A.
B.

Windshield
Wellnuts (D = 5), Plastic Washers (D
= 11.5) and Windshield Bolts (D = 5,
L = 20)

the windshield bolts to the specified
• Tighten
torque.
Torque: 0.50 N·m (0.05 kgf·m, 4.4 in·lb)

Front Axle
Model)

Slider

(Equipped

the collars and sliders so that their
• Assemble
surfaces are aligned.
• The right side collar has boss.

A. Mirror
and adjustment of the right side
• Installation
mirror is common with the left side. Follow
the procedure specified for the left side.

Windshield (Equipped Model)

the wellnuts (D = 5) and windshield.
• Install
Install
the plastic washers (D = 11.5) and
• windshield
bolts (D = 5, L = 20) on the windshield.

ASSEMBLY 11

A. Collars
B. Sliders
C. Surfaces
D. Left Side
E. Right Side
F. Boss
the front axle slider assembly and
• Install
washer (both sides).
the front axle slider bolt (D = 10, L =
• Install
300) from the left side.
• Tighten the front axle slider nut.
Torque: 34 N·m (3.5 kgf·m, 25 ft·lb)

A. Cap

Single Seat
Model)

○Refer

Cover

(Equipped

NOTE

to the Battery Service section in the
PREPARATION chapter.

French Label (For Canada Model)
When required, apply French label in the parts
bag over English label on the vehicle.
Wipe off any oil or grease from English label.
Refer to the following figure for the label location.
Peel the label in the parts bag off the backing
sheet and apply it over English label.

•
•

A. Front Axle Slider Assembly
B. Washer
C. Front Axle Slider Bolt (D = 10, L = 300)

• Install the cap (both sides).

A. Vehicle Emission Control Information

12 PREPARATION

(For single seat cover equipped model)
The single seat cover removal and installation
is the same procedure as the passenger’s seat
removal and installation.
Insert the ignition key into the seat lock.
Lift the front part of the passenger’s seat upward while turning the key clockwise.
Remove the passenger’s seat forward.
Remove the ignition key.

•
•
•
•

B. Important Drive Chain Information
C. Tire and Load Data

Brake Disc Cleaning

the front and rear brake discs using
• Clean
oilless solvent.

WARNING
An anticorrosive treatment applied to
the brake discs will increase braking
distance and can cause an accident
resulting in serious injury or death. Remove the anticorrosive treatment using
an oilless solvent.

A. Ignition Key
B. Passenger’s Seat

• Slide the seat lock bracket.

A. Seat Lock Bracket
the rear part of the rider’s seat upward to
• Pull
clear the projections, and remove the rider’s
A. Brake Disc

seat backward.

Preparation
Battery Service
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.

Seats Removal
The seats can be removed by in order of the
passenger’s seat then the rider’s seat.

A. Projections
B. Rider’s Seat

PREPARATION 13

Battery Removal

the battery.
• Remove
• Clean the battery terminals.

Battery Activation
Electrolyte Filling

sure that the model name of the elec• Make
trolyte container matches the model name of
the battery. These names must be the same.

Battery Model Name
ZR900A/B: FTX9-BS

DANGER
Sulfuric acid in battery electrolyte can
cause severe burns. To prevent burns,
wear protective clothing and safety
glasses when handling electrolyte. If
the electrolyte comes in contact with
your skin or eyes, wash the area with
liberal amounts of water and seek medical attention for more severe burns.
the battery on a level surface.
• Place
Check
see that the sealing sheet has no
• peeling,totears,
or holes in it.
• Remove the sealing sheet.

NOTE

○The battery is vacuum sealed.

If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.

A. Model Name of the Electrolyte
B. Model Name of the Battery

NOTICE
Each battery comes with its own specific
electrolyte container; using the wrong
container may overfill the battery with
incorrect electrolyte, which can shorten
battery life and deteriorate battery performance. Be sure to use the electrolyte
container with the same model name as
the battery since the electrolyte volume
and specific gravity vary with the battery
type.

A. Sealing Sheet
B. Filler Ports
the electrolyte container from the
• Remove
vinyl bag.
the strip of caps from the container
• Detach
and set aside, these will be used later to seal
the battery.

NOTICE
Do not remove the aluminum sealing
sheet from the filler ports until just prior
to use. Be sure to use the dedicated
electrolyte container for correct electrolyte volume.

NOTE

○Do not pierce or otherwise open the sealed

cells of the electrolyte container. Do not attempt to separate individual cells.

14 PREPARATION

A. Strip of Caps
B. Sealed Cells

A. Air Bubbles
B. Tap the Container

the electrolyte container upside down
• Place
with the six sealed cells into the filler ports

the container in place. Don’t remove
• Keep
the container from the battery, the battery re-

of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.

quires all the electrolyte from the container for
proper operation.

NOTICE
Removal of the container before it is
completely empty can shorten the service life of the battery. Do not remove the
container until it is completely empty.

NOTE

○Do not tilt the electrolyte container.

After filling, let the battery sit for 20  60
• minutes
with the electrolyte container kept in

•
•
the electrolyte flow.
• Check
If
no
air
are coming up from the filler
• ports, orbubbles
if the container cells have not emp-

place, which is required for the electrolyte to
fully permeate into the plates.
Make sure that the container cells have emptied completely, and remove the container
from the battery.
Place the strip of caps loosely over the filler
ports, press down firmly with both hands to
seat the strip of caps into the battery (don’t
pound or hammer). When properly installed,
the strip of caps will be level with the top of
the battery.

tied completely, tap the container a few times.

NOTE

○Be careful not to have the battery fall down.

A. Strip of Caps

PREPARATION 15

○Charging

NOTICE
Once the strip of caps is installed onto
the battery, never remove the caps, nor
add water or electrolyte to the battery.

NOTE

○Charging the battery immediately after filling
can shorten service life.
Initial Charge

activated sealed batteries require an
• Newly
initial charge.
Standard Charge:

NOTE

rates will vary depending on how
long the battery has been stored, temperature, and the type of charger used. If voltage
is not at least 12.8 volts, repeat charging cycle.
○To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.8 volts
repeat the charging cycle and load test. If still
below 12.8 volts the battery is defective.

Battery Installation

the ignition switch off.
• Turn
Place
on the battery case.
• Connectthethebattery
red
capped
positive (+) cable to
• the positive (+) terminal first.
connect the negative (–) cable to the
• Then
negative (–) terminal.
a light coat of grease on the terminals to
• Put
prevent corrosion.
the positive (+) terminal with the red
• Cover
cap.

0.9 A × 5  10 hours

a recommended battery charger, fol• Iflowusing
the charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S
the above chargers are not available, use
• Ifequivalent
one.
Let
battery
30 minutes after initial charge,
• then check sitvoltage
using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the
battery sit for given time.)

A. Red Cap
B. Negative (–) Terminal
C. Positive (+) Terminal

Seats Installation
(For single seat cover equipped model)
The single seat cover removal and installation
is the same procedure as the passenger’s seat
removal and installation.
Insert the hooks at the front of the rider’s seat
under the seat bracket.
Insert the projections on the rider’s seat into
the grommets on the frame.

•
•

16 PREPARATION

A.
B.
C.
D.

Hooks
Seat Bracket
Projections
Grommets

the seat lock bracket into the hole of the
• Slide
rider’s seat completely.

A.
B.
C.
D.

Hook
Slot
Seat Latch
Latch Hole

up the front and rear ends of the pas• Pull
senger’s seat to make sure they are securely
locked.

Coolant
Coolant Level Inspection

the motorcycle so that it is perpen• Position
dicular to the ground.
the coolant level through the coolant
• Check
level gauge on the reserve tank located to
the behind of the engine. The coolant level
should be between the F (Full) and L (Low)
level lines.
A. Seat Lock Bracket
B. Hole
C. Rider’s Seat
the hook at the rear of the passenger’s
• Insert
seat into the slot of the frame.
the seat latch at the front of the passen• Insert
ger’s seat into the latch hole of the frame.
down the front part of the passenger’s
• Push
seat until the lock clicks.
A. F (Full) Level Line
B. L (Low) Level Line
C. Reserve Tank

NOTE

○Check the level when the engine is cold (room
or atmospheric temperature).

the amount of coolant is insufficient, add
• Ifcoolant
into the reserve tank.

PREPARATION 17

Coolant filling

the cap from the reserve tank and
• Remove
add coolant through the filler opening to the F
(Full) level line.

A. Front Brake Fluid Reservoir
B. Upper Level Line
A. Reserve Tank Cap

• Install the reserve tank cap.

the reservoir cap bolts to the specified
• Tighten
torque.
Torque: 1.5 N·m (0.15 kgf·m, 13 in·lb)

WARNING

NOTE

○A permanent type of antifreeze is installed in

the cooling system when shipped. It is mixed
at 50% and has the freezing point of –35 °C
(–31 °F).

Front Brake
Front Brake Fluid Level Inspection

the front brake fluid reservoir held hor• With
izontal, check that the fluid level must be
above the lower level line.

When working with the disc brake, observe the precautions listed below.
Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time.
Do not mix two types and brands of
fluid for use in the brake. This lowers
the brake fluid boiling point and could
cause the brake to be ineffective. It
may also cause the rubber brake parts
to deteriorate.
Do not leave the reservoir cap off for
any length of time to avoid moisture
contamination of the fluid.
Do not change the fluid in the rain or
when a strong wind is blowing.
Brake fluid quickly damages painted
surfaces; any spilled fluid should be
completely wiped up immediately.
If any of the brake line fittings or the
bleed valve is opened at any time,
the AIR MUST BE BLED FROM THE
BRAKE LINE.

•
•
•

•
•
•
•

A. Front Brake Fluid Reservoir
B. Lower Level Line
fluid level in the reservoir is lower than
• Ifthethelower
level line, check for fluid leaks in the

•
•

front brake lines and fill the reservoir.
Loosen the reservoir cap bolts to remove the
front brake fluid reservoir cap and diaphragm.
Fill the reservoir to the upper level line with
DOT4 brake fluid, reinstall the diaphragm and
reservoir cap.

the brake lever several times.
• Operate
If
it
feels
• brake line.spongy, there might be air in the
• Ifline.necessary, bleed the air in the front brake
check for fluid leakage around the fit• Also
tings.

18 PREPARATION

Brake Line Air Bleeding

•

Loosen the reservoir cap bolts to remove the