Crankshaft Sensor Bolts
Timing Rotor Bolt
Regulator/Rectifier Mounting Nuts
Bracket Mounting Screws
Alternator Rotor Bolt
Stator Coil Bolts
Alternator Lead Holding Plate Bolt
Alternator Cover Bolts
Engine Ground Terminal Bolt
Spark Plugs

G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
R: Replacement Parts

N·m
5.0
3.8
10
11
6.0
10
6.0
39
7.0
2.5
155
12
10
10
10
13

Torque
kgf·m
0.51
0.39
1.0
1.1
0.61
1.0
0.61
4.0
0.71
0.25
15.8
1.2
1.0
1.0
1.0
1.3

ft·lb
44 in·lb
34 in·lb
89 in·lb
97 in·lb
53 in·lb
89 in·lb
53 in·lb
29
62 in·lb
22 in·lb
114
106 in·lb
89 in·lb
89 in·lb
89 in·lb
115 in·lb

Remarks

L

L
L
L

16-8 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-9
Exploded View
No.
1
2
3
4
5
6
7
8
9

Fastener
Switch Housing Screws
Fuel Pump Bolts
Frame Ground Terminal Bolt
Gear Position Sensor Bolt
Gear Position Sensor Holder Bolt
Side Stand Switch Bolt
Oil Pressure Switch
Water Temperature Sensor
Oxygen Sensor

10. ZX1000R/S
11. ZX1000Z
12. Immobilizer Amplifier (Equipped Models)
13. Fuel Reserve Switch
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
3.5
10
7.0
10
5.0
9.0
15
12
25

Torque
kgf·m
0.36
1.0
0.71
1.0
0.51
0.92
1.5
1.2
2.5

ft·lb
31 in·lb
89 in·lb
62 in·lb
89 in·lb
44 in·lb
80 in·lb
11
106 in·lb
18

Remarks
S
L, S
L
L
L
LG

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

Standard
Sealed Battery
YTZ10S
12 V 8.6 Ah
12.8 V or more
3.2 kg (7.1 lb)
0.45 L (27 cu in.)
Three-phase AC
48  72 V @ 4 000 r/min (rpm)
0.110  0.164 Ω @20°C (68°F)
14.3  14.7 V @20°C (68°F)

376  564 Ω @20°C (68°F)
1.9 V or more
0.85  1.15 Ω @20°C (68°F)
6.7  9.1 kΩ @20°C (68°F)
100 V or more
NGK SILMAR9B9
0.8  0.9 mm (0.031  0.035 in.)

12.05 mm (0.4744 in.)
(Service Limit: 6.55 mm (0.258 in.))
20  24 Ω @20°C (68°F)
22  26 Ω @20°C (68°F)
123  125 Ω at meter connector
ON after about 10 mm (0.39 in.) of pedal travel
When engine is stopped: ON
When engine is running: OFF
in the text

ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1405

Flywheel & Pulley Holder:
57001-1605

Peak Voltage Adapter:
57001-1415

Rotor Holder:
57001-1666

Lead Wire - Peak Voltage Adapter:
57001-1449

Rotor Holder Attachment:
57001-1689

Key Registration Unit:
57001-1582

Key Registration Adapter:
57001-1853

Grip:
57001-1591

Liquid Gasket, TB1211F:
92104-0004

16-12 ELECTRICAL SYSTEM
Parts Location
Timing Rotor [A]
Crankshaft Sensor [B]
Horn [C]
Oil Pressure Switch [D]

Rear Brake Light Switch [A]
Oxygen Sensor [B]

Alternator [A]
Stator Coil [B]
Gear Position Switch [C]
Side Stand Switch [D]

Immobilizer Amplifier (Equipped Models) [A]
Radiator Fan Motor [B]

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

ELECTRICAL SYSTEM 16-13
Parts Location
Starter Lockout Switch [A]
Ignition Switch [B]
Immobilizer Antenna [C] (Equipped Models,
Included in Ignition Switch)
Meter Unit [D]
Front Brake Light Switch [E]

Air Switching Valve [A]
Stick Coils [B]
Spark Plugs [C]

Water Temperature Sensor [A]
Starter Motor [B]

Vehicle-down Sensor [A]
Fuse Box (2) [B]
Starter Relay [C]
Battery 12 V 8.6 Ah [D]
Diode Array (Starter) [E]
Fuel Pump Relay [F]
ETV Actuator Relay [G]

ESD ECU [A]
Turn Signal Relay [B]
Radiator Fan Relay [C]

16-14 ELECTRICAL SYSTEM
Parts Location
Fuel Reserve Switch [A] (Included in Fuel
Pump)

ELECTRICAL SYSTEM 16-15
Parts Location
This page intentionally left blank.

16-16 ELECTRICAL SYSTEM
Wiring Diagram (ZX1000R without Immobilizer)

ELECTRICAL SYSTEM 16-17
Wiring Diagram (ZX1000R without Immobilizer)

16-18 ELECTRICAL SYSTEM
Wiring Diagram (ZX1000R with Immobilizer)

ELECTRICAL SYSTEM 16-19
Wiring Diagram (ZX1000R with Immobilizer)

16-20 ELECTRICAL SYSTEM
Wiring Diagram (ZX1000S/Z without Immobilizer)

ELECTRICAL SYSTEM 16-21
Wiring Diagram (ZX1000S/Z without Immobilizer)

16-22 ELECTRICAL SYSTEM
Wiring Diagram (ZX1000S/Z with Immobilizer)

ELECTRICAL SYSTEM 16-23
Wiring Diagram (ZX1000S/Z with Immobilizer)

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 leads for signs of burning, fraying, etc. Poor
leads 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.

the wiring for continuity.
•○Check
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 0 Ω, the lead is defective. Replace the lead or the wiring harness [A] if necessary.

16-26 ELECTRICAL SYSTEM
Battery
Battery Removal

the ignition switch off.
• Turn
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
the negative (–) cable [A].
• Disconnect
Slide
the
red
[B].
• Disconnect thecappositive
(+) cable [C].
•

NOTICE
Be sure to disconnect the negative (–) cable first.

• Remove the band [D] and the battery.
Battery Installation

inspect the surface of the battery container.
• Visually
If any signs of cracking or electrolyte leakage from the

•
•
•
•
•

sides of the battery.
Put the battery into the battery case.
Install the band [A].
Connect the positive (+) cable [B] (red cap) to the positive
(+) terminal first, and then the negative (–) cable [C] to the
negative (–) terminal.
Apply a light coat of grease on the terminals to prevent
corrosion.
Cover the positive (+) terminal with the red cap [D].

NOTICE
If each battery cable is not correctly disconnected
or connected, sparks can arise at electrical connections, causing damage to electrical and DFI parts.

Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying
off the seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
Give refresh charge for 5 to 10 hours with charge current shown in the text (see Refreshing
Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions.

NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).

ELECTRICAL SYSTEM 16-27
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medical
attention for more severe burns.

Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

○Battery charging condition can be checked by measuring

•
•

battery terminal voltage with a digital voltmeter [A].
Remove:
Battery (see Battery Removal)
Measure the battery terminal voltage.

NOTE

○Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.8 V or more, refresh charge is not
required, however, if the read is below the 12.8 V, refresh
charge is required.
Battery Terminal Voltage
12.8 V or more
Standard:

Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]

Refreshing Charge

the battery (see Battery Removal).
• Remove
refresh charge by following method according to the
• Do
battery terminal voltage.

WARNING
This battery is sealed type. Charge with current and
time as stated below.

16-28 ELECTRICAL SYSTEM
Battery
Terminal Voltage: 12.0  12.7 V
Standard Charge: 0.9 A × 5  10 h (see following chart)
Quick Charge: 4.5 A × 1 h

NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: 12 V or lower
Charging Method: 0.6 A × 20 h
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S

the recommend chargers are not available, use equiv• Ifalent
one.

NOTE

○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D].
Determine the battery condition.
○Determine the battery condition left for 30 minutes after
completion of the charge by measuring the terminal voltage according to the table below.

•

Criteria

Judgement

12.8 V or higher

Good

12.1  lower than 12.8 V

Charge insufficient → Recharge

lower than 12.0 V

Unserviceable → Replace

ELECTRICAL SYSTEM 16-29
Charging System
Alternator Cover Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
•
•

Removal in the Frame chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Open the clamp [A] and free the alternator lead.
Disconnect the alternator lead connector [B].