Kawasaki NINJA ZX-10R User manual

Type
User manual
Ninja ZX–10R
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 topic required.
Quick Reference Guide
General Information 1 j
Periodic Mainte nance 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
Appendix 17 j
Ninja ZX–10R
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 & M achinery
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 i mprovements incorporated after this publication.
All information contained in this publication is based on the l atest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2004 Kawasaki Heavy Industries, Ltd. First Edition (1): Jan. 9, 2004 (M)
LIST OF ABBREVIAT IONS
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, K awasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United S tates E nvironmental 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 crankcase 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 they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air A ct, 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 r emove or render inoperative any device or element of design installed
on or in a m otor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or m otor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with r egulations 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
interpre ted as f ollows:
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 dura bility of t he motorcycl e.
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,
THE VIOLATION OF WHICH IS PUNISHA BLE BY CIVIL PENALTIES NOT EXCEEDING
$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 m aintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to i ts 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 t o constitute tampering are the acts l isted below:
•
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
•
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. 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 s hould 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 work 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 repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest l ife 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
Ka
wasaki 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 Us e This M anual
In preparing this manual, we divided the prod-
uct into its major systems. These systems be-
came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a sin-
gle chapter.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information, for exam-
ple, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate t he Periodic Maintenance chap-
ter. Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug sec-
tion.
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 w hich, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures w hich, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more 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 INFORMATION 1-1
1
General Information
Table of Con tents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................. ........................................................ .................. ...... 1-7
General Specifications......................................................... ............................. ...................... 1-9
Technical Information – Immobilizer System .......................................................................... 1-12
Technical Information – Exhaust Device System.................................................................... 1-15
Technical Information.............................................................................................................. 1-16
Unit Conversion Table ............................................................................................................ 1-17
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground wire
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (-) wire to the neg-
ative terminal.
Edges of Parts
Lift large or heavy parts w earing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and C leaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a c lean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or rec-
ommended by KAWA SAKI. Gaskets, O rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
specified sequence to prevent case warpage or deformation
which can lead to malfunction. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally. Often, the tightening sequence is followed twice
-initial tightening and final tightening with torque wrench.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced m allet w henever tapping is necessary.
Gasket, O-ri ng
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains be-
fore applying liquid gasket or locking agent. Do
not apply
them excessively. Excessive application can clog oil pas-
sages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to m aintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless r emoval is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the i nner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
GENERAL INFORMATION 1-7
Model Identification
ZX1000–C1 (Europe) Left Side View
ZX1000–C1 (Europe) Right Side View
1-8 GENERAL INFORMATION
Model Identification
ZX1000–C1 (US and Canada) Left Side View
ZX1000–C1 (US and Canada) Right Side View
GENERAL INFORMATION 1-9
General Specifications
Items ZX1000–C1 (Ninja ZX–10R)
Dimensions
Overall Length 2 045 mm (80.5 in.)
Overall Width 705 mm (27.8 i n.)
Overall Height 1 115 mm (43.9 in.)
Wheelbase
1 385 mm (54.5 in.)
Road Clearance 125 mm (4.9 in.)
Seat Height 825 mm (32.5 i n.)
Dry Mass 170 kg (375 lb)
Curb Mass:
Front 102 kg (225 lb)
Rear 94 kg (207 lb)
Fuel Tank Capacity 17 L ( 4.5 US gal)
Performance
Minimum Turning Radius 3.3 m (10.8 ft)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Liquid-cooled
Bore and Stroke 76.0 × 55.0 mm (3.0 × 2.2 in.)
Displacement 998 mL (60.9 cu in.)
Compression R atio 12.7 : 1
Maximum Horsepower 128.4 kW (175 PS) @11 700 r/min (rpm),
(FR) 78.2 kW (106 PS) @11 500 r/min (rpm),
(CA),(CAL),(US)–––
Maximum Torque
115N·m(11.7kgf·m,49ft·lb)@9500r/min(rpm),
(CA), (CAL), (FR), (US) – – –
Carburetion System FI (Fuel injection), MIKUNI 43EIDW
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter in ECU )
Ignition Timing 10° BTDC @1 100 r/min (rpm)
Spark Plug NGK CR9EIA–9
Cylinder Numbering Method Left to right, 1–2–3–4
Firing Order 1–2–4–3
Valve Timing:
Inlet:
Open 46° BTDC
Close 74° ABDC
Duration 300°
Exhaust:
Open 66° BB DC
Close 46° ATDC
Duration 292°
Lubrication System Forced lubrication (wet sump with cooler)
1-10 GENERAL INFORMATION
General Specifications
Items ZX1000–C1 (Ninja ZX–10R)
Engine oil:
Type API SE, SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W–40
Capacity 3.7 L (3.9 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 1.611 (87/54)
Clutch Type Wet multi disc
Transmission:
Type
6–speed, constant mesh, return shift
Gear Ratios:
1st 2.533 (38/15)
2nd 2.053 (39/19)
3rd 1.737 (33/19)
4th 1.524 (32/21)
5th 1.381 (29/21)
6th 1.304 (30/23)
Final D rive System:
Type Chain drive
Reduction Ratio 2.294 (39/17)
Overall Drive Ratio 4.821 @Top gear
Frame
Type Tubular, diamond
Caster (Rake Angle) 24°
Trail 102 mm (4.0 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 M/C (58W)
Rear Tire:
Type Tubeless
Size 190/50 ZR17 M/C (73W)
Front Suspension:
Type Telescopic fork (upside-down)
Wheel Travel 120 mm (4.7 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 125 mm (4.9 in.)
Brake Type:
Front Dual discs
Rear Single disc
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Kawasaki NINJA ZX-10R User manual

Type
User manual

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