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NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
Summary
Service Manual
Kawasaki
Ninja ZX-10R
Ninja ZX-10R ABS
Ninja ZX-10RR
Motorcycle Service Manual
Third Edition (1) : Nov. 30, 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
Self-Diagnosis System – 17
Appendix – 18
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
KAWASAKI | ZX10R | 2017 |
1 Associated Document
Manufacturer Communications
99924-1509-03
https://www.nhtsa.gov/recalls?nhtsaId=10109091
MC-10109091-9999.pdf 10026.053KB
https://static.oemdtc.com/TSB/MC-10109091-9999.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
- 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
- Full synthetic 5W-40 diesel engine oil with Triple Protection Plus technology protects against wear, deposits, and oil breakdown
- Improved wear performance with significantly increased level of protection against harmful engine wear (compared to previous generation API CJ-4 engine oils)
- Enhanced fuel economy capability of 1.5% 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
- Resists breakdown by heat to provide continuous protection throughout the service interval, and also provides improved low-temperature flow compared to conventional 15W-40 oils
- 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
- 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)
Last update on 2024-06-10 / 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 1-10 Unit Conversion Table 1-13 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-12 Special Tools 2-14 Periodic Maintenance Procedures 2-15 Fuel System (DFI) 2-15 Air Cleaner Element Replacement 2-15 Idle Speed Inspection . 2-15 Idle Speed Adjustment 2-15 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-16 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-20 Fuel Hose Replacement . 2-22 Evaporative Emission Control System Inspection (Other than US and CA Models) 2-24 Cooling System 2-24 Coolant Level Inspection. 2-24 Cooling System Inspection . 2-25 Coolant Change 2-25 Radiator Hose and O-ring Replacement. 2-28 Engine Top End . 2-29 Valve Clearance Inspection 2-29 Valve Clearance Adjustment. 2-31 Air Suction System Damage Inspection 2-34 Clutch. 2-34 Clutch Operation Inspection . 2-34 Engine Lubrication System 2-35 Engine Oil Change 2-35 Oil Filter Replacement 2-36 Wheels/Tires 2-37 Air Pressure Inspection. 2-37 Wheels and Tires Inspection. 2-37 Wheel Bearing Damage Inspection 2-38 Final Drive 2-39 Drive Chain Lubrication Condition Inspection . 2-39 Drive Chain Slack Inspection 2-39 Drive Chain Slack Adjustment 2-40 Wheel Alignment Inspection . 2-41 Drive Chain Wear Inspection 2-41 Chain Guide Wear Inspection . 2-42 Brakes 2-43 Brake System Inspection 2-43 Brake Operation Inspection 2-44 Brake Fluid Level Inspection. 2-44 Brake Fluid Change 2-45 Brake Hose and Pipe Replacement 2-47 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-50 Brake Pad Wear Inspection 2-54 Brake Light Switch Operation Inspection 2-54 2-2 PERIODIC MAINTENANCE Suspension 2-55 Suspension System Inspection. 2-55 Steering . 2-57 Steering Play Inspection . 2-57 Steering Play Adjustment 2-57 Steering Stem Bearing Lubrication . 2-59 Electronic Steering Damper Oil Leak Inspection 2-59 Electrical System . 2-60 Lights and Switches Operation Inspection 2-60 Headlight Aiming Inspection . 2-63 Side Stand Switch Operation Inspection. 2-65 Engine Stop Switch Operation Inspection. 2-66 Spark Plug Condition Inspection. 2-67 Spark Plug Replacement 2-67 Others 2-67 Chassis Parts Lubrication 2-67 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-68 Fuel System (DFI) Table of Contents Exploded View 3-3 DFI System. 3-10 DFI Components Naming . 3-12 DFI Parts Location 3-20 Specifications . 3-23 Special Tools and Sealant 3-24 DFI Servicing Precautions 3-25 DFI Servicing Precautions . 3-25 Troubleshooting the DFI System 3-27 Outline . 3-27 Inquiries to Rider 3-31 DFI System Troubleshooting Guide . 3-34 Warning Indicator Light (LED) 3-39 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-39 ECU 3-40 ECU Identification . 3-40 ECU Removal . 3-40 ECU Installation 3-41 ECU Power Supply Inspection 3-42 DFI Power Source 3-45 ECU Fuse Removal 3-45 ECU Fuse Installation . 3-45 ECU Fuse Inspection 3-45 Fuel Line. 3-46 Fuel Pressure Inspection 3-46 Fuel Flow Rate Inspection 3-47 Fuel Pump 3-49 Fuel Pump Removal . 3-49 Fuel Pump Installation 3-50 Fuel Pump Operation Inspection 3-51 Fuel Pump Operating Voltage Inspection . 3-51 Pressure Regulator Removal 3-52 Fuel Pump Relay Removal/Installation. 3-52 Fuel Pump Relay Inspection . 3-52 Fuel Injectors 3-54 Primary Fuel Injector Removal/Installation . 3-54 Secondary Fuel Injector Removal/Installation. 3-54 Primary Fuel Injector Audible Inspection 3-54 Fuel Injector Resistance Inspection 3-54 Fuel Injector Power Source Voltage Inspection 3-54 Fuel Injector Output Voltage Inspection 3-54 Fuel Injector Fuel Line Inspection . 3-54 Throttle Grip and Cables 3-55 Free Play Inspection . 3-55 Free Play Adjustment 3-55 Cable Installation 3-55 Cable Lubrication 3-55 Throttle Body Assy . 3-56 Idle Speed Inspection/Adjustment 3-56 Synchronization Inspection . 3-56 3-2 FUEL SYSTEM (DFI) Throttle Body Assy Removal. 3-56 Throttle Body Assy Installation 3-58 Throttle Body Assy Disassembly 3-59 Throttle Body Assy Assembly . 3-60 Nozzle Assy 3-62 Nozzle Assy Removal. 3-62 Nozzle Assy Installation 3-62 Nozzle Assy Disassembly. 3-63 Nozzle Assy Assembly 3-63 Air Cleaner 3-64 Air Cleaner Element Removal/Installation 3-64 Air Cleaner Element Inspection 3-64 Air Cleaner Oil Draining 3-64 Air Cleaner Housing Removal. 3-64 Air Cleaner Housing Installation 3-65 Air Cleaner Housing Disassembly 3-66 Air Cleaner Housing Assembly . 3-66 Air Line . 3-68 Air Intake Duct Removal . 3-68 Air Intake Duct Installation 3-68 Air Intake Duct Disassembly. 3-68 Air Intake Duct Assembly 3-68 Air Intake Solenoid Valve Removal. 3-70 Air Intake Solenoid Valve Installation 3-70 Air Intake Solenoid Valve Unit Test 3-70 Vacuum Chamber Removal 3-70 Vacuum Chamber Installation . 3-70 Fuel Tank 3-71 Fuel Tank Removal . 3-71 Fuel Tank Installation 3-73 Fuel Tank and Cap Inspection 3-76 Fuel Tank Cleaning . 3-76 Evaporative Emission Control System (Other than US and CA Models) . 3-77 Parts Removal/Installation 3-77 Hose Inspection 3-77 Purge Valve Inspection . 3-77 Canister Inspection 3-77 Cooling System Table of Contents Exploded View 4-2 Coolant Flow Chart. 4-5 Specifications . 4-7 Special Tools and Sealant 4-8 Coolant . 4-9 Coolant Deterioration Inspection. 4-9 Coolant Level Inspection. 4-9 Coolant Draining . 4-9 Coolant Filling . 4-9 Pressure Testing . 4-9 Cooling System Flushing 4-10 Coolant Reserve Tank Removal . 4-10 Coolant Reserve Tank Installation 4-10 Water Pump 4-11 Water Pump Removal. 4-11 Water Pump Installation 4-11 Water Pump Inspection. 4-11 Water Pump Impeller Disassembly/Assembly 4-11 Water Pump Impeller Inspection. 4-11 Water Pump Housing Disassembly 4-12 Water Pump Housing Assembly . 4-12 Mechanical Seal Inspection 4-12 Radiator 4-13 Radiator and Radiator Fan Removal 4-13 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-16 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-17 Thermostat . 4-18 Thermostat Removal. 4-18 Thermostat Installation 4-19 Thermostat Inspection 4-19 Hoses and Pipes 4-20 Hose Installation . 4-20 Hose Inspection 4-20 Water Temperature Sensor 4-21 Water Temperature Sensor Removal/Installation . 4-21 Water Temperature Sensor Inspection . 4-21 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-8 Special Tools and Sealant . 5-9 Clean Air System. 5-11 Air Suction Valve Removal. 5-11 Air Suction Valve Installation 5-11 Air Suction Valve Inspection 5-12 Air Switching Valve Removal . 5-12 Air Switching Valve Installation 5-12 Air Switching Valve Operation Test 5-13 Air Switching Valve Unit Test . 5-13 Clean Air System Hose Inspection 5-13 Cylinder Head Cover . 5-14 Cylinder Head Cover Removal 5-14 Cylinder Head Cover Installation . 5-14 Camshaft Chain Tensioner 5-16 Camshaft Chain Tensioner Removal 5-16 Camshaft Chain Tensioner Installation . 5-17 Camshaft, Camshaft Chain . 5-19 Camshaft Removal 5-19 Camshaft Installation . 5-20 Camshaft, Camshaft Cap Wear Inspection 5-22 Camshaft Runout Inspection 5-23 Cam Wear Inspection 5-23 Camshaft Chain Removal 5-23 Camshaft Chain Installation . 5-24 Cylinder Head 5-25 Cylinder Compression Measurement 5-25 Cylinder Head Removal. 5-26 Cylinder Head Installation 5-27 Cylinder Head Warp Inspection . 5-28 Valves 5-29 Valve Clearance Inspection . 5-29 Valve Clearance Adjustment 5-29 Valve Removal . 5-29 Valve Installation 5-29 Valve Guide Removal 5-29 Valve Guide Installation . 5-30 Valve-to-Guide Clearance Measurement (Wobble Method). 5-30 Valve Seat Inspection 5-31 Valve Seat Repair 5-31 Throttle Body Assy Holder. 5-36 Throttle Body Assy Holder Removal 5-36 Throttle Body Assy Holder Installation . 5-36 Muffler 5-37 Muffler Body Removal 5-37 Muffler Body Installation. 5-38 Premuffler Chamber Removal . 5-39 Premuffler Chamber Installation 5-40 Exhaust Pipe Removal. 5-40 Exhaust Pipe Installation 5-42 Exhaust Butterfly Valve Cable Removal 5-43 Exhaust Butterfly Valve Cable Installation . 5-44 Exhaust Butterfly Valve Actuator Removal 5-45 Exhaust Butterfly Valve Actuator Installation . 5-46 Exhaust Butterfly Valve Actuator Adjustment 5-47 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 Removal. 6-7 Clutch Lever Installation 6-7 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-10 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 Spring Plate Free Play Measurement. 6-16 Spring Plate Free Play Adjustment . 6-17 Clutch Plate, Wear, Damage Inspection . 6-18 Clutch Plate Warp Inspection 6-18 Clutch Spring Inspection . 6-18 Clutch Housing Finger Inspection. 6-19 Clutch Housing Spline Inspection . 6-19 Damper Cam Inspection . 6-19 Engine Lubrication System Table of Contents Exploded View 7-2 Engine Oil Flow Chart. 7-4 Specifications . 7-5 Special Tools and Sealant 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 Pressure Relief Valve 7-10 Oil Pressure Relief Valve Removal . 7-10 Oil Pressure Relief Valve Installation 7-10 Oil Pressure Relief Valve Inspection. 7-10 Oil Pump. 7-11 Oil Pump Removal 7-11 Oil Pump Installation . 7-11 Oil Pump Drive Gear Removal/Installation . 7-12 Oil Pump Drive Gear Installation. 7-13 Oil Pump Drive Gear Shaft Removal 7-13 Oil Pump Drive Gear Shaft Installation . 7-13 Oil Cooler 7-14 Oil Cooler Removal. 7-14 Oil Cooler Installation 7-14 Oil Pressure Measurement. 7-16 Oil Pressure Measurement . 7-16 Oil Pressure Switch 7-17 Oil Pressure Switch Removal . 7-17 Oil Pressure Switch Installation 7-17 Engine Removal/Installation Table of Contents Exploded View 8-2 Special Tool 8-4 Engine Removal/Installation . 8-5 Engine Removal 8-5 Engine Installation. 8-8 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-9 Crankcase . 9-10 Crankcase Splitting 9-10 Crankcase Assembly . 9-11 Crankshaft and Connecting Rods 9-17 Crankshaft Removal 9-17 Crankshaft Installation . 9-17 Connecting Rod Removal 9-18 Connecting Rod Installation . 9-18 Crankshaft/Connecting Rod Cleaning 9-22 Connecting Rod Bend Inspection 9-23 Connecting Rod Twist Inspection. 9-23 Connecting Rod Big End Side Clearance Inspection 9-23 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-23 Crankshaft Side Clearance Inspection 9-25 Crankshaft Runout Inspection 9-26 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-26 Pistons. 9-28 Piston Removal 9-28 Piston Installation. 9-29 Cylinder (Upper Crankcase) Wear Inspection 9-30 Piston Wear Inspection 9-30 Piston Ring, Piston Ring Groove Wear Inspection 9-31 Piston Ring Groove Width Inspection 9-31 Piston Ring Thickness Inspection 9-31 Piston Ring End Gap Inspection 9-32 Balancer 9-33 Balancer Removal 9-33 Balancer Installation. 9-33 Balancer Adjustment 9-33 Balancer Damper Inspection 9-34 Balancer Assembly 9-34 Torque Limiter 9-35 Torque Limiter Removal. 9-35 Torque Limiter Installation 9-35 Starter Motor Clutch 9-37 Starter Motor Clutch Removal 9-37 Starter Motor Clutch Installation. 9-37 Starter Motor Clutch Disassembly 9-38 Starter Motor Clutch Assembly 9-38 Starter Motor Clutch Inspection . 9-38 Transmission . 9-39 Transmission Assy Removal 9-39 Transmission Assy Installation. 9-39 Transmission Assy Disassembly . 9-40 Transmission Assy Assembly 9-40 Transmission Shaft Removal . 9-42 Transmission Shaft Installation 9-42 Transmission Shaft Disassembly. 9-42 Transmission Shaft Assembly 9-43 Shift Drum and Fork Removal 9-46 Shift Drum and Fork Installation. 9-46 Shift Drum Disassembly/Assembly.9-46 Shift Fork Bending Inspection 9-46 Shift Fork/Gear Groove Wear Inspection 9-46 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-47 Gear Dog and Gear Dog Hole Damage Inspection . 9-47 External Shift Mechanism 9-48 Shift Pedal Removal 9-48 Shift Pedal Installation . 9-48 External Shift Mechanism Removal 9-49 External Shift Mechanism Installation . 9-50 External Shift Mechanism Inspection 9-51 Ball Bearing, Needle Bearing, and Oil Seal. 9-53 Ball and Needle Bearing Replacement. 9-53 Ball and Needle Bearing Wear Inspection 9-53 Oil Seal Inspection . 9-53 Wheels/Tires Table of Contents Exploded View 10-2 Specifications . 10-6 Special Tools 10-7 Wheels (Rims) 10-8 Front Wheel Removal . 10-8 Front Wheel Installation 10-8 Rear Wheel Removal 10-10 Rear Wheel Installation. 10-10 Wheel Inspection 10-12 Axle Inspection 10-12 Balance Inspection 10-13 Balance Adjustment 10-13 Balance Weight Removal (ZX1000R/S) 10-13 Balance Weight Installation (ZX1000R/S). 10-13 Balance Weight Removal/Installation (ZX1000Z) . 10-15 Tires 10-16 Air Pressure Inspection/Adjustment 10-16 Tire Inspection 10-16 Tire Removal. 10-16 Tire Installation 10-16 Tire Repair 10-18 Hub Bearing 10-19 Hub Bearing Removal (ZX1000R/S). 10-19 Hub Bearing Installation (ZX1000R/S) 10-19 Hub Bearing Inspection. 10-19 Hub Bearing Lubrication . 10-20 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 Guide Wear Inspection 11-6 Drive Chain Removal/Installation 11-6 Sprocket, Coupling . 11-10 Engine Sprocket Removal 11-10 Engine Sprocket Installation . 11-10 Rear Sprocket Removal 11-11 Rear Sprocket Installation. 11-11 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. 11-13 Sprocket Wear Inspection. 11-14 Rear Sprocket Warp Inspection 11-14 Brakes Table of Contents Exploded View 12-2 Specifications . 12-8 Special Tool . 12-9 Brake Lever, Brake Pedal 12-10 Brake Lever Removal/Installation 12-10 Brake Lever Position Adjustment. 12-12 Brake Pedal Position Inspection . 12-12 Brake Pedal Position Adjustment 12-12 Brake Pedal Removal 12-12 Brake Pedal Installation . 12-13 Calipers . 12-14 Front Caliper Removal. 12-14 Front Caliper Installation 12-14 Rear Caliper Removal 12-15 Rear Caliper Installation. 12-16 Front Caliper Disassembly. 12-16 Front Caliper Assembly 12-16 Rear Caliper Disassembly . 12-16 Rear Caliper Assembly 12-17 Caliper Fluid Seal Damage 12-17 Rear Caliper Dust Boot and Friction Boot Damage . 12-17 Caliper Piston and Cylinder Damage. 12-18 Rear Caliper Holder Shaft Wear 12-18 Brake Pads 12-19 Front Brake Pad Removal 12-19 Front Brake Pad Installation. 12-19 Rear Brake Pad Removal . 12-19 Rear Brake Pad Installation . 12-20 Brake Pad Wear Inspection . 12-20 Master Cylinder . 12-21 Front Master Cylinder Removal . 12-21 Front Master Cylinder Installation 12-21 Rear Master Cylinder Removal 12-22 Rear Master Cylinder Installation. 12-22 Front Master Cylinder Disassembly 12-23 Rear Master Cylinder Disassembly 12-23 Master Cylinder Assembly . 12-23 Rear Master Cylinder Inspection (Visual Inspection). 12-23 Brake Disc . 12-24 Brake Disc Removal 12-24 Brake Disc Installation . 12-24 Brake Disc Wear Inspection. 12-25 Brake Disc Warp Inspection. 12-25 Brake Fluid 12-26 Brake Fluid Level Inspection 12-26 Brake Fluid Change . 12-26 Brake Line Bleeding. 12-26 Brake Hose 12-30 Brake Hose Removal/Installation. 12-30 Brake Hose Inspection. 12-30 Anti-lock Brake System (Equipped Models). 12-31 Parts Location 12-31 ABS Servicing Precautions 12-34 ABS Troubleshooting Outline. 12-35 Inquiries to Rider 12-38 Self-diagnosis Outline 12-42 Yellow ABS and Yellow Warning Indicator Lights (LED) Inspection 12-42 ABS Hydraulic Unit Removal . 12-43 ABS Hydraulic Unit Installation 12-45 ABS Hydraulic Unit Inspection . 12-46 Front Wheel Rotation Sensor Removal 12-46 Front Wheel Rotation Sensor Installation . 12-47 Rear Wheel Rotation Sensor Removal 12-47 Rear Wheel Rotation Sensor Installation . 12-48 Wheel Rotation Sensor Inspection 12-48 Wheel Rotation Sensor Air Gap Inspection 12-49 Wheel Rotation Sensor Rotor Inspection 12-49 ABS Solenoid Valve Relay Fuse (15 A) Removal . 12-50 ABS Motor Relay Fuse (25 A) Removal 12-50 Fuse Installation. 12-50 Fuse Inspection 12-50 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Rebound Damping Force Adjustment. 13-9 Compression Damping Force Adjustment 13-10 Spring Preload Adjustment . 13-11 Front Fork Removal (Each Fork Leg) . 13-11 Front Fork Installation (Each Fork Leg) 13-12 Front Fork Oil Change 13-13 Front Fork Disassembly 13-21 Front Fork Assembly. 13-22 Inner Tube Inspection . 13-23 Dust Seal Inspection . 13-24 Spring Tension Inspection. 13-24 Front Fork Scrapping 13-24 Rear Shock Absorber . 13-25 Rebound Damping Force Adjustment. 13-25 Compression Damping Force Adjustment 13-25 Spring Preload Adjustment . 13-25 Rear Shock Absorber Removal 13-26 Rear Shock Absorber Installation . 13-27 Rear Shock Absorber Inspection 13-27 Rear Shock Absorber Scrapping 13-28 Swingarm 13-29 Swingarm Removal. 13-29 Swingarm Installation 13-30 Swingarm Bearing Removal . 13-31 Swingarm Bearing Installation 13-32 Swingarm Bearing, Sleeve Inspection 13-33 Swingarm Bearing Lubrication 13-34 Tie-Rod, Rocker Arm 13-35 Tie-Rod Removal 13-35 Tie-Rod Installation . 13-35 Rocker Arm Removal 13-35 Rocker Arm Installation. 13-36 Tie-Rod and Rocker Arm Bearing Removal 13-36 Tie-Rod and Rocker Arm Bearing Installation. 13-37 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-38 Rocker Arm/Tie-Rod Bearing Lubrication . 13-38 Steering Table of Contents Exploded View 14-2 Special Tools 14-4 Steering 14-5 Steering Inspection . 14-5 Steering Adjustment 14-5 Electronic Steering Damper (ESD). 14-6 Electronic Steering Damper Removal. 14-6 Electronic Steering Damper Installation 14-6 Electronic Steering Damper Oil Leak Inspection 14-7 ESD ECU Removal. 14-7 ESD ECU Installation 14-7 Steering Stem. 14-9 Stem, Stem Bearing Removal. 14-9 Stem, Stem Bearing Installation 14-10 Steering Stem Bearing Lubrication . 14-12 Steering Stem Warp Inspection 14-13 Stem Cap Deterioration, Damage Inspection . 14-13 Handlebar. 14-14 Handlebar Removal 14-14 Handlebar Installation . 14-15 Frame Table of Contents Exploded View. 15-2 Seats . 15-10 Front Seat Removal. 15-10 Front Seat Installation 15-10 Rear Seat Removal (ZX1000R/S) 15-10 Rear Seat Installation (ZX1000R/S) . 15-10 Single Seat Cover Removal (ZX1000Z). 15-11 Single Seat Cover Installation (ZX1000Z). 15-11 Single Seat Cover Assembly (ZX1000Z). 15-11 Fairings 15-13 Lower Fairing Removal 15-13 Lower Fairing Installation . 15-14 Upper Fairing Assembly Removal 15-15 Upper Fairing Assembly Installation . 15-16 Upper Fairing Disassembly 15-16 Upper Fairing Assembly. 15-17 Inner Cover Removal. 15-19 Inner Cover Installation 15-19 Inner Fairing Removal 15-19 Inner Fairing Installation. 15-20 Fuel Tank Cover Removal 15-20 Fuel Tank Cover Installation. 15-21 Seat Covers. 15-23 Seat Cover Removal 15-23 Seat Cover Installation. 15-25 Fenders . 15-27 Front Fender Removal. 15-27 Front Fender Installation 15-27 Flap Removal. 15-27 Flap Installation 15-28 Flap Disassembly. 15-28 Flap Assembly . 15-29 Rear Fender Removal 15-30 Rear Fender Installation. 15-32 Frame 15-34 Rear Frame Rear Removal 15-34 Rear Frame Rear Installation. 15-34 Rear Frame Front Removal . 15-34 Rear Frame Front Installation 15-34 Frame Inspection . 15-35 Windshield . 15-36 Windshield Removal 15-36 Windshield Installation . 15-36 Guard. 15-37 Mud Guard Removal 15-37 Mud Guard Installation. 15-37 Rear View Mirrors 15-38 Rear View Mirror Removal. 15-38 Rear View Mirror Installation 15-38 Side Stand. 15-39 Side Stand Removal 15-39 Side Stand Installation . 15-40 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-12 Wiring Diagram (ZX1000R without Immobilizer) 16-16 Wiring Diagram (ZX1000R with Immobilizer) . 16-18 Wiring Diagram (ZX1000S/Z without Immobilizer) . 16-20 Wiring Diagram (ZX1000S/Z with Immobilizer) 16-22 Precautions. 16-24 Electrical Wiring 16-25 Wiring Inspection 16-25 Battery 16-26 Battery Removal . 16-26 Battery Installation 16-26 Precautions . 16-26 Interchange . 16-27 Charging Condition Inspection 16-27 Refreshing Charge 16-27 Charging System 16-29 Alternator Cover Removal. 16-29 Alternator Cover Installation 16-29 Stator Coil Removal 16-30 Stator Coil Installation . 16-30 Alternator Rotor Removal . 16-30 Alternator Rotor Installation 16-31 Charging Voltage Inspection. 16-33 Alternator Inspection . 16-33 Regulator/Rectifier Removal 16-35 Regulator/Rectifier Installation 16-35 Regulator/Rectifier Inspection. 16-35 Ignition System. 16-38 Crankshaft Sensor Removal. 16-38 Crankshaft Sensor Installation 16-39 Crankshaft Sensor Inspection. 16-40 Crankshaft Sensor Peak Voltage Inspection. 16-40 Timing Rotor Removal 16-41 Timing Rotor Installation . 16-41 Stick Coil Removal 16-41 Stick Coil Installation. 16-41 Stick Coil Inspection 16-42 Stick Coil Primary Peak Voltage Inspection 16-42 Spark Plug Removal . 16-43 Spark Plug Installation 16-43 Spark Plug Condition Inspection. 16-43 Interlock Operation Inspection 16-44 IC Igniter Inspection 16-45 Electric Starter System. 16-48 Starter Motor Removal 16-48 Starter Motor Installation. 16-48 Starter Motor Disassembly 16-48 Starter Motor Assembly 16-49 Brush Inspection . 16-51 Commutator Cleaning and Inspection. 16-51 Armature Inspection 16-51 Brush Lead Inspection 16-51 Right-hand End Cover Inspection. 16-52 Starter Relay Inspection 16-52 Lighting System 16-54 Headlight Beam Horizontal Adjustment 16-54 Headlight Beam Vertical Adjustment. 16-54 Headlight Bulb Replacement 16-54 Headlight Removal 16-55 Headlight Installation. 16-55 City Light (LED) Removal . 16-55 City Light (LED) Installation 16-55 Tail/Brake Light (LED) Removal 16-55 Tail/Brake Light (LED) Installation. 16-55 License Plate Light Bulb Replacement . 16-55 Front Turn Signal Light Removal 16-57 Front Turn Signal Light Installation . 16-57 Rear Turn Signal Light Bulb Replacement 16-57 Turn Signal Relay Inspection 16-58 Air Switching Valve . 16-60 Air Switching Valve Operation Test . 16-60 Air Switching Valve Unit Test 16-60 Air Intake Solenoid Valve 16-62 Air Intake Solenoid Valve Operation Test 16-62 Air Intake Solenoid Valve Unit Test . 16-62 Radiator Fan System 16-64 Fan Motor Inspection 16-64 Meter, Gauge, Indicator Unit. 16-66 Meter Unit Removal 16-66 Meter Unit Installation . 16-66 Meter Unit Disassembly 16-66 Meter Operation Inspection. 16-67 Meter Unit Inspection 16-69 Immobilizer System (Equipped Models) . 16-74 Operational Cautions 16-74 Key Registration 16-74 Immobilizer System Parts Replacement. 16-93 Immobilizer System Inspection . 16-95 Switches and Sensors 16-97 Brake Light Timing Inspection. 16-97 Brake Light Timing Adjustment . 16-97 Switch Inspection 16-97 Water Temperature Sensor Inspection . 16-98 Fuel Reserve Switch Inspection 16-98 Oxygen Sensor Removal 16-99 Oxygen Sensor Installation . 16-100 Oxygen Sensor Inspection 16-100 Oxygen Sensor Heater Inspection 16-100 Gear Position Sensor Removal. 16-100 Gear Position Sensor Installation 16-101 Gear Position Switch Inspection . 16-101 Relay 16-102 Relay Inspection . 16-102 Diode Removal . 16-102 Diode Installation 16-103 Fuse 16-105 30 A Main/15 A ECU Fuse Removal. 16-105 Fuse Box Fuse Removal. 16-105 Fuse Installation 16-106 Fuse Inspection. 16-106 Self-Diagnosis System Table of Contents Specifications . 17-5 Special Tools 17-7 Self-Diagnosis 17-8 Self-Diagnosis Outline 17-8 Self-Diagnosis Procedures . 17-10 Service Code Reading 17-13 Service Code Erasing . 17-13 Backups 17-16 Throttle Position Sensor (Service Code 11) (DTC P0120, P0121, P0122, P0220, P0223) 17-22 Throttle Position Sensor Removal 17-22 Throttle Position Sensor Input Voltage Inspection 17-22 Throttle Position Sensor Output Voltage Inspection . 17-23 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107). 17-26 Intake Air Pressure Sensor #1 Removal. 17-26 Intake Air Pressure Sensor #1 Installation 17-26 Intake Air Pressure Sensor #1 Input Voltage Inspection. 17-26 Intake Air Pressure Sensor #1 Output Voltage Inspection 17-28 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112). 17-32 Intake Air Temperature Sensor Removal 17-32 Intake Air Temperature Sensor Installation . 17-32 Intake Air Temperature Sensor Output Voltage Inspection . 17-32 Intake Air Temperature Sensor Resistance Inspection . 17-34 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) 17-35 Water Temperature Sensor Removal/Installation . 17-35 Water Temperature Sensor Output Voltage Inspection. 17-35 Water Temperature Sensor Resistance Inspection. 17-36 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228). 17-38 Intake Air Pressure Sensor #2 Removal. 17-38 Intake Air Pressure Sensor #2 Installation 17-38 Intake Air Pressure Sensor #2 Input Voltage Inspection. 17-38 Intake Air Pressure Sensor #2 Output Voltage Inspection 17-40 Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123, P2125, P2128) . 17-42 Accelerator Position Sensor Removal 17-42 Accelerator Position Sensor Input Voltage Inspection 17-42 Accelerator Position Sensor Output Voltage Inspection . 17-43 Accelerator Position Sensor Resistance Inspection . 17-44 ABS Hydraulic Unit Communication Error (Service Code 1B, ZX1000S/Z) . 17-46 ABS Hydraulic Unit Communication Line Inspection 17-46 Crankshaft Sensor (Service Code 21) (DTC P0335) 17-48 Crankshaft Sensor Removal/Installation. 17-48 Crankshaft Sensor Resistance Inspection 17-48 Crankshaft Sensor Peak Voltage Inspection. 17-48 Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158). 17-49 Rear Wheel Rotation Sensor Signal Inspection 17-49 Gear Position Sensor (Service Code 25) (DTC P0914, P0917). 17-52 Gear Position Sensor Removal/Installation 17-52 Gear Position Sensor Input Voltage Inspection 17-52 Gear Position Sensor Output Voltage Inspection 17-53 Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500) 17-56 Front Wheel Rotation Sensor Signal Inspection . 17-56 Air Intake Solenoid Valve (Service Code 2D) (DTC P0660). 17-59 Air Intake Solenoid Valve Removal/Installation. 17-59 Air Intake Solenoid Valve Inspection. 17-59 Vehicle-down Sensor (Service Code 31) (DTC C0064) . 17-60 Vehicle-down Sensor Removal. 17-60 Vehicle-down Sensor Installation 17-60 Vehicle-down Sensor Input Voltage Inspection. 17-61 Vehicle-down Sensor Output Voltage Inspection 17-62 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132). 17-65 Oxygen Sensor Removal/Installation 17-65 Oxygen Sensor Inspection 17-65 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E) 17-68 Exhaust Butterfly Valve Actuator Sensor Removal/Installation. 17-68 Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection. 17-68 Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection 17-69 Exhaust Butterfly Valve Actuator Sensor Resistance Inspection 17-70 Immobilizer Amplifier (Service Code 35, Equipped Models) 17-72 Antenna Resistance Inspection 17-72 Amplifier Input Voltage Inspection. 17-72 Blank Key Detection (Service Code 36, Equipped Models) . 17-73 Ignition Key Inspection 17-73 ECU Communication Error (Service Code 39) (DTC U0001). 17-74 ECU Communication Line Inspection . 17-74 Purge Valve (Service Code 3A, Other than US and CA Models) (DTC P0443) . 17-76 Purge Valve Removal/Installation . 17-76 Purge Valve Inspection . 17-76 ESD ECU Communication Error (Service Code 3C) 17-78 ESD ECU Communication Line Inspection. 17-78 Quick Shifter Sensor (Service Code 3E) (DTC P0826) 17-80 Quick Shifter Sensor Removal/Installation 17-80 Quick Shifter Sensor Input Voltage Inspection 17-80 Quick Shifter Sensor Output Voltage Inspection. 17-81 Quick Shifter Sensor Resistance Inspection. 17-82 Primary Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204). 17-83 Primary Fuel Injector Removal/Installation . 17-83 Primary Fuel Injector Audible Inspection 17-83 Primary Fuel Injector Resistance Inspection. 17-83 Primary Fuel Injector Power Source Voltage Inspection. 17-83 Primary Fuel Injector Output Voltage Inspection. 17-85 Primary Fuel Injector Fuel Line Inspection 17-86 Fuel Pump Relay (Service Code 46) (DTC P0627) 17-89 Fuel Pump Relay Removal/Installation . 17-89 Fuel Pump Relay Inspection . 17-89 Return Spring (Service Code 49) (DTC P2119) . 17-90 Return Spring Removal. 17-90 Return Spring Inspection 17-90 Secondary Fuel Injectors #1, #2, #3, #4 (Service Code 4A, 4B, 4C, 4D) (DTC P0205, P0206, P0207, P0208) 17-91 Secondary Fuel Injector Removal/Installation. 17-91 Secondary Fuel Injector Audible Inspection 17-91 Secondary Fuel Injector Resistance Inspection 17-91 Secondary Fuel Injector Power Source Voltage Inspection 17-92 Secondary Fuel Injector Output Voltage Inspection 17-93 Secondary Fuel Injector Fuel Line Inspection. 17-95 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) . 17-97 Stick Coil Removal/Installation 17-97 Stick Coil Primary Winding Resistance Inspection . 17-97 Stick Coil Input Voltage Inspection 17-97 Radiator Fan Relay (Service Code 56) (DTC P0480) 17-99 Radiator Fan Relay Removal/Installation 17-99 Radiator Fan Relay Inspection 17-99 ETV Actuator (Service Code 58) (DTC P2100) 17-101 ETV Actuator Removal . 17-101 ETV Actuator Input Voltage Inspection . 17-101 ETV Actuator Relay Inspection . 17-102 Exhaust Butterfly Valve Actuator (Service Code 63) (DTC P0475) 17-103 Exhaust Butterfly Valve Actuator Removal . 17-103 Exhaust Butterfly Valve Actuator Installation 17-103 Exhaust Butterfly Valve Actuator Inspection . 17-103 Exhaust Butterfly Valve Actuator Resistance Inspection 17-103 Air Switching Valve (Service Code 64) (DTC P0410). 17-105 Air Switching Valve Removal/Installation 17-105 Air Switching Valve Inspection 17-105 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 17-106 Oxygen Sensor Heater Removal/Installation 17-106 Oxygen Sensor Heater Resistance Inspection . 17-106 Oxygen Sensor Heater Power Source Voltage Inspection . 17-106 Fuel Supply System (Service Code 94) (DTC P0170) . 17-109 Fuel Supply System Inspection. 17-109 Battery Voltage (Service Code 97) (DTC P0562). 17-110 Battery Voltage Inspection 17-110 ETV Control Circuit (Service Code 98) (DTC P0607). 17-111 ETV Control Circuit Inspection 17-111 ESD Actuator Error (Service Code E2E) 17-112 ESD Actuator Removal . 17-112 ESD Actuator Installation 17-112 ESD Actuator Resistance Inspection 17-112 ESD Actuator Input Voltage Inspection. 17-112 ESD ECU Error (Service Code E3B) 17-114 ESD ECU Removal. 17-114 ESD ECU Installation 17-114 ESD ECU Power Supply Inspection . 17-114 ESD Calibration Error (Service Code E3F) 17-116 IMU (Inertial Measurement Unit) (Service Code E8E) 17-117 IMU Removal 17-117 IMU Installation . 17-117 IMU Power Supply Inspection. 17-117 IMU (Inertial Measurement Unit) Communication Error (Service Code E8F). 17-119 IMU Communication Line Inspection 17-119 ABS Service Codes (ZX1000S/Z) 17-121 Solenoid Valve Inspection (Service Code B13, B14, B17, B18) . 17-121 ABS Solenoid Valve Relay Inspection (Service Code B19) 17-121 Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code B25). 17-121 ABS Motor Relay Inspection (Service Code B35). 17-121 Front Wheel Rotation Sensor Signal Abnormal (Service Code B42) 17-122 Front Wheel Rotation Sensor Wiring Inspection (Service Code B43). 17-123 Rear Wheel Rotation Sensor Signal Abnormal (Service Code B44) 17-123 Rear Wheel Rotation Sensor Wiring Inspection (Service Code B45) . 17-124 Power Supply Voltage Inspection (Low-Voltage) (Service Code B52) 17-124 Power Supply Voltage Inspection (Over-Voltage) (Service Code B53). 17-125 17-4 SELF-DIAGNOSIS SYSTEM ECU Inspection (Service Code B55). 17-125 CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code B57) CAN Communication (Reception) Monitor Inspection (Service Code B58). 17-125 ECU Communication Line Inspection (Service Code B62). 17-126 IMU Communication Line Inspection (Service Code B63) 17-127 Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code B83) . 17-127 Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code B84) . 17-127 Fluid Pressure Sensor Supply Voltage Inspection (Service Code B89) 17-128 IMU Inspection (Service Code B94) 17-128
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