No.
1
2
3

Fastener
Meter Cover Bolts
Turn Signal Light Lens Screws
License Plate Light Screws

4. Special Edition Models

N·m
0.50
1.0
1.2

Torque
kgf·m
0.05
0.10
0.12

ft·lb
4.4 in·lb
8.9 in·lb
11 in·lb

Remarks

16-6 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-7
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Fastener
Switch Housing Screws
Front Brake Light Switch Screw
Side Stand Switch Bolt
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Gear Position Sensor Bolt
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
Stator Coil Bolts
Alternator Rotor Bolt
Starter Motor Clutch Bolts
Crankshaft Sensor Bolts
Crankshaft Sensor Cover Bolts
Timing Rotor Bolt
Starter Motor Through Bolts
Brush Holder Screw
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Starter Motor Cable Terminal Nut
Starter Relay Terminal Bolts
Engine Ground Cable Terminal Bolt

22. Immobilizer System Equipped Models
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
R: Replacement Parts

N·m
3.5
1.2
8.8
15
2.0
10
12
12
12
155
12
6.0
12
39
5.0
3.8
9.8
11
5.9
3.9
10

Torque
kgf·m
0.36
0.12
0.90
1.5
0.20
1.0
1.2
1.2
1.2
15.8
1.2
0.61
1.2
4.0
0.51
0.39
1.0
1.1
0.60
0.40
1.0

ft·lb
31 in·lb
11 in·lb
78 in·lb
11
18 in·lb
89 in·lb
106 in·lb
106 in·lb
106 in·lb
114
106 in·lb
53 in·lb
106 in·lb
29
44 in·lb
34 in·lb
87 in·lb
97 in·lb
52 in·lb
35 in·lb
89 in·lb

Remarks

L
LG
G
L
L
L
L
L (1)

16-8 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-9
Exploded View
No.
1
2
3
4

Fastener
Spark Plugs
Water Temperature Sensor
Fuel Pump Bolts
Oxygen Sensor

L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
13
12
9.8
44

Torque
kgf·m
1.3
1.2
1.0
4.5

ft·lb
115 in·lb
106 in·lb
87 in·lb
32

Remarks

L, S

16-10 ELECTRICAL SYSTEM
Specifications
Item
Battery
Type
Model Name
Capacity
Voltage
Gross Weight
Electrolyte Volume
Charging System
Type
Charging Voltage
(Regulator/Rectifier Output Voltage)
Alternator Output Voltage
Stator Coil Resistance
Ignition System
Spark Plug:
Type
Gap
Stick Coil:
Primary Winding Resistance
Secondary Winding Resistance
Primary Peak Voltage
Crankshaft Sensor:
Resistance
Peak Voltage
Electric Starter System
Starter Motor:
Brush Length
Air Switching Valve
Resistance
Switches and Sensors
Rear Brake Light Switch Timing
Engine Oil Pressure Switch Connections
Water Temperature Sensor Resistance
Fuel Level Sensor Resistance:
Full Position
Empty Position

Standard
Sealed Battery
FTX9-BS
12 V 8 Ah (10 HR)
12.6 V or more
3.0 kg (6.6 lb)
0.41 L (25 cu in.)
Three-phase AC
14.5  14.9 V @25°C (77°F)
AC 41.6  62.4 V @4 000 r/min (rpm)
0.176  0.264 Ω @20°C (68°F)

NGK CR9EIA-9
0.8  0.9 mm (0.031  0.035 in.)
1.11  1.50 Ω @20°C (68°F)
6.4  9.6 kΩ @20°C (68°F)
95 V or more
376  564 Ω @20°C (68°F)
3.0 V or more

12 mm (0.47 in.) [Service Limit: 6.5 mm (0.26 in.)]
20  24 Ω @20°C (68°F)
ON after about 6 mm (0.24 in.) of pedal travel
When engine is stopped: ON
When engine is running: OFF
in the text
9.6  12.4 Ω
222  228 Ω

ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Peak Voltage Adapter:
57001-1415

Flywheel & Pulley Holder:
57001-1605

Lead Wire - Peak Voltage Adapter:
57001-1449

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1615

Needle Adapter Set:
57001-1457

Stopper:
57001-1679

Key Registration Unit:
57001-1582

Rotor Holder:
57001-1690

Grip:
57001-1591

Key Registration Adapter:
57001-1746

16-12 ELECTRICAL SYSTEM
Special Tools and Sealant
Liquid Gasket, TB1211F:
92104-0004

ELECTRICAL SYSTEM 16-13
Parts Location
Timing Rotor [A]
Crankshaft Sensor [B]
Oxygen Sensor [C]

Alternator [A]
Oil Pressure Switch [B]
Gear Position Sensor [C]
Side Stand Switch [D]

Radiator Fan Motor [A]
Water Temperature Sensor [B]
Starter Motor [C]

Horn [A]
Regulator/Rectifier [B]
Fuse Box (1) [C]

Rear Brake Light Switch [A]

16-14 ELECTRICAL SYSTEM
Parts Location
Immobilizer (Immobilizer Equipped Models)/Kawasaki
Diagnostic System Connector [A]
Fuse Box (2) [B]
Battery 12 V 8 Ah [C]
Turn Signal Relay [D]
Starter Relay [E]

Relay Box [A]
ECU [B]

Air Switching Valve [A]
Stick Coils [B]
Spark Plugs [C]
Immobilizer Amplifier (Immobilizer Equipped Models) [D]

Starter Lockout Switch [A]
Ignition Switch [B] (Immobilizer Equipped Models: Including Immobilizer Antenna)
Meter Unit [C]
Front Brake Light Switch [D]

ELECTRICAL SYSTEM 16-15
Parts Location
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16-16 ELECTRICAL SYSTEM
Wiring Diagram (ZR900A without Immobilizer Models)

ELECTRICAL SYSTEM 16-17
Wiring Diagram (ZR900A without Immobilizer Models)

16-18 ELECTRICAL SYSTEM
Wiring Diagram (ZR900A with Immobilizer Models)

ELECTRICAL SYSTEM 16-19
Wiring Diagram (ZR900A with Immobilizer Models)

16-20 ELECTRICAL SYSTEM
Wiring Diagram (ZR900B without Immobilizer Models)

ELECTRICAL SYSTEM 16-21
Wiring Diagram (ZR900B without Immobilizer Models)

16-22 ELECTRICAL SYSTEM
Wiring Diagram (ZR900B with Immobilizer Models)

ELECTRICAL SYSTEM 16-23
Wiring Diagram (ZR900B with Immobilizer Models)

16-24 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is on, or while the engine is
running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor windings.
○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).

ELECTRICAL SYSTEM 16-25
Electrical Wiring
Wiring Inspection

inspect the wiring for signs of burning, fraying,
• Visually
etc.
If any wiring is poor, replace the damaged wiring.
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a tester between the ends of the leads.
If the tester does not read about 0 Ω, the lead is defective.
Replace the lead or the wiring harness [B] if necessary.

•
•

16-26 ELECTRICAL SYSTEM
Battery
Battery Removal

the ignition switch off.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-

•

ter)
Disconnect the negative (–) cable [A].

NOTICE
Be sure to disconnect the negative (–) cable first.
out the positive (+) terminal cap [B] and disconnect
• Slide
the positive (+) cable [C].
• Remove the battery.

Battery Installation

the ignition switch off.
• Turn
Put
the
into the battery case.
• Connectbattery
the
positive
[A] first.
• Connect the negative(+)(–)cable
cable
• Apply a light coat of grease on [B].
the terminals to prevent
• corrosion.
the positive (+) terminal with the cap [C].
• Cover
Install
front seat (see Front Seat Installation in the
• Frame the
chapter).

Battery Activation
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.

•

Battery Model Name
ZR900A/B: FTX9-BS

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.

ELECTRICAL SYSTEM 16-27
Battery
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.

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
• or holestoinseeit. that the sealing sheet has no peeling, tears,
• 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.
the electrolyte container from the vinyl bag.
• Remove
Detach
the
of caps [A] from the container and set
• aside, thesestrip
will be used later to seal the battery.

NOTE

○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.

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

NOTE

○Do not tilt the electrolyte container.

16-28 ELECTRICAL SYSTEM
Battery
the electrolyte flow.
• Check
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.

NOTE

○Be careful not to have the battery fall down.
the container in place. Don’t remove the container
• Keep
from the battery, the battery requires 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.
filling, let the battery sit for 20  60 minutes with the
• After
electrolyte container kept in 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.

the strip of caps [A] loosely over the filler ports,
• Place
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.