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NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
Summary
Service Manual
Kawasaki
Z900
Z900 ABS
Motorcycle Service Manual
First Edition (0) : Dec. 1, 2016
Quick Reference Guide
General Information – 1
Periodic Maintenance – 2
Fuel System (DFI) – 3
Cooling System – 4
Engine Top End – 5
Clutch – 6
Engine Lubrication System – 7
Engine Removal/Installation – 8
Crankshaft/Transmission – 9
Wheels/Tires – 10
Final Drive – 11
Brakes – 12
Suspension – 13
Steering – 14
Frame – 15
Electrical System – 16
Appendix – 17
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
KAWASAKI | Z900 | 2017 |
1 Associated Document
Manufacturer Communications
99924-1525-01
https://www.nhtsa.gov/recalls?nhtsaId=10109090
MC-10109090-9999.pdf 15974.042KB
https://static.oemdtc.com/TSB/MC-10109090-9999.pdf
- Formulated with Trizone technology to protect all 3 critical zones: engine, clutch and gearbox
- Race derived technology for maximum engine acceleration
- Extreme high temperature air-cooled performance and water-cooled engine performance
- Excellent shear stability to prevent viscosity breakdown
- Exceeds API SL and JASO MA-2
- 100% Synthetic Ester
- Formulated To Meet The Latest Manufacturers' Specifications
- Improved High Temperature Deposit Protection And Sludge Control
- Ensures Optimum Clutch Performance At Start-Up, Acceleration, And Full Speed
- Standards: Ape Sn, Jasso Ma2
- Optimal lubrication in all operating conditions, ensures low oil consumption
- Very high shear and ageing stability, highest levels of wear protection
- Tested and approved for catalytic converters, optimal engine cleanliness
- Ideally suited for wet clutches
- Specifications and Approvals: API, SM, ACEA A3-04, JASO, MA2
- Optimal lubrication in all operating conditions, ensures low oil consumption
- Very high shear and ageing stability, highest levels of wearing protection
- Tested and approved for catalytic converters, optimal engine cleanliness
- Ideally suited for wet clutches
- Specifications and Approvals: API, SM, ACEA A3-04, JASO, MA2
- Please see Product Description regarding the California Proposition 65 Warning
- Practiced and tested extensively with KTM, Husqvarna, Yamaha, Kawasaki, Honda, Aprilia, BMW, Suzuki, Ducati, Triumph, and Moto-Guzzi motorcycles
- High performance full synthetic oil utilizing the latest lubrication technology
- Excellent engine protection in all conditions including extreme high stress racing conditions
- Excellent cold start lubrication, low oil evaporation tendency, suitable for motorcycles with catalytic converters
- Full synthetic 5W-40 diesel engine oil with Triple Protection Plus technology protects against wear, deposits, oil breakdown, and improves low-temperature flow
- Exceptional wear protection for longer life in a wide range of heavy-duty engine applications — from pickup trucks to tractors to semi rigs
- Enhanced fuel economy capability of 1.5 percent without compromising engine protection or durability (compared to 15W-40 oils)
- Multi-functional dispersant additives provide an enhanced level of protection against the effects of soot, dirt, and other contaminants (compared to previous formulation)
- Increased shear stability for better viscosity control and optimal engine oil pressure
- XPS synthetic 4-stroke oil is specifically engineered to meet the particular lubrication requirements of Can-Am, Spyder and Sea-Doo vehicles equipped with Rotax 4-TEC 4-stroke engines.
- Powersport formula with premium anti-wear and anti-corrosion additives
- Designed for high-performance off-road, on-road and PWC 4-stroke engines, including turbo or supercharged Powersports engines
- Provides superior engine and transmission protection against rust and corrosion even in extreme conditions
- Ambient temperature operating range: -31°F / 104°F (-35°C / 40°C)
- 100% Synthetic Double Ester
- Designed for highly modified engines
- Electrochemical bonding to metal parts
- Up to 5x higher film strength
- 0% shear loss on Bosch ASTM D6278 test
Last update on 2024-03-12 / Affiliate links / Images from Amazon Product Advertising API
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SEOCONTENT-START
General Information Table of Contents Before Servicing . 1-2 Model Identification. 1-7 General Specifications 1-9 Unit Conversion Table 1-12 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-11 Special Tools 2-13 Periodic Maintenance Procedures 2-14 Fuel System (DFI) 2-14 Air Cleaner Element Replacement 2-14 Idle Speed Inspection . 2-15 Idle Speed Adjustment 2-15 Throttle Control System Inspection. 2-15 Engine Vacuum Synchronization Inspection. 2-16 Fuel System Inspection. 2-19 Fuel Filter Replacement 2-20 Fuel Hose Replacement . 2-22 Evaporative Emission Control System Inspection (Equipped Models) . 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-25 Coolant Change 2-25 Water Hose and O-ring Replacement. 2-28 Engine Top End . 2-29 Valve Clearance Inspection 2-29 Valve Clearance Adjustment. 2-30 Air Suction System Damage Inspection 2-34 Clutch. 2-35 Clutch Operation Inspection . 2-35 Engine Lubrication System 2-36 Engine Oil Change 2-36 Oil Filter Replacement 2-37 Wheels/Tires 2-38 Air Pressure Inspection. 2-38 Wheels and Tires Inspection. 2-38 Wheel Bearing Damage Inspection 2-39 Final Drive 2-40 Drive Chain Lubrication Condition Inspection . 2-40 Drive Chain Slack Inspection 2-40 Drive Chain Slack Adjustment 2-41 Wheel Alignment Inspection . 2-42 Drive Chain Wear Inspection 2-42 Chain Guide Wear Inspection . 2-43 Brakes 2-44 Brake System Inspection 2-44 Brake Operation Inspection 2-45 Brake Fluid Level Inspection. 2-45 Brake Fluid Change 2-46 Brake Hose and Pipe Replacement 2-48 Master Cylinder Rubber Parts Replacement 2-52 Caliper Rubber Parts Replacement 2-53 Brake Pad Wear Inspection 2-57 Brake Light Switch Operation Inspection 2-57 2-2 PERIODIC MAINTENANCE Suspension 2-58 Suspension System Inspection. 2-58 Steering . 2-60 Steering Play Inspection . 2-60 Steering Play Adjustment 2-60 Steering Stem Bearing Lubrication . 2-62 Electrical System . 2-63 Lights and Switches Operation Inspection 2-63 Headlight Aiming Inspection . 2-65 Side Stand Switch Operation Inspection. 2-66 Engine Stop Switch Operation Inspection. 2-67 Spark Plug Replacement 2-68 Others 2-68 Chassis Parts Lubrication 2-68 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-69 Fuel System (DFI) Table of Contents Exploded View. 3-4 DFI System 3-10 DFI Components Naming 3-12 DFI Parts Location. 3-19 Specifications 3-22 Special Tools and Sealant . 3-24 DFI Servicing Precautions. 3-26 DFI Servicing Precautions 3-26 Troubleshooting the DFI System . 3-28 Outline 3-28 Inquiries to Rider. 3-32 DFI System Troubleshooting Guide 3-35 Self-Diagnosis . 3-40 Self-Diagnosis Outline . 3-40 Self-Diagnosis Procedures 3-41 Service Code Reading . 3-43 Service Code Erasing 3-43 Backups . 3-45 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-48 Main Throttle Sensor Removal/Adjustment. 3-48 Main Throttle Sensor Input Voltage Inspection. 3-48 Main Throttle Sensor Resistance Inspection 3-49 Main Throttle Sensor Output Voltage Inspection. 3-49 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) 3-52 Intake Air Pressure Sensor #1 Removal 3-52 Intake Air Pressure Sensor #1 Installation . 3-52 Intake Air Pressure Sensor #1 Input Voltage Inspection 3-53 Intake Air Pressure Sensor #1 Output Voltage Inspection . 3-54 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) 3-58 Intake Air Temperature Sensor Removal/Installation 3-58 Intake Air Temperature Sensor Output Voltage Inspection . 3-58 Intake Air Temperature Sensor Resistance Inspection . 3-59 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117). 3-61 Water Temperature Sensor Removal/Installation 3-61 Water Temperature Sensor Output Voltage Inspection . 3-62 Water Temperature Sensor Resistance Inspection . 3-63 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) 3-64 Intake Air Pressure Sensor #2 Removal 3-64 Intake Air Pressure Sensor #2 Installation . 3-64 Intake Air Pressure Sensor #2 Input Voltage Inspection 3-65 Intake Air Pressure Sensor #2 Output Voltage Inspection . 3-66 Crankshaft Sensor (Service Code 21) (DTC P0335). 3-68 Crankshaft Sensor Removal/Installation 3-68 Crankshaft Sensor Resistance Inspection 3-68 Crankshaft Sensor Peak Voltage Inspection 3-68 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158). 3-69 Rear Wheel Rotation Sensor Signal Inspection. 3-69 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) 3-71 Gear Position Sensor Removal/Installation 3-71 Gear Position Sensor Input Voltage Inspection. 3-71 Gear Position Sensor Output Voltage Inspection. 3-72 Vehicle-down Sensor (Service Code 31) (DTC C0064) 3-74 Vehicle-down Sensor Removal 3-74 Vehicle-down Sensor Installation . 3-74 Vehicle-down Sensor Input Voltage Inspection. 3-75 Vehicle-down Sensor Output Voltage Inspection. 3-76 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) 3-79 Subthrottle Sensor Removal/Adjustment. 3-79 Subthrottle Sensor Input Voltage Inspection 3-79 Subthrottle Sensor Output Voltage Inspection 3-80 Subthrottle Sensor Resistance Inspection 3-82 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) 3-83 Oxygen Sensor Removal/Installation 3-83 Oxygen Sensor Inspection. 3-83 Immobilizer Amplifier (Service Code 35, Equipped Models). 3-86 Antenna Resistance Inspection . 3-86 Amplifier Input Voltage Inspection 3-86 Blank Key Detection (Service Code 36, Equipped Models). 3-87 Ignition Key Inspection. 3-87 ECU Communication Error (Service Code 39). 3-88 ECU Communication Line Inspection 3-88 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) 3-89 Fuel Injector Removal/Installation 3-89 Fuel Injector Audible Inspection. 3-89 Fuel Injector Resistance Inspection 3-89 Fuel Injector Power Source Voltage Inspection. 3-90 Fuel Injector Output Voltage Inspection 3-91 Fuel Injector Fuel Line Inspection 3-92 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) . 3-94 Stick Coil Removal/Installation. 3-94 Stick Coil Primary Winding Resistance Inspection . 3-94 Stick Coil Input Voltage Inspection 3-94 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-96 Radiator Fan Relay Removal/Installation 3-96 Radiator Fan Relay Inspection. 3-96 Subthrottle Valve Actuator (Service Code 62) (DTC P2100). 3-97 Subthrottle Valve Actuator Removal 3-97 Subthrottle Valve Actuator Inspection 3-97 Subthrottle Valve Actuator Resistance Inspection . 3-97 Subthrottle Valve Actuator Input Voltage Inspection. 3-98 Air Switching Valve (Service Code 64) (DTC P0410) 3-100 Air Switching Valve Removal/Installation 3-100 Air Switching Valve Inspection . 3-100 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-101 Oxygen Sensor Heater Removal/Installation 3-101 Oxygen Sensor Heater Resistance Inspection . 3-101 Oxygen Sensor Heater Power Source Voltage Inspection 3-102 Fuel Supply System (Service Code 94) (DTC P0170) 3-104 Fuel Supply System Inspection 3-104 Purge Valve (Service Code 3A, Equipped Models) (DTC P0443). 3-105 Purge Valve Removal/Installation 3-105 Purge Valve Inspection 3-105 Warning Indicator Light (LED) . 3-107 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-107 ECU. 3-108 ECU Identification 3-108 ECU Removal 3-108 ECU Installation . 3-109 ECU Power Supply Inspection. 3-109 DFI Power Source . 3-112 ECU Fuse Removal . 3-112 ECU Fuse Installation 3-112 ECU Fuse Inspection . 3-112 ECU Main Relay Removal/Installation 3-112 ECU Main Relay Inspection . 3-112 Fuel Line 3-113 Fuel Pressure Inspection . 3-113 Fuel Flow Rate Inspection . 3-114 Fuel Pump . 3-116 Fuel Pump Removal 3-116 Fuel Pump Installation . 3-117 Fuel Pump Operation Inspection . 3-117 Fuel Pump Operating Voltage Inspection 3-118 Pressure Regulator Removal. 3-119 Fuel Pump Relay Removal/Installation 3-119 Fuel Pump Relay Inspection 3-119 Throttle Grip and Cables . 3-121 Free Play Inspection 3-121 Free Play Adjustment. 3-121 Cable Installation . 3-121 Cable Lubrication . 3-121 Throttle Body Assy 3-122 Idle Speed Inspection/Adjustment 3-122 Synchronization Inspection/Adjustment. 3-122 Throttle Body Assy Removal 3-122 Throttle Body Assy Installation. 3-123 Throttle Body Assy Disassembly . 3-125 Throttle Body Assy Assembly 3-126 Air Cleaner. 3-127 Air Cleaner Element Removal/Installation 3-127 Air Cleaner Element Inspection . 3-127 Air Cleaner Oil Draining . 3-127 Air Cleaner Housing Removal 3-127 Air Cleaner Housing Installation. 3-128 Fuel Tank. 3-129 Fuel Tank Removal 3-129 Fuel Tank Installation . 3-131 Fuel Tank and Cap Inspection . 3-132 Fuel Tank Cleaning 3-133 Evaporative Emission Control System (Equipped Models) 3-134 Parts Removal/Installation . 3-134 Hose Inspection . 3-134 Purge Valve Inspection 3-134 Canister Inspection . 3-134 Cooling System Table of Contents Exploded View 4-2 Coolant Flow Chart. 4-4 Specifications . 4-6 Special Tools and Sealant 4-7 Coolant . 4-8 Coolant Deterioration Inspection. 4-8 Coolant Level Inspection. 4-8 Coolant Draining . 4-8 Coolant Filling . 4-8 Pressure Testing . 4-8 Cooling System Flushing 4-9 Coolant Reserve Tank Removal . 4-9 Coolant Reserve Tank Installation 4-9 Water Pump 4-10 Water Pump Removal. 4-10 Water Pump Installation 4-10 Water Pump Inspection. 4-12 Water Pump Impeller Disassembly/Assembly 4-12 Water Pump Impeller Inspection. 4-12 Water Pump Housing Disassembly 4-12 Water Pump Housing Assembly . 4-13 Mechanical Seal Inspection 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-15 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-16 Thermostat . 4-17 Thermostat Removal. 4-17 Thermostat Installation 4-17 Thermostat Inspection 4-18 Hose and Pipes 4-19 Hose Installation . 4-19 Hose Inspection 4-19 Water Temperature Sensor 4-20 Water Temperature Sensor Removal/Installation . 4-20 Water Temperature Sensor Inspection . 4-20 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-8 Special Tools and Sealants . 5-10 Clean Air System. 5-12 Air Suction Valve Removal. 5-12 Air Suction Valve Installation 5-12 Air Suction Valve Inspection 5-13 Air Switching Valve Removal . 5-13 Air Switching Valve Installation 5-13 Air Switching Valve Operation Test 5-13 Air Switching Valve Unit Test . 5-13 Clean Air System Hose Inspection 5-14 Cylinder Head Cover . 5-15 Cylinder Head Cover Removal 5-15 Cylinder Head Cover Installation . 5-15 Camshaft Chain Tensioner 5-17 Camshaft Chain Tensioner Removal 5-17 Camshaft Chain Tensioner Installation . 5-17 Camshaft, Camshaft Chain . 5-18 Camshaft Removal 5-18 Camshaft Installation . 5-19 Camshaft, Camshaft Cap Wear Inspection 5-22 Camshaft Runout Inspection 5-22 Cam Wear Inspection 5-23 Camshaft Chain Removal 5-23 Camshaft Chain Installation . 5-23 Cylinder Head 5-24 Cylinder Compression Measurement 5-24 Cylinder Head Removal. 5-25 Cylinder Head Installation 5-26 Cylinder Head Warp Inspection . 5-27 Valves 5-28 Valve Clearance Inspection . 5-28 Valve Clearance Adjustment 5-28 Valve Removal . 5-28 Valve Installation 5-28 Valve Guide Removal 5-28 Valve Guide Installation . 5-29 Valve-to-Guide Clearance Measurement (Wobble Method). 5-30 Valve Seat Inspection 5-30 Valve Seat Repair 5-31 Cylinder, Pistons 5-36 Cylinder Removal. 5-36 Cylinder Installation 5-36 Piston Removal 5-37 Piston Installation. 5-38 Cylinder Wear Inspection. 5-38 Piston Wear Inspection 5-39 Piston Ring, Piston Ring Groove Wear Inspection 5-39 Piston Ring Groove Width Inspection 5-39 Piston Ring Thickness Inspection 5-40 Piston Ring End Gap Inspection 5-40 Throttle Body Assy Holder. 5-41 Throttle Body Assy Holder Removal 5-41 Throttle Body Assy Holder Installation . 5-41 Muffler 5-42 Muffler Body Removal 5-42 Muffler Body Installation. 5-44 Exhaust Pipe Removal. 5-46 Exhaust Pipe Installation 5-46 Clutch Table of Contents Exploded View 6-2 Specifications . 6-4 Special Tool and Sealant 6-5 Clutch Lever and Cable 6-6 Clutch Lever Free Play Inspection 6-6 Clutch Lever Free Play Adjustment 6-6 Clutch Cable Removal 6-6 Clutch Cable Installation . 6-6 Clutch Cable Lubrication. 6-6 Clutch Lever Assembly Installation . 6-6 Clutch Lever and Cable 6-7 Clutch Lever Removal. 6-7 Clutch Lever Installation 6-7 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-9 Release Shaft Installation . 6-10 Clutch Cover Disassembly 6-10 Clutch Cover Assembly. 6-11 Clutch . 6-12 Clutch Removal. 6-12 Clutch Installation 6-13 Clutch Plate Assembly Length Inspection. 6-16 Clutch Plate Assembly Length Adjustment . 6-16 Clutch Plate, Wear, Damage Inspection . 6-17 Clutch Plate Warp Inspection 6-17 Clutch Housing Finger Inspection. 6-17 Clutch Housing Spline Inspection . 6-17 Clutch Pressure Plate and Clutch Hub Inspection 6-18 Clutch Spring Inspection . 6-18 Engine Lubrication System Table of Contents Exploded View 7-2 Engine Oil Flow Chart. 7-4 Specifications . 7-5 Special Tools and Sealants 7-6 Engine Oil and Oil Filter 7-7 Oil Level Inspection. 7-7 Engine Oil Change 7-7 Oil Filter Replacement 7-7 Oil Pan 7-8 Oil Pan Removal. 7-8 Oil Pan Installation 7-8 Oil Screen. 7-10 Oil Screen Removal 7-10 Oil Screen Installation . 7-10 Oil Screen Cleaning 7-10 Oil Pressure Relief Valve 7-11 Oil Pressure Relief Valve Removal . 7-11 Oil Pressure Relief Valve Installation 7-11 Oil Pressure Relief Valve Inspection. 7-11 Oil Pump. 7-12 Oil Pump Removal 7-12 Oil Pump Installation . 7-12 Oil Pump Drive Gear Removal 7-13 Oil Pump Drive Gear Installation. 7-13 Oil Cooler (MY Model) 7-14 Oil Cooler Removal. 7-14 Oil Cooler Installation 7-14 Oil Pressure Measurement. 7-15 Oil Pressure Measurement . 7-15 Oil Pressure Switch 7-16 Oil Pressure Switch Removal . 7-16 Oil Pressure Switch Installation 7-16 Oil Pipe . 7-17 Oil Pipe Removal 7-17 Oil Pipe Installation . 7-17 Engine Removal/Installation Table of Contents Exploded View 8-2 Engine Removal/Installation . 8-4 Engine Removal 8-4 Engine Installation. 8-6 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-8 Crankcase Splitting 9-9 Crankcase Splitting 9-9 Crankcase Assembly . 9-10 Crankshaft and Connecting Rods 9-15 Crankshaft Removal 9-15 Crankshaft Installation . 9-15 Connecting Rod Removal 9-15 Connecting Rod Installation . 9-16 Crankshaft/Connecting Rod Cleaning 9-20 Connecting Rod Bend Inspection 9-20 Connecting Rod Twist Inspection. 9-20 Connecting Rod Big End Side Clearance Inspection 9-21 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-21 Crankshaft Side Clearance Inspection 9-23 Crankshaft Runout Inspection 9-24 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-24 Balancer 9-27 Balancer Removal 9-27 Balancer Installation. 9-27 Balancer Adjustment 9-28 Balancer Damper Inspection 9-28 Starter Motor Clutch 9-29 Starter Motor Clutch Removal/Installation 9-29 Starter Motor Clutch Disassembly 9-29 Starter Motor Clutch Assembly 9-29 Starter Motor Clutch Inspection . 9-29 External Shift Mechanism 9-30 Shift Pedal Removal 9-30 Shift Pedal Installation . 9-30 External Shift Mechanism Removal 9-31 External Shift Mechanism Installation . 9-31 External Shift Mechanism Inspection 9-32 Transmission . 9-34 Transmission Shaft Removal . 9-34 Transmission Shaft Installation 9-34 Transmission Shaft Disassembly. 9-34 Transmission Shaft Assembly 9-35 Shift Drum and Fork Removal 9-40 Shift Drum and Fork Installation. 9-40 Shift Drum Disassembly. 9-40 Shift Drum Assembly . 9-41 Shift Fork Bending Inspection 9-41 Shift Fork/Gear Groove Wear Inspection 9-41 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-41 Gear Dog and Gear Dog Hole Damage Inspection . 9-42 Ball Bearing, Needle Bearing, and Oil Seal. 9-43 Ball and Needle Bearing Replacement. 9-43 Ball and Needle Bearing Wear Inspection 9-43 Oil Seal Inspection . 9-43 Wheels/Tires Table of Contents Exploded View 10-2 Specifications . 10-4 Special Tools 10-5 Wheels (Rims) 10-6 Front Wheel Removal . 10-6 Front Wheel Installation 10-6 Rear Wheel Removal 10-7 Rear Wheel Installation. 10-8 Wheel Inspection 10-10 Axle Inspection 10-10 Balance Inspection 10-11 Balance Adjustment 10-11 Balance Weight Removal 10-11 Balance Weight Installation. 10-11 Tires 10-13 Air Pressure Inspection/Adjustment 10-13 Tire Inspection 10-13 Tire Removal. 10-13 Tire Installation 10-13 Tire Repair 10-15 Hub Bearing 10-16 Hub Bearing Removal. 10-16 Hub Bearing Installation 10-16 Hub Bearing Inspection. 10-16 Hub Bearing Lubrication . 10-17 Final Drive Table of Contents Exploded View 11-2 Specifications . 11-4 Special Tools 11-5 Drive Chain. 11-6 Drive Chain Slack Inspection 11-6 Drive Chain Slack Adjustment 11-6 Wheel Alignment Inspection/Adjustment 11-6 Drive Chain Wear Inspection 11-6 Drive Chain Lubrication. 11-6 Drive Chain Replacement . 11-6 Sprocket, Coupling . 11-10 Engine Sprocket Removal 11-10 Engine Sprocket Installation . 11-10 Engine Sprocket Cover Disassembly 11-11 Engine Sprocket Cover Assembly 11-11 Rear Sprocket Removal 11-11 Rear Sprocket Installation. 11-12 Coupling Installation 11-12 Coupling Bearing Removal . 11-12 Coupling Bearing Installation 11-13 Coupling Bearing Inspection . 11-13 Coupling Bearing Lubrication 11-13 Coupling Damper Inspection. 11-14 Sprocket Wear Inspection. 11-14 Rear Sprocket Warp Inspection 11-14 Brakes Table of Contents Exploded View 12-4 Specifications . 12-10 Brake Lever, Brake Pedal. 12-11 Brake Lever Position Adjustment 12-11 Brake Pedal Position Inspection . 12-11 Brake Pedal Position Adjustment 12-11 Brake Pedal Removal . 12-11 Brake Pedal Installation 12-12 Calipers 12-13 Front Caliper Removal 12-13 Rear Caliper Removal. 12-13 Caliper Installation 12-13 Front Caliper Disassembly 12-14 Front Caliper Assembly. 12-14 Rear Caliper Disassembly 12-14 Rear Caliper Assembly . 12-15 Caliper Fluid Seal Damage Inspection 12-15 Caliper Dust Seal Damage Inspection 12-15 Rear Caliper Dust Boot and Friction Boot Damage Inspection. 12-16 Caliper Piston and Cylinder Damage Inspection 12-16 Rear Caliper Holder Wear Inspection . 12-16 Brake Pads. 12-17 Front Brake Pad Removal. 12-17 Front Brake Pad Installation 12-17 Rear Brake Pad Removal 12-17 Rear Brake Pad Installation 12-18 Brake Pad Wear Inspection 12-18 Master Cylinder 12-19 Front Master Cylinder Removal 12-19 Front Master Cylinder Installation . 12-19 Rear Master Cylinder Removal. 12-19 Rear Master Cylinder Installation 12-20 Front Master Cylinder Disassembly 12-21 Rear Master Cylinder Disassembly. 12-21 Master Cylinder Assembly 12-21 Master Cylinder Inspection (Visual Inspection). 12-22 Brake Disc 12-23 Brake Disc Removal . 12-23 Brake Disc Installation 12-23 Brake Disc Wear Inspection 12-23 Brake Disc Warp Inspection 12-23 Brake Fluid . 12-24 Brake Fluid Level Inspection. 12-24 Brake Fluid Change 12-24 Brake Line Bleeding 12-24 Brake Hose. 12-27 Brake Hose and Pipe Removal/Installation. 12-27 Brake Hose and Pipe Inspection. 12-27 Anti-Lock Brake System (Equipped Models) 12-28 Parts Location. 12-28 ABS Servicing Precautions . 12-31 ABS Troubleshooting Outline 12-33 Inquiries to Rider. 12-36 Self-diagnosis Outline . 12-40 Self-diagnosis Procedures 12-40 Service Code Clearing Procedures. 12-41 How to Read Service Codes. 12-44 How to Erase Service Codes 12-44 Yellow ABS Indicator Light (LED) Inspection 12-46 ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) . 12-49 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-49 Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code 25) . 12-49 ABS Motor Inspection (Service Code 35) . 12-50 Wheel Rotation Sensor Signal Abnormal Inspection (Front: Service Code 42) (Rear: Service Code 44) . 12-50 Front or Rear Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-51 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-53 Power Supply Voltage Abnormal Inspection (Service Code 52: Low Voltage) (Service Code 53: High Voltage) 12-55 ABS Hydraulic Unit Internal Error Inspection (Service Code 55) 12-55 ABS Hydraulic Unit Removal 12-56 ABS Hydraulic Unit Installation . 12-57 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-58 Front Wheel Rotation Sensor Installation . 12-59 Rear Wheel Rotation Sensor Removal. 12-59 Rear Wheel Rotation Sensor Installation 12-61 Wheel Rotation Sensor Inspection 12-61 Wheel Rotation Sensor Air Gap Inspection 12-62 Wheel Rotation Sensor Rotor Inspection 12-62 Fuse Removal. 12-62 Fuse Installation 12-62 Fuse Inspection. 12-62 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Rebound Damping Force Adjustment (Left Front Fork Only) . 13-9 Spring Preload Adjustment (Left Front Fork Only) 13-9 Front Fork Removal (Each Fork Leg) . 13-10 Front Fork Installation . 13-10 Front Fork Oil Change 13-10 Front Fork Disassembly 13-25 Front Fork Assembly. 13-27 Inner Tube, Outer Tube Inspection . 13-28 Dust Seal Inspection . 13-29 Spring Tension Inspection. 13-29 Rear Shock Absorber . 13-30 Rebound Damping Force Adjustment. 13-30 Spring Preload Adjustment . 13-30 Rear Shock Absorber Removal 13-30 Rear Shock Absorber Installation . 13-31 Rear Shock Absorber Inspection 13-32 Rear Shock Absorber Scrapping 13-32 Swingarm 13-33 Swingarm Removal. 13-33 Swingarm Installation 13-33 Swingarm Bearing Removal . 13-34 Swingarm Bearing Installation 13-35 Swingarm Bearing, Sleeve Inspection 13-36 Swingarm Bearing Lubrication 13-36 Chain Guide Inspection. 13-36 Tie-Rod, Rocker Arm 13-37 Tie-Rod Removal 13-37 Tie-Rod Installation . 13-37 Rocker Arm Removal 13-38 Rocker Arm Installation. 13-39 Tie-Rod and Rocker Arm Bearing Removal 13-39 Tie-Rod and Rocker Arm Bearing Installation. 13-40 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-40 Rocker Arm/Tie-Rod Bearing Lubrication . 13-40 Steering Table of Contents Exploded View 14-2 Special Tools 14-4 Steering 14-5 Steering Inspection . 14-5 Steering Adjustment 14-5 Steering Stem. 14-6 Stem, Stem Bearing Removal. 14-6 Stem, Stem Bearing Installation 14-7 Steering Stem Bearing Lubrication . 14-9 Steering Stem Warp Inspection 14-9 Stem Cap Deterioration, Damage Inspection . 14-10 Handlebar. 14-11 Handlebar Removal 14-11 Handlebar Installation . 14-11 Frame Table of Contents Exploded View 15-3 Seats 15-14 Rear Seat Removal. 15-14 Rear Seat Installation 15-14 Front Seat Removal 15-14 Front Seat Installation . 15-15 Single Seat Cover Removal (Special Edition Models) 15-15 Single Seat Cover Installation (Special Edition Models). 15-15 Single Seat Cover Disassembly (Special Edition Models) 15-16 Fairings. 15-17 Upper Fairing Removal. 15-17 Upper Fairing Installation 15-18 Upper Fairing Disassembly. 15-19 Upper Fairing Assembly 15-20 Fuel Tank Cover Removal. 15-20 Fuel Tank Cover Installation 15-20 Ignition Switch Cover Removal. 15-20 Ignition Switch Cover Installation 15-20 Middle Fairing Removal 15-21 Middle Fairing Installation . 15-21 Middle Fairing Disassembly 15-21 Inner Cover Removal 15-22 Inner Cover Installation . 15-22 Lower Fairing Removal. 15-22 Lower Fairing Installation 15-22 Side Covers 15-23 Frame Cover Removal 15-23 Frame Cover Installation. 15-23 Frame Sub Cover Removal 15-23 Frame Sub Cover Installation . 15-23 Side Cover Removal. 15-24 Side Cover Installation 15-24 Side Cover Disassembly. 15-25 Seat Covers 15-26 Seat Cover Removal. 15-26 Seat Cover Installation 15-27 Fenders 15-28 Front Fender Removal 15-28 Front Fender Installation . 15-28 Flap Removal 15-28 Flap Installation. 15-28 Rear Fender Removal. 15-29 Rear Fender Installation 15-29 Battery Case Removal 15-31 Battery Case Installation . 15-32 Frame . 15-33 Frame Inspection 15-33 PAD Installation. 15-33 Windshield (Special Edition Models) 15-34 Windshield Removal . 15-34 Windshield Installation 15-34 Guards 15-35 Mud Guard Removal. 15-35 Mud Guard Installation 15-35 Frame Slider Removal (Special Edition Models) 15-35 Frame Slider Installation (Special Edition Models) . 15-37 Crankcase Ring Installation (Special Edition Models) 15-38 Front Axle Slider Removal (Special Edition Models) 15-38 Front Axle Slider Installation (Special Edition Models) . 15-39 Radiator Guard Removal (Special Edition Models) 15-39 Radiator Guard Installation (Special Edition Models) . 15-39 Side Stand 15-40 Side Stand Removal . 15-40 Side Stand Installation 15-40 Rear View Mirrors. 15-41 Rear View Mirror Removal 15-41 Rear View Mirror Installation. 15-41 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-13 Wiring Diagram (ZR900A without Immobilizer Models) 16-16 Wiring Diagram (ZR900A with Immobilizer Models). 16-18 Wiring Diagram (ZR900B without Immobilizer Models) 16-20 Wiring Diagram (ZR900B with Immobilizer Models). 16-22 Precautions. 16-24 Electrical Wiring 16-25 Wiring Inspection 16-25 Battery 16-26 Battery Removal . 16-26 Battery Installation 16-26 Battery Activation 16-26 Precautions . 16-29 Interchange . 16-30 Charging Condition Inspection 16-30 Refreshing Charge 16-30 Charging System 16-32 Alternator Cover Removal. 16-32 Alternator Cover Installation 16-32 Stator Coil Removal 16-33 Stator Coil Installation . 16-33 Alternator Rotor Removal . 16-33 Alternator Rotor Installation 16-34 Charging Voltage Inspection. 16-36 Alternator Inspection . 16-36 Regulator/Rectifier Removal. 16-38 Regulator/Rectifier Installation 16-38 Regulator/Rectifier Inspection. 16-38 Ignition System. 16-41 Crankshaft Sensor Removal. 16-41 Crankshaft Sensor Installation 16-42 Crankshaft Sensor Inspection. 16-44 Crankshaft Sensor Peak Voltage Inspection. 16-44 Timing Rotor Removal 16-45 Timing Rotor Installation . 16-45 Stick Coil Removal 16-45 Stick Coil Installation. 16-45 Stick Coil Inspection 16-46 Stick Coil Primary Peak Voltage Inspection 16-46 Spark Plug Removal . 16-47 Spark Plug Installation 16-47 Spark Plug Condition Inspection. 16-47 Interlock Operation Inspection 16-48 IC Igniter Inspection 16-48 Electric Starter System. 16-51 Starter Motor Removal 16-51 Starter Motor Installation. 16-51 Starter Motor Disassembly 16-51 Starter Motor Assembly 16-52 Brush Inspection . 16-54 Commutator Cleaning and Inspection. 16-54 Armature Inspection 16-55 Brush Lead Inspection 16-55 Right-hand End Cover Inspection. 16-55 Starter Relay Inspection 16-55 Lighting System 16-58 Headlight Beam Horizontal Adjustment 16-58 Headlight Beam Vertical Adjustment. 16-58 Headlight Bulb Replacement 16-58 Headlight Unit Removal 16-59 Headlight Unit Installation . 16-59 City Light Bulb Replacement. 16-59 Tail/Brake Light (LED) Unit Removal 16-60 Tail/Brake Light (LED) Unit Installation . 16-60 License Plate Light Bulb Replacement . 16-61 Turn Signal Light Bulb Replacement 16-62 Turn Signal Relay Inspection 16-63 Air Switching Valve . 16-66 Air Switching Valve Operation Test . 16-66 Air Switching Valve Unit Test 16-66 Radiator Fan System 16-68 Fan Motor Inspection 16-68 Meter, Gauge, Indicator Unit. 16-69 Meter Unit Removal 16-69 Meter Unit Installation . 16-69 Meter Unit Disassembly/Assembly . 16-69 Meter Operation Inspection. 16-70 Meter System Inspection 16-72 Meter Unit Inspection 16-73 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-80 Immobilizer System (Equipped Models) . 16-83 Operational Cautions 16-83 Key Registration 16-83 Immobilizer System Parts Replacement. 16-101 Immobilizer Amplifier Replacement 16-102 Immobilizer System Inspection . 16-103 Switches and Sensors 16-105 Brake Light Timing Inspection. 16-105 Brake Light Timing Adjustment . 16-105 Switch Inspection 16-105 Water Temperature Sensor Inspection . 16-106 Oxygen Sensor Removal 16-106 Oxygen Sensor Installation . 16-107 Oxygen Sensor Inspection 16-107 Fuel Level Sensor Inspection 16-107 Gear Position Sensor Removal. 16-108 Gear Position Sensor Installation 16-108 Gear Position Sensor Inspection 16-109 Accessory Socket Removal/Installation (Special Edition Models) 16-109 Relay Box . 16-110 Relay Box Removal/Installation 16-110 Relay Circuit Inspection 16-110 Diode Circuit Inspection 16-111 Fuse 16-113 30 A Main/15 A ECU Fuse Removal. 16-113 Fuse Box Fuse Removal. 16-113 Fuse Installation 16-113 Fuse Inspection. 16-113
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