NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
Pad Installation Positions [F]
Section X - X [G]
Battery Case Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
(DFI) chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Screws [A]
Kawasaki
Diagnostic System Connector [B]
ABS Kawasaki Diagnosis System Connector (ABS
Equipped Models) [C]
Remove the following parts from the battery case.
Battery Positive (+) Lead Connector [D]
Turn Signal Light Relay [E]
Fuse Box (2) [F]
Clamp [G]
• Remove:
Bolts [A] and Collars
Bolts [B]
15-32 FRAME
Fenders
the evaporative emission control system equipped
• For
models, remove the following parts.
Purge Valve Bracket Bolts [A]
Purge Valve [B]
• Remove the battery case [A] upward.
the evaporative emission control system equipped
• For
models, remove the following parts.
Canister Holder Bolts [A]
Canister Holder [B]
Battery Case Installation
is the reverse of removal.
• Installation
Tighten:
•
Torque - Canister Holder Bolts: 1.1 N·m (0.11 kgf·m, 10
in·lb)
Purge Valve Bracket Bolts: 1.1 N·m (0.11 kgf·m, 10
in·lb)
FRAME 15-33
Frame
Frame Inspection
inspect the frame for cracks, dents, bending, or
• Visually
warp.
○If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident resulting in injury or death. If the frame
is bent, dented, cracked, or warped, replace it.
PAD Installation
the pad [A] is in place on the frame.
• Install
About 5 mm (0.20 in.) [B] (Distance from the welding
bead)
About 30 mm (1.18 in.) [C]
About 6 mm (0.24 in.) [D] (Distance from the end of the
curve)
15-34 FRAME
Windshield (Special Edition Models)
Windshield Removal
• Remove:
Windshield Bolts [A] and Washers
Windshield [B]
Windshield Installation
is the reverse of removal.
• Installation
• Tighten:
Torque - Windshield Bolts: 0.50 N·m (0.05 kgf·m, 4.4 in·lb)
FRAME 15-35
Guards
Mud Guard Removal
• Remove:
Muffler Body (see Muffler Body Removal in the Engine
Top chapter)
Bolt [A]
Quick Rivet [B]
• Remove:
Bolts [A]
Mud Guard [B]
Mud Guard Installation
• Installation is the reverse of removal.
Frame Slider Removal (Special Edition Models)
• Remove:
Frame Slider Cover Bolts [A]
Frame Slider Cover [B]
15-36 FRAME
Guards
• Remove:
Middle Front Engine Mounting Bolt [A], Collar and O-ring
Frame Slider Bolt [B], Collar and O-ring
Collar [C]
Frame Slider [D]
• Remove:
Bolt [A]
Bracket [B]
• Remove:
Frame Cover (see Frame Cover Removal)
Bolt [A]
Bracket [B]
FRAME 15-37
Guards
Frame Slider Installation (Special Edition Models)
the bracket [A], and tighten its bolt [B].
• Install
the frame cover (see Frame Cover Installation).
• Install
Apply
a
non-permanent locking agent to the threads of
• the bolt [C].
the bracket [D], and tighten the bolt.
• Install
the O-rings [E] with new ones.
• Replace
Install:
• O-rings
•
Collars [F]
Frame Slider [G]
Tighten the frame slider bolt [H] and middle front engine
mounting bolt [I].
Torque - Middle Front Engine Mounting Bolt: 44 N·m (4.5
kgf·m, 32 ft·lb)
the frame slider cover [J].
• Install
• Tighten:
Torque - Frame Slider Cover Bolts [K]: 0.50 N·m (0.05
kgf·m, 4.4 in·lb)
15-38 FRAME
Guards
Crankcase Ring Installation (Special Edition
Models)
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the crankcase ring sticking positions. Dry
•
them with clean cloth.
Stick the crankcase rings [A] in places.
Left Side [B]
Right Side [C]
Front Axle Slider Removal (Special Edition
Models)
the flat tip screw driver [A], remove the cap [B] on
• Using
both sides.
• Remove:
Front Axle Slider Bolt [A] and Nut
Washer (Both Sides)
Front Axle Slider [B] and Collar (Both Sides)
FRAME 15-39
Guards
Front Axle Slider Installation (Special Edition
Models)
the collars [A] and sliders [B] so that their sur• Assemble
faces [C] are aligned.
Left Side [D]
Right Side [E]
○The right side collar has the boss [F].
the front axle slider nut with a new one.
• Replace
Install:
• Front Axle Slider [A] and Collar (Both Sides)
Washer [B] (Both Sides)
Front Axle Slider Bolt [C] and Nut
Insert
the front axle slider bolt from the left side.
○
Tighten:
•
Torque - Front Axle Slider Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Install the caps.
Radiator Guard Removal (Special Edition Models)
• Remove:
Inner Covers (see Inner Cover Removal)
Radiator Guard Bolts [A]
Radiator Guard [B]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
Radiator Guard Installation (Special Edition
Models)
that the pads [A] are in place on the radiator guard.
• Check
Install
the
radiator guard, and tighten its bolts.
•
Torque - Radiator Guard Bolts: 6.9 N·m (0.70 kgf·m, 61
in·lb)
• Install the removed parts (see appropriate chapters).
15-40 FRAME
Side Stand
Side Stand Removal
• Remove:
Side Stand Switch Bolt [A]
Bracket [B]
Side Stand Switch [C]
Dampers
Collar
• Remove:
Spring [A]
Side Stand Nut [B]
Side Stand Bolt [C]
Collar [D]
Side Stand [E]
Side Stand Installation
grease to the sliding area [A] of the side stand [B]
• Apply
and collar [C].
• Install:
Side Stand
•
Collar
Side Stand Bolt [D]
Tighten:
Torque - Side Stand Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)
the side stand nut [E] with a new one.
• Replace
Tighten:
•
Torque - Side Stand Nut: 29 N·m (3.0 kgf·m, 21 ft·lb)
the spring [F] so that the long spring end faces up• Hook
ward.
○Install the spring hook direction as shown.
• Install:
Dampers [G]
•
Collar [H]
Bracket [I]
Side Stand Switch [J]
Apply a non-permanent locking agent to the thread of the
side stand switch bolt [K], and tighten it.
Torque - Side Stand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
FRAME 15-41
Rear View Mirrors
Rear View Mirror Removal
the dust cover [A].
• Slide
the rear view mirror nut (lower) [B], and remove
• Loosen
the rear view mirror [C].
○The rear view mirror locknut (upper) and rear view mirror
stay are left-hand thread.
Rear View Mirror Installation
• Tighten the rear view mirror nut (lower) [A].
Torque - Rear View Mirror Nut (Lower): 30 N·m (3.1 kgf·m,
22 ft·lb)
the rear view mirror stay [B] until the fully position.
• Tighten
Adjust
the
view mirror stay to assure the safe condi• tions of therear
rear with the rider sitting on the motorcycle.
○The rear view mirror locknut (upper) [C] and rear view
•
mirror stay are left-hand thread.
Tighten the rear view mirror locknut (upper).
Torque - Rear View Mirror Locknut (Upper): 18 N·m (1.8
kgf·m, 13 ft·lb)
the dust cover [D].
• Install
Adjust
the rear view mirror [E] by slightly moving only the
• mirror portion
of the assembly.
○Installation and adjustment of the right side are common
with those of the left side. Follow the procedure specified
at the left side.
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Parts Location.........................................................................................................................
Wiring Diagram (ZR900A without Immobilizer Models)..........................................................
Wiring Diagram (ZR900A with Immobilizer Models)...............................................................
Wiring Diagram (ZR900B without Immobilizer Models)..........................................................
Wiring Diagram (ZR900B with Immobilizer Models)...............................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Battery ....................................................................................................................................
Battery Removal ...............................................................................................................
Battery Installation ............................................................................................................
Battery Activation ..............................................................................................................
Precautions .......................................................................................................................
Interchange .......................................................................................................................
Charging Condition Inspection..........................................................................................
Refreshing Charge............................................................................................................
Charging System ....................................................................................................................
Alternator Cover Removal.................................................................................................
Alternator Cover Installation..............................................................................................
Stator Coil Removal ..........................................................................................................
Stator Coil Installation .......................................................................................................
Alternator Rotor Removal .................................................................................................
Alternator Rotor Installation ..............................................................................................
Charging Voltage Inspection .............................................................................................
Alternator Inspection .........................................................................................................
Regulator/Rectifier Removal .............................................................................................
Regulator/Rectifier Installation ..........................................................................................
Regulator/Rectifier Inspection...........................................................................................
Ignition System .......................................................................................................................
Crankshaft Sensor Removal .............................................................................................
Crankshaft Sensor Installation ..........................................................................................
Crankshaft Sensor Inspection...........................................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Timing Rotor Removal ......................................................................................................
Timing Rotor Installation ...................................................................................................
Stick Coil Removal............................................................................................................
Stick Coil Installation.........................................................................................................
Stick Coil Inspection..........................................................................................................
Stick Coil Primary Peak Voltage Inspection ......................................................................
Spark Plug Removal .........................................................................................................
Spark Plug Installation ......................................................................................................
Spark Plug Condition Inspection.......................................................................................
Interlock Operation Inspection ..........................................................................................
IC Igniter Inspection ..........................................................................................................
Electric Starter System ...........................................................................................................
Starter Motor Removal......................................................................................................
Starter Motor Installation...................................................................................................
16-4
16-10
16-11
16-13
16-16
16-18
16-20
16-22
16-24
16-25
16-25
16-26
16-26
16-26
16-26
16-29
16-30
16-30
16-30
16-32
16-32
16-32
16-33
16-33
16-33
16-34
16-36
16-36
16-38
16-38
16-38
16-41
16-41
16-42
16-44
16-44
16-45
16-45
16-45
16-45
16-46
16-46
16-47
16-47
16-47
16-48
16-48
16-51
16-51
16-51
16
16-2 ELECTRICAL SYSTEM
Starter Motor Disassembly................................................................................................
Starter Motor Assembly ....................................................................................................
Brush Inspection ...............................................................................................................
Commutator Cleaning and Inspection...............................................................................
Armature Inspection..........................................................................................................
Brush Lead Inspection ......................................................................................................
Right-hand End Cover Inspection .....................................................................................
Starter Relay Inspection....................................................................................................
Lighting System ......................................................................................................................
Headlight Beam Horizontal Adjustment ............................................................................
Headlight Beam Vertical Adjustment.................................................................................
Headlight Bulb Replacement ............................................................................................
Headlight Unit Removal ....................................................................................................
Headlight Unit Installation .................................................................................................
City Light Bulb Replacement.............................................................................................
Tail/Brake Light (LED) Unit Removal ................................................................................
Tail/Brake Light (LED) Unit Installation .............................................................................
License Plate Light Bulb Replacement .............................................................................
Turn Signal Light Bulb Replacement ................................................................................
Turn Signal Relay Inspection ............................................................................................
Air Switching Valve .................................................................................................................
Air Switching Valve Operation Test ...................................................................................
Air Switching Valve Unit Test ............................................................................................
Radiator Fan System..............................................................................................................
Fan Motor Inspection ........................................................................................................
Meter, Gauge, Indicator Unit...................................................................................................
Meter Unit Removal ..........................................................................................................
Meter Unit Installation .......................................................................................................
Meter Unit Disassembly/Assembly ...................................................................................
Meter Operation Inspection...............................................................................................
Meter System Inspection ..................................................................................................
Meter Unit Inspection ........................................................................................................
Fuel Level Sensor Line Self-Diagnosis Mode Inspection..................................................
Immobilizer System (Equipped Models) .................................................................................
Operational Cautions ........................................................................................................
Key Registration................................................................................................................
Immobilizer System Parts Replacement ...........................................................................
Immobilizer Amplifier Replacement ..................................................................................
Immobilizer System Inspection .........................................................................................
Switches and Sensors ............................................................................................................
Brake Light Timing Inspection...........................................................................................
Brake Light Timing Adjustment .........................................................................................
Switch Inspection ..............................................................................................................
Water Temperature Sensor Inspection .............................................................................
Oxygen Sensor Removal ..................................................................................................
Oxygen Sensor Installation ...............................................................................................
Oxygen Sensor Inspection................................................................................................
Fuel Level Sensor Inspection............................................................................................
Gear Position Sensor Removal.........................................................................................
Gear Position Sensor Installation......................................................................................
Gear Position Sensor Inspection ......................................................................................
Accessory Socket Removal/Installation (Special Edition Models) ....................................
Relay Box ...............................................................................................................................
Relay Box Removal/Installation ........................................................................................
Relay Circuit Inspection ....................................................................................................
Diode Circuit Inspection ....................................................................................................
Fuse........................................................................................................................................
16-51
16-52
16-54
16-54
16-55
16-55
16-55
16-55
16-58
16-58
16-58
16-58
16-59
16-59
16-59
16-60
16-60
16-61
16-62
16-63
16-66
16-66
16-66
16-68
16-68
16-69
16-69
16-69
16-69
16-70
16-72
16-73
16-80
16-83
16-83
16-83
16-101
16-102
16-103
16-105
16-105
16-105
16-105
16-106
16-106
16-107
16-107
16-107
16-108
16-108
16-109
16-109
16-110
16-110
16-110
16-111
16-113
ELECTRICAL SYSTEM 16-3
30 A Main/15 A ECU Fuse Removal.................................................................................
Fuse Box Fuse Removal...................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................
16-113
16-113
16-113
16-113
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
- 💯【Conta.ct us for Support Directly】If you met any...
- 🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW...
- 🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS...
- 🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full...
- 🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE...
- 【TURN OFF CEL】 This AL319 car scanner diagnostic tool...
- 【EXTENSIVE APPLICATION】 Autel AL319 Compatible with...
- 【FOR END USER & DIYERS】 This error code reader AL319 is...
- 【USER-FRIENDLY DESIGN】 This OBD2 scanner and check...
- 【HIGH-QUALITY SERVICES】 12 months war.ranty from the...
Last update on 2026-06-23 / Affiliate links / Images from Amazon Product Advertising API
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: 99924-1525-01
Replacement Service Bulletin Number:
MFR Communication Date: 2017-01-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
Last update on 2026-07-02 / Affiliate links / Images from Amazon Product Advertising API
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
Last update on 2026-07-08 / Affiliate links / Images from Amazon Product Advertising API
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
Last update on 2026-07-02 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.