Kawasaki Service Manuals. Kawasaki Factory Service Repair Manual PDF 1. Kawasaki Motorcycle Service Manuals 2. Kawasaki ATV Service Manuals. Kawasaki Ninja ZX-10R (ZX1000) 2004-2015 Download: Kawasaki Ninja ZX-11 (ZZ-R1100) 1993-2001 Download: Kawasaki Ninja ZX-12R (ZX1200) 2000-2006.
. Ninja ZX-10R Motorcycle Service Manual. Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2008 Kawasaki Heavy Industries, Ltd. First Edition (1): Jan. 11, 2008 (M). LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current. EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation.
Use proper tools and genuine Kawasaki Mo-. torcycle parts.
Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done. GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.Model Identification. General Specifications.Technical Information-KIMS (Kawasaki Ignition Management System). 1-12 Unit Conversion Table.1-13. 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area.
Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
GENERAL INFORMATION 1-7 Model Identification ZX1000E8F (US and CA Models) Left Side View ZX1000E8F (US and CA Models) Right Side View. 1-8 GENERAL INFORMATION Model Identification ZX1000E8F (EUR Models) Left Side View ZX1000E8F (EUR Models) Right Side View Frame Number Engine Number. FI (Fuel injection), KEIHIN TTK43 × 4 Starting System Electric starter Ignition System Battery and coil (transistorized) KIMS (Kawasaki Ignition Management System) Timing Advance Electronically advanced (IC igniter in ECU) Ignition Timing From 10° BTDC @1 100 r/min (rpm) Spark Plug. 1-10 GENERAL INFORMATION General Specifications Items ZX1000E8F Lubrication System Forced lubrication (wet sump with oil cooler) Engine Oil: Grade API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train Primary Reduction System: Type. GENERAL INFORMATION 1-11 General Specifications Items ZX1000E8F Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 0.5/4.1 W (LED) Alternator.
Technical Information-KIMS (Kawasaki Ignition Management System) Overview This motorcycle is equipped with the Kawasaki ignition management system which was developed as a rider aid for track riding using technology borrowed from racing machines. Experienced racers or track riders can deliberately cause wheel spin to occur when exiting mid/high speed corners. How- ever, they rely on precise throttle control to maintain the optimum acceleration level without sacrificing too much wheel spin. GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 Nm ×. PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart.Torque and Locking Agent. 2-13 Special Tools.
2-15 Maintenance Procedure.2-16 Fuel System (DFI). 2-16 Throttle Control System Inspection.
2-16 Engine Vacuum Synchronization Inspection.2-16 Idle Speed Inspection. 2-2 PERIODIC MAINTENANCE Steering Damper Oil Leak Inspection.2-40 Electrical System. 2-41 Lights and Switches Operation Inspection.
2-41 Headlight Aiming Inspection. 2-43 Sidestand Switch Operation Inspection.2-44 Engine Stop Switch Operation Inspection. 2-45 Others.2-45 Chassis Parts Lubrication. PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection FREQUENCY Whichever. ODOMETER READING comes ×. 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever. ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (12) (15) (20) (24) ITEM Every. Brake hose and pipe damage-inspect year 2-35. PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever.
ODOMETER READING come × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (24) (30) ITEM Every Air cleaner element # - replace Every 18 000 km (12 000 mile) 2-48. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Coolant By-pass Fitting Bolt 0.92 80 inlb Thermostat Housing Cover Bolts 0.61 53 inlb Thermostat Housing Mounting Bolts 89 inlb Oil Cooler Mounting Bolts Water Hose Fitting Bolts 89 inlb Water Passage Plugs Radiator Bracket Mounting Bolt. 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Muffler Body Clamp Bolt Muffler Body Mounting Bolt Muffler Body Front Cover Bolts 0.71 62 inlb Muffler Body Rear Cover Bolts 0.71 62 inlb Clutch Clutch Lever Clamp Bolts 0.80 69 inlb Clutch Cover Bolts (M6, L = 25). PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Crankcase Bolt (M7, L = 85) Crankcase Bolts (M6, L = 45) 106 inlb Crankcase Bolts (M6, L = 40) 106 inlb Shift Drum Bearing Holder Screws 0.51 44 inlb Plate Screw.
2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Front Brake Reservoir Cap Stopper Screw 0.12 11 inlb Front Caliper Assembly Bolts Front Caliper Mounting Bolts Front Master Cylinder Bleed Valve 0.55 48 inlb Front Master Cylinder Clamp Bolts 97 inlb Brake Pedal Bolt 0.90. PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Front Fender Mounting Bolts 0.40 35 inlb Windshield Mounting Bolts 0.40 0.041 3.5 inlb Electrical System Meter Unit Mounting Screws 0.12 11 inlb Front Turn Signal Light Lens Screws 0.10 9 inlb Rear Turn Signal Light Lens Screws.
2-12 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –. 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Other than EUR and CA Models: Front 3.6 mm (0.14 in.) 1 mm (0.04 in.) Rear 5.3 mm (0.21 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 km/h (80 mph): 3 mm (0.12 in.) Air Pressure (when Cold).
PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Throttle Sensor Setting Adapter: 57001-143 Steering Stem Nut Wrench: Extension Tube: Jack: Pilot Screw Adjuster, D: Oil Filter Wrench: Jack Attachment: Vacuum Gauge:. 2-16 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection.
Check the throttle grip free play A. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard:.
PERIODIC MAINTENANCE 2-17 Maintenance Procedure. Remove the rubber caps A from the fittings of each throt- tle body. For the California and Southeast Asia models, pull off the vacuum hoses B. Connect a vacuum gauge and hoses A (Special Tool: ) to the fittings on the throttle body. 2-18 PERIODIC MAINTENANCE Maintenance Procedure. Start the engine and warm it up thoroughly.
Check the idle speed, using a highly accurate tachometer A. Idle Speed Standard: 1 100 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment). PERIODIC MAINTENANCE 2-19 Maintenance Procedure If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchroniza- tion, adjust the bypass screws A Using the pilot screw adjuster B.
Front View C Special Tool - Pilot Screw Adjuster, D:. 2-20 PERIODIC MAINTENANCE Maintenance Procedure. Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit. PERIODIC MAINTENANCE 2-21 Maintenance Procedure Idle Speed Adjustment.
Start the engine and warm it up thoroughly. Turn the adjusting screw A until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
2-22 PERIODIC MAINTENANCE Maintenance Procedure Evaporative Emission Control System Inspection (CAL and SEA Models). Inspect the canister as follows. ○ Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). ○ Remove the canister A, and disconnect the hoses from the canister. PERIODIC MAINTENANCE 2-23 Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). Check the coolant level in the reserve tank A with the motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L”. 2-24 PERIODIC MAINTENANCE Maintenance Procedure Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter). PERIODIC MAINTENANCE 2-25 Maintenance Procedure ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve A ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders.
2-26 PERIODIC MAINTENANCE Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.300 1.325 1.350 1.375 1.400 1.425 1.450 1.475 1.500 1.525 1.550 1.575 1.600 1.625 1.650 1.675. PERIODIC MAINTENANCE 2-27 Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
2-28 PERIODIC MAINTENANCE Maintenance Procedure. Connect the following parts temporarily. Inlet Air Temperature Sensor Connector A Secondary Fuel Hose B (see Fuel Hose Replacement) NOTE ○ When the ignition switch is turned ON with inlet air tem- perature sensor connector disconnected, the ECU de- tects the service code 13 (see Self-diagnosis Outline in the Fuel System (DFI) chapter). PERIODIC MAINTENANCE 2-29 Maintenance Procedure WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. Turn the adjuster A so that 4 ∼ 6 mm (0.16 ∼ 0.24 in.) B of threads is visible. 2-30 PERIODIC MAINTENANCE Maintenance Procedure Wheel/Tire Damage Inspection.
Remove any imbedded stones A or other foreign parti- cles B from tread. Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement. PERIODIC MAINTENANCE 2-31 Maintenance Procedure Wheel Bearing Damage Inspection. Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter).
Special Tool - Jack: Jack Attachment:. Turn the handlebar all the way to the right or left.
2-32 PERIODIC MAINTENANCE Maintenance Procedure. Apply oil to the sides of the rollers so that oil will 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. PERIODIC MAINTENANCE 2-33 Maintenance Procedure. 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. 2-34 PERIODIC MAINTENANCE Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
PERIODIC MAINTENANCE 2-35 Maintenance Procedure Brake Hose Damage and Installation Condition Inspection. Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main- tained. 2-36 PERIODIC MAINTENANCE Maintenance Procedure. Follow the procedure below to install the front/rear brake fluid reservoir cap correctly.
○ First, tighten the brake fluid reservoir cap B clockwise C by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn D while holding the brake fluid reservoir body A. PERIODIC MAINTENANCE 2-37 Maintenance Procedure If it does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light Removal in the Electri- cal System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter) Front Brake Light Switch A (see Switch Inspection in.
2-38 PERIODIC MAINTENANCE Maintenance Procedure Rear Shock Absorber Oil Leak Inspection. Visually inspect the shock absorber A for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Rocker Arm Operation Inspection. PERIODIC MAINTENANCE 2-39 Maintenance Procedure Steering Play Adjustment.
Remove the steering stem head with the handlebars (see Handlebar Removal in the Steering chapter). Straighten the claws A of the lock washer B. Remove: Steering Stem Locknut C Lock Washer. 2-40 PERIODIC MAINTENANCE Maintenance Procedure Steering Stem Bearing Lubrication.
Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. PERIODIC MAINTENANCE 2-41 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step. Set the gear position in the neutral position.
Turn the ignition switch ON. The following lights should go on according to below table. City Lights A Go on Taillight B. 2-42 PERIODIC MAINTENANCE Maintenance Procedure Second Step. Turn the ignition switch to P (Park) position. The city light, taillight and license plate light should go on. If the light does not go on, inspect or replace the igni- tion switch (see Switch Inspection in the Electrical Sys- tem chapter).
PERIODIC MAINTENANCE 2-43 Maintenance Procedure. Set the dimmer switch to high beam position.
The low beam A and high beam B headlights should go on. The high beam indicator light (LED) C should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following parts. 2-44 PERIODIC MAINTENANCE Maintenance Procedure Sidestand Switch Operation Inspection. Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). Inspect the sidestand switch A operation accordance to below table. Sidestand Switch Operation Gear Clutch Engine.
PERIODIC MAINTENANCE 2-45 Maintenance Procedure Engine Stop Switch Operation Inspection First Step. Set the gear position in the neutral position. Turn the ignition switch ON. Turn the engine stop switch to stop position A. Push the starter button.
2-46 PERIODIC MAINTENANCE Maintenance Procedure Cables: Lubricate with Rust Inhibitor Clutch Cable Throttle Cables. Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
PERIODIC MAINTENANCE 2-47 Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Radiator Bolts Exhaust Pipe Holder Nuts Exhaust Manifold Clamp Bolt Premuffler Chamber Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt Clutch Lever Pivot Bolt Nut Engine Mounting Bolts and Nuts Engine Bracket Bolts Wheels. Install a new element A so that the screen side B faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number ).
Using another air cleaner element will wear the engine prema- turely or lower the engine performance. PERIODIC MAINTENANCE 2-49 Maintenance Procedure For Primary Fuel Hose (Fuel Tank ∼ Throttle Body Assy). Be sure to place a piece of cloth A around the fuel hose joint. Insert a thin blade screwdriver B into the slit C on the joint lock D. 2-50 PERIODIC MAINTENANCE Maintenance Procedure. Turn A the driver to disconnect the joint lock B.
Pull the fuel hose joint C out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. PERIODIC MAINTENANCE 2-51 Maintenance Procedure.
For the United States, Canada and California models, note the following. ○ Run the fuel hose to the hole A of the rubber plate B. Front C. Insert A the fuel hose joint B straight onto the delivery pipe until the hose joint clicks.
2-52 PERIODIC MAINTENANCE Maintenance Procedure Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. PERIODIC MAINTENANCE 2-53 Maintenance Procedure.
Fill the radiator up to the radiator filler neck A with coolant, and install the radiator cap. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. 2-54 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hose and O-ring Replacement. Drain the coolant (see Coolant Change). Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Thermostat Housing A (see Thermostat Housing Re- moval in the Cooling System chapter) Oil Cooler B (see Oil Cooler Removal in the Engine Lubrication System chapter) Water Pump C (see Water Pump Removal in the Cool. PERIODIC MAINTENANCE 2-55 Maintenance Procedure Engine Oil Change. Situate the motorcycle so that it is vertical after warming up the engine.
Remove the engine oil drain bolt A to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). 2-56 PERIODIC MAINTENANCE Maintenance Procedure Oil Filter Replacement. Drain the engine oil (see Engine Oil Change). Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). Remove the oil filter A with the oil filter wrench B. Special Tool - Oil Filter Wrench:.
PERIODIC MAINTENANCE 2-57 Maintenance Procedure Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. 2-58 PERIODIC MAINTENANCE Maintenance Procedure. Change the brake fluid.
2016 Kawasaki Zx10r Hp
○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. Open the bleed valve A. Apply the brake and hold it B. PERIODIC MAINTENANCE 2-59 Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly. Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). Remove the seal cover A, circlip B, connector C and O-ring D.
2-60 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Assembly. Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. PERIODIC MAINTENANCE 2-61 Maintenance Procedure. Using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ Install a rubber gasket A and a wooden board B more than 10 mm (0.39 in.) thick on the caliper half, and fas- ten them together with a suitable bolt and nut as shown.
2-62 PERIODIC MAINTENANCE Maintenance Procedure. Replace the fluid seals A with new ones. ○ Apply silicone grease to the fluid seals, and install them into the cylinders by hand. Replace the dust seals B with new ones.
○ Apply silicone grease to the dust seals, and install them into the cylinders by hand. PERIODIC MAINTENANCE 2-63 Maintenance Procedure. Using compressed air, remove the piston. ○ Cover the caliper opening with a clean, heavy cloth A. ○ Remove the piston by lightly applying compressed air B to where the brake line fits into the caliper.
WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. 2-64 PERIODIC MAINTENANCE Maintenance Procedure. Apply brake fluid to the outside of the piston, and push it into the cylinder by hand as far as it will go. Replace the friction boot A and dust boot B with new ones. FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View.Water Temperature Sensor DFI System.3-10 Output Voltage Inspection.3-58 DFI Parts Location.3-16 Water Temperature Sensor Specifications.3-18 Resistance Inspection.3-59 Special Tools and Sealant.3-20 Atmospheric Pressure Sensor DFI Servicing Precautions. 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Input Radiator Fan Relay Inspection.3-96 Voltage Inspection.
3-75 Subthrottle Valve Actuator (Service Vehicle-down Sensor Output Code 62). 3-98 Voltage Inspection. 3-76 Subthrottle Valve Actuator Subthrottle Sensor (Service Code Removal.3-98 32). 3-78 Subthrottle Valve Actuator Subthrottle Sensor. FUEL SYSTEM (DFI) 3-3 Fuel Flow Rate Inspection. 3-120 Throttle Body Assy Removal.3-135 Fuel Pump. 3-122 Throttle Body Assy Installation.3-137 Fuel Pump Removal.3-122 Throttle Body Assy Disassembly.
2007 Kawasaki Zx10r Owners Manual
3-138 Fuel Pump Installation.3-123 Throttle Body Assy Assembly. 3-4 FUEL SYSTEM (DFI) Exploded View. FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks Nm kgfm ftlb Inlet Air Temperature Sensor Screw 0.12 11 inlb Air Inlet Duct Mounting Bolts 0.71 62 inlb Air Cleaner Housing Bracket Bolt 0.71 62 inlb Air Cleaner Housing Mounting Bolt (Upper) 0.71 62 inlb Air Cleaner Housing Mounting Bolts (Lower). 3-6 FUEL SYSTEM (DFI) Exploded View.
2016 Kawasaki Zx10r Owners Manual
FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks Nm kgfm ftlb Delivery Pipe Assy Mounting Screws (Nozzle 0.35 30 inlb Assy) Nozzle Assy Mounting Bolts 0.71 62 inlb Delivery Pipe Assy Mounting Screws (Throttle 0.35 30 inlb Body Assy) Throttle Body Assy Holder Clamp Bolts 0.20 18 inlb. 3-8 FUEL SYSTEM (DFI) Exploded View. FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks Nm kgfm ftlb Exhaust Butterfly Valve Actuator Mounting Screws 0.44 38 inlb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 inlb Separator Bracket Bolts 0.71 62 inlb Canister Bracket Bolts 0.44 38 inlb 5. 3-10 FUEL SYSTEM (DFI) DFI System DFI System. FUEL SYSTEM (DFI) 3-11 DFI System 1. Battery 12 V 10 Ah 3. Inlet Air Pressure Sensor 4.
Subthrottle Valve Actuator 5. Main Throttle Sensor 6. Subthrottle Sensor 7.
Inlet Air Temperature Sensor 8. Secondary Fuel Injectors 9. Fuel Pump 10. 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram. FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1.
Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Stick Coil #1, #2, #3, #4 5. Air Switching Valve 6. Crankshaft Sensor 7.
Secondary Fuel Injector #1 8. Secondary Fuel Injector #2 9.
3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: G 3.
Subthrottle Valve Actuator: BK/BL 4. Gear Position Switch: W/Y 5. Oxygen Sensor #1 (Equipped Models): W/BL 6. Power Supply to Sensors: BL 8.
Air Switching Valve: R/BL 63. Primary Fuel Injector #1: BL/R 64. Secondary Fuel Injector #1: O/R 65. Secondary Fuel Injector #4: O/Y 66.
Stick Coil #3: BK/W 67. Fuel Pump Relay: BR/Y 68. Stick Coil #4: BK/O.: KDS (Kawasaki Diagnostic System). Fuse Box C (Ignition Fuse 15 A, ECU Fuse 10 A, Oxy- gen Sensor Heater Fuse 10 A (Equipped Models)) ECU A Relay Box B (Fuel Pump Relay, Radiator Fan Relay) Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector C Vehicle-down Sensor D Atmospheric Pressure Sensor E.