Z900
Z900 ABS

Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki Z900 and Z900 ABS.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.

© 2016 Kawasaki Heavy Industries, Ltd.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

NOTICE
NOTICE is used to address practices not
related to personal injury.

NOTE

○NOTE indicates information that may help or
guide you in the operation or service of the
vehicle.

Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.

Oct., 2016

Table of Contents
Uncrating ......................................................................................
Opening Crate .............................................................................
Parts Check .................................................................................
Assembly ......................................................................................
Handlebar Weight........................................................................
Clutch Cable................................................................................
Frame Slider (Equipped Model) ..................................................
Frame Cover ...............................................................................
Rear View Mirrors........................................................................
Windshield (Equipped Model) .....................................................
Front Axle Slider (Equipped Model) ............................................
Single Seat Cover (Equipped Model) ..........................................
French Label (For Canada Model) ..............................................
Brake Disc Cleaning ....................................................................
Preparation ...................................................................................
Battery Service ............................................................................
Coolant ........................................................................................
Front Brake..................................................................................
Rear Brake ..................................................................................
Clutch Lever and Cable ...............................................................
Drive Chain..................................................................................
Front Fork ....................................................................................
Rear Shock Absorber ..................................................................
Tire Air Pressures........................................................................
Fuel .............................................................................................
Engine Oil (4-stroke) ...................................................................
Throttle Grip and Cable ...............................................................
Rear Brake Light Switch ..............................................................
Idle Speed Adjustment ................................................................
Headlight Aim ..............................................................................
Digital Meter ................................................................................
Fastener Check ...........................................................................
Standard Torque Table ................................................................
Test Ride the Motorcycle .............................................................
A & P Check List .........................................................................

3
3
5
8
8
8
8
9
9
10
10
11
11
12
12
12
16
17
18
20
20
22
22
23
23
23
24
25
26
26
27
28
30
30
30

UNCRATING 3

Uncrating
Opening Crate
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.

WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.

out all the bolts and screws and remove
• Take
the top and sides of the crate.
the front axle holding nuts.
• Loosen
Remove
• discard it.the left front support bracket bolt and
the front axle holding nuts, left front
• Remove
support bracket and rubber washer, and discard them.

A.
B.
C.
D.

Front Axle Holding Nuts
Left Front Support Bracket
Left Front Support Bracket Bolt
Rubber Washer

the right front support bracket bolt
• Remove
and discard it.
the front axle holding bolt, right front
• Remove
support bracket and rubber washer, and discard them.

a space about 6 m (20 ft) square to give
• Clear
yourself plenty of space to work.
the crate upright on its base.
• Place
the cardboard cover.
• Remove
Remove
the parts box.
•

NOTICE

When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other components with the crate bracket.

A.
B.
C.
D.

Front Axle Holding Bolt
Right Front Support Bracket
Right Front Support Bracket Bolt
Rubber Washer

the clean closes on the front footpegs
• Cover
to prevent damage.
the lower support bracket bolts on
• Remove
the left and right sides and discard them.
the vehicle upward about 10 cm (4 in.)
• Lift
and remove the lower support brackets and
rubber washers on the left and right sides.
Roll the vehicle off the crate base.

4 UNCRATING

A. Lower Support Bracket Bolts
B. Lower Support Brackets
C. Rubber Washers

NOTICE
When rolling the vehicle off the crate
base, sharp edges on the crate can cut
or damage tires.
Cover sharp edges with waste cloth for
tire protection as necessary.

UNCRATING 5

Parts Check

the parts box, and check the parts against the illustrations. There may be minor differences
• Open
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.

No.
1
2
3
4
5
6
7
8
9
10
11

Part Name
Right Handlebar Weight
Weight Bolt with a Non-permanent Locking Agent
Left Rear View Mirror
Right Rear View Mirror
Left Frame Cover
Right Frame Cover
Socket Bolt
Washer
Pad
Battery Electrolyte, FTX9-BS
Owner’s Manual

Qty
1
1
1
1
1
1
4
4
2
1
1

Remarks
D = 8, L = 30

D = 5, L = 12
D = 5.2
12 V 8 Ah

6 UNCRATING

UNCRATING 7

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Part Name
(Equipped Model only)
Windshield
Socket Bolt
Washer
Wellnut
Left Frame Slider
Right Frame Slider
Left Bracket
Right Bracket
Socket Bolt with a Non-permanent Locking Agent
Collar
O-ring
Flange Bolt
Collar
O-ring
Left Frame Slider Cover
Right Frame Slide Cover
Socket Bolt
Wellnut
Cap
Bolt
Washer
Slider
Left Collar
Right Collar
Nut
Single Seat Cover
(French Label for Canada Model only)
French Table
Important Drive Chain Information
Tire and Load Data
Vehicle Emission Control Information

Qty
1
4
4
4
1
1
1
1
2
2
2
2
2
2
1
1
4
4
2
1
2
2
1
1
1
1
1
1
1
1

Remarks

D = 5, L = 20
D=5

D = 6, L = 12
D = 10.5, L = 8.1
D = 15.8 × 2.4
D = 6, L = 16
D = 6.5, L = 8.1
D = 11 × 2.4

D = 5, L = 16
D=5
D = 10, L = 300

L = 25.5
L = 29.5

8 ASSEMBLY

Assembly
Handlebar Weight

the handlebar weight on the right end
• Install
of the handlebars with the bolt (D = 8, L =

Frame Slider (Equipped Model)

the middle front engine mounting
• Remove
bolt (D = 10, L = 65) and collar (D = 10.5, L
= 34).

30) with a non-permanent locking agent and
tighten them.

A. Handlebar Weight (Right)
B. Bolt (D = 8, L = 30)

Clutch Cable

a light coat of grease on the clutch inner
• Apply
cable.
up the slots on the clutch lever and ad• Line
juster.
the tip of the clutch inner cable into the
• Fit
lever socket, slide the inner cable through the

A. Middle Front Engine Mounting Bolt (D
= 10, L = 65)
B. Collar (D = 10.5, L = 34)
the frame cover (see in the Frame
• Install
Cover section).
the bracket with the bolt (D = 6, L =
• Install
12) with a non-permanent locking agent and
tighten them.

slots, and release the outer cable into the adjuster.

A. Frame Cover
B. Bracket
C. Bolt (D = 6, L = 12)

A.
B.
C.
D.

Clutch Cable
Adjuster
Cable Tip
Clutch Lever

the collar (D = 10.5, L = 34) and frame
• Install
slider.
the collar, O-ring and frame slider bolt
• Install
(D = 6, L = 16).
the collar, O-ring and tighten the middle
• Install
front engine mounting bolt (D = 10, L = 65).
Torque:

44 N·m (4.5 kgf·m, 32 ft·lb)

ASSEMBLY 9

A. Collar (D = 10.5, L = 34)
B. Frame Slider
C. Frame Slider Bolt (D = 6, L = 16), Collar
and O-ring
D. Middle Front Engine Mounting Bolt (D
= 10, L = 65), Collar and O-ring
the frame slider cover, wellnuts and
• Install
tighten frame slider cover bolts (D = 5, L =
16).
Torque:

A.
B.
C.
D.

Frame
Pad
Edge of Frame
10 mm (0.39 in.)

the left frame cover, and tighten its
• Install
bolts (D = 5, L = 12) together with the washers (D = 5.3).

0.50 N·m (0.05 kgf·m, 4.4 in·lb)

A. Left Frame Cover
B. Bolts (D = 5, L = 12) and Washers (D
= 5.3)
A. Frame Slider Cover
B. Wellnuts and Frame Slider Cover Bolts
(D = 5, L = 16)

the right frame cover in the same man• Install
ner as the left frame cover.

Rear View Mirrors
Frame Cover
NOTE

○Before installing the frame cover,

check the
Coolant section in the PREPARATION chapter.

the pad is in place on the frame (both
• Install
sides).
• Align the frame edge and pad edge as shown.

up the rubber boot.
• Slide
the lower end of the left rear view mirror
• Screw
into the holder all the way, and tighten the rear
view mirror nut (lower) to the specified torque.
Torque: 30 N·m (3.1 kgf·m, 22 ft·lb)
the stay to assure visibility to the rear
• Turn
with the operator sitting on the motorcycle by
loosening the rear view mirror locknut (upper)
(left-hand thread) clockwise.
Hold the nut (lower) and tighten the locknut
(upper).
Torque: 18 N·m (1.8 kgf·m, 13 ft·lb)

•

10 ASSEMBLY

A.
B.
C.
D.

Nut (Lower)
Locknut (Upper)
Rubber Boot
Stay

the rubber boot.
• Reinstall
Adjust
the
rear view mirror by slightly moving
• only the mirror
portion of the assembly.