NHTSA ID Number: 10109087
Manufacturer Communication Number: 99924-1519-01_ZX
TSB/Document Date: 2017-08-01
Summary
Service Manual
Items
Dimensions
Overall Length
Overall Width
Overall Height/High Position
Wheelbase
Road Clearance
Seat Height
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Fuel System
Fuel Type:
Minimum Octane Rating:
Research Octane
number (RON)
Antiknock Index (RON +
MON)/2
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plug
Cylinder Numbering Method
Firing Order
ZX1000WH
2 100 mm (82.68 in.)
790 mm (31.10 in.)
1 185 mm (46.65 in.)/1235 mm (48.62 in.)
1 440 mm (56.69 in.)
130 mm (5.12 in.)
815 mm (32.1 in.)
235 kg (518 lb)
(US, CA) 234 kg (516 lb)
(IN: with Saree Guard equipped model) 239 kg (527 lb)
121 kg (267 lb)
(US, CA) 120 kg (265 lb)
114 kg (251 lb)
(IN: with Saree Guard equipped model) 118 kg (260 lb)
19 L (5.0 US gal)
3.1 m (10.2 ft)
4-stroke, DOHC, 4-cylinder
Liquid-cooled
77.0 × 56.0 mm (3.03 × 2.20 in.)
1 043 cm³ (63.6 cu in.)
11.8:1
104.5 kW (142 PS) @10 000 r/min (rpm)
(SEA-B1,TH) 100.9 kW (137 PS) @9 800 r/min (rpm)
(AU) 105 kW (143 PS) @10 000 r/min (rpm)
(US, CA, CAL) --111.0 N·m (11.3 kgf·m, 82 ft·lb) @7 300 r/min (rpm)
(SEA-B1,TH) 109.0 N·m (11.1 kgf·m, 80 ft·lb) @7 300 r/min (rpm)
(AU) 111 N·m (11.3 kgf·m, 82 ft·lb) @7 300 r/min (rpm)
(US, CA, CAL) --FI (Fuel injection), KEIHIN TTK 38 × 4
95
90
Electric Starter
Battery and coil (transistorized)
Electronically advanced (IC igniter in ECU)
10° BTDC @1 100 r/min (rpm) 40.2° BTDC @5 200 r/min (rpm)
NGK CR9EIA-9
Left to right, 1-2-3-4
1-2-4-3
GENERAL INFORMATION 1-9
General Specifications
Items
Valve Timing:
Intake:
Open
Close
Duration
Exhaust:
Open
Close
Duration
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
ZX1000WH
25° (BTDC)
65° (ABDC)
270°
58° (BBDC)
18° (ATDC)
256°
Forced lubrication (wet sump)
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
4.0 L (4.2 US qt)
Gear
1.627 (83/51)
Wet multi disc
6-speed, constant mesh, return shift
2.600
1.950
1.600
1.389
1.238
1.107
(39/15)
(39/20)
(24/15)
(25/18)
(26/21)
(31/28)
Chain drive
2.733 (41/15)
4.925 at Top gear
Tubular, diamond
24.5°
102 mm (4.02 in.)
Tubeless
120/70 ZR17 M/C (58W)
J17M/C × MT3.50
Tubeless
190/50 ZR17M/C (73W)
J17M/C × MT6.00
1-10 GENERAL INFORMATION
General Specifications
Items
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
High Beam
Low Beam
Brake/Tail Light
Alternator:
Type
Maximum Output
ZX1000WH
Telescopic fork (upside-down)
120 mm (4.72 in.)
Swingarm
144 mm (5.67 in.)
Dual discs
Single disc
12 V 8 Ah (10 HR)
Semi-sealed beam
LED
LED
LED
Three-phase AC
14 V - 24.3 A @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Units of Length:
Symbol
M
k
c
m
μ
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
=
=
=
=
=
=
=
=
=
gal (US)
gal (IMP)
qt (US)
qt (IMP)
pint (US)
pint (IMP)
oz (US)
oz (IMP)
cu in.
=
=
=
=
kg
lb
N
lb
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
×
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
×
×
×
×
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in.
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cmHg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
Units of Force:
N
N
kg
kg
km
m
mm
0.1020
0.2248
9.807
2.205
Units of Temperature:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Power:
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System (DFI)................................................................................................................
Air Cleaner Element Replacement....................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Throttle Control System Inspection...................................................................................
Engine Vacuum Synchronization Inspection.....................................................................
Fuel System Inspection.....................................................................................................
Fuel Filter Replacement....................................................................................................
Fuel Hose Replacement ...................................................................................................
Evaporative Emission Control System Inspection (Other than US and CA Models) ........
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Cooling System Inspection ...............................................................................................
Coolant Change ................................................................................................................
Water Hose and O-ring Replacement ...............................................................................
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Air Suction System Damage Inspection............................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection .............................................................................................
Engine Lubrication System ..................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheels and Tires Inspection.............................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Final Drive............................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Wheel Alignment Adjustment............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Wear Inspection ...........................................................................................
Brakes..................................................................................................................................
Brake System Inspection ..................................................................................................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Fluid Change ..........................................................................................................
Brake Hose
and Pipe Replacement..................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Brake Pad Wear Inspection ..............................................................................................
2-3
2-5
2-12
2-14
2-15
2-15
2-15
2-16
2-16
2-16
2-17
2-20
2-21
2-23
2-24
2-25
2-25
2-26
2-26
2-29
2-30
2-30
2-31
2-35
2-36
2-36
2-37
2-37
2-38
2-38
2-38
2-38
2-39
2-40
2-40
2-41
2-41
2-41
2-41
2-42
2-42
2-43
2-43
2-44
2-44
2-45
2-46
2-50
2-51
2-54
2
2-2 PERIODIC MAINTENANCE
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Suspension System Inspection.........................................................................................
Steering ...............................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Side Stand Switch Operation Inspection...........................................................................
Engine Stop Switch Operation Inspection.........................................................................
Spark Plug Replacement ..................................................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication ................................................................................................
Condition of Bolts, Nuts and Fasteners Tightness Inspection ..........................................
2-55
2-56
2-56
2-57
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TSB/Document ID: 99924-1519-01_ZX
Replacement Service Bulletin Number:
MFR Communication Date: 2016-12-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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