NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
Damper [F]
Viewed from Bottom [G]
Viewed from Top [H]
Viewed from Left [I]
FRAME 15-33
Fenders
the rear fender by the reverse of removal.
• Install
Run
the
leads and cables correctly (see Cable, Wire, and
• Hose Routing
section in the Appendix chapter).
Apply
a
non-permanent
locking agent to the ECU cover
• bolts.
the ECU cover.
• Install
• Tighten:
Torque - ECU Cover Bolts: 3.0 N·m (0.31 kgf·m, 27 in·lb)
• Install the removed parts (see appropriate chapters).
15-34 FRAME
Frame
Rear Frame Rear Removal
the rear frame rear [A] from the rear fender (see Rear
• Free
Fender Removal).
• Remove:
ECU (see ECU Removal in the Fuel System (DFI) chapter)
Rear Frame Rear Bolts [B]
Rear Frame Rear
Rear Frame Rear Installation
a non-permanent locking agent to the threads of
• Apply
the rear frame rear bolts and tighten them.
Torque - Rear Frame Rear Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Install the removed parts (see appropriate chapters).
Rear Frame Front Removal
• Remove:
Rear Frame Rear (see Rear Frame Rear Removal)
the rear frame front [A] from the rear fender (see
• Free
Rear Fender Removal).
Remove:
• (ZX1000R/S)
Rear Footpeg Bracket Bolts [B]
•
Left Rear Footpeg Bracket [C]
(ZX1000Z) Remove:
Muffler Stay Bolts [D]
• Remove:
Rear Frame Front Bolts [A]
Rear Frame Front [B]
Rear Frame Front Installation
a non-permanent locking agent to the threads of
• Apply
the rear frame front bolts and tighten them.
Torque - Rear Frame Front Bolts: 44 N·m (4.5 kgf·m, 32
ft·lb)
Rear Footpeg Bracket Bolts (ZX1000R/S): 25 N·m
(2.5 kgf·m, 18 ft·lb)
Apply a non-permanent locking agent to the
• (ZX1000Z)
threads of the muffler stay bolts and tighten them.
Torque - Muffler Stay Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Install the removed parts (see appropriate chapters).
FRAME 15-35
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.
15-36 FRAME
Windshield
Windshield Removal
• Remove:
Bolts [A] and Washers
Windshield [B]
Windshield Installation
• Install the wellnuts [A].
• Install:
Windshield [A]
•
Bolts, L = 16 mm (0.63 in.) [B] and Washers
Bolts, L = 20 mm (0.79 in.) [C] and Washers
Tighten:
Torque - Windshield Mounting Bolts: 0.40 N·m (0.04 kgf·m,
3.5 in·lb)
FRAME 15-37
Guard
Mud Guard Removal
• Remove:
Bolts [A]
•
Chain Cover Mounting Bolt [B]
Clamp [C]
Remove the rear brake hose
banjo bolt and clear the
brake hose from the mud guard (see Rear Caliper Removal in the Brakes chapter).
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.
• Remove the mud guard [D].
Mud Guard Installation
the brake hose through the hole of the mud guard.
• Run
Install
the rear brake hose (see Rear Caliper Installation
• in the Brakes
chapter).
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.
a non-permanent locking agent to the following
• Apply
bolts.
•
•
Bolts, L = 22 mm (0.87 in.) [A]
Bolts, L = 14 mm (0.55 in.) [B]
Chain Cover Mounting Bolt (Left) [C]
Install:
Mud Guard [D]
Clamp [E]
Collar [F]
Washer [G]
Tighten:
Torque - Chain Cover Mounting Bolt: 3.0 N·m (0.31 kgf·m,
27 in·lb)
the rear brake effectiveness (see Brake Operation
• Check
Inspection in the Periodic Maintenance chapter).
15-38 FRAME
Rear View Mirrors
Rear View Mirror Removal
• Remove:
Inner Covers (see Inner Cover Removal)
Disconnect
the turn signal light lead connector [A].
•
• Remove:
Bolts [A]
Rear View Mirror [B]
Rear View Mirror Installation
a non-permanent locking agent to the mirror mount• Apply
ing bolts.
sure to fit the hole [A] of the upper fairing to the boss
• Be
of the upper fairing bracket.
the rear view mirror.
• Install
the turn signal light lead through the hole [B].
• Run
Run
the turn signal light lead correctly (see Cable, Wire,
• and Hose
Routing section in the Appendix chapter).
Tighten
the
bolts.
• Install the removed
parts (see appropriate chapters).
•
FRAME 15-39
Side Stand
Side Stand Removal
• Raise the rear wheel off the ground with the stand [A].
the side stand switch bolt [A] to free the side
• Remove
stand switch [B].
• Remove:
Spring [A]
Cotter Pin [B]
Side Stand Bolt [C] and Collar
Side Stand [D]
•
•
If the side stand bracket removal is necessary, follow the
below procedures.
Remove:
Shift Lever Bolt [A]
Take the shift lever [B] off the shift shaft.
• Remove:
Bolt and Washer [A]
Side Stand Bracket Bolts [B] and Washers
Side Stand Bracket [C]
15-40 FRAME
Side Stand
Side Stand Installation
installing the side stand bracket [A], apply a non
• When
-permanent locking agent to the side stand bracket bolts
•
•
[B].
Install:
Side Stand Bracket
Washers [C]
Tighten:
Torque - Side Stand Bracket Bolts: 50 N·m (5.1 kgf·m, 37
ft·lb)
the cotter pin [D] with a new one.
• Replace
Apply
grease
to the sliding areas [E].
• Install:
• Side Stand [F]
•
Collar [G]
Tighten:
Torque - Side Stand Bolt [H]: 45 N·m (4.6 kgf·m, 33 ft·lb)
the cotter pin from upper side [I] and bend the pin
• Insert
ends.
40° [J]
Install the tube [K] to the spring [L].
Install the spring as shown.
○Check that the spring ends fit to the groove of the installation portion.
Install the side stand switch [M].
Apply a non-permanent locking agent to the side stand
switch bolt [N], and tighten it.
•
•
•
•
Torque - Side Stand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Parts Location.........................................................................................................................
Wiring Diagram (ZX1000R without Immobilizer) ....................................................................
Wiring Diagram (ZX1000R with Immobilizer) .........................................................................
Wiring Diagram (ZX1000S/Z without Immobilizer) .................................................................
Wiring Diagram (ZX1000S/Z with Immobilizer) ......................................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Battery ....................................................................................................................................
Battery Removal ...............................................................................................................
Battery Installation ............................................................................................................
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...................................................................................................
Starter Motor Disassembly................................................................................................
16-4
16-10
16-11
16-12
16-16
16-18
16-20
16-22
16-24
16-25
16-25
16-26
16-26
16-26
16-26
16-27
16-27
16-27
16-29
16-29
16-29
16-30
16-30
16-30
16-31
16-33
16-33
16-35
16-35
16-35
16-38
16-38
16-39
16-40
16-40
16-41
16-41
16-41
16-41
16-42
16-42
16-43
16-43
16-43
16-44
16-45
16-48
16-48
16-48
16-48
16
16-2 ELECTRICAL SYSTEM
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 Removal............................................................................................................
Headlight Installation.........................................................................................................
City Light (LED) Removal .................................................................................................
City Light (LED) Installation ..............................................................................................
Tail/Brake Light (LED) Removal........................................................................................
Tail/Brake Light (LED) Installation.....................................................................................
License Plate Light Bulb Replacement .............................................................................
Front Turn Signal Light Removal ......................................................................................
Front Turn Signal Light Installation ...................................................................................
Rear Turn Signal Light Bulb Replacement........................................................................
Turn Signal Relay Inspection ............................................................................................
Air Switching Valve .................................................................................................................
Air Switching Valve Operation Test ...................................................................................
Air Switching Valve Unit Test ............................................................................................
Air Intake Solenoid Valve........................................................................................................
Air Intake Solenoid Valve Operation Test..........................................................................
Air Intake Solenoid Valve Unit Test ...................................................................................
Radiator Fan System..............................................................................................................
Fan Motor Inspection ........................................................................................................
Meter, Gauge, Indicator Unit...................................................................................................
Meter Unit Removal ..........................................................................................................
Meter Unit Installation .......................................................................................................
Meter Unit Disassembly ....................................................................................................
Meter Operation Inspection...............................................................................................
Meter Unit Inspection ........................................................................................................
Immobilizer System (Equipped Models) .................................................................................
Operational Cautions ........................................................................................................
Key Registration................................................................................................................
Immobilizer System Parts Replacement ...........................................................................
Immobilizer System Inspection .........................................................................................
Switches and Sensors ............................................................................................................
Brake Light Timing Inspection...........................................................................................
Brake Light Timing Adjustment .........................................................................................
Switch Inspection ..............................................................................................................
Water Temperature Sensor Inspection .............................................................................
Fuel Reserve Switch Inspection........................................................................................
Oxygen Sensor Removal ..................................................................................................
Oxygen Sensor Installation ...............................................................................................
Oxygen Sensor Inspection................................................................................................
Oxygen Sensor Heater Inspection ....................................................................................
Gear Position Sensor Removal.........................................................................................
Gear Position Sensor Installation......................................................................................
Gear Position Switch Inspection .......................................................................................
Relay ......................................................................................................................................
Relay Inspection ...............................................................................................................
Diode Removal .................................................................................................................
16-49
16-51
16-51
16-51
16-51
16-52
16-52
16-54
16-54
16-54
16-54
16-55
16-55
16-55
16-55
16-55
16-55
16-55
16-57
16-57
16-57
16-58
16-60
16-60
16-60
16-62
16-62
16-62
16-64
16-64
16-66
16-66
16-66
16-66
16-67
16-69
16-74
16-74
16-74
16-93
16-95
16-97
16-97
16-97
16-97
16-98
16-98
16-99
16-100
16-100
16-100
16-100
16-101
16-101
16-102
16-102
16-102
ELECTRICAL SYSTEM 16-3
Diode Installation ..............................................................................................................
Fuse........................................................................................................................................
30 A Main/15 A ECU Fuse Removal.................................................................................
Fuse Box Fuse Removal...................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................
16-103
16-105
16-105
16-105
16-106
16-106
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
No.
1
2
3
4
Fastener
Meter Unit Mounting Screws
License Plate Light Mounting Screws
Rear Turn Signal Light Lens Screws
Rear Turn Signal Light Mounting Screws
N·m
1.2
1.2
1.0
1.2
Torque
kgf·m
0.12
0.12
0.10
0.12
ft·lb
11 in·lb
11 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
Fastener
Starter Motor Through Bolts
Brush Holder Screw
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Starter Motor Cable Terminal Nut
Crankshaft Sensor Cover Bolts
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TSB/Document ID: 99924-1509-03
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:
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