Kawasaki 2004 NINJA ZX1200-B3 User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

Ninja ZX-12R
Motorcycle
Service Manual
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific t opic required.
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Troubleshooting 17 j
Ninja ZX-12R
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at t he time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual m odel component parts.
© 2002 Kawasaki Heavy Industries, Ltd. Fourth Edition (1) : Mar. 5, 2004 (K)
LIST O F ABBREVIATIONS
A
ampere(s)
lb
pound(s)
ABDC after bottom dead center
m
meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of cranckcase vapors into the atmosphere. Instead, the
vapors are routed through an oil separator to the inlet side of the engine. While the engine is
operating, the vapors are drawn into combustion chamber, where t hey are burned along with the
fuel and air supplied by the fuel injection system.
2. Exhaust Emission Control S ystem
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s " tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or m otor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor v ehicle engines, or who operates a f leet of m otor v ehicles know-
ingly t o remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
â—‹
The phrase "remove or render inoperative any device or element of design" has been generally
interpreted a s follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or d urability o f the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
•
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
•
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This m anual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair w ork. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the w ork care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all r epairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
•
Follow the Periodic Maintenance Chart in the
Service Manual.
•
Be alert for problems and non-scheduled
maintenance.
•
Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
•
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
•
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divited into its
major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists i n locating their chapters. Each
chapter in turn has its own comprehensive
Table of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to f ind the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four m ore symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
NOTE
â—‹
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
•
Indicates a procedural step or work to be
done.
â—‹
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMAT ION 1-1
1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......................... 1-9
Technical Information – Monocoque Frame ........................................................................... 1-12
Technical Information – Spark Plug ........................................................................................ 1-13
Technical Information – Immobilizer System (ZX1200-B3)..................................................... 1-14
Torque and Locking Agent...................................................................................................... 1-17
Special Tools and Sealant ...................................................................................................... 1-22
Cable, W ire, and Hose Routing (ZX1200-B1/B2)................................................................... 1-29
Cable, W ire, and Hose Routing (ZX1200-B3) ........................................................................ 1-46
Unit Conversion Table ............................................................................................................ 1-60
1-2 GENERAL INFORMATION
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip-
tions have been included wherever necessary. Nevertheless, even a detailed account has limitations,
a certain amount of basic knowledge is also required for successful work.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Cables
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motor cycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated w hile disconnecting the leads from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery.
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. But if this Service
Manual has installation or assembly procedures, follow them. Note parts locations and cable,
lead, and hose routing during removal or disassembly so they can be i nstalled or assembled in
the same way. It i s preferable to mark and record the locations and routing as much as possible.
(4) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes
and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid
distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. Where
there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must
be tightened in the order and method indicated.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable t orque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine w hat may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in order
to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is Stoddard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.
(10)Liquid Gasket, N on-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause seri-
ous damage. An example of non-permanent locking agent commonly available in North America
is Loctite Lock’n Seal (Blue).
(11) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.
GENERAL INFORMATION 1-3
Before Servicing
(12) Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace
any ball or needle bearings that were removed with new ones, as removal generally damages
bearings. Install bearings with the marked side f acing out applying pressure evenly with a suitable
driver. Only press on the race that forms the press fit with the base component to avoid damaging
the bearings. This prevents severe stress on the balls or needles and races, and prevent races
and balls or needles from being dented. Press a ball bearing until it stops at the stopper in the
hole or on the shaft.
(13) O il Seal and Grease Seal
Replace any oil or grease seals that w ere removed with new ones, as removal generally dam-
ages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks
facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with
the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes
through a seal, apply little high temperature grease on the lips to reduce rubber to metal friction.
(14) Circlip, Retaining Ring, and Cotter Pin
Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as
removal weakens and deforms them. When installing circlips and retaining rings, take care to
compress or expand them only enough to install them and no more.
(15) Lubrication
Engine wear is generally at its maximum while t he engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever
is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be c leaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don’t use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS
2) and molybdenum disulfide
oil in the assembly of certain engine and chassis parts. The molybdenum disulfide oil is a mixture
of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1), which can be made in
your work shop. Always check manufacturer recommendations before using such special lubri-
cants.
(16) Electrical Leads
All the electrical leads are either single-color or two-color and, with only a few exceptions, must
be connected to leads of the same color. On any of the two-color leads there is a greater amount
of one color and a lesser amount of a second color, so a two-color lead is identified by first the
primary color and then the secondary color. For example, a yellow lead with thin red stripes is
referred to as a "yellow/red" lead; it would be a "red/yellow" lead if the colors were reversed to
make red the main color.
(17) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.
1-4 GENERAL INFORMATION
Before Servicing
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deteriorat ion Seizure
(19) Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the m easurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
(20) Instrument
Use a meter that has enough accuracy for an accurate measurement.
Read the manufacturer ’s instructions thoroughly before using the meter.
Incorrect values may lead to improper adjustments.
GENERAL INFORMATION 1-5
Model Identification
ZX1200-B1 Left Side View
ZX1200-B1 Right Side View
1-6 GENERAL INFORMATION
General Specifications
Items ZX1200-B1 ∼ B3
Dimensions
Overall Length 2 085 mm (82.09 in.)
Overall Width 740 m m (29.13 in.)
Overall Height 1 200 mm (47.24 in.)
Wheelbase 1 450 mm (57.09 in.)
Road Clearance 120 m m (4.72 in.)
Seat Height 820 m m (32.28 in.)
Dry Mass 210 kg (463 lb)
Curb Mass:
Front 125 kg (276 lb)
Rear 121 kg (267 lb)
Fuel Tank Capacity 19.0 L (5.0 US gal)
Performance
Minimum Turning Radius 3.0 m (9.8 ft)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Liquid-cooled
Bore and Stroke 83.0 × 55.4 mm (3.27 × 2.18 in.)
Displacement 1 199 mL (73.16 cu in.)
Compression Ratio 12.2
Maximum Horsepower (H) 131 kW (178 PS) @9 500 r/min (rpm),
(AU) ZX1200-B1/B2: 130 kW (177 PS) @10 500 r/min ( rpm),
(AU) ZX1200-B3: 131 kW (178 PS) @10 500 r/min (rpm),
(HR) 78.2 kW ( 106.4 PS) @8 500 r/min (rpm),
(MY) ZX1200-B1/B2: 131 kW (178 PS) @ 9 500 r/min (rpm),
(MY) ZX1200-B3: 128 kW (174 PS) @9 500 r/min ( rpm)
(US), (CA) – – –
Maximum Torque (H, AU) 134 N·m (13.7 kgf·m, 99 ft·lb) @7 500 r/min (rpm),
(MY) ZX1200-B1/B2: 134 N·m (13.7 kgf·m , 99 f t·lb) @7 500
r/min (rpm),
(MY) ZX1200-B3: 130 N·m ( 13.3 kgf·m, 96 ft·lb) @7 500 r/min
(rpm),
(HR) 111 N·m (11.3 kgf·m, 82 ft·lb) @5 000 r/min (rpm),
(US), (CA) – – –
Carburetion System FI (Fuel Injection), ZX1200-B1/B2: MIKUNI 46 EIS × 4
ZX1200-B3: KEIHIN ( 46 × 4)
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU)
Ignition Timing 10° BTDC @1 000 r/min (rpm)
Spark Plugs NGK CR9EKPA
Cylinder Num bering Method Left to right, 1-2-3-4
Firing Order 1-2-4-3
GENERAL INFORMATION 1-7
General Specifications
Items ZX1200-B1 ∼ B3
Valve Timing:
Inlet:
Open 46° BTDC
Close 74° ABDC
Duration 300°
Exhaust:
Open 69° BBDC
Close 45° ATDC
Duration 294°
Lubrication System Forced lubrication (wet sump with cooler)
Engine Oil:
Grade API SE, SF or SG
API SH or SJ with JASO MA
Viscosity
SAE 10W-40
Capacity 3.6 L (3.8 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction R atio 1.596 (83/52)
Clutch Type Wet, multi disc
Tr ansmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.429 (34/14)
2nd
1.824 (31/17)
3rd
1.440 (36/25)
4th
1.250 (30/24)
5th 1.130 (26/23)
6th 1.033 (31/30)
Final Drive System:
Type Chain drive
Reduction R atio 2.556 (46/18)
Overall Drive Ratio 4.215 @Top gear
Frame
Type Press backbone
Caster (Rake Angle) 23.5°
Trail
98 mm (3.86 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 M/C (58W)
Rear Tire:
Type Tubeless
Size 200/50 ZR17 M/C (75W)
1-8 GENERAL INFORMATION
General Specifications
Items ZX1200-B1 ∼ B3
Front Suspension:
Type
Telescopic fork (upside-down)
Wheel Travel
120 m m (4.72 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 140 m m (5.51 in.)
Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen) × 2
Tail/Brake Light 12 V 5/21 W × 2
Alternator:
Type Three-phase AC
Rated Output 31 A/14 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
AU: Australian Model
US: U.S.A. Model
CA: Canadian Model
MY: Malaysian Model
HR: WVTA Approval Model, Honeycomb Catalytic Converter (Restricted Power)
H: WVTA Approval Model, Honeycomb Catalytic Converter
GENERAL INFORMATION 1-9
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM
Since the emission regulations become more severe, Kawasaki has adopted a type of simplified
KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys-
tem, according to each r egulation of different countries.
The muffler with built-in catalyst has the same durability as the conventional muffler, however, do
not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without
ignition damages catalyst.
Refer to the ZX900E Service Manual (Part No. 99924-1255) for more information about the KLEEN
(theory, m aintenance, and handling precautions), including the secondary air injection system.
Honeycomb Type Catalytic Converter
â—‹
The converter is a three-way catalytic converter, and its surface is covered w ith alumina upon which
platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-
ing a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter. The
honeycomb structure is convenient for t he catalytic converter because it has a large surface area
but small size to react effectively and has low exhaust resistance. In addition, its i nherent strength
helps resist vibration, and has simple structure welded directly on the silencer.
â—‹
Generally, the temperature of the exhaust gas must be higher than activation temperature, so the
converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is
still high. And, the converters will be activated even under low load conditions.
â—‹
After the exhaust gas is diluted with the secondary air injection, the catalytic converter works well
because of rich oxygen to reduce CO, HC , and NO
x. Accordingly, we can keep the exhaust gas
emission within regulation.
â—‹
This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,
and NO
x than the pipe type c atalytic converter because of its more and denser catalysts.
1. Manifold
2. Silencer
3. Honeycomb Type Catalyst
4. Non-Catalyst
5. Mark for M anifold
6. Mark for Silencer
1-10 GENERAL INFORMATION
Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM
Exhaust System (ZX1200-B1/B2)
78.2: Horsepower 78.2 kW (106.3 ps)
Full: Full Power
H: Honeycomb Type Catalyst
UK: United Kingdom Model
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Kawasaki 2004 NINJA ZX1200-B3 User manual

Category
Motorcycles
Type
User manual
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