eral minutes until the oil settles.
With the motorcycle held level, check the engine oil level through the oil level inspection
window. The oil level should come up between the upper and lower level lines next to
the oil level inspection window.

24 PREPARATION

A. Oil Level Inspection Window
B. Oil Filler Cap
C. Upper Level Line
D. Lower Level Line
oil level is too high, remove the excess
• Ifoilthe
through the oil filler opening using a syringe

•
•

or some other suitable device.
If the oil level is too low, add oil to reach the
correct level. Use the same type and brand
of oil that is already in the engine.
When replacing the cap, be sure the O-ring is
in place, and tighten the cap in finger tight.

Recommended Engine Oil
Type:

API SG, SH, SJ, SL or SM with
JASO MA, MA1 or MA2
Viscosity: SAE 10W-40
Capacity: 3.2 L (3.4 US qt)
[when filter is not removed]
3.6 L (3.8 US qt)
[when filter is removed]

Throttle Grip and Cable
Throttle Grip Free Play Inspection

the throttle grip free play. If the free
• Inspect
play is incorrect, adjust the throttle cables.

Throttle Grip Free Play:
2  3 mm (0.08  0.12 in.)
that the throttle grip moves smoothly
• Check
from full open to close, and the throttle closes

•

quickly and completely by the return spring in
all steering positions.
If the throttle grip does not return properly,
check the throttle cable routing, grip free play,
and for possible cable damage. Then lubricate the throttle cables.

NOTE

○Do not add any chemical additive to the oil.
Oils fulfilling the above requirements are fully
formulated and provide adequate lubrication
for both the engine and the clutch.

Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.

A. Throttle Grip
B. Throttle Grip Free Play
the engine at idle speed, and turn the
• Run
handlebars all the way to the right and left to
ensure that the idle speed does not change.
If the idle speed increases, check the throttle
grip free play.

PREPARATION 25

WARNING
Operation with incorrectly routed, improperly adjusted or damaged cables
could result in an unsafe riding condition. Be sure the cables are routed
correctly, properly adjusted and are not
damaged in any way.

it does not, turn the adjusting nut at the rear
• Ifbrake
light switch as required.
the clean cloth on the muffler body to
• Cover
prevent damage.
• Remove the right front footpeg bracket bolts.

Throttle Grip Free Play Adjustment

the locknut at the upper end of the
• Loosen
throttle cable, and turn the throttle cable ad-

•

juster until the specified amount of play is obtained.
Tighten the locknut.

A. Right Front Footpeg Bracket Bolts
B. Right Front Footpeg Bracket
the footpeg bracket a little bit outward.
• Pull
To
adjust
rear brake light switch, move the
• switch up the
or down by turning the adjusting nut.

A. Locknut
B. Adjuster
C. Throttle Cable (Accelerator Cable)

Rear Brake Light Switch
Rear Brake Light Switch Adjustment

the ignition switch on. The brake light
• Turn
should illuminate when the brake pedal is depressed about 6 mm (0.24 in.)

A.
B.
C.
D.

Rear Brake Light Switch
Adjusting Nut
Lights sooner
Lights later

NOTICE
To avoid damaging the electrical connections inside the switch, be sure that
the switch body does not turn during adjustment.
the right front footpeg bracket.
• Reinstall
Tighten
the
front footpeg bracket bolts to
• the specifiedright
torque.
A. Brake Pedal
B. 6 mm (0.24 in.)

Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

26 PREPARATION

Idle Speed Adjustment

the engine and warm it up thoroughly.
• Start
the idle speed to 1 050  1 150 r/min
• Adjust
(rpm) by turning the idle adjusting screw.
Idle Speed: 1 050  1 150 r/min (rpm)

A. Horizontal Adjuster
B. Vertical Adjuster

WARNING

A. Idle Adjusting Screw
and close the throttle grip a few times
• Open
to make sure that the idle speed does not

•

change.
With the engine idling, turn the handlebars to
each side. If handlebars movement changes
the idle speed, check the throttle cable routing
and free play.

WARNING
Operation with incorrectly routed or
damaged throttle cable could result in
an unsafe riding condition. Be sure the
throttle cable is routed correctly, properly adjusted and is not damaged in any
way.

The cooling fins at the rear of headlight
become hot during normal operation
and can cause serious burns. To prevent burns, never touch the cooling fins
at the rear of headlight while the engine
is running or shortly after it has been
stopped.
For US and Canada Models

NOTE

○On high beam, the brightest point should be

slightly below horizontal. The proper angle is
0.4 degrees below horizontal. This is a 50 mm
(2.0 in.) drop at 7.6 m (25 ft) measured from
the center of the headlight, with the motorcycle on its wheels and the rider seated.

for any exhaust leaks and correct if
• Check
necessary.

Headlight Aim
The headlight beam is adjustable both horizontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as oncoming drivers. In most areas it is illegal to ride
with an improperly adjusted headlights.
The left and right (high beam and low beam)
headlight aim can be adjusted individually.

Horizontal Adjustment

the horizontal adjuster in or out until the
• Turn
beam points straight ahead.

Vertical Adjustment

the vertical adjuster in or out to adjust
• Turn
the headlight vertically.

A. 50 mm (2.0 in.)
B. Center of Brightest Spot
C. 7.6 m (25 ft)
D. Height of Headlight Center

PREPARATION 27

For other than US and Canada Models

NOTE

○On high beam, the brightest point should be
slightly below horizontal with the motorcycle
on its wheels and the rider seated. Adjust
the headlight to the proper angle according to
local regulation.

Digital Meter
Check the Unit Setting: km/h, mph
Mph·km/h Display can alternate between
English and metric modes (mph and km/h)
on the digital meter. Make sure that mph or
km/h is correctly displayed according to local
regulations before sale.

NOTE

A. Left Meter Button
B. Right Meter Button
C. Display Units
the right meter button while pushing the
• Push
left meter button to select the meter display
units. The display units can be shifted in the
following order.

○Do not operate the vehicle with the digital me-

ter displaying the wrong unit (mph or km/h) of
the digital meter. Shift the mph km/h display
on the digital meter as follows.

the ignition switch on.
• Turn
the left meter button
• Push
odometer.

to select the

NOTE

○The data is maintained even if the battery is
disconnected.

28 PREPARATION

Fastener Check

torque values listed are for assembly and preparation items only, see the appropriate Service
• The
Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before
retail delivery. Also check to see that each cotter pin or circlip is in place.

PREPARATION 29

No.

Fastener

Steering
1 Handlebar holder bolts (Lower)
Clutch
2 Clutch lever clamp bolts
Brakes
3 Front master cylinder clamp bolts
4 Front caliper bleed valve (Left and Right)
5 Front caliper mounting bolt (Left and Right)
6 Rear master cylinder mounting bolt
7 Rear brake bleed valve
8 Rear caliper mounting bolt
Wheel
9 Front axle clamp bolt (Right)
10 Front axle
Suspension
11 Upper front fork clamp bolt (Left and Right)
12 Lower front fork clamp bolts (Left and Right)
13 Lower rear shock absorber nut
14 Tie-rod nuts
Others
15 Rear view mirror locknuts (Upper)
16 Rear view mirror nuts (Lower)
17 Front footpeg bracket bolt (Left and Right)
18 Rear footpeg bracket bolt (Left and Right)
Engine Oil Drain
19 Engine oil drain bolt
Cotter Pin or Circlip
20 Front footpeg pin circlip (Left and Right)
21 Rear footpeg pin circlip (Left and Right)
22 Rear axle nut cotter pin
23 Rear master cylinder push rod cotter pin

N·m

Torque
kgf·m

ft·lb

25

2.5

18

11

1.1

97 in·lb

11
5.4
25
25
5.4
22

1.1
0.55
2.5
2.5
0.55
2.2

97 in·lb
48 in·lb
18
18
48 in·lb
16

20
108

2.0
11.0

15
79.7

20
20.5
44
44

2.0
2.09
4.5
4.5

15
15.1
32
32

18
30
25
25

1.8
3.1
2.5
2.5

13
22
18
18

29

3.0

21

–
–
–
–

–
–
–
–

–
–
–
–

Remarks

30 PREPARATION

Standard Torque Table
This table relating tightening torque to thread
diameter, lists the basic torque for bolts and
nuts. Use this table for only the bolts and nuts
which do not require a specific torque value.
All of the values are for use with dry solvent
-cleaned threads.

General Fasteners
Threads
dia.
(mm)
5
6
8
10
12
14
16
18
20

Torque
N·m

kgf·m

ft·lb

3.4  4.9
5.9  7.8
14  19
25  34
44  61
73  98
115  155
165  225
225  325

0.35  0.50
0.60  0.80
1.4  1.9
2.6  3.5
4.5  6.2
7.4  10.0
11.5  16.0
17.0  23.0
23.0  33.0

30  43 in·lb
52  69 in·lb
10.0  13.5
19.0  25
33  45
54  72
83  115
125  165
165  240

Test Ride the Motorcycle

• Complete the test ride checklist.

Control Cables:
Throttle cables must work without binding
in any steering position.
Steering:
Action is free from lock-to-lock.
Suspension:
Check operation front and rear.
Engine:
Electric starter works properly and engine
starts promptly. Good throttle response and
return.
Transmission and Clutch:
Smooth operation.
Brakes:
Adequate, smooth stopping power, No drag.
Digital Meter:
Check operation

Electrical System:
Headlight - check high and low beams.
Taillight - check operation.
Brake Light - check operation.
Turn Signal Lights - check operation.
Horn - check operation.
Instrument Lights and Indicator Lights Check operation.
Engine Stop Switch Works:
Starter Interlock Switch Works:
No Unusual Noises:
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
PREPARATION COMPLETE.

WARNING
New tires are slippery and may cause
loss of control and serious injury or
death. A break-in period of 160 km (100
miles) is necessary to establish normal tire traction. During break-in, avoid
sudden and maximum braking, acceleration, and hard cornering.

A & P Check List

• Complete the A & P Check List.

Part No.99931-1579-01

MODEL APPLICATION
Year
2017
2017

Model
ZR900AH
ZR900BH

Name
Z900
Z900 ABS