Kawasaki ZZ-R1100 Motorcycle Service ManualQuick Reference Guide General Information 1 Fuel System 2 Cooling System 3 Engine Top End [4 Clutch 5 Engine Lubrication System 6 Engine Removal/installation 7 Crankshaft/Transmission 8 Wheels/Tires 9 Final Drive 10 Brakes 11 Suspension 12 Steering 13 Frame [14 Electrical System 15 Thia quick reference guido wil ssiet you in Appendix 16 tere he pages back oath he Back tab Supplement — 1999 - 2001 Models | 17 of the desired chapter number with the black tab on the edge at each table of contents page. ‘eRefer to the sectional table of contents for Ine exact pages to locate the specific topic. required.LIST OF ABBREVIATIONS. A ‘ampere(s) Ib pound(s) ABDC _ | after bottom dead center m meter(s) AC alternating current min minute(s) ATDC | after top dead center N newton(s) BBDC — | bofore bottom dead center Pa pascal(s) BDC bottom dead cenier PS. horsepower BTDC | before top dead center psi pound(s) per square inch 6. degroo(s) Colsius ' revolution pc direct current rpm revolution(s) por minute F farad(s) TDC top dead center Fs degree(a) Fahrenheit TR total indicator reading ft oot, feet v volt(s) ‘orar(s) w watt(s) h hour(s) o ohms) liter(s) This warning may apply to any of the following components or any aseombly containing one oF more of these components: Brake Shoes or Pads CCluten Friction Material Gaskets Insulators WARNING. ‘CONTAINS SAFETY INSTRUCTIONS ASBESTOS ecg Raa eOperate if possible out of doors or in a well ‘Sensor ventilated place ve heath ePreferably use hand tools or low speed tools ‘equipped, if necessary. with an appropriate dust extraction facility. If high speed tools are used, they should slays be so equipped if possible, dampen before cutting or driling. @Dampen dust and place it in properly closed receptacte and dispose of it sately. Fotow stew Read OWNER’S MANUAL before operating.EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable reaulations of the United Statos Environmental Protection Agency and California Air Rosourcos Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vopors are routed through an oil separator to the intake side of the engine. While the engine Js operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharaed into the atmosphere by the exhaust of this motorcycle, The fual and ignition systems of this motorcycle have beon carsfully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead, fuel vapors ate routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is cought by a vapor separator and returned to tho fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is, commonly referred to as the Act's "tampering provisions.” "Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A)_ for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this tile prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchasor. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with reulations under this, title following its sale and delivery to the ultimate purchaser..." (Continued on next page.)NOTE © The phrase "remove or render inoperative any device or element of design” has been generally interpreted as follows: 7. Tampering does net inclide the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a. Meladjustment of vehicle components such that the emission standards are exceeded b. Use of replacement parts or accessories which adversely affect the performance : or durability of the motorcycle. c. Addition of components or accessories that result in the vehicle exceeding the standards. d Permanently removing, disconnecting, or rendering inoperative any component 5 or element of design of the emission control systems. == WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE 8Y CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law probibits the following acts or tho causing thereof; (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repeit, or replacement, of any device or oloment of design incorporated into any new vehicle for the purpose of noise control prior {0 its sale or delivery to the ultimate purchaser of whila itis in use, or (2) the use of the vehicle after such device or element of design hes been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: ‘e Replacement of the original exhaust system of muffler with a component not in compliance with Federal regulations. ‘Removal of the muffler(s) or any internal portion of the mufiler(s). ‘@ Removal of the air Dox or air box cover. @ Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such ‘modifications result in increased noise levels,Foreword This manual is designed primarily for use by trained mechanics in 8 properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires 10 perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must bbe understood in order to cary out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, ell adjustments, maintenence, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do tho work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substi- tute tools may adversely afiect safe operation, For the duration of the warranty period, we recommend that all repaits and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repait Procedure not performed in accordance with this manual may void the warranty. To get the longest lite out of your motorcycle. Follow the Periodic Maintenance Chart in the Service Manual ‘@8e alert for problems and non-scheduled mainte- nance. @Uso propor tools and genuine Kawasaki Motorcy: cle parts, Special too’s, gauges, and testers that ‘are necessary when servicing Kawasaki motorcy- cles are introduced by the Special Too! Manual, Genuine parts provided as spare parts are listed in the Parts Catalog. @Follow the procedures in this manual carefully. Don't take shortcuts. @Remember to keop complete records of mainte ance and repair with dates and any new pars installed. How to Use This Manual In prepering this manual, we divided the product imto its major systems. These systems became the manual's chapters. All information for a particular system from edjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own compre- hensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for roquired maintonance operations. If you want spark plug information, for example, 90 to the Periodic Maintenance Chart first. The chart tolls you how frequently to cloan and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then. use the Table of Contents on the first page of the chapter to find the ‘Spark Plug section, Whenever you seo these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. AAWARNING This warning symbol identifies special instructions or procedures which. if not correctly followed, could result in personal injury, or loss of life. ‘CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE © This note symbol indicates points of partic ular interest for more efficient and convenient operation. ‘@lndicates a procacural step or work to be cone. COlndicates a procedural sub-step or how ta do the work of the procedural step it follows. It also precedes the text of a NOTE. 4tIndicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of, the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent uring assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing. Modol Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent Special Tools and Sealart .... Cable, Wire, and Hose Routing1-2_GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work, Photographs, diagrams, notes, cautions. warnings. and detailed descriotions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Din Bofore removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work 25 an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, ciean off any dust or metal flings. (2) Battory Ground Remove the ground (-) lead from the bettery before performing any disassembly operations on the motorcycle. This prevents: (a) the possibilty of accidentally turning the engine aver while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tightening Sequence Generally, when installing @ part with several bolts, nuts, or screws, start thom all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avold distortion of the pert and/or causing gas or oil leakage. Conversely when loosening the bolts. nuts, or sorews, fist loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and methad indicated. (4) Torque ‘When torque values are given in this Service Manual, use them. Either ta0 litle or too much torque may lead to serious damage. Use a good quailty, reliable torque wrench, (5) Force Common sense should dictate how much force is necessary in assembly and disessembly. If « part seems especially difficult to remove or install, siop and examine what may be causing the probiem. Whenever topping is necessary, tap lightly using a woaden or plestic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Wotch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent 'A hiigh-flash point solvent ie recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufscturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring ‘Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smocth to avoid oil or compression leaks. (8) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil pessages and cause serious damage. An example of a non-permanent locking agont commonly available in North America is Loctite Lock'n Seal (Blue) (10) Press: ‘A patt installed using @ press or driver, such as a wheel bearing, should first be coated with oil on its outer ‘inner circumference so that it will go into place smoothly. (11) Ball Bearing and Neadle Beating Do not remove any ball ot needle bearings that ore pressed in unless it is necessary. Ifthey are removed. replace them with new ones. ‘When installing a bearing. press it in with the marked side facing out using a suitable driver until it is botiomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction.GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole (13) Seal Guide A seal guide is required for certain oll or grease seals during installation to evoid damage to the see! lips. Before a shaft passes through @ seal, apply a litte high temperature grease on the lips to reduce rubber 10 metal friction. (14) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, es removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (18) Cotter Pin Roplace any cotter pins that were removed with new ones, as removal deforms and breaks them. (10) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricate film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its ubricatve fim. Old grease and dicy oii should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in carain applications and may be harmful if used in an epplication for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS: ) in the assembly of certain engine and chassis parts, Always check manufacturer recommendations before using such special lubricants (17) Electrical Wires Al the elecvical wires are either single-color or two-color and, with only 2 few exceptions, must be connected to wires of the samo color. On any of the two-color wires thare is a greator amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color an then the secondary color. For example, a yellow wire with thin red stripes is referred to as.a "yellow/red” wit it would be a “red/yellow" wiea if the colors wore reversed to make red the main color. ‘Wire (cross-section) Name of Wire Color Red Wire Strands Yellow/ Red Yellow Red (18) Replacement Fans When there is a replacement instruction, replace these parts with new ones every time they are removed, These replacement parts will be damaged or lose thoir original function once removed. (18) Inspection When paris have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt es to the condition of thom, replace them with new ones. Abrasion rack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizuro (20) Specifications Specification terms are defined as follows: "Standards": Show dimensions or porformancos which brand-naw parts or systems have. “Service Limits”: Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, repiace the damaged parts1-4 GENERAL INFORMATION Model Identification 2X1100-D1 (US and Canadian Models) Left Side View: 2X1100-D1 (US and Canadian Models) Riaht Side View:GENERAL INFORMATION 1-5 2X1100-D1 (European Model) Right Side View: 2X1100-D1 (European Model) Right Side View:1-6 GENERAL INFORMATION Item 2x1100-D1- Dimensions: Overall length 2165 mm, (Gi (N) (S) (SW) (GR) 2180 mm Overall wth 730 mm Overallheignt 4205 mm Wheelbase 1495 mm, D3 ~: (G)[EU)'SP)INLY 1 )(FUK)IN)(GR) 1500 mm Road elearance 110mm ‘Seat heignt 780 mm Dry mass: 233 kg. (Cal) 233.5 ko Curbmass: Front 190 kg Rear 139 kg, (Cal) 139.5ko Fuol tank capacity 240 Performance: Minimurn turning radius 20m Engine: Type ‘Coating system Bore and stioke Displacoment ‘Compression ratio ‘Maximum horsepower Maximum torque Carburetion system Starting sysiom Ignition system Timing advance Ignition timing 4-stroke, DOHC, +-cylinger Liquid-cooled 76.0 x58.0 mm 4052 mL. VOE1 (F)IO.N 4108 kW (147 PS) @ 10500 ¢/min (rpm), JAR) (K) 74 KW (190 PS) @9000 ¢/min (1pm), (F) 75.1 kW (-) @8509 din (rom) (UTAC'S norm), 03~:75.1 KW (-) @8400 rimin (rpm) {UTAGS norm), (S) $5 kW (75 PS) @6000 r/min (rom), (SW) 68 KW (@2 PS) @8500 r/min (rpm), (u)-. (UK) 92 KW (-~) @9500 r/min (rom) (ISO4106), DB: 108 KW (147 PS) @ 10500 renin (rpm) (G) 74 KW (100 PS) @9000 rmin (rpm) (DIN) Ds: (G) 74 kW (100 PS) @9500 rimin (rpm) (DIN) Dé ~: (G) 72 kW (98 PS) @9300 r/min (1pm) (DIN) 440. Nem (11.2 kgm, 81 ft1B) @ 8500 e/min (pm). (AR) (&) 90 Nem (9.2 kgm, 67 feb) @ 7000 rimin (Pm), (FU) (UK) ~, (5) 90 Nem (9.2 kg-m, 67 fulb) @5500 rimin (rpm), (SW) 86 Nom (8.8 kgm, 64 f-lb) @4500 rimin (rpm), (G) 30NN-m (9.2 kgm, 67 t-bo) ©7000 s/min (pr) (DIN) Ds ~: (G) 93 N-m (9.5 ko-m, 69 ft-lb) {©5000 r/min (pm) (DIN) Carburetors, Keihin CVK:D 40 x 4 Electric starter Battery and coll (vansistorized) Electronically advanced From 10° BTDC @1000 r/min (rpm) to 40” BTDC @6000 r/min (rpm) (Cal) From 75° BTDG @ 1200 rimin (rpm) to 40° BTDC @6000 vin (rom) (S),D8 ~ () From 7.5" BTOC 6 1300 ¢/min (1pm) to 40° BTDC @6000 ymin (rpm) (U) (C) From 75" BTDG @ 1000 r/min (rpm) to 40" BTDC 6900 r/min (rpm)GENERAL INFORMATION 1-7 tem zx1100-01 ~ ‘Spark plug NGK CAGE 07 ND U27ESR-N Cylinder numbering method Lett to right, 1-2-3-4 Firing ordor 1.243 Vaive timing: Inlet Open 40° BTDC. (F) 20° Close 70) ABDG, (F) 50° Duration 290" (F) 260" Exhaust Open 63° BBDC. (F) 45° Close 43° ATDC, (F) 25° Duration 286° (F) 250° Lubrication system Forced lubrication (wet sump with elor) Engine Grade SE,SF, oF SG class Viscosity SAE1OW.40, 10W-50, 20W.-£0, or 20W-50 Capacity 35L Drive Train: Primary reduction system Type Gear Reduction ratio 1.637 (98/58) Clutch type Wet muti disc Transmission: Type 6-speed, constant mesh, retum shit Geerratos: 1st 2,800 (42/15) 2nd 2.055 (37/10) ard 1.890 (35/22) ath 1.238 (32/24) ‘th 1.183 (8028) ath 1.035 (29/28) Final drive system: Type Chain drive Reduction ratio 2.647 (45/17), DS ~: (GFUK)(GF)(N\EU)SPHINL) 1) 2588 (44/17) Qveral crive ratio Frame: Type Caster (rake angie) Trail Fronttire: Type Size Rear tio: Type size Front suspension: Type Wheel travel ear suspension: Type Wheel travel Brake type Front Fear 4.490 @ Top gear D3~: ()(FYUK)(GA)N)IEUYEPHNLY |) 4.990 @Top gear Tupuiar, double cradle 255° 107 mm Tupeiess 320/70 ZR17 Tuboless 180155 ZR17 ‘Telesconic fork 420 mm ‘Swing arm (uni-trak) 112mm Dual dice Single disc1-8 GENERAL INFORMATION tem 2x4100-01 - Electrical Equipme Battery r2V12 An Headlight: Type ‘Semisealed beam Bulb 2V60/55W (quartz-halogen) Tailorake light 42.V/5/21 W x2 (C) (Cal) (U) 12V8/27W x2 Aternator: Type Three-phase AC Rated output 28.6 A 6000 r/min (rem), 14 Spectications subiect to change without notics, and may not apply to every country. (AS) + Australia Modal (8) = Switzerlana (AR) = Austria Mode! (GA): South Africa Modo! (©) = Canada Model (SW): Sweden Model (Cal) + California Model (WU) » USA. Modo! ©): France Model (UK): UK Mode! (@) + Germany Model (EU): Europe Model (GR) : Greece Mode! (SP): Span Model (1) = Maly Model (NL): Netherlands Model (N)_ = Norway Model (6): Korea Mode!Periodic Maintenance Chart GENERAL INFORMATION 1-9 Tho scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenanes is vitally important and must not be neglected. iahever IN PELUEY wri ay TODOMETER READING Efs [s/s /§ 4 Ss [S/S] 8 (S/S) 5 OPERATION S /E/E/S /E/E/S trey [/s /e/e/e (efe/e Spark plug -clean and gap" elelefelele Valve cloaranes - check” e e ° e ‘Ar suction valve - check" elelelelele Ar leaney element and air vent filer- clear ° ° ° Air cleaner element and air vent fiter- replace |S cleaning ° Throtle op play - check * . e . . Tele spoad- chock * elelelelelele Engine vacuum Synchronization - check e@lelejelelele Fuel system - check * e . ° Fuel hoses, connections ~ check = elelelelele Coolant change 2years ° Evaporative omiasion contol syaien (Cal) -check” SASS ETS sR. Engine ol change years | © ° . = ‘Oi tier = repiace [le ° e ° Radiator hoses. connections - chack * _years | © e e ° Fuel fiter-replace . . . Fuel hose replace ayears ‘Clutch fuid level - check ™ month |e [elelelelel|e ‘Guutch tid charge 2years ° (Cluteh hose and pipe - replace a years ‘Clutch master cylinder cup and dust seal replace | 2 years ‘Ciutch slave cylinder piston seal - replace. 2years Dive chain woar -cheok ™ elelelelele Dive chain ~ lubricate OOK | Drive chain slack - check * 800 km Brake ped wear - check = elelelelele Brake fuidlevel- check” month |e [ele|elelele Brake fuid- change: years ° | Brake nose - replace years Brake hoses, connections ~ check" elelelelele Brake master cylinder cup and dust seal replace | 2 years Caliper piston seal and dust seal - replace 2 years Brake light awitch - check * Lelelelelelele Steering check * elelelelelele Steering stem bearing - lubricate 2years ° Front fork cil~ change . : Tite wear - check" —— =| elelelelele ‘Swing arm pivot, unitrak inkage lubricate ° ° ° Battery electrolyte level - check ™ month | @ [elelelelele General lubrication - perform T elelelelele Nuts, boli, and fasteners tighin@ss Gheok = ° ° ° e Coolant fiter- clean “Tyee | F: For higher odometer readings, repeat at the frequency interval established here. (Cal) : California Mode! only Replace, add, adjust, clean, or torque i necessary.1-40 GENERAL INFORMATION (Other than U.S.A. and Canada Models) Whichever ODOMETER READING FREQUENCY ey a < ever Lf is Brey > Ag ‘Spark plug -clean and G20" e Vawe learance check” ° e “Airsucton valve = check = ° ‘cleaner element and ai vent fitar clean Throtle gp play - check * ° ° ide speed - check * e e ‘Carburetor synonronization - check ° Fual hoses. connections - chek” ° Coolant = change 2yeare e Engine oll- change Sronhs| © felelelelele Oilfiter -replace ° e e e adhator hoses, connections - check ° Cich fu evel - check * Tom |e [elelelelele ‘Giuteh uid chenge Byears e Cluich hose and pipe - replace a years ‘utch mastor cylinder cup and dust seal years = replace Glutch stave cylinder piston seal- replace ‘Tyears Drve chan wear = check elelelelele Drive chan -lubicate BOOK Drive chain slack - chook = 7000 «re Brake pad wear check." e[elelelele Brake fluid level - check * month | @ |e@|e|el/elele Brake uid - change 2 years ° ‘Brake hoses, connections - check elelelelele [aia otro eed seat a Caliper pston seal and dust seal replace a years Brake fight switch - check” @l[el[elelelele Steering - check” elfelelelelele ‘Soaring stem baaving -Wbicate 2 years e Front fork ol - change 2 years Oo Front fork oll leak Check” ° ° ° ear shock absorber oll eak check ° e ° Tire wear - check" elelelelele Swing arm pivot, uni tak kage — lubricate ° ° ° Battery electroyte level -check™ Srontns elelelelele ‘General lubrication - perform e| Te ° Nuts, Gots, and fasteners ighinass - cveck™ ° ° ° ° Coolant fiter= clean year T : For higher odometer readings, repeat at the frequency interval established here. * + Replace, add, adjust. clean, or torque if necessary.GENERAL INFORMATION 1-17 Torque and Locking Agent The following table list the tightening torque for the msjar fasteners, and the pats requiring use of @ non-permanent focking agent or liquid gasket Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads, 0: Appian cil to the threads, seated surface, or washer 'S = Tighten tho fasteners following the specified sequence. SS: Apply sifcone sealant to the threads. Fastener Torque Remarks Nm kgm ft-lb Cooling System: Fen switch 18 18 139 Water temperature sensor 15 15 110 ss Bleed valve 78 | 080 69 in-tb Water pump cover bolts 98 10 Water pump drain plug 98 10 Engine Top End: Camshaft cap bolts 12 12 s Rocker shaft end bolts 5 25 Oil hose fitting 22 2.2 Oil hose banjo bolt 25 25 Carburetor holder bolts qua! =A L Cylinder head bolts: 11 mm dia. 51 52 os 10 mm dia. 38 40 | as 6mmdia 98 10 87 in-tb Cylinder bolts 15 4B Sao Upper chain guide mounting bolt - - =< il) oa Rear chain guide mounting bolts 0 20 145 L Chain tensioner mounting bolts 98 10 87 in-lb Camshaft sprocket bolts 15 15 110 L Clutet Clutch hose banjo bolts 26 25 18.0 Clutch pipe nipple 18 18 130 Clutch lever pivot nut 59 0.60 52 in-lb Clutch master cylinder clamp bolts 4 14 95 in-b 8 Clutch slave cylinder bolts - - - LQ) Bleed valve 78 080 89 inl Right cover bolts = - La) Right cover damper boks - - - L Clutch spring bolts " 14 95 in-ib Clutch hub nut 130 135 98 Engine Lubrication Syster Oil hose banjo bolts (14 mm dia.): Coolor side 26 26 180 Oil pan side 34 35 25 Gil hose banjo bolti& mm ia.) 15 15 110 Gil pan bolts = - 2 Lay Drain plugs 29 30 22 il pressure switch 6 15 11.0 ss Gil pen plug 20 20 145 L Crankcase mein oil pessage plug 18 18 130 Crankcase plug 18 18 1301-12 GENERAL INFORMATION Fastener Torque Remarks Nem ko-m ft-lb Oil pipe banjo bolts(12 mm cia.) B 25 180 Oil pimp gear holder screws - - - L Oil pump mounting boks 12 12 108 in-Ib ig Oil fiter bolt 20 20 145 Engine Removal/Installati Engine mounting nuts. = 8mm 20 20 148 10mm 44 45 33 Down tube mounting bolts 4a 45 33 Crankshaft/Transmission: Crankshaft cap bolts 2 33 24 Balancer shaft guide pin plate bolt - - - L Balancer shaft clamp lever mounting bolt - - - L Alternator shaft chain tensioner bolts - - = L Crankcase botts: 9mm dia 2 33 24 s 3 mm dia ) Sey 28 20 Timea, ||| 9B 48 130 6 mm dia. 18 18 11.0 Connecting 1od big end cap nuts See p8-11 ‘Altemator shaft chain sprocket bolt 25 26 180 Altenator shaft nut 89 60 43 Alternator shaft boit 2 25 180 One-way clutch bolts 12 12 104 in-Ib L Shift drum bearing holder bolts - = - L External shift mechanism return spring pin 23 30 22 L External shift mechanism cover bolts 98 10 87 in-lb Lay Neutral switch 15 15 11.0 Wheels/Tires: Front axle nut 145; 150 110 Front axle clamp bolts 20 2.0 145 Rear axle nut 110 10 80 Final Drive: Engine sprocket nut 125 130 94 Engine sprocket cover damper bolts - - - L Rear sprocket nuts 74 78 54 Rear sprocket studs - - = L Chain adjuster clamp boks 39 40 29 Brakes: Brake lever pivot nut 88 0.90 78 in-Ib Front moster cylinder clamp boits " 1. 95 in-tb s Brake hose banjo bolts 25 25 180 Bleed valves 78 0.80 69 in-Ib Caliper mounting bolts: Front 34 35 25 Rear 25 25 18 Front caliper assembly bolts a 24 150 Brake disc mounting bolts 23 23 165 Brake pedal pivot bolt 88 0.90 78 in-ib Rear master cylinder mounting bolts 23 23 165 Push rod nut 18 18 130 Torque link bolts/nut 25 25 18.0GENERAL INFORMATION 1-13 Fastonor Torque Remarks Nm kgm ftlb ‘Suspension: Front fork top plugs 23 23 165 Front fork clamp bolts(Upper) 2B 29 2 Front fork clamp nuts(Lower) a 24 150 Front fork bottom Allen bolts a 62 45 L Front axle clamp bolts 20 20 145 Rear shock absorber mounting nuts 59 60 43 ‘Swing arm pwvot nut 8 9.0 65 Rocker arm pivot nut 59 60 43 Tie-rod bolts 59 60 43 Steering: Handlebar weight bolts - - - i Handlebar holder bolts 20 20 145 Steering stem head nut 39 40 29 Stooring stom nut 49 050 43 in-tb Frame: Downtube bolts a4 45 33 Side stand switch sorews - - - L Center stand spring hook bolts - = - L Side stand bracket mounting bolts 49 50 26 L Side Stand Bolt a“ 35 25 Electrical System: Spark plugs 14 14 400 up coil cover bolts, - - - L2) iming rotor bolt 6 25 180 Pickup coil holder bolts L Alternator mounting bolts 25 25 180 Alternator coupling bolts 98 10 87 in-lo Alternator cover nuts, 44 0.45 39 in-to Aterator cover studs 8g 090 18 in-Io The table below, relating tightening torque to Basic Torque for General Fasteners thread diameter, lists the basic torque for the bolts Frege dia, To and nuts, Use this table for only the bolts and nuts pa which do not require a specific torque value. All of fore Naw fem Fe the values are for use with dry solvent-cleaned 6 | 94-49 [035~050 | 30~ 43 in-tb threads. 6 | &9~78 |0.80 ~ 0.80) 62 ~ 69 in-ib 8 ta~19 | 14-19 | 100~135 10 | 25~34 | 26~35 | 190~250 12 «| 44-61 | 45~62 | 33 ~45 14 | 73~98 | 74~100| 54 ~72 16 [115 ~155/11.5~160| 63~115 1g |165~ 225] 17.0~ 230) 125 ~ 165 20__|225~325| 23~33 | 165 ~2404-14 GENERAL INFORMATION Special Tools and Sealant Bearing Puller Adapter: 5701-138 @ ‘Compression Gauge: §7001-221 @ ‘Steering Stem Bearing Driver. §7001-137 Valve Spring Compressor Assembly: 5701-241 =. NO Inside Circlip Pliers: §7001-143 Bearing Puller Adapter: 57001-317 Bozring Puller: 57001-1658 Piston Pin Puller Assembly: 7001-910 Hand Tester: 87001-1394GENERAL INFORMATION 1-15 il Seal & Bearing Remover: 67001-1058 Piston Ring Compressor Grip: 67001-1095, oS TS Le Steering Stem Bearing Driver Adapter: 57001-1074 Piston Ring Compressor Belt, 067 ~ 979: 57001-1097 hoa Head Pipe Outer Race Press Shatt: 57001-1075 ‘Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver. 57001-1076 Head Pipe Outer Race Remover, 57001-1107 | les Head Pipe Outer Race Driver 57001-1077 Valve Seat Cutter. 45" ~ 0275: 57001-1114 ©1-16 GENERAL INFORMATION Valve Seat Cutter, 45° ~ 082; 67001-1116 Valve Seat Cutter, 32° - 933: 57001-1199 2 © Valve Seat Cutter, 32° - 30: 57001-1120 Valve Spring Compressor Adapter, 22: 57001-1202 2 & Valve Seat Cutter, 60° - 30: 57001-1123 Valve Guide Arbor, @5: 57001-1203 © a Valve Seat Cutter Holder Bar. 87001-1128 Valve Guide Reamer, 05: 57001-1204 a oe Bearing river Set §7001-1129 Valve Seat Cutter Holder, @5: 67001-1208 seGENERAL INFORMATION 1-17 Fork Outer Tube Weight: 57001-1218 Piston Base, 96: 57001-1263 Front Fork Oil Seal Driver: 67001-1219 Bearing Removor Shatt: 57001-1285 Coil Tester: 57001-1242 Bearing Remover Head, 15x O17: 57001-1267 & ‘Spark Plug Wrench, Hex 16: 57001-1262 Fork Oil Level Gauge: 97001-1290 s- Jack: 57001-1238 Bearing Remover Head, ©20 x ©22: 57001-1293 &1-18 GENERAL INFORMATION ‘Compression Gauge Adapter, M10 X 1.0: 57001-1317 Kewasaki Bond (Liquid Gasket ~ Black): 92104-1003 = foe Valve Seat Cutter, 60° — 33: 57001-1334. Kawasaki Bond (Liquid Gasket - Stver): 92104-002 8 gy \ Hexagon Wrench, Hex 29: 57001-1335 & = Vacuum Gauge: 57001-1369 Kawacaki Bond (Silicone Sealant): 58019-120 “Ba ioe eeGENERAL INFORMATION 1-19 Cable, Wire, and Hose Routing 3, Main Hames 4. Water Temp. Sensor Leads 5. Ground Load 8. Fan Motor Lead 7. #2,3 Ignition Coil Leads 8, Right Hom Lead 9. Alternator Lead 10. Pickup Coil Leod 411. Battery (-) Lead 12. Oil Pressure Switch Lead 13. Rear Brake Switch Lead. 14, Junction Box Load, 15. Fuel Level Gauge Lead 16. Tail/Brake Light Lead 17. Right Turn Signal Lead 18. Licence Light Lead 19. Left Turn Signal Lead 20. Tum Signal Relay Lead 21. Rectifier Lead 22.1C Igniter Lead 23. Starner Relay Lead 24. Fuel pump Relay lead 25, Side Stand Switch Lead 28. Noutral Switch Load 1 2. Cable passing in Right Hole 27. 28, 29. 30. 31 32 33 34. 36. Cables passing in Left Hole Throwtle Cable Choke Cable Ignition Switch Leacs Left Switch Case Leeds Main Hames Right Switch Case Leads Cooling Fan Switch Lead Loft Horn Lead Loft Hendleber Switch Lead Right Handlebar Switch Lead Ignition Switch Leads Clamp White Color Tape Wound ‘on Main Harness #1, 4 Ignition Coil Leads Fuel Pump Lead