1900

1.913

92180-0908

1913

1.925

92180-0909

1925

1.938

92180-0910

1938

1.950

92180-0911

1950

1.963

92180-0912

1963

1.975

92180-0913

1975

1.988

92180-0914

1988

2.000

92180-0915

2000

2.013

92180-0916

2013

2.025

92180-0917

2025

2.038

92180-0918

2038

2.050

92180-0919

2050

2.063

92180-0920

2063

2.075

92180-0921

2075

2.088

92180-0922

2088

2.100

92180-0923

2100

2.113

92180-0924

2113

2.125

92180-0925

2125

2.138

92180-0926

2138

2.150

92180-0927

2150

2.163

92180-0928

2163

2.175

92180-0929

2175

2.188

92180-0930

2188

2.200

92180-0931

2200

2.213

92180-0932

2213

2.225

92180-0933

2225

2.238

92180-0934

2238

2.250

92180-0935

2250

2.263

92180-0936

2263

2.275

92180-0937

2275

2.288

92180-0938

2288

2.300

92180-0939

2300

2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Air Suction System Damage Inspection

the air switching valve hose [A] from the lower
• Disconnect
air cleaner housing [B] (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter).

the following parts temporarily.
• Install
Fuel Pump Lead Connector [A]
Extension Tube [B]
Air Cleaner Housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter)
Special Tool - Extension Tube: 57001-1578

the engine and run it at idle speed.
• Start
Plug
the
air switching valve hose end [A] with your finger
• and feel vacuum
pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

Clutch
Clutch Operation Inspection

the clutch lever just enough to take up the free play
• Pull
[A].
the gap between the lever and the lever holder.
• Measure
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2  3 mm (0.08  0.12 in.)

PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
the adjuster [A] so that 2  3 mm (0.08  0.12 in.) [B]
• ofTurnthreads
is visible.

both adjusting nuts [A] at the bracket [B] on the
• Loosen
clutch cover as far as they will go.
the clutch outer cable [C] tight and tighten the adjust• Pull
ing nuts against the bracket.
the adjuster at the clutch lever until the free play is
• Turn
correct.

WARNING
Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
the adjustment, start the engine and check that the
• After
clutch does not slip and that it releases properly.

Engine Lubrication System
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.

Engine Oil Change

the motorcycle so that it is vertical after warming
• Situate
up the engine.
the engine oil drain bolt [A] to drain the oil.
•○Remove
The oil in the oil filter can be drained by removing the filter

•
•

(see Oil Filter Replacement).
Replace the drain bolt gasket [B] with a new one.
Tighten the drain bolt.
Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)

2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Remove the oil filler plug [A].

• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity:

SAE 10W-40

Capacity:

2.9 L (3.1 US qt) (When filter is not removed)
3.3 L (3.5 US qt) (When filter is removed)
3.7 L (3.9 US qt) (When engine is completely
dry)

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.
the O-ring of the oil filler plug with a new one.
• Replace
grease to the new O-ring.
• Apply
Install
oil filler plug.
• Check the
the
level (see Oil Level Inspection in the Engine
• LubricationoilSystem
chapter).

Oil Filter Replacement

• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
•
•

Frame chapter)
Drain the engine oil (see Engine Oil Change).
Remove the oil filter with the oil filter wrench [A].
Special Tool - Oil Filter Wrench: 57001-1249

PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
the filter with a new one.
• Replace
Apply
grease
to the gasket [A] before installation.
• Tighten the filter
with the oil filter wrench.
•
Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb)

NOTE

○Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
in the specified type and capacity of oil (see Engine
• Pour
Oil Change).

Wheels/Tires
Air Pressure Inspection

the air valve cap.
• Remove
Measure
tire air pressure with an air pressure gauge
• [A] when the
the tires are cold (that is, when the motorcycle

•

has not been ridden more than a mile during the past 3
hours).
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: Up to 180 kg (397 lb) load:
250 kPa (2.50 kgf/cm², 36 psi)
Rear:

Up to 180 kg (397 lb) load:
290 kPa (2.90 kgf/cm², 42 psi)

Wheels and Tires Inspection
Wheel/Tire Damage Inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread.
Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.

•
•
•

Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

•

2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tread Depth
Standard:
Front:
ZX1000R/S 3.6 mm (0.14 in.)
ZX1000Z
Rear

3.5 mm (0.14 in.)
5.0 mm (0.20 in.)

Service Limit:
Front

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)

Rear

2 mm (0.08 in.) (Up to 130 km/h (80
mph))
3 mm (0.12 in.) (Over 130 km/h (80
mph))

WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.

NOTE

○Most countries may have their own regulations a minimum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.

Wheel Bearing Damage Inspection

the front wheel off the ground with a stand.
• Raise
Turn
the
all the way to the right or left.
• Inspect thehandlebars
roughness
the front wheel bearing by push• ing and pulling [A] the ofwheel.
[B] the front wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
the rear wheel off the ground with the stand (see
• Raise
Rear Wheel Removal in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling [A] the wheel.
[B] the rear wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Final Drive
Drive Chain Lubrication Condition Inspection
Lubrication is necessary after riding through rain or on wet
roads, or any time that the chain appears dry.
Use a lubricant for sealed chains to prevent deterioration
of chain seals. If the chain is especially dirty, clean it using a
cleaner for sealed chains following the instructions supplied
by the chain cleaner manufacturer.

NOTICE
The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, observe the following rules.
Use only chain cleaner for cleaning of the O-ring of
the drive chain. Any other cleaning solution such
as gasoline will cause deterioration and swelling
of the O-ring. Immediately blow the chain dry with
compressed air after cleaning. Complete cleaning
and drying the chain within 10 minutes.
chain oil to the sides of the rollers so that oil will
• Apply
penetrate to the rollers and bushings. Apply the oil to the

•
•

O-rings so that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]
Wipe off lubricant that gets on the tire surface.

Drive Chain Slack Inspection
NOTE

○Check the slack with the motorcycle setting on its side
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
the wheel alignment (see Wheel Alignment Inspec• Check
tion).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:

25  35 mm (1.0  1.4 in.)

2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Adjustment

the cotter pin [A], and loosen the rear axle nut
• Remove
[B].
the both chain adjuster locknuts [C].
• Loosen
If the chain is too loose, turn out the left and right chain

•

adjusters [D] evenly.
If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.
Turn both chain adjusters evenly until the drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E] on the left wheel alignment
indicator [F] should align with the same swingarm mark or
position [G] that the right indicator notch aligns with.

WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
the both chain adjuster locknuts securely.
• Tighten
Tighten
the rear axle nut.
•
Torque - Rear Axle Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb)

the wheel, measure the chain slack again at the tight• Turn
est position, and readjust if necessary.

• Insert a new cotter pin [A].
NOTE

○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] along the nut [B].
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.

PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Wheel Alignment Inspection

that the notch [A] on the alignment indicator [B]
• Check
aligns with the same swingarm mark or position [C] that
the other side alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).