOOB..()(l()()(l1-{)1
2000
ZXTOOB..()
12452-{)17000
ZXTOOB-01
200
1
..()
1
245
1
ZXTOOB-017001-{)28000
ZXTOOB..()28001on
ZXT1OC-OOOOO1-013000
ZXT1OC-Ol3001on
ZXT1OC-024001on
ZXT100-000001-020000
ZXT100
-
020001on
ZXTl00
-
032001on
ZXTl
00
-
039001on
ZXTl
00-045001on
JKAZX2Al-EAOOOOOlon
j
~i:~~~~
JKAZX2A1-F
B505301on
JKAZX2Al-GA03
1
001on
JKAZX.2Al-GB512701on
JKAZXCA
1-GAOOOOO1on
JKAZXCA
1
-GB500001on
JKAZXCA1
-HA014801on
JKAZXCA1
-HB508401on
JKAZXCB1-JAOOOOOl
on
JKAZXCB1-KA0
1
2001on
JI<AZXCBHA028001
on
JKAZXBC1-
LAOOOOO1on
JKAZXBC1-LBOOOOOlon
JKAZXBC1-MAOl
300
1"()24000
~~~gi:=;~
1
1~
JKAZXBC1-N
B5046010n
JKAZXBC1-PB508201on
JKAZXBD1-
PAOOOOO1on
JKAZXBD1-PB50000
1
on
JKAZXBD1-RA020001on
JKAZXBD1-RB502701on
~~~gi:~;~~
:
JKAZXBD1-TA039001 -
045000
JKAZXBD1-TB506951-509100
JKAZXBD1-
VA045001on
JKAZXBD1-V9509101on
Engioanumbar
ZX9OOAEOOOOOlon
ZX9OOAEOOOOO1on
ZX9OOAEOl9001on
ZX9OOAEOl9001on
ZX9OOAE040001on
ZX9OOAE046001on
ZX9OOAE048501
on
ZX9OOAE048501
on
ZX9OOAE048501
on
ZX900AE048501
on
ZXTOOAEOOOOO
l
on
ZXTOOAE021001
on
ZXTOOAE028501on
ZXTOOAE027801
on
ZXTOOAE028501
on
ZXTOOAE028501
on
ZXTOOAE028501on
ZXTOOAE028501on
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOO1on
ZXT1OCEOOOOO1on
ZX9OOAEOOOOOlon
ZX9OOAEOOOOOlon
ZX9OOAEOl9001on
ZX9OOAEO
l
9001on
ZX9OOAE040001on
ZX9OOAE040001on
ZXTOOAEOOOOO1on
ZXTOOAEOOOOO1on
ZXTOOAE021001on
ZXTOOAE021001on
ZXTOOAE028501
on
~OOAE040301on
ZXT1
OCEOOOOO1on
ZXT1OCEOOOOO1on
ZXT1OCEOOOOOlon
ZXT1OCEOOOOO1on
ZXT1
OCEOOOOO1on
ZXT1OCEOOOOO
l
on
ZXT1OCEOOOOO
l
on
ZXT1
OCEOOOOO
l
on
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOO
l
on
lXT1OCEOOOOO
l
on
ZXT1OCEOOOOO
l
on
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
ZXT1OCEOOOOOlon
Buying spare parts
Oneeyouhaveloundallu...ldenlJlieatlOfl
numbers, ,ecord them lor relerence when
Iluy'ingparta.Sincethemaoufacturersct\aoge
speciticalkloa.parts andvendors(COITIpanieol
that manul
aclufe
variol.ls
componeots
on
the
machIne).providingthe I
Dnumbersialheonty
wwytobereuonably
SIn
that you
....
buying
IheCXln'eCtpartS.
~
pouible,
take
the
worn part to
lhldealar$Odirectcomparison
with
th8new
Identification numbers 0ยท 9
component
e.l
be
made.
Along
the
1rlIiI/n)m
the
mlWlUfacturerlotheparlsshelf,lt1ere_
OlIIT'I8roU5p1acesthalthepartcanlnlupwith
lhewrungnumberorbelistedi'v::orree1!y.
The
lWo places to purchase
new
partS
lor
your motOfCycle-theacces.sorystoreandtl\e
Ir
anchl!l8d
dealer-differ
In
the
type
oi
par111
they
carry. While
dealers
can
obtain
virtuaUy
evยซypartloryourmotorcyde,theaccessory
dealer
is
usually limiled to normal
high
wear
items
such"
IIhock
abso<bers. tune-up
parts,varIolGengk'Mlgaskets,cables.chaN,
brake part
s,
etc. Rarely will an acceS80lY
OUIlethavemajor'uspen,ioncomponenta,
cylinders.
transmlssioogears,orcases.
Used
parts
can
be
obIaIned for roughly hall
lhepriceolnewones,bu1youcan"aIwaysbe
$Ure
of
what you're getting.
Once
agaln. take
yourwom
part to the
wre<:
k
l"llyard
(breakelj
for
direct
comparison.
VVhether
buying new,
used
or
rebuitt parts,
the
best
course
I,
to
deal directly with
someone
who
speclaliz
..
in
parts
lor
your
pa-ticularmake.
0.
,0
Safety first!
Professiooal rnechanics are trained
in
&a!&
working procedures.
How
e~er
Mllhusias1ic
you
may
be
about
getting
on
w~h
tlMI
job
at
hand.takeltletlmeto.....,.,..lhjdyoursalety
isnol
puI
at
1'iIk.
A moment'.
I..cI<
01
attention
can
result In
an
accidenl.
es
canfailu.e
to
obaer\tfI simple precauhona
Tl\ei"e
will
always
be
new
ways
of
having
accidents, and the following ia not โ€ข
eomprehensr..
lisl
of
an
dangers; It
Is
Intended
ralhflrto
make you aware
of
the
risks
andtoeocou'a>I88aaleapproachtoallworll
you carry
OIJI
on your bike.
Asbestos
โ€ข Certain frielioo'l, insulating. sealing and
ot
herprodliCla
ยท
such
as brake pads, clutch
linings.
gasket.,
elc.-conlainllsb&$to
โ€ข.
exlr_ca,e
mUSI
be
laken
10
avoid
ImloIiIIion
of
dust from
such
producIssince
~
la h.azardous
to
health.
II in doobt,aSS<Jme
ltlattheydocontalnesbesloS.
Fire
โ€ข
Rememberataltm.thIIlpetroIishighty
1\arnmabIe.NevยซsmoI<.eorhoa .... fJllYkindoi
naked flame
around.
when working on
the
vehlcla.Bullhe.lakdoll.notendther8-8
sparkcausedbyanelectrieal$hOrt-circuil,by
two metal
su1aces
contacting
NCh
other,
by
careless use
01
lools, or .... en
bystalic
electricitybuiltupinyourbodyundefcertaln
cond~loos.
can
Ign~e
petrol vapour, which In
aconfir>ed s
pacalshighlyexpiosive.Never
use
petrol
as
a cleaning soIIIent.
Use
an
approYedsafetyflOlvent.
Reme
mber
...
If
Don't star1 tha angiIna WIthout first
MCeotaininQlhatlhltrmsmllllonisin
.........
If
Don't
SU(i(IenIy
removeltlepressuracap
from a
hoi
cooling system - cover
~
WIth
a
eIothandraleaM!hepr.suragraduaiyfirst,
oryoum;rygeltealdedbyeacaplngcoolant
If
Don't
aUempt
to
drtlin
011
untli you IIt'e
lure
it
has eoolad suMiciently 10
Ivold
aceldingyou.
If
Don't
grasp
any
pan
of
the englna
or
a~h.ust
syslem
without
fir$1
ueertalning
that
~
Is cool anough not
to
b\A"n
you.
If
Don't
allow
braka nuld
oranhfreeze
to
contact tha mtlchine's
pelnlworloc
or
plastic
-""","".
If
Don't
Slp/'Ion
toxic
liquids suc:h
as
1ueI.
hydraulic flukl
Otantlfr
..
za
by
mouth.
Ot
aIIowtt-nloremainonyourskin
If
Don't
Inhaie dust -
~maybelnjurloualo
health
(seeAlbeslos
heading)
If
Don't
allow
any spillfld
oil
or
grease to
remain
on
the
IIoor
-
WIpe
~
up right away,
beforasomaona slips on
~.
If
Don'
t use
II
I-fittIng
spannen
or ott>ar
toots
which may slip
and
cause injl.lf)l
If
Don't
lit! a
hNvy
componam
..mIch
may
bebeyondyourcepabiMyยทgatassistarU.
โ€ข Always diaconn&et Ihe
battery
eanh
Ierminal before worklng on any pat1 of lhe fuel
or
el&etrleal s
ystem
, and never risk
spiliinll
IueI
onlOa
hoi
enginot or exhaust.
โ€ข
II
III
recommended that a
fQ
e~1inguisher
of a
typesu~ablefor
fuel and electr\callires
is
kept
handy In the garage or workplaee at all
times. Never try
to
ex
t
inlluish
a
luel
or
eIectrIcaI
..
....ntlwater.
Fumes
โ€ข Certain
fume
s are highly
lode
and
can
Quickly
causeunconaclousnHs
snd
even
death
IIIn11a1ed
to
any
e~tent.
Petrol vapour
comes
Into
this
category,
as
do
the
vapours
from
certain solvents
sucf1
as
trlchloro-
:~~:::::;ei,~~~
~r~~'I~g
:;
:,'::!n~n
o~ s~~~
"""tilated_.
โ€ข
When~~"uid
sandto/wlnts,
read
the
instn.octlons carefully. Naver
use
materials
from
unmarked
contalnen
- they
mayg
....
oIIpoisonousvapour!l
โ€ข
Neverrunthe
.-.ginaof
amot
orvehidein
an~spacesuc:hasagarage.Exhaust
fum"
contain
carbon
monoxida
which
Is
extremelypoisonou
a:
If
you need 10
nJn
the
engina. alway$ do so In the open
airor
at leasl
hava
tha
raar
01
the
vehicle
oufald
a
th
e
The
battery
โ€ข Nev
areau
se
II
spark,
Or
all
ow
a naked
!ight
near the vehicIe'a beltery. II will
normally
be
giving
011
a certain
amount
01
t>ydrogen
gas
,..mIchlshighlyaKploslYe.
If
Do
n'
t rush
to
finish a
Job
Ot
take
urwerifIadshoncuts.
If
Don
't
allow
ehlklran
or
animailin
or
around
an
unattended
vehide
If
D
on'
t Inflate a tyra
above
Ihe
recommanded
Pfassure. Apart
from
overstrasslngthe carcass. in
extremlcases
tha~mayblowolllorcibly.
"" Do
.......
thattha"**-
..
~ad
securely
at
IU
times.
This
Is
espacially
important~thamachlnaisblockadup
lOaklwhMlorlork.-.rr'lOY8l
.
",
Do
takecarawhanaltamptingtolooMn
aSllbbomnotorbolt.hlsganeratybetler
to
pull on a
spanner,fltherthan
push.
so
Ihat
If you slip, you fall away from
the
mactune
ratherthanonto~
"'
Do
wear
aye Pfot&elion when using
p<JWer
lools
wch
as
drln, sander.
bench
gMdtrak:.
""
Do
use a barrier craam
on
your
hands
Pfior
to
undartalunll
dirty
tabs, It will
proteCI
your
skin
Irom
Infection
II
well
as
makingthedWIaasiarIOMfTKlVtlafI_ads;
but
make
sure
your
hands
.r
...
ยท,
left
slippery. Note that iongยทterm
contacl
witt>
usadenginaoilcanbeahaal
t
hhazafd.
""
Do keep
loose
clothing
(cufls,
tlasetc
andlonghair)welootol!heWW'jolfTlOW"lg
--.
โ€ข Always
disconnect
the
battery
ground
(aartll)t&mlinalbeloreworklngonthaluelor
elยซ:lrIcaIsy$t_(exceptwherenoted).
โ€ข IlpossIbIe,loosoonthefillerpiugsorCOYer
wilen charging
the
baUeryfrom
an
a~temal
source.
Do
not
cf1argeal
an
axcessive rate or
t
he
battery may burst.
โ€ข
Tal<e
car
e when
topping
uP. cleaning or
carrying
lhebatteoy.
The lICid alectroly1a.
avenwhen
diluted.
Is very corrosive and
should
not
ba altowad
to
eonlac:tthe eyas or
$kin. Aiway$
wearrutx-glov
H and
\IOIIIIies
or a
face
shield. If'fOlJ ever nead
to
preparl
eleclrotyteyourull.alwaysaddtheaeid
sIowfytothewater,.-acidthewaiartoftw
"" .
Electricity
e When ualng an
ele<:
trlc:
power
tool
,
Inspection light ate., alwaya
ensurathat
the
appliance
is correctly
connectad
to
Its
plug
and that.
whera
necessary. It Is properly
grounded
(eanhfKl).
Do
not
usa a
.....
h
appliances
In
damp
condition
. and. again.
beware
of
ereatlng a
spark
or
apptylng
aKcessiveheatinlhevicinllyoffu~ortu"
vllj)OUr. Also If\SUra
lhat
the appliances meet
nattonal
safetystandard
s
e A severa
electric
shock
car1
result from
touc:hingcertaln
partS
01
thaalectricalSy$lem
,
suc:hasthaspar1<plugwQs(HTIeads).~
tk
a engine Is running or
bainll
crankad.
particularly If
componenta
are
damp
Ot
th
a
Insulation
i,dafective.
W""'
a an electronic
Ign~ion
system
I,
used
.
thaMCOfldary(tfT)
voltage
is
mucf1
h9>erandoould
prove fatal.
'"
Do remove rings, wristwatch
etc
..
before
workinll
on
the
vehicle - especially
"'1
aIectricaIsystem.
""
Do
kaep)'Ollfworkarlllltldy-~isonly
~:.aYIOfaIiOveranleleslefiIYlng
'"
Do
exercise eaution
when
compo-essing
8f)rI"II5for~orinstalla"on.Ensurti
thalthet-.onillllpfliiedanclraleasedina
controlled
manner, uSing su
it
able
lools
whlc:h
pracIude
the
powblilty
of
ftwsprlng
.......
-
""
Do
ensuralhaterrvlilbnglKkleosedhas
a"'eworlongloedratinglldequateforlhe
"".
""
Do
gil
someone
10
check
periodically
thaI all is well. when WOfIIing alone on
lhe
.......
""
Do
carryootwori<inaloglcalSlQUlflCl
and
check
that
avarylhlng
is
COff&etly
a_bled
and
tlghtlInOlKI
al1_lIrds
'"
Do remember
lhat
yo..
vehicle's $Bfaly
alleclsthat
01
yourself
and
others. If In
doublon
.ny
point.
get
po-ofesslonal
-.
e lf
inspoteolfoilowingtheWprecautlon
โ€ข.
you
are
unfortunall
enough
to
injura
yoursaI!.seekmedlc:alanentlonassoonas
-.
Daily (pre-ride) checks 0' "
1
Clutch
and
brake
fluid
level
check
A
W,mlng
:
s,..l1.
_
IIytkaullc
ffuld
,
un
"arm
)"OUr
eyes
and
โ€ข
dama".
palrt'fKI
sul1l1CeS,
so
use
extreme
caution
when
handling
.nd
pollring't
end
coWll"
surrounding surfaces
with
1719
.
Do
1'10\
use
fluid
thllt
hilS
been
stand;"fI
open
fOI'
some
time,
liS
It
IIbsonn
moisture
from
the
air which
eson
<;:.9use
a
dangonxlS
Ion
of
braliing/clutch
effedivene
u.
1
~~~h
t~:~
;'~t~"~~S
:~t~~
~s=
body.
is
not below t
he
lower level mark.
The mark Is
In
the form of a raised line
cas
t into the reservoir
body.
Before you start:
'"
Make
aur.
yoo have
the
COfT8Ct hydraulic
fluid
-
OOT
4.
'"
With the
motorcycle
hilid
level,
tum
tile
handlebars until
the
top
of
!he master cylinder
Is
as
level as possible.
If
necessary, loosen
the brake lever
clamp
bo
l
ls
and rOlale the
master cylinder assembly slightly
10
make It
-.
'"
On
the rear brake reservoir.
loc
ated behind
the
rlght-han.d sidepanel (ZX900 and 1000
models)
or
under
the
seal
(ZXl100
C/O
modeIl).
the
fluid level is visible through
the
~
material
01
the
rese.voir;
~
should
be
betwe.l
the
upper
and
lower
level
marks
on
the
side
01
the
reservoir.
2
~~c=.t,:r~:~=es~~~
cap
(as applicable). and remove the
diaphragm: nOle
Ihal
later models have a
plale fined above the diaphragm
on
the frool
rese!"'J~r.
When
the
Ik.Iid
level Is correct.
dean
and
dry the diaphragm. fold it
into
its
compressed state
and
relit
it. togather with the plate (later
models).
10
the
reservoir.
Refil
lhe
reservoor
cover
and
retaining
screws
or
thol
reservoor
cap
and
lighlan it securety.
Bike
care:
โ€ข
In
order
10
ensure
proper
operalioo
of
the
hydraulic
disc
brake. the flu
id
level In the
maSle. cylinder reservoir must
be
property
maintained.
If
the
brake fluid level was
lOW,
Inspect the brake system for leaks.
โ€ข The fluid In the brake master cylinder
rese<voir wi
ll
drop
~ightly
as
the brake
padS
_rdown.
โ€ข Check the
operatio<1
of
the brakes before
taking the machine on the road: If there is
evidence of air
In
the
system
(spongy
feet
to
1eva1.
h
must
be
bled.
โ€ข Before removing
tha
master cylinder cap.
protect
the
motorcycle
from
braJ<to
nuid Spills
(which wiQ damage
the
paint)
and
remove
III
dust
and
dirt from the araa
around
the
cap.
3
~~~ya
=jU~~,=~
I~~~.
~~h:
reservoir to
lhe
upper level mark.
On
the
Ironl
brake and clutch reservoirs the
upper level marl< is
In
the form of a line. cast
on
the
Inside 01 t
he
frool face of t
he
reservoir.
0. ' 2 Daily (pre-ride) checks
2
Coolant
level
check
Before
you
start
:
.,
The
enoone
must
be
eoId for
!he
resutts
to
be ItC(:lIrale.
110
alwayw.
perform
this
check
befOfe starting the
..,-,.glne
for
the
first
lime
""'0.,.
.,
Place the
motorcycle
on
the
centerstand.
Make sure the
mo
torcycle i$ OOievelllround.
Bike care:
โ€ข Use only
the
specWied coolant
mi~lln.
It Is
important thaI
an~free~e
i$
used
In
the
cooling
system all year round. not jll5\ during the
WIfllermonllw.
โ€ข In IIIl'IIII'QBflC
~
diatiIed water
alone
may
be
U$I!Id 10 top up
~
$)'Stem,
but
remember
thaI this
will
diklee
the
coolant
and
reduce
it3
degree
of
protection
agam 1reezrIg.
โ€ข
011
ZX900
models
the
tank
i$
behind
the
right-hand
sldepaneI
, wtlich
must
be
removed
\0
gain aocess to it.
On
ZXtOOO
A models
tilt
.~panllon
tank is
behind
the
lower faIring
MClIon, the coolant level
matI<s
being
on
the
f
Ping
MClIon rather ItIan the
e
~pansIon
tank
Itsell. The ZX1000
Band
ZXl100
C
models
heve
the
expansloo lank
m(l<Jnted
in the right-
hand
side
01
the
upper
fairing,
the
coolant
level marks
b&lng
vtslble from
the
loskle
of
the
lalring.
On
ZXt
100 0 models
the
expansion
tank
II
beneath
the
tall secbon
on
tile rlght-
hand
sicIe
.
1\$
coolant level can
be
checked by
observing
the
level
mao'ks
on
the
front portion
of
the
Iri
onot
the
seat
t.as
'-'
removed. "
the
marks
are
indIStinct.
remove
lhe lali
sectiOn
for
a
belIef
view
.
โ€ข If lhe coolant level falls steaaoly,
chack
the
system
for
I6aks as deseribed In Chapter
3.
N
no
leaks ara found
and
the levellllil
~
to
fatt,
II
is 16COiIW.,,,,oded that
the
machine
b4i
taken
to
an authorized Kawasaki dealer
wOO
will
presaure lesl
the
system .
โ€ข
Do
1101
overlililhe
o.:ootan
t
r8$el"\lOOr.
โ€ข If the
coolant
is
significantly
above
the
higher mark at any time,
the
surplus
coolant
should
be
siphoned oft
10
prevent II
from
being elCpelled 0iJI
of
the
breather
hoM
~
the engine
has
warmed up.
Warning:
Anrm.u.1s
poisonous
-
doo't
siphon
by
mo",,"
1
:aU~~~I~
a;:h;~!r;~s~er:~~:
~:;:r
t~
a
~rl~~;:i~~:~
2
:~~::
~~~
::::~:t~
t
::
~ed
~~(':
t
~
~&I
marks
~ng
visible from
lhe
inside
01
the
fairing.
and
using only the
apecif~
ingredients as described In
Chepleo-
3.
โ€ข . lnICI"ew
the
.-voir
cap
and
use a
coolant
mixture
of
the
required strength
and
specification
(
see
Chapter
3)
10
bring
~
up
above
the
LOW
line.
Daily (pre-ride) checks 0-13
3 Engine/transmission oil level
Before
you
start
:
!I'
Place tile motorcycle on t
he
cen
l
ersl
and
.
then
start the engine and alIQw It to reach
nQrTTIaI
opendlng
l
empera
l
Uf9.
Caution: Do
no
t run
the
engine
In
an
enclosed
spactllWCh
a
โ€ขโ€ข
gar8gOl
or
-
01
Sl
op
t
he
8!'Iglne a
nd
allow t
he
m
achi
ne
10
sat
...-.dist
urbed
lor
a
bou
t five minutes.
Bike care:
. " you have 10
add
oIIlrequentIy,
you
should
check
whe
ther you have any
oil
leaks. If
tI
.....
I,
no
sign 01
011
fflakage from t
he
Join
ts and gaskets the engine could
be
bumlng
oil
(see Fau
lt
Finding in the Reference
seclloo).
The c
orrect
oil
โ€ข
Modem.
high~rewIO!I
engines
place
great
demand
s
OIl
thftir oil. It is
very
impOrtant
thallhe
correct
oil
for
your
bike
Is
used
.
โ€ข
Always
l
op
up
with
II
good
quality
oU
of
the
speci1ied
type
and
viscostty
and
do
not
overlill
the
engine.
"'-
API g
rade
SE
or
SF
(minimum)
"'''"''....,
SAE
10W/
40. tOW/SO,
2CNI140
or
2OW15O
1
~
:c=g~:!~
h
:l
~
he
be
oo
Y
i:~:Y~~~
h
~
~
=
2
Top
up
using
!he rec:ommended
011
by
way
of
the
fin. cap at
the
lop
of
the
casing.
window,
be
tween
the
lEw
ei
marks
(arrowed).
4 Suspension, steering and drive chain
Suspension
and
steering
:
โ€ข Makt'
sure
the
sl
aยซlng
opMIles
smoothly,
without
IcIosef-.
and
wi1tIout
twoding.
โ€ข Check Iront
.nd
rear suspension
for
:smooIt1
operation.
Drive
cha
in:
โ€ข M
ak
e sure the drive chain
isn't
out of
ad
jus
tment.
โ€ข Although the chain fitted
as
starodard
eq
ui
pment is
of
the O-
ri
rog
ty
pe,
grease
beirog
sealed I
nt
o the Intemal bearing suriacH
by
O-rings at each
end
01 the roI\ef$, lu
bricat
ion
is still required
to
prevent the railers 'rom
wearing on the
sproektt
tetttl
arod
to prevent
the
Q-ring$
from drying
up.
A heavy
(SA.E
90)
gear all or one
of
the proprietary aerosol
applied
chain Iubr\C8nls
..
bes
t
A Wamlng:
some
propeHanls
I
lind
In
~
o;;aU$O
the
โ€ข O-rings to
detllf10nlte
....,.
-.pIdIy,
so
malre c:ertain
that
tM
pmduct
J. mar1ced
...
being
suitable
IOf"
UN
with
a _ring
I)'pe
chams.
r=
Apply
chalro
/u/Jrlcaro
t to t
he
โ€ข Joiro"
t..fWHro
the side
HIN
pla
'es,
piros,
bushirogs a
nd
rollers
to
pro",ide lubrlcRtkm
ot
lhe
Inl
emelload
beamlg
areas
-
fIO
l
!he
mlddlfl at '
he
roIlfHs.. WIIh t
he
bike
on
Its cenlet3terod,
hoJd
the
plastic
nozzle
nu
r
the
edge
of
the
chain
. rod
tum
1M
wheel
by
hand
lIS
t
he
lubricant
spR)I1I
out;
,..".a
l
this
procedure
on
the
InsJde
edge
at t
he
cham.
Whilst
splnrolrog
the back wheel. spray ckain
lube onto t
he
top
of the cha
inยท,
10_
run -
centrifugal force
wilt
wort<
t
he
lube Into the
chain when the bike is moving.
0" 4 Daily (pre-ride) checks
5 Tyres
lYre care:
โ€ข Check
the
<:::ondllion
of
the
lyre
valve and
enIIUI'e
!he
dust
cap
18
in
place.
โ€ข Pick out /Iny stones
or
nails whIch
may
he.,.
become embedded in
the
lyre
tread. If
lell.
they will event
ua
lly penetrate
tlvough
the
C8$lng
and
cause
II
punctu.&.
โ€ข
II
lyre
damage
is
IIPP11ffl1lI,
or
ur.e~
loss
of
pressure Is elq)8fieoced, seek
the
advice
ole
lyre Iitt.ng specialist without delay.
โ€ข Check the
lyrH
care/ully
for
cuts. tears.
embedded
nails
or
other sharp
objec
ts and
excessive
w&a
โ€ข.
Operation
of
the
motorcycle
Wllh excessively
worn
lyres
I,
.x\.ltITIely
tlazardous.
as
traclion arid handling are
directly
aflected.
Tyre
tread
depth:
โ€ข
AI
the
time
01
writing UK law requires
that
tread
depth
must
be
et least t
mm
over
314
of
the
tread
bl'eadth
all
the
way
around
the
tvre,
with no
bald
pa
t
chet.
Many
ridM"S.
however,
cooslder 2
mm
tread depth minimum
to
be
a
safer
l
im~.
โ€ข Many tyres
now
Incorporata wear indicator.!
in the tread.
Identify
the
triangular
pointer
on
ttle
lyre
~ewall
10
locale
the
indlcalOf bar
and replace
the
lyre
II the tread hes worn
down
to
t
he
bar.
The correct pressures:
โ€ข The
lyres
must
be
checked
when
cold
,
oot
Immediatety after rlchng.
Note
thai
low
tyre
pressures
may
eause the
tyre
to
sr.p
00
the
rim
~come
off. High tyre
presS<JrM
will
cause
abnormal tread W&8I and unsafe handling.
โ€ข Use an aecunl1e
pressure
gauge.
T
yre
pr
essures
UK
ZX900
Alto
M
models
Up
to
215 Ib
load,
below
130
mph
215to
399lb
load, below 130 mph
Above
130 mph
UK
ZX900
A7 -on
models
US
ZX900
Alto
A3
models
Up
10
2151b load
215
to
397 Ib load
UK ZXl{lOO A
models
Below
130 mph
Above 130
mph
UK ZXl{lOO B
models
Up
to
215 Ib load, below 130 mph
21510
399lb
load. below
\30
mph
Above 130 mph
US ZXl(l(J() A
and
ZXl(l(J() B
rnocIeIs
ZXl100
C/O
modela
โ€ข Prope< air pr8U4.lr. will
increne
tyre
life
and provide
ma~lmum
stability and ride
~'''''
,,-
.....
32
psi
(2.25 kg/emยป
36
psi (2.50
kglemยป
36
psi (2,50 kg/emยป 36
psi
(2.50 kg/ctni)
36
psi (2.50 kg/emt)
41
psi
(2.90kglemยป
36
psi (2.50
kglcm')
41
psi
(2.90
kglcm')
32 psi (2.25 kglctni)
36
psi
(2.50
kglemยป
36
psi (2.50 kg/emยป 36 psi (2.50 kg!"ctni)
36
psi (2.50 kg/emยป
36
psi
(2.50 kg!"cmยป
36
psi (2.50
kglemยป
41
psi
(2.90
kglcmยป
36
psi (2.50 kg/emยป
36
psi
(2.50 kg/emยป
36 psi (2.50 kg/emยป
41
psi
{2.90k(jlcmยป
36
psi (2.50
kg/emยป
4\
psi
(2.90
kg/emยป
36
psi
(2.50
kglanยป
41
psi
(2.90 kg/emยป
41
psi
(2.90
kglanยป
41
psi
(2.90
kQlcm>l
Measure the tread
depth
at
the
centre
of
the
lyre
using
II
tread
depth
gauge.
3
~:ti:ad,,:~~~~nd:
l
o;hebar
!~~
,.......,.
6 Legal and safety
checks
Lighting
and
signalling
:
โ€ข Take
II
minute
10
eheck that the headlight.
taillight, brake hght
and
tum
signals all
worI<
~
..
โ€ข
Check
that
the
hom
$Ounds
wtlen
the
switch
Is operated.
โ€ข A working speedometer
is
a s
latutory
requlfemenl in the
UK.
Safety
:
โ€ข
Check
that the throttle
grip
rotates
smoothly
and
snaps shu! when released.
In
all
sleerlng
positions.
โ€ข
Check
that
the
eng.ine
shuts off
when
the
kill
switch is operated.
โ€ข
Check
that
sidestand return spring
holds
the
stand
securely
up
when retract
ed.
The
IIOlme
applies
to
the centerstand (where
fi
tted).
โ€ข Following the
procedure
in your
owner's
1T\III"IU8I.
check
the
opeqtion
of
the sldestand
switch.
Fuel:
โ€ข This may seem obvious.
bu
t eheck that you
have
enough fuel to complete your journey.
II
you notice signs
of
fuel leakage - rectify the
cause immediately.
โ€ข Ensu-e you use the correct
grade
fuel - see
Chapter
4 SpecificaOOos.
Specifications
Engin
e
Oil
capacity:
At oil change:
ZXl1QO
C/O
All
other
models
........
.
..
โ€ข โ€ข โ€ข . .
At
oil and filter change:
ZXl100
C/O models
All
other
models
.
Spark plug type:
ZX900
and
ZXl
000 A
models:
UK
models
US
models
ZXl000
Band
ZXl100 C/O models:
UK
models
........................
โ€ข .
US
models
Spar1<
plug gap:
ZX900 and
ZXl
()()()
A models
ZXl000BandZX1'OOCIDmoclels.
Valve
clearances
-
engine
cold:
Inlel:
ZX900 and
ZXl000
A
models
ZXl000B
and
ZXl100
C/O models
Exhaust:
ZX900 and
ZXl000
A models
....................
.
ZXl000 B and ZXl100 C/O
models.
Idle
speed:
ZXl000
A and
ZXl100
0 California models
AI!
other
models
Throttle
cable
free
play
-
measured
at
twistgrip
.
Choke lever free
play
-
measured
at
the
base
of
lever
3.2 Iii (5.7
Imp
pV3.4
US
qtj
2.7 lit (4.8
Imp
ptl2.9
US
qt)
3.5 lit (6.2
Imp
ptl3.7
US
qt)
3.0
tit
(5.3
Imp
pV3.2
US
qt)
NGK
OASES
DSEA
CAgE
C9E
0.6 -
0.7
mm
(0.024 -
0.028
in)
0.7 -
0.8
mm
(0.028 -
0.032
in)
0.13 - 0.18
mm
(0.005 -
0.007
in)
0.13 - 0.19
mm
(0.005 - 0.007in)
0.
18
- 0.23
mm
(0.007 -
0.009
in)
0.
18
- 0.24
mm
(0.007 -
0.009
in)
1150-1250rpm
950 - 1050
rpm
2-
3
mm
(0.08
-0.12
in)
2
-3
mm
(0.08
-0.12
in)
Nip
po
n-den
so
X27ESA-U
X24ES-U
U27ESA-N
U27ES-N
1. 2 Servicing Specifications
C
yc
le pa
rt
s
Brake
pad
fTiction
mateo1a
l thickness"
ZX900Al
to
A6
and
ZXl000
A models
ZX,OOO
B
model
s
...............
,
..
ZX900A7-oo and
ZX"OOCIO
models'
,~,
"=
Service
lim~
all-
~
..
_
........
.
Rear brake pedal heighl(below top
01
Iootrest):
ZX9QOmodeIs.
ZXl000Amod~s
ZXl00Q B and
ZX
" OOmodels
,.
Drivechaintree~ay:
ZX,OOO
B models
Al
l
othermodels
..........
.
D!ivechainleoglh-20
I
inkleogth
:
ZXl000Amodets
Servicelim~
..
All
other models
$ervic(olim~
..
Front l
oO<.s:
QiICSpaci!y(approx)pe<leg at oil chaoge"
ZX900A,toA6models
ZX900A7-onmodels
ZX1(IOOAmodeis
ZXl00Q B models
zx"ooCmodels
ZJ(11(l()Dr1'lOdels
FoO<.oil'e\lelยท
4.85mm{O.
191
in)
4.50mm
(0.177
in)
4.
00mm
(0.157
in)
4.50mm
(0.177
In)
1.00
mm
(0.039
inJ
29-39mm(1.14-1.54in)
Approx
37
mm{1.46
in}
Approx
45mm
(1.77 In)
30-40mm(1.
1
8-1.57in)
35-40mm(1.38-1.57in)
381.0-381.8
mm
(15.00-
1
5.04
in)
389.0mm(15.31
in)
317.5-318Amm(12.50-12.54in)
323.0mm
(12.72
in)
'"
'"
'"
""
390
'"
I
mpnoz
'.5
14.8
10.4
12.7
13.7
ZX900A,
to
AS
models
357
",2
mm{14.1
,,0.08
io)
ZX900A7
-onmod
els 110
:t2rnm(4.3:tO.08in)
ZXl000 A models
348:t
4 mm (13.7 ยฑ 0.16in)
ZXl000
B models 1
30ot2mm(5.1,.0.08ln)
ZXl
1
00C
models
149,.
:2mm
(5.9,.
0.08
in)
ZX,,00Dmodels
.........
.
..
.
.....................
133ยฑ2mm(5
.
2ยฑO.08in)
usnoz
"
14.2
10
,0
1
22
1
3.2
13.9
~e:;:~s=rad
from
rile
lop
of
the stanchion with the
fori<
spring
r>lmOVI'ld.
Measuremenr
is
raken
with fo/1I.lege/rherluilycompressedOl'
T
Ylllpressureslyres-cold:
UKZX900A
1
10A6mode1sยท
Upl097
.5
kg
(215
Ib)
load.
bt:tIow
1JO
mph
(210 kmh)
....
97.5-
181
kg(2
1
5399
Ib)
Ioad,below
130
mph
(210 kmh)
Abovf!lJOmph(210kmh)
UKZX900A7-onmodels
.
us ZX900 Al
10A3mode1s:
Up
10
97.5
kg (215 1b)
load
97.5-1BOkg(215-397Ib)1oad
UKZX1000AmodeIs:
Below
lJOmph(210
kmh)
Above
130
mph
(210 kmh)
UK
ZX
l
000B
models
Upt097.5kg(215Ib)Ioad,belowl30mph(2
1
0kmh)
....
97.5
- 181
kg(2
1
5-399
Ib)
load.
bt:tIow
130
mph
(210 kmh}
AbovelJOmph(2
1
0kmh)
. . .
US
ZXl000
A
and
ZXl000
B
models
ZXl100
CIU
models
Re
commend
ed
flui
ds
a
nd
lubri
c
ant
s
Frontlol"ksยท
ZX900Al
to
A6and
ZXl000
A
models
.
..
ZX900A7
_on.ZX1000Band
ZX1100ClUmodei
s
Brakeandclutchllukl
Rna
l
dnvecllaln
...
.
..................
.
Wheel
bearings
and
speedometer
dnve
gearbox.
Steeringheadbearlngs
.................
.
Swinging
armands
llSP8"sion
li
nkagepivots
.........
.
Allcontrolpivots.stand,standpivotsandthrottletwislgnp
Conlrojca~es
2.25
kglcm>(32
psol
2.50
kglcm> (36
pso")
2.50kglcm>
(36 psi)
2.50kglcm>(36
pso)
2.25
kglcm>(36
pso)
2.50
kglcm> (36
psol
2.SOkglcm>(36psol
2.SOkglcm>(36psol
2.
SO
kglCm> (36
P5'1
2.50
kglCm> (36
psol
2.50
kglcm> (36 psi)
2.SOkglcm>(36
pso)
2.90
kglcm2
(41
psi}
2.50
kglcm>{36
pso)
2.50
kglcm> (36
pso)
2.90kglcm>(41
psI)
290
kglcm>
(41
pSI)
2.501<g/cm2(3Eipsi)
2.50
kglcm> (36
pso)
2.
SO
k
glcm2(36pso)
2.90kglcm>(41psol
2.SOkglcm>(36psol
2.90kglcm>(4
1
psol
2.90kglcm>(4
1
PS/)
2.90kglcm>{41psi)
2.90kglcm>(41psj)
SAE 10W/40. l
OW/SO.
20W/40
or
2fJW/SO
SE
or
SF
class
(minimum)
Uoleacled
or
1eacIed. Minimum octane rating 91 (Researd1methodlRON)
SAE JO engine oil.
SEciass
SAE lfJWloI"koil
SAE1OWl2Oforkoil
OOT4speci1ication
SAE90gearoil
Highmel!ing-poinlgmase
Geoeral pyrpose grease
Molybdenum-di
su
lphidegrease
Goodqua!itygeneralpyrposegrease
Engi
ne
oil
Note:
The
pre-ride inspection outlined
in
the owner's manual covers
checks
and maintenance that should be carried out on a daily basis. It's
condensed and included at the beginning
of
this Manual to remind you
of
its importance. Always
perlorm
the
pre-ride
inspection
at
every
maintenance
interval
(in
addition
to
the procedures listed).
The
intervals
listed below are the shortest intervals
recommended
by
the
manufacturer
for
each particular operation
during
the
model
years
covered in this manual. Your
owner's
manual may have different
intervals
for your model.
Daily
or before riding
o See 'Daily (pre-ride) checks' at
the
beginning
of
this
Manual.
After the initial 500 miles (800 km)
Note:
This
check
is
usually perlormed
by
a Kawasaki dealer after the
first 500 miles from new. Thereafter, maintenance is carried
out
acccording to the following intervals
of
the schedule.
Monthly
or
every 500 miles (800 km)
o Adjust the drive chain (Section
1)
rD
Check the suspension settings (Section
2)
o Check the battery (Section
3)
Every 3000 miles (5000 km)
o Check the spark plugs (Section
4)
o Check the fuel and oil lines (Section
5)
o Check the air
suct
ion valves (US and
ZX11
00 0
models) (Section
6)
o Check and synchronise the carburettors (Section
7)
o Check the brake
pads
(Section
8)
o Check the drive chain (Section 9)
o Check
the
steering (Section 10)
o Lubricate the cables, stands and controls
(Section 11)
o Check the head
lamp
alignment (Section 12)
Every 6000 miles (10 000 km)
Ail
of
the 3000 miles maintenance tasks plus the following
o Change the engine/transmission oil and filter
(Section 13)
o Clean the air filter element (Section 14)
o Renew the spark plugs (Section 15)
o Check and adjust the valve clearances (Section 16)
o Clean/renew
the
fuel filter (Section 17)
o Change the fork oil (Section 18)
o Check the cooling system (Section 19)
o Clean the coolant filter (Section 20)
o Lubricate the swinging arm and suspension linkage
bearings (Section 21)
o Check fastener security (Section 22)
o Check the wheels (Section 23)
Every 12 000 miles (20 000 km)
All
of
the 6000 miles maintenance tasks plus the following
o Renew
the
air filter element (Section 24)
o Renew
the
brake and clutch fluid renewal
(Section 25)
o Lubricate the steering head bearings
(S
ection 26)
Every 24 000 miles (40 000 km)
All
of
the 12 000 miles maintenance tasks plus the following
o Renew the
coo
lant (Section 27)
Every 2 years
o Overhaul the brake and clutch
com
ponents
(Section 28)
o Renew
the
anti-dive unit seals (ZX900 A 1
to
A6 and
ZX
1 000 A models) (Section 29)
Every 4 years
o Renew
the
hydraulic hoses and fuel lines
(Section 30)
1ยท 4 Component locations
ZX900 A component
locations
on
lett-hand
akk
4 Idle
speed
aqUstw
7
-"Jr
fiIr&r
5 &litftHy 8 Engine
oil
/eYeI
sJghtgiass
6 DrIve
chain
9 Engine oil
NI8r
pj.JfJ
ZX900 A component
Iocatlons
on
right-hand
IJide
Coo/a'tl
filtlP' (UK} 7 Front brake
fluid
re5fIfVOir
AJr
suction vaIve5
(1.JS)
8 F
ori<
oil drain
pkJ{J
Steering Ile8d
bearings
9 Eng/rIe
0/1
drIJjn
pJugs
10
Engine
01/
filter
1.6 Component locations
I
Clutch
fluid
res8I'VOir
2
Valves
wrd
5PfIrl<
plugs
3 Idle
spftd
~r
..
I RearbtMe
fluid
~
2
AJr~tter
3 CooIiJnt filter (UK)
%)[1000 B c:ompc>nenlloc:ations
on
left-hand
,Idt
-4
FlAIl
tank
and
pump
fiIfer3
7 Engine
oil
'-111
sightglau
.5
Banet)' 8
Engine
oil fiRer
c.,
6
DrivIJ
chain
%)[100(1 B
o;omponenllocations
on
right-"-"d-'de
..,
Air
suction vafves
(US)
7 Coolant reservoir
5 SIMring head .btI;Irlngs 8
Bra~8
pad$
8
Front
bnlke fluid
reservoir
,--
10
Forltoil
chin
plug
9 Engine oil dr8in plugs
10 Et'If}ine
oil
1iitf1r
Component locations
"7
ZX1100
C/O componenllo<:ati(>nS
on
right-hand tide
Valves
and
sperl{
plIfp
6
Front
bmIre
fluid
~
Sfetlti1g
htMId
~
7 Brake
pttds
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Kawasaki ZX900 A GPZ900R 1987 Service and Repair Manual

Kawasaki
Brand
Kawasaki
Model
ZX900 A GPZ900R 1987
Category
Motorcycles
Type
Service and Repair Manual
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