Kawasaki ZX-9R (B1-B4 1994-1997) Service Manual

Kawasaki Ninja ZX-9R
•
..
Motorcycle
Service Manual
••
Quick Reference Guide
General Information
Fuel System
Engine Removal/Installation
Crankshaft/Transmission
Wheels/Tires
Final Drive
Steering
Frame
Electrical System
This quick reference guide will assist you in

· locating a desired topic or procedure.
• Bend the P"Qes ~k to match the black tab
of the desired chapter number with the black
tab on the edge at each table of contents
page.
• Refer to the sectional table of contents for
the exact pages to locate the specific topic
required.
GENERAL INFORMATION 1-1
General Information
• Table of Contents
Before Servicing ..........................................................................................................1-2

Model Identification ....................................................................................................1-4
General Specifications ................................................................................................1-6
Periodic Maintenance Chart .......................................................................................1 -9
Technical Information - Maintenance Free Battery ................................................1·1 0
(I) Construction ....................................................................................................1-1 0
(II) Main Features .................................................................................................1 ·1 0
(Ill) Principia of Sealing Structure .......................................................................1 -10
(IV) Filling the Battery with ElectrOlyte ...............................................................1-11
(V) Initial Charge ..................................................................................................1-12
(VI) Precautions ....................................................................................................1 -13
(VII) Interchangeability with Ordinary Battery .................................................... 1 -13
Technical Information - Alternator Unit ..................................................................1-14
Technical Information - Engine Lubrication System ..............................................1-14
Technical Information - Swingarm ..........................................................................1-16
Torque and Locking Agent .......................................................................................1-16
Special Tools and Sealant ........................................................................................1-21
Cable. Wire, and Hose Routing ................................................................................1-27
1-2 GENERAL INFORMATION
Before Servici ng
Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate
unnecessary worlt. Photographs, diagrams, notes. cautions, warnings. and detailed descroptions have been
included wherever necessary. Nevertheless, even a deta1led account has limitations. a cenam amount of basic
knowledge is also required for successful work.
Eapecially no te the f o llo w ing:

.. (1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will
worlt as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new
part clean off any dust or metal filings.
( 2) Battery Ground
Remove the ground ( - ) lead from the battery before performing any disassembly operations on the
motorcycle. This prevents:
(a) the possibility of accidentally turning the engine over while partially disassembled.
(b) sparks at electrical connections w hich will occur when they are disconnected.
(c) damage to electrical parts.
(3) 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 evenly in a cross pattem. This is to avoid distortion of the
part and/ or causing gas or oil leakage. Conversely when loosening the bolts, nuts. or screws, first loosen
ail of them by about a quarter tum and then remove them. Where there is a tightening sequence indication
in this Service Manual, the bolts, nuts, or screws must be tightened in tne order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use tnem. Either too little or too much torque may
lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems
especially difficult to remove or install, stop and examine what may be causing the problem . Whenever
tapping is necessary, tap lightly using a wooden or plastic· 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
Watch 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 tuming it over.
(7) High- Flash Point Solvent
A nigh -flash point solvent is recommended to reduce fire danger. A commercial solvent commonly
available in North America Is Stoddard solvent (generic name) . Always follow manufacturer and container
directions regarding the use of any solvent.
(8) Gasket. O · Ring
~Do not reuse a gasket or 0 - ring once it has been in service. The matmg surfaces around the gasket
should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(9) 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 passages and cause serious damage. An
example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal
(Blue) .
(1 0) Press
A part installed using a press or driver, such as a wheel bearing. should first be coated with oil on its outer
or inner circumference so that it will go into place smoothly.
(11 ) Ball Bearing and Need le Bearing
Do not remove any ball or needle bearings that are pressed in unless it is necessary. If they are removed.
replace them with new ones.
When installing a bearing. press it in w ith the marked side facing out using a suitable driver until it is
bottomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by
friction.
• GEN ERAL INFO RMATI ON 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 oil or grease seals during installation to avoid damage to the seal lips.
Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to
metal friction.
(14) Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as 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.
(15) Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.
(16) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing
surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil 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 certain
applications and may be harmful if used in an application 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
All the electrical wires are either single-color or two-color and, with only a few exceptions, must be
connected to wires of the same color. On any of the two-color wires there is a greater amount of one color
and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then
the secondary color. For example, a yellow w ire with thin red stripes is referred to as a •yellow/red" wire;
it would be a ·red/yellow· wire if the colors were reversed to make red the main color.
Name of Wire Color
Red
Wire Strands
Yellow/Red
Yellow
Red
\
(18) Replacement Parts

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 their original function once removed.
(19) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other
damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20) Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
•service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated
performance, replace the damaged parts.
1-4 GENERALINFORMATION
Model Identification
ZX900-B1 (US end Cenede Models) Lett Side View:
ZX900-B1 (US end Cenade Modele) Right Side View:

GENERAL INFORMATION 1 -6
ZX90()..81 (Europe Model) left Side View:
ZX900-81 (Europe Model) Right Side VIew:

1 ·6 GE NERAL INFORMATI O N
General Specifications
Items ZX900- B1 ZX900-B2 ZX900-B3

Dimensions:
Overall length 2085mm.
(FG)(GR)( NR)(SD)(ST) 2 195 mm.
.......
(In 2105 mm ...
Overall width 725mm .... ....
Overall height 1165mm .... ....
Wheelbase 1 440mm .... ....
Road clearance 125mm +- ...
Seat height 800mm
215 kg, (CA) 216 kg
...
...
...
Dry mass 218 kg, other
than US, CN
Curb massFront 125 kg ...
... ....
Rear 118kg, (CA) 119kg 120 kg, other
than US, CN
Fuel tank capacity 20 L .... ...
Performance:
M inimum turning 3.5m ... ...
radius
Engine:
Typa 4-stroke, DOHC, 4-cylinder ...... ......
Cooling system Liquid-coolad
Bore and stroke 73.0 x 53.7 mm ...... ......
Displacement 899ml
Compression ratio 11 .5,(FR)(Sn1 0.1 ...... ......
Ma~imum 10 r.w (139 PS) @10 500 r/min (rpm7.
horsepower (AR)(FG) 74 kW (1 00 PS) (U K)102kW(139
@1 0 000 r/min (rpm)(DI N), (FR) 75.1 kW PS) @10 500
13/~P (1 02 PS) @9 800 r/min(rpm) r/min(rpm)
(UTAC's norm), (SO) 63 kW (86 PS) (FG)72kW(98
@ 10 000 r/min, (ST) 45 kW (61 PS) PS)@1000
@6 000 r/ min (rpm), ~ltj 92kW (125 PS) r/min (rpm)
(j19 699 r/mia (spm)(tSe), ('=IS) ---
Ma~imum torque 96 N-m(9.8 kg-m, 70.9 11-lb) ... ...
@9 000 r/ min(rpm), (FG)78 N-m(8.0 kg-m (AR)78 N-m(8.0
(/1.f+-ll 57.5 11-lb) @7 000 r/min (rpm) (DI N), kg-m,57.0f1-lb)
(AR) 79 N-m (8.1 kg-m, 58.6 ft-lb) , @7000r/min(rpm)
@7 000 r/min (rpm) (DIN) , (FG)77N -m(7.9kg -m,
}.
(SO) 74 N-m (7.6 kg-m. 55.0 11-lb) 57 .Oft-lb)@7000
@7 000 r/ min (rpm) , (ST) 72 N-m r/min(rpm) (DIN)
(7.3 kg-m, 52.8 11-lb) @6 600 r/min (rpm),
(FR)(UK)(US) ---
Carburetion system Carburetors, Keihin CVKD 40 x 4 .... ...
Starting system Electric starter ...
Ignition system Battery and coil (transistomed) ...... ...
......
Timing advance Electronically advanced(digiull igniter)
Ignition timing From 10" BTDC @1 100 r/min (rpm) to ...
45' BTOC @5 BOOr/min (rpm)
(CA) From 10" BTDC @1 300 r/ min (rpm)
to 45' BTDC @5 800 r/ min (rpm),
(Sn From 5' BTDC @1 300 r/ min (rpm) to
40' BTDC @5 800 r/min (rpm)
GEN ERAL IN FOR M ATIO N 1 -7
Items ZX900- B1 ZX900- B2 ZX900- B3
Spark plug NGK CR9EK or NO U27ETR +- +-

Cylinder numbering Left to right. 1-2 -3-4 +- +-
method
Firing order
Valve timing:
Inlet
1-2 - 4 -3 +-
+-
--
Open 39• BTOC, ( FR)(ST) 20" BTOC +- +-
Close 69• ABDC.(FR)(ST) 5o- ABOC +- +-
Dunnion 288". (FR)(ST} 25o- +- +-
Exheust
Open 65• BBOC,(FR)(ST) 5o- BBOC +- +-
Close 35• ATOC. (FR)(ST} 20" ATOC +- +-

Duration 28o·. (FRHST> 2so· +-
Lubrication system Forced lubrication (wet sump with cooler) +- +-
Engine oil:
Grade SE. SF or SG class +- +-
Viscosity SAE10W· 40, 10W- 50, 20W-40. or 20W-50 +- ....
Capacity 4.0 l +- +-
Drive -T rain:
Primary reduction
system:
Type Gear +- +-
Reduction ratio
Clutch type
Transmission:
Type
1.634 (89/58)
Wet multi disc
6-speed. constant mesh, return shift

+-
+-
+-
-
+-
+-
Gear ratios:
1St 2.857 (40/14) (E}(FG}(IT) (NL) (AR}(GR}(NR)
(SP) (UK)2.785 2.786(39/14)
(39/14)
2nd 2.055 (37 / 18) ( E)(FG)(IT)(NL) (AR)(GR)( NR )
(SP)(U K)2.000 2.000(36/1 8)
(36/ 18)
3rd 1 .650 (33/20) (E)(FG)(IT)( NL) (AR)(GR)(NR )
(SP)(U K) 1 .619 1.61 9(34/21 )
(34/ 21)
4th 1 .391 (32/23) .... +-
5th 1.222 (33/27) .... +-
6th 1.1 03 (32/29) +- +-
Final drive system:
Type
Reduction ratio
Overall drive ratio
Chain drive
2. 750 ( 44/1 6)
4.656 @Top gear
+-
+-
....
--
+-
GEN ERAL IN FORMATION 1 -9
ma-
Periodic Maintenance Chart
The echeduled maintenance must be done in IICCOrdenoe with this chart to keep the moton:ycle in good running
condition. The lftlllel Is vllaUy Important - muat nol be neglectod.
Refw to P.16-11 IO< '96 ZX900-B3 other than U.S. and Canadian Models.
Whichever .. I 1000METER READING
~'~
FREQUENCY
' ~~ ~~~6()~ ~~~ ~()~ ~()~~()~

OPERATION ~~ ~~ ~<:) ()~ ()() <t)() <t)<:)
Every '<> <t) '\- '\- 't,; 't,; ">
Spark plug - clean
• • • • • •
Spark plug - check "
• • • • • •
Valve clearance - check"
• •• • •
Air suction valve - check·
• • • • •
Air cleaner elemi!nt and air vent filter - clean
• • • •
Air cleaner element and air vent filter - reolace 5 clean inc!
•
Throttle grip play--check" • • • •
Idle soeed - check·
• • • • •
• •
• •
i Engine vacuum synchronization -check •
• • •• • ••
Fuei~YS~em--check •
•
Coolant - change 2years
•
Evarr::live emission control system
Cal - check" • • • • • • •
Engine oil - change year
• • • •
Oil filter - replace
• • • •
Radiator hoses, connections - check" veer
• • • •
Fuel filter - replace
Fuel hose - replace 4 years
• • •
Clutch fluid level - check • month
• • • • • • •
Clutch fluid - change
Clutch hose and pipe - replace
2 years
4years
•
Clutch master cylinder cup and dust seal
-
Clutch slave cylinder piston seal - replace
2 years
2 years
OriV8 chein wear -check •
Drive chain - lubricate 300km
• • • • • •
Drive chain alack - check • 800km
Brake oad wear -check·
• • • • • •
Brake fluid level -check· month
• • • • • • •
Brake fluid - change
Bmka hoee - replace
2 years
4 years
•
Brake master cylinder cup and dust seal 2 years
- replace
Caliper piston seal and dust seal - replace 2 vears
Brake light switch - check"
• • • • • • •
Steering - check·
• • • • • • •
Stwing stem bearing - lubricate 2 years
•
Front fOlk oil - change
•
rn wear - check" • • • • • •
Swongarm pivot. uni-trak linkage - lubricate
General lubrication - perfonn
• •
• • • •
•
• •
Nuts. bolts, and fasteners tightness - check·
• • • •
t : For higher odometer readings, repeat at the ftequency interval est<!blished hera.
• · Replace. add, adjust, clean, or torque II neceasary.
Technical Information - Maintenance Free Battery
A maintenance free battery is i11$UIIed in mis model. The maintenance free battery is a sealed type. and 10 cannot be
oedormed !111! ejtc!roMe level check and topping-up.
(I) Corwlruct.l on
/ Scoalirlg plug
Fllter
Terminal
(lead-calcium alloy)
Pole
(lead-calcium alloy) --.L.J
Negative plate
(lead and lead-calcium alloy)
Container (P.P.)
Special separator
Positive plate
(lead and lead-calcium alloy)
(II) Main Feeturw

1) Maintenance free......................................... It is not necessary to check me electrolyte level and top-up the
electrolyte.
2) No electrolyte leakage................................. Aa the electrolyte is retained firmly in the special separators, there is no
free electrolyte in the battery.
3) lnmnt activation Sy!l!em............................. It can be used instantly after filling only the electrolyte without initial
charge.
4) One-push motion electrolyte filling............ It Ia possible to fill the electrolyte by eaSV one-pysh motion.
5) Sefe!y oonstruction .................................. ... If the banery internal pteSSUre rises abnonnally high, the safety valve
opens to release the gas •nside the banery to n!S!Ore the nonnol pn!SSure
and p<event the banery from rupturing. After reetoring me nonnal
pressure. the safery valll'e closes and the banery IS seeted again.
Moreover, a ceramoc fiher is disposed on top of the safery valll'e undo< !he
lid to remove nslt of ignition or explosion caused by fire from outside.
6) Compact and high performance ................. No ~ce of free electrOlyte allows !he battery made lower In height.
thus resulting in enhanced volume efficiency. M oreover. gas being
absorbed inside the banery eliminates the need for a gas exhaust tube.
7) Strong charge/discharge characteristics .... It can amply withstand deep charge/discharge cycles.
(Ill) Principle of Sealing Structure
A lead-acid benery operates under the following chemical reaction:
(+) (- ) Oischarge (+) (- )
Pb02 + 2HzSO• + Pb ~ PbSO• + 2Hz0 + PbSO•
(lead peroxide) (Sulfuric acid) (Spongy lead) Charge (Lead sulfate) (water) (Lead sulfate)
Positive ective Electrolyte Negative active Positrve active Electrolyte Nagative active
matO<ial material material material
Normally in an ordinary lead-acid banery when it comee to an end of a charge. where !he lead sulfate being a diSCharge
product rwtums to lead peroxide and spongy lead, the charge current flowmg thereafter is used excluSively to decompose
electrolytically water from the electrolyte. thus resulting m generatoon of hydrogen gas from the negatrve plate and oxygen
gas from the positive plate. The gases so generated are released out of the banery. caus•ng the amount of electrOlyte
decreased to require coccasional water replenishment.
A maintenance free battery. however. is so designad that. when 11 is overcharged, even if the positive plate is fully charged.
the negative plate remains not fully turned to spongy lead. Therefore, even when the positive plate is overcharged generating
oxygen gas. the negative plate is no fully charged, hence generating no hydrogen gas.
Moreover. the oxygen gas generated from the positive plate Immediately reacts with the charged active material on the
negative plate. and returns to water, with the ultimate result of no water loss.
GENERAL INFORMATI ON 1 - 11
Pb .. 1/2 Ot .... (PbO)

Negative active Oxygen generated Negative active
material from positive plate material
(charged atate)
(PbO) .. H2SO.
Electrolyte
-+ PbSO•
Negative active
+ H20
Water
material
(charged state)
Thus. ths negatiVe plata is made as not to get fully charged. Even if the OVe<Charge continues. the oxygen ges generated
InSide the battery is absorbed by the negatiV$ plate, a PIOC'!SS called oxygen cycle, which kMPS wate< loss m80<8tically at
nil, and allows me batte<y to be ..,led.
(IV) RBing the Batte<y with Electrolyte

CAliTION
Do not-•.,.
lull-reuse.
elumlnum Mil eh- Heling lhe IIIIer potts until
Be lift 10 UH lhe dedicated -rolytoo contal,_ lor eo<rect

electrolrt- volume.
e Check to see that there is n o peeling, tears or holes in the sealing sheet.
• Place the battery on e level s u rface.
eRemOV1l the sealing sheet [A].
OWhen removing, check to hear an air-sucking sound "Shooshl" from
fillet ports [B).
NOTE
OA luttery whose soaling sheet hss any ptNJI/ng, tears, holos. or from
which the sir·sucl<ing sound was not heard requirss a refreshing
ctwge (initial charge).
e Tske the eleciJOiyte container out of the vinyl bag.

e Detach the strip of cape [A] from the container.
NOTE
ODo not disCIH'd tho strip of Clips bec~uss it Is used as the battery
plugs t.lllr.
ODo not peei/Hck or p/elco the suled arMs [B). A
• Place ths electrQiyta conta1ne< upside down w ith me s1x sealed areas
in hne wrth the six battery IiilO< ports.
• Push ths container down strongly enough to break the seals. Now the
electrolyte ahould start to flow into the battery.
NOTE
ODo not tilt tho contsin!N ss the alectrolyt• flow mey be intenupted.
1-12 GENERALINFORMATION
e Malte eure air bubbles [ A) are coming up from all six folie< ports
0 leeve the c:onlainar this way for 5 minutes or Ionge.-.
NOTE
o If no eir bubblss aro coming up from a fillar port tap the bottom of
th8 bottle two or three times. Navar remove the container from the
betteoy. .~
"} ~ ..
®-" ':· I~ ·..
0
• Be certain that all the electrolyte has flowed out

• Tap the bottom the same way as above if there is any electrolyte leh
in the container.
• Now pull the container gently out of the batteoy.
e l.et the batteoy sit for 20 minutes. During this time. the electrolyte
J)<llmeates the special separators and the gas generated by chemical
reaction Is released.
• Fit the strip of caps [A) tightly into the filler ports until the strip is at
the same level as the top of the battery.
NOTE
OOo not hemmer. Press down evenly with both hands.
o.- you "lnalllllecl ... atrtp ol - - filling ... INttlery, never

remove II, nor add any waler or electrolyte.
M Initial Charge
While a maintenance free battery can be used aher only filling w ith electrolyte. a batteoy may not be able to sufficiently
move a atanar motor to start an engine in the cases shown in the table below, where an initial charga is required before use.
However. if a betteoy shows a terminel vollage of higher than 12.5 V aher 10 m inutes of filling (Nooot ). no initial charge is
necessaoy.
Condition requiring lnMial ctoorge Cloorglng method

At low temperarures (lower then O'C) 1.2 A x 2 - 3 hours
Battery has been sto<ed in high temperature and humidity.
Seal hea been removed. or bfol(en - peeling, tear or hole.
(If you did not hear the air-oucking 1100nd ·shooshl• as you removed the seal.)
1.2 A x 1 5 - 20 hours
Battery as old as 2 years or more ahar manufacrure.
Baneoy manufacturing date is printed on battery top.
Example) ll 1.Q ~ IL
Day Month Year Mfg . location
Note 1 : Terminal voltage - To measure battery terminal voltage. usee digital voltmeter.
(VI)P.....won.
1) No need oftopping-up
No topptng-up is necessary in this batt""f unttltt ends tiS life under nonnal usa. EorcibiV ertino off !ht ~t~lioo olug to
odd W§!8[ ia wry dangerous. Ne-m do lhaJ.
2) Refreahing charge
If an &nQine will not stan. a hom sounds weak. or lamps are dim, it indicates the batte<y has been d iocharged. Give
refrfth charQe for 5 to 10 hours with charge current shown in the specification (see the Elec:lrical System chapter).
When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions
indicated on the battety.
CAI.I110N
Thll betiMy II d"lgned to auotaln no unuaual ~erlorallon H reCresll-charged according to the malhod apec"led ellove.
tlow••er, 11!1 ballerY'a DMiormence max I!! r:l!luced IISII!!;eiii4Y " sharoed under cond!Jiona !IIIII[ IbiD g~eo tbooe.
Nutr rtmoyt I!• atallna plug during rettm cbara• ·
.....
Hby ch.,.. an axcnarve a.,_.,t of g.. Ia g-..ted due 1o overcharging, the aalely varve opera... lo keep the balliory
3) When you do not use !ht motorcycle IO< monthl

G... a refT8Ih charge before you store the motorcycle and store it w ith the negatillelead removed. GAle a refresh charge
-v &IX months during storage.
4) 8ll!ery life
If the bal!ery will not start the engine even after several refresh charges, the battery has exceeded its useful l ife. Replace
it. (Provided, how911e<, the vehicle's starting systom has no problem.)
i•WARNING
KMp h ballery -•Y lrom sparta and open llamea during charging, since the ballery glv• oil an axploal. . gaa mixture
of hydrogen and o-n. When uolng a balltlry charger, connacllhe baftery to the chiiJ'IIM llalora Jumlng on the charger.
Thla procedure pr...nta sparta at the banery ranntnala which could lgllno any balltlry gaaea.
No lire allould be drawn near the batlary, or no llrmlnela should ha¥8 thetW!tenlng looaened.
Tha aloctrolyte conllllna aulurlc ocld. Be cara4ul not lo have It touch your lkln or eyH. "lojlched, wull I oil with liberal
amount of water. Get medlcalalliantlon H severe.
(VII) ~lity with Ordinary Battery

A maontenance free ban""f can fully display its performance only when combined w ith a proper vehicle elec1ric system.
Th...tore, replace a maintenance free battery only on a motorcycle which was originally equipped with a mainlllnance free
banety.
Be careful.~ a maintllnance free battety is installed on a motorcycle which had an ordinaty banety aa original equipment,
tht maintenance free bottety's life will be shortened.
1 -14 GENERAL INFORMATION
Technical Information - Alternator Unit
An alternator [A] with a regulator/rectifier 001k in is mounted on the
crankcase, behind me cyllnde<. The conventional alternator is installed
on the crankshaft end.
Benlfrts ara as follows: Shortened engine width offers larger banking
engle end smaller Inertia when turning the motorcycle. The alternator
output is increased comparing with the conventional alternator owing to
in~ alternator capeclt)l itself. increased alternator speed over the
cranksheft speed. and me alternator cooling fan.
Technica l Information - Engine Lubricat ion System
The ZX·9R oil system has duel oil pumps, with one pump (Sub· Oil
Pump Rotor) (A] feeding pr-urised oil to the oil coole< and the other
(M ain Oil Pump Rotor) [B] to the top end, crank. and transmission.
However, the main oil pump rotor width, at a mere 14 mm. significantly
reduces mechanical loso. This two-pump system helps ensure reliable
lubrication by avoiding drops in oil p111SSUre during extrllme riding
conditions.
To cool the oil, a liquid-cooled oil coole< [ A) is employed, which

offn several advantages over the air-cooled type.
First having almost me same cooling capability, the liquid-cooled oil

cooler Is more compact than the air-cooled oil cooler, fined easily in tho
engine, and helps easy maintenance of engine. Next, since the cooler IS
Installed right on the crankcase without oil hoses, there is linle chance
of a mator oil leak and littJe oil pressure drop In the cooter.
Liquid-cooled Oil Cooler [A)

Hot Oil [ B)
Cold Oil [C)
Cold Coolant [D)
Hot Coolant (E]
1M ...,;.dry sump system is designed to reduce oil stirring loss by

keeping 11M oil from collecting in the CW~kcase below the Ctllnkshalt and
in the clutch. Baffles [A] and passages (B] are fined 10 the crankcase
below 11M tnmsmission to collect the ool 81 once as 11 returns from the
~ aystem, feeding it to the oil pump onlet [C] and eway from the
crenkceM and clutch besket.
Technical Information - Swingarm
The awlngarm pivots are equipped with low-friction needle bearings for smooth working. On the rightside is a ball
bNring which aupports the thrust loads and elominotes even slight lateral play of the swingarm. This strengthens swingarm
ngodity, eepecially its torsional rigidity, offering the motorcycle easier and smoother drive under - riding conditions..
The povot pariS a<e tightened against the frame in thos Older: the collar [ B] and pivot shalt [E], the pivot nut [G], and the
Pf"'OIocknUt [A], so the pivot shalt [E] and ball baarong [F] can be installed without any frame deformation and any gap
10 the frlme.
Th• ~ta ICnlping of the seating surfaces and possoble gaps among the aluminum pivot parts.
® c ®
\
Right Vlew YY
A Swongarm Pi110t Locknut D. Sleeve G. Swingarm Pivot Nut

B. Coller E. Swingarm Pivot Shalt H. Frame
C. Needle Bearings F. Ball Bearing
Torque and Locking Agent
The following tables list the tightening torque for the The table below, relating tightening torque to thread
major fastenerw requiring use of a non-pennanent locking diameter, lista the basic torque for the bolts and nuta. Use
egent or liquid gasket. this table for only the bolts and nuts which do not require
a specific torque value. All of the valuee ere for use with
Letters used in the "Remarka" column mean: dry solvent-cleaned threads.
L : Apply a non -permanent locking agent to the
threadl. B•lc Torqutl for Gen...l Futonera
LG : Apply liquid gasket to the threads. Threads dia. Torque
lh : Left-hand threads.
M : Apply molybdenum dl&ulfide grease. (mm) N-m kg -m ft-lb
0 : Apply an oil to the threads and seating aurfllce. 5 3.4 - 4.9 0.35 - 0.50 30-43 in -lb
S : Tighten the fastenera following the specified 6 5.9 - 7.8 0.60-0.80 52- 691n -lb
sequence. 8 14- 19 1.4-1.9 10.0- 13.5
SS : Apply atlicone sealant 10 25 - 34 2.6- 3.5 19.0-25
St Stake the fasteners to p""""'t loosentng. 12 44 -61 4.5- 6.2 33-45
R : Replacement parts 14 73-98 7.4-10.0 54-72
16 11 5-155 11 .5 - 16.0 83- 115
18 165 - 225 17.0 - 23.0 125- 165
20 225 - 325 23-33 165 -240
Fastener Torque Remarks

N -m kg-m ft-lb
Fu el System:
Carburetor Holder Bolts 12 1.2 104 in-lb
Fuel Tap Plate Screws 08 0.08 7 in-lb
Vacuum Vlave Drain Screw 1.0 0.10 9 in-lb
Cooling System:
Water Hose Clamp Screws 2.5 0.25 22 in-lb
Water Pipe Bolt (W ater Pump) 9.8 1.0 87 in-lb
Coolant Air Bleeder Bolt (Water Pump) 9.8 1.0 87 in-lb
Coolant Drain Plug (Water Pump) 9.8 1.0 87 in -lb
Radiator Fan Switch 18 1.8 13.0
WatfK Temperature Sansor 7.8 0.80 69 in-lb ss
Watar Pump Cover Bolts 9.8 1.0 87 in-lb
Engine Top End:
Spark Plugs 13 1.3 113 in -lb
Air Suction Valve Cover Bolts 9.B 1.0 B7 in-lb
Cylinder Head Cover Bolts 9.8 1.0 B7 in-lb
Pickup Coil Cover Bolts 9.B 1.0 B7 in-lb L
Camshaft Chain Tensioner Mounting Bolts 12 1.2 104 in-lb L
Camshaft Chain Tensioner Cap Bolts B.3 O.B5 74 in -lb
Camshaft Cap Bolts 12 1.2 104 in- lb s
Water Pipe Flange Bolts ( Cylinder Head) 12 1.2 104 in- lb
Water Hose Fitting Bolts (Cylinder) 9.B 1.0 87 in-lb
Oil Hose Banjo Bolt 34 3.5 25
Cylinder Head Bolts: M1 0 (New Parts) 54 5.5 40 S, 0 (Washer)
M1 0 (Used Parts) 49 5.0 36 S. 0 (Washer)
M6 12 1.2 104 in-lb s
Left Cylinder Head Cover Screws 4.9 0.50 43 in-lb
Cylinder Head Jacket Plugs 25 2.5 1B.O L
Camshaft Chain Guide Bolt 25 2.5 1B.O
Inlet Pipe Fittings 4.9 0.50 43 in -lb
Inlet Pipe Plugs 4.9 0.50 43 in-lb
Cylinder Damper Cover Bolts 9.8 1.0 87 in-lb l
Exhaust Pipe Clamp Bolts 12 1.2 104 in-lb
Carburetor Holder Bolts 12 1.2 104 in-lb
GENERALINFORMATION 1 -17
Fastener Tor que Remark s

N -m kg -m h-lb
Clut ch
Clutch Lever Pivot Bolt 1.0 0.10 9 in-lb
Clutch Lever Pivot Bolt l.o<:knut 5.9 0.60 52 in-lb
Starter l.o<:kout Switch Screws 1.0 0.10 9 in-lb
Outch Slave Cylinder Bleed Valve 7 .8 0.80 69 in- lb
Outch Reservoir Cap Screws 1.5 0.15 13 in-lb
Outch Master Cylinder Clamp Bolts 11 1.1 95 in-lb s
Oil Filler Plug 1.5 0.15 13 in-lb
Outch Cover Bolts 9.8 1.0 87 in-lb L(2. Front)
Outch eo- Damper Bolts 9.8 1.0 87 in-lb L
Outch Hub Bolts 25 2.5 18.0 L
Clutch Spring Bolts 8 .8 0.90 78 in-lb
Clutch Hub Nut 135 14.0 100 R
Clutch Hose Banjo Bolts 25 2.5 1B.O
Engine lubrication System:
Oil Filler Plug 1.5 0.15 13 in-lb
Engine Drain Plug 20 2.0 14.5
Oil Fillet( Cartridge type) Hand-Tight Hand-Tight Hand-Tight R. 0
or9.8 or1.0 or 87 in-lb
Oil Filter M ounting Bolt 25 2.5 18.0 L(Tap End)
Oil Pan Bolts 12 1 .2 104 in- lb
Exhaust Pipe Clamp Bolts 12 1.2 104 in-lb
Oil Pressure Relief Valves 15 1.5 11 .0 L
Oil Pressure Sw itch Terminal Bolt 1.5 0.15 13 in: lb
Oil Pressure Switch 15 1.5 11 .0 ss
Oil Pump Bolts 12 1.2 104 in-lb L
Oil Cooler Bolt 49 5 .0 36 0
Oil Hose Clamp Screws 2.5 0.25 22 in-lb
Oil Pipe Flange Bolt (Crankcase Front) 9 .8 1.0 87 in-lb
Oil Hose Elbow Bolts (under pickup coil cover) 9 .8 1.0 87 in -lb L
Oil Hose Banjo Bolts (Cylinder Head) 34 3 .5 25
Cnmkcase Main Oil Passage Plugs 20 2.0 14.5 ss
Alternator Shah Oil Pipe Bolt 12 1.2 104 in - lb L
Transmission Oil Pipe Holder Bolt (Right Side) 12 1.2 104 in-lb L
Eng ine Removal/ lnata lletion :
Side Stand Bracket Bolts 49 5.0 36
Down Tube Bolts and NuiS 44 4.5 33
Engine Collar Bolts 9.8 1.0 87 in-lb
Eng1ne Mounting Locknuts 49 5 .0 36
Engine Mounting Bolts and Nuts
Front 44 4.5 33
Rear 59 6.0 43
Engine Mounting Brecket Bolts
Front 44 4.5 33
Crank•haft/Transmisslon:
Upper Alternator Chain Tensioner Pivot Bolt 12 1.2 104 in-lb L
Upper Alternator Chain Tensioner Set Bolt 12 1.2 104 in-lb L
Upper Chain Tensioner Locknut 25 2.5 18.0
Lower Alternator Chain Tensioner Bolts 12 1.2 104 in·lb L. Automatic
Alternator Shah Bearing Holder Bolts 12 1.2 104 in-lb L
Alternator Shaft Oil Pipe Bolt 12 1.2 104 in- lb L
Alternator Shah Bolt 25 2.5 18.0 Engine
1-18 GENERAL INFORMATI ON

N-m kg-m ft-lb
Camshaft Chain Guide Bolt 25 2.5 18.0
Crankcase Bolts <1>9 44 4.5 33
<1>8 27 2.8 20
<1>6 20 2.0 14.5
Crankcase Main Oil Passage Plugs 20 2.0 14.5 ss
Transmission Oil Pipe Bolt (Right Side) 12 1.2 104 in-lb L
Alternator Shaft Oil Pipe Bolt (Right Side) 12 1.2 104 in-lb L
Shift Rod Retainer Bolt (Right Side) 12 1.2 104 in-lb L
Connecting Rod Big End Nuts in the text +- +- ....
Battery Negative Lead Terminal Bolt 4.9 0.50 43 in-lb
Oil Pressure Relief Valves 15 1 .5 11.0 L
Oil Pipe Flange Bolts (Crankcase Front) 9.8 1.0 87 in-lb
Timing Rotor Bolt 25 2.5 18.0
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in -lb
Oil Pressure Switch 15 1.5 11.0 ss
Starter Clutch Holder Bolts 12 1.2 104 in -lb L
External Shift Mechanism Cover Screws 4.9 0.50 43 in -lb L
External Shift Mechanism Cover Bolts 9.8 1.0 87 in -lb L
Engine Sprocket Nut 125 13.0 94 0
Gear Positioning Lever Bolt 9.8 1.0 87 in -lb L
Neutral Positioning Lever Nut 9.8 1.0 87 in -lb
Shift Shaft Return Spring Pin (Bolt) 25 2.5 18.0 L
Neutral Switch 15 1.5 11.0
Shift Drum Bearing Holder Bolts 12 1.2 104 in -lb L
Shift Drum Cam Holder Bolt 12 1.2 104 in -lb L
. Pickup Coil Cover Bolts 9.8 1.0 87 in -lb L
Wheels/Tires:
Front Axle Clamp Bolts 20 2.0 14.5 s
Front Axle Nut 145 15.0 110 s
Rear Axle Nut 145 15.0 110
Final Drive:
Engine Sprocket Cover Bolts 9.8 1.0 87 in-lb
Engine Sprocket Cover Damper Bolts - - - L
Engine Sprocket Nut 125 13.0 94 0
Rear Sprocket Nuts 74 7.5 54
Rear Sprocket Studs - - - L
Rear Axle Nut 145 15.0 110
Brakes:
Bleed Valves 7.8 0.80 69 in-lb
Brake Hose Banjo Bolts 25 2.5 18.0
Brake Lever Pivot Bolt 1.0 0.10 9 in-lb
Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in- lb
Front Brake Reservoir Cap Screws 1.5 0.15 13 in-lb
Front Brake Light Switch Screws 1.0 0.10 9 in-lb
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in- lb s
Brake Hose Joint Mounting Bolts ( Front) 69 0.70 61 in- lb
Pad Spring Screws (Front Caliper) 2.9 030 26 in -lb
Caliper Mounting Bolts (Front) 34 3.5 25
Caliper Assembly Bolts (Front) 21 2.1 15.0
Front Brake Disc Mounting Bolts 23 2.3 16.5
Rear Brake Reservoir Bolt 6.9 0.70 61 in -lb
Rear Brake Hose Holder Bolts 6.9 0.70 61 in -lb
GEN ERAL INFORMATION 1 -19
Fastener Torque Remarka

N-m kg-m ft-lb
Rear Brake Disc Mounting Bolts 23 2.3 16.5
Calipef Mounting Bolts (Rear) 25 2.5 18.0
Rear Master Cylinder Mounting Bolts 23 2.3 16.5
Rear Master Cylinder Bracket Locknut 18 1.8 13.0
Brake Pedal Shaft Bolt (Footpeg Holder Bolt) 34 3 .5 25 L
Suspension:
Front FO<It Clamp Bolts (Upper) 21 2.1 15.0
Front FO<It Clamp Bolts (Lower) 28 2.9 21
Front Fortt Top Plugs 23 2.3 16.5
Piston Rod Nut 15 1.5 11 .0
Front Fortt Bottom Allen Bolts 39 4.0 29 L
Front Fortt Damper Adjuster Holder 18 1.8 13.0
Front Axle Clamp Bolts 20 2.0 14.5 s
Rear Shock Absorber Nuts 59 6.0 43
Rear Shock Absorber Upper Brackets Nut 59 6.0 43
Swingerm Pivot Shaft 20 2.0 14.5 s
Swingerm Pivot Nut 98 10.0 72 s
Swingarm Pivot Locknut 98 10.0 72 s
Uni-Trak
Rocker Arm Nut 59 6.0 43
Tie-Rod Nuts 59 6.0 43
Steering:
Steering Stem Head Nut 39 4.0 29
Steering Stem Nut Hand -Tight Hand -Tight Hand -Tight
or4.9 or 0.50 or 43 in - lb
Brake Hose Joint Mounting Bolts (Front) 6.9 0.70 61 in-lb
Handlebar Bolts 34 3.5 25 L
Handlebar Holder Bolts 23 2.3 16.5
Handlebar Holder Position Bolts 9.8 1.0 87 in-lb L
Handlebar Weight Screws - - - L
Handlebar Switch Housing Screws 3.4 0.35 30 in-lb
Front Fortt Clamp Bolts (Upper) 21 2.1 15.0
Front Fork Clamp Bolts (Lower) 28 2.9 21
Frame:
Rear Frame Bolts and Nuts 44 4.5 33
Down Tuba Bolts and Nuts 44 4.5 33
Footpeg Holder Bolts ( Roght. Left) 34 3.5 25 L
Side Stend Bracket Bolts 49 5.0 36
Electrical System:
Sparlt Plugs 13 1.3 113 in-lb
Alternator Mounting Bolts 25 2..5 18.0
Alternator Coupling Nut 54 5.5 40 Alternator
Alternator Asseembly Nuts 4 .4 0.45 39 in-lb
Alternator Bearing Reteiner Screws 2.5 0.2.5 2.2 in-lb Alternator
Housing
Alternator Regulator Screws 3.4 0 .35 30 in-lb
Alternerot Leed Terminal Screws 3.4 0 .35 30 in- lb
Alternator Brush Screws 3.4 0.35 30 in-lb
Alternator Cover Screws 3.4 0.35 30 in-lb
Pickup Coil Cover Bolts 98 1.0 87 in-lb L
Pickup Coil Bolts 78 0.80 69 in -lb

N-m kg-m ft-lb
Timing Rotor Bolt 25 2.5 18.0
Starter Motor Tenninal Locknut 11 1.1 95 in -lb
Starter Motor Terminal Nut 4.9 0.50 43 in -lb
Startar Relay Terminal Bolt 4.9 0.50 43 in -lb
Starter Motor Through Bolts 5.9 0.60 52 in -lb
Starter Motor Mounting Bolts 9.8 1.0 87 in -lb
Starter Motor Clutch Bolts 12 1.2 104in-lb L
Turn Signal Light Lens Screws 1.0 0.10 9 in -lb
Handlebar Switch Housing Screws 3.4 0.35 30 in -lb
Radiator Fan Switch 18 1.8 13.0
Water Temperature Sensor 7.8 0.80 69 in -lb ss
Oil Pressure Switch Tenninal Bolt 1.5 0.15 13 in -lb
Oil Pressure Switch 15 1.5 11.0 ss
Neutral Switch 15 1.5 11.0
Starter Lockout Switch Screws 1.0 0.10 9 in-lb
Side Stand Switch Screws - - - L
Special Tools and Sealant
Piston Ring Pliers: 67001 · 116 Valve Spring Compressor Assembly: 57001-241
Inside Circl1p Pliers: 57001 · 143 Piston Pin Pull« Assembly: 57001 -91 0
e
0
0
Outside Circlip Pliers: 67001 · 144 Hand Tester. 57001-1394
Oil Pressure Gauge, 10 kg/cm1 : 57001 -164 Fuel level Gauge: 57001 -1 017
eomp...ion Gauge: 57001 -221 Oil Pressure Gauge Adapter. PT %: 57001 -1033
Oil Seal & Bearing Remover: 67001 -1 058 Steering Stem Nut Wrench: 57001 -1 1 00
Head Pipe Outer Race Press Shaft: 57001 -1 075 Valve Seat Cutter, 45• - <1>27.5: 57001 -1114
Head Pipe Outer Race Drivers: 57001-1077 Valve Seat Cutter, 45• - <!>32: 57001 -1115
Piston Ring Compressor Grip: 57001 -1 095 Valve Seat Cutter, 32• - <!>28: 57001 -11 19
Piston Ring Compressor Belt, <!>67 - <!>79: 57001 -1097 Valve Seat Cutter, 32• - <1>30: 57001-1120
Valve Seat CuttO<, so· - <1>30: 57001 -1123 Hexagon Wrench, Hex 8: 57001 -1234
Valve Seat Cutter Holder Bar. 67001 -1128 Jack: 57001 -1 238
Bearing Ori\/Of Set: 57001-1129 Clutch Holder: 57001 -1243
Valve Spring Compressor Adapter, <1>22: 57001 -1202 Oil Filter Wrench: 57001 -1249
Fork Outer Tube Weight: 57001 -1218 Bearing Remover Shaft: 57001 -1265
CArburetor Drain Plug Wrench, He• 3: 57001 • 1 269 Fo ri< Piston Rod Puller, M 10 • 1.0: 57001 • 1298
Fori< Oil Seal Driver, <1>41 : 57001 • 1288 Compression Gauge Adapter, M1 0 X 1 .0 : 57001-1 317
Fori< Oil Level Gauge: 57001 • 1 290 Valve Seat Cutter Holder. <1>4.5: 57001 • 1 330
Pilot Screw Adjuster, C: 57001 • 1 292 Valve Guide Arbor. <1>4.5: 57001 - 1331
Fori< Cylinder Holder: 57001 • 1 297 Valve Guide Reamer, <1>4.5: 57001 . 1333
GENERAL INFORMATION 1- 25
FOil< Spn119 Compressor. 57001 • 1 338 Crankcase Splitting Tool Assembly: 57001 • 1362
Steering Stom Bearing Driver. 57001 •1 344
S-i119 Stem Beering Driver Adapter. 57001 • 1 345 Socket Wrench: 57001 • 1 370
8eenng R.....,_ Head. <1>25 x 4>28: 57001 • 1 346 Pilot Screw AdjuS1er Adapter. <1>5: 57001·1372
Sodcet Wrench: 57001.1347 Pilot Screw AdjuS1er Driver: 57001 · 1373

Forie Spring Stopper: 57001 · 1 374 Kawasaki Bond (Silicone Sealant): 5601 9· 1 20
Vacuum Gauge Bolt Washer: 92022· 304
Sperle Plug Wrench, 16mm: 9211 0·1154
VSQJum Gauge Bolt: 92150· 1161
Pressure Cable Luber: k6601 9· 021

Cable, Wire, and Hose Routing
Clamp Clamp
Section AA Section BB
Position the white !ape here.
Strap (Right Handlebar Switch"Loads and
connectors.
Position the connectors
the headlight ~:kel~~~~jj~~~~~~~!~~~ij~~i~~~=

boi'Mien the melllr unk Front View
and
I. Main Hameu 4. Upper Fairing 7 . Meter Unit

2. Headlight Bracket 5. M eter Bracket 8. Right Handlebar Switch Leads
3. Left Tum Signal Leads 6. White Tape 9. Left Handlebar Switch Leads
...'
II.)
1. Meter Unit 7. ResonatoJS 13. Sanery 00
2. Air Cleaner Housing 8. Drain Hoses 14. Sanery Positive Lead
9. Radiator 15. Tum Signal Relay G)
3. Main Harness
m
4. Rear Frame Nut 10.
11.
l ower Fairing Sracket
Cross Pipe
16. Starter Relay
17. Spoodometer Csble
z
m
5. Seat l ock Cable
:a
6. Air In take Ducts 12. Starter Motor Cable
,..J>
Front
-z
"TI
¢:J 0
:D
s:
~
0
z
Run th e hose between the radiator tank and

the fairing bracket.
GENERAL IN FORMATION 1· 29
Front 1. Left Handlebar Switch

2. City l.Jg hI
3. Right Handlebar Switch
4. Meier Unit
5. Headlight Diode
6. Handlebar Switch Leads
7. Hoodlight
8. Front Right Turn Signal Light
9. Water Temperature Sensor Laad1
1 0 . Radl31or Fan Motor
1 1. Ignition Switch
12. lgnttion Coil #2. #3
1 3. Neutral Sw itch
14. Side Stand Sw itch
1 5. Alternator
16. Pickup Coil
17. Fuel Pump
18. Fuel Level Sensor
19. M ain Hamess Holder
20. Main Hamess Ground
21 . Engtne Ground Lead
2.2. 8ane<y Ground Lead
Run the fuel hose through the

brackeL
Clamp
Install the breather hose
parallel to the cross pipe.
Cross Pipe
23. Fuel Pump Relay
24. Rear Brake Light Switch
25. Electrical Accessory
26. 1C Igniter
27. Rear Rtght Tum Signal light
28 Rear l.ah Tum Signal Ught
29. L.tcense Ltght
30. Tati/ Brake Ltghts
31 . Junction Box
32. Starter Relay
33. Turn Signal Relay
34. Battery
35. Banery Positive Lead
36. Fuel Hose (Fuel Filter - Fuel Tap)
37. Starter Motor Cable
38. 1gntllon Coil #1, #4
39 Front FO<k
40. Radtator Fan Switch
41 . Hom
42. Front Leh Turn Signal Light
43. Carb<iretors
44. Fuo1Tap
...'
1. Ucense Light
2. Rear Left Turn Signal Light
7. Battery Negative Lead 12. Electrical Accessory ~
8. Engine Ground Lead 13. Fuel Pump Relay
3. Tail/Brake Lights 9. Main Harness 14. Rear Brake Light Switch (i)
4. Rear Right Turn 10. m
Signal Ught Connectors
Ignition Coil, Ignition Switch,
Hom, Radiator Fan. and
15. Water Temperature Sensor
Leads
z
m
I!
5. IC Igniter Radiator Fan Switch 16. Headlight Diode
II
6. Rear Frame Nut , 1. Front
Headlight 17. Front Right Turn Signal Light
c:::> "TI
0
::u
s::
)>
.....
Run the main harness over the 0
frame nut
z
(Main Hamess and Bracket)

GENERAL INFORMATION 1- 31
Run the brake hose inside lhe leh

front foli<.
Front
~
,- -- ' Front
8
c:::>
7-- ~ ~~---;- ft
1. Right Front Foli< 4. Front Brake Reservoir 7. Rear Brake Caliper

2.. Brake Hoae Joint 5. Front Brake Caliper 8. Rear Brake Master Cylinder
3. Front Brake M aster Cylinder 6. Rear Brake Reservoir
Run the choke cable on the leftside of the

vacuum switch valve hose.
Run the throttle cables over the ---r..__

air vent hose.
'·
Front
c::>
Run the hose inside the frame and
outside the rear brake light switch lead.
10
"' !/
Run the hose over the
rear frame nut.
11
The clamp screw points downward.
SectionAA
Clamp
1. Ignition Coil #1, #4 5. Choke Cable 9. Brake Hose

2. Ignition Coil #2, #3 6. Air Vent Hose 10. Rear Shock Reservoir Hose
3. Clutch Hose 7. Vacuum Switch Valve 11. Clamp Screw
4. Front Fork 8. Throttle Cables 12. Rear Frame Nut
Top View
Front
Front View
c>
The yellow marl< POints upward.
Face the Hange of the collar toward

the coolant reserve tank. ------, B)I~J:;~!I.:·~~w UM
Align the yellow marl<

wtth the cente<iine of
the ptp8.
Align the yellow marl<

Align tho whtto marl< with t ho partong line with tho parting ltno of
of the thermostat hoosing.
.. the thermostat houstng.
Face the screw head downward.

Run the reserve tank vent hose in front
of the reserve tank hose.
Run the hoee t);iiween

tho fainng and
=:__ _,tho ~ntu~-- _ _ _
1 Yellow Mart<J
2 Whtto Mark
3 Water Temperature Sensor
4 Th~totHo~ng
5 Coolant RM«Ve Tank
6. Reoerve Tank Hoso
7. Reoerve Tonk Vent Hose
8. Downtube
9. Fairing
10. Fuel Tenk Drain Hose
11. Fuel Tank
Holder
1- 34 GENERAL INFORMATION
Front View
Push the hose onto tho elbow unttl the

hose contacts the head of the crankcase
bolt.
/
Piece the clamp about 2 mm awtry from
the hosa end.
Front
1. PickuJ> Coil Cover

2. Elbow
3. Pickup Coil leads
4 . Oil Pressure Switch load
5. Oil Pressure Switch
6. Oil Hose
7. lower Crankcase
8 Clamp
9. Crankcase Bolt
1 0. Alternator
11 . Alternator lead
12. Electric Starter
13. Cross Pipe
14. Water PumJl
15. Side Stand Switch lead
16. Neutral Switch
Front
Run the hoses so they touch the
¢=:J holes rnslde as shown.
Clamp
California M odel
- - - - - - - - - - - - face upward.
Run the h06e under the spat!< plug
leads and the vacuum switch valve
~><:::::::::}17r~--l\.--:::k-r---::::-=Jb-~h:ose. Connect
-1
the smalle< bend
of the hoae to the
vacuum valve.
the hose so rt touches the hole inside as shown.
1. Band marked with • A" 6. Carburetors 11 . To 112 Inlet Pipe

2. Air Intake Ducts 7. Vacuum Switch Valve Hose 12. T Joint (CA)
3. Frame Holes B. Band matl<ed with "L" 13. Carburetor Vent Hose (Yellow )
4. Air Vent Hoses 9. Vacuum Valve (CA) CA: California
6. Air Vent FiltO<S 10. Vacuum Valve Hose (CA)
Evaporative Emission Control System (California)
Run the hose over the alternator. -

Front
Run these hoses behind

the water pipe.
About 15- 20 mm
Evaporative Emiealon Control System (California )
Smaller Bend Run these hoses under the cross pipe.
®+-<=ti>~~~=T ~";:::::=~
®
Run the hose undM the cross pipe. Install the canister so its inlet
faces down.
Remove any oil fTom the hoses

when insalllng. This prevents
the hoses ITOm slipping off.
~~
Smaller Bend
1. Vacuum Valve 10. Air Cleaner Housing 19. Vacuum Hose (White)
2. Fuel Top 11 . Carburetors 20. Alternator
3. Fuel Tank 12. Canister 21. Catch Tanks
4. Vacuum Velva Hose 13. Vacuum Switch Valve 22. Water Pump
5. Carburetor Vent Hose 14. Fuel Pump 23. Cross Pipe
6. Carburetor Vent Hose (Yellow) 15. Fuel Pump Filt8f 24.Banery
7. Breether Hose (Blue) 16. Breather Hose (Blue) 25. Fuel Tank Drain Hose
8. Return Hose (Red) 17. Purge Hose (Green) 26. Inlet Pipe #3
9. Engine 18. Separator 27. Canister Inlet
1·38 GENERAL INFORMATION
D
Front
Smaller
5
Remove oil from tl>e when Installing.
Th1s prevenrs the hoses from slipping off.
California M odel
Smalle<
Remove any oil from the hoses when installing.

This prevenrs the hoses from slipp1ng off.
1. Hose marked with "L• 4. Air Cleaner Housing 7. Air Vent Hose
2. Vacuum Switch Valve 5. Vacuum Switch Valve Hose 8. Purge Hose (Green, CA)
3. Hose marked with "R" 6. Vacuum Valve (CA) CA:California
FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded V'tew ..........................................................2 -2 Air Cleaner ...............................................................2 -1 6

Spec~ications ............................................................2-5 Housing Removal ...............................................2-16
Throttle Grip and Gables ...........................................2-6 Housing Installation ...........................................2-16
Free Play Inspection .............................................2-6 Element Removal ................................................2 -16
Free Play Adjustment ...........................................2 ·6 Element Installation ............................................2 -16
Cable Installation ..................................................2-6 Element Cleaning and Inspection ......................2-17
Cable Lubrication .................................................2 · 6 Oil Oraining ............. ...........................................2 -17
Choke Cable ............................................... ...............2 · 7 Air Vent Filter Cleaning ..................................... 2 -17
Free Play Inspection .............................................2- 7 Fuel Tank ................ .................................................2-18
Free Play Adjustment ...........................................2-7 Fuel Tank Removal .............................................2-18
Cable lrl$18llation ..................................................2 · 7 Fuel Tank Installation .........................................2 -18
Cable Lubrication ...................... ........................... 2 -7 Fuel Tank Inspection ..........................................2 -18
Carburetors ................................................................2-8 Fuel Tank Cleaning ..... ........................................2-19
Idle Speed lnspection ................... ........................2 -8 Fuel Tap Removal ...............................................2-19
Idle Speed Adjustment .........................................2 -8 Fuel Tap Installation ........................................... 2 -19
Synchronization lnspection ..................................2-8 Fuel Tap lnspection ............................................2-20
Synchronization Adjustment ....... ......................... 2-9 Fuel Level Sensor Removal/Installation ............ 2-20
Service Fuel Levellnspection ............................... 2 -9 Fuel Pump, Fuel Filter ............................................. 2 -21
Service Fuel Level Adjustment ...........................2-1 0 Fuel Pump, Fuel Filter Removal .................. ....... 2 -21
Fuel System Cleanliness Inspection .................. 2-11 Fuel Pump, Fuel Filter Installation .....................2-21
Carburetor Removal ................................... ..... .... 2 -11 Fuel Pump Inspection ........................................ 2 -21
Cerburetor Installation ........................................ 2 -11 Fuel Filter Inspection .......................................... 2 -21
Carburetor Disassembly/Assembly .................... 2-12 Evaporative Emission Control System
Carburetor Separation/ Assembly .......................2 -13 (Csli1omia Model Only) .......................................2-22
Carburetor Cleaning ...........................................2 -13 Parts Removal/Installation .................................2 -22
Carburetor Inspection .........................................2-14 Hose lnspection ........ ..........................................2-22
High Altitude Performance Separator Inspection ..........................................2-22
Adjustment (US model) ..................................2 -15 Separator Operation Test ...................................2-22
Coolant Filter Cleaning Vacuum Valve lnspection ................................... 2 -23
(AR, FG, FR, IT, NL, ST, UK) ..........................2 -15 Canister lnspection .. ...........................................2-24
2-2 FUEL SYSTEM
Exploded View
(CA)
orJ!
()
CA: california
1 . Resonators 4. Check Valve 7. Air Vent Filters

2. Air Clean..- Housings 5. Catch Tank 8. Vacuum Switch Valve
3. Air Cleaner Element 5. Vacuum Valve (CA) AO: Apply high ·quality· foam-air·filter oil.
FUEL SYSTEM 2-3
T1
1. Throttle Cable (accele<ator)

2. Throttle Cable (decelerator)
3. Choke Cable
4 . Pilot Screw
5. Pilot (Stow) Jet
6. Air Bleed Pipe
7. Main Jet
8. Plug (US, ST)
9. Jet Needle
1 0. Fuel Pump
11. Fuel Filter
G: Apply grease.
CL: Apply cable lubricant.
ST: Switzerland
US: United States
Tl: 12 N-m {1.2 kg-m, 104 in -lb)
2· 4 FUEL SYSTEM
1. Vacuum Valve
2. Catch Tank
3. Separator
4. Canister
T1: 0.8 N·m (0.08 kg-m, 7 in·lb)
Evaporative Emission Control System

(Calif ornia Modal)
FUEL SYSTEM 2-5
Specifications
lbtm Standard
ZX900-B1 ZXSOO.B2 ZX9QO.B3
Throllle Grip F""' Play 2- 3mm .... ....
Choke C.ble Free Play 2- 3mm .... ....
C.rbwelora:
Make, type KEIHIN, CVKD40 x 4 .... ....
Idle speed 1100 :1: 50 r/min (rpm), .... ....
(CA)(ST) 1300 :1: 50 r/min (rpm)
Pilot screw (turns out) 1 % :1: \4,(FR) 1 % :1: J4(ST) .... +-
(US) - Synchronization vacuum
2.7 kPa (2 em Hg) or less (AR)1 ll :1: J4 (AR)1~±J4
difference between any two cart>uretors
Setvice fuel level 6 :1: 1 mm below the mark +- ....
Float height 13 :1:2 mm .... ....
Main jot #190 #190 (E)(FG)(GR)(N) (AR) #200
( NL)(IT) (SP)(SD)( UK)
#200
Main air jot #50 ....
AJr bleed pipe <1>0.6 mm x12 for 1, 4 cyl .... ....
<1>0.5 mm x 16 for 2, 3 cyl
Needle jet #6 .... +-
Jot needle mark N67T (1, 4 cyl), N67U (2, 3 cyl) .... +-
Pilot jot (slow jot) #35 +- +-
Pilot air jet (slow air jot) #120 +- +-
Starter jot • #58 .... +-
Throttle valw angle 11. .... +-
High altitude cart>uretor .... +-
specifications (US)
Pilot jet #32 (92064-1117) .... +-
Main jet #186(92063- 1390) +- ....
Air CIHner Element 011
Grade SE, SF, or SG class .... ....
Viscosity SAE30 .... +-
(AR): Austria (FR): France (SP): Spain

(CA): California (GR): Greece (ST): Switzerland
(E): Europe (IT) : Italy (SO): Sweden
(FG): German (N): Norway (UK): U.K
(NL): Netherlands (US): United States
Throttle Valve (A] Needle Jet [G]

Pilot Scnsw [B] Pilot Air Jet [H)
Pilot Jet [C] Main Air Jet [I]
Main Jet [ D] Fuel Strainer [J]
Air Bleed Pipe [E] Valve Seat [ K]
Jet Needle [F] Float Valve (L]
Special Tools- Pressure Coble Luber: 1<56019-021

Vacuum Gauge Bolts: 92150-1161 (as required)
Vacuum Gauge Bon Washers: 92022-304 (as required)
Vacuum Gauge: 57001-1369
Pilot Screw AdJuster, C: 57001-1292
Pilot Screw AdJuster Adapbtr, <1>5: 57001-1372
Pilot Screw Adjuster Drtver: 57001-1373
Carburetor Drain Plug Wrench, Hex 3: 57001-1269
Fuel Level Gauge: 57001-1017
Fork Oil Level Gauge: 57001-1290
2-6 FUEL SYSTEM
Throttle Grip and Cables
Free Play Inspection

e Check the throttle grip free play [A).
*If the free play is incorrect, adjust the throttle cable.
Throllle Gr1p Free Play

SIUidard: 2 - 3 mm
Free Play Adjustment

• Loosen the locknut [A) .
e Tum the adjuster [B] until the proper amount of free play can be
obtainad.
e Tighten the locknut securely.
*II the proper amount of free play cannot be obtainad by using the
adjuster only, use the adjuster in the middle part of the accelerator
cable.
• Loosen the locknut and screw the adjuster at the upper end of the
accelerator cable all the way in.
e Remove the fuel tank and air cleaner housing (see Fuel Tank Removal
and Air Cleaner Housing Removal).
e Loosen the locknut [ A) at the middle part of the accelerator cable.
e Turn the adjuster [B] until the proper amount of throttle grip free play
is obtained.
*If the proper amount of free play can not be obtained in the adjustable
range of the adjuster, use the adjuster at the upper end of the acceler-
ator cable again.
Cable Installation
e lnstall the throttle cables in accordance with Cable Routing section in
General Information chapter.
e lnstall the lower ends of the throttle cables in the cable bracket on the
carburetor after installing the upper ends of the throttle cables in the
grip.
e After installation, adjust each cable properly.
Operation wllh lncot.-.ctty rOUiad or lmpropet'ly adjuated cabin

could ....,It In an u - riding condMion.
Cable Lubrication
Whenever the cable is removed, lubricate the throttle cable as follows:
e Apply a thin coating of grease to the cable lowe< ends.
• Lubricate the cable with a penetrating rust inhibitor.
Special Tool- P........... cable Luber: kS6019~21 [A]
FUEL SYSTEM 2-7
Choke Cable
Fm Pkly Inspection
e Check that the choke inner cable slides smoothly by moving the choke
~er (A] to the front and rear.
*If there is any irregularity, check the choke cable play (B] .
e Push the choke lever all the way to the front.

e Check choke cable free play [A] .
ODetermine the amount of choke cable play at the choke lever. Pull the
choke t9119f until the starter plunger lever (B] at the carburetor touches
tile starter plunger [C]; the amount of choke lever lower end travel is
tho amount of choke cable play.
*"the free play is incorrect, adjust the choke cable.
Chol<t Coble F,... Play

Sllndord: 2 - 3 mm
Free Play Adjustment

e Rernovethe fuel 'tank and air cleaner housing (see Fuel Tank Remvoal
and Air Cleaner Housing Removal) .
e l.oosen the locknut [A], and tum the adjuster [ B] until tho cable has
the proper amount of free play.
er~ghten the locknut securely.
!·
Cable Installation
e lnstall the choke cable in accordance with the Cable Routing secrion
in the General Information chapter.
eAftor installation, adjust the cable properly.
Cable Lubrication
Whenever the choke cable is removed, lubricate the choke cable as
follows:
eApply a thin coating of grease to the cable upper end.
e Lubricate111e cable with a penetrating rust inhibitor.
lpeci81Tool- Ptetture Cable Luber. k56019~2t (A]
2-8 FUEL SYSTEM
Carburetors
Idle Spssd Inspection
e S~art lhe engine and warm it up thoroughly.
e WIIh !he engine idling, tum !he handk!baf to bolh sidea.
*II handlebar movement changes !he idle~. !he throttle cables may
be lmp!Operty adJusted or inconectly routed, or damaged. Be sure to
correct any of tt.. conditions before riding <- Cable Routing
section in Genen~llnformatioo chapter) .
Operation will Improperly ecllualecl. lncotreeUy rouled, or damaged

cablae could ....,Min an unaale riding condition.
e Check idle speed.

* II !he idlelpaed Ia out of !he specified range, adjust it.
1,100 :t 50 r/mln (rpm)

(Calllomla, Swlu M -) 1,300 :t 50 rlmln (rpm)
ld/8 Speed Adjustment

e Stllrt the engine and warm it up thoroughly.
e Turn the edjuatlng screw [A] until the idle speed is correct.
0 Open and close the throttle a lew times to make aure that the idle
speed 18 within lhe specified range. Readjust if necessery.
Synchronization Inspection
e Remove the fuel tank<- Fuel Tank Removal) .
e Supply fuel to the carburetors with an auxiliary fuel tank.
e S14rt the engine and warm it up thoroughly.
e Check Idle speed.
e For the modela other than the California model, remove the inlet pipe
plugs and lnstBII the vacuum gauge bolts (92150· 1161) [A] and
washers.
e Anach the vacuum gauge [A] to the bolts-on the cylinder head.
Special Tool - y _ , Gauge: 57001-1361
e StBrt the engine and lei it idle to measure the carburetor intake vecuum.
*If the vacuum is incorrect. adjust the synchronization.
C.111uNtor Syndlfonlzlollon VIICUI.WTI

~: Laae than 2.7 kPa (2 cmHg) diller....,.
befwHn any two carturl4oN.
FUEL SYSTEM 2-9
Synchroniration Adjustment
e Tum the adjusting screw to synchronize tile carburetors.
OFirst synchronize the left two and then the right two carburetors by
meena of tile left and rigllt adjusting saews (A. C). Then synchronize
the left two carburetors and the right two carburetors usong the center
adJusting screw [ B].
* IIthe carburetor synchronization cannot be obtaonad by using the
adjusting scrnws, check for dirt or blockage, and then check the pilot
screw settings.
&p.clal Toole - Pilot Screw Adjualltr, C: 57001· 1292
Pilot Screw Adjuster Adapler, <1>6: 57001·1372
Pilot Screw Adjuster Driver: 57001 ·1373
e Check the carburetor synchronization again.
NOTE
ODo not turn the pilot scri!Ws ciJie!essly during carburetor synchronl·
urion. You mBJ1 cause poor running at low engine 1peed.
e For the models other then the California model. rernow tile vacuum
geuge bolts and ins~all the inlet pipe plugs end washers.
e Check Idle speed.
S61Vice Fuel Level Inspection

i•WARNING
Gaeol.,ele ...,..mely f....,mable and can be exploelve under cerl81n
COndlllone. Tum the Ignition • - OFI'. Do notemoke. Make aura
.,. .,.. le wel.,..._lalad end free fr«n any source of flame or
eperb; lhla lncb:lee any -'lance with a pllo4 light.
e Situate the motorcycle so that it is perpendicular to the ground.

e Rerno\18 the fuel tank (see Fuel Tank Removal) .
e l'repere an auxiliary fuel tank and oonnect the fuel hose to the
carburetors.
e Prepare a fuel hose (6 mm india.,_ and about 300 mm long) .
e Connect the fuel level gauge [A] to the carburetor float bowl with the
lual hose.
!jleclal Tool - Fuel Level Gauge: 57001·1017
• Hold the gauge vertically against the side of the carburetor body so
thai the •zero• line [B] is several millimeters higher than the mark [C]
on the carburetor body.
e Feed fuel to the carburetor, then tum the carburetor drain plug (D) out
e few tums.
e Weit until the fuel level in the gauge settles.
• Keeping the gauge wrticat align the *zero· line with the mar1<.
NOTE
ODo nor lower tiHJ *zero• line below the m.n< of the carburetor body.
If the gauge is lowered and then raised ag11in, the fuM levM musured
lhowt somewhat higher than the actu11/ fuM level. If the gauge is
lowered too fsr. dump the fuM into B sut111ble contamet and •~tt the
procedure over ~~gain.
e Read the fuel level [ E] in the gauge and compare to the specification.
• Screw in the carburetor drain plug.
2-10 FUEL SYSTEM
e Stop feeding and remow the fuel level gauge.

* II the fuel level Is incorTeet, adj ust it (see Selv•ce Fuel Level Adjust·
ment).
S..VIce F\Jel ........

(be- the mar1< on the ..l'llurellor body)
Slanclard: 5 :t1 nvn
StNVice Fuel Level Adjustment
llamm--
i • WARNING
Gaeollne 1e . - e l y ca.n be erpo.tte under Cltltaln
conditions. Tum the lgnMion -llctl OFF. Do nac - ·· Melle SUN
lhe erN Ia well-ventllal8d - INe from any ,.....,. of llama .,..
oparb; lhll lnclucleo any appliance wllh a pilot light.
e Remow the carburetor, and drain the fuel into a su~able container.
e Remove the float bowl.
e Remove the screw [A] and take out the float [B] .
e Bend the tang [A] on the ftoat arm vary sf~ghtly to change the float
height. Increasing the float height lowers the fuel level and deaeasing
the float height raises the fuel level.
Float Height
Standard: 13 :t 2 mm
N OTE
ODo not push the needle rod [A]In during the float height messurtt·
ment [8].
e Assemble the carburetO<, and recheck 1he fuel level.
* II the fuel level cannot be adjusted by this method, the lloet orthe float
valve [C] is damaged.
FUEL SYSTEM 2-11
Fuel System Cleanliness Inspection

i•WARNING
Gaoollne lo e><1remety flammable and can be exploolve under certain
c:cndHiono. Turn the Ignition switch OFF. Do not smoke. Mako auro
the area Ia well-ventilated and free ITom any source of flame or
aparb; this Includes any aPt>llance with a pilot light.
e Remove the fuel tank (see Fuel Tank Removal)

e Connect a suitable hose (A] to the fitting at the bottom of each
carburetor float bowl.
e Run the lower ends of the hoses into a suitable container.
e Turn out each drain plug [B) a lew turns .and drain the float bowls.
e Check to see if water or dirt comes out.
e Tighten the drain plugs.
*If any water or dirt appears during the above inspec1ion, clean tholuol
system (see Carburetor Cleaning and Fuel Tank Cleaning) .
Catburetor Removal
A WARNING
Gasoline lo extremely flammable and con be explosive undor certain
conditions. Tum the fllnlllon switch OFF. Do nol smoke. Make aura
the area Is well-ventilated and free from any source of flame or
!1!>8rb; lhlo Includes any appliance wllh a pllotlfllhl
eRemove:
Seats (see Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Air Cleaner Housing (see Air Cleaner Housing Removal)
Throttle Cables
Choke Cable
Fuel Hose
eLoosen the carburetor clamps [A), and remove the carburetors.
eStuff pieces of lint· free, clean cloth into the carburetor holders to keep
dirt out of the engine.
Carburetor Installation
e Route the cables, harness, and hoses correctly (see General Informa-
tion chapter).
e Tighten the clamps(A]Ior the carburetor holders.
2-12 FUEL SYSTEM
eCheck fuel leakage from the carburetors.
eAdjust the following items if necessary.

Idle Speed
Carburetor Synchronization
Throttle Cables
Choke Cable
Carburetor Disassembly/Assembly
A WARNING
o ....une Ia exnmely flamm11ble and can be explotllve under certain
c:ondlllona. Tum the Ignition awllell OFF. Do not smoke. M ake sura
the 81811 Is welkentllalecl and tree from any source of flame or
aper1cs; this Includes any appliance wllh a pilot light.
• For the US and Swiss models, remove the pilot screw plug as follows:
o Punch a hole in the plug and pry there with an awl or othe< suitable
tool.
eTum in the pilot screw and count the number of turns until it seats fully
but not tightly, and then remove the screw. This is to set the screw to
its original position when assembling.
eAfter installing the upper chamber cover, check that the vacuum piston
slides up and down smoothly without binding in the carburetor bore.
During csrl>llrelor dlsaosembly, be careful not to damago the

dl..,ragm. N•- uaa a aharp edge to remove the diaphragm.
eTum in the pilot screw [A] fully but not tightly, and then back it out
the same number of turns counted during disassembly.
eFor the US and Swiss models, install the pilot screw plug as follows:
o Install a new plug [B] in the pilot screw hole, and apply a small
amount of a bonding agent [C] to the circumference of the plug to fix
the plug.
Do not apply too much bonding agent 1o the plug or the pilot scr-
llael may be fixed.
eSiip the needle through the hole in the center of the vacuum piston,
and put the spring seat [A] on the top of the needle. Tum the seat so
that it does not block the hole [B] at the bonom of the vacuum piston .
FUEL SYSTEM 2-13
Carburetor Separadon/Assemb/y
e Read the WARNING in Carburetor Disassembly/Assembly.
eThe oenter lines ol the carburetor bores must be parallel both horizon- •
tally and vertically. If they are not. loosen the mounting screws and
align the carburetors on a flat surfaoe. Retighten the mounting screws.
eAfter assembling the choke mechanism. check to see that the starter
plunger lever slides right to left smoothly without abnormal friction.
CAUTION
Fuel mixture trouble could reeult H lhe starter plunger lever does not
Hat properly In Ita rest pooltlon an... the chol<e lever Is returned.
evisually synchronize the throttle (butterfly) valves.

0 Gheck to see that all throttle valves open and close smoothly without
binding when turning the pulley.
OVisually check the clearance [A) between the throttle valve and the
calburetor bore in each carburetor.
*"there Is a difference between any two carburetors. tum the balanoe
adjusting screw(s) [8] to obtain the same clearance.
•
Carburetor Cleaning
i•WARNING
Clean lhe carburetors In a well-ventilated area, and take care that
there II no sparks or flame enywllere near the worl<lng area; thll
Includes any appliance with a pilot light. Because of the danger ol
highly flammable liquids, do not use guollne or low flash-point
sol¥- to clean the carburelora.
Do not use compreued air on an assembled carburetor, or the floats

may be crushed by the preaaure, and lhe vacuum piston diaphragms
may be damaged.
Remove as many rubber or plastic parts from the carburetor aa
possible belo,. cleaning the carburetor with a cleaning solution.
This will p,.vanl damage to or deterioration of the parte.
The carburetor body has plaotlc parts that cannot be removed. Do
not use a atrong carburetor cleaning solution which could enact<
Illata parts; Instead, use a mild high flaoh-polnt cleaning solution
tale ,.. plastic parts.
Do not uae wtre or any other hard lns1rument to clean carburetor
parts, espaclally Jets, as they may be damaged.
e Disassemble the carburetor.

e lmmerse all the metal parts in a carburetor cleaning solution.
eRinse the parts in water.
eWhen the parts are clean. dry them with compressad air.
e Biow through the air and fuel passages with compressed air.
e Assemble the carburetor.
2-14 FUEL SYSTEM
CBtburetor Inspection
i•WARNING
GIIIOIIne Ia ...,.mely flemmable and can ba exploolve under - I n
oondlllona. Tum the lgnnton awllch OFF. Do notamolce. Mal<e aura
the area Ia welkenlllalad and ITM from any.....,... of flame or
apar1ca; IIIIa lncl - any appliance wNh a p4lolllght.
• Remove the carburetors.

• Before disassembling the catbunttons, check the fuel level (see Fuel
~ Inspection).
* II the fuel level is incorT8CI, inspect the rest of the carburetor before
con-ecling it
e Movetheatarter plunger I~ 10 the left and release ilto check that the
starter plungers move smoothly and return by spring tension.
* If the llarter plungers do not w orl< properly, replace the carburetors.
e Turn the throttle cable pulley to check that the throttle butterfly valves
[AJ mow smoothly and return by spring tension.
* "the throttle valves do not move smoothly, replace the cartluretors.
• Disassemble the carburetors.

e Ciean the carburetors.
e Check that the 0 -rings on the float bowl and pilot screw and the
dlaphregm on the vacuum piston ara in good condition.
* If any of the 0-rings or diaphragms ere not in good condition, replace
them.
e Check the plastic tip [A ) of the float valve needle [B). It should be -+--{a
smooth, without any gnooves, scratches. or tears.
* II the p4astic tip is damaged [C). replace the needle.
e Push the rod [OJ in the other end of the float valve needle. and then
rel-it.
t:e-@
* If the rod does not spring ou~ replace the needle.
e Check the tapered portion [A) of the pilot screw [B) for wear or
damage.
* If the pilot screw is worn or damaged on the tapered portion, it will
prevent the engine from idling smoothly. Replace it.
• Check that the vacuum piston [A) moves smoothly in the carburetor
body. The surface of the piston must not be excessively worn.
* II the vacuum piston does not move smoothly, or if it is very loose 1n
carburetor body, replace the carburetor.
FUEL SYSTEM 2-15
High Altitude PBfformance Adjustment (US model)

OTo improve the EMISSION CONTROL PERFORMANCE of vehicle
open~ted above 4000 lee!, Kawasaki recommends the following
Environmental Protection Agency (EPA) approved modification.
e Change·the main jet and pilot jet for high altitude use.
High A - carb<lrelllr Speclftcetlons
Pilot Jet # 32 (92084-1117)
Main Jet: # 185 (92063-1390)
Coolant Filter Cleaning (AR, FG, FR, IT, NL, ST, UK)
Before winter season starts, clean the filter of carburetor system.
• Raroove the fairings.
eDrain the coolant (see Cooling System chapter).
e Remove the filter from the cooling hoses of carburetor system.
e Biow off dirt and sediment on the filter with compressed air.
Engine Rlgf11 Side VIew
i /
Engine La41 Side VIew i !
5 /
'
'
1. Connect to cartluretor 8. Clamp

2.Hotle 7. Clamp
3.Hoae &.Clamp
4.Hoae 9. Wawr Aller
5.Ciamp 10.Valve Any
2-16 FUEL SYSTEM
Air Cleaner
Housing Removal
e Remove:
Sells (see F - chaP18<)
Fuet Tank (see Fuel Tank Removal)
Clomp& (leh and right) [A]
Engine Breather Hose (B]
Ajr Cleaner Drein HC$80 [C]
Vacuum Switch Valve Hose [OJ
Rubber Plugs [E]
Mounting Bolts (A)

Air Cleaner Housing [B]
Housing Installation
e Be sure to lh the following hoses.
Engine Breather Hose
Vacuum Switch Valve Hose
Air Cleaner Drain Hoses
e lnsteli the nJbber plugs in place.
Element Removal
e Remove:
Seats (see Freme chapte<)
Upper Housing Mounting Bolts [A]
Upper Housing (BJ
Element
•
Element Installation
e lnll4ll the element [A ] with the foam etement side (gray) fecong up.
e lnstalllhe screen (B] above the element.
FUEL SYSTEM 2-17
•
Element Cleaning and Inspection
i•WARNING
Cle.,llle element In a wel~ventllated a-, and ,..Itt .... 111at......,
.,. no -111.1 0< llame anrw'*- near lht wO<ltlng-
a_... ol tile danger ol highly flammable ltquldo, do not ...
guotlnt or t tow ftaf>.potntaolvent to clean the ttamanl.
e Remove the air cleaner element [A] (see Element Removal).

e Ciean the element in a bath of high flash -point solvent and then dry
It with compressed air or by shaking i~
e After cleaning, saturate a clean. lint· free towel with SE. SF, or SG class
SAE 30 oil and apply the oil to the element by tapping the element
outside with the towel.
e Vilually cheek the element for tearspr breaks.
'*If tht ttement hu any tears of.bl'eaks, replace the element.
;
.·
Oil Draining
Two drain hOS<JS [A] are connected to the front and rear bonom of thE
elr claener housing, to drain water or oil accumulated In the housing.
t VIauelly check the catch tank [B] of the rear drain hose II tho water or
oil accumulates in the tank.
*If any water or oil accumulates in the tank. drain it by taking off the
drain plugs (C] at the lower end of the front and rear drain hoses.
It.,.to....._. ... plug in the drain hote - dnlnlng. 011 on

...., • • molltlltm ·~ and can ca... an .cclclent - lnlury.
AI Vent FiltBf Cleaning

I Removt:
Inn• Fairing <- Frame chapter)
Air Cleaner Housing (other than California model)
A<r Vent Filter (A]
I Clean the filter by directing a steam of compressed a" lrom the clean
Side {B] to tha dirty side (C].
2-18 FUEL SYSTEM
Fuel Tank
r
--In
Fuel Tsnk Removal
n.mm--••WA RNING
-11·•--
GMoOne II.,..,.,,_, can be uploelve
coudllloo._ lilm lhelgl\lllon - OFF. Do notemolle. M8ke ....
the .,..ale end lrM from any -..oe ol n.me or
epub; IIIII lncludee -r applla,_ with a pllolllgllt.
CAliTlON
For California modal, Nguollne, solvent, wat.r or any other liquid
_,.the canlet.r, tile canlet.r' a vapor abeorblng capacity le gnlllly
reduced. Wthe cenlet.r doea become contaminated, replace II wllh
anew one..
e Remove:
Seeta (see Frame cllapter)
I nne< Fairings (see Frame chapt er)
e Tum tha fuel tap (A] to tha OFF position.
e Remove lheact8W (B] and take off the fuel !lip.
e Remove:
Mounting Bolts (C]
Fuel Hose
Fuel Level Sensor lead Connector
Evaporative Emission Hoses (California model)
• Remove the fuel tank.
.. .
FuBI Tsnk Installation l'
e R&Id the above WARN ING.
• Route the hoeee and leads correctly (see General lnfo""ation chapter). \
• Be sore the hoeee ere clamped securely to prevent leaks.
Fuel Tsnk Inspection

e Remove the hoee(s) loom tha fuel tan!(. and open the tank cap
e Chack to see if the boeather pipe (also the luel oelum pope for the
California model) in the tank is not clogged. Check the tank cap
boeather also.
* II they are clogged, remove metank and draon it. and then blow the
breather hee with compressed air.
FUEL SYSTEM 2-19
Do nol apply comprnaed air to lhe air vlf'll l>olea [A) In lhe lank cep.
Thill - . l d - .,.,_and clogging ollhe labyt1n1h In lhe cap.
Fuel Tank Cleening

i • WARNING
Clean lhe 18'* In a well-ventlla1ad area, and wke care lhet !here are
no apalb or name anywhere near lhe working area. Becauoe ollhe
~ ollllghly flammable llqulclo, do notuae gaoollne or tow flaoll-
polnl oolv- to c - lhe tar«.
• Remove lhe fuel tank and drain iL

e Pour some high flash-point solv$nt into the fuel tank and shake the
1enk 10 remove din and fuel deposits.
e Pour !he solvent oul of the tank.
e Remove lhe fuel tap from the tank (see Fuel Tap Removal).
e Ciean lhe fuel tap filter sCffiOns in a high flash-point solvent.
e Pour high flash-point solvent through the tap in all lover positions.
e Ory the tank and tap with compressed air.
e lnmll the tap in the tank.
e lnstllll the fuel tank.
Fuel Tap Removal

e Remove the fuel tank and drain it.
e Removethe mounting bolts [A) with nylon flat washers and take out
the fuel tap [B).
Fuel Tap Installation

e Bewre the 0 - ring is in good conditton to prevent leaks
e lla ..... to clamp the fuel hoses to the tap to prevent leaks.
e Be ..,,. the nylon washers are in good condittOfl to prevent leaks.
OOo not use steel washers in place of the nylon washl<$, because they
wtH not-lthe bolts properly and fuel wtll leak.
2-20 FUEL SYST EM
Fuel Tap Inspection

• Remove the fuel tap.
e Check the fuel tap filter screens [A) for any breaks or deterioration.
*If the fuel tap screens have any breaks or are deteriorated, they may
allow dirt to reech the carburetor, causing poor running. Replace the
fuel tap.
Fuel Level Sensor Removal/Installation

i•WARNING
Gaeollne Ia .U••oef) flammable end can be e.q>loolve --~~~

-.dlllone. Tum the lgn•lcn -Itch CIA'. Do no1 omoke. Make ...,.
the area Ia well ven4tlaled end free lrom MY"""""' oC flame .,..
apart<o; tlololnclud• any appliance wl1h a piiOCIIght.
• Before removing the fuel level sensor. check that tho fuel level in the
fuel tank is low enough to remove the sensor. The fuel level should...
be below the opening for the sensor mounting.
e Remove;
Mounting Bolts [A)
Fuel level Sensor [B]
e Check the gasket on the sensor for damage.
*If~ is damaged, repleoa it w ith a naw one.
e Be sure to install the gasket in~ place.
...... ,
FUEL SYSTEM 2-21
Fuel Pump, Fuel Filter
Fuel Pump, Fuel Filter Removal

i•WARNING
Guollne Ia extremely flammable and can be exploelve under certain
conditione. Turn thelgnlllon awltch OFF. Do not amoke. Make aure
the area Is well-venlllated and fnle from any source of llama oo-
aparko; lhla lncludas any appliance wHh a pllollf9hl
eRemove:
Fuel Hose [A)
Fuel Pump Lead Connector [ B)
Bracket Mounting Bolts [C)
eRemove the fuel pump [D) and fuel filter [E) from the bracket.
Fuel Pump, Fuel Filter Installation

e lnstall the fuel filter so that the arrow [A) on it shows the fuel flow
from the fuel tank to the fuel pump.
e Be sure to route the hoses so that they w ill not be kinked or stretched.
e Fasten the ground terminal [B) with the right bracket mounting bolt
[C).
FueiPumpln~ion
Refer to Electrical System chapter.
Fuel Filter Inspection

eRemove:
eVisually inspect the fuel filter.
1rlf the filter is clear with no signs of dirt or other contamination, it is
OK and need not be replaced.
1rlf the filter is dark or looks dirty, replace with a new one. Also, check
the rest of the fuel system lor contamination.
2-22 FUEL SYSTEM
Evaporative Emission Control System (California Model Only)
The Evepomive Emission Control System routes fuel vapors from the
fuel aystem into the running engine or stores the vapors in a canister
when the engine is rtopped. Although no adjustments are required. a
tholough visual iNj)eetion must be made at the lntM~ail specifoed by the
Periodic M ain111nance Chan.
PBit$ RemoVBI/InstJJ/Iation
i•WARNING
0-.ollne te extnmety l t a m - and can be •"''loehle under cer111n
condlltone. Tum lie Ignition awllch OFF. Do noc emoke. MMe oure
the area 11 -u.venltleted and - from any IOUI'CI o4 flame or
opuko; thto lncludN any appliance wllh a pllolllghl.
N P"llne, .otvant,- «any -l~ld .-..lie can-r, the

_.,,, ' o vapor _.,,no
capacity te greetty reduced. I lie
......... -~ ... conlamlndod, ~··lito a--·
e To prevent the guoline from flowing into or out of the canoster, hold
the separator perpendicular to the ground.
e Connect the hOiell according to the diagram of the system. M ake sure
they do not get pinched or kinked.
Host~ Inspection
e Check that the hoses are securely connected.
• Replace eny kinked, deterioreted or damaged hoses.
Separator Inspection
e Disconnect the hOMOS from the liquid/vapor separator. and remove the
separetor ITom the motorcycle.
e Visualty Inspect the separator for cracks and other damage.
* If the separator has any cracks or is badly damaged, replace it with a
new one.
Separator Operation Test

.;.wARNING
Guotlne te extrwnely fllmmable and con be npiOINe under cei18tn
cond-. Tum lie Ignition switch OFF. Do noc emoloe. Make - .
lie area to -ll·venlllaled and - from any sourc:. o4 flame or
eperb; thil lndud• any appliance with a pHo4 light.
e Connect the hoses to the separator. and install the separator on the
motorcycle.
FUEL SYSTEM 2-23
• OIICOnn«t !he breather hose from the separator. and InJect about 20
ml of geiOiine into lhe separator through the hose fitting.
eOIICOnnec~lhe luet retum hose from the fuel tank.
• Run lha open and of lhe mum hose into the conuuner and hold it level
Wl1h lha tank top.
e SIJfllha engine. and let it idle.
* It the gasoline in the separator comes out of the hose, the separator
wof1<l well. If it does not. replace the separator w ith a new one.
VIICuum Velve Inspection

eAemove:
Stm (tee Frame chapter)
AA Cleaner Housing (see Air Cleaner Hous1ng Removal)
Vacuum Valw Hoses
e Remow the vacuum vaNe [ A] from the rubber dam!* [ B).
e Remova the drain screw (A) from the bottom of the chamber [8] .
t lf "'Y liquid aooumulai8S in the chamber, drain it.
e Repla<» the 0-ring [C] with a new one.

eAAerdraining, install the drain screw w ith the 0 -ring.
T.... - y......., Valve Drain Sc:nr. 1.0 N-m (0.1 kg.m, t - )
eu..ng lha vacuum gauge and fork oil level gauge, 1nspect the vacuum Vacuum Velve Opetatfon
"""'opatlltion <-Vacuum Switch Valve Test '" Engine Top End
chaptor).
"*Ill Toolo - Vecuum Gauge: 57001-13Cit
Forie 011 LOYal Gauge: 57001·12110
OWhan applying vacuum (1.5 cmHg) to the vacuum sensing fining
[A], airflows from pipe (B] to p ipe [C], and vice versa.
OWhen stopping applying vacuum, air ftows from p1pe [ B] to pipe
[D), and vloa versa.
*Neve"heleea if the vacuum valve does not operate as described,
'IJllaca it with a new one.
t A1t flows
Dt Mt we compt 111ed air during the v•tve chedt, 0t 1he vacuum

-maybo~.
t A if flows
2-24 FUEL SYSTEM
Csnister Inspection
e Remove the caniste<, and disconnect the hoiWI8 from the canister.
e Viaually inspect the canister lor cracks and other damage.
* lithe canister haa any cracks or bed damage, replace it w ith a new one.
NOTE
0 The CJJnlstN Is deslgfllld to work wei/through the motorcycltls Ide
without any ~Nintenance if it is ustKJ under norrMI conditions
COOLI NG SYST EM 3-1
Cooling System
Table of Contents
Exploded View ............................................................................................................3-2

Coolant Flow Chart .....................................................................................................3 -3
Specifications ..............................................................................................................3 -4
Coolant ........................................................................................................................3 - 5
Coolant Level Inspection ........................................................................................3- 5
Coolant Draining .....................................................................................................3 -5
Coolant Filling .........................................................................................................3-6
Pressure Testing ......................................................................................................3-7
Water Pump .................................................................................................................3-8
Water Pump Removal .............................................................................................3·8
Water Pump Installation .........................................................................................3-8
Water Pump Inspection ..........................................................................................3-8
Radiator, Radiator Fan ................................................................................................3-9
Radiator, Radiator Fan Removal .............................................................................3-9
Radiator lnspection ...............................................................................................3·10
Radiator Csp lnspection .......................................................................................3·10
Thermostat .................................................................................................................3·12
Removal ................................................................................................................3-12
lnstallation ............................................................................................................. 3·12
Inspection .............................................................................................................3-1 2
Radiator Fan Switch, Water Temperature Sensor ....................................................3-13
Radiator Fan Switch, Water Temperature Sensor Removal ................................3-13
Radiator Fan Switch, Water Temperature Sensor lnstellation.............................3-13
Radiator Fan Switch, Water Temperature Sensor Inspection .............................3-13
3-2 COOLING SYSTEM
Exploded View
EO: Apply engine oil.

SS: Apply silicone sealant
1. Radiator Fan Switch 5. Water Filter T1: 2.5 N-m (0.25 kg m, 22 on-lb)
2. Water Temperawre Sensor 6. Valve Assy T2: 9.8 N-m (1 .0 kg-m, 87 in-lb)
3. Air Bleeder Bolt T3: 18 N-m (1 .8 kg-m, 13.0 ft-lb)
4. Drain Plug T4: 7.8 N-m (0.80 kg m, 69 in- lb)
COOLING SYSTEM 3-3
Coolant Flow Chart
.. Hot Coolant
Q Cold Coolant
9. To Reserve Tank
1. Water Pump coupled with oil pump When the engine is very hot. the pressure
valve in the radiator cap allows air and vapor
2. Air Bleeder Bolt to escape into the reserve tank. When the
engine cools down, the pressure drop draws
3. Cylinder Jacket
the vacuum vatve (another small valve) open.
4. Cylinder Head Jacket admining coolant from the reserve tank into
the radiator.
5. Thermostat
6. Water Temperature Sensor 10. Reserve Tank
7. Hole (Air bleeder hole) 11. Radiator

When the engine is cold, the thermostant is 12. Radiator Fan
closed so that the coolant flow is restricted
13. Radiator Fan Switch
through the air bleeder hole, causing the
engine to warm up more quickly, 14. Liquid -cooled Oil Cooler
8. Radiato~ Cap 15. Drain Bolt
3-4 COOLING SYSTEM
SpecifiCations
Item Standa rd
Coolant provided when shipping:
Type Permanent type antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Color Green
M ixed ratio Soft water 50%, coolant 50%
Freezing point - 35·c ( - 31 •F)
Total amount 2.4L ( reserve tank full level including rediator and engine)
~----------------------4-
I-
R..:ad
.:..:.:
l•..: r .:.
t .:.o:..ca::P:..__ __ _..:..:R.:.
el..:
ie_f .::.
pr..:es
.:.s:..:':..
''e:...:_-+-=9 3 - 123 kPa (0 .95 - 1.25 kg/em•, 14 - 18 psi)
Thermostat:
Valve opening temperature 80 - 84•c (176 - 183 •F)
Valve full opening lift Bmm or more @95•c (203 •F)
L-------------~~-------L
s-a.ne - Kaw * ' Bond (Silicone -lenC): 5601 ~120

COOLING SYSTEM 3-5
Coolant
Coo~ntLev~ln~c&on
NOTE
OChock the /evol when the engine is cold (room or ambient tempor-
atu~).
eCheck the coolant level in the reseove tank with the motorcycle held
perpendicular.
*"the coolant level is lower than the "L" (Low) level line [A], add
coolanttothe • F• (Full) level line [B].
For refilling, add the specified mlxlure of coolant and soli wawr.
Adding water alone dilutes the coolant and degrades lis anticorro-
sion propenlea. The diluted coolant can ali8Ci< the aluminum engine
paris. In an emergency, aolt wetar alone can be added. But llle
dlklled coolant must be returned lo the correct mlxlunt raHo wllllln a
lewdaya.
I coolant mua1 be added oltan, or lie rnMYolr ta'* has run
complel81y dry; there Is probably leakage In the cooling ayatem.
Choct lie syatam fer leaka.
Coolant Draining
i•WARNING
To avoid burna, do not remove the radiator cap or try lo change the
coolant when the engine Ia still hoi. Well until II cools down.
Coolant on tires will make them alippely and can cause an accident
and Injury. Immediately wipe up or waah away any coolant that spllla
on the frame, engine, or other painted paris.
Since coolant is !)armful to the human body, do not use lor drl,..lng.
eRamow:
Right Inner Fairing and Lower Fairings (see Frame chapter)
Radiator Cap [A)
ePiace a container under the drain plug [A] at the bottom of the water
pump [B] .
eDrain the coolant from the radiator and engine by removing the drain
plug.
3-6 COOLING SYSTEM
eRemove:
Hose [A]
Mounting BollS [B] and Roserv& Tank [C]
e Remova the cap [OJ and pour the coolant into a container.
Coolant Filling
e Tighten the drain plug.
Torque - Drain Plug: 9.8 N-m (1.0 k~, rrT ln-lb)
e Fill the radiator up to the thermostat housing cover [A] filler neck [B)
with coolant and install the radiator cap.
NOTE
OPour in the coolant slowly so that it can expel the air from the engine
and radiator.
e Fill the reserve tank up to the "F" Ievelline with coolant. and install the
cap.
Soli or distilled water must be used with the antlreeze (aea below tor
antifreeze) In the cooling .yllem.
I hard water Is used In the system, It cauaea .:alee accumulation In
the water -•ages, end considerably reduces the efllclency ol the
cooling ayotern.
Water and Coolant Mlxlura Rallo (Recommended)

Soli Water 501/o
Coolant SO~o
Freezing Point -35'C (- 31"'1')
Total Amount 2.4 L
NOTE
0 Choose a suitable mh<tura ratio by refening to the coolant
manufacturers dirtJCtions.
e Remove the rubber cap [A], and loosen the air bleeder bolt [B), until
the coolant begins to flow out the, air bleeder bolt hole (that is, when
all the remaining air has been forced out).
e TIQhten the air bleeder bolt
COOLING SYSTEM 3 -7
• Suwt the engine. warm it up thoroughly until the radiator fan turns on
and then atop the engine.
• Chedt the coolant level in the reserve tank ahe< the engine cools down.
* If the ooolant lew! is lower than the "L• level hne. add ooolant to the
• f• level line.
I Do noteclcl ,_..coolant-.~ level line.
PrBSSure Testing
• Remove the innerfairing (see Frame chapter).
• Remove the radiator cap, and install a cooling system pressure tester
[A] on the filler neck.
NOTE
0 W« th#l ~p &eating &utfaces with w•IM or coot•nt to prevent
preuure '-Its.
• Build up p.-re in the system carefully until the pressure reaches 123
kP1 (126 kg/ em'. 18 psi).
CAliTlON
During prMM~re IHIIng, do not exceed lhe preooure lor which the
o~..m Ia d..lgned. The maximum pr..oure lo 123 kPo (1 .25
kg/em', 18 pol).
• Watdltha gauge for at least 6 seconds.

* If the pressure holds steady, the system is all right.
* If the pr-ure drops soon, checi< for leaks.
3-8 COOLIN G SYST EM
Water Pump
Water Pump Removal

• Drain the coolant (see Coolant Draining) .
e Remove:
Water Hose [A)
Bolt [B] and Wale< Pipe [C]
Bolts [0] and Water Pump [E]
Water Pump Installation

• Note the position of the oil pump shaft projection [A] and tum the
walllr pump shaft [B) so that the projection fits into the slot [C].
Water Pump Inspection

e Check the drainage outlet passage [A] at the side of the wate< pump
body for coolant leaks.
*II the mechanical seal is damaged, the coolant leaks through the seal
and drains through the passage. Replace the water pump unit with a
new one.
e Visually inspect the impeller [A) .

*Ifwater
the surface is corroded, or if the blades are damaged, replace the
pump unit with a new one.
COOLING SYSTEM 3- 9
Radiator. Radiator Fan
Rlldiator. Radiator Fan Removal

.-.wARNING
Tile,............, 1o ..,. •. - dlreclly 1o the Mltery. Tile radlalo< fan
miiY llart - Wthe Ignition IWitcll lo oft. NEVER TOU<:1t THE
RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS
DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR
IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN
BLADES.
e Remove:
Fuel Tank (see Fuel System chapter)
Upper and Lower Fairings (see Frame chapter)
Coolant <- Coolant Draining)
Radiator Fan Connector [A)
Fan Switch Leads [A)

Radiator Hosa [B)
Radiator Hoses [ A)
Radiator Mounting Bolts [A)

Radiator
3-10 COOLING SYSTEM
Radiator Fan Mounting Bolts [A]

. Radiator Fan (8]
Radiator Inspection
• Check tha radiator core.
*If 111ere are obstructions to air flow. remove them.
*If 111e oorrugatad fins are defonned, carefully straighten them.
*If the air passages of the radiator core are blocked more than 20% by
unremovable obstructions or irreparably deformed fins, replace the
radiator with a new one.
When cleaning the radla!or will 11811111 cleaner, be caralul ollhe

lollowlng 1o pravent radla!or damage.
1) Keep lie mam go.. away more llan 0.5 m from the red IalOr ccwe.
2) Hold lhe lleam gun perpendicular to the core ourtace.
3) Run lie oleam go.. verttcelly following the core fln direction.
Running II mrlzontally may damage the lin.
Radiator Cap Inspection

eCheck the condition of the top (A) and bonom [ B) valve seals. B
*If any on a of them shows visible damage, replace the cap w ith a new
one.
elnstallthe cap (A) on a cooling system pressura tester [B] .
NOTE A
0 Wet the cap sealing surfaces with w8ter or coolant to prevent

pr8$sure leaks.
COOLING SYSTEM 3-11
e Wetching the pressure gauge. slow ly pump the pressure taste< to build
up the pressure. The gauge pointer must remain wothon the relief
~re renge in the table below at Ieist 6 seconds. Continue to
pump the teeter until the relief valve opens, indocated by tile gauge
POinter flic:b downward The relief valve must open wothin the
specified renge.
Redlator C.p Relief "'-'••

St e - 113 - 123 kPa (0.95 - 1.25 kglcm',14 - 18 pel)
* If the cap cannot hold the specified pressure, or if it holds too much
P<OSSure. replace it w ith a new one.
3-1 2 COO LING SYSTEM
Thennostat
R81110VBI
e R8111011e:
Coolam <-Coolant Draining)
R_....Tank Hose [A)
Thenn<lelat Housing Cover Bolts [B)
Then'noetat Housing Cover [C)
Tl'le!mooltat
Installation
e Be sure to Install the 0-ring [A) on the housing oover.
e Fill the radiator with coolant.
Inspection
8 Remove the th ennostat. and inspect th e thennostat valve [A) at room
temperature.
* If the valve Is open. replace the thermostat w ith a new one.
e To check valve opening temperatlJre. suspend the thenn0$tat [ A) 1n a

contain~< of water and raise the temperature of the water.
[B) Thennometer
* If the measurement Is out of the specified range, replace the thermostat
with a new one.
Thermoe181 Valve Opening Temperature
80 - 84' C (1 T8 - 183' F)
COOLING SYSTEM 3-13
Radiator Fan Switch. Water Temperature Sensor
Radiator Fan Swftch. Water Temperature Sensor Removal

CAU110N
The fan swhch or the water temperature sensor should rMrVer be
allowed to fall on a hard surface. Such a tllock to lhelr partl can
damagellem.
eDrain the coolant (see Coolant Draining).

eRemove:
Radiator Fan Switch Lead [A]
Switch Cover [ B]
Radiator Fan Switch [C]
Water Temperature Sensor Lead Connector [A]

Water Temperature Sensor [B]
Radiator Fan Swftch, Water Temperature Sensor Installation

eApply silicone sealant to the threads of the water temperature sensor.
eTighten the fan switch and water temperature sensor.
Torque- Radiator Fan Swlldt: 18 N-m (1.8 kg-m,13.0 fl-lb)
Water Temperature Senoo<: 7.8 N-m (0.80 kg-m, 891n-lb)
Radiator Fan Swftch. Water Temperature Sensor Inspection

eReter to Electrical System chapter for these inspection.
ENGINE TOP END 4-1
Engine Top End

Table of Contents
Exploded View ..........................................................4-2 Valve Clearance Adjustment ..............................4·16

Specifications ...............•............................................4 -4 Valve Removal ...... ..............................................4-20
Clean Air System ... ....................................................4-6 Valve Installation ................................................4-20
Air Suction Valve Inspection ..... ....... ....................4-6 Valve Guide Removal ................................ .........4 ·20
Vacuum Switch Valve Installation .•...•..•.......•......4-6 Valve Guide Installation .....................................4-20
Vacuum Switch Valve Test ............................ ... ....4 -6 Valve-to·Guide Clearance Measuroo>ent
Clean Air System Hose lnspection .......................4-7 (Wobble Method) ............................................4-20
Cylinder Head Cover .................................................4-8 Valve Seat Inspection .........................................4-21
Cylinder Head Cover Removal .............................4-8 Valve Seat Repair ............................................ ....4-21
Cylinder Head Cover Installation .........................4-8 Seat Cutter Operation Care: ...........................4-22
Camshaft Chain Tensioner .....•..................................4-9 Marks Stamped on the Cutter: ............•.•.•.••..4-22
Camshaft Chain Tensioner Removal. ................... 4 -9 Operating Procedures: ...................................4-22
Camshaft Chain Tensioner Installation ..........•.....4-9 Cylinder, Pistons .....................................................4-25
Camshaft. Camshaft Chain .................................... .4-10 Cylinder Removal ...............................................4-25
Camshaft Removal .......................................... .. .4-1 0 Cylinder lnstallation ............................................4-25
Camshaft Installation ..........................................4-1 0 Piston Removal ................................................... 4-25
Camshaft, Camshaft Cap Wear ....................... ...4-11 Piston Installation ....................................•......•...4-26
Camshaft Chain Removal. ..................................4-12 Cylinder Wear .....................................................4-26
Camshaft Chain Wear .........................................4-12 Piston Wear ........................................................4-27
Rocker Shalt. Rocker Ann ......................................4-1 3 Piston Ring, Piston Ring Groove Wear .............4-27
Rocker Shaft, Rocker An11 Removal ..................4· 13 Piston Ring End Gap ..............•.••..............•.•.......4-27
Rocker Shaft. Rocker Ann Installation ............... 4-13 Carburetor Holder ...........•........................................4 ·28
Cylinder Head ....................•.•..•.•.•....•..•....................4-14 Carburetor Holder lnstallation ......................••....4-28
Cylinder Compression Measurement ........... ...... 4 · 14 Muffler .....................................................................4 ·29
Cylinder Head Removal. .....................................4-14 Muffler Removal .................................................4-29
Cylinder Head Installation ........•.........................4-15 Muffler Installation ............................•......•.........4-29
Valves ......... ............................................................. 4-16
4 -2 ENGINE TOP END
Exploded View
1. Anow points to the front

2. Cloeed coil end face~ downward.
3. R mM<ed aide facel up.
CA: California
L; Apply a non-peomenent locking agent
M : Apply molybdenum disulfide g,_.
R: Replacement Parts
S: Follow the specific tightening sequence.
(Kawasaki Bond: 56019 -120).
6
0
0
...•
•
~If>
®--4
,, 0
r$
®--\
'
ENGINE TOP END 4-3
Tl : 13 N·m (1.3 kg-m. 113 in-lb)

T'2: 98 N-m (1 .0 kg-m. 87 in-lb)
T3: 12 N-m (1 .2 kg· m. 104 in-lb)
T4: 83 N-m (0.85 kg-m. 74 in-lb)
T5 34 N-m (3.5 kg-m. 25 ft-lb)
T6: 54 N-m (6.5 kg-m. 40 ft-lb) (new pans)
T7: 49 N-m (5.0 kg-m. 36 ft-lb) (used pans)
T6: 4.9 N-m (0.60 kg-m. 43 in-lb)
T9: 25 N-m (2.6 kg-m. 18.0 ft-lb)
4-4 ENGINE TOP END
Specifications
Item Standard Service limit

Clean A ir System:
Vacuum switch valve closing pressure: Open .... Close
57 - 65 kPa (430 - 490 mmHg) ---
Camshafts
Cam height: Exhaust 36.480 - 36.620 mm, 36.38 mm
35.063- 35.179 mm ( FR) 34.96 mm
Inlet 36.667 - 36.807 mm, 36.56 mm
35.063 - 35.179 mm (FR) 34.96 mm
Camshaft journal, camshaft cap clearance 0.048 - 0.091 mm (#1.114) 0.18 mm
O.D78 - 0.1 21 mm (#2. #3) 0.21 mm
Camshaft journal diamatar 23.930 - 23.952 mm (#1. #4) 23.90mm
23.900 - 23.922 mm (#2. #3) 23.87 mm
Camshaft bearing inside diameter 24.000 - 24.021 mm 24.08 mm
Camshaft runout Tl R 0.02 mm or less TIR 0.1 mm
Camshaft chain 20-link length 127.00- 127.36mm 128.9mm
Rocker arm inside diameter 1 2.000 - 1 2.018 mm 12.05 mm
Rocker shaft diameter 11.966- 11 .984mm 11.94 mm
Cyli nder Head:
Cylinder compression (usable range)
960 - 1 470 kPa ---
(9.8 - 15.0 kg/ em', 139 - 21 3 psi)
@340 r/ min (rpm)
Cylinder head warp - -- 0.05 mm
Valv a.:
Valve clearance: Exhaust 0.21 - 0.26 mm ---
Inlet 0.18 - 0.23 mm ---
Valve head thickness: Exhaust 0.7- 0.9mm 0.5mm
Inlet 0.4- 0.6mm 0.25mm
Valve stem bend Tl R 0.01 mm or less TIR 0.05 mm
Valve stem diameter: Exhaust 4.455- 4.470 mm 4.44mm
Inlet 4.475 - 4.490 mm 4.46 mm
Valva guide inside diameter Exhaust 4.500 - 4.51 2 mm 4.58 mm
Inlet 4.500 - 4.51 2 mm 4.58 mm
Valve/valve guide clearance
(wobble method): Exhaust 0.090- 0.171 mm 0.37mm
Inlet 0.031 - 0.113 mm 0.32 mm
Valve seat cutting angle 45·. 32·. eo· ---
ENGINE TOP END 4-5
Item Standard Service Limit

Valve seat surface:
Width: Exhaust
Inlet
0.5- 1.0mm
0.5- 1.0mm
----
--
Outside diameter: Exhaust 24.4 - 24.6 mm -- -
Inlet 28.4 - 28.6 mm - --
Valve spring free length: Exhaust, Inlet 41 .8 mm 40.1 mm
Cylinder, Piston:
Cylinder inside diameter 73.000 - 73.01 2 mm 73.1 mm
Piston diameter 72.942 - 72.958 mm 72.8mm
Piston/cylinder clearance 0.042 - 0.070 mm ---
Piston ring/groove clearance: Top 0.05 - 0.09 mm 0.19 mm
Second 0.03 - 0.07 mm 0.17 mm
Piston ring groove width: Top 0.84 - 0.86 mm 0.94mm
Second 0.82 - 0.84 mm 0.92mm
Piston ring thickness: Top 0.77 - 0.79 mm 0.70mm
Second 0.77- 0.79 mm 0.70mm
Piston ring end gap: Top 0.20 - 0.35 mm 0.65 mm
Second 0.20 - 0.35 mm 0.65mm
Oil 0.20 - 0.70 mm 1.0mm
(FR): France
Special Tools -
For1< 011 Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Spartt Plug Wrench,16mm: 92110.1154
Compreulon Gauge: 57001·221
Compression Gauge Adapler, M10 X 1.0: 57001-1317
Hexagon Wn1nch, Hex 8: 57001·1234
Valve Spring CompNSsor A.-nbly: 57001-241
Valve Spring Compn111or Adapter, <1>22: 57001·1202
Valva Guide Art>or, <1>4.5: 57001·1331
Valve Guide Reamet, <1>4.5: 57001-1333
Valve Seat Cutter, 45' - <1>32: 57001-1115
Valva Seat Culler, 32'- <1>30: 57001-1120
ValveSeatCulter,80' - <1>30: 57001·1123
Valve Seat Cutter, 45' - <1>27.5: 57001-1114
Valve Seat Culter, 32' - <1>28: 57001-1119
Valve Seat Culter Holder, <1>4.5: 57001-1330
Valve Seat CUtter Holder Bar: 57001·1128
Ploton Ring Compressor Grip: 57001·1095
Ploton Ring Compressor Belt, <1>87 - <1>79: 57001·1097
Ploton Pin Puller Assembly: 57001410
Ploton Ring Pllen: 57001-115
Sealant- KAiwual<l Bond (Silicone Sealant): 56019-120
4-6 ENGINE TOP END
Clean Air System
Ai Suction Vslvs Inspection

8 V11Ualty inapeclthe reeds [ A) lor Cll!cks, fokls. warps. heat damage,
Of other damege.
* II there is eny dollb1 as to the oondition of the reed, replece the air
Miction valw as en _....bly.
e Check the reed oontact areas [ B) of the valve holder for grooves,
ecrau:hee. any signs of separation from the holder, or heat dam119a.
*II there is any doubt as to the oondition of the read contact areas,
replace the air auction valva as an assembly.
*II any carbon or other foreign particles have accumulated between the
read and the reed contact area, wash the valve asaornbly with a high
flash· pOintaolvent
Do not ecra~ all m.

~Ia with a ICI1I~r aa tflle could damage
m. ~. NqUirlng ....,..ement of.,. ouctlon valve aoaembly.
VtJCuum Switch Vslve /nstsllation

e lnstall the vacuum switch valve so that the air hole (A] faces
downwards.
e Route the hoses correctly( see General information chapter) .
VtJCuum Switch Valve Test

Uslng the vacuum gauge and a syringe. inspect the vacuum switch
operatioo as followo:
• Remove the vacuum switch valve.
e Connect the vacuum gauge (A] and syringa [ B) or fork oil level gauge
to the vacuum hoses as shown.
S~lal Toole - Vacuum Gauge: 570tn·13&9
l'ortc on Ln•l Gauge: 57001-1290
ENGINE TOP END 4-7
e Gnodualty raise the vacuum (lower the pressure) applied to the vacuum
switch lllllllll. and check the valve operation. When the vacuum is low.
the llliCUum switch valve should permit air to flow. When the vacuum
raisel to 67 - 65 kPa (430 - 490 mm Hg). it should stop"" flow.
*" the vacuum switch valve does not ope<ate as deecnbed. replace it
with a new one.
NOTE
0 To check air flow through the vacuum switch valve. just blow
through the air cleaner hose.
Yocuum Swllch Valva Cloolng Pressure (Open -+ Clooa)

Standard: 57 - 65 kPa (430 - 490 mmHg)
2. Dvrlng Engine Braking
II II
Cle6n Air System Hose Inspection

e ea certain that all the hoses are routed without being flattened or
kinked, and are connected correctly to the air cleaner housing. vacuum
swllch valve, #1 and #4 carburetors and air suction valve covers.
*If they are no~ correct them. Replace them if they are damaged.
4-8 ENGI NE TOP END
Cylinder Head Cover
Cylinder H8Bd Cover RBITIOVBI

e Remove:
Se<~1S (see Frame chapter)
Air Cleaner Housing (see Fuel System chapter)
Vacuum Switch Vallie and H018S
Ignition Coils
Bolt [A] and Baffle Plate [B)
e Remove the cylinder head cover bolts (C] and take off the cover [ D).
'
Cylinder Head Cover lnst811Btion
e Apply silicone sealant to the cylinder head as shown [A].
e Replace the head cover gasket w•th a new one rt damaged.

e Apply silicone sealant to the right and the wrong side at the areas [A)
of the head co- gasket [B) as shown.
8
A
e Check that the upper chain guide [A) bottoms out •n the head cover
n the uppott chain guide- not botlom ou~ the camahllft chain can
ralae the guide - the cylinder head cover Whlcll could c.._ oil
r-.g• .
e Tighten the cylinder head cover bolts.

Torque - Cylinder Head Cover Bolte: 9.8 N-m (t.O kg-m, 87 I n-Ib)
ENGINE TOP END 4-9
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal

CAUT10N
Thlo Ia a non-retum type camlhall chain tenoloner. The push rod
does not return ID lis original posHion once H moves oullo take up
camlllaft chain slaclc. Obeerve alllhe Nles llstad below:
When removing lhe lenoloner, do not lake oUIIhe mounllng bolls only
hallway. RetlghiBnlng lhe mounllng boHI from lhla poslllon could
damage lhe lensloner and lhe camshaft chain. Once lhe boHI are
1ooaenecl, lhelensloner muot be removed and reoel as deocrlbed in
•camlllaft Chain Tenaloner lnalallatlon."
Do notlum over lhe crankahall while the lenoloner Is removed. Thlo
could upsetlhe camshaft chain Uming, and damage lhe valvea.
eRemove:
Carburetors (see Fuel System chapter)
cap Bolt [AJ
Washer [B)
Spring [C)
eRemove the mounting bolts [D) and take off the camshaft chain
tensioner.
Camshaft Chain Tensioner /nstalla6on

eReleese the stopper[A] and push the rod [B) into the tensioner body
[C).
elnstall the tensioner body so that the stopper faces upward.
eApply a non-permanent locking agent to the threads of the tensioner

mounting bolts (A) and tighten them.
Torque - CamlllaftChaln Tensloner Mounting Bolls: 12 N-m (1.2kg-m,
1041r>-lb)
elnstall the spring and washer.
e Tighten the cap bolt [B).
Torque - Camshaft Chain Tensloner Cap BoH: 8.3 N·m (0.85 kg-m, 74
ln·lb}
4-10 ENGINE T OP END
Camshaft. Camshaft Chain
C6mSM!t Removal
• Remove:
Engine (see Engine Romoval/ lnltallation chapter)
Cylinder Head Cover c- Cylinder Head Cover Removal)
PickUp Coil Cover
• Position the crankshaft at #1, 4 piston TOC.
[A) TDC mark for #1 , 4 Pistons
[ B] Timing Mark
• Remove:
c.n.haft Chain Tensioner c-
Camshaft Chain Tensioner Removal)
Camshaft Cap Bolts
Camshaft Cap [A)
Camshafts [ B)
• Stuff a clean cloth into the chain tunnel to keep any parts from
dropping Into the crankcase.
, . ~ mey be - willie ... . , . , _ - ......... eel.

Alw8Y8 pull lie dlaln taut willie turning ... """*"h8fL Thla avoldt
kinking.,. ct.ln on lie - (cnorQNII) ..,........ A klr*ecl elwin
oould clemege bolh lha cheln - lha sprocket.
Camshaft Installation
• Apply engine oil to all cam pans end journals.
• 11 a new camshaft is to be used, apply a thin coat of molybdenum
disulfide grease to the cam surfaces.
NOTE
0 TM UMust CllmShalt hilS IN! £X nw*(Ajand ~inlet csmsh11ft h.s
•n IN mark( B). 8 11 ~ulnot to milt up thiiSe shafts.
• Position the crankshaft et #1, 4 piston TDC (see Camshaft Removal) .
CAIIrlON
'l1le . . . - may be IUIMd while lhe caiMhafb are removed.
Alw8Y8 pull the cheln taut wflile turning .,. cranbhaft. This avoldt
klr*lng the cheln on the lower (c:r- ) ..,........ A klr*ecl c:heln
could damaga bolh lie cl\aln and.,. ..,.......et.
EN G INE TOP END 4-11
e Pull the tension side (exhaust side) of the chaon taut to install the
chain.
• Engage the camshaft chain w ith the camshaft sprockets so that the
timing matb on the sprockets are positioned as &hown.
OT"-Ilmlng matl<s must be aligned w ith the cytonde< head u~ surface
[A].
e tnatsll the camshaft caps in the correct loca tions as shown.

[A] #1 [C) #3
[8]112 [0]114
1"- camehoft capo are machined w llh lhe cylinder heed. So, H a C8l'
II !Nailed In • wrong location, lhe camahall mey aalu beca. . . of
" ' - ' o i l clearance In lie bearing~.
eT~ghten the right camshaft cap bolts [E] first

0 The cap hes two set rings.
[F] Front
e Tighten the camshaft cap bolts.
Torque - Csmahell Cap-= 12 N.., (1.2 kg...., 1041n-lb)
CMTISh8ft. Camshaft Cap Wear

e Meeaure each clearance between the camshaft JOurnal and the
camshaft cap using plastigage (press gauge) [A] .
e T!llhten the camshaft cap bolts.
Tor..,. - Camaheft Cap Botts: 12 N..,(1 .2 kg·m, 104 ln·tb)
NOTE
0 Do not turn tha camshaft whan tha p/astigaga is b81waan tha ioumal
1nd c1mshaft cap.
* If any clearance exceeds the service limit, measure the doamoter ol each
camshaft journal with a micrometer.
Camahaft Jouma~ Camshaft Cap Clean~ nee

NU4Joumalo
S - r d: 0.048 - 0.091 mm
S..Vtce Limit 0.18 mm
112,113 Joumale
8-rd: O.OTS - 0.121 mm
s.....lcellmlt 0.21 mm
4 -12 ENGINE TOP END
* If the camt/laft joumal diameter is less than the servtca lim•~ replace
the camshaft with a new one and measure the clearance agam.
* If the cfearence still remains out of the limit. replace the cvt•nder head
unit
CIJITI$haft Chain Removal

e Split the crankcase<- Crenkshaft/Trensmission chapter) .
• Remove the camthaft chain from the crankshaft sprockot.
Camshaft Chain Wear

e Hold the chain taut with a Ioree of about 5 kg in some manner. and
measure a 20-llnk length. Since the chain may w ear unevenly. take
measurement at several pieces.
*If any measuremeot eKceeds the service limit. replace the chatn.
Camshaft Chain 20-llnk lAngth
Stllndanl: 127.00 - 127.36 mm
Setvlce Limit 121.1 mm
EN GINE TOP END 4-13
Rocker Shaft. Rocker Arm
RocktJt ShMI. Roclcer Ann Removal

e Remove:
Engine<- Engine RemovaVInstallation)
Camlllahs < - Camshaft Removal)
Left Cylinder Head Cover [A] and Oil Hose [8]
e Ualng a suitable bolt (M S P1 .25 x more than 20 mm long) [A), pull

the rocker shalt [8] ouL
e Remove the rocker arms [C) and springs [0) .
OMarl< and record the rocker arm locations so that the rocker arm can
t.. reinstalled in their original positions.
Roclcer Shaft. Rocker Arm Installation

e Apply engine oil to all the rocker arms and the rocker shafts.
OThe Inlet rocker shaft [A] has a blue paint merk and a groove [8],
Be cereful not to mix up the inlet and exhaust rocker shafts.
e lnstall the rocker shalt from the left side of the cylinder head so that the
plug [C] end goes in forst.
e lnstall the rocker errns in their original positions.
e lnstall the spring as shown.
[OJ Red Paint
[E) Blue Paint
e Puah the rocker shaft all the way in. The end of the rocker shalt should
t.. r~ 0.1 - 0.9 mm inside the left side rocker shalt support. lUI
[A] Left Cytind8f Head CoV8< [D) Cyiind8f Head
[ 8] Rocker Shalt [E) Rocker Shaft Support 0.1-0.9 mm
[C] 0 -ring
e lnltall the left cylinder head cover. Be careful not to pinch the 0 -ring.
e Tighten the left cylinder head cover screws and oil hose banjo bolt.
Torque - IAII Cylinder Head Cover ScNwo: 4.9 N-m (0.50 kg-m, 43
ln-lb)
011 HOM Banjo Bolt 34 N-m {3.5 kg-m, 25 11-lb)
Cylinder Head
Cylinder COf'fiiJ'SSSion M BBSUrement

• warm up the engine thoroughly.
• Stop t he engln., end remove the spark plugs.
Spec..l Tool - Spett Plug WNnCh, 16mm: 821 1().11 54
• M-urethe cylinder comPf9SSion.
o Using the lltllrter motor, tum the engine over w ith the thronle fully
open until the compreuion gauge stops rising; the compression is the
highest reading obtainable.
Special Toolt - Camp-Ion Gauge: 57001 ·221 [A]
Comp.-lon Gauge Adapter, MtO X 1.0: 57001-1317
[8 ]
NOTE
OB• sure th• ~rwy is fully clwged.
OBe sure no elr leeks out of the cylinder head gasket.
eya,der COinpi IIII DIII
~" -: teO - 1C70 kPa (t.a - 15.0 kg/em' ,
13t - 213 psi) @ 340 rfrnfn (rpm)
0 Repeet the -..rement l or the other cylinder.
*If cylinder compreaeion is higher than the usable range, check the
following;
(1) Carbon build -up on the cylinder head combustion chamber end
the piston crown.
(2) Cytinder head gasket is not the original part.
(3) Valve stem oil seals and/or p iston rings are damaged.
* II cylinder compression is low er than the usable range. check the
following;
(1) Condition of the valve seat is wrong.
(2) Valve clearance is too small.
(3) Piston/cylinder clearance is excessive.
(4) Cytinder head is warped and/or head gask81 is damaged.
(5) Pitton ring/ piston ring groove clearance is excessrve.
CylindtN HIIBd Removal

• Remove:
Engine (180 Engine Removal/ Installation chapter)
Cylinder Head Cover (see Cylinder Head Cover Removal)
Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal)
Camshafts (see Camshaft Removal)
Left Cylinder Head Cover [A] and Oil Hose [B]
• Remove the 8 mm cylinder head bolts [A]. and then the 10 mm

cylinder head bolts [8], using the hexagon wrench .
Specie! Tool - Heugon Wr - . Hex II= 57001·t234
• Taka off the cylinder head.
ENGINE TOP END 4-15
Cylinder Head lnsl811ation

tlnsllll a new cylinder head gasket with ·up• (A) matl<od side facing
up.
NOTE
0 The CBm$hsft csps srs m schinsd with ths cylindsr h~Md so H B nsw
cylinder head is insts/lsd, usa ths csps thtt trtt suppllsd with th11 n11w
h!Md.
e When the air suction pipes (A) are removed, install the popes so that
the IWO 0-rings (B) side faces down (cylinder heed side).
• Aillllv engine oil to both sides (C) of the cylondet heed bolt washers.
e lnstalltl>e 10 mm bolts. Place the cut head bolts [A) in the rear holes.
e Tighten the 10 mm cylinder head bolts following the tightening CUt
Mquence [1 - 1 0) .
Torq. . - Cylinder Heed Bolts (10mm):
Fhl . 20 N-m (2.0 k~ , 14.5 ll·lb)
Flnll
-- 54 N-m (U k~, 40 fl..lb)
U.ed Bolts 49 N-m (5.0 k~ , 3e fl..lb)
e Tigh18n the 6 mm cylinder head bolts (1 1 - 1 2].
Torque - Cylinder Heed- (6 mm): 12 N-m (1.2 k~. 104 Jr>.l>)
elnst~U the left cylinder head OOVfl/f. Be Qreful not to ponch lhe O·ring.
e roghten the left cylinder head OOVfllf screws and ool hose banJO boiL
Torque - LAft Cylinder Heed Cover Screwa: 4.8 N-m (0.50 ke-m. 43
ln·l>)
011 HOM Banjo Bolt 34 N-m (3.5 kg-m, 25 ft-lb)
e lnstall the front camshaft chain guide (A) with ots proJection (B) up.
Pusl> the guide all the w ay down.
(C) Rear Camahaft Chain Guide
4-16 ENGINE TOP END
Valves
Valve Cltw8nc8 Adjustment

NOTE
0 V-'w ~ must IHl ch&elclldand ad;usllld wh., the engme is
cold f•t room ltlmpenture).
e Remove'
Right Lower Fairing (see Frame chapter}
Coolant Reserve Tank
Pickup Coli Cover
Cylinder Head Cover (see Cylinder Head Cover Removal)
• Using a thickness gauge [A], measure the valve clearance betweon the
roebr arm [B) end the shim [C].
0 When -ltlonlng 114 pilton TDC at the end ollhe compr-lon 1troke:
Inlet valve clearance of #2 and #4 cylinders
Exhaust valve clearance of #3 and #4 cylinders
....
• ; Measuring Volvo
0 When poeltlonlng 111 p181Dn TDC atlhe end of l1e eompr-lon IOirclce:
Inlet valve c learance of #1 and #3 cylinders
Exhaust valve clearance of #1 and #2 cylinders
e ;Measuring Valve
Vatvea..-
s.ndard: IN: 0.18 - 0.23 mm
EX: 0.21 - 0.28 mm
*If the valve clearance is not within the specified range. first record the
clearance, and then adjust it
e To change the valve clearance, slide the rocker arm [A) sideways and
change the ahim [B). Replace the shim with one of a different
thicknesa.
NOTE
0 M•rk •nd rectHd the $him locations so that the m tms can be
reinst•JJad In their origiMI positions.
ENGINE TOP END 4- 17
eTo select a new shim which brings tho valva clearance within tho
specified range, refer to the Valve Clearance Adjustment Charts.
e App/y a thin coat of molybdenum disulfide grease to the rod<er arms.
O Remeasure any valve clearance that was adjusted. Readjust if
necessary.
CAlSTlON
Do not pulshbn olock under the ahbn. This may cause the shbn to
-out at high rpm, causing extensive engine damage.
Do nol grind the shim. This may cauoe H to fracture, causing
eXIenolve engine damage.
4-18 ENGINE TOP EN D
VALVE CLEARANCE ADJUSTMENT CHART

INLET VALVE
·sHIM
PART No. (92180 ·l 11~4 ~ 1~111~11~110~ ,_
MARK ~5580H~7&180l~laot5ooi~1015~M0035~"~
(mm) J L~I uoj2.oo tz.es l 2- ~ l2.75l>.eo j2.&5j2.9o 12.95 13.00 13.0113.1013.11 13.~112513.30 13.3513.~13 ." 13.~
0 .00- 0.03 / / / / 1.00 2.66 1.00 2.16 2.70 2.75 2.80 1.85 2.80 2.95 3.00 3.05 3.10 3.16 3.20 3.26 3.30
0.04- 0.08
0.09- 0.13
0.14 - 0.17
./ ./ ./
v
v
1.~
~/"" 1.50 2.55 2.00 1.05 2.70 2.75 2.90

2.60 2.56 2.00 us 1.70 2.75 2.80 2.~
........
2.65 2.80 2.86 1.70 2.75 2.90 2.85 1.90 2.95 3.00 3.06 3.10 3.16 3.20 3.%6 130 3.36
2.90 2.96 3.00 3.~ 3.10 3.16 3.~
2.96 3.00 3.05 3.10 3.16 3.20 3.25 3.30 3.36

3.M 3.30 3.35
3. ~
·-~
1"
0.18- 0 .23 SPECIFIED CLEARANCE/NO CHANGE REQUIRED
iE 0.2.4 - 0.28 1.55 2.80 2 .85 2 .~ 2.75 2.90 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3 .~ 3.25 3.30 135 1~ 3." 1 3.~1
• 1.70 1.76 2.90 2.85 2.90 2.96 3.00 3.05 3.10 115 3.26 3.00 3.35 3.45 3.50 I
·-~
0.29- 0.33 2.80 1.~ 3.~
t 0.34-0.38 us 2.70 2.76 2.90 2.85 2.90 2.9& 3.00 3.06 3.10 3.15 3.20 125 3.30 3.35 3 .~ 3.46 3.~
us 3.25 3.30 3.36 3.~ 3.45 3.50

·-~
2.70 2.75 2.90 2.85 1.90 3.00 3.05 3.10 3.15
..
0 .39- 0.43
0.44- 0.48 2.75 2.90 2.86 2.90 2.95 3.00 3.06 3.10 3.15 3.10 3.25 3.30 3.35 3.~ 3.45 3. ~
z
w 0.49 - 0.53 2.90 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.. 30 3.35 3.~ 3.46 3.60
:E
w 3.45 3.50
.."'
:>
0.64- 0.68
0.59- 0 .53
~ 0.84 - 0.68
2.85 2.90 1.95 3.00 3.06 S.10 3 .15 3.20 3.26 3.30 3.35
2.90 2.95 3.00 3.06 3.10 3.15 3.~ 3.25 3.00 3.35 3. ~
3.~
3.45 3 .50
.. 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.~ 3.46 3 .~
:E
0 .89- 0.73 3.00 3.05 3 .10 3.15 3.~ 3.25 3.30 3 .35 3.~ 3.45 3.50
u
•..z 0.74- 0.78
0.71- 0.83
3.05 3.10 3.15
3.10 3.15 3.~
3.~ 3.25 3.30 3.36 3.~
3.25 3.30 3.35 3.~ 3.45 3.50

3.45 3.50
...u~
..
...>
0.84-0.88
0.89-0.93
3.15
3.~
3.~ 125 3. 00 3.35
3.25 3.30 3.35 3.~
3.~
3.46
3."
3.~
3.~
INSTALL THE SHIM OF THIS THICKNESS tmml

•> 0.94- 0 .98
0.99- 1.03
3.25 3.30 3.35 3.40 3.45 3.50
3.30 3.35 3.~ 3.45 3.50
1.04- 1.08 3.35 3.~ 3.45 3.50
1.09- 1.13 3.~ 3.46 3.60
1 .14- 1.18 3.44 3.~
1.19-1.23 3.~
1. Measure the clearance (when engine is cold) .

2. Checl< present shim size.
3. Match clearance in vertical column with present shim size in horizontal
column.
4. Install the shim specified where the lines intersect. This shim will give
the proper clearance.
Example: Present shim is 3.05 mm
Measured clearance is 0.35 mm
Replace 3.05 mm shim with 3.20 mm shim.
5. Remeasure the valve clearance and readjust if necessary.
Be sure to remeuure the cSeerance after eelectlng a shim according

to the table. Tho clearance can be out ollhe apeclfted range because
ollhellllm IOlorance.
NOTE
Olf the valve c!eatance is.smaller (target) than the standard. select a
thinner (thicker) shim and then messure the clearance again.
ENGINE TOP END 4-19
VALVE CLEARANCE ADJUSTMENT CHART

L' 2..1 ~ 0- I i) l
-,
1
..., .EXHAUST VALVE
- - .., ~·~ 1:>?
(
~
u "'"'-
J
L,
~
_
' SHIM
~
·A·T~I0-1 1101A 110101
llmml
60 eo 16 70 75 eo 81 to 85 I oo
t.IO 12.16 12.80 IUS 12.70 12.75 l 2.eo 12.85 12.10 12.15 13.00 , .. 10 15 20 21
!10 36 40 4l 10
[3.10 l>.ilIUOii:U [3.30 13.35 13.40 13. 1>.10
0.00 -
0.01-0.10
o..os ./ ./ ./ ./
./ / v
2.60
2.10 2.55 2.10 us 2.70 2 .75 2.10 2.85 2.10 2.se s.oo 0.01 3.10 3.15 3.20
2.!15 2.00 2.11 2.70 1.71 2.10 Z. IS 2.10 2.11 3.00 S.OI 2.10 J. 15 3.20 1.25 1.30 Ul
.... uo
0.11 - 0 .115 I/ / 2.10 255 2.10 2.01 2.70 2. 71 uo 2.15 2.10 2.15 3.0C 3.01 J. 10 1.15 3.20 3.25 3.30 1.31 3.40
0.11 - G..20 I/ 2.10 211 2.10 2.15 2.70 2.71 2.80 1.16 210 2.16 3.00 S.OI J. 10 J.." u o S.2S 3.30 3.31 3.40 l M
G.21 - O.M SPECIFIED CLEARAN CEI NO CHANGE R EQUIRED
iI.
0.%7- 0.31
o.u- 0.311
0.37 - 0.41
2.11 2.10 2..11 2.70 2 .15 2.80 2.1 5 2.80 2.H ••oo • .05 3.10 3.16 • •20
uo 2.N 2.70 1 .75 2.10 2 .15 2.10 2.05 ••00 J.05 S.10 3.15 3.20 us
2.N 2.70 2. 75 2.10 2.15 2.10 2.16 • .00 3.05 3 . 10 1 .15 3.20 3.21 • .30
uo ....
U l J.OO 3.36 3.40 ualo.10 l
1.40 3.46 3.501
1.35 3.40 3.41 3.60
0.42- 0.44 2..70 2 .71 2.10 2.15 2.10 2.95 3.00 3.01 3.10 1 .15 3.20 3.25 3.30 3.:16 3.40 3.48 3.60
0 .47 - 0.51 2.71 2.10 2.11 2.10 2.96 3.00 3.01 3.10 3. 11 3.20 3.25 3.30 3.36 3.40 3.411 3.50
~
"...:1 0.52- OM 2.10 2.18 2.10 Z.H 3.00 3.05 3.10 3. t l 3.20 s.:u 3.30 3.35 3.40 3.46 uo
c 0.17-0.11 us 2.10 2. 18 3.00 3.05 3.10 3. 15 3.20 .3.21 3.30 3.35 3.40 3.41 3.10
:>
•~
.... o.n-
:1
0.12-
0.17 -
o...
0 .71
0.12 - 0.71
2.H 300 3.01 2.10 3.11 3.20 .... .... ....
2.10 2.18 3.00 3.01 3.10 3.1 5 3.20 3.U 3. !10 3.3:1 3.40 3.46 3.10
330
3.00 3.01 3. 10 l .U 3.20 3.ZS 3.30 331 3.40
u o 3.46 2.50
3.50
2 0.11 3.01 3.10 3..15 l.ZO 3.ZS 3.30 3.35 3.40 U ll 3.60
c
c O.az. - O.M 1 .10 1.1 1 1.20 3.25 3.30 3.35 3.40 3.441 J .IO
....~ 0.17- 0.91

o.t2-o.se
1.11 3.20 3.21 3 .30
I .ZO 3.:U 3.30 3.36
3.35 3.40 3"46 3.50
3.40 3.45 3.60
~> 0 .87 - 1 .01 3.21 3.30 3.35 3.40 3.46 3.50
INSTALL THE SHIM OF THIS T HICKNESS lmml
t.oz- 1.oe 3.30 3.35 3.40 3.46 3.&0

1.07 - 1.11 3.31 3.40 3.46 3.60
1.12 - 1.11 3.40 3.441 3.10
1.17 - 121 3.411 3.10
1.22 - 1.21 3. 60
1. Measure the clearance (when engine is cold) .

2. Check present shim size.
3. Match clearance in vertical column w ith present shim size In horizontal
column.
4 Install the shim specified w here the lines intersect. Thos shorn w ill give
lhe proper clearance.
£umplr. Present shim Is 3.10 mm.
Measured clearance is O.AO mm.
Replace 3.10 mm shim w ith 125 mm shim.
5. Remeasure the valve clearence and readjust i f necessary.
Be..,,. to remea...,. the clearance all8r selecting a ahlm according
.....
10 the table. The clurance C8R be oul of the specified range -
-~.
NOTE
Off the valve cltJal'ence Is smaller ( larger) than the stdndard. select a
thinner (thicker) shim end then measure the clearanCtJ again.
4-20 ENGINE TOP END
VaNe RBfTIOVBI
e Remova the cylinder head (see Cylinder Head Remvoal).
e Swing open the rocker arm.
OMIItt and '*"lrd the shim locations so that the shoms can be installed
in lheOr original positions.
e uaing the valw spring compressor assembly, remove the valve.
Special Tooloo - Valve Spmg ~ Auembly: 57001-241 [A]
Vai... SpmgCom-A~r. 4>22: 57001-1202
[B]
Valve Installation
• Replace the oil seal with a new one.
e Apply a thin coat of molybdenum disulfide grease to the valve stem
before valve installation.
e lnalllllthe sp<ings so that the closed coil end faces downwards.
[A] Valve Stern [E] Retainer
(8] Oil Seal [F] Split Keepe.s
(C) Spring Seat [G] Oosed Coil End
(OJ Spring
Valve Guide Removal

e Remove:
Valve (see Velva Removal)
Oil Seal
Spring Seat
• Heet the area around the valve guide to 120 - 160"C (248 - 302
"F), and hammer lightly on the valve guide arbor [A] to remove the
guide from the top of the heed.
S,.Ciel Tool - Valve Guide Art>or, <1>4.5: 57001 ·1 331
Valve Guide Installation

e Apply ool to the valve guide outer surface before installation.
e Heat the area around the valve guide hole to about 120 - 160 ·c (248
- 302 "F).
e Orlw the valve guide in from the top of the head using the valve guide
arbor. The circlip stops the guide from going in too far.
S,.Cial Tool - Valva Guide Art>or, <1>4.5: 57001-1331
e Ream the valve guide w ith valve guide roomer [A] even if the old guide
it reused.
Special Tool - Valva G<llde RearM<, <1>4.5: 57001-1333
Valve-to-Guide Clearsnce Measurement (Wobble Method)

If a ~mall bore gauge is not available, inspect the valve guide wear by l
,_rong the valve to valve guide clearance woth the wobble method
81 indicated below.
e lnaert a new valve [A] into the guide [8 ] and set a dial gauge agamst
the stern perpendicular to it as close as possoble to the cylinder head
mating surface.
e Move the atern back and forth [C) to measure velve/valve guide
clearance.
0 Repeat the measurement in a direction at a right angle to the first.
* II the reeding exceeds the service limi~ replace the guide.
'
ENGINE TOP END 4-21
NOTE
0 Tit. ruding is not actuol volve/ valve guide clearanca because 1/111
mHSuring point is above l/le guide.
Yat.e/Vat.e Guide Clearance (Wobble Me.lhod)
Slandard Service llml
..let 0.031 - 0.113 mm 0.32mm
!lcllauat 0.090- 0.171 mm 0.37mm
Vs/ve StNJt Inspection

e Remove the valve (see Valve Removal).
e Check the valve seating surface [A] between the valve [B) and valve
seat [C] .
OMaewre the outside diameter (OJ of tho seating parte<n on the valve
seat.
*II the outside diameter is too large or too small. repair the seat (see Seat
Repoir).
Yat.a .._... ~ Oulalcle Dlem-
Siandercl: Inlet 28.4 - 28.& mm
ExhMISI 24.4 - 24.8 mm
OMeasure the seat width [E] of the portion where there is no build-up
calbon (white portion) of the valve seat with a vernier caliper.
*If the width Is too wide. too naiTOw or uneven, repair the seat (see
Valve Seat Repair) .
Vol.. SMtlng SurfiCe Width

~: .,le~ Exhaust 0.5 - 1.0 mm
Vllve SBBt Repair

I Repair the valve seat w ith the valve seat cunars.
Special Toole - Valve Seal CUrter Holder, 4>4.5: 57001-1330
Valve Seat Cuner Holder Bar: 57001-1128
(F« Inlet Valve Seal]

ValveS.atCU-,45' - <1>32: 57001·1115
Valva Seat CUtler, 32' - <1>30: 57001·1 120
Valve Seat CuM<, 80' - <1>30: 57001-1123
['or Exhauol Valva Seat]
Valve Seal Cutler, 45' - <1>27.5: 57001·1114
Valve Seal Cutler, 32' - <1>28: 57001 -1111
Valve Seat Cutler, 60' - ~30: 57001·1123
* If the manufacturet's instructions are not available. use the following

PfOOI(Iura.
4-22 ENGINE TOP END
Seat CUtter O~ion Care:

1. This valve seat cutter is developed to grind the valve for repair.
Therefore the cuner must not be used for other purposes than seat
repair.
2. Do not drop or shock the valve seat cuner, or the diamond particles
may fall off.
3. Do not feil to apply engine oil to the valve saat cutter before grinding
the saat surface. Also wash off ground particles sticking to the cuner
with washing oil.
NOTE
ODo not use a wire brush to remove the metalparticlss from the cutter.
It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cuner in
one hand. Do not apply too much force to the diamond portion.
NOTE
0 Prior to grinding, apply engine oil to the cutter and during the
operetkJn. wash off any ground particles sticking to the cutter with
washing oil.
5. After usa, wash it with washing oil and apply thi.n layer of engine oil
before storing.
Marks Stamped on the Cutter.

The marks stamped on the back of the cutter [A) represent the
following.
60' ......................................... Cuner angle [B)
37.5<!>....................•...••.........••0uter diameter of cuner (C)
Operating Procedures:
e Ciean the saat area carefully.
e Coat the seat with machinist's dye.
eFit a 45~ cutter into the holder and slide it into the valve guide.
ePress down lightly on the handle and tum it ri9ht or left. Grind the
seating surface only until it is smooth. Widened width ot
engagement bv machining
CAUTION with 45" cuner
Do not gr1nd the Hat too much. Overgrlndlng will r - . valve 32'
claarenc:e by oinking lha valve Into tile heed. Nlhe valve sinks too far
Into tile head, II wUI be lmpoul>le to adjust lhe clearance, and the
cylinder head must be replaced.
e Measure the outside diameter of the seating surface with a vernier

caliper.
*If the outside diameter of the seating surface is too small, repeat the
45' grind until the diameter is within the specified range.
*If the outside diameter of the seating surface is too large, make the
*"32' grind described below.

the outside diameter of the seating surface is within the specified
range, measure the seat w idth as described below.
e Grind the seat at· a 32' angle until the seat O.D. is within the specified
range.
ENGINE TOP END 4-23
OTo make the 32• grind, tit a 32• cutter into the holder, and slide it into
the valve guide.
OTum the holder one tum at a time while pressing down very lightly.
Check the seat after each tum.
CAUTION
The 3r cutlllr ,..,ovea malarial very qulcl<ly. Checlt the seat outside
dlametarlrequenHy to prevent ove'llrtndlng.
OAtter making the 32• grind, return to the seat 0.0. measurement step
above.
e To measure the seat width, use a vernier caliper to measure the width
ot the 45• angle portion of the seat at several places around the seaL
*It the seat width is too narrow, repeat the 45• grind until the seat is
slighdy too wide, and then return to the seat 0 .0 . measurement step
above.
*"the seat width is too wide, make the eo· grind described below.
*If the seat width is within the spec~ied range, lap the valve to the seat
as described below.
e Grind the seat at a so· angle until the seat width is within the specified
range.
OTo make the so• grind, fit eo• cutter into the holder, and slide it into
the valve guide.
OTum the holder. while pressing down lightly.
o Atter making the eo· grind, return to the seat width measurement step
above.
e Lap the valve to the seat once the seat width and 0 .0 . are within the
ranges specified above.
o Put a little coarse grinding compound on the face of the valve in a
number of places around the valve head.
OS pin the valve against the seat until the grinding compound produces
a smooth. matched surface on both the seat and the valve.
0 Repeat the process with a fine grinding compound.
[A) Lapper
[ B) Valve Seat
[ C) Varve
e The seating area should be marked about in the middle of the valve
face.
*If the seat area is not in the right piece on the valve, check to be sure
the valve is the correct part. If it is, it may have been refaced too much;
replace it.
• Be sure to remove all grinding compound before assembly.
e When the engine is assembled, be sure to adjust the valve clearance
(see Valve Clearance Adjustment).
(
t
START
I I Mec:htnlst's
dyo on seat
J
+
45° Grind
Tool: 46° Cutter
Pur pop: m1ke seating area
smooth tnd round
+
Mtewre Stating Are• 0. D.
Tool: Vernier Caflper
Purpose: chock,.., 0.0.
191innspec.
I
R'jlto
t
I Toosmall I
t l
I OK I I Too big I
; t
I I
45° Grind Machinitt's
Tool: 45° Cutter dye on seat
PurpOJt: increase 0.0. of seat
area to spec.
Tool :
Purpose :
'
32° Grind
32QCutter
reduce 0 .0. of Mit ertl
to spec.
MtiMHt Seat Width

Tool Vern•tr C.ehper
Pll<poso. chedc. seat width
agiiOit spec.
I
Re'i"l"
t t
I Too narrow I
t
I OK I I 't
Toowlde I
Tool:
Purpote:
46° Grind
46° Cutter
Increase width of seat
I Machinist's
dye on seet l
area beyond $p~. to
lncreese 0 .0 .
t
eo• Grind
Tool : so• Cutter
Purpose: reduce Hit w idth
10 SptC.
lop VtiYt
Tools V1tve Iepper, grinding
compound
Purpose: perfectly match valve ( FINISHED l
end seat erea; check
vatve head for damage
ENG IN E TO P END 4 -25
Cyli nder, Pistons
Cylinder Removal
e Remove:
Engine (see Engine Removal/ Installation chapter)
Cylinder Head (see Cylinder Head Removal)
Water Hose
Front camshaft Chain Guide
e Remove the cylinder.
Cylinder Installation
e lnstall the new cylinder gasket (A).
e Apply engine oil to the cylinder bore.
e Prepare two auxiliary head bolts with their head cut.
e lnstallthe two bolts [B) diagonally in the crankcase.
• Position the crankshaft at #2. 113 piston TDC.

e lnstall the cylinder block [A).
[B) Auxiliary HE!ad Bolts
[C) Pistons
Sj>ecfal Tools - Plolon Ring Compressor Grip: 57001-1095
Piston Ring Compressor Bell, <1>67 - <1>79: 57001-1097
Piston Removal
e Remove the cylinder (see Cylinder Removal) .
e Piace a clean cfoth under the pistons and remove the piston pin snap
ring from the outside of each piston.
e Remove the piston pins.
Special Tool - Ploton Pin Puller Assembly: 570cn-910 [A]
e Remove the top and second rings with piston ring pliers.
<r>l
Special Tool - Piston Ring Pliers: 57001·115
e lf the special tool is not available, carefully spread the ring opening
with your thumbs and then push up on the opposit side of the ring
[A) to remove it.
e Remove the 3 · piece oil ring with your thumbs inthe same manner.
4-28 ENGINE TOP END
Piston lnst81/ation
e oo not mix up the top end second ring.
Olnalllll the top ring [ A) 10 that the " R" marl< [ B) faces up.
Olns!all the second ring [C) so thetlhe "RN" marl< [D) faces up.
e The piston ring openings must be ~itioned as shown in the figure.

The openings of the oil ring SIMI reifa must be about 30 - 40" of angle Opening P01ition
fmm the opening of the lOp ring. 30°- 40° 30°- 40°
[A] Top Ring [0) Oil Ring Expander @(~@~)£>

[E] Arrow
©
[B] Second Ring
[C] Oil Ring Steel Rella
e The IIT'OW on the piston head mull point toward the front of the
engine.
II
®®
Do not - ....., rings, n removal weakeno and delonns them.
They could tall out and - • the cy,._ wall.
Cylinder Wear
-""_
e Since there is a difference in cylinder wear in diHerent directions, take
a side-to-side and a front-to-beck measu....,ent at each of the two
toc.tiont (total of four measurements) shown in the figure. t
* If any of thecyfinde< inside diameter measurements exceeds the serviCe
r--· ®
limit, the cyfinde< will have to be bored to oversize and then honed. .
[A] 10 mm ~
[8]60 mm
~
LJ
-,"''"-
Cylinder InaIde Dla_,

&Ia- 73.000 - 73.012 mm
Sefvlce Limit 73.1 mm
ENGINE TOP END 4 -27
Piston Wear
e Measuro the outside diameter [A] of each piston 5 mm [ B] up from
the bottom of the piston at a right angle to tho direction of the piston
pin.
*If the measun!ment is under service limit, replace the piston.
Plolon Diameter
S1andard: 72.942 - 72.958 mm ®
Service Limit 72.8 mm
I I
Piston Ring. Piston Ring Groove Wear

e Check for uneven groove wear by inspecting the ring seating.
*The rings should fit perfectly parallel to groove surfaces. If no~ the
piston must be replaced.
e With the piston rings in their grooves. make several measurements with
a thickness gauge [A] to detennine piston ring/groove clearance.
Pitton Ring/Groove Clearance

Slanderd Service LlmM
Top 0.05 - 0.09 mm 0.19mm
Second 0.03 - 0.07 mm 0.17 mm
Piston Ring End Gap

• Place the piston ring [A] inside the cylinder, using the piston to locate
the ring squarely in place. Set it close to the bottom of the cylinder, ~·
where cylinder wear is low.

eMeasure the gap [B] between the ends of the ring w ith a thickness r r
gauge.
Pitton Ring End Gap
Slandard Service Umh
Top 0.20 - 0.35 mm 0.65mm
Second 0.20 - 0.35 mm 0.65mm i
4-28 ENGINE TOP END
Carburetor Holder
CNbur8tor HoldBr Installation

e lnstallthe carbureto< holder 8S shown in the figure. ru1 1
(A] H~
ENGINE TOP END 4-29
Muffler
MuffiBf R8fTIOval
t Romove:
Coolant (drain, see Cooling System chapter)
Radiator (see Cooling System chapter)
t l.oosen the muffler clamp boh [A).
t Remove the mounting bolt (B) and take off the muffler body (C) .
t Remove:
Muffler Clamp Boh [A)
Holder Nuts (A]

Elchauat Pipe Holders ( 8)
t Romove the exhaust pipe [ C) .
Muffler ln$18/lation
t Replace the exhaust pipe gaskets wittt new o nes.
CLUTCH 5-1
Clutch
Table of Contents
Exploded View ............................................................................................................6-2

Specifications .............................................................................................................. 6 -3
Clutch Fluid .................................................................................................................6 -4
Fluid level lnspection ................................................•....•.......................................S-4
Cluteh Auid Change ................................................•....................•........................•S-4
Bleeding the Clutch line ........................................................................................6 -5
Clutch Master Cylinder ...............................................................................................6 -6
Clutch Master Cylinder Removai ............................................................................S-6
Clutch Master Cylinder Installation .................................................•...•..................6-6
Clutch Master Cylinder Disassembly ...............................................•......................6 -6
Clutch Master Cylinder Assembly .......................................•.....•.....•......................5 -7
Clutch Master Cylinder Inspection (Visual Inspection) ........................................5 -7
Clutch Slave Cylinder ..................................................................................................S-8
Clutch Slave Cylinder Removai ................................•..........•.....•.....•......................S-8
Clutch Slave Cylinder Installation ..........................................................................5-6
Clutch Slave Cylinder Disassembly ........................................................................6 -8
Clutch Slave Cylinder Assembly ..................•..........................................................S-9
Clutch .............................................................•....•......•....•.•.......................................6-1 0
Clutch Removal ............................................................•.............••........................5-1 0
Clutch Installation ............................................................•.••...•.............................6 -10
Clutch Cover Assembly ........................................................................................ 5-13
Spring Plate Free Play M easurement ...................................................................5-13
Spring Plate Free Play Adjustment ......................................•...............................5-14
Clutch Plate, Wear, Damage Inspection ..............................................................5 -15
Clutch Plate Warp lnspection ..........................•....•...............................................S-15
Clutch Spring Free length Measurement ........•...................................................S-15
Damper Cam Inspection .......................................................................................5-15
6-2 CLUTCH
Exploded View
EO: Apply engine oi~anentlocking agent.

l : · Apply
M a no~enum
Apply moly e disulfide grease.
~· tightemng
R· · Replacement Parts . seQ uence.
0
S
si:: Apply
Follow the spec ICse (ex. PBC grease) .
4 silicone grea
(
I
1.0 N-m (O.~g k~:m: 52 in-lb)

k m 9 in-lb)
T1 :
T2: 5.9 N-m (O. k -m, 69 ~n-Ib)
T3 7.8 N-m (g-~ k~-m, 13 in-lb)
T4· 1 5 N-m (1 1 kg -m, 95 in-lb)
T5. 11 N-m ( . -m 87 in -lb)
T6· 9 8 N-m ( 1 O kg .18.0 ft-lb)
n · 25 N-m (2. 5 kg -m, 78 ~n-Ib)
T8: 8 8 N-m (O
90
T9: 135 N-m(14 0 g
~-~. 100 ft-lb)
CLUTCH 5-3
Specifications
ttem St andard Service limit

Recommended Clutch Fluid:
Grade D.O.T4 ---
Brand Castrol Girting-Universal -- -
Castrol GT (LMA) - --
Castrol Disc Brake Fluid ---
Check Shock Premium Heavy Duty ---
Clutch Lever Position 4-way adjustable (to suit rider) ---
Clutch Lever Free Play Non -adjustable ---
Clutch:
Spring plate free play (new plates) 0.05 - 0.35 mm (Usable range) ---
Spring plate free play (no new plates) 0.16 - 0.75 mm (Usable range) -- -
Friction and Slael plate warp 0.2 mm or less 0.3mm
Clutch spring free length 42.9 mm 40.9mm
5i*:lel Tooll - lnalde Cltdlp Pliers: 57001-143

Clutch Holder. 57001·12A3
See1ant - ~-kl Bond (Silicone Sealanl): 56018-120

6-4 CLUTCH
Clutch Fluid
Fluid Level Inspection

eCheck the clutch fluid level in the reseiVOir.
Lower Level Line[A)
Upper Level Line[ B)
NOTE
0 Hold the restNVoir horizon/1JI when checking clutch fluid level.
* If the fluid level is lower than the lower level line. fill the reservoir to the
upper level line in the reservoir.
I • WARNING
Cllange the ftuld In the clutdl line completely If the fluid mutt be
reftllecl bul the type and brand ol the lluld that already lo In the
reearvolr era unldenlllled.
Aftar c:hanglng the ftuld, use only the aeme type and brand of lluld
thereaftar. Milling dlflei'Md types and brands of fluid lowers the fluid
bofllng pclntand could cause the - h to be lnellecllve. H may aloo
causa the rubber ciUich parts to deteriorate.
Recommended Clutch Fluid

Grade: D.O.TA Heavy Duly Brake Fluid
Brand: C4Sirol Glrllng-Unlvenal
CUirol GT (LMA)
C4alrol Dlac Brake Fluid
Check Shoclc Premium Heavy Duty
NOTE
OS!nce the clutch fluid is the same as the brake fluid. refer to Brake
Fluid Section in Brakes chapter for futrher details.
Clutch Fluid Change

e Level the clutch fluid reservoir.
• Remove the reservoir cap.
eRemove the rubber cap from the bleed valve o n the clutch slave
cylinder.
eAttach a clear plastic hose to the bleed valve and run the other end of
the hose into a container.
• Fill the reservoir with fresh fluid.
eChange the clutch fluid as follows:
COpen the bleed valve. [A)
OSqueeze the clutch lever and hold it. [B)
o Close the bleed valve. [ C]
0 Release the clutch lever. [D]
0 Repeat this operation until fresh fluid comes out from the plastic hose
or the color of the fluid changes.
0 Check the fluid level in the reservoir often, replenishing i t as necessary.
NOTE
Off the fluid in the reservoir tuns completely out any time during fluid
changing. the bieading operation must be done since sir will have
enreted the line.
CLUTCH 5-5
8/eeding the Clutch Line

e WIIh the .-voir cap off, slowly pump the clutch teve< several times
until no air bubbles can be seen rising up through the fluid trom the
ho4el at the bonom ollhe reservoir. This bleOOs the"" from the master
cylinder end ollhe line.
NOT E
OTIP the clutch hose lightly going from thelowtN end ro the upper
tnd tnd bleed the air off at the rBServoir.
e Attach a clear plastic hose to the bleed valve on the clutch slave
cyllnde<, and run the other end of the hose Into a containO<.
e Biaad the clutch line as follows:

0 Pump the clutch lever a lew times until it becomes hard and then hold
it aqueezed. [A]
o Quickly open and close the bleed valve. [8]
ORejeesethe clutch lever.[C]
ORepeet this operation until no mont air can be._, coming out in to
the plastic hoee.
OCheclt the ftuid leve4 in the rese<voir often, replenoshing it as necessary.
NOTE
0 If the fluid in the restNVOir runs complerely our MY lime during
bleeding. the bleeding operation must be done over ag1in from t/>8
beginning since air will have antllred the line.
5-6 CLUTCH
Clutch Master Cylinder
Clutch MastN Cylinder Removal

e Oisconnect the starter lockout switch connector (A].
eRemove the banjo bolt (A] to disconnect the clutch hose from the
master cylinder.
e unscrew the clamp bolts [B), and take off the master cylinder (C) as
an assembly w~h the reservoir, clutch lever, and starter lockout switch
installed.
Clutch MastN Cylinder Installation

elnstall the clutch master cylinder so that its mating surface [A]
positions by 5 mm [B) reaiWard from the mating surface [C] of the
sw~ch housing as shown.
OThe master cylinder clamp must be installed with the arrow mark
upward.
OTighten the upper clamp bolt first, and then the lower clamp bolt
Torque - Ctull:h Master cylinder Clamp bolls: 11 N-m (1.1 kg-m, 95
I!Hb)
e Replace the washers that are on each side of the hose fitting with new
ones.
e nghten the clutch hose banjo bolt.
Torque - CIUII:h Hoae Banjo Bolt 25 N-m (2.5 kg-m, 18.0 11-lb)
• Bleed the clutch line (see Bleeding the Clutch line).
Clutch Master Cylinder Disassembly

e Rernove the master cylinder.
e Remove the reservoir cap and diaphragm, and pour the clutch fluid
into a container.
e Unscrew the locknut and pivot bolt, and remove the clutch lever.
e Push the dust oover out of place, and remove the circlip.
Special Tool - InaIde Clrcllp Pllenl: 57001-143
e Pull out the piston (A], secondary cup (B). primary cup [C], and
return spring [OJ.
CLUTCH 5-7
Clutch Msster Cylinder Assembly

t Before assembly, clean all parts including the master cylinde< with
cluu:h fluid 0< alcohol.
CAUTION
Ute only diM: br8ke/clutch t!Uid, llopfopyl alcohol."" d!yl alcohol,
lotciMnlng pel18. Do not ... wry- ~uld to. ciHnlng- pel18.
~. motor ol~ or 8111- pebcleum dlo1lllate win c.UM
- - of - rubber pel18. Ott opllled on any pari win be
dlllcuh lo walh off completely, and will .....,trualty -rto.ate the
ru-. uaed I n - cylinder.
t Apply clutch fluid to the parts removed and to the inne< wall of the
cylinder. Take care not to scratch tho piston or the inner wall of tho
cylinder.
t Check to see that the piston return spring pusheds back the piston to
its rest position when the spring is cO<npressed.
t lnstall the push rod with the dust seal fined into the groove.
OThe push rod round end must be faced inwards.
t l!ae 1 new flat washer on each side of the hose fining.
t Tighten the benjo bolt.
r.,_ - Clutctl Hose Banjo- 25 N..,., (2.5 k~, 11.0 - )
t Foll the ciU1ch fluid into the clutch line and bleed the clutch line (see
Clutch Fluid Change and Bleeding the Clutch Une).
Clutch Msster Cylinder Inspection (Visusllnspection)

t Check that thoro are no scratches, rust or pining on the inside of the
master cylinde< and on the outside of the piston.
*If the maste< cylinder or piston shows any damage, replace them.
tlnspect the primary cup and secondary cup.
*If 1 cup Is worn, damaged. softened (roned), or swollen, the p iston
1118fnbly should be replaoed to renew the cups.
t lf fluid leakage is noted at the clutch lever. tho pi11on assembly should
be replaoed to renew the cups.
t Check the dust cover for damage.
t lf it is damaged, replace it.
t Chec:lt thet the relief and supply pons are not plugged
* If the small relief port becomes plugged. the clutch woll slop Blow the
por11 cleen with compressed air.
t Chec:lt the piston rerum spring for any damego.
* If the spring is damaged. ropalee it.
5-8 CLUTCH
Clutch Slave Cylinder
Clutch Slave Cylinder Removal

eRemove:
Left Lower Fairing (see Frame chapter)
Banjo Bolt [A]
Mounting Bolts [B]
Slave Cylinder [C]
CAIJTlON
lmmedlablly wash -•Y any clutch fluid that spills. It may damage
painted euriacee.
e Perform the following if the clutch slave cylinder is to be removed but

not dis3S1l8mbled.
CAIJTlON
If the clulch alava cylinder Ia removed and left alone, the pio1on will
ba p..hed out by the spring and the clulch fluid will drain oul
0 Remove the clutch slave cylinder from the engine with the hose and
push the piston into the cylinder as far as it will go.
OSqueeze the clutch laver slowly and hold it with a band.
NOTE
0 Holding the clutch levtN keeps the piston from coming out.
Clutch Slave Cylinder Installation

eReplace the washers on each side of the clutch hose fining with new
ones.
• Tighten the banjo bolt.
Torque - Clulch Hoae BanJo Bolt 25 N-m (2.5 k~. 18.0 ft.lb)
e Check the fluid level in the master cylinder reservoir, and bleed the air
in the clutch line.
e Check the clutch operation.
Clutch Slave Cylinder Disassembly

e Using compressed air [A], remove the piston.
OCover the cylinder opening with a clean, heavy cloth [B).
0 Face the opening downwards.
0 Remove the piston by lightly applying compressed air to where the
clutch line fits into the slave cylinder.
If the fluid seal Ia removed from the piston, replace the seal with a
new one. Removal would damage the aaal.
CLUTCH 5-9
i•WARNING
To avoid Mrloua Injury, never p i - your ftngara or palm In front o1
1M cylinder -lng. If you apply high compraaaed air to lhe
cyllnder,lhe plsllln may Injure your hand or llngen.
Clutch Slave Cylinder Assembly

eApply clutch fluid to the outside of the piston and the fluid seal.
elnstall the fluid seal as shown in the figure.
[A] Cylinder [C) Auid Seal
[ B) Piston [D) Spring
CAUTlON
Repl.,. lila lluld - 1 wllh a new one N H wu removed from lhe
pl8ton.
5-10 CLUTCH
Clutch
C/lltch Rsmo~l
e Remow:
Engine Oil (drain, see Engine Lubrication $)'Stem chapte<)
Right Lower Fairing (see Frame chapter)
Coolant A_... Tank (A)
Clutch Cover Bolts [B)
Clutch Cover [C)
Clutch Spring Bolts [A)

Clutch Springt
Clutch Spring Plate [B)
Friction Platee, Steel Plates

Clutch Hub Nut [A)
o Holding me sub clutch hub [ B). remove the nut.
Speclel Tool - Clulch Holder. 57001 ·1243 [C)
e Remow:
Torque Limiter Spring [OJ
Sub Clutch Hub
Toothed Washer
Clutch Hub [E)
Clutch Houting [A]

Collar [B)
Clutch Installation
e When replacing any one of the following parts, adrust the spnng plate
free play (see Spring Plate Free Play Measurement).
Clutch Spring Plate
Friction Plate
Steel Plate
CLUTCH 5-11
e Fit the pins [A] of the drive gear [B] into the holes [C] in the clutch
housing (0].
e lnstall the collar [A] .
e lnstall the clutch hub (A).

e lnstall the toothed washer [B] so that the groove side [C] faces
inward.
eEngege the cam followers [A] (Clutch Hub) with the cams [ B] (Sub
Clutch Hub) .
e Pile up the two torque limiter springs [A] so that their shift angle of
so·. and then fit the spring tongues [ B] in the sub clutch hub (CJ.
5-12 CLUTCH
·~the clutch hub nut w ith a new one.

e Holcling the sub clutch hub, tighten the clutch hub nut
Special Tool - CIUicfl-. 57001-12.43
Torque - Clutch Hub Nut 135 N.., (14.0 ~g..,, 100 ll~b)
e lnstell the friction plates and ateel plates, starting w ith a lnction plate
and artemsting them.
Nn- dry lrlcllon pletes .,.,IIMI platao are lnllallecl, apply engine
oil to the auof8ces of UCh plate to evold clUtch pleta seizure .
0 lnstell the last friction plata [ A) fitting the tangs in the grooves 1n the
housing • shown.
e Apply molybdenum disulfide greaae [A) to the push rod [ B) and

pusher (C) end.
e lnstellthe clutch spring plate and tighten the clutch spring boltS.
Torque - Clutch Spring Bob: 8.8 N.., (0.90 ~g-m, 78 ln-lb}
e Replace the cover gasket with a new one.

e Apply elllcone sealan t to the area (A) where the mating surface of the
crankcase touches the clutch cover gasket
Sealant - Kawauki Bond (Sit" ' - S..lant): 56019-120
CLUTCH 5-13
e lnstall the clutch cover [A].

e Apply a non-pennanent locking agent to the threads of the two clutch
cover bolts (B].
• T~ghten the clutch cover bolts.
Torque - Clutch Cover Bolla: 9.4 N-m (1 .0 k!l-fTI, 87 ln-lb)
Clutch Cover Assembly

e Apply silicone sealant [A] to the clutch cover as shown.
Sealant- Kawa.ukl Bond (Silicone Sealant): 5601&-120
e Replace the damper cover gasket with a new one.
e Apply a non-pennanent locking agent to the threads of the damper
bohs, and tighten them.
Torque - Clulch Cover Damper Bol1a: 9.8 N-m (1 .0 kg-m, 17 ln-lb)
Spring Plate Free Play Measurement

Insufficient clutch free play will cause the engine braking effect to be
more sudden, resulting in rear wheel hop. On the other hand, if the free
play is excessive, the clutch lever may feel "spongy" or pulsate when
pulled.
e Remove oil from the clutch plates.
e Hold an extra drive shaft in a vise and install the following clutch parts
on the shalt
[A] Collars
[ B] Drive Sprocket
[ C] Clutch Housing
[OJ Clutch Hub
[ E] Sub Clutch Hub
[F] Friction Plates and Steel Plates
[G] Spring Plate
5-14 CLUTCH
• Engege the cam followers (Clutch Hub) with the cams (Sub Clutch
Hub).
e To ,_,.1M free play, set a dial gauge [A] "9••nst the raiSed cente<
[B] of the clutch spring plate.
e M 011e the clutch housing gear back and forth [C] . The dtfference
between the highMt and lowest gauge readings is the amount of free
play.
[D] Drive Shalt
Spring Plate Free Play Adjustment

e When using all the original clutch plates, do the following.
0 M easure the spring plate free play (see Spring Plate Free Play
M easurement).
Spring Plate F,... Play (With original friction plat. .)

Uoable rMge: 0.15 - 0.75 mm
* "the free play Ia not w ithin the usable range, chonge all of the friction
plates.
• When replacing all the friction plates, do the followtng.
0 Install the Ileal plates and all the new friction plates '" the houSing
tempo<anly for measurement purpose (Standatd Steal Plate: 2.3 nvn
~~~~ w e and 2.0 mm or 2.6 mm th.,._ x 1).
0 Measure the apnng plate free play (see Spring Plate Free Play
Measurement.
Spring Plate F,... Play (With aU new lriction plates)

Uoable range: 0.05 - 0.35 mm
* If the free play Is not w ithin the usable range, change one of the steel
plates to a thick er o r thin ner o ne to get the correct free play.
SteeiPiatee
ThlckneH (mm) Pat1 Number
2.0 13089-D26
2.3 13069·1004
2.6 13069·1087
CLUTCH 5-15
Clutch Plate, Wear. Damage Inspection

e vis<oally inspect the friction and steel plates for sogns of seizure,
ov.heating (discoiO<ation), 0< uneven wear.
* If any pla1es show signs of damage. replace them w1th new ones.
Clutch Plate Warp Inspection

• Place each friction plate or steel plate on a surface plate and measure
the gap between the surface plate [A) and each friction plate or steel B
plate [B) w ith a thickness gauge [C]. The gap is the amount of
friction or steel plate warp.
* If any plate is warped over the service limil. replace 11 wnh a new one.
frlcllon and s-1 P18te Warp

S~Mdarc!: 0.2 mm or lea
S.nlce Limit 0.3 mm
Clutch Spring Free Length Measurement

• Measure the free lef'lgth of the clutch springs (A ].
*If any spring Is shorter than the sOfVice limit, it must be replaced.
Clutch Spring FI'H Length

Sllmd•rd: 42.9 mm
Service Unll: 40.9 mm
DIIITipef Cam Inspection

e Remove the clutch (see Clutch Removal).
e Visually inlf)8Ct the damper cam [A], cam follower [ 8], and the torque
limiter spring [ C].
e Replacethe part if it appears damaged.
ENGINE LUBRICATI ON SYSTEM 6-1
Engine Lubrication System

Table of Contents
Engine Oil Flow Chart .................................................................................................6 · 2

Exploded View ............................................................................................................6 -4
SpecifiCations ..............................................................................................................6 -5
Engine Oil and Oil Filter ..............................................................................................6 -6
Oil Level Inspection ................................................................................................6 -6
Engine Oil Change ..................................................................................................6 -6
Oil Filter Change .....................................................................................................6 -7
Oil Cooler.....................................................................................................................6 -8
Oil Cooler Removal .................................................................................................6 -8
Oil Cooler Installation .............................................................................................6 -8
Oil Pan .........................................................................................................................6 -9
Oil Pan Removal .....................................................................................................6 -9
Oil Pan lnstallation ..................................................................................................6 -9
Oil Pump ...................................................................................................................6-10
Oil Pump Removal ........................................................... .....................................6-1 0
Oil Pump Installation ............................................................................................6- 10
Oil Pressure Measurement ........................................................................................6 -11
Relief Valve Opening Pressure Measurement ......................................................S-11
Oil Pressure Measurement ....................................................................................B-11
6-2 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
1. Oil Screen
2. Oil Pump Main Rotor
3. Oil Pump Subrotor
4. Relief Valve for Main Oil
Passage
5. Oil Passage to Oil Filte<
6. Oil Fiher
7. Oil Passage from Oil Filter
8. Main Oil Passage
9. Oil Hose to Cylinder Head
10. Left Side Cylinder Head
Cover
11. Camshaft Caps
12. Camshafts
13. Rocker Shafts
14. Oil Nozzle
15. Alte<nator Shaft Oil Pipe
16. Alte<nator Shaft
17. Alternator
18. Electric Starter
19. Relief Valve for Oil Cooler
20. Oil Passage to Oil Cooler
21 . Liquid Cooled Oil Cooler
22. Water Hoses
(see Coolant Flow Chart)
23. Oil Pan
24. Crankshaft
25. Oil Pipe for Transmission
Shafts
26. Drive Shaft
27. Output Shaft
28. Oil Pipe for Gears
29. Oil Return Hose .. HotOil
30. Oil Pressure Switch ¢:J ColdOil
31. Oil Pump Sprocket .,__ __ Blowby Gas
32. Breather Hose
33. Air Cleaner Housing Oil Flow : CD->@
34. Water Pump
35. Oil Drain Plug
1
ENGINE LUBRICATION SYSTEM 6- 3

1.: Apply a non-permanent locking agent
''
T1 : 20 N -m (2.0 kg-m, 14.5 ft-lb)

T2· HancHight Of 9.8 N-m (1.0 kg-m, I
87 in-lb)
TJ: 25 N-m (2.5 kg· m, 18.0 1!-lb)
T4: 12 N-m (1 .2 kg-m, 104 in· lb)
®
TS: 16N-m (1 .5kg-m, 11.011-lb)
T6: 49 N -m (5.0 kg-m, 36 ft-lb)
T7: 2.5 N -m (0.25 kg-m, 22 in -lb)
T8: 9.8 N -m (1 .0 kg-m, 87 in-lb)
T9: 34 N -m (3.5 kg -m, 25 ft-lb)
Exploded View
A.....Ju engine~nent
EO: ,.,....., oil. locking agent.
Apply. 000·~··-
l: _,..,, Parts
R: Rep! 'licone sealant.
SS: Applyll
@SS
T1 : 20
T2: N-~ <2 ·0or~~"'N-m·
Hand·bgh1
14 5 ft-lb)
(1.0 kg-m.
87 in·lb) · m 8.0 ft· lb)

T3: 25 N-m (2.6 kg 1 in-lb)
• 104
T4· 1 2
12 N·m < · kg-m, 11 o ft· lb)
T6: 16 N·m (1. 5 kg-m. 36·ft.lb)
60
~,;, S7
T6: 49 N-m < · kgk· m;, 22 in-lb)
T7: 2.6 N·m (0. 25 in -lb)
TS· 9.8 N-m <1·0 kg •25 ft-lb)
T9: 34 N-m (3.5 kg· m,
ENGINE LUBRICATION SYSTEM 6-5
Specifications
Item Standard
Engine Oil:
Grade SE. SF. or SG class
Viscosity SAE 10W- 40. 10W· 50. 20W-40, or 20W- 50
Capacity 3.4l (when fitter is not removed)
3.5l (when fitter is removed)
4.0l (when engine is completely dry)
level Between upper and lower level lines
011 Pressure Measurement:
Relief valve opening pressure 430 - 590 kPa (4.4 - 6.0 kg/em•, 63 - 86 psi)
Oil pressure @4,000 r/min(rpm),
oil temp. 90' C(194' F) 305 - 365 kPa(3.1 - 3.7 kg/em•. 44 - 53 psi)
Spectool Toolo - 011 fln.r Wrench: 57001·12At

011 p , _ . . G.uge, 10 kg/em': 57001 ·1414
011 p _ , . G.uge Ado~*<. PT :4: 57001·1033
~ Dltver Set 57001·1128
SMiaoll - Kaw- Bond (Silicone SMIIInt): ste)1t-120
Engine Oil and Oil Filter
••WARNING
__..oil
Motooc,cle opeoallon wllllnldllclenl, ~111 looa'-<1, o r - -
w l l - eccele.- waar- may ,.....KIn
hnem...lon eetzur., accldeuC, and InJury.
or -lne
Oil Level Inspection

e Check that the engine oil level is between the upper [A) and lower
[B) levels in the gauge.
NOTE
OS/tuete the motorcycle so that it is pt!l"pendiculer to the ground.
Off the motorcycle hes just been used. wait several minutes for ell the
oil to dr11ln down.
0 If th• oil hils ju$1 bHn ch11nged. stert the engine end run It for sevt!l"lli
minutes er Idle speed. This fills the oil filre< with otl Stop the engine.
then w11it seven/ minuttJS until the oil seales.
Racing.,. -lne belorellle oil~ evarypertcan cauoe -Ina

oelzure.
N.,. -lne oil geta ell1remely low or IIIIa oil pump or oil .,....g..
clog up or olherwloe do nol function proparly, lila oil pre11ura
wamlng light will light. N IIIIa light lla)'l on when lila engine II
running abovaldle -ad, 1top llle engine Immediately and ftnd the
CIJUM.
Engine Oil Change

e SuJ>pon the moton:ycle perf)endicular to the ground after wannong UJ>
the engine.
e Remove the engine drain f)lug [A) to drain the oil.
0 The oil in the oil fiHer can be drained by removing the filter (see Oil
Filter Change).
*Replace the drain J>lug gasket [B] with a new one if it is damaged.
e Tighten the drain plug.
Torque - Engine Drain Plug: 20 N-m (2.0 kg·m, 14.5 ft·lb)
e Pour in the specified type and amount of oil.
Engine 011
-
Gr..w. SE. Sf' or SG claU
Vllcoally: SA£ 10W40, 10W50, 20W40, or 20W50
SA L (- I I - Ia not removed)
3..5 L (When II... Ia remcved)
4.0 L (w'- _ .... Ia cornplelely dry)
ENGINE LUBRI CATION SYST EM 6-7
Oil Filter Change

e Orain the engine oil <- Engine Oil Change).
• Remove:
Left Lower Fairing (sea Frame chapter)
011 Pipe Flange Bolt [A] and Oil Pipe [B)
e Remove the oil filter [C) with the oil filter wrench [OJ .
Special Tool - 011 Filler Wrench: 57001·1249
• Replace the filter w ith a new one.

e Apply engine oil to the gasket before insuollation.
e Tighten the filter with the oil filter wrench or w ith hands about% turns
after the gasket contacts the mounting surface of the engine.
Torque - 011 Finer: 9.8 N·m (1.0 kg-m, rrt Jn.lb) or Hand-light
e Apply engin e oil to the 0 -rlng on the oil pipe, and tighten the oil pipe
flange bolt.
Torque - 0 11 ~ Flengellol: 1.8 K-m (1.0 IIQ-<n, 87 ln-lb) or Han0-41ght
e Pour in the specified type end amount of oil (sea Engine Otl Change).
Oil Cooler
Oil Coolttr Removal

e o,.rn:
Engine Oil (- Engine Oil Change)
Coolent <-Cooling System chapte<)
e Remow the oil cooler hoee [A] from the ntdiator.
e Remove:
Oil Cooler Bolt [A)
Oil Cooler [B)
e Remove the oil cooler hoses [A] from the oil cooler.
Oil Cool8f Installation

e lnstllllation le the reveree of removal. Note the following.
e lnstall the oil cooler oo that the crankcase rib [A) fits the slot [ B) of the
oil cooler.
e Apply engine oil to the oil cooler bolt and tighten h.
TO<que - 011 Cooler Bolt 48 N-m (S.O kg-m, 36 ft.lb)
* If the muffler is not removed, the oil cooler bolt can be tightened to the
specified torque using a wrench and a hand spring scale. Pull the
wrench at a point of 300 mm from the center of the bolt with the spring
scale unit It indicates 17 kg.
e Pour:
Engine Oil (see Engine Oil Change)
Coolant (see Cooling System chapter)
Oil Pan
Oil Pan Removal

e Drain:
Engine Oil (see Engine Oil Change)
Coolant (see Cooling System chapter)
e Remove:
Muffler (see Engine Top End chapter)
Down Tubes (A]
Oil Hose [A]

Oil Pan Bolts (B]
Oil Pan (C)
ORernove the oil pipe [A), oil pressure relief valves [B) and oil screen
[C) as necessary.
Oil Pan Installation

e Replace the oil pan gasket whh a new one.
e Replace the 0-ring (A] with a new one if it is damaged. The 0 -ring
between the oil pan and the crankcase must be installed with the flat
side (B) facing the crankcase.
e Apply a non -permanent locking agent to the threads of the relief valves
(A), and tighten them.
Torque - 011 Preuure Relief VaiYes: 15 N-m (1,5 k!J-m, 11.0 11-lb)
elnstall the oil screen so that the crankcase rib [B) fhs the slot (C) of
the oil screen.
e Tighten the oil pan bolts.
Torque - 011 Pan Botta: 12 N-m (1.2 kg-m, 104 ln-lb)
Oil Pump
Oil Pump RtJmOvsl

• Drain the engine oil (aee Engine Oil Change)
• Remove:
Right ~ Fairing ( - Frame chapter)
Clutch c- Clutch chapter)
Alternator Chain (aee Crankshaft/Transmission)
Oil Pump 8ott. [A]
Oil Pump Aatembly [8]
Oil Pump Installation

OWhen ~ing the needle bearing [A] into the pump cover [8], align
the ~2.6 mm hole [C] in the bearing w ith the <1>3.0 mm hole [OJ in
the oov..
~Toot - ketlng DrMrSet: 57001-1121
•Install the main rotor [A] and the pump body [B] onto the pump shaft
[C].
• Install the pin [0] into the pin hole [E].
• Install the subrotor (A) so that the mart< [B] on the sub<otor aligns
with the pln [C).
• Install the pump cover (A] .

• Tum the oil pump shaft so that the pump shalt P«>J8CIIOO [ B] lrts the
slot (CJ rn the end of the water pump shalt.
• Apply 1 non·permanentloclting agent to the threads ol the ool pump
bolts. end tighten them.
To~ - 011 Pump Bolla: 12'1kn (1.2 kg-m, 1041n·lb)
Oil Pressure Measurement
Relief Valve Opening Pressure Measurement

NOTE
0 Measure the oil pressure before the engine is warmed up if you want
to t11st rofil!f valvo op~~ning prossurs.
eRemove:
Right Lower Fairing (see Frame chapter)
Oil Pressure Switch
eAnach the oil pressure gauge (A] and adapter [B] to the oil pressure
switch hole.
Special Tools - 011 Pressure Gauge, 10 kg/an": 57001-184
011 Pressure Gauge Adapter, PT %: 57001·1033
To prevent a flre, be sure to kHP the on pressure gauge hose away

from the eJdlauot .,_,..
e Read the maximum oil pressure while running the engine at various
speeds. A normal relief valve keeps the maximum oil pressure between
the specified values.
Relief Valve Opening Prnslll"8

Slandard: 430 - 590 kPa (4A - 6.0 kg/an2 , 63 - 85 pal)
*If the reading is much higher than the standard or is much lower than
the standard, check the left relief valve. the oil pump. or the oil
passages.
e Apply silicone sealant to the oil pressure switch, and tighten it.
Sealant- Kawasaki Bond (Silicone Sealant): 56019-120
Torque - 011 Pre01ure Swlll:h: 15 N-m (1.5 kg-m, 11.0 ft..lb)
Oil Pressure Measurement

NOTE
0 Measure the oil pressure aher the engine is warmed up.
eAtl<lch the oil pressure gauge and adapter to the oil pressure switch
hole (see Relief Valve Opening Pressure Measurement) .
To prevent a lire, be sure to keep the oil pressure gauge hose away
from the exhaust pipe.
011 Pressure
Standard: 305 - 365 kPa (3.1 - 3.7 kg/em•, 44 - 53 psQ
@4000 r/mln (rpm), 90'C (194'F) ol oil temp.
*II the oil pressure is much lower than the standard, check the oil pump.
left relief valve, and/or crankshaft bearing insert wear immediately.
e lnstall the oil pressure switch (see Relief Valve Opening Pressure
• Measurement) .
ENGIN E REMOVAL I INSTALLATION 7-1
Table of Contents
Exp loded View ............................................................................................................7-2

Specifications ..............................................................................................................7 -3
Engine Removal/lns1allation .......................................................................................7-4
Eng ine Removal ......................................................................................................? -4
Engine Installation ..................................................................................................7 - 5
7-2 ENGINE REMOVAL / INSTALLATION
Exploded View
l
\~
T1 : 49 N-m (5.0 kg-m. 36 ft-lb)

T2: 44 N-m (4.5 kg-m, 33 ft-lb)
T3: 9.8 N-m (1 .0 kg-m, 87 in-lb)
T4: 59 N-m (6.0 kg -m, 43 ft-lb)
7-4 ENGINE REMOVAL I INSTALLATION
Engint1 Removal
e Remove:
Engine Oil (Drain, see Engine LubriGation System chapter)
Coolant (Drain, see Cooling System chapter)
Clutch Slave Cylinder (see Clutch chapter)
Air Clean~~< Housing (see Fuel System chapter)
Ignition Coils (see Electrical System chapter)
Carbt.lretors (see Fuel System chapter)
Fuel Pump (see Fuel System chapter)
Baffle Plate on the Cylindllf Head Cover
Oil Cooler Hoses
Muffler (see Engine Top End chaptllf)
Shift Pedal
Engine Sprocket (see Final Drive chapter)
• DIICOnnect wiring from the engine and free them from the clamps.
Pickup Coil Lead and Oil Pre88ura Switch Lead Connector [A)
Banery Ground Lead (B)
Staner Motor Lead [C)
Side Stand Switch Connector
Altemator Lead Connector [D)
Neu!rtll Switch Connector
e Suppon the rear pan of the frame on the jack [A].

Special Tool - Jacl<: 57001·1238
e Squ-e the brake lever slowly end hold it with a band.
e Remove:
Front Engine Mounting Bolts [B) and Brackets [C)
Down Tube Bolts [D)
Down Tubes [E)
e Suppon the engine with a stand [A).

• Remove the nuts [B) from the rear engine mounting bolts.
ENGINE REMOVAL I INSTALLATION 7-5
e Loosen the engine mounting locknuts [A]. using the socket wrench
[B] .
Special Tool - Socket Wrench: 57001·1347
e Screw back all the engine collar bolts (C) for clearance around the
engine.
e Remove the rear engine mounting bolts.
NOTE
0 The drive chain will be removed from the output shaft when
removing the engine.
e Uft up the engine and move it to the right to free the output shaft from
the drive chain.
e Remove the engien.
Engine Installation
eBefore engine installation, install the collar bolts and then screw back
them fully.
e Hang the drive chain over the output shaft just before moving the B
engine into its final position in the frame.
e lnsert the rear mounting bolts from the left side of the engine. Leave
them protruding about 55 mm (A] as shown.
®
(B] Collar Bolt
B
(C] Collar
[OJ Rear Mounting Bolt (Upper)
[E] Rear Mounting Bolt (Lower)
(F] Engine
e lnstall:
Down Tubes
Front Engine Mounting Bolts, Nuts and Brackets (temporarily)
Torque - Down Tube Bolts and Nuts: 44 N-m (4.5 kg-m, 33 fl.lb)
Engine Collar Iloilo: 9.8 N-m (1.0 kg-m, 87 ln-lb)
e Tighten the engine mounting locknuts. engine mounting bolts and
nuts.
Special Tool - Sodcet Wrench: 57001-1347
Torque - Engine Mounting locknuts: 49 N-m (5.0 kg-m, 3611-lb)
Roar Engine Mounting Bolts and Nuts: 59 N-m (6.0 kg-m, 43
ft.lb)
Front Engine Mounting Bolts and Nuts: 44 N-m (4.5 kg..m, 33
11-lb)
elnstall the removed parts (see appropriate chapters).
e Adjust:
Throttle cables (see Fuel System chapter)
Choke Cable (see Fuel System chapter)
Drive Chain (see Final Drive chapter)
C RANKSHAFT I TRANSMISSION 8-1
Crankshaft I Transmission
Table of Contents
Exploded VifrN ..........................................................8 -2 Start..- Clutch Ass«nblv .....................................8· 1 7

Specifications ............................................................8 -4 Alternator Shaft Chain W881 ..............................8 -17
Crankcase Splitting ...................................................8-6 Chain Guide Wear ..............................................8-18
Crankdlse Splining ...............................................S-6 Starter Clutch lnspectlon ....................................S-18
Crankc.ase Assembly .............................................8 -6 Starter Motor Idle Gear ........................................... 8 -19
Crankshaft and Connecting Rods .............................S-8 Starter M otor Idle Geer Removai .......................S-19
Crankshaft Removal .............................................. 8 -8 Starter Motor Idle Gear Installation ......•............8-19
Crankshaft lnstalladon ......................................... .8 -8 Transmission .... ..... ...................................................S-20
Connec1ing Rod Removal ..........•..........•..•....•....•.8-8 Shift Pedal Removai .................•...........•.............S-20
Connecting Rod Installation ................................8 -8 Shift Pedal l nstallauon .......................................8 -20
Connecting Rod Big End Searing External Shift Mechanism Removai... ................S-20
lns""/Crankpin W ear .......................................8 -1 1 External Shift Mechanism Installation ...............8 -21
Crankshaft Main Searing Insert/Journal Wear ..8-12 External Shift M echanism Assembly ..... ............8 -22
Crankshaft Side Clearance ..... ............................ 8 - 14 Transmission Shaft Removal. ........ .....................8 -22
Alt8mator Chain I Alternator Shaft 1 Transmission Shaft lnatallation .........•................8-22
Sta- Clutch ........................................................8-15 Transmission DtSaSSembly .................................8 -22
Alternator Chain Adjustment..............................S-15 Transmission Ass«nblv ......................................8 -22
Alternator Chaon Removal ..............•............•......8-1 5 Shrft DI\Jm and Fork Removai ........................•. .S-23
Alternator Chain Installation .............................•8-16 Shift Drum and Fori< lnstallation ........................8 -23
Alternator Shaft. Starter Clutch Removai. ..........S-16 Shfit Drum Disassombly .....................................8 -24
Alternator Shaft, Starter Clutch Installation .......8 -17 Shfit Drum Assembly .....................................•...8-24
Starter Clutch Disassembly ................................8 -17
8-2 CRANKSHAFT I TRANSMISSIO N
Exploded View
Do not apply any grease.
UpperCase
1
®
Lower Ca$e
T1 : 12 N-m (1 .2 kg-m, 104 in-lb)

T2: 25 N-m (2.5 kg -m, 18.0 ft-lb)
T3: 44 N-m (4.5 kg-m, 33 ft-lb)
T4: 27 N-m (2.8 kg·m, 20 ft-lb)
T5: 20 N-m (2.0 kg ·m, 14.5 ft·lb)
T6: See the text.
T7: 15 N-m (1 .5 kg-m, 11.0 ft·lb)
T8: 4.9 N-m (0.50 kg -m, 43 in-lb)
T9: 9.8 N-m (1.0 kg-m, 87 in -lb)
TlO: 125 N·m (13 kg -m, 94 ft-lb)
TRANSMISSION 8-3
= =======::=~~~~~~C~
RA~N~K~SH~A~FT~~=======
I
8-4 CRANKSHAFT I TRANSMISSION
Specifications

Alternator Chain:
Alternator chain 20 link length 158.8 - 159.2 mm 159.8mm
Crankshaft, Connecting Rods:
Connecting rod big end side clearance 0.13- 0.38 mm 0.6mm
Connecting rod big end bearing insert/crankpin clearance 0.036 - 0.066 mm 0.10mm
Crankpin diameter: 34.984 - 35.000 mm 34.96mm
Marking None 34.984 - 34.992 mm ---
0 34.993 - 35.000 mm ---
Connecting rod big end bore diameter: 38.000 - 38.016 mm ---
Marking None 38.000 - 38.008 mm ---
0 38.009 - 38.016 mm ---
Connecting rod big end bearing insert thickness:
Brown 1.475 - 1.480 mm ---
Colorless 1 .480 - 1 .485 mm ---
Blue 1.485 - 1 .490 mm ---
Connecting rod big end bearing insert selection:
Con-rod Big End Crankpin Diameter Booring Insert
Bore Diameter
Mal1<ing Marking Size Color Part Numbef
None 0 Brown 9202B-1714
None None Colorless 92028-1713
0 0
0 None Blue 92028-1712
Connecting Rod Bolt Stretch

(Usable Range)
New connecting rod 0 .20 - 0.32 mm ---
Used connecting rod 0 .24 - 0.36 mm -- -
Cnlnkshaft side clearance 005- 020mm 0 .40mm
Cnlnkshaft runout TIR 0.02 mm or less TIR 0.05 mm
Crankshaft main bearing insert/
journal clearance 0.020 - 0.044 mm 0.07mm
Crankshaft main journal diameter. 32.984 - 33.000 mm 32.96 mm
Marking None 32.984 - 32.992 mm ---
1
Crankcase main bearing bore diameter:
32.993 - 33.000 mm
36.000 - 36.016 mm
---
---
Marking 0
None
36.000 - 36 008 mm
36.009 - 36.016 mm
---
---
Cnlnkshalt main bearing insert thickness:
Brown 1 490- 1.494 mm ---
Colorless
Blue
1.494 - 1.498 mm
1.498 - 1.502 mm
---
---
Crankshaft main bearing insert selection:
Crankcase Main Crankshaft Main Bearing Insert'
Bearing Bore Journal Diameter
Diameter Marking Marking Size Color Part Number Journal Nos.
92028-1717 1. 3. 6
0 1 Brown
92028-1720 2. 4
None 1 Colorless 92028-1716 1. 3. 6
0 None 92028-1719 2. 4
None None Blue 92028·1715 1. 3. 5
92028-1718 2.4
'The bearing inserts for Nos. 2 and 4 journals have an oil groove. respectively.
CRANKSHAFT I TRANSMISSION 8-6
Item Standard Service l .i mit

Transmission:
Shift fork ear thickness 5.9 - 6.0 mm 5.8mm
Gear shift fori< groove width 6.05 - 6.15 mm 6.25 mm
Shift fork guide pin diameter 7.9 - 8.0mm 8.1 mm
Shift drum groove width 8.05 - 8.20 mm 8.3mm
Special Toots - Outolde Clrcllp Pllera: 57001·144

S..rlng Driver Set: 57001·1129
lnelde Clrcllp Pl'-ra: 57001·143
s.a•nt - Kawaoakl Bond (Silicone Sealant): 5601t-120
Crankcae Splitting
Ctsnkcast~ Splitting
e Remove me engine <-Engine Removal/Installation chapter)
e Set me engiM on a clean surface and hold the engine steady while
peru .,. being removed.
e Remove:
Clutch <- Clutch chapter)
<-
Alternator Chain A~emator Chain Removal)
Oil Pump<- Engine lubrication System chapter)
Pickup Coil < - Electrical System chapter)
* If the crankshaft iato be removed. remove the pistons (see Engine Top
End chapter).
*If the alternator shaft is to be removed. remove the following.
Alternator
Altemator Coupling <-Alternator Shaft. Starte< Clutch Removal)
e Rernove me upper crankcase bolts.
0 Finotlooeen the 6 mm bolts.
6 mm Bolt$ (A]
8 mm Bolt$ [ B]
• Remove the lower crankcase bolts.

0 First looaen the 8 mm bolts.
6 mm Bolte [A)
8mm Bolt [B)
9 mm Bolts [C]
e Tep lightly around the crankcase mating surface with e plastic melle~
and split the crankcase. Take care not to damage the crankcase.
Crankcast~ Assembly
The . _ r 8nd lower cnnkcue halves .,. machined at the lectory

In the - b l e d slllll, ao the crankcase helv• muel be replaced
•eaML
eWith a high -flesh point solvent. clean off the m ating surfaces of the
crankcases halves and wipe dry.
e Uaing compreaed air. blow out me oil passages in the crankcase
halves.
e lnstall:
Camshaft Chain (A]
Crankshaft end Connecting Rods [ B)
Alternator Shaft and Starter Clutch Assembly [C]
St111er Motor Idle Gear Assembly [ OJ
T,.,.,ialon Oil Pipe [ E)
Dowel Pins [F]
Nouleand 0 -ring (G]
Plug [ H)
Set Pins [I]
Set Rings (J]
Transmission Shafta and Gears
Shift Drum
Shift Forks and Shift Rods
e Before fitting the lower case on the upper case. check the followong.
0 Be sure 10 hang the camshaft chain [A] on the crank.shafl.
oCheck !he nozzle [8] so tha11he bigger diameter sode faces upward.
o Checlt to - !hat the shill drum and ttansmossoon gears are in !he
neutral paaotoon.
e Apply silicone real ant (A]to the mating surface of the lower crankcase
half.
Sealant - Kawaaeld Bond (Silicone Seelent): 56018·120
~ ; ..
if
~-
!
lj
e Tighten the lower crankcase bolts.
0 Following the sequence numbers on the lower crankcase half. tighten
the 9 mm bolts [A].
Torque - Cnl'*ca•• e mm Botll: 44 H-m (4.5 kg-m, 33 Mbl
OTighten the 8 mm bolt [8].
Torque - Cnlnkcaae 8 mm Bon: 'r1 N-m (2.8 kg-m, 20 fl·lb)
OTighten the 6 mm bolts [C].
Torque - cn.-caae 6 mm Bolla: 20 N-m (2.0 kg-m, 14.5 fl4bl
e Tighten the upper crankcase bohs.

Torque - Crankcaae 8 mm Bolli (A]: 'r1 H-m (2.8 kg-m, 20 ft.lb)
Crankcaae 8 mm Bolli [ B]: 20 H-m (2.0 kg·m, 14.5 11-lbl
e Aftertightening all crankcase bolts. check the following otems.

O Orive shell and output shafls tum freely.
O While spinning the output shaft. gears shill smoothly from the 1st to
6th gear, and 6th to 1st.
OWhen the output shaft stays still the gear can not be shofted to 2nd
gear or other higher gear positions.
Crankshaft and Connecting Rods
Cranksh8ft RBmOvsl
e Split the cr~ <- Crankcase Splitting).
• R~ the cnnlclllaft.
Crankshaft Installation
CAliTlON
If the cr•'*lhell, bMring Jnserto, or c,.n~cca. helv. . ere NPI8ced
wl1h M W - Mlecllhe ~ Jnserto--
......... -led.
• plaiUgiiJ8-. -..bUng -ine c...,.,_
lo beaure the cor.-~
wl1h
e Apply angina oil to the crankshaft main bearing inserts.

e lnotall the crankshaft with the camshaft chain hanging on iL
ConnBCting Rod RBTTioval

e Spllt the crankcase (see Crankcase Splitting).
• Remove the connecting rod nuts.
e Remove the crankshaft.
NOTE
0 M1rl< 1nd r1e0rd the locations of thtl connBCting rods Md their big
lnd caps so th•t they can be fHSStJmbi«J in their orlgln111 positions.
• Remove the connecting rods from the crankshaft.
Connacting Rod Installation

CAliTION
To mlnlmln vlbrdon, • fH1Ir of connecting rode (Jell two roda or right
two) ahould hevallle arne -lght merit.
Big End Cap [A]

Connecting Rod (B]
Weight Mark. Alphabet (C]
Diameter Mark [OJ
e lf the connecting rods, big end bearing inserts, or crankshaft are

replaced with new on.. select the bearing insert and check clearance
with a plast!Qage before assembling engine to be sure the COtTect
bearing onseru are installed.
e Apply molybdenum disulfide grease to the upper inner surface of the
connecting rod big end.
e Appty eng1ne oil to the inner surface of upper and lower bearing
inserts.
Apply molybdenum disulfide grease [A].
Do not apply grease [B].
011 [C].
O The connecting rod big end is bolted using the - plastic region fasten -
ing method".
OThis method preci$ety achieves the needed clampi ng fotce wtthout
exceeding it unnecessarily. allowing the use of thinner. hghte< bolts
further d~ng connecting rod weight
OTher• are two typeS of the plastic region fastening . One 11 a bolt length
measurement method and other is a t ightening t orque method.
Observe one of the following two. but the bolt length measurement
method is preferable because this is a more reliable way to tighten the
big end nuts.
CAliTION
The comec11ng rod bolla are designed 1o ttreleh whtn tightened.
Never reuoellle connecting rod bolla. S..llle table below lor correct
boll and nut uoage.
(1) Bolt Length Measurement Method

• Be sure to clean the bolts. nuts. and connecting rods thoroughly with
high· flash point solvent. because the new connecting rods. bolts, and
nuts are treated with an anti-rust solution.
A WARNING
c...n lila bolla, nut., and connecting rode In a well-ventilated area,
and take care lllet lllere Is no opario: or flame anywhere near lila
working area. Thlt lnciUcln any applla.- wllh a pilot light. s-uoe
ol ... d8nger ol highly bmmable l.lde, do not . .e gasoline or
low.ftM/1 polnl..,..,eutalo clean lhem.
lmmedletely dry lila bolls and null with compreteed elr alter
cleanJne.
Clean and dry lila bolls and null completely.
e lnstall new bolts In reused connecting rods.

• Dent both bolt head and bolt tip with a punch as shown.
e Before tightening, use a point mie<ometer to measure the length of
now connecting rod bolts and record the values to find tho bolt stretch.
Connecting Rod [A)

Dent here w ith a punch [ B).
Nuts (C)
Frt mictometet pins into dents [ D) .
• roghten the big end nuts until the bolt elongatron reaches tho length
apacifled in tho table. D
e Chack the length of the connecting rod bolts.
* II the stretch is more than the usable range, tha bolt has stretched too
much. An ovorolongated bolt may break in u se.
Bolt Length Bolt Length
• Stretch
afte< tightening before tightening
Connecting Usable Range of

RodAay Bok Nut Connecting Rod
Bolt Strotch
Use the bolts Attached to
New attached to new con-rod 0.20 - 0.32 mm
new con-rod.
New
Replace the boltl Used
Used" 024- 0.36mm
with new ones. New
(2) Tightening Torque Method

* If you don't have a point micrometer. you may tighten the nuts using
the "Tightening Torque Method".
• Be sure to clean the bolts, nuts, and connecting rods thoroughly with
high-flesh point solvent. because the new connecting rods, bolts, and
nuts are treated with an anti -rust solution.
••WARNING
CINn.,.-......., and ....,_111111 roda In a welkemllal8d a,..,
and lllle ..,. llwl - . . • no ~ « - any- a n. .r tile
n.•-
WO<t<lng • ...._ any II'PIIanoa wltlla pilot light Becauoe
ol the danger of ~ ftanvnable llquldo, do not . . . gaoollne or
low-ftuh p o l n l - - l o - them.
lm"*'lately dry the bolla and nuto wltll compre- air _ ,

claanlolgc.
CIMn and dry.,. bolla and null complotlely.
e Apply a small amount of engine oil to the threeds [A) and seating
surface [B) of the connecting rod null.
• Firat. tighten the nuts to the opecified torque. See the table below.
e Next. tighten the nuts 120' more.
0 M ark [ A] the connecting rod big end capa and nuts so that nuts can
be turned 120' ( B) properly.
0 Tighten the hexagon nut by 2 comers.
Connecting Torque + Angle

Rod Assy Bolt Nut N -m (kg -m, ft-lb)
Attached to 18 (1.8, 13.0)
New Use the bolts new con-rod + 120'
' attached
to new con-rod. New 20 (2.0, 14.5)
+ 120'
Used 24 (2.4. 17.4)
Used Replace the bolts + 120'
with new ones New 25 (2.6, 18.8)
+ 120'
CAU110N
Since the friction forc:e of the seating surface and thread portion of
new nuts Ia dlfterenf from !hat of used oneo, the nut tightening to<q...,
should be changed as specKled In the above table.
Be careful no1 to overtighten the nuts.
Connecting Rod Big End Bearing lnsert/Crankpin Wear

e Using a plastigage (press gauge) [A] , measure the beaJing
I
insert/etankpin [B] clearance.
NOTE I
0 Tighum the connecting rod big end nuts to the specified torque (see
Connecting Rod Installation).
o Do not move the connecting rod and crankshaft during clearance
I
musurement.
Connecting Rod Big End Bearing lnsert/Crankpln Clearance
Standard: 0.036 - 0.066 mm
*it clearance is within the standard. no bearing replacement is required.
*it clearance is between 0.066 mm and the service limit ( O.t 0 mm),
replace the bearing inserts with inserts painted blue [C] . Check
insert/crankpin c learance with the plastigage. The clearance may
exceed the standard slightly, but it must not be less than the minimum
in order to avoid bearing seizure.
*If the clearance exceeds the service limi~ measure the diameter of the
crankpins.
Crankpln Diameter
Standard: 34.984 - 35.000 mm
Sarvlce LlrnR: 34.96 mm
*If any crankpin has worn past the service limit. replace the crankshaft
with a new one.
*If the measured crankpin diameters are not less than the service limit.
but do not coincide with the o riginal diameter markings on the
crankshaft make new marks on it.
Crankpln Dlametor Mar1<s

None 34.984 - 34.992 mm
0 34.993 - 35.000 mm
~: Crankpin Diameter M arks. "0" mark o r no mar1<..
8-12 CRANKSHAFT I TRAN SMISSION
e M-.ure the connecting rod big end bore diameter. and mark each
connecting rod big end in acoordance with the bore diamate<.
Bore Diamater Marl< (Around Weight Marl<) [A): •o• or no marl<.
NOTE
0 Tighten the connecting rod big end nuts to the spscHied torqus (sss
Connsctlng Rod lnstsl/stion).
0 The mark slrtNJdy on the big end should almost coincide with ths
mHSUremtMt.
Cooooecti!IQ Rod Big End !lore Dla.- Marl<a

None 311.000 - 311.001 mm
0 311.ootl - 38.018 mm
e Selectthe proper bearing insert In accordance with the combination
of the connecting rod and crankshaft coding.
e lnstallthe new inserts in the connecting rod end check insert/cronkpin
clearance with the plastigage.
Con -rod Big End Oankpin Bearing Insert

Bore Diameter' Diemela<
Marl<ing Marl< Size Color Part Numbe<
None 0 Brown 9202B-1 714
None None
Colorless 92028 -1713
0 0
0 None Blue 9202B-1712
Crankshaft Main Bearing lns8ft/Journal Wear

e Uslng a plastigage (press gauge) [A]. measure the bearing
lnsert/joumal [B) clearance.
NOTE
0 Tlght.n ths cnnlccass bolts to the spscHied torqus (sH Ctenltcsss
Assembly).
0 Do not tum the crsnlcshllft during citNJrlnce measurement.
OJournM citNJrence less th11n 0.025 mm csn not be msosured by
plllst/gll(l&, however. using genuiM palls msint.tins the minimum
s~ndsrd clssrsncs.
Cr anklheft M ain Bearing lntart/Journal Clearance

Slllnderd: 0.020 - 0.044 mm
Service Limit 0.07 nvn
* If clurance is within the standard. no bearing replacement IS required
* If cMirance is betw-. 0.044 mm and the se<vioe limit (0 07 mm).
replace the bearing insMs with insens painted blue (C) Check
Insert/journal clearance with the plastigage. The clearance may exceed
the standard slightly. but it must not bo loss than the minimum 1n orde<
to avo4d bearing seizure.
*If cl&arance exceeds the se<vice limit, measure the diamete< of the
crankshaft main joumal.
Crankallall Main Joumal Dlameler

Slandard: 32.984 - 33.000 mm
Se...,lce Umlt 32.96 mm
*If any journal has wom past the service limit, replace the crankshaft
wi1:h a new one.
* II the measured journal diameters are not less than the service limit but
do not coincide with the original diameter markings on the crankshaft.
make new marks on it.
Crankalleii·Maln Joumal Diameter Marks

None 32.984 - 32.992 mm
1 32.993 - 33.000 mm
0: Crankshaft Main Journal Diameter Marl<s, "1" mark or no mark
eMeasure the main bearing bore diameter, and mark the upper
crankcase half in accordance with the bore diameter.
0: Crankcase Main Bearing Bore Diameter Marl<s, "o• mark or no
mark.
NOTE
0 Tighten the crankcase bolts to the specified torque (see Crankcase
Assembly).
o Themsrk slready on the upper crankcase half should almost
coincid8 with the measuremBnt.
Crankcaae Main S..rlng Bore Dlamalar Marko

0 36.000 - 38.008 mm
None 36.009- 36.016 mm
e Select the proper bearing insert in accordance with the combination
of the crankcase and crankshaft coding.
e lnstall the new inserts in the crankCilSe halves and check insert/journal
clearance with the plastigage.
Crankcase Main Crankshaft Main Bearing Insert'

Bearing Bore Joumal Diameter
Diameter Marking Marking Size Color Part Numbe< Journal Nos.
0 1 Brown 92028 -1717 1, 3, 5

92028-1720 2,4
None 1 Colorless 92028-1716 1, 3, 5
0 None 92028 -1719 2, 4
None None Blue 92028 -1715 1, 3, 5
92028 ·1718 2, 4
"The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
Cnnksh8ft Side Clearanoo

e lnM~t a !hickness gauge belwa.l !he crankcase main bearing and !he
ctenk web at !he No. 2 joumal [A] to determine clearanoa [8].
* If !he clea111nce exceeds the service limit replace the crankcase halvea
[C] Ill' 1 set.
CAUTlON
The upper mel lower crenkoau heiVM .,. machined 11 the ~
In --·-emblecf atate, eo the cranlccue hlltwes rnuet be llt=IJ cJd
••Hl
Cranbheft Slcle Clear._
SGndard: 0.115 - 0.20 mm
S.rvloa Limit 0.40 mm
Alternator Chain I Alternator Shaft I Starter Clutch
AltBmBtor Chain Adjustment
NOTE
0/f til• •lt..mttN <:Min [A] mllku noiu. «!just ~ UP/W •lterMttN
ch•ln ttlflsiofMI [8].
e Remove:
Clutch <-
Clutch cNpter)
LowM Alternator Chain Tensioner [C]
e loocon:
Upper Alternator Chain Tensioner Pivot Bolt [A]
Upper Alternator Chain Tension81' Set Bolt [ B]
Upper Alternator Chain Tensioner Locknut [ C]
e Tum the upper alternator chain tensioner adjusting bolt [OJ coonter-
clocl<wise undl m. lower part of m. chain is tau~ and touch m. he.!
of adJusting bolt to crankcase [E]-
e Appty a non-permanent locking agent tom. threadl of cNin tensioner
pivot bolt and let bolt and tighten them.
r.,.... - Upper A - Chain Tena- Pivot Bolt
12 N-m {1.2 ~, 104 ~lb)
Upper Allernalor Chain Tenaloner Set Bolt
12 N-m (1.2 ~,104 ~lb)
e Push m. lower etternator chain tensioner pawl [A] to release m.

tensloner rod and push the rod [B].
e Whlle holding the tensloner rod, install the lower alternator chain
tensioner.
e Apply a non-permanent locking egent to the threadt of chain tensioner
bolts, and tighten them.
Torque - Lower Alt..,alor Chain Tenaloner Bolli: 12 N-m (1.2 kg-m,
1041n-lb)
.®
Alternator Chain Removal

e Remove:
Clutch (see Clutch chapter)
Lower Alternator Chain Tensioner [A]
Upper Alternator Chain Tensioner [B]
Alternator Shalt Oil Pipe [C]
Circlipa (0]
Speclel Tool - OUIIIde Clrellp Pllerl: 57001·144
e Remow the alternator chain along with the drive sprocket [A] . collar
(8], altennator driven sprocket [C] , oil pump driven sprocket [OJ, and
the chain guide (E) .
Altemator Chain Installation

e lnstall:
Chain Guide
Driw Sprocket and Collar
Oil Pump Driven Sprocket
Alternator Chain and Alternator Driven Sprocket
Circlips ·
Alternator Shaft Oil Pipe
e Appty a non-permanent locking agent to the threads of the alternator
shaft oil pipe bolt. and tighten it.
Tcwque - Allemator Shalt 011 Pipe Bolt 121kn (1.2 kg-m, 1041n-lb)
e Adjust the alternator chain (see Alternator Chain Adjustment) .
Alternator Shaft. Starter Clutch Removal

e Remove:
Engine (see Engine Removal/Installation)
Alternator
Pickup Coil Cover
e Unscrew the alternator shaft bolt [A] while holding the timing rotor
h6l<llgon head, and remove the alternator coupling dam petS (B] .
e Split the crankcase (see Crankcase Splitting).

e Remove: .
Drive Shaft and Output Shaft
Alternator Shaft Bearing Holder (A]
Alternator Shaft (B] and Alternator Shaft Bearing (C]
Starter Clutch ·
Alternator Shaft. Starter Clutch lnstJJI/ation

*If the alternator shaft right end ball bearing is removed. replace the
bearing with a new one.
0 Press the bearing with the bearing driver set until it stops.
Sjleclal Tool - Bearing Driver Set: 57001-1129
e Apply a non-permanentlock.ing agent to the threads of the alternator
shaft bearing holder bolts. and tighten them.
Torque - Allemator Shalt Bearing Holder Bolts: 12 N-m (1.2 kg-m, 104
ln-lb)
• Hold the timing rotor hexagon heed, tighten the coupling bolt.
Torque - Allemalor Shalt Bolt 25 N-m (2.5 k~ , 18.0 11-lb)
Smrter Clutch Disassembly

e Remove the circlip [A] and flat washer (B].
e Pull the starter clutch gear and take off the needle bearing and flat
washer.
• Holding the starter clutch assembly in a vise, remove the holder Allen
bohs and take off the one-way clutch.
Special Tools - Outside Clrc41p Pliers: 57001-144
Inside Clrcllp Pliers: 57001-143
I
SUlrter Clutch Assembly
I
e Be sure to install the one-way clutch (A] so that the flange [ B] of it
fits in the holder recess [C] .
e Apply a non-permanent locking agent .to the threads of the starter
clutch holder bolls. and tighten them.
Torque- Starter Clutdl Holder Bolli: 12 N-m (1.2 kg-m, 104 ln-lb)
Special Toola - Inside Clrcllp Pllefa: 57001·1•3
OuiBfde Clrcllp Pllefs: 57001-144
Alternator Shaft Chain Wear

• Hold the alternator shaft chain so that it may be pulled tight.
e Measure the length ol20 links (21 pins) with a vernier caliper.
*If the 20 link length of the alternator shalt chain is greater than the 20.1ink Length
seNice limt replace it. 21st
AHemator Shalt Chain 20 link Lengh

Standard: 158.8 - 159.2 mm
-
Ch8in Gukle Wsar
e VIIIUIIIy inrpec~lhe rubber on the guide.
*"the rubber io c:ut or domaged in any way, replace the guide.
Stllfter Clutch lnspBCtion

e Remove the llllrter motor.
e Tum the alllrter motor idle gear [A] by hand. When viewed from the
left side of the engine, the idle gear should tum counten:loclcwioe fnlely
[8], but should not tum clocl<wise (C].
* If the 111111er clutch- not .,_ate 8S it should or if it makea noise,
go to the nexlllep.
e D~ble the 111111er clutch. and visually inspect the clutch pans.
*"there it any wom or damaged part. replace it.
NOTE
OExMnlne m. st/lltet clutch fJHI •s well. Repl•c• it HIt Is worn or
demeged.
Starter Motor Idle Gear
Starter Motor Idle Gear Removal

e Aemove:
Alternator Shaft [A) and Starter Clutch [B) (see Alternator Shaft.
Starter Clutch Removal).
e Pull out the starter motor idle gear shaft and take off me idle gear [C).
Starter Motor Idle Gear Installation

e lnstall the starter motor idle gear so that me small diameter gear (OJ
faces the starter motor side (right side).
8·20 CRANKSHAFT I TRANSMISSION
Transmission
Shift Pedal Removal

eMarl< the position of the shift leve< on the shift shaft so that it can be
installed later in the same position.
• Remove the shift leve< and shift pedal.
Shift Pedal Installation

e lnstall the shift pedal [A] so that the shift leve< [ B] positions at right
angles [C] with the shift rod (D] and the center of the shift pedal
meets the cente< line [E] of the shift rod by loosening the front and rear
locknuts [F) and turning the rod.
NOTE
0 Ths locknut nsxt to tht1 knurled portion of th~ rod has left-hand
th-ds.
*If necessary, adjust the pedal position from the standard position to
suit you as follows.
• Loosen the front and rear rod locknuts.
eTum the rod to adjust the pedal position.
e Tighten the locknuts securely.
External Shift Mechanism Removal

e Remove:
Water Pump (see Cooling Syste<n chapte<)
Engine Sprocket (see Final Drive chapter)
Shift Pedal (see Shift Pedal Removal)
Rear Wheel (see Wheels/Tires chapter)
• Move the rear pan of the drive chain toward the right [A] and then
move the front pan toward the rear to clear the output shaft [B].
e Remove the swingarm pivot shaft [C] and uppe< shock absorber bolt
[ D] (see Suspension chapter).
• Move the drive chain toward the left and put the chain on the chain
guard.
eMove the swingarm [A] and drive chain (B] toward the rear to remove
the external shift mechanism cover [C].
NOTE
OPisce sn oil psn beneath ths sxtsrnal shift mechanism covsr.
e Remove:
Bolts [D] and Flat Head Screws [E]
External Shift Mechanism Cover
•
• Remove the shift shaft [A] while pushing (B] the shift mechanism arm
[ C] toward the shaft.
eRemove:
Bolt [A]
Gear Positioning Lever [B]
Spring [C]
Nut [0]
Neutral Positioning Lever [E]
Spring [F]
External Shift Mechanism Installation

e lnstall the gear positioning lever [A] and neutral positioning lever (B]
as shown.
Springs [C] Collars [E]
Washer [0] Nut [F]
Torque - Neutral Positioning ....,er Nut 9.8 N-m (1.0 kg-m, 871n-lb)
eApply a non-permanent la<:king agent to the threads of the gear
positioning lever bolt [G], and tighten it.
Torque - Gear Positioning Lever Bolt 9.8 N-m (1.0 kg-m, 87 ln-lb)
e Apply silicone sealant to the crankcase halves mating surface on the

front and rear sides of the external shift mechanism cover mount
Sealant - Kawaaakllklncl (Silicone Seal!"'!): 56019-120 [A]
• Replace the cover gask81 with a new one.

e Apply high temperature grease to the oil seal lips.
elnstall the cover and tighten the cover bolts.
OApply a non-permanent la<:king agent to the bolts (A] and screws
[B) .
Torque - External Stilt! Mechanism Cover Bolts: 9.8 N-m (1.0 kg-m, 87
ln-lb)
External Stlllt Mechanism Cover Screwo: 4.9 N-m (0.50 kg.m,
431n-lb)
e Check;
Drive Chain Slack
Engine Oil Level
ExtBfnaf Shift Mechanism Assembly

elnstall the retum spring [A] on the shift mechanism ann [B). noting
the hook direction.
Transmission Shaft Removal

e Split the crankcase (see Crankcase Splitting).
e Remove the drive shaft (A] and output shaft [B).
Transmission Shaft Installation

e Apply engine oil to the sliding portion of the.gears and bearings.
e Check to see that the set pins (A] and sat rings [B) are in place.
el nstall the drive shaft and output shaft into the upper crankcase half.
Transmission Disassembly
eRemove the transmission shafts (see Transmission Shaft Removal) .
eRemove the circlips. disassemble the transmission shafts
Special Tool- Oublde Clrcllp Pllera: 57001·144
eThe 6gh gear (A] on the output shaft has three steel balls assembled
into it for the positive neutral finder mechanism. Remove the 6th gear.
OSat the outptJt shaft in a vertical position holding the 3rd gear (B).
OSpin the 5th gear quickly [C) and pull it off upward.
Transmission Assembly
e lnstall the. gear bushings (A] on the shaft with their oil holes [B)
aligned with the shaft oil holes.
e Fit the steel balls into the 5th gear holes as shown.
View A- A: (see the output shaft illustration)
[A] Gear (6th)
[B] Shaft
[ C] Steel Balls
CAUTION
Do nolapply greaoelo lhe slllel balls 1o hold them In piiiCtl. Thlo will
causelhe poelllve neutral finder mechanism 1o malfunction.
eReplace any circlip that were removed with new ones.

e lnstal the circlips [A] so that the opening is aligned witll a spline
groove [B] .
Shift Drum and Fork Removal

e Removo:
Lower Crankcase Half {see Crankcase Splitting)
Extemal Shift Machanism (see External Shift Mechanism Removal)
Shift Rod Retainer [A] {Right)
Shift Drum Bearing Holder [B] (Loft)
e Pull out the shift rods [C), and take off lhe shift forks.
e Pull outtho shift drum [OJ .
Shift Drum and Fork Installation

elnstall the shift rods, noting the groove position. The rods are identical.
e Three shift forks ere used. Fit each shift fork into the groove of the
proper gear so that the shift fork guide pin is in the proper groove on
the shift drum.
• Position the one with shortest ears on the drive shaft and place the pin
in the center groove in the shift drum.
e ot the two forks on the output shaft. each longer rib faces inward.
[A] Shift Rods [ D) Longer Forks {output)
[ B] Grooves [E] Longer Ribs
[C] Shorter Fork (drive) [ F) Front
e Apply a non-permanent locking agent to me threads of the shift rod
ratainer bolt and shift drum bearing holder bolts, and tighten them.
Torque - Shill Rod Retainer Boll: 12 N-m (1.2 k!l'ftl, 104 ln·lb)
Shill Drum Bearing Holder Bolts: 12 N-m (1.2 kg.<n, 1041n-lb)
Shfit Drum Disassembly

• Remove the shift drum (see Shift Drum and Fotk Removal).
ewhile holding the shift drum with a vise, remove the shift drum cam
holder bolt
[A) S~ift Drum Cam Holder Bolt
(B) Dowel Pins
Shfit Drum Assembly

eBe sure to install the dowel pins.
eApply a non-permanent locking agent to the threads of the shift drum
cam holder bolt, and thighten it.
Torque- ShiH Drum Cem Holder Boll: 12 N-m (1.2 kg-m,1041n-lb)
1.
2.
3.
4.:
5. ~
6. (
7.1
DriYe SMII
1. Bearing Outer Race 7. Bushing 13. 5th Gear

2. Circlip 8. Toothed Washer 14. Bushing
3. Needle Bearing 9. Circlip 15. 1st Gear (Drive Shaft)
4. ThNSt Washer 10. 3rd/4th Gear 16. Ball Bearing
5. 2nd Geer 11. Circlip
6. Top (6th) Gear 12. Toothed Washer
OulpUISheft
1. Collar (force tit) 8. Circlip 15. Steel Ball

2. Ball Bearing 9. Toothed Washer 16. 51hGeer
3. OutpUt Shalt 10. 4th Gear 17. 1st Gear
4. 2nd Gear 11. Bushing 18. ThNst Wesner
5. Toothed Washer 12. 3rd Gear 19. Needle Bearing
8. Circlip 13. Toothed Washer 20. Bearing Outer Rece
7. Top (6th) Gear 14. Clrclip
WH EELS I TIRES 9-1
Wheels I Tires
Table of Contents
Exploded View ............................................................................................................9· 2

Specifications .............................................................................................................. 9· 3
Wheels (Rims) ............................................................................................................9 -4
Front Wheel Removal .............................................................................................9-4
Front Wheel lnstallation .......................................................................................... 9 -4
Rear Wheel Removal .............................................................................................. 9·5
Rear Wheel lnstallation ...........................................................................................9-5
Wheel Inspection ....................................................................................................9 -6
Axle Inspection .......................................................................................................9 -6
Balance Inspection .................................................................................................9-6
Balance Adjustment ................................................................................................9· 7
Balance Weight Removal .......................................................................................9· 7
Balance Weight Installation ....................................................................................9· 7
Tires .............................................................................................................................9· 9
Air Pressure Inspection/Adjusunent .......................................................................9· 9
Tire Inspection ........................................................................................................9· 9
Tire Removal ...........................................................................................................9· 9
Tire lnstallation ......................................................................................................9·10
Repair ....................................................................................................................9·11
Hub Bearing ..............................................................................................................9·12
Hub Bearing Removal ..........................................................................................9·12
Hub Bearing Installation .......................................................................................9·12
Hub Bearing lnspection ........................................................................................9 -12
Speedometer Gear Housing ......................................................................................9 -1 3
Disassembly and Assembly ..................................................................................9 -13
lubrication ............................................................................................................9 -13
9-2 WHEELS I TIRES
Exploded View
G : Apply grease.
R : Replacement Parts
S : Follow the specilic lightening sequence.
WL: Apply soap and water solution or
rubber lubricanL
T1 : 20 N-m (2.0 kg-m, 14.5 ft-lb)
T2 : 145 N-m (15.0 kg-m, 110 ft-lb)
WHEELS I TIRES 9-3
Specifications

Wheels (Rims):
Rim runout: Axial --- 0.5mm
Radial --- O.Smm
Axle runout/100 mm 0.05 mm or less 0.2mm
Wheel balance 10 g or less ---
Balance weights 1 0 g. 20 g. 30 g ---
Tires:
Air pressure: (when cold)
Front Up to 165 kg (364 lb) load:
250 kPa (2.5 kg/em• 36 psi) ---
Rear Up to 165 k.g (364 lb) load:
290 kPa (2.9 kg/em•, 41 psi) ---
Tread depth:
Front BRIDGESTONE: 3.4mm 1 mm
DUNLOP: 3.4mm 1 mm
MICHELIN: 5.0mm 1 mm
Rear BRIDGESTONE: 5.8mm Up to 130 km/h
(80 mph): 2 mm
DUNLOP: 5.9mm Over 130 km/h
(80 mph) : 3 mm
MICHELIN: 7mm
Standard tires: Make, Type Size
Front BRIDGESTONE, BATTLAX BT-50F,
RADIAL J (tubeless)
BRIDGESTONE, BATTLAX BT-54F
BRIDGESTONE, BATTLAX BT-50F, SS -TYPE3
DUNLOP, D203FG (tubeless) 12ono ZR17
DUNLOP, D204FJ (tubeless)
METZELER, ME Z1 FRONT
MICHELIN, A89X (tubeless)
MICHELIN ,TX11
PIPELLI, MTR01
Rear BRIDGESTONE, BATTLAX BT-50R,
J RADIAL (tubeless)
BRIDGESTONE, BATTLAX BT-54R
BRIDGESTONE. BATTLAX BT-50R SS-TYPE3
DUNLOP, D203G (tubeless) 180/55 ZR17
DUNLOP, D204L (tubeless)
METZELER. ME Z1
MICHELIN, M89X (tubeless)
MICHELIN, TX 23
PIPELLI MTR02
Special Toola - Jack: 57001-1238

IMide Clrcllp Pile,.: 57001-143
Bearing Driver Set: 57001-1129
Bearing Remove< Shall: 57001-1265
Bearing Remove< Head, <1>25 x <1>23: 57001·1346
9-4 WHEELS I TIRES
Wheels (Rims)
Front Wh6el Removal

e Remove:
Lower Fairings (see Frame chapuw)
Front Fender (see Frame chapter)
Sp~ometer Cable Lower End [A]
Brake Caliper Mounting Bolts [BJ
e Looeen:
Right Side Axle Clamp Bolts [A]
Axle [B]
• Raise the front wheel off the ground.

Special Tool - Jack: 57001·1238
• Pull out the a>de to the right end drop the front wheel out of the forks.
watpthe dllc. Plllca blocka . . -...

loucl!tlle_...s.
-to
Do not lay the wheel down on one of the c111ca. This can .wnee- at
-the dloc cloee not
Front WheellnstJJIIarion I
e lnstallthe speedometer gear housing so that its projections [A] fltlnto
the gear drive notches (B] In the wheel hub.
e Fit the collar on the right side of the hub.

R
e Fit the speedometer gear housing stop[A) In the fork leg stops[B] .
e nghten the axle nut and axle clamp bolt.
••
0
Tot- - Front Ald& Nut: 1451Mn(15.0 kg-m, 110 - )
Front Axle Clamp..,._, 20 1Mn(2.0 k4t<11. 14.5 11..1>)
e lnstall the front brake caliper
• Check tha front brake.
<- Brakes chapter).
:~
W H EELS I T IRES 9·6
••WARNING
Do not etlempl to di'IYe lie noololcycle Willi • lull - · lever II

-lned by pumping the brake lever unHI the peda ere egelnat the
dlec. The brake wtll not fUnction on the 11.-1 appllcallon of the lever
If thla II no1 done.
R88f Wheel Removal

e Remove:
Lower Fairings (see Freme chaJ)ter)
Right Lower Fairing Stay
Side Stand
e Uslng the jack [A), raise the rear wheel off the ground.
&peclal Tool - Jack: 57001 ·1 238
e Remove:
Cotter Pin [A]
Axle Nut [B)
Axle [C)
e Rernove the drive chain [A] from the rear SJ>rocket toward the left.
e Move the rear wheel back end remove the wheel from the rear caiiJ)er.
• Remove the rear wheel.
Do not lay the -

-10-
on tile ground will the d*> lacing down. TNa
'*'damage or watpthe dlac. Pr- blocks onlerthe
.... d l a c - n o t - lie ground.
RINir Whee/Installation
• Engage the drive chain with the rear sprocket.
• l,.tall the caliJ)er bracket [A] onto the swingarm stop [8].
0 Insert the aJde from the right aide of the wheel. and tighten the axle
nut
Torque - Rear Axle Nut 14$ Horn (15.0 kg.m. 110 ft.lb)
• Adjust the drive chain slack after installation (see Final Drive chapter).
• Check the rear breke.
9-6 WHEELS I TIRES
••WARNING
Do not -mpl to drive the motorcycle unUI a lull bnlke pedal Ia
- - by pumping the bralle pedal until the pede ere against the
disc. The brake will notluncllon on the first appllcllllon of the pedal
Nthle II not dOne.
Whee/Inspection
eRaise the fronVrear wheel off the ground.
Special Tool- Jack: 57001-1238
eSpin the wheel lightly, and check for roughness or binding.
*If roughness or binding is found, replace the hub bearings.
elnspect ihe wheel for small cracks, dents, bending, or warp.
*If there is any damage to the wheel, replace the wheel.
eRemove the wheel, and support it without the tire by the axle.
eMeasure the rim runout, radial [A] and axial [B], with a dial gauge.
*If rim runout exceeds the service limit check the hub bearings.
*If the problem Is not due to the bearings, replace the wheel.
Rim Runout
Sorvlce Limit Axial 0.5mm
Redial 0.8 mm
••WARNING
- 1111emp1 to repair a damaged wheel. If there Ia any dam-

beold" Wheol beufng., the wheel muot be replaced to Insure oafe
operetlonal condition.
Axle Inspection
eVisually inspect the front and rear axle for damages.
*If the axle is damaged or bent replace it.
eMeasurethe axle runout with a dial gauge.
*If axle run out exceeds the secvice limit replace the axle.
Axle Runoul/100 mm
Stendlrct 0.05 mm or Ieos
Service Uml: 0.2 mm
Balance Inspection
eRemove the wheel.
eSupport the wheel so that it can be spun freely.
eSpin the wheel lightly, and mark (A] the wheel at the top when the
wheel stops. ·
o Repeat this procedure several times. If the wheel stops of its own
accord in various positions, it is well balanced.
*If the wheel always stops in one position, adjust the wheel balance.
WHEELS I TIRES 9· 7
Balance Adjustment
e lf lhe wheel alweys stopS in one posmon, provisionally mach a
balance weight [A) on the rim at the marl<ing using edhellwtape.
e Rotate the w heel!' turn ( B], and see whether or not the wheel &tops
in this posit ion. If it does. the correct balance weight is being used.
* If the wheel rotates and the weight goes up, replace the weight with
the next heavier size. If the wheel rotates and the weight goee down,
replace the weight with the next lighter size. Repeet theee steps until
the wheel remains at rest aftet being rotated 14 tum.
• Rotate the wheel another I' tum and then another !4 tum to see if the
wheel is correctly balanced.
• Repeet the entire procedure as many times as nec:.aary to achieve
oonect wheel balance.
• Permanendy install the balance weighL
Balance Weight
Part Number W eight(grams)

41075-1014 10
41075-1015 20
41075 -1016 30
Bslancs Wsight RBmOval

(a) When the tire is not on the rim.
• Push the blade portion toward the outside with a regular tip screw
driwr. and slip the w eight off the rim ftange.
• Discard the used balance weight.
(b) When the tire is on the rim.

• Pry the balance weight off the rim flange using a regular tip screw
drive< as shown in the llgure.
Olnsert a tip of the scrow drive< between 'the tire bead [A) and weight
blade (B] until the end of the tip reaches the end of the weight blade.
0 Push lhe drive< grip toward the tire so that the balance weight slips
off the rim flange.
• Discard the used be lance weight.
Bslsnce Weight Installation

• Check If the weight portion has any play o n the breda-and-clip plate.
* If it does. discard it.
i•WARNING
W.,. balance welghl hu eny play on.,. rtm flange, lie -end/or
clip have been ab - - R..,_ the looae be lance welghl
Do not reuse used be- welghL
9-8 WHEELS I TIRES
• Lubricate the balance weight blade. tire bead, and rim fl.lnge with a
.oep and wttw aolution or rubber lubricant. Thil helpe the balance
weight slip onto the rim flange.
Donal IUbr-.,. are - with engine oil or petrallum dlltlll•lle

bec•. . ller wlllclelerlonlto lhe tire.
e lnstall the balance on the rim.

0 Slip the weight on the rim flange by pushing or lightly hammering the Rim Flanp:
weight in the direction shown in the figure.
0 Clleck that the blade and weight seat fully on the rim fl.lnge, and that
the clip it hooked over the rim ridge and reaches rim flat portion.
lnatalllng laiMce Weight
(e) P,.. or lightly hemmer the weight in.
(b) l natallation comp~ed.
Olo
•
WHEELS I TIRES 9-9
nres
h Prsssurelnsp8Ction/Adjustment
• M-.rethe tire air pressure w ith an air praasure gauge [A ] when the
tirea are cold.
* Adjust the tire a ir pressure acco<ding to the specif>eations H necessary.
Air ..,_,..('"'*>cold)
Front Up to 165 kg 260 kPa

(3641b) (2.5 kg/ em'. 36 psi)
Rear Up to 165 kg 290 kPa
(3641b) (2.9 kg/em•. 41 pel)
Tire Inspection
• Remove any imbedded stones or other foreign particles from the tread.
e Visually inspect the tire for cracks and cuu. replacing the tire in case
of damege. Swelling or high spots indicate internal damege, requiring
tire replacement.
• M-.rethe treed depth at the oanter of the treed with a depth gauge
[ A]. Since the tire may wear u,_,ly, take ,_rement at _,1
placa
* II anv meesurement is less than the service limit. replace the tire.
Treed Deptll
Front
Slandarcl: U mm (BRIDGEBTONE, OUNLOP)
5.0 mm (MICHELIN)
Service Limit 1 nvn
Aur.
Standard: 5.8 mm (BRIOOESTONE)
5.1 nvn (DUNLOP)
7.0 nvn (MICHEUN)
Service Uml: 2 mm(Up ID 130 km/h)
3 mm(0-130 km/h)
- l n g and -ay, UM only fie

-rei-lor repiecemenl, _ . . , ... -rd...-...
To-..,. - II CO I i i * lied
NOTE
0 Ch.ck and IHI/ance the wheel when 11 tire i$ repleced with 11 now one.
Tirs Removal
e Rernove:
Wheel (188 Front Wheel Removal, Raar Wheel Removal)
OIIC (a)
Valve Core (let out the air)
e To maintain wheel bllan~. mar1< the valve stem po41it ion [A] on the
tore with chalk so that the tire can bl reinstalled in the same position.
9-10 WHEELS I TIRES
e lubricate the tire beads and rim flanges on both sides with a soap and
water solution or rubber lubricant This helps the tire beads slip off the
rim flanges.
- lubrlc:ale with engine oil or pelroleum dlsllllales because they

will da-.18 the liN.
e Remove the tire from the rim using a suitable commercially available
tire changer.
NOTE
0 The tires cannot be removed with hand tools bttcsuse they fit the
rims too tightly.
Tire Installation
e lnspect the rim and tire, and replace them if necessary.
e Ciean the sealing surfaces of the rim and tire, and smooth the sealing
surfaces of the rim with a fine emery cloth if necessary.
• Remove the air valve and discard it.
CAIJTJON
Roplacathe air valve whanaverlhellrais "'fllac:ed.
Do not reuH the alr·valve.
elnstall a new valve in the rim.

ORemove the valve cap, lubricate the stem seal [A) with a soap and
water solution or rubber lubricant. and pull the valve stem through the
rim from the inside out until it snaps into place.
CAUTION
Do not uoa engine oil or petroleum distillates to lubricate lhe at.m
because they will deleriorale lhe rubber.
[ A) Valve Cap [C) Stem Seal [E) Valve Seat

[ B) Valve Core [D) Valve Stem [F) Valve Opened
e Apply a soap and water solution, or rubber lubricant to the rim flange
and tire beads.
WHEELS I TIRES 9-11
• Check the tire rota1ion matk on the front and rear t i,.. and instan them
on the rim accordingly.
NOTE
0 Thtl direction of the titlt rotation [A] is shown by tm arrow [8] on
the tire sidewall.
• Position the tire on the rim so that the valve is at the tire balance marl<
(the chall< marl< made during removal, or the yellow paint mark on a
new tire) .
elnstall the tire on the rim using a suitable commercially available tire
changer.
• Lubricate the tire beads and rim flanges with a soap and water solution
or rubber lubricant to help seat the tire beads in the sealing surfaces
of the rim while inflating the tire.
e CAnter the rim in the tire baacls, and inflate the tire with compreeaed
air unti l the tire beads seat in the sealing surfaces.
n WARNING
Be ...,. 10 - I I .,. valve _.. whe,._ lnlletlng the tire, Md do
not lnllm lie tlreiO more .,.n 400 kl'-<4.0 kg/em', 57 pel). Overln-
lllltlon cen explode lie lire with -'>lilly of Injury •nd IOM of lit..
e Check to see that the rim linN [A] on both sides of the tire sidewalls
are parallel with the rim flangea.
* II the rim flanges and tire sidewall rim lines are not parallel, remove the
valve eo<e.
• Lubricate the rim flanges end tin!l baads.
e lnstallthe valve core and inflate the tire again.
e After the tire beads seat in the rim flanges, check for air leaks.
0 Inflate the tire slightly abow atandard inflation.
0 Uae a soap and water solution or submerge the tire. and check for
bubbles that would indicate leakage.
e Adjust the air pressure to the &pacified pressure.
e lnstall the brake disc(a) so that the disc 'rotation mark aligns with the
tire rotation.
e Adjust the wheel balance.
R8p8ir
Currently two types of repair lor tubeless tires have come into wide
uae. One type is called a temporary (external) repair which can ba carried
out without removing the tire from the rim, and the other type Is called
permanent (internal) repair which requires tire removal. It Ia generally
understood that higher running dumbility is obtained by permanent
(Internal) repairs than by temporary (external) ones. Also, permanent
(internal) repairs have the advantage of permitting a thorough examine·
tion lor secondary damage not visible from external inspection of the tire.
For these reasons. Kawasaki does not recommend temporary (external)
repair. Only appropriate permanent (internal) repairs are recommended.
Repair methods may vary slightly from make to make. Follow the repair
methods indicated by the manufacturer of the repair tools and materials
10 that safe results can ba obtained.
9-12 WHEELS I TIRES
Hub Bearing
Hub Bearing Removal

e Remove the wheel, and take out the following.
Collars
Coupling (out of rear hub)
Gnl858 Seals
Circlips
5!*'181 Tool - lnalcle Cln:llp Pllenr. 57001·143 [ A)
Speedometer Gear Drive [B) (out of front hub)
e Take the bearings [A) out of the hub.
CAUTlOH
Do no1 ley the wheel on lie ground with the dlec tac:Mg down. Thla
can damage or warp the dlec. Place bloc*a under the wlleel oo that
the dlac doea nollouch the ground.
Special Toole- Bearing ReOMVer Shaft: 57001·1265 (B)

Bearing Re!MVer Head, <1>25 x 4>28: 57001·1346 [C)
Hub Bearing Installation

e Betore installing the wheel bearings, blow any dirt or foreign particles
out of the hub with oompressed air to prevent oontaminatlon of the
bearings.
e Replace the bearings wijh new ones.
e Press in the bearings until they are bottomed.
Special Tool - Bearing Drtver Set: 57001·1129 ( A]
NOTE
0 Install the bearings so that the marked side faces out.
e Replace the circlips with new ones.

Special Tool - lnolcle Cln:llp Pllera: 57001·143
• Replace the grease seals with new ones.
• Press in the grease seals so that seal surface is flush with the end of the
hole.
OApply high temperature grease to the grease seal lips.
Special Tool - Bearing Dotver Set 57001-1129 [A)
Hub Bearing Inspection

NOTE
Oft Is not necessary to remove any bearings for inspection. If any
bearings are removed, they will need to be replaced with new ones.
e Spin it by hand to check its condition.
*If it is noisy, does not spin smoothly, or has any rough spots, it must
be replaced.
e Examine the bearing seal for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.
WHEELS I TIRES 9-13
Speedometer Gear Housing
Disassembly and A ssembly

NOTE
0 It is recommended that the assembly be replaced rethBr then
attempting to repair the components.
e lnstall the speedometer gear housing so that it fits in the speedometer
gear drive notches (see Front Wheel Installation).
Lubrication
e Ciean and grease [A) the speedometer gear housing [B).
FINAl DRIVE 10-1
Final Drive
Table of Contents
Exploded View ..........................................................................................................10-2

Specifications ...................................•........................................................................10 -3
Drive Chain ................................................................................................................10-4
Slack lnspection ....................................................................................................10-4
Slack Adjustment ..................................................................................................10-4
Wheel Alignment Inspection Adjustment ............................................................10-4
Drive Chain Wear lnspection................................................................................10-5
Lubrication ............................................................................................................10 -5
Drive Chain Removal ............................................................................................10-6
Drive Chain Installation ........................................................................................10-6
Sprocket. Coupling ...................................................................................................10-7
Engine Sprocket Removal ....................................................................................10 -7
Engine Sprocket Installation ......... •.......................................................................10-7
Rear Sprocket Removal ........................................................................................l0-8
Rear Sprocket lnstallation .....................................................................................10·8
Sprocket Wear Inspection ....................................................................................10-8
Rear Sprocket Warp lnspection............................................................................1 0·8
Coupling Bearing Removal ..................................................................................10-8
Coupling Bearing Installation ............................................................................... 10-9
Coupling Installation ............................................................................................10-9
Coupling Bearing Inspection and Lubrication .....................................................10-9
10·2 FINAL DRIVE
Exploded View
G : Apply g191lse. T1 : 9.8 N-m (1 .0 kg-m, 87 in -lb)

HO: Apply heavy oil T2 : 125 N-m (13.0kg -m, 94 ft-lb)
L : Apply a non-pennanent locking agent. T3 : 74 N-m (7.5 kg· m. 54 ft-lb)
0 : Apply oil. T4 : 145 N-m (15.0kg-m, 110ft- lb)
R : Replacement Pa11s
FINAL DRIVE 10-3
Specifications

Drive Chain :
Standard chain
Make ENUMA ---
Type EK50UV-X, Endless ---
Link 1121inks ---
Chain slack 10-15mm Too tight more than 15 mm
Too loose: less than 10 mm
20-link leng1h 317.5 - 318.2 mm 323mm
Sprockets:
Rear sprocket warp 0.4 mm or less 0.5mm
Special Toolo - lnolde Clrcllp Pliers: 57001-143

Bearing Driver Sal: 57001-1129
Jack: 57001-1238
10-4 FINAL DRIVE
Drive Chain
Slack Inspection
NOTE
o Check the slack with the motorcycle setting on its side stBnd.
OCI88n the chain if it is dirty, end lubricate it if it apptNJrs dry.
•Check the wheel alignment (see Wheel Alignment Inspection). •
• Rotate the rear wheel to find the position where the chain is tightsst.
• Push up the chain at the rear end of the lower chain guard [A], and
measure the distance (chain slack) [8] from the chain upper end to
the swing arm [ C].
... •• ..
*If the chain slack exceeds the standard, adjust it
Chain Slack
Sta...Sard: 10 -15mm
Too Tight more than 15 mm
Too ~..Dose: len than 10 mm
Slack Adjustment
• Loosen the both chain adjuster locknuts (A) .
• Remove the cotter pin [B], and loosen the axle nut (C] .
*If the chain is too loose, turn out the left and right chain adjuster [0]
evenly.
*If the chain is too tigh~ tum 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 swing arm mark or position [G] ihat the right indicator notch
aligns with.
Misalignment ol the wl\eel will ......n In abnormal wear a...S may

resuft In an unsafe riding condition.
• Tighten both chain adjuster locknuts securely.

• Tighten the axle nut
Torque - Rear Axle Nul: 145 N-m (15.0 kg-m, 110 lt-lb)
• Turn the wheel, measure the chain slack again at the tightest position,
and readjust if necessary.
• Insert a new cotter pin and spread its ends.
Wheel Alignment Inspection Adjustment

• Check that the notch (A] on the left alignment indicator [B) aligns
with the same swingann mark or position [C) that the right alignment
indicator notch aligns with.
*If they are not, adjust the chain slack and align the wheel alignment
(see Slack Adjustment).
NOTE
0 Wheel alignment can be also be checked using the straightedge or
string method.
FINAL DRIVE 10-5
Misalignment of the wheal will reoull In abnonnal wear, and may

reaull in an unsafe t1cllng condition.
Drive Chain Wear Inspection

eRemove:
Chain Cover
..
e Rotate the rear wheel to inspect the drive chain for damaged rollers.
and loose pins and links.
*If there is any irregularity, replace the drive chain.
*Lubricate the drive chain if it appears dry.
e StJetch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A)
on the chain.
e Measure the length of 20 links [ B) on the straight part [C) of the chain
from the pin center of the 1st pin to the pin center of the 21st pin.
Since the chain may wear unevenly, take measurements at several
places.
*If any measurements exceed the service limit. replace the chain. Also,
replace the front and rear sprockets when the drive chain is replaced.
Drive Ctlaln 20-llnl< Langth
Standard: 317.5 - 318.2 mm
Se"'lce Umlt 323 mm
i•WARNING
If the drive chain wear exceada tha ae"'lce limit, replace tha chain
or an unsafe riding condftlon may result. A chain that breaka or I
jumps off lhe apoocteta could SNig on lhe engine sprocket or lock lhe
reer wheal, severely damaging the motorcycle and causing Ilk> go
oul of control.
For safely, usa only lhe llanderd chain. II Is an endleu type and
I
should not ba cui lor lnstallallon.
Lubrication
e lf a special lubricant is not aVllilable, a heavy oil such as SAE 90 is
preferred to a lighter oil because it will stay on the chain longer and
provide bener lubrication.
e lf the chain appears especially dirty, clean it before lubrication.
IZl: Apply oil.

10-6 FINAL DRIVE
The o..1ngto -een.,. aide plaiN - l in lie lubricant-.... lie

pin - lie buahing. To awkl dllmaglng tha 0-rlnga and .-nenl
lon ollubriclln~ observe the following rules.
Uae Only keroaene or dleael oil lor cleenlng en ()-ring drive chain.
Arry other cleening oolullon auch •• ~or trichloroethylene wnl
.....,.e d-oratlon end •-lllng ollie o.ring.
lm,..._ly -
m-.
the chitin dry will compreued air -
Complatt c-.lng -drying.,. clleln within 10
cleenlng.
• Applyo<ltothesides of the rollera so thll oil w ill penetrlle to the rollers

end buahings. Apply the oil to the O· rings so that the O · ringt will be
coated wlth oil.
• Wipe off any excess oil.
Drive Chain Removal

• Remove:
Engine Sprocket (see Engine Sprocket Removal)
Reer Wheel (see Wheels/Tires chaplet)
Chain Cover Screws [A]
Chain Cover [B]
Swingarm (tee Suspension chapter)
• Remove the drive chain [A] from the engine output shah [8].
Drive Chain Installation

• Install:
Swingarm (see Suspension chapter)
Rear Wheel (see Wheels/To,. chapter)
Engine Sprocl<et (see Engine Sprocket Removal)
• Ad!uat the chaon slack aher o.nstalhng the chaon (see Slack AdJUSIJ'nent).
FINAL DRIVE 10-7
Sprocket. Coupling
Engine Sprocket Removal

• Remove:
Lower Fairings (see Frame Chapter)
Engine Sprocket Cover Bolts [A)
Engine Sprocket Cover [ B)
Chain Cover
• Flatten out the bonded washer [A].

•Remove the engine sprocket nut [B) and washer.
NOTE
0 When loosening the engine sprocket nut hold the rear brake on.
• Using the jack, raise the rear wheel off the ground.
Special Tool - Jack: 57001·1238
• Loosen the drive chain (sea Slack Adjustment).
• Remove the drive chain from the rear sprocket toward the right.
• Pull the engine sprocket [A) off the output shah [B) along with the
chain.
• Remove the engine sprocket.
Engine Sprocket Installation

• Replace the sprocket washer and axle cotter pin.
• Install the engine sprocket onto the output shaft with the driva chain
engaged.
o Either side of the sprocket may ba faced out
• Apply oil to the threads of the output shaft and the seating surface of
the engine sprocket nut
e After torquing the engine sprocket nut[A), bend the one side[B) of
the washer over the nut.
NOTE
0 Tighten the nut while applying the rear brake.
Torque - Engine Sprocket Nut : 125 N-m (13.0 kg.m, 941Nb)
e Adjust the drive chain slack after installing the sprocket (see Slack
Adjustment).
10-8 FINAL DRIVE
RtNJr Sprock.« Rsmoval

• Remow the,_ wheel<- Wheel/Tires chapter).
Do not lily ... w'-1 on ... ground wW. ... d-., fllclng down. nu.
~- -1101-...
0101dllm8georwarp.,.dl8c. P18ce- unclw.,._..,_
grcuncL
• Remove the rear sprocket nuts [A).
• Remove the rear sprocket [ B ].
Rear Sprocket Installation

• loatell the sprocket facing the tooth number marl<lng [ A) outward.
•T~ghten the reer sprocket nuts.
T~ - Reer Sprock.C Nut : 74 N-m (7.S kg-m, 541l· lb)
• lnltllll the .-wheel<- Wheels/ Tires chapter) .
Sprocket WBBr Inspection

• Visually Inspect the engine and rear sprocket teeth for wear and
damage.
*If the teeth are wom es illustrated. replace the sprocket. end inspect the
drive chain wear (see Drive Chain Wear Inspection) .
[A) Wom Tooth (Engine Sprocket)
[8] Wom Tooth (Rear Sprocket)
[C] Direction of Rotation
NOTE
0 ff • sptOCkflt f«/Uites rep/8CtiiTieflt. V.. ch6in is probeb/y wom elsa.
WIIM r~ • $1N0Ckflt. insp«:t V.. chein.
Rear Sprock.« Warp Inspection

• Raise the reerwheet off the ground<- Wheats/Tires chapter) so that
it will tum freely.
• Set a dial gauge [A) against the reer sprocket [ B) neer the teeth as
ahown, and rotste [C] the rear wheel to measure tha sprocket runout
(warp). The difference between the highest and lowest dial gauge
readlnga Ia the amount of runout (warp).
*If the runout exceeds the service limit. replace the rear sprocket.
R. .r 8proclcet Warp
S18ndatd: OA mm or -
SerYtce Limit> 0.5 mm
Coupling Bearing Removal

• Remove:
1-
Coupling
Grease Seal
Circlip [A)
Sp.dal Tool - Clrcllp Pliers: 57001·1 43 [ B]
FI NAL DRIVE 10-9
• Remove the bearing by tapping ITOm the wheel aide.

Sj>eclal Tool - -ring O.lver s.t: 57001 ·112t [A]
Coupling Bearing Installation

• Replace the bearing with a new one.
• Press in the bearing until it is bottomed.
S!*:lal Tool - Boring Driver s.t: 57001 ·112t [A)
• Pod< the bearing with high temperature g . -.
• Rep'- the ci rclip with a new one.
Sj>eclal Tool - tnalde Clrcllp Pliers: 57001·143
e Replece the grease seal with a new one.

e Prees in the grease seat so that the seal surfece is ftuah w ith the end
of the hole.
OApply high tempef8ture grease to the grease seollipe.
Sj>eclal Tool - Bearing Driver s.t: 57001·112!1 (A]
Coupling Installation
e GreHe the following and install the coupling.
Ball Bearing [A)
Coupling Grease Seal [B)
Coupling Internal Surface [C)
Coupling Bearing Inspection and Lubrication

NOTE
Oft is not nectJ$UI"f to remove the coupling IHMing lor inspection •nd
lubrictJIJon. II the be.ring is removed, II will nHd to be repl~~eed
with • nltW one.
eWaah the bearing with a high flash-point aolvent doy it (do not spin
it whole it is doy), and oil it. Spin it by hand to check ita condition.
*If it is noisy, does not spin smoothly, or has any rough spots, it must
ba replaced.
10-10 FINAL DRIVE
• Peck the bearing with good quality bearing grease. Tl.om the bearing
eround by hand • fiiW lima to make sure the or- is distributed
unifonnly lnti<M the beMtlg.
BRAKES 11 -1
Brakes
Table of Contents
Exploded View ........................................................11 -2 Front MasterCylinder Installation .................. .11 - 13

Specifications ........................... ............................... 11 -4 Rear· Master Cylinder Removal ........................11-13
Brake Pedal .............................................................11 ·5 Rear Master Cylinder lnstallation .....................11-14
Brake Pedal Position Adjuslment ......................11 -6 Front Master Cylinder Disassembly .................11 - 14
Calipeno ....................................................................11 -6 Rear Master Cylinder Disassembly ..................11-14
Front Caliper Removal... .....................................11-6 Master Cylinder Assembly ...............................11-16
Rear Caliper Removal .........................................11 -6 Master Cylinder Inspection
Caliper Installation ..............................................11 -6 (Visuallnspection) .........................................11 - 15
Front Caliper Disassembly..................................11-7 Brake Disc .............................................................11-16
Front Caliper Assembly ......................................11-8 Brake Disc Removal .........................................11 -16
Rear Caliper Disassembly ...................................11 -8 Brake Disc lnstallation ......................................11 -16
Rear Caliper Assembly........................................11-9 Brake Disc Wear ...............................................11-16
Brake Pads ............................................................11 -11 Brake Disc Warp ...............................................11 -16
Front Brake Ped Removal. ............................. ..11 -11 Brake Fluid ............................................................11 -17
Front Brake Pad Installation .............................11-11 Level inspection ...............................................11.17
Rear Brake Pad Removal.. ................................11 -11 Brake Fluid Change ..........................................11-17
Rear Brake Pad Installation ....................... .......11 -11 Bleeding the Brake Line ...................................11 - 18
Lining Wear ......................................................11-12 Brake Hose ............................................................11 -21
Master Cytinder .....................................................11 -13 Brake Hose Removal/Installation ....................11-21
Front Master Cylinder Removal .......................11 -13 Brake Hose Inspection .....................................11 -21
11-2 BRAKES
Exploded. View
US: U.S. Model

CN: Canadian Model
8: Apply brake fluid.
G: Apply grease.
L: Apply a non ·pennanent locking agent
S: Follow the specific tightening sequence. I 9A
Si: Apply silicone grease (ex. PBC grease) . @
T1: 7.8 N-m (0.80 kg-m, 69 in-lb)
T2: 25 N·-m (2.5 kg-m, 18.0 ft-lb)
T3: 1.0 N-m (0.10 kg-m, 9 in-lb)
T4: 5.9 N-m (0.60 kg-m, 52 in -lb)
T5: 1.5 N-m (0.15 kg-m, 13 in -lb)
T6: 8.8 N-m (0.90 kg-m, 78 in-lb)
T7: 6.9 N-m (0.70 kg-m, 61 in-lb)
T8: 2.9 N-m (0.30 kg-m, 26 in -lb)
T9: 34 N-m (3.5 kg -m, 25 ft- lb)
T1 0:21 N -m (2.1 kg-m. 15.0 ft-lb)
T11: 23 N -m (2.3 kg-m, 16.5 ft-lb)
T12: 18 N-m (1 .8 kg-m, 13.0 ft-lb)
ZX900·B3 (oll>er Ulan US.CN Models)

--------,~--,
BRAKES 11-3
J
11-4 BRAKES
Specifications

Brake Lever. Breke Pedal:
Brake lever position 4-way adjustable (to suit rider) ---
Brake lever free play Non-adjustable ---
Pedal free play Non-adjustable ---
Pedal position About 43 mm below footpeg top ---
Brake Fluid:
Grade D.O.T.4 ---
Brand (recommended) Castro! Girling-Universel ---
Castro! GT (LMA) ---
Castro! Disc Brake Fluid
Check Shock Premium Heavy Duty
---
---
Brake Pads:
Lining thickness: Front 4mm 1 mm
Rear 5mm 1 mm
Brake DiiiCS:
Thickness: Front 4.B- 5.2 mm 4.5mm
Rear 5.B- 6.1 mm 5.5mm
Runout 0.2 mm or less 0.3mm
Special Toole - lnelde Cln:llp Pllere: 57001-143

Jack: 57001-1238
BRAKES 11 -5
Brake Pedal
Brake Pedal Position Adjustment

e Check that the brake pedal [A] is in the correct position.
[B] Footpeg
"*!at Poaltlon [C)

Standard: About 43 mm below top of looll>eg
*If it is not, adjust the broke pedal position.
NOTE
0 Usually It Js. not necessary to adjust the pedal position, but always
adjust it when tha master cylindBr is disassembled.
e When the brake pedal is in its rest position, measure the length
indicated in the figure.
Length [A]
Standard: 67±1mm
*If the length is not within the specified length, adjust the hex head
[B] as following.
0 Loosen the bracket locknut [ C].
OTum the hex head to obtain the specified length.
OTighten the locknut.
Torque - Rur Maaler Cylinder Brad<et Loc:l<nut: 181Hn (1.8 kg.m, 13.0
ft.tb)
NOTE
o If tha pedalposition cannot be.adjusted by turning the hex head. the
brake pedal may be deformed or Incorrectly installed.
e Check the brake light switch operation (see Rear Brake Light Switch
Adjustment in Electrical System chapter).
11 · 8 BRAKES
Calipers
Front Calip¥ Rernovt~l

e l.oolen 111e banjo bolt [A] at 1he bnlke hole 1oww end, end tigh_, h
looMiy.
e u n - 111e celiper mounting bohs {B), and detach the cetiper [CJ
from lhe dilc.
Do not looMn tile caliper - b l y bob [D). TMe out only tile
cellper m-ng bollll lor caliper remow•l. Looeenlng tile caliper
- b l y boll8 w i l l - brMe fluid IMlcege.
e Unscrew the banjo bolt and remove the brake hose {E]Irom the caliper
(see Brake Hose Removal/Installation).
Re/Jf Caliper Removal

e looeen the banjo boh [A] at the brake hose lower end. and tighten it
loosely.
e unscrew the caliper moonting bolts [B), end detach the caliper [C)
from the dlac.
• Unacrew the banjo bolt and remove the brake hoee [0] IYom the
caliper (see Breke Hose Removal/Installation).
l lnwnedlatloly · - -ay e n y = - e pUIII.

NOTE
0/f rhe c11liper Is to be diusstJmbled ttfter remov11l11nd If compressed
e/r Is not IIVIIilllbie, dis11ssemble rh~ CllliptN before rhe breke hose is
removed (SIItl R1111r Csl/per Disassembly).
CalipBf lnstBIIatlon
e lnmli the caliper and brake hose lower end.
0 Replace the washers that are on each side of hose fitting with new
ones.
e Tighten the caliper mounting bohs and banjo bolt.
TOI'qlle - Cellper M-ng Bob (Front): 34 N-m (3.5 ko-<n, 25 tt-lb)
C8ttper Mowlllng Bolt8 (Rur): 25 N-m (2.5 ko-m. 11.0 ft.ll)
Breke HoM 8enjo Bol: 25 N-m (2.5 ko-m. 11.0 - )
• Check the fluid level in the breke reservoirs.
e Bieed 1he breke line (see Bleeding the Brake Una) .
• Check the brake tor good braking power, not breke dreg, and no fluid
leakage.
BRAKES 11-7
i•WARNING
Do not atlempt 1o drive liMo motorcycle until a lull brake lever or pedal
II oblalnad by pumping the brake lever or pedal until llw pede .,..
agelnat the dl8c. The brakeo will notlunetion on the 111'81 -llcallon
of llle lever or pedal II lhla II not done.
Front Caliper Disassembly

eRemove the pad spring and brake pads (see Front Brake Pad
Removal).
• Remove the front caliper.
e Remove the front caliper assembly bolts [A] and split the front caliper.
• Remove the piston insulators and the 0 -rings.
e Using compressed air, remove the pistons. One way to remove the
pistons is as follows.
0 Install a rubber gasket [A] and a wooden board (B] more than 10 mm
thick on the caliper half, and fasten them together with a suitable bolt
and nut as shown. Leave one of the oil passages (C] open.
o Lightly apply compressed air [OJ to the oil passage until the pistons
hit the rubber gasket. Block the hose joint opening [E] during this
operation if the caliper half has the opening.
[F] Bolt and Nut ·
[G] Oil Passage sealed by Rubber Gasket.
[ H] Push down .
i•WARNING
To avoid - · Injury, never place your llngen or palm In front of
the pilton. II you apply compresoed air Into the caliper, the pilliOn
may crush your hand or llngero.
0 Pull out the pistons by hand.

e Rernove the dust seals [A] and fluid seals [B].
e Remove the bleed valve [C) and rubber cap [0].
• Repeat the previous step to remove the pistons from the other side of
the caliper body.
11-8 BRAKES
Front Caliper Assembly

• Cleen the caliper pans except for the pads.
l'or cl•nlng the perla, u• onl)' disc brae lklld, Isopropyl •lcohol,
or ethyl •lcohol.
e lnstalllhe bleed valve and rubber cap,

r_.. - B - Velvr. 7 .a Nom (OJO kiJ-m, 1111 .....,)
e Replecethe fluid seals [A) with new ones.

OApply brllke fluid to tha fluid-~~. and install them into the cylinders
by hand.
e Raplaoa the dust seals [B) with new ones if they are damaged.
OApply brake fluid to the dust aeall, and install them Into the cyllndMS
by hand.
e RepiiC8the 0-rings [A) if they are damaged.

e Apply brake fluid to the outside of the pistons, and push them Into
eech cylinder by hand.
e Ba aura to install the O ·rings.
e Tighten the caliper assembly bolts.
Torq&HI - Front Cellpet -mbl)' Bob: 21 N-m (2.1 ......... 15.0 ft.lb)
e lnstall the piston insulators [ B).
e lnatall the pads (see Front Brake Ped Installation).

e Wipe up any spilled brake fluid on the caliper with wet cloth.
Resr Cslipef Disassembly •

• Remove the rear caliper.
• Remove the pads and anti-rattle spring (see Rear Brake Pad Removal) .
•
• Remove the piston insulator.
• Using compressed air, remove the piston.
•
oeo- the caliper opening with a clean, heavy cloth [A] .
O Remove the piston by lightly applying compressed air [B) to where the
brake line fits into the caliper.
BRAKES 11-9
' i•WARNING
To avoid .-tous Injury, never place your flngere or palm lnelde the
caliper opening. II you -'Y cornpreulld air lnlo the caliper, the
plllon may crulh your hand or llngere.
e Remove the dust seal and fluid seal.

• Remove the bleed valve and rubber cap.
NOTE
Off compressed air is not available. do as follows with the brake hose
connected to the caliper.
OPrepare container for brake fluid. end perform the work above it
ORemove the pads and spring (see Rear Brake Pad Removal).
o Pump the brake pedal to remove the caliper piston.
Rear Caliper Assembly

e Ciean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only dlac brake fluid, loopropyl alcollol,
orellylalcohol.
e lnstall the bleed ~lve and rubber cap.

Torque - Bleed Valve: 7.B N-m (O.BO kg-m, 69 ln·lb)
• Replace the fluid seal [A] with a new one.

OApply brake fluid to the fluid seal, and install it into the cylinder by
hand.
e Replace the dust seal [ B] with a new one if it is damaged.
OApply brake fluid to the dust seal, and install it into the cylinder by
hand.
e Apply brake fluid to the outside of the piston, and push it into the
cylinder by hand.
e Replace the shaft rubber friction boot [A] and dust cover [B] if they
are damaged.
e Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper
holder shafts (C] and holder holes [0] (PBC is a special high
temperature, water-resistance grease).
11 -10 BRAKES
e lnstall the anti-rattle spring [AJ in the caliper as ahown.

e lnstall the piaton inwletor.
e lnstall the peds(- R- Brake Pad Installation).
e Wipe up any spilled b<ake fluid on the caliper with - cloth.
BRAKES 11-11
Brake Pads
Front Brake Pad Removal

e Unscrew the caliper mounting bolts.
e Detach the caliper from the disc.
eUnscrew the pad spring screws [A], and remove the pad spring (8].
e Draw out the clip [A], and take off the pad pin [8] .
e Remove the brake pads [ CJ.
Front Brake Pad Installation

e Push the caliper pistons in by hand as far as they will go.
e lnstall the brake pads.
elnstall the pad pin and clip. The clip must be •outside" of the pads.
elnstall the caliper (see Caliper Installation).
i•WARNING
Do no1 attampl 1o drive tile m-rcycle ..,Ill a full brake lever Ia
-lned by pumping the brake lever ..,,II the peda are agalnat lie
dlac. The brake will not luncllon on the tlrot application ol the lever
It this Ia not done.
Rear Brake Pad Removal

e Unscrew the caliper mounting bolts.
• Detach the caliper from the disc.
e Draw out the clip [A], and take off the pad pin [8] .
e Remove the brake pads [C] .
Rear Brake Pad Installation

e Push the caliper piston in by hand as far as it will go.
e lnstall the anti-rattle spring in place.
e lnstall the brake pads.
e lnstall the pad pin and clip. The clip must be " outside" of the pads.
e lnstall the caliper (see Caliper Installation).
11 -12 BRAKES
.u. WAnNINC~
Do not -.ptlo....,.. ... .. - . ,......... lull ........ peclel .

~!If purnp~no.,. -·pedal-.,.....- -eooolrwt.,.
dloc.. " " " - . wll n o t - on h tint~ of h pedel
.... . not_
Lining Wear
e Check the lining thickness of the pads in each caliper.
* If the lining thickness of either pad is less than the aervice limit [A] ,
replace both pads in the caliper as a set.
Peel Lining~
~ Ff'ont [ 8 ] 4mm
RMr [C] 5mm
Ser.loe Llnl• 1 mm
•
••
•
I
BRAKES 11 -1 ~
Master Cylinder
Front Master Cylinder Removal

e Oilconnect the front breke liQtlt switch connectors (A) .
e Remove the banjo bolt (A] to disconnect the breke hOM from the
master cytinder (see Brake Hoee Removal/Installation) .
e Unscrew the clamp bolts (8], and take off the mastar cylinder (C] ea
an assembly with the reee(IIOir, brake lever, and brake switch installed.
Front Master Cylinder lnst811ation

e lnstall the front mastar cytlndar ao that the mating surface (A] of the
switch housing is aligned with the mating surface (B] of the master
cylinder clamp to level the reservoir.
e The master cylinder clamp must be installed with the arrow mark (C]
upward.
• TiQhten the upper clamp bolt firat. and then the lower clamp bolt.
The<e w ill be a gap at the lower pan of the clamp after tightening.
T~ - Front lol- CyUnder Clomp - U N-m (O.tO q.m, 71
-)
e Replace the washers that are on each side of the hose fitting with new
ones-.
e Tighten the brake hose banjo bolt
Torque - Brake- hnlo Bolt 25 N-m (2.5 kg-m, 11.0 ft.lb)
e Bieed the brake line (see Bleeding the Brake Line).
e Checl< the brake for good braking power, no brake dreg, end no ftuid
leakage.
RtNJr Master Cylinder Removal

e Pull off the reservoir hose lower end (A], and drain the brake fluid into
a container.
e Unscrew the brake hose banjo bolt ( B] on the master cylinder (see
Brake Hose Removal/ Installation) .
• Rarnove the cotter pin.
• Pull off the joint pin ( C] .
NOTE
0 Pull oH thtJ joint pin while prusing down the bme ptld•l.
e unscrew the master cylinder mounting bolts (OJ, and take off the
master cylinder (E] and matter cylinder cover (F).
BRAKES
. Jr Master Cylinder Installation

e Replace the cotter pin with a new one.
e Replace the washers that are on each side of hose fitting with new
ones.
eTighten the following bolts.
Torque- RearM- Cylinder Mount~ Bolla: 23 N-m (2.3 kg.m,tU
11-lb)
Brake HoM BanJo Bolt 25 N-rn (2.5 kg-m, 18.0 fl·lb)
eBieed the brake line (see Bleeding the Brake Line).
eCheck the brake for good braking power, no brake drag, and no fluid
leakage.
Front Master Cylinder Disassembly

eRemove the front master cylinder.
eRemove the reservoir cap end diaphragm, and pour the brake fluid into
a container.
eUnscrew the locknut and pivot bolt. and remove the brake lever.
ePush the dust cover out of place, and remove the circlip.
Special Tool - IMide Clrcllp Pliers: 57001·143
ePull out the piston [A], secondary cup [B], primary cup [C] , and
return spring [OJ .
CAUTION
Do not rem<lft the , _ , . , y cup from the p111on alnce removal will
dam_ II.
Rear Master Cylinder Disassembly

eRemove the rear master cylinder.
eSiide the dust cover on the push rod out of place. and remove the
circlip.
Speclel Tool - IMide Clrcllp Pile"" 57001·143
e Pull out the push rod with the piston stop.
eTake off the piston [A], secondary cup [BJ, primary cup [CJ , and
return spring [ 0] .
Do not remove the oecondary cup lrom the plolcn olnce removal will
da,._ll.
BRAKES 11-15
Master Cylinder Assembly

• Belote essembly, clean aU parts including the ~"' cylind"' with
b<ake fluid or alcohol.
Excepl for 1M dlec peda and diK, . . . only dloo brae ~ld, loopopyl
-·~lei lor cleaning lhese par1a, Gaoollna, angina ol~ or any-·

alcohol, or ethyl alcohol tor cleaning br81ta par1a. Do no1 uaa any
palrolaum dlaUIIN will ceuaa -rloratlon oi!M rubber par1a. 011

oplllad on any part will be dllllcuH 1o w uh oil completely, and will
avanlually - rlorN 1M rubber uaeclln lila dlac bralca.
e Apply brake fluid to the removed parts and to the Inner well of the
cylinder.
. . u---
e Teke care not to scratch me piston or the inner well of the cylinder.
e Tighten the bnlke 1 - pivot bolt and the locknut.
Torque - llnftle-Pivctllolt 1.0 lkn(0.101qt-m, I - )
Locknut 5.1 lkn (0.10 klt'fft, 5 2 - )
Master Cylinder Inspection (Visual Inspection)

• Olaeuemblethe front and rear master cylinders.
e Check that there are no scratches, rust or pining on the inner wall of
each master cylinder [A] and on the outside of e&eh pilton [B].
*If a master cylinder or piston shows any damage, repl&ee them.
e lnspect the primary [C) and secondary [OJ cupe.
* If a cup Ia wom, damaged softened (roned), or awollen, the piston
auembly should be replaced to renew the cupe.
* If fluid leakage is noted at the brake lever, the piston assembly should
ba .-placed to renew the cups.
e Check the dust covers [E) for damage.

* If they ere damaged, replace them.
e Check that relief [F) and supply [G) ports ere not plugged.
* II the relief port becomes plugged, the brake peds will dreg on the disc.
Blow the ports claan with compressed eir.
e Check the piston return springs [H] for any dameged.
*II the springs are damaged, replace them.
11-16 BRAKES
Brake Disc
Brake Disc Removal

eRemove the wheel (see Wheels/Tires chapter) .
eUnscrew the mounting bolts, and take off the disc.
Brake Disc Installation

elnstall the brake disc [A] on the wheel so that its rotation mark (B]
aligns with the tire rotation [C] indicated by the arrow on the tire
sidewall.
eTighten the mounting bolts [D] .
TO<C!U8- Brake Dllc Mounting-: 23 N-m (2.3 kg-m, 18.511-lb)
Brake Disc Wear

*Replace the disc (A] if it has wom pas1 the service limit.
[ B] Measuring Area ·
Front Disc Thlclmaa
Standanl: 4.8 - 5.2 mm
Sarvlca LinIt 4.5 mm
Rear DIK Thlclmeu

Standard: 5.8 - 8.1 mm
Sarvlca LinIt 5.5 mm
Brake Disc Warp

eJack up the motorcycle so that the wheel is off the ground.
Special Tool - Jack: 57001-1238
e For front disc inspection, tum the handlebar fully to one side.
eSet up a dial gauge against the disc [A] as shown and measure disc
runout
[ B] Tum the wheel by hand.
*If runout exceeds the service limit, replace the disc.
Dloc Runoul
Standard: 0.2 mm or lass
Service Umlt 0.3 mm
BRAKES 11-17
Brake Fluid
Level Inspection
• Check that the brake fluid 191/el in the front breke reservoir (A] is abow
the lower IBIItllline [B).
NOTE
0 Hold 1M restJtVoir horizon1M by wming 1M hllndlebM when
r:htiCking brtJke fluid levM.
*If the fluid level is lower than the lower level line. fill tho ,_,-voir to the
upper level line [A] In the reaeovoir [B).
• R"""""' the S8B1. and checlt that the brake fluid level in the , _ brake
111Se!V0ir [A] is between the upper [B] and the lower [C) levellinae.
*If the fluid IBIItll is lower than the lower level line, fill the reservoir to the
upper 18\/tll line.
" WARNING
a..nge the broke fkMd In the broke line complelel) I.,. brlke tllald
- be refilled but ... type end brand of the brlke fluid ...t It
olreedy In the .......,olr ore unldentllled. Alllor chMglng the fluid,,_
only the tome type and brond ol ftuld the.-fler.
R~ Dloc llnlte Fluid

Grade: D.O.TA
a.- Culrol Glrtlntt-IJnl'leruJ
Ceelrol GT (LMA)
Ceelrol Dllc Broke Fluid
Chock Shock Premium Heavy Duty
Brake Fluid Change

NOTE
0 The procedure to chenr;e the front brlike fluid is ss follows.
Chsng/ng ths rsar brake fluid is the same ss for the front breke.
11 -18 BRAKES
• LI!II&I the brake fluid reservoir.

• Remove the reset'VOir cap.
• Remove the rubber cap from the bleed valve [A] on the caliper.
• Attach a clear plastic hose [B] to the b leed valve, and run the other
end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
• Change the brake fluid as follows:

0 Repeat this operation until fresh brake fluid comes out from the plastic
hose or the color of the fluid changes.
1. Open the bleed valve [A].

2. Apply the brake and hold it [8].
3. CI06e the bleed valve (C].
4. Release the brake [0].
NOT E
0 The fluid level must b8 checkBd often during the changing operation
and replanishBd with fresh brake fluid. If the fluid In the resBTVoir
runs out any tim8 during the changing operation, the brakes will
neBd to be b!Bd since air will have MtsrBd the brake line.
OF'i'oni Brake: Repeat the above steps for the other caliper.
ORear Brake: RIIP88t the above steps for the other bleBd valve.
• Remove the clear plastic hose.
• Install the reservoir cap.
• Toghten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 ,...., (0.80 kg-fn, 8911Hb)
• After changing the fluid, check the brake for good braklng power, no
brake drag, and no fluid leakage.
*If necessaJy, bleed the air from the· lines.
Bleeding the Brake Line

The brake fluid has a very low compression coefficient so that almost
all the movement of the brake lever or pedal is transmitted directly to the
caliper for brakJng action. Air, however. is easily compressed. When air
enters the brake lines, brake lever or pedal movement will be pa"ially
used in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
Be .,...to bleed tile air.from lila-·

i•WARNING
.,-1 acllon teals soft or "-'IIY -

line wllerMWer bt8ke lever or
lhe brake ftuld Ia changed, or
wheneYer a brake line ftltlng haa baan ~- tor any .....on.
B RAKES 11·19
NOTE
0 TIN procedure to biHd 1M front brake fine is •s follows. B/Hding
the re.r brake fine Is the SMN •• for the front brake.
e Romove the r""""'oir cap. and fill the reseNOir with freth brake fluid
to the UJlll<lr level line in the reservoir.
e With the reSeNOir cap off, slowly pump the brake lever several times
unlll no air bubbles can be seen rising up through the fluid II'Om the
holes at the bottom of the reHrvoir.
0 Bleed the air completely from the master cylinder by th;. ope<ation.
e lnstallme reservoir cap.
e Remove me rubber cap from me bleed valve on the caliper.
e Attach a clear plaelic hole to me bleed valve, and run the 04her end of
the hose into a container.
• Bleed me brake line and the caliper ae follows:
0 Rapaat this operation until no mora air can be seen oomlng out into
the plastic hose.
1. Pump the brake lover until it becomes hard, and apply the brake
and hold it [A) .
2. Quickly open and cloee[B]the bleed valve while holding the brake
applied.
3. Release the bn11ce [C].
NOTE
o Tho fluid level must INJ chtJCktld ofren during the b/Hdlng optntion
and replenished with fresh brako fluid as nfiCesury. If the fluid in
the reservoir runs completely our any time during bletld/ng, the
bleeding operation must bo done over again from the INJglnn/ng
sine• 8ir will have entertld the line.
0 Tap the brake hose llghl/y from tho C81iptN' to the restN'VO/r for more
compfetB bleeding.
OFront Brake: Reput the abovesreps for the other ceHpar.
O R- Brake: ReptNJt the ebova llllps fOf the other biHd valva.
• Remove me clear plastic hole.
e roghten me bleed valve, end install me rubber cap.
Torque - Bleed Valve: 7.8 N..., (0.10 kg-m, 69 lr>-lb)
e Check the fluid level.
e After bleeding is done, check the brake for good braking power. no
brake dreg. and no fluid leakage.
11-20 BRAKES
••WARNING
- wor1dr~g with lila dl8c brake, obeerve lila precaullona llaled
below.
1. Nowr reuse old brake fluid.

2. Do n01 use fluid from a container that has been left unsealed or
that has been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake.
This lowers the brake fluid boiling point and could cause the
brake to be ineffectiw. It may also cause tho rubber btake parts
to deteriorate.
4. Don't leave the reservoir cap off for any length of time to avoid
moisture contamination of the fluid.
5. Don't chango tho fluid in the rain or when a strong wind is
blowing.
6. Except for the disc pads and disc. use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do
not use any other fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillats will cause deterioration of tho
rubber parts. Oil spilled on any part w i ll be difficult to wash off
completely and will 9118ntually deteriorate the rubber used in tho
disc brake.
7. When handling the disc pads or disc, be careful that no disc brake
fluid or any oil gets on them. Clean off any fluid or oil that
inadwrtently gets on the pads or disc with a high-flash point
solwnt. Do not use one which will leave an oily residue. Replace
the pads with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilled fluid should
be completely wiped up immediately.
9. 1f any of the·brake line fittings or the bleed valve is opened et any
time, the AIR MUST BE BLED FROM THE BRAKE UNE.
BRAKES 11-21
Bl'8ke Hose
BrBke Hose Removal/lnstJJI/ation

CAUTION
...... ftllld "'lckly ruins ~ <K piMtlc .....tace.; ony ~~~~- ftuld
-'-ld be~ wiped up lrnmed-ly w.,- cloe\.
e When nJmoving the brake hose, take care not to apill the brake fluid
on the painted or plastic parts.
e When removing the brake hose, temporarily aecure the end of the brake
hOM to some high piece to keep fluid loss to a minimum.
e There are washers on each side of the brake hose fitting. Replace them
with new ones when installing.
e When installing the hoses, avoid sharp bending, kinking, flattening or
twisting, and route the hoses according to Hoce Routing aection in
General lnfonnation chapter.
e Tighten the banjo bolts at the hose fittin~.
Torque - Brae- Banfo Bolla: 25 N-m (2.5 -g.<n, 11.0 ll-lb)
• Bleed the ~a l ine after installing the b!'aka hoM <- Bleeding the
Brae Une).
Brake Hose Inspection

e Tha high presaure inside the brake line can cause fluid to leak or the
hose to burst if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
*Replace It if any cracks or bulges are noticed.
SUSPEN SION 12-1
Suspension
Table of Contents
Exploded View ..........................................................................................................1 2-2

Specifications ............................................................................................................1 2-4
Front For1<. ..................................................................................................................1 2-5
Rebound Damping Force Adjustment .................................................................12-5
Compression Damping Force Adjustment ...........................................................12-5
Spring Preload Adjustment ..................................................................................12-6
Front For1<. Removal (each for1<. leg) .....................................................................12-6
Front For1<. Installation ...........................................................................................1 2-7
Fork Oil Change ....................................................................................................1 2-7
Front For1<. Disassembly ......................................................................................1 2-1 0
Front For1<. Assembly...........................................................................................1 2-11
Inner Tube Inspection ...............................................................................:........1 2-1 2
Dust Seal Inspection ..........................................................................................1 2-1 2
Spring Tension ....................................................................................................12-13
Rear Shock Absorber ..............................................................................................12-14
Re!Jound Damping Force Adjustment ...............................................................12-14
Compression Damping Force Adjustment.. .......................................................12-14
Spring Preload Adjustment ................................................................................12-14
Rear Shock Absorber Removal ..........................................................................12- 1 5
Rear Shock Absorber Installation .......................................................................12-16
Rear Shock Absorber Scrapping ........................................................................12-16
Swingarm ................................................................................................................12-1 7
Swingarm Removal ............................................................................................12-17
Swingarm Installation .........................................................................................12-1 8
Swingarm Bearing Removal.. .............................................................................12-18
Swingarm Bearing lnsta llation ...........................................................................12-1 8
Tie- Rod, Rocker Arm ..............................................................................................12-1 9
Tie- Rod Removal ................................................................................................1 2-1 9
Tie- Rod Installation ............................................................................................1 2-1 9
Rocker Arm Removal ..........................................................................................1 2-1 9
Rocker Arm Installation ......................................................................................1 2-1 9
Needle Searing Inspection .................................................................................1 2-20
Tie- Rod, Rocker Arm Sleeve Inspection ............................................................12-20
12- 2 SUSPENSION
Exploded View
0
0
T1 :21 N-m (2.1 kg-m.15.01t-lb)
US: U.SA T2: 28 N-m (2.9 kg-m. 21 h·lb)
CN: C.neda T3: 23 N·m (2.3 kg-m. 16.5 h ·lb)
1 . FOI1< Spring: Smaller end laces up. T4: 15 N-m (1.5 kg-m. 11.0 h -lb)
F: Apply Iori< oil. T5: 39 N-m (4.0 kg-m, 2911-lb)
L: Apply a non -permanentlocking agent T6: 18 N-m (1 .8 kg-m, 13.0 h -lb)
M: Apply molybdenum disulfide grease. n : 20 N-m (2.0 kg-m. 14.5 h · lb)
R: Replacement Parts TB: 59 N-m (6.0 kg-m, 43 h-lb)
S: Follow the specific tightening sequence. T9: 98 N-m (10.0 kg·m, 72 ft· lb)
SUSPENSION 12-3
2. Needle Bearings: Face the

manufacturer's marks out.
12-4 SUSPENSION
Specifications
Item Standard
Front Fork (per one unit):
Fori< inner tube diameter 4> 41 mm
Fori< spring preloed setting Adjuster protrusion is 15 mm (6 Marks)
(Usable Range: 5 - 20 mm)
Air Pressure Atmospheric pressure (Non-adjustable)
Rebound damper setting 6th click from the first click of the tully clockwise position
(Usable Range: 1 +--+12- 13 clicks)
Compression damper setting 5th click from the first click of the fully clockwise position
(Usable Range: 1 +--+ 7 - 9 clicks)
Fork oil viscosity KAYABA01 (SAE5W)
Fork oil capacity 463 ± 4 ml (completely dry),
ZX900-B3 other than US, CN. 457 ± 4 ml (completely dry)
approx. 395 ml (when changing oil),
390 ml ZX900- B3 other ·than US, CN (when changing oil)
Fori< oil level Fully compressed. without fori< spring, below from
outer tube top 86 ± 2 mm,
ZX900- 83 other than US. CN 90 ± 2 mm
Fori< spring free length 304.6 mm (Service limit 300· mm),
ZX900-B3 other than US, CN 387.4 mm
(Service limit 380 mm)
Rear Shock Absorber:
Rebound damper set No. 2 of 4 positions
Compression damper set 1Oth click (12th click. ZX900-B3 other than US. CN)
from the first click of the fully clockwise position
(Usable Range: 1 +--+ 16 - 22 clicks)
Spring setting position
Standard Spring free length minus 12 mm
Usable range Spring free length minus 12 mm to 22 mm
(weaker to stronger)
ZX900-B3 other than US. CN
Standard Spring length 212 mm
Usable range Spring length 212 mm to 206 mm (weaker to stronger)
Spring Free Length
(ZX900-B3 otherthan US, CN)
Standard 226mm
Gas pressure 980 kPa (10 kg/em•. 142 psi. Non -adjustable)
Spacial Tools - Forte Spring Compreucr. 57001-1338

Fori< Spring Slopper: 57001-1374
Fori< Plslon Rod Puller, M10 X 1.0: 57001-1298
Fori< Oil lAval Gauge: 57001-1290
Fori< Oular Tuba Weight 57001-1218
Fori< Cylinder Holder: 57001-1297
Fori< 011 Seal Driver, <1>41: 57001-1298
-ring.Stem Nut Wrenchn: 57001-1100 (2)
Socket Wrench: 57001-1370
011 Seal & Bearing Remover. 57001-1058
Bearing Driver Set. 57001-1129
Inside Cln:llp Pllera: 57001-143
Jaclc: 57001-1238
SUSPENSION 12-5
Front Fork
Rebound Damping Force Adjustment

eTo adjust the rebound damping force, turn the rebound damping
adjuster [ A] until you feel a click.
O The standard adjuster setting for the average-build rider of 68 kg (150
lb) with no passenger and no accessories is the 8th elicit from the 1st
click of the fully clockwise position.
Wboth adf"*re.,.. not a d j - equally, handling may be l""'"'lred

end a hazardous condftlon may r811UII.
O The damping force can be left soft for average riding. But it should
be adjusted harder for high speed riding or riding w ith a passenger. If
the damping feels too soft or too stiff, adjust it in accordance with the
following table.
Rebound Damping Force Adjuolmant

Adjustef Damping
Positiop Force Setting Load Road Speed
12-13 Weak Soft Ught Good Low
t t t t t t
l l ~ l ~ l
1 Strong Hard Heavy Bad High
Compression Damping Force Adjustment

eTo adjust the compression damping force, tum the compression
damping adjuster [A] until you feel a click.
OThe standard adjuster setting for the average-build rider of 68 kg (150
lb) with no passenger and no accessories is the !llh elicit from the 1 st
click of the fully clockwise position.
--- ---~._wA!'l~'i'j(>_ ______ --~~

If both adjllllerl ara noladjulled equally, handling may be Impaired
and a hazardoua condftlon may raouiL
O The damping force can be left soft for average riding. But it should
be adjusted harder for high speed riding or riding with a passenger. If
the damping feels too soft or too stiff, adjust it in accordance w ith the
following table.
Adjuster Damping
Position Force Setting Load Road Speed
7- 9 Weak Soft Light Good Low
i i t t i t
l ! l ! l l
1 Strong Hard Heavy Bad High
12-8 SUSPENSION
Spring PreloMJ Adjustment

e Tum the ~!)ring Pf8loed adjuster [A] to change spring Pf8loed Mtting.
OThe standard adjuster setting for the ayerage-bulld rider of 68 kg (160

lb) with no passenger and no accessories is the 6th marl< [A] (16mm)
[ B] from top as shown.
Ad)- Pralrualon (lrom top)
s.ndarcl: .., Mart< (15 mm)
UMble Aenge 1 - llh Mart< (5 - 20 mm)
•-IICQuoton.,.
•nd •11ezan1ow1
not 8djustocl ~Uy,
c:cnd"lon may ...ult.
'*-• m"Y be lmpelred
O The spring preload can be left soft for average riding. But it should
be adjusted harder for high speed riding or riding with a passenger. If
the spring ection feels too soft or too stiff, adjust it In accordance with
the following table.
Spring Action
Adjuster Dumping
Position Force Setting Load Ro8d Speed
8(20mm) Week Soft Light Good Low
l l l l l l
! ! ! ! ! !
1(6mm) Strong Hard Heavy Bad High
Front Fork Removal (88Ch fork leg)

e Remove:
Upper and L o - Fairings (see Ffame chaJ)Ier)
Front Wheel <- Wheels(Tiras chapter)
Front Fender Rear <- Frame chapter)
* Looeen the handlebar holder bolt [ A), upper fork clamp bolt [ B) end
fori< top plug [C) beforehand if the fori< leg is to be doaauembled.
NOTE
o Loosen thfl top plug after loosening the hendltlbar holder bolt end
upper fork clt~mp bolt.
SUSPENSION 12-7
e l.ooeef1 the handlebar holder bolt [A), uppet" fOfk clamp bolt [ B) and
lowet ton< clamp bolt [ CJ.
e Wrth a twisting motion. wort< the fOfk leg down and out
Front Fork Installation

e lnstall the fork so that the top end [A) of tha <Mer tube Ia lluah with
the UPP« aurface of the handlebar holder.
• Tighten the lowO< fork damp bolt and fork top bolt.
Tor- - ,_l'ofk CWnp - (.._): 21 N-m (U ....,, 21 a.lb)
,_l'ofk Top """' 23 lkn (2.3 lqa-m, 1U .._.)
e Tlghten the handlebar holder bolt and upper fork clamp bolt.
T..,.._- Front
""'""'~' -llolt231kn(2.3....,, 1U.._.)
~
l'ofk Clamp -(Upper): 21 N-m 1 ....,, 15.0 .._.)
NOTE
0 Tighttlfl the top plug beforfl tightening the httndiMJIN hold11r bolt1tnd
uppllr fotk clttmp bolt.
e ln81811 the removed parts (see appropriate chapt8<1).
e Adjuet the spring preload and the damping Ioree.
Fork Oil Changs

e Remove the front fork (see Front Fork Removal) .
• Hold the inner tube IOWO< end in a vise.
• Unacrew the top plug [A] out of the outer tube [B) .
e lnsO<t the fork spring compressor [C) along whh the fork spring
stopper [OJ betwaan the fOil< top plug and the apecO< guide [E]. c
Spec:l•l Toole - fork Spring Compre-: 57001·1331 I
Fork Spring Stiopper: 57001 ·1374
* "the apeciel tools cannot be inserted, tum the spring preload adjuster B
-~
[F] clockwise until the special tools can be inserted.
e Whlle holding up the top plug [A] by one petaon, ~h down [BJ the
apeciel tools end Insert the fOil< spring stoP!* [C) ~ the piston
rod nut [OJ and the spacer guide [E) .
e While pushing the fork spring stopper, pull out the fork spring
compraaor [F].
12-8 SUSPENSI ON
-
eHolding 1M pilton tod nut [A] with a w.....ch [ B] , remove the loft< 101>
plug fJom the pilton tod.
e Remove:
Rebound Damping Adjuster Rod [A]
Fork Spring Stopper [ B]
N OTE
0 While holding down the Spi/C8r [ C]. puH out the lorlr spring stOPfW.
e R411tl()W;
Spacer Guide [OJ end Spacer
Fork Spring
e orain the fork oil into a suitable container.

0 Pump the piston tod [A] up and down at least ten times to expel the
oil from the fork.
• Hold 1M loft< tube upright. press the outer tube and the piston tod ell
the w-vdown.
N OTE
o The spring should not be instslled.
• Fill the front fork to the top with the specified oil.
Recommended 011
KAYA8A &I or SAE5W
• Purge the air from the fork cylinder by gently moving the tod puller
[A] up and down live timM.
Sjleclal Tool - Fort<""*"" Rod Puler, 11110 a 1.0: 57001-12M
A
SUSPENSION 12-9
e Purge 1he air fTom 1>8-.U.. lnne< and oute< tubel by pumping the
outer tube up and down.
NOTE
o While doing this. IMe CMt to ktHJp the oil levtlf topped off so thet it
saws ebovtl thstwo holes tAl ntHJr the top fo thelnntirtube [B).
e After purging the air from the asae<nbly, let it sit for about five minutes
10 that any suspended air bubblea can surface.
e Set the oil level gauge stopper [A) 10 that its low« tide .now. 1he oil
level d istance specified.
Special Tool - Fork Otl l.eftl GM-. 57001-1290 [B)
NOT E
0 The gauge tubs is grodueted In 1 em division.
0 The gauge body is gredueted In 10 mL division. ucludlng the geuge
tube olsbout 5 mL CllpBC/ty.
e w.m 1he fO<k fully com~. intert the gauge tube into the inne<
tube and position the 810!ll* acroa the top of the ou1e< tube.
e Pull the handle slowly to drew out all excess oil
OII IA'tel (fully c:ooo~p uoed, wlthoullortt ~)

Sllond•rd: ee :!: 2 mm (bllow from outer U..lop)
80 :1: 2 mm (be- from oulet tube top, ZXI00-113
ol!ot l11n US. CN)
• Pull the piston rod [A] up above the outer tube top.
e Tighten the rod nut [B] finger- tight
OChe<:k that the visible thread length is at least 12 mm [C] .
e lnaert the rebound damping adjuster rod into the piston rod.
e screw the fork piston rod pulltlf onto the end of the rod.
Special Tool- Fork PilliOn Rod Puller, M10 x 1.0: 57001-1218
e lnstall the fork spring with the smaller end facing upwaod.
e lnstall the spacer and spacer guide.
12-10 SUSPENSION
e While holding up the fork piston rod puller [A] by one person, push
down [B] the fork spring compressor [C] and fork spring stopper
[OJ, and insert the fork spring stopper between the piston rod nut
[E] and the spacer guide [F]. !(!}.
Specia l Toolol - Fori! Spring Camp...._: 57001 ·1338 .!}
"""' Spring Stopper. 57001 ·1374
e While pushing the fork spring stopper, pull out the fork spring
compressor.
e Remove the fork piston rod puller.
e Check the 0 -ring [A] on the top plug and replace it w ith a new one
if damaged.
e Screw in the damper adjuster [BJ of the top plug so that the distance
between the adjuster bottom and t he spring adjuster [C] end is 25
mm [OJ.
e Holding the top plug (A] with a wrench, tighten the piston rod nut
[B] against the top plug.
Torque - Pla1on Rod Nut: 15,..., (1.5 kgofl'l, 11.0 11-lb)
e Rernove the fork spring stopper [C].
N OTE
0 While holding down the spacer [D], pull out the fork spring stopper.
e Raise the outer tube and screw the top plug into it.
elnstell the front fork (see Front Fork Installation).
Front Fork DiS8SS8mb/y

e Rernove the front fork (see Front Fork Removal).
e orain the fork oil (see Fork Oil Change).
e Hold the front fork in a vise [A].
e Stop the cylinder [B] from turning by using the fork cylinder holder
[C] .
Special Tool- Fori! Cylinder Holder: 57001-1297
e Unscrew the Allen bolt [OJ, then take the bolt and gasket out of the
bottom of the inner tube.
e Take the piston cylinder unit [A].

o Do not disassemble the piston cylinder unit
SUSPENSION 12-11
e 5epata1e the inner tube from the outlf tube as follows.

OSiide up the dust seal
0 Remove the retaining ring [A) from the outer tube.
O Grap the inner tube and strOke the outer tube up end down MYif1ll
times. The shock to the loti< seal separates the inner tube from the
OUtlf tube.
* II the tubes are tight. uee a fork outlf tube weight.
Special Tool - For1<01MrTubeWalght 57001·1218
• Remove the inner tube guide bushing [A], outer tube guide buahing
(B), washer (C), oil seal [D), retaining ring and dust seal from the
lnnet tube.
Front Fork Assembly

e Replace the follow ing parts with new one.
Oil Seal
Guide Bushings
• Place an oil coated plastic beg [A) ov« the end of the inn« tube to
proleet the dust seal [B) and oil eeal.
OThe inner tube bushing groove has a sharp edge that can cut the
Mtling lip of the seals aa they are puahed down OYO< the innet tube.
e lnstallthe following parta onto the inn« tube.
Dust Seal
Retaining Ring
Oil Seal
Washer
Out&< Tube Guide Bushing
Inner Tube Guide Bushing
12-12 SUSPENSION
ewhen assembling the new outer tube guide bushing, hold the washer
against the new bushing and tap the washer with the fori< oil seal
driver (A] until it stops.
Special Tool - Fork OIIS..I Driver, <1>41: 57001-1288
eAfter installing the washer, install the oil seal by using the Iori< oil seal
driver. ·
elnstall the retaining ring and dust seal by hand.
elnstall the piston cylinder unit in the inner tube.

• Replace the bottom Allen bolt gasket with a new one.
e Stop the cylinder from turning by using the fork cylinder holder.
Sp.clal Tool - Foft Cylinder Holder: 57001-1297
e Apply a non-pennanent locking agent to the Allen bolt and tighten it.
Torque - Front Fork Botlom Allen Bolt 39 N-m (4.0 kg.m, 29 ft·lb)
e Pour in the specified type of oil (see Fori< Oil Change).
Inner Tube Inspection

e Visually Inspect the inner tube, and repair any damage.
• Nicks or rust damage can sometimes by repaired by usi ng a wet-stone
to remove sharp edges or raised areas which cause seal damage.
*" th& damage is not repairable, replace the inner rube. Since damage
to the inner tube damages the oil seal, replace the oil seal whenever the
inner tube is repaired or replaced.
eTernporarily assemble the inner and outer rubes, and pump them back
and forth manually to ch&ck for smooth operation.
CAUTION
II lie Inner lUbe le IM!dly bent or c r . - , replace II. Exceeatve
bencllng.lollowed by subeequent alralghtenlng, can weaken lie Inner
tubs.
Dust Sea/Inspection
e lnspect the dust seals [A) for any signs of deterioration or damage.
*Replace it if necessary.
SUSPENSION 12·13
Spring Tension
• Since a spring becomel lhortllr 11 it weakens. check ill ' - length
[A] to determine its condition.
*If the spring of either fork leg Ia ahorter than the S81Vice limit. it must
be replaced. If the length of a replacement spring and that of the
remaining spring vary greatly, the remaining spring should also be
replaced in order to keep the fork legs balanced for motorcycleltabllity.
Spring Fr•!Anglh
ZX80011 , 12, 13 (US, CH) ~
.._ 304JI nvn 387..4 mm
hMce limit 300 mm 380 mm
12-14 SUSPENSION
Reer Shock Absorber
Rebound Damping FtXC8 Adjustment

e Ta adjuat the n!bound damping force. tum the rebound damping
adjulter [A] to the desired number [B] until you feel a click end the
number aligns with the marl< [C] .
OThe ltlndard adjuster setting for an ave<age-build rider of 68 kg (160
lb) with no passenger and no eccesaories is number 2.
* If the damping feels too aoft or too stiff, adjult it.
Rebound o.mplng Force A. . .b ; -
Adjuster Damping
Pa.ition Force Sening Load Road Speed
1 Weak Soft Light Good low
t t t t t t
L L L L L L
4 Strong Herd HeeiiY Bad High
Compr6$$iOn Damping Force Adjustment

e Ta adjust the compr883ion damping force, tum the compreealon
damping adjuster [A] on the gaa rnervoir until you feel a click.
OThe 1tandard adjuster setting for the average-build rider of 88 kg (160
Ib) with no passenger end no accessories is the 1Oth . - (12111 clfclc
ZXI00-83 - tt.1 US. CN) from the 1st click of the fully clockwlee
I)Oiition.
OThe damping force can be left aoft fo r - - riding. But it lhoold
be adjuatad hafder fo< high speed riding or riding with a pun OQef. If
the damping feels too aoft or too Iliff, adjust it in accordance w ith the
following table.
Compruafon Damping Force Ad,...,.enl
Adjuster Damping
Position Fon:e Setting Load Road Speed
18-22 Weak Soft light Good Low
t t t f f f
L 1 L 1 L 1
1 Strong Herd Heavy Bad H;gh
Spring Preload Adjustment

Refer to P.12-6 for ZX900- B3 other than U.S. and Canadian Models.
• Remove the rear shock abeorbe< from the frame <- Rear Shock
Abeorbe< Removal).
• Looeen the locknut and tum out the adjusting nut to free the apring.
Speclel Toot - s..tnQ Stem Nut WNOICMe: 57001-1100 (2)
e Measure the spring free length.
SUSPENSION 12-15
e To adjust the spring preload, turn in the adjusting nut [A) to the
desired position and tighten the locknut [B).
(C] Spring Length
Spring Preloecl Setting
Sllondard: Spring ,,_ length min,. 12 mm
Uaable Range: Spring 1.- length min,. 12 to
22 mm < - •r to stronger)
OThe standard adjusting nut setting for an average-build rider of 68 kg
(160 lb) with no passenger and no accessories is compressed 12mm
than free length.
*If the spring action feels too soft or too stiff, adjust it.
Spring AdJustment
Adjuster Damping
Position Force Setting Load Road Speed
12mm Weak Soft Light Good Low
i t t t t t
l l l l l l
22mm Strong Hard Heavy Bad High
Rear Shock Absorber Removal

e Rernova:
Side Covel$ (see Frame chapter)
Battery
Lower Fairings (see Frame chapter)
Rear Brake Reservoir Mounting Boh [A)
• Loosen the clamp· screws (B) and remove the gas reservoir [C) from
the bracket [D).
e Rernove:
Muffler Body (see Engine Top End chapter)
Right Lower Fairing Stay
Side Stand
e Remove:
Lower Shock Absorber Boh [A)
Upper Tie- Rod Bolt [B)
Upper Shock Absorber Bolt [A)

e Remove the shock absorber with the gas reservoir toward the ground.
12-16 SUSPENSION
Rear Shock Absorber Installation

ePack the rocker arm needle bearings with molybdenum disulfide
grease.
elnstall the rear shock absofber so that the rebound damping adjuster
[A] end gas reservoir hose fitting [8] face rearward.
elnstall.the gas reservoir clamp screws under the reservoir.
eTighten the following nuts:
Torque - Reer Shock Abeorber Nuts: 58 N-m (8.0 kg-m, 4311-lb)
TloHbl Nula: 58 N-m (8.0 kg-m, 43 ft..lb)
Rear Shock Absorber Scrspping

i•WARNING
Sinal lie r•ervolr lank of the rear ahock abaortlerc:ontalna nllrogen
gu, do not Incinerate lhe r-rvolr tank wllhout 11rwt releaalng the
gaa or n may explode.
e Rernove the shock absorber (see Rear Shock Absorber Removal).

e Rernove the valva cap [A] and release the nitrogen gas completely
from the gas reservoir.
e Remove the valva.
Since lhe high preeaure 11• Ia dangetoua, do not point lhe valve
-•rei )'OW' Ieee or body.
Spring Preload Adjustment (ZX900-83 other than US, CN)

eRemove the rear shock absorber from the frame (see Rear Shock
Absorber Removal).
• Loosen the locknut and turn out the adjusting nut to free the spring.
Special Tool - Sleerlng Slem Nut Wrench: 57001-1100 (2)
e Measure the spring free length.
Spmg Free Langill
Slendard:. 228 mrn
1+----{C )--+1
e To adjust the spring preload, turn in the adjusting nut [A] to the
desired position and tighten the locknut [B] .
[C] Spring length
Spring Preload Selling
Slendard: Spring lenglh 212 mm
Usable Rang•: Spring lenglh 21210 208 mm (weaker 10 a1ronger)
O The standard adjusting nut setting for an average-build rider of 68 kg
(150 lb) with no passenger and no accessories is 212 mm spring
length.
*If the spring action feels too soft or stiff, adjust it.
Spring Adjualrnent
Adjuster Damping
Position Force Setting load Road Speed
212mm Weak Soft light Good low
t t t t f f
l l l l ! !
206mm Strong Hard Heavy Bad High
SUSPENSION 12-17
Swingarm
Swingsrm Rsmoval
e Remo'ole:
Rear Wheel <- Wheels!loes chapter)
Chain Cover [A]
Brake Hose Clamp [ B]
Muffler body [C] <-Engine Top End chapter)
Lower Shock Absorber Bolt [A]

Upper Tle· Rod bolt (B]
e unecrew the swingarm pivot locknut [A], ualng the lOCket wrench
[B].
Special Tool - Socket Wrench: 57001-1370
e Untetew the swingarm pivot nut [A], end tooaen the awingerm pivot
ahefl [ 8 ].
t Pull off the pivot shaft and remove theswingarm.
t Aemove th left collar (A] and right collar from the swingarm [ 8 ].
12-18 SUSPENSION
Swing/Jim Installation
e Apply plenty of molybdenum disulfide g , _ to the bell bearing,
needle beMngs and gt8Me seals.
e lnm" the eollara. twingarm [A] and pivot shaft (B] .. shown.
OPI-Ihe left collar [C] on the stopper [OJ inside the freme (E].
o lneert the pivot shalt into the frame from the left side.
e Tightan the pivot lheft.
Torque - SW!ngarm Pivot- 20 N-m (2.0 ko-<n, 14.1 ....lb)
e Tlghten th!t pivot nut.
TOf'qUa - SWingerm Pivot Nut: 88...., (10.0 kgom, 72 ft.lb)
e Tigh1en the pivot lock nut [F] using the socket wrench.
Spacl81 Tool - Sockal WNnCh: 57001·1370
TOf'CIU8 - SWingorm ,_Lac* Nut 1N1...., (10.0 kg-m, 72 ....lb)
e lnstall the removed parts <-appropriate chap1811).
S wingMm B81Nin g Removal

e Aemova:
Swingarm
Collara
GreaseSeala
Sleeve
C4 rclip (right aida)
Spacial Tool - llwlcla Clrcllp Pllara: 57001 -143
• Remove the bell beating and needle bearings using the oil - ' &
bearing remover [A] .
Spacial Tool - Oil leal & ~ R..,_ar: 57001·1051
Swing11m1 888/'ing Installation

e Apply plenty of molybdenum disulfide to the bell beanng and needle
bearings.
e lnstall the bearings so lhatlhe manufacturer's marks f - out.
Spacial Tool - IIMtlng Drlftr Set 57001·1121 [A]
SUSPENSION 12-19
Tie-Rod, Rocker Arm
Tie-Rod Removal
e Remove:
e Using the jack. raise the rear wheel off the ground.
e Remove the upper tie-rod bolt [A) and lower tie-rod bolt (B), and take
out the tie-rods [C) .
Tie-Rod Installation
e Apply molybdenum disulfide grease to the inside of the needle
bearings and oil seals.
e Tighten the upper and lower tie-rod bolts.
T..-que - Tle-Rod Nuta: 59 N-m (6.0 kg-m, 431t·lb)
Rock.er Arm Removal

e Remove:
Spllclal Tool - Jack: 57001·1238
e Remove:
Lower Rear Shock Absorber Bolt [A)
Lower Tie-Rod Bolt [B)
Rocker Arm Bolt [C)
Rocker Arm [D)
l
I
I
Rocker Arm Installation

t Apply molybdenum disulfide grease to the inside of the needle
bearings and oil seals.
t T!Qhten the rocker arm bolt, tie-rod bolt and shock absorber bolt
Tor'IU8 - Rocker Arm Nut 59 N-m (6.0 kg-m, 431!-11)
Tie-Rod Nut 59 N-m (8.0 kg-m, 4311-lb)
Rear shock Absorber Nut: 59 N-m (6.0 kg-m, 431!-lb)
12-20 SUSPENSION
Needle Bearing Inspection

*II there is any doubt as to the cond~ion of eigher needle bearing,
replace the bearing and sleeve as a set.
Tie-Rod. Rocker Arm Sleeve Inspection

*II there is visible damage, replace the sleeve end needle bearing as s
set.
STEERIN G 13-1
Steering
Table of Contents
Exploded View ..........................................................................................................13· 2

Specifications ............................................................................................................13· 3
Steering .....................................................................................................................13· 4
Steering lnspection ...............................................................................................13· 4
Steering Adjustment .............................................................................................13· 4
Steering Stem ............................................................................................................13· 5
Stem. Stem Bearing Removal ...............................................................................13· 5
Stem, Stem Bearing lnstallation ...........................................................................13· 5
Stem Bearing Lubrication .....................................................................................13· 7
Handlebar ..................................................................................................................13· 8
Handlebar Removal ..............................................................................................13· 8
Handlebar lnstallation ...........................................................................................13· 8
13-2 STEERING
Exploded View
AD: Apply adhesive.

G: Apply grease.
L: Apply a non-permanentlocking agent.
T1: 39 N-m (4.0 kg-m, 29 ft-lb)
T2: 4.9 N-m (0.50 kg-m, 43 in -lb)
or Hand-tight
T3: 6.9 N-m (0.70 kg-m, 61 in-lb)
T4: 34 N-m (3.5 kg-m, 25 ft-lb)
T5: 23 N-m (2.3 kg-m, 16.5 ft· lb)
T6: 9.8 N-m (1.0 kg-m, 87 in-lb)
T7: 3.4 N-m (0.35 kg-m, 30 in-lb)
T8: 21 N-m (2.1 kg-m, 15.0 ft-lb)
T9: 28 N-m (2.9 kg-m, 21 ft-lb)
STEERING 13-3
Specifications
S,.Cial Tool8 - - l n g SIMn Nut w..-: 57001·1100
-Pipe 0... A-. p,_ SNit 57001-1CI7S
- P i p e 0... "-Driven: 57001-1 077 (2)
s•urkog SIMn ~ Drtvet: 57001·1144
Stoorloog SIMn BMrlng om.~ 57001-1:M5
13-4 STEERING
Steering
SttWing Inspection
• Checlt 1he lteMng.
o Uft the flont wheel off the ground using the jack.
Special Toot - Jeclc 57001-1238
OWIIh the flont wheel pointing S'lraight ahead, allemately tap Nch end
of the hendleber. The front wheel should swing fully left and right
from the forc:e of gravity until the fork hits the atop.
* If the wheel binds or catches before the stop, the steering ~ too tight.
o Feel for steering looseness by pushing and pulling the forl<a.
*If you laellooseneas. the steering is too loose.
NOTE
0 The cables end wiring will have some effect on the motion of the
forlc which must be taken into eccount
Be sur. the wires end cables ate prof)Miy routed.
0 The beMfngs must be in good condition and prof)Miy lubricated in
Olthr f01 •ny test to be veNd.
Steering Adjustment
e Remove>
Upper fairing (see Frame chapter)
Air Cleener Houaing [A] (see Fuel System chapter)
Reer Vi- Mirror Bracket [B] and Mounting Botu [C]
e t.ooeen:
Lower Fork Clamp Bolts (both sides)
Stem Head Nut [A]
e Adjustthe ateering.
Speclotl Toot - S~ Sliam Nut Wrlftdl: 57001-1100 (I ]
* "the steering is too tight loosen the stem nut a fraction of a turn.
*"the steering iatoo loose, tighten the nut a fraction of a tum.
NOTE
0 Tum the stem nut 1!8 tum ere time maximum.
e Tighten the at--'ng stem head nut and lower fork clamp botu.
Torque - Sill lng S1em - - 3t N-m(4.0 kg.m, 2111-11)
l'ron1Foo1c Clemp- (Lower): 21 tHn (2.t kg-m, 21 - )
e Checlt the stMfino again.
* II the steering is IIiII too tight or too loose, repeetlhe edturtment.
STEERIN G 13-5
Steering Stem
Stem. Stem 888fing Removal

e ReniO\Ie:
Upper and lowe< Fairings (see Frame chapte<)
Fuel Tank (see Fuel SVS!em chapter)
Air Cleener Housing (see Fuel Sys!em chapte<)
Rear V1ew M inor Bracket
Brake HOM Joint Mounting Bolts [A]
Front Wheel (see Whoelsmres chapter)
Front Follt (see Suspension chapter)
Steering Stem Head Nut and Washer
Steering Stem Haad
e Pushing up the stem base, and remove the lock washer (A] , atern nut
[B],IIem cap [C] and 0-ring,then remow the ateering stem [OJ and
stern base.
Speclel Toot - s...nng S1em NutWNnch: 57001-1100
e Removethe upper stern bearing inner race.
e To remove the outer races [A] pnassed into the heed pipe [B], Insert
a bar [C] into the head pipe, and hammer evenly around the circum-
ference of the opposite race to drive it out
NOTE
0 If ttlthar stttttring stem besting is dsm11gttd. It Is recommttndttd thst
both the upper and lower bearings (Including outer ractts) should
be replecttd with new ones.
• ReniO\Ie the lowe< stem bearing ( w ith ita g , _ ...1) w h ich • P<....t
onto the ateering stem with a suitable commercially evailable bearing
pulle<.
SU!m. Stem Bearing Installation

e Apply grease to the outer races, and driw them into the heed pipe at
the aame time
Speclool T - - -Pipe 0...... Axe PNee SNit 57001-107$ {A]
H. .d Pipe OUte.- R - DriYerl: 57001-1077 (II] (2)
13-6 STEERING
e.Apply grease to the lower inner race [A]. and drive it onto the stem.
Special Toole - Sleerlng Slllm Bearing Driver: 57001-1344 [ B]
Sleerlng Slllm Bearing Driver Adapler: 57001-1345
[CJ
eApply grease to the upper inner race, and install it in the head pipe.
elnstall the stern through the head pipe and the upper inner race, and
install the 0-ring on the stem shaft while pushing up on the stem base
[A].
elnstall the stern cap [8], and hand tighten the stem nut [C].
NOTE
Olnsta/1 the ste8fing stem nut so that the st8pped side [D] factJS
down.
elnstallthe stern head.

elnstallthe washer, and tighten the stern head nut lightly.
eSetttethe inner races in place as follows:
OTighten the stem nut to 39 N-m (4.0 kg· m, 29 ft· lb) of torque. (To
tighten the steering 818111 nut to the specified torque, hook the wrench
on the stem nut. and pull the wrench at the hole by 22.2 kg [A] force
in the direction shown.)
Special Tool - S1eerlng Slam Nut Wrench: 57001-1100 (B)
OCheck that there is no play and the steering stem tums smoothly
without rattles. If not. the bearings on the inner races may be
damaged.
OAgain back out the stem nut a fraction of a tum until it tums lightly.
eTum the stem nut lightly clockwise until it just becomes hard to turn.
Do not overtighten, or the steering will be too tight.
Torque - Sleerlng Slam Nut Hand-Ught or 4.9 N.., (0.50 kg..,, 43 ln·lb)
•Install the front fori< (see Suspension chapter) .
NOTE
0 TightiNI the fork upper clamp bolts first next the stem htJBd nut last
the fork JowtJr clamp bolts.
Torque - SIHrlng S1em- Nut: 39 ~ (4.0 kg-m, 29 fl.lb)
Front Fork Clamp Bollll (Upper) : 21 N.., (2.1 kg-m, 15 11-lb)
(Low..,: 28 N-m (2.8 kst-m. 21 - )
elnstall the removed parts (see appropriate chapters).
Do not Impede !be hancllebolr turning by routing the cabiH,

h . , . _ and - Imp operly (IH General Information chapter).
STEERING 13-7
Stem BBBfing Lubrication

e Remove me st.nng stem.
e llsing a high flash-point sot.ent. wash the uppe< and lower tapered
roller bearings in the cages, and wipe the uppet and lower oulllf riiC8I,
whic:h ere p<eoa· fitted iniO the frame head pipe, c:Je.1 off g . - end
dirt.
e visually check the outer races and the rollers.
*Replace the bearing -..biles if they show wear or damage.
• Pack the upper and lower tapered roller bearlnga [A) In the cagee with
grease, and apply 1 light coat of grease to tha upper and lower outer
111C8S.
elnstall the stearlng stem, and adjust the ateerlng.
13-8 STEERING
Handlebar
Handlebar Removal
eRemove:
Clutch Mester Cylinder
left Handlebar Switch Housing
Front Brake Master Cylinder
Right Handlebar Switch Housing
Throttle Grip
Handlebar Bolts (A]
Handlebar Holder Position Bolts (B)
Handlebar Holder Bolts (C)
e Remove the handlebar holder (D) from the front fork, and then pull
out the handlebar [E) .
Handlebar Installation
eApply a non-permanent locking agent to the threads of handlebar
holder position bolts and handlebar bolts. and tighten the following
bolts.
Torque - Handlebar Holder Bolb: 23 N-m (2.3 kg-m, 18.5 tt.lb)
Handlebar Holder Poeltlon Bolli: 9.8 N-m (1.0 kg-m, rt1 Jn.tb)
Handlebar Bolla: 34 N-m (3.5 k!l-f11, 2511-lb)
elnstallthe removed parts (see appropriate chapters) .
FRAM E 14-1
Frame
Table of Contents
Exploded View ..........................................................................................................14-2

Seats ..........................................................................................................................14-5
Rear Seat Removal ...............................................................................................14- 5
Rear Seat Installation ............................................................................................14- 5
Front Seat Removal ..............................................................................................14- 5
Front Seat lnstallation ...........................................................................................14-5
Side Covet-s ...............................................................................................................14- 6
Side Cover Rernoval .............................................................................................14-6
Fairings ......................................................................................................................14-7
Inner Fairing Removal ..........................................................................................14-7
Inner Fairing lnstallation .......................................................................................14- 7
Upper Fairing Removal .........................................................................................14-7
Lower Fairing Removal ........................................................................................14- 7
Fenders ......................................................................................................................14-8
Front Fender Removal ..........................................................................................14-8
Rear Fender Removal ...........................................................................................14-8
Rear Frame ................................................................................................................14--9
Rear Frame Removal .............................................................................................14-9
Rear Frame Installation .........................................................................................14 -9
14-2 FRAME
Exploded View
. L:Apply .a non-pennanent
• locktng agent
0. Apply oil.
(ZX900-B3 otlle< dian US. CN)
(ZX900· B3
~ ~ '-USC'J~
T1: 44N m(4S .

T2: 34 N:m . kg· m, 331t· lb)
Ta: 49 N -m ~~-~ :g-m, 251!-lb)
· g -m. 361t·lb)
FRAME 14-3
14- 4 FRAME
AR: Austria
CN:Canada
FG: Germany
GR: Greek
NR: Norway
SO: Sweden
ST: Switzerland
US: United States
FRAM E 14-5
Seats
RtNif SBBt Removal

e lr\Mit the ignition switch key into the 188tlock [A]. tumino the key
counterclockwise, pulling up on the rur of the a.t [B], and pulling
1M- lotward.
RtNJr SBBt Installation

e Siip the rear loop [A] under the hooks [B] on the hook bracket [C].
e lnsert the seat pin [0] into the latch hole (E) .
• Push down the rear part of the seat until the lock clicka.
Front SBBt Removal

e Remove:
Rear Seat
Bola (A] and Hook Bracket [B]
e Removo the front seat [C] by pulling it up on the rear and to the rear.
Front SBBt Installation

e Siip the front seat hook [A] under the brace ( B) on the fuel tank
bracket [C), and insert the seat pins (OJ into the holae [E] in the
frame.
J d
14-6 FRAME
Side Covers
Side Cover Removal

eRemove:
Seats
Bolts [A) (ZX900-B3 other than US, CN)
Passenger Grab Rail [B) (ZX900-B3 other than US, CN)
Screws (A)
Clamps [B)
Tail/Brake Lights Lead Connector.
ePull the left and right side covers with the tail/brake lights backward.
eRemove:
Tail/Brake Lights Bracket [A) and Bolts [B)
Screws [C)
Left Side Cover, Right Side Cover and Rear Center Cover [D)
FRAME 14-7
Fairings
Inner Fairing Removal

e Remove the screws [A], and pull the front part of the inner fairing
[B) upward [C) to clear the stopper
• Remove the inner fairing.
• Remove the other inner fairing in the same manner.
Inner Fairing Installation

e Fit the projection [A) on the inner fairing [B) Into the hole [C) in the
air intake duct [OJ.
e lnstall the screws.
Upper Fairing Removal

e Remove:
Inner Fairing
Rear View Mirrors [A]
Bracket Nuts [B)
Screws [C)
Headlight Connector
Tum Signal Ught lead Connectors
City Light Connector (other than US, Canada and Australia)
• Remove the upper fairing.
Lower Fairing Removal

e Rernove:
Screws [A) [B)
Allen Bolts [C)
Clamp [ OJ
e Pull the lower front part of the lower fairing outward to clear the
stoppers [E).
e Remove the lower fairing.
e Remove the other lower fairing in the same manner.
NOTE
o If when the left and right lower fairings rM>ovtJd at the same time,
do not remove the screws [8] (both sides), clamp [D) and stoppers
[E).
14-8 FRAME
Fenders
Front Fender Removal

e Remove the screws [A] and take off the front fender front [B].
e Remove:
Brake Hose Clamps [A]
Speedometer Cab I~ Clamp [ B]
Bolts [C]
• Remove the front fender rear [0].
Rear Fender Removal

e Remove:
Seats
Side Covers
Junction Box
Starter Relay and Main Fuse
Tum Signal Relay
Fuel Pump Relay
Battety
Rear Brake Reservoir Mounting Bolt
Tum Signal Light Lead Connectors
Gas Reservoir
Hooks [A]
Bolt [B]
e Remove the !'OOr fender· [C].
FRAME 14-9
Rear Frame
Rear Ff11m6 Removal

e Rem011e:
Seetl
SideCove<s
Junction Box
Staner Relay and Main Fuse
Tum Signal Relay
Fuel Pump Relay
Battery
Rear Brake Reservoir Mounting Bolt
IC Igniter
Tum Signal Light Lead Connector
Gee Reservoir
Rear Footpeg Bracket [ A)
Frame Bolts and Nuts [B]
R88f Fr81718 Installation

e Tlghten the frame bolts and nuts.
Tol'<l" - Rear Frame Bolla and Nuts: 44 IHn (4.5 k~ , 33 ft.lb)
ELECTRICAL SYSTEM 15·1
Electrical System
Table of Contents
Pan. Location .........................................................15-2 Assembly ..........................................................15-32

EJcploded View ........... .............................................15-3 Brush Inspection ..............................................15-33
Specificetiona ..........................................................15-5 Convnutator Cleaning and lnspection .............15-33
ZX900-81 , 82 Wifing Diagram (US and Caneda)15·7 Annatwe lnlt*OO.o ......................................... 15-33
ZX900- 81 , 82 Wiring Diagram (Australia) ............1 5· 8 Brush Lead Inspection .....................................15-34
ZX900- 81 , 82 Wiring Diagram Brush Plate and Terminal Bolt lnapectJon .......16-34
(United Kingdom) ...................................................15-9 s- Relay lnspection ...................................16-34
ZX900-81 , 82 Wiring Diagram Lighting System ....................................................15-36
(European Models e~oapt United Kingdom) .......15-10 Headlight Beam Horizontal Adjuatment ..........15-36
Precautlona............................................................1 6 -11 Headlight Baem Vertical Ad)uatment ...............16-36
Electrical Wiring ....................................................16-12 Headlight Bulb Replecement ...........................16-37
Wiring lnspection .............................................16-12 Headlight Diode Inspection
Batteoy .............................................................. .....16-13 (Europe models ~cept U.K.) ...........................16-37
Charging Condition Inspection .......................16-13 Tail/Brake Light Bulb Replacement .................16-40
Refreehlng Charge ............................................16-1 3 License Plate Light Bulb Replacement ............15-40
Altemator ...............................................................16-15 Turn Signal Relay lnspection ...........................15-40
Removal ............................................................15-15 Fuel Pump .............................................................15-43
lnatalletlon ........................................................16-16 Removal/Installation ........................................15-43
Oisauembly ......................................................16-16 Fuel Pump Relay lnapeclion ............................15-43
Allembly ..........................................................16-17 Fuel Pump Operationellnspectlon ..................15-43
Ope<a~ional Inspection .....................................15-1 9 Rediator Fan Systam .............................................15-45
Teat No. 1-Betteoy Discharged ....................15· 19 Fan System Circuit lnspectlon .........................15-45
Teat No. 2·Bat181Y Overcharged .................16-20 Fan Motor lnapeclion .......................................15-45
Test No. 3-Noise .........................................16-20 Meters, Gaugee .....................................................15-45
Stetor Coillnapectlon ......................................15·20 Removal ............................................................15-46
Rotor Coillnapeclion .......................................16-21 M eter, Gauge Disassembly ..............................15-46
Slip Ring Cleaning ...........................................16-21 Bulb Replacement ............................................15-46
Slip Ring Diameter ...........................................! 6 -22 Meter, Gauge Assembly ..........,........................15-46
Carbon Brush Length .......................................I 5 -22 Tachometer lnspection .....................................15-47
Rectifier lnspectlon ...........................................16·22 Water Temperatura Gauge Inspection .............16-48
Regulator Inspection ........................................16. 22 Fuel Gauge Operation lnapectlon ....................15-49
Altemetor Ball Bearing lnspection ...................16-23 Sw itches and Sensora ...........................................15-60
Ignition Syatern ............................................. ........1 6 -24 Front Brake Light Switch lnapectlon ...............16-60
Pickup Coil Rernoval. .......................................16-26 Rear Brake Light Switch Ad)uatment ..............15-60
Pickup Coil Installation ....................................16-26 Radiator Fan Switch Inspection ......................15-60
Pickup Coil Inspection .....................................16- 26 Water Temperature Sensor Inspection ............15-51
Ignition Coil Removal/Installation ...................16- 26 Fuel Level Sensor Inspection ...........................15-51
Ignition Coilln.spection ....................................16-26 Junction Box.........................................................15-52
Sp&l1t Plug Romoval.........................................15-27 Junction Box Fuse Circuit lnapection .............15-52
Spar!< Plug lnstallatlon .....................................15-28 Starter Cirruit/Headlight Relay lnapeclion ......15-52
Spall< Plug Gap lnapeclion ..............................15-28 Diode Circuit Inspection ..................................1 5-53
IC Igniter Inspection.........................................! 5 -28 Fuse .......................................................................15-55
Startat Motor .........................................................15·31 30A Main Fuse Removal .................................15-55
Removal ............................................................15-31 Junction Box Fuse Removal. ...........................15-55
Installation ........................................................16-31 Fuse Installation ...............................................15-55
Olaassernbly ................................................. .....15-31 Fuse Inspection ................................................15-66
15-2 ELECTRICAL SYSTEM
Parts l..ocation
1. Ignition Coils 7. S'-rtor Lockout Switch 13. IC Ignitor

2. Alternator 8. Radiator Fen Switch 14. Rear Brake Light Switch
3. S~Motor 9. Neutral Switch 15. Front Brake Ught Switch
4. Fuel Pump 10. Side Stand Switch 16. Water Temperature Sensor
5. Fuel Pump Relay 11. Turn Signal Raley 17. Pickup Coil
6. Junction Box 12. Stertor Relay and Main Fuse 16. Oil Preuure Switch
ELECTRICAL SYSTEM 16-3
Exploded View
1. City Light (Except AS, CN, US)

2. Headlight (AS, CN, UK, US)
3. Headlights (Europe except UK)
4. Tum Signal Lights
5. Pickup Coil
6. IC Igniter
7. Taii/Bral(e Lights
8. Ucense Light
AS: Australia IT: Italy
L: Apply a non-permanent locking agent.
n : 13 N-m (1 .3 kg-m, 113 in-lb)
T2: 9.8 N-m (1 .0 kg-m, 87 in -lb)
T3: 7.8 N-m (0.80 k.g-m, 69 in-lb)
T4: 25 N-m (2.5 k.g-m, 18.0 ft-lb)
T5: 1.0 N -m (0.10 kg-m, 9 in-lb)
1. Fuel Pump Relay

2. Fuel Pump
3. Starter Motor Clutch
4. Starter Relay

L: Apply a non·pennanent locking agent.
M: Apply molybdenum disulfide grease.
T1: 25 N-m (2.5kg-m, 18.0 ft-lb) T6: 11 N-m (1.1 kg-m, 95 in-lb)
T2: 54 N-m (6.5 kg-m, 40 ft- lb) n: 4.9 N-m (0.50 kg-m, 43 in-lb)
T3: 4.4 N-m, (0.45 kg-m, 39 in-lb) T8: 5.9 N-m (0.60 kg-m, 52 in-lb)
T4: 2.6 N-m (0.25 kg-m, 22 in -lb) T9: 9.8 N-m (1 .0 kg-m, 87 in-lb)
T5: 3.4 N-m (0.35 kg· m, 30 in -lb) T1 0: 12 N-m (1 .2 kg-m, 104 in-lb)
I fTl
~~
©-& ~
'1--®
1. Headlight Diode
2. Tum Signal Relay
3, Junction Bo•
4. Rad~ Fan Switch
5. Watlll T8mi*81Ur8 Senter
6. Radiator Fan
L: ~ 1 non-pennanent loclting agenL 7. Oil Pressure Switch
SS: Apply silicone sealanL 8. Neutral Switch
T1 : 3.4 N-m (0.35 kg-m, 30 in-lb) 9. Front Brake light Switch
T2: 18 N-m (1.8 kg-m, 13.0 ft-lb) 10. Ignition Switch
T3: 7.8 N-m (0.80 kg-m, 69 in-lb) 11. Side Stand Switch
T4: 15 N-m (1 .5 kg-m. 11.0 ft-lb) 12. StBrter Lockout Switch
T6: 1.0 N· m (0.10 kg -m, 9 in-lb) 13. Rear Brake Ught Switch
Specif"IC8tions
Item Standard
Battery:
Type MF (Maintenance Free) Battery
Capacity 12V10Ah
Voltage 12.6 V or more
Alternator (Charging Syatam):
Type Three-phase AC (built-in regulator/rectifier)
Charging voltage 14.2- 14.8 V@ engine speed 4 000 r/min(rpm)
Rotor coil resistance 2.3-3.50
Stator coil resistance 1.0 0 or less
Slip ring diameter 14.4 mm (Service Umit 14.0 mm)
Carbon brush length 10.5 mm (Service Umit 4.5 mm)
Ignition s.,.tem:
Pickup coil air gap 0.4 - 0.6 mm (Non-adjuStable)
Pickup coil resistance 375 - 565 0 (. 1 00 0)
Ignition coil:
3 needle arcing distance 7 mmormore
Primary winding resistance 2.3 - 3.5 0 (. 1 0)
Secondary winding resistance 12 -18k0 (• 1 kO)
Spark plug:
Spark plug gap 0.7 - 0.8 mm (Twin - electrode Spark Plug)
Spark plug cap resistance 3.75 - 6.25 kO (. 1 kO)
IC igniter resistance in the text
Elact.r ic Stllrter System:
Starter motor:
Brush length 12 mm (Service limit 8.5 mm}
Commutator diameter 28 mm (Service limit 27 mm)
Fuel Pump:
Fuel pump relay internal resistance in the text
Fuel pump pressure 11 - 16 kPa (0.11 -0.16 kg/em•. 1.6- 2.3 psi)
Switch and Sensor:
Rear brake light switch timing ON aher about 10 mm pedal travel
Engine oil pressure switch connections When engine is stopped: ON
When engine is running: OFF
Fan switch connections
Rising temperature From OFF to ON @ 93 - 1OJ+C (199 - 217•F)
Felling temperature From ON to OFF@ 91 - 95•c (196 - 20J+F)
ON: Less than 0.5 0
OFF: More than 1 MO
Water temperature sensor resistance 47 - 57 0 @80•C (176•F)
25 - 30 o @1 oo·c (212·F>
Fuel level sensor resistance FULL position: 1 - 5 0
EMPTY position: 103- 117 0
ttend r-. srocn.ee3

Specl81 Toole -
Crankc- Splllllng TooiAuembly: 57001·1362
Belting Driver Set 57001-1129
Sperle Plug Wrench, 18mm: 92110.1154
Sealant - Kaw-1 Bond (SIIIconelleelanl)e 5801 ..120
ZX900-81. 82. 83 Wiring Diagram (US and Canada)
RIGht HandlebaT SwltChll

t . Front erakt LIGht Switch
2.Entlnt SlOP SWitch
Radiator Fan SYitch 3. starter Button soan P
lonlt l on ~IL/'1 -
SWitCh
LJo-oL/IK-t---,
water remo. Stnaor
r--1.,_ Y/'1--
Neutral Indicator liGht
I! VI. 4W ~11/T-t-h
Tachometer Llal'lt
12V1. TWl2
Qk_ n:[!J::Ikfl=-
t achometer
QJ-"'Fan
;.d 1a tor
SDIIdDmlttr LIGht
UVt. 7WX2
water Temoarature
GIUOI
Fuet eauoe
water TemP/Fuel aauot

LIOht 12'11. TY
Hloh eean Indicator
L I OI'It 12Y3. 4'1f
turn Slonat Indicator
t.IQht UV3. 4W
Oi l Preaaurt warn I no
LIOht 12V3.4W
Hlldi i OM
1ZVI0/55W
(
SICII Sl
Stand Sl
Sw l tof'l s.
Left Handlebar swltchea
1. Horn Button
2. Turn Slonat Switch
3. 0imme r Sw i tch
4.Starter Loclout Swi tch
ELECTRICAL SYSTEM 1 5-7
sun Pluoa
Junct: I on lot
-
I. HOfft FUll 10A
2. lonltlon FUll tOA
l. Till I IOht FUll lOA
4.Htldl IOht FUll lOA
5. Fan FUll lOA
8 . ACC 'UII lOA
t. Turn Sltnat Lltht Turn
FUll lOA
stonal
11111
.. :
.J~
~
v M
• •
.
-
•
~
r;_ '\
~ j
IIIID
..: s.
j;::
I ""'
llortor
li llY
i~
I~~
steno
Htutral
SWitCh
~ 1-
1----'
~lim Starter
hl1en AI urnetor Wotor
EAL :EltOtriCil ACCIIIOf Y lead&
--, '-·
T
~ ''""
lr_or_ _II
(ti0$1·UotC)C
ZX900-81, 82, 83 Wiring Diagra"? ,(~p~ralia)
IIOht Handltbar SWitChll

l.Front Bra•• LI Ght SWitch
a.Enolnt stoo Swttcn
Rad iator F&n SWitch 3. starttr Button SPirt Ph
(!)
r~mltlon
SWitch
1,,0 '""·
~.
1tn1tlo.1
tolls
Neutral Indicator Lloht
uu."
Tacho-.ttr Lloht I~
12Yl. fWI2
Tf
TO.ChOMttr
iI I
SPeedometer Lloht
12YI.TWI2 ...___
water ro..eraturo
84UOI
~
~ ,.: I=r- r- --
Fut I Oauoe lJ .
-
...--· r_-
~- ~~i ,·,_ L
water Ttmplfutl Bauoe f&l....__

r;::' ·= t --,
L I Oht 12Yl. TW -
Hlon Beam Indicator
L loht 12VS.4W
~,......-H--+-J
Turn sronat tndtcator
Ll oht 12V3.4W
011 Preeaurt warn rno
Ll oh t t2V3.4W
. ....
~
~
'II I
HlldiiOht
L
t2VI0/55W
v - i
~Ill ~
-
~
:
l~ FUll
WI lX I t ~P~· T..J
uvat
sensor
~ (f) <D (j) S\Cie Sl

Horn
uvz. 5A
Stano
S'W Itch ,,
Sl
Front Rloht TUrn Slonal Ltft Handlebar SVItchea

liGht 12V23V 1. Horn Button
2. Turn Slonat Switch
a.DIMmtr switch
4.Starter Loclout Swi tch
Front Lett Turn Slonat
Lloht t2Y23W
'-"' -·
H.4110 I 'iliil'
lana sw :en o1o ,., fciii"
Y color t/ color 1111 II II!
o LO c. ""."""
-
ZX800-B3 WOdtl
-
....
~
I
..... ,,.,.,
hlar
' IW\IW\
~
-!unction 101
1. H.orn fUll lOA
2. tonltlon PUll lOA
3. Till liGht PUll lOA
4.Htedllaht Putt lOA
~t
5. Fin FUll lOA
I. ACC PUll 104
T. Turn lienal LIOht
Turn
FUll lOA Sltnol
ltnlt I on
col Ia lillY
.l:_TlY• 1~~~
~I
-
n
1f=i
0
•' ... i'ff'-;1

L
~ -•
~
0.
SlOt
stand
SY ICCh
~
Htutret
SWitch
Alternator
starter
Motor Color code
PICkUP
COli
l!~
Oil
Preaaure
SWitCh
1 ifaif
I L I lot
. .,....
EAl : EitctriCII ACCIIIOrY ltldl
I I lrtWfl
H C I Ill
DC Dtr lrllft
T lrlf
Lltlllt IIUI
LI ''"' lliM
0 orantt
t
""'
Jlurtlt
ItO
USot)C
w • •
ntov
:
ZX900-81, 82, 83 Wiring Diagram (United Kingdom)
l tont Handl tbtr swttchta

I. Kitdlllftt SW itCh
l . f ront erttt Ll t ht SV I tc~
Radi ator fan !w ltoft J.fnt tntttoo SY i tc:rt SPariP
c. u.ar ur Iutton
a> <%) ( <D
t tnl tiOft
Swl tol'l k '5 ln. r-'I L~tlJ
Wtttr TIMO StntOr
l I~
~Tft - ..
I lA It I~
1- '- Ctlll
Ntutral tndt oator Lloht .- ,
i
12WS.4W
Ql n::t:::JO::I~l=t::.. ;•
T aono~ttr Ll ont ~
UVt. TWU
~~,~·~ ..
G):H++..., ~adlator ~ ,,, -
••• '
S~ttd~tt r
UVS. TWU
Lt ont
- j I I
~
..."
Wtttr T..otrtturt
. '
--
fUll 81UU --
water Tt. ./,Utl l tuot
LI OI'It UVl . 'PY
Hton lttM tndtoator
liOI'It UYS. 4W
Turn stontl tndt oetor
L loht UVJ. 4W
011 Prttaurt Wtrntno
- 1-
.-
--...,
L l ant UVJ. cw
\ Ct .. LI Ohl
IIYSW cr:Q
,9Jif'LI4~"-·~·h==========~---l
~~
r.===tt---tt-Htt-1-filtr
,:. ..:. :.;.
-. s ~
•
~
~ ' ' :'f:'7~
Mtadttont ~
IIYU/UW ~ ~
v -· ~
t
•
Lent
Futl ~
~ d
•••
LOY
Stnaor son
1101
stt.n•
Front t ltht Turn Sltnt l
Ll t ftt uvuw "''"
nn. u Lift Hl n41 eDer Swl tcnea
t . Horn luteo"
" I-tt
2. Turn ll t~l l t vlccn

3. Dl-.r swttcn
•. scarc er Loo•out twitch
s.,aaa tne Iutton
'ron t Li ft Turn tltna t
Ll t l'lt UVUW
ELECTRICA L SYSTEM 1 5- 9
f ltChll
I
'It twitCh
tch SPi rt PIUGI
I
lttl 11
.., ..., ,,...
.... ·,-
ri.tt l
lltl'lt
Juno t 1on lox
tt lu 'i.tll t wncll a :1)
~:~
~ r--- ltareer
Clrtul \
t. Horn fuat toA
t. Jt nlt l on FUl l t OA
.1,~ mr
(J)(i) J. T&ll l lont !fUll tOA
• • Httd l ltht !fUll t OA
1?- u
~ =~
s. ' an 'utt lOA
I. ACC 'UII tOA
f. Turn II t nt I ~l aht Turn
~~ ~
PUll tOA
t ontt ton
COlla
II $1 ~
IJ...._I SI OMl
Ri l l Y
- 1-= ~ ~
! ~
=-
:rr ~
7:
! I~~~~
$$===~ --;;::: •
~ Ill ,I I
I
0
._'-
r -_!!_~--'-ifi) ltor
Turn st
9hl
II 9ntl
'- "'"-" l lOIII I tvUW
- -=- Tall / I f l kl
J.,V LI Oht
:'V"1Wi +H" \
U YI/2 t Wit
L~
.••..""fTt'. 1 ~ llctnu PiaU
li Ght t 2VI W
- - I :.....(50.""1
l l lr Uf t
II Turn Sl ona t
lt aht t zvuw
L
I
5
~
M ~
n,
~li! ~ ~ ~
~ 1;2 ~ • ~
R 1111,
surttr
I
Ii-i:.
r~~·l I ~~~ ~::
' .... 6 (~
G
2
fUll
~ ~
Ufll
Stnaor )('~:· \j,_ IC ltnlltr
ll2¥io"" I ~ " Plctuo

colt
~ 1
lldt
SURd
Neutral
SWitCh
. surur
Motor
011
PftiiUrt
s wttch
SWi tch AI ternator
( IIU I-U U I )C
..
Z)(e00-13 WOdll
...1 .. ,
:• , ,,_
,,_ •
:•••• ..., .,...
SOir l PtUtl
: •~ ~ ~= IYitc"
Llltlt
...
., ,
CIUII Cl) JUMt I on 101
S. Horn fUi t SOA
~f !! ~~ 1' ~
• 2.1 t nltlon f Ul l SOA
Clfnlt
I•• 3. Tl l l l lt ht fUl l lOA
mr
• • MIICIIIt ht 'UII lOA
5. fin FUit SOA
~:m ~ ~! ' *
I. ACC fUit S OA
1.Turn Sl onal Lloht Turn
fUll lOA I t onal
'I I Ill.,
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-- ltfl ...r01 1
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I
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~, •,.i(i) 1111 II
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rate
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li Ght II VIW
- 'C'---5(;.."1~tier Llf t
II Turn li t nt l
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e
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ae1av
~
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:
0 ('
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,...
ftl ltf
IIUCI'I
2
Neutral
IV Itch
~~
W?am1i
AI tlrnator
1Slf'~:l" ,u..
Starter
wotor
\j
:~ ;;
-
1111~
IC lonlttr
"OtUO lil~
Coli
Oil
,,..aun
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It
COlor COde
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ll
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ll aa•
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ELECTRI CAL SYSTEM 15-11
Precautio ns
The<e ate a number of impo<14nt precautions that .,. mu.t~ when
seMc:ing electrical systems. Leem and observe all the rulee below.
0 Do not reverse the battery lead connections. This will bum out the
diodes on the electrical peru.
OAiways check battery condition before condemning other parts of an
electrical system A fully charged battery is a must fO< conducting
eccurate electrical system teeta.
O The electrical parts should never be struck sharply, as with a hammer,
or allowed to fall on a hard aurface. Such a shock to the peru can
dernage them.
O To ~ danage to elecblcal pert3, do not disconnect the batbary
leeds or any other electrical connections when the ignition switch is
on. or while the engine il running.
0 Because of the large amount of current n,_. kaep the starter button
puaned when the staner motor will not tum CNer, or the current may
burn out tne staner motor windings.
0 Do not use a meter illumination bulb rated for other than voltega or
wattage specified in the wiring diagram, as tne meter or gauge panel
could be warped by el<C8Uive heet radiated from the bulb.
O Teke care not to ohon the leeds thet are directly connected to the
battllry positive ( +) terminal to the chassis ground.
0 Trouble& may involve on. or in some cases all items.
Never replace a defective pan without determining what CAUSED the
failure. If the failure was caused by some other item or items. they too
must be repaired or repleced, or tne new replecement will soon fail
again.
0 Meke sure all connectors in the circuit are clean and light end examine
wires for signs of burning, fraying, etc. Poor wires and bed
connections will effect electrical system operation.
OMeesure coil and winding reelstance when the pan Is cold (at room
temperature).
0 Color Codes:
BK Bleck G Green p Pink
BL Blue GY Grey PU Purple
BR Brown LB Light blue R Red
CH Chocolate LG Light green w White
OG Dar!< green 0 Orange y Yellow
0 Electrical ConnectO<t
Female Connectors (A]
® .,,.
Male Connectors [B)

®
Electrical Wiring
w;ing Inspection
• Visually intpeet the w iring for signs of burning, ITaying, etc.
*If any wiring Ia poor, replace the damaged w iring.
• Pull each conMCtO< [A] apart and inspect it for c:orro.ion. d irt. and
damoge.
*II the connec1or Is corroded or dirty, clean it carefully. If it is damaged,
replace it.
• Checi< the wiring for continuity.
0 Use the w iring diagram to find the ends of the lead whk:h iaauspacted
of being a problem.
0 Connect tha hand teste< between the ends of the leads.
Specl8t Tool - Hand T - 57001·1394
0 Set the teeter to the • 1 n range, and read the tester.
*If the teeW doea not reed 0 Q the lead is defiiCiive. Replace the leed
or the wiring hameea [ B] if necessary.
Battery
Charging Condition Inspection

Battery charging condition can be checked by measuring batte<y
terminal voltage.
e Remove:
Seat(s)
• Disconnect the batte<y terminal leeds.
I Be sure to dloconnect the nega=lnallead nr.t
• Measure the battery tenninal voltage.

NOTE
. . '
fCU
0 Measure with a digital voltmeter [A] which can be read one declm8/
place voltage.
*If the reading is below the specified, refreshing charge is required.
Bellery T!tnnlnal Vollage

0
>
..f
: :m-
~~~~T~~~~
12.0 - - _____
Slandare 12.8 v "" .._.
11 .5
0 25
I I
50
1
t
75 100
Battery Charge (%)
Refruhing ch1f91 k )I(; )I( )I
is required Note Good
Refreshing Cha~ge
e oisconnect the battery terminal leads (see Charging Condition
Inspection).
e Remove the battery [A]. 0
e Refresh-charge by following method according to the battery terminal
voltage. e
CAUTION
This benary Ia sealed type. Ne¥er remove sealing cape [ B] even at
cha'lllng. Never add waler. Cha'lle with current and lime as staled
below.
D
Terminal Voltage: 11.5 - lesa !han 12.8 V
Standard Charge
1.2 Ax 5 - 10 h (see following chart)
Quick Charge
5.0 A X 1.0 h
CAUTION
If posalble, do not quick charge. If lie quick cha'lle Ia done due to
unavoidable circumstances, do standard charge laler on.
Terminal Voltage : less than 11.5 V

Cha'lllng Method: 1.2 Ax 20 h
NOTE
ORaise the voiUJge initially (25 Vas maximum), and charge for about
5 minutes as s yardstick. If ammeter shows no change in current
J~B~
after 5 minutes, you nssd a ntJW battery. The cuffOnt Hit can flow After 5 minutes ~
into the battery, tends to become excessive. Adjust the voltage as
often as possible to keep the CUffent at standard value (1.2 A).
Battery [A]
B
Battery Charger (B]
Standard Value [C]
( 11 ) te.lt
12
10
li• 8
...
~ 6
6"
•
2
0
11. 5 12. 0 12. 5 13. 0
Ballery Terminal Volla!le
( V)
• Oetennine battery condition after refreshing charge.

o Detennine the condition of the battery 30 minutes after completion of
the charge by measuring the terminal voltage according to the table
below.
Criteria Judgement
12.6 V or higher Good
12.0- 12.6 v Charge insufficient ... Recharge.
or lower
12.0 V or lower Unserviceable ... Replace

ELECTRICAL SYST EM 15-15
Alternator
Removal
NOTE
O Do n<Jt remove the altJJmator to remov• the r«:tlfier, regu/etor, mo
CMbon IHush 11ssambly. They c.n be removed eftM removing the
llltMn~~tor co.....
• Remove the following.

Left Lower Fairing
Alternator Lead Connector [A]
W ater Pump Pipe and Hose
• Remove the alternator mounting bolts [A] .
• Remove the alternator [A].
fnstaf!ation
• Apply a small amount of engine oil to the 0 -ring [A].
• Tighten the alternator mounting bolts.
Torque - AllemiiiDr Mounllng - 25 N-m(Z.S kg-m, 18.0 ft.lb)
Disassembly
• Remove 1he alternator (see this chapter).
• Remove the following.
AltemiiO< Cover [A]
eRemow:
Bru•h Assembly [A]
Rectifier [B]
Regulator [C]
OUnsolder [OJ the leads on the rectifier.
When unoolderlng lhe allemeiOt ~ on lhe reclttler terminal-, do

II quicily. If high lemperalurea ere IIPI>IIed lOt mo.-. lhan a few
,_,.,.,.reel-·- may be dam~.
elf it is necessary to remove the carbon brush, unsolder the brush lead
[A).
eRemove the alternator coupling to disassemble the rest of the parts as

follows.
O Hold the alternator with a vise and unscrew the coopling nut [A).
OThe coupling nut has right-hand threads and tum the nut counter·
clockwise [8] .
0 Remove the coupling nut and coupling.

0 Unscrew the alternator assembly nuts [ A] .
O Remove the alternator frame [B).
*If the alternator frame [A) is difficult to remove, use the crankcase
splitting tool assembly [B] .
Special Tool- CrankcueSplltllngTooiAIIembly: 57001-1382
o Be sure to put a washer (0.0 .12 x I. D. 6 mm)[C] on the alternator
rotor [ D) to prevent its damage.
OScrew the 5 mm bolts all the way.
o Tighten the center bolt on the bearing puller to split the alternator
halves.
o once the alternator is split, remove the special tool, and remove the
alternator frame.
ELECTRI CAL SYSTEM 15-11
e P - out the alternator rotor [A] from the alt8mator houaing [ 8].
e To remove the frame ball bearing [A] from the alternator rotor [ 8], use
a suitable bearing puller (C].
e Oiacard the frame ball bearing.
• Remow the bearing retainer and nlltiOYt the alternator housing
bearing and oil seal using the bearing driver oet.
SpecMI Tool - a...mg- SM: 57001·11211
• Oilcard the ~ng bearing and oil seal.
Assembly
e Poaltlon the alternator housing [A] on a auiteble prees fixture [8] .
e Preu [C] the new housing ball bearing [OJ into tha alternator housing
with bearing driver set (special tool).
Special Tool - Baarlllg Drtftr Set 57001·1121
• Install the housing bearing, using the bearing dnvw MI.

Special Tool - BNrlng Driver Set 57001·1121
e tnstall the bearing retainer [A] w ith its mounting acrews.
Torque - Allernetor Bearing Relalner Screw11: U N-m (0.25 kg.m, 22
ln·lb)
e Pocition the new housing ball bearing [A] so that the inne< race is
- e d on a suitable press fixture [8].
e Preu (C] the alternator rotor [OJ into the housing bell beanng.
•Press the new frame ball bearing [A] and bearing covers [B] onto the
rotor shaft The wide band [C] on the outer race goes up.
Ring [0]
Altern·ator Housing [E]
Press Fixture [F]
D
c
®
ePosition the frame ball bearing ring [A] so that the ring projection
[B] almost aligns with the groove chamfer [C] where the groove is the ""''
deepest This makes alternator frsme installation easier.
e Press in the oil seal so that the spring band faces out and the seal end
is flush with the end of the hole.
Eccentric Ring Groove [ 0 ]
elnstall the alternator frame on th alternator rotor.
e Tighten the alternator assembly nuts.
Torque - Altemetor M . .mbly Nuls: 4.4 N-m (OA5 kg-m, 39 ln-lb)
e Solder the carbon brush lead [A] with the brush holder [ B]as shown.
eRun the alternator leads [A] into the grooves [B) as shown.
CAlmON
When soldering the ahemator l e - to the rectifier terminals, do I
quickly. If high temperaturee are applied lor more than a lew
aeconda, the rectlller'a dlodea may be damaged.
Torque - Altarnetor Regulator Screwa, Allemetor Bruah Screwa,

Altamator Lead T"""lnal Sc,.....: 3.4 N-m (0.35 kg-m, 30
ln-lb)
• Fit me projection [A] of the altemato< cov. in the alternato< frame

groove [ BJ.
T..._ - AllomMDr Cover Scte1n: 3A N-m (0.35 kg.m, 30 liMb)
·-Coupling - 5' N-m (5.5 kg.m. 40 _ ,
Operations/Inspection
For any charging SY$tem problems, alw8Y$ check the charging system
wiring lim (see Wiring Inspection). and then check the system with the
following tests shown in the troubleshooting guide.
~ngGulde
Teat
Trouble Sympto<ns
No.
1 Banerv discharged Starter not rotating
2 Banery overcharged Electrolyte level lowering quickly
3 Noise Alternator or alternator chain noise
Te.t No. 1 -Birttery Discharged

e Remova:
e Remove the screws holding the alternator cover [A], and take off the
COIIW.
e Check that me alternator leeds and connectors are in good condition.
* II not, .-pair or replace me damaged parts.
e Replace the discharged battery with a good banery.
e Connect the hand t - (A] to the battery leeds aa Jhown.

e Check chargi ng voltage with the engine running.
* II the charging voltage is higher than 13.5 V, the charging SY$tern is
in good condition. [D -@
"'
* "the charging voltage is lower than 13.5 V, check the following.
-~ /
Chllrglng Voltllge 14.2 - 14.8 V @engine opeH 4000 r/mln(.,.,)
+ -
Banery
~~
e Ground the F tsnninaf [A] of the regulato< to the engine with an
auxiliary wire.
e Start the engine, and check the charging voltage w ith the engine
runn•ng.
* "the cherging voltage is higher than 13.5 V, check the regulator.
* II the charging voltage is lower then 13.5 V, check the following.
Stator Coil
Rotor Coil
Slip Ringo
Carbon Brushes
Rectifier
T..t No. 2- a.n.tv Ove< cheiged

e Chec:l< the .-gutator Md/tx rotor.
* Repair or replace the damaged par1S.
T..t No.3-Nol8e
e Chec:k the altemator chain slack and adjust it if neceuaJY <-
Crankahlft/Tranamisslon chapter).
e Checlt thla~emator shaft ball bearings.
e Checlt the altamator ball bearings, stator coil, and/or rectifier if the
alternator makaa a noise.
* Repair or replace the damaged parts.
Stator Coil Inspection

e connect the hand taater { • 1 0 range) between the coil loads and
rud the teeter.
*" the t - doeo not read as specified, replace the alternator frame.
- C o i i R • - : 1.00or-
• Using the hlghMt hand tester range, me-.ra the~~
the stator coil etxe and eech of the coil windings.
* If there ia any radlng at all. the stator coil winding has a shon and the
alternator frame must be repLaced.
ELECTRI CA L SYSTEM 16-21
-
®
.-.~--W---' I
2P
BK--frl- W
BR-{!,J-BR
1. Alternator 5. Regulator 9. Main Fuae 30A

2. Rotor 6. Recrifier 10. Load
3. Carbon Brush 7. Ignition Switch 11 . Battery
4. Stator Coil 8. Starter Relay
RoteN Coil Inspection

e Connect the hand tester (x 1 n range) between the slip rings [A] and
read the tester.
*If the tester does not read as specified, replace the rotor [B) .
R'*" Coli RMiatance: 2.3 - 8.5 (}

• Using the highest tester range, measure the resistance between the
rotorshaft [C] and each of the slip rings.
* If the<e is any reading at ell, the rotor coil has a short end must be
repleced.
Slip Ring Cleaning

e Visually inspect the slip ring for dirt or pitting.
*If necessary, smooth the slip ring with No. 300 - No. 600 emery
cloth.
Slip Ring Diameter

* If the -rwnent is 1-Uien the seMce limit. ~ the rotor
[A).
~AingDI...,...r
81Md8rd: 14,4 mm
5erYice Limit 14.0 mm
Catbon Brush Length

• Measure the length [A) of both carbon brust.M thattticl< out of the
hold e<.
* If eithe< one is wom down to less t han the aeovice lim I~ replace it
--11:
Cartlon BrueiiiAngltl (po ojeded portion)
Serllce Limit
10-S mm
4.5 mm
Rectifier Inspection
• Set the hand tester to the 1 kO range.
e Zero the hand tester, and connect it to each terminal [A] to check the
resistance in both directions.
-
OThe reaiatanc:e should be low in one direction and mo<e than ten
times n much in the other direction. If the rectifier [ B) ahows low
or high In both directions. the rectifier is defective and the rectifier
must be replaced.
NOTE
0 The Ktuel I'IHitJir rHdlii(J ,.,;.., with the mettN UHd Mid the
indlvldue/ teetifitlf, but. genenl/y ~PNking, the kJwtlf rellding
should be from ztlfo to ons hs/1 the see/e.
I• a...._, or a - . . .
. ......,win bedolm~.
~-II)~ II.-, .,.I .
Regulator Inspection
• " - *ling tools.
Test light Bulb rated 12 V 3.4 W
Batteries: Two 12 V batteries
Testwlrea: Three auxiliary wires
The - llglll - H an lnd- - aloe a .,..,._ lim- ID

p - II• ~from exceulftculftrlt Do not UM a n - -
lnalelld of a -UghL
• Connect the test light and the 12 V banory to the regulator as shown.
OThe tNt light should go on at this time.
Do nol _ , _ the regul8tor IMial - wllh the wiNe from the

bll*ry ( +).,.. (-) Wnnlnal during ... -
*II the test light does not go on, the regulator Ia damaged and must be
replaced.
e Connect the test light and two 12 V baneriee to the regulator [A) as
shown.
O Theteet light should not go on at this time.
* II the tast light goes on, the regulator Is damaged and must be
~laoad.
e Set the hand tester (special tool) to the 1 kO range.

e Check the realatance between IG and F terminals In both directions.
*If the reeding shows zero or Infinity (no reading) in both directions, the
regulator [A] ia defective and must·be replaced.
Alternator 8111/ BBaring Inspection

CAU110N
Do nol dluooemble the aJt•mator lot bMrlng lnopecllon olnce
dlNoeembllng the allemator damaogeo tho bMrlnge.
e Tum the alternator shaft back and fonh while checking for plays,
roughness or binding of bearings.
*II bearing play, roughness, or binding is found, dlaaaaernble the
alternator end replace the bearings.
Ignition System
Ignition Spam Cln:ult
ECI tl
CD (j)
~
""
... ,
"" ""a::
"" I I ""
I I .., j
I
I ""
""
r--
!
rn
.........
>-
......... !1:,...
!1:
...""
..."' g p ..................
~
u ""
""
12
....
<.!)
>-
.........
...
""
® .· @
1. Junction Box 6. Ignition Coils 1 1. Side Stand Switch

2. Ignition Switch 7. Tachometer 12. Main Fuse 30A
3. Engine Stop Switch 8. Ignition Fuse 1OA 13. BattE!fy
4. Starter Button 9. Neutral Switch 14. IC Igniter
5. Spark Plugs 10. Starter Lockout Switch 15. Pickup Coil
The lgnllon system~ ub••,.ly high 'fOIIeea. Do

lie lpllill plup, lgnlllon oolle, 01 opeill plug - Willie h -
not- Ina
lo IUI'Inlng, or ycu could ..-lYe a oevara elaclrlcal """'*·
CAI.mON
Do not dloc:otined the batlllry IMdo oo- any - -leal
_,.,«Ilona When Ill lgnllton owlecll II on, .,.. wl\111 h _.no 11
"""lng. 1l* II to prwen!IC lgnlllor dol• - ·
Do not - • Ill ...-y ·-\wwda. The.,.........,_.,..,,.. olcle II g - .
1l* 1110 . , . - ....,_ 10 hdtodel - I C lgn-.
Pickup Coil Remov11/

e Aemove the follow ing.
Fuel Tank (soo Fuel Syatem chapter)
Pickup Coil Lead Connector
Right Lower Fairing
Pickup Coil Cover
e Remow the pickup c6il [A] by taking off the pickup coil bolts [8] .
Pickup Coillnstalll ltion

e Route the pickup coil lead correctly (see Cable. Wire. and Hose
Routing in the General/Information chapter).
e lnstall the pickup coil and tighten the pickup coil bolts.
Torq.. - Plclwp Coli Bolla: 7.81kn (0.10 kg..n, 88 ln-lb)
e Apply silicone sealant [A] to the crankcase halves mating aurfeos on
the front and rear sides of the piclwp ooil cover mount.
SMIMI - KawaNikl ~ (SIIIcona Sealanl): 5601..1 20
e Apply a non· permanent locking agent to the pickup coli cover bolts
[A] and tighten them.
T01que - Pick..., Coli Cover Bolts: 8.81kn (1 .0 kg..n, 871rHb)
15-26 ELECTRICAL SYST EM
Pickup Coil Inspection

e Remow the following.
Pickup Coil Lead Connector [A]
e set the hand tester to the x 100 0 range and connect it to the pickup
coil lead connector.
*If there is more resistance than the specified value, the coil has an open
lead and must be replaced. Much less than this resistance means the
coil is shorted, and must be replaced.
Pickup Coli Aeslllance: !75 - 565 0

• Using the highest resistance range of the tester, measure the resistance
between the pickup coil leads and chassis ground.
*Any tester reading less than infinity ( oo) indicates a short. necessitat-
ing replacement of the pickup coil assembly.
lgn#ion Coil Removal/Installation

e Remow the air cleaner housing (see Fuel System chapter) .
• Disconnect the leads and remow the ignition coils.
e lnstall the ignition coils. Note the following.
OConnect the primary winding leads to the ignition coil terminals.
Black Lead [A] .... to #1 , #4 Coil [B)
Green Lead [C) .... to #2. #3 Coil [D)
Red Leads [ E) .... to both Coils
elnstall the spark plug caps in the order of #4. #1 , #2. and #3.
Ignition Coil Inspection

e Remove the ignition coils(see this chapter).
e Measure the arcing distance with the suitable commercially available
coil tester (A) to check the condition of the ignition coil [ B).
e Connect the ignition coil (with the spark plug cap left attached at the
end of the spark plug lead) to the·tester in the manner prescribed by
the manufacturer and measure the arcing distance.
Ignition Coli Arcing DlaleMe : 7 mm «more

To avoid utr•• ...., high vollege - . , do no1 - fie oo1t body

MINda.
*If the distance reading is lees than the specified value, the Ignition coil
0< spark plug caps are defective.
e To determine which part Is defective, measure the arcing distance
again with the spark plug caps removed from the ignition coli. Ramove
the caps by turning them counte<clockwise.
*II the arcing distance il aubnonnal as before. the trouble il with the
Ignition coil i1self. If the arcing diltance is now normal, the trouble il
with the spark plug cap.
* If the coil taster is not available, the coil can be checked fO< a broken
or badly shorted winding with the hand taster( spacial tool).
NOTE
0 Th11 h11nd test11r csnnot dllt«:tl11ysr shorts 11nd shorts fiiSuhing from
Insulation breskdown undtlf high voltJige.
• Measure the primary winding resistance as follows.
0 Connect the hend - belwMn the coil terminals.
o Set the taster to the x 1 0 renge, and read the taster.
• M-.re the secondary winding resistance as follows.
0 Remove the plug caps by turning them counterclockwiStJ.
O Connect the tester between the spark plug leads.
0 Sat the tester to the x 1 kO range and read the tester.
Measure primary winding resistance (A).
Measure secondary winding resietance '[B).
Ignition Coil [C).
lgnltlcn Coil Winding A • I I -

PrirMry Wlndlnp: 2.3 .. 3.5 Q ( x 1 0)
Secondary Wlndlnge: 12 .. 11 kO ( x 1 tO)
* If the tester does not read as specified, replace the coil.
O To install the plug cap, tum it clockwise.
Spark Plug Removal

• Ramove the following.
Air Cleaner Housing
Spark Plug Gaps
• Remove the spark plugs uslng the 16 mm plug wrench.
aw-'1 Tool - Sperk Plug Wrench, 11 mnr. 92110-1154
Spark Plug Installation

elnaelt the spark plug vertically into the plug hole with the plug [A]
installed in the plug wrench [8].
• Tighten the plugs.
Torque- Spall< Plugo: 13 N·m (1.3 kg-m,113 ln-lb)
• Fit the plug caps securely.
Spark Plug Gap Inspection

e Measure the gaps with a wire· typa thickness gauge.
*II the gaps are Incorrect. carefully bend the side electrode with a
suitable tool to obtain the correct gaps.
Spark Plug Gap : 0.7 - 0.8 mm

Insulator (A] Plug Gap (C]
Center Electrode [B] Side Electrodes (D]
IC Igniter Inspection
• Remove the side covers.
e Remove the IC igniter [A] and pull out the connectors.
e Set the hand tester (special tool) to the x 1 kO range and make the
measurements shown In the table.
Special Tool- Hand T-r: 57001·1394
*If the tester readings are not as specified, replace the IC igniter.
Use only Hand T - 57001·1394 tor IIIIo test. A ""'ler- lllan 1118
Kawasaki Hand Tuter mey - dll.,.ntreadlnge.
I a megger or a meter wllll a large-capacity battery Ia used, tile IC
Igniter will be damaged.
IC lgnller Internal Reolotance (4P) Unit: kO

Tester ( +) Lead Connection
Tenninal 1 2 3 4
1 - 00 00 00
(-). 2 00 - 0-0.8 28- 100

3 00 0-0.8 - 28 -100
4 00 26 -100 26- 100 -
(-)':Tester(-) Lead Connection
Unit 110
TIller ( +) Lead Connection
Tennlnal 5 6 7 8 9 10 11 12
6 - 00 co co co ao co co
6 30-150 - 24-90 19-80 30- 150 45-300 co 15-60
7 6.6-26 7-28 - 2-4.6 6.5- 26 5.6-22 00 3.8- 15
8 3.8- 16 4.4- 18 1.8-7.5 - 3.8- 16 2.8-11 co 1.8-7.5
( - )' 9 ao ao ao ao - ao ao ao
10 ao 00 ao ao ao - co ao
11 ao 00 ao ao ao 00 - ao
12 1.4-5.5 1.6- 6.6 2-8 1.6-6 1.4- 5.5 5-20 co -
(-)': Teete< (-)Lead Connection
IC IFittr Troubllthoolilll 1 )IC ignitllr or pickup coil damaged

2)Evan if the preceding checks show good, it may be
defectiw in some ·m anner not readily detectable with the
hendtesllM'.
BegiMing
Inspect IC IFitar
and pici<up coils.
No Replace damaged
part,
<D
No
Replace IC
Igniter.
Yes
Replace part
which is not replaced
No above step.
Yes
No
Replace pickup
coils.
Yes
Yes
Trouble may be caused
by other Ignit ion system
parts or engine Itself.
Starter Motor
RBmOval
e Remove the following.
Left Lower Fairing <- Frame chapter)
Engine Sprocket Cover (1" Final Drive chapter)
eRemove the starter motor terminal nut [A) and the mounting bolts
[B) .
e Remove the starter [A).
lnst811ation
Do not a.p the - . molot ahloll or body. T-lng the ahloll or body
could damage the motor.
eWhen installing the atarter motor, clean the starter motor • (A] and
crankcase whenl the 8W1er molor is grounded.
e Apply a small amount of engine oil to the 0-ring [A).

Torque - Starter M040r Mounting BollS: 9.8 N-m {1.0 kg-m, 871n-lb)
SISrter M040r Termll\ll Nut 4.9 N-<n {0.50 kg-m, 43 ln-lb)
Disassembly
e Take off the starter motor through bolts (A] and rernova both end
covers [B] and pull the ermeture out of the yoke.
OThe brush plate [A] and brushes oome off with the left-hand end oover
[B).
eRemow the terminal locknut [A) and tenninal bolt [B] • and thet1
remow the brush with the brush plate [C] from the left- hand end
cover.
Assembly
elnstall the brush plate and brushes [A], and thet1 put the ennature
[ B] among the brushes.
elnstall the 0-rings [A] as shown.
eAJign the notch [A) in the brush plate with the end cover notch [B]
and the mark [C] on the yoke.
e AJign the lines (A] marl<ed on the yoke with the right·hend end eov«
bolt hole [B].
Tor.... - Stii""Molof'Tllrollgh- U Nom (0.80~, 52 lrHb)
Brush Inspection
eMeesurethelength [A] of each brush.
*If any is worn dow n to the service limit, replace the carbon brush
holder assembly [B) end the terminal bolt assembly [C].
Stl"" Molof B"""l..etlgll

Sl8ndanl: 12 mm
...,... Limit 1.5 """
Commutator Cleaning and Inspection

e Smooth the commutator surface [A] if necessary with fine emery cloth
[B], and clean out the groo\186.
e M_u,. the diameter [A] of the commutator [B).

* Rep!- the Sl8l18f motor with a n-one if the commutator diameter
is leu then the service limit.
Commuulor DWneler
S18nclard: 28 mm
._Ice Limit 27 mm
Armature Inspection
e Using the x 1 0 hand taster range, measu"' the ,..iatanoe ~any
two commutator segments (A].
* If there Ia a high resislanoe or no reading (co) ~ any two
segments, a winding is open and the starter motor must be replaced.
e Using the high811 hand tester range, meesu"' the ,..imnoe between
the segmenl8 and the shaft ( B].
* If there Ia any raading at all, the armature hea a ahort and the starter
motor must be replaced.
NOTE
OEvBn if the foregoing checks show the armature to be good. It may
be dBfective in sotm manner not readily detectable with the hand
t~ter. If all other starte1 motor and startar motor circuit compontN1ts
chack good. but tha startiJf' motor still does not tum over or only
tums over weakly, rep/see the starter motor with s new one.
Brush Lead Inspection

• Using the x 1 0 hand tester range, measure the resistance as shown.
Tonninal Bolt and Positive Brush [A]
Brush Plate and Negative Brush [ B]
*If there is not close to zero ohms, the brush lead has an open. Replace
the terminal bolt assembly and/or the brush holder assembly.
Brush Plate and Terminal Bolt Inspection

• Using the highest hand tester range, measure the resistance as shown.
Terminal Bolt and Brush Plate [A]
Tonninal Bolt and Negative Brush Holder [B]
Tonninal Bolt and Left-hand End Cover [C]
*"there is any reading, the brush holder assembly and/or terminal bolt
assembly have a shon. Replace the brush holder assembly and the
terminal bolt assembly.
Starter Relay Inspection

• Remove the seats.
e Remove the staner relay.
e Connect the hand tester [A] and 12 V battery [B] to the staner relay
[ C] as shown.
*If the relay does not work as specified, the relay is defective. Replace
the relay.
Tea~ Relay
Tester Range: x 1 0 range
Crllerla: When baU.ry Ia connecled -+ 0 0
When baU.ry Ia dl..,.,.,._led -+ oo 0
Electric Stat18r ClrcuH
®~®
EC51
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........ ................
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6P~::~I e>cx
................
........
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"""" ........
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CD
jw CD
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1. Ignition Switch 5. Starter Circuit Relay 9. Starter Motor

2. Engine Stop Switch 6. Ignition Fuse 1OA 10. Starter Relay
3. Starter Button 7. Starter Lockout Switch 11. Main Fusa 30A
4. Junction Box 8. Neutral Switch 12 Battery
Lighting System
The US, canada, and Australia models adopt the daylight system and
have a headlight relay in the junction box. In these models, the headlight
does not go on when the ignition switch and the engine stop switch are
first tumad on. The headlight comes on after the starter button is
released end stays on until the Ignition switch is tumad off. The
headlight will go out momentarily whenever the starter button is pressed
alld come back on when the button is released.
Headlight Beam HorirontDI Adjustment

eTum the horizontal adjusters [A) on the headlights in or out until both
beams point straight ahead (Europe models except U.K. model).
e Tum the horizontal adjuster [B) on the headlight in or out until the
beam points straight ahead (Except above models).
Headlight Beam Vertical Adjusf17'1ent

eTurn the vertical adjusters [C) on tha headlights in or out to adjust the
headlights v81tically (Europe models except U.K. model).
eTurn the vertical adjuster [D) on the headlight in or out to adjust the
headlight vertically (Except above models).
NOTE
0 On high b&am, th& brightest points should be slightly below
horizontal with the motorcycle on its wheels and the rider seated.
Adjust the headlight(s) to the proper angltJ according to local
r&gu/ations.
OFor US model. thtJ proper angle is 0.4 degrees below horizontal.
This is 50 mm (2 in) drop at 7.6 m (25ft) measured from the center
of the headlights with the motorcycle on its wheels and the rider
seated.
50 mm (2 in) (A]
Center of Brightest Spot [ B)
7.6 m (25 It) [C)
Height of Headlight Center [D]
H88dlight Bulb Replacement

e Remove:
Headlight Connector
Headlight Bulb Dust Cover [A]
Hook [B)
CAUTlON
When handling the quartz-halogon bulb, never touc11 the g l -
porllon wllll baN hancla. AIWaya ... a ciHn cloth. ON -mlnelloft
&om - .,.. dlrly .-ge can Nduce bul> lh .,.. - the bull tD
e~
e Replace the headlight bulb.

e Fit the dust wv. [A] with the Top mar1< (B] upward onto the bulb
[C] firmly as shown.
e After installation, adjust the headlight aim (see this chapter).
Good Bad
H88d/ight Diode Inspection (Europe mod81s BXC8Pf U.K.)

e Rernove the upper fairing.
• Pull the diode (A) out of the main harness.
e zero the hand tester (special tool), and connect it to each terminal to
check the resistance in both dlnsctlons.
OThe resistance should be low In one direction and more than ten times
as much in the other dinsction.
* If the diode shows low or high in both directions, the diode is defectiw
and the diode must be replaced
NOTE
0 The 11ctual meter reading v•IIM with the meter used •nd tho
individual diode. but gener11l/y spe~~king, the lowet reeding should
b11 from zero to one helf the sc11/e.
Headi!G'!I Cln:uH (U.K.)
.. ..
~-
Heedllghl Circuli (U.S., Canada, and Australia)

ICIII
6P
<D ~~=[[F~
r.-. l'i!T-U/Y !![IJ._IK/Y
\V ISL-R/U "1.r,...._
LJ.J R/IK
tP
(AS): Auetralla
1. Ignition Switch 6. High Beam Indicator Light 11. Main Fuse 30A
2. Headlight Switch 7. Headlight 12. Battery
3. Junction Box 8. City Light 13. Headlight Relay
4. Taillight Fuse 1OA 9. Dimmer Switch
5. Headlight Fuse 1OA 10. Passing Button
ltll17
(IT): I Ill•
1. lgnhion Switch 6. High 8eMI lnc:hc.otor Light 11. Dimmer Switch

2. Headlight Switch 7. City Light 12. Passing Button
3. Junction Box 8. Right Headlight (Low) 13. Main Fuse 30A
4. Taillight Fuse 10A 9. Left Headlight (High) 14 . Battery
5. Headlight FuM 1OA 10.Diode
Tail/Brake Light Bulb Replacement

• Remove the rear seat.
e Turn the socket counterclockwise (A] and remove the bulb and socket
[B] ,
ePush the bulb [A) in the socket and tum the bulb counterclockwise
[B].
e lnsert the new bulb in the socket and tum the bulb clockwise.
elnsert th~ socket by aligning the projection [A] on the triangular mark
[B] with the notch [C] and tum the socket clockwise.
Licens8 Plate Light Bulb Replacement

e lnstall the·bulb lens so that the "TOP" mark [A] on the lens points up.
• Do not overtighten the lens mounting screws.
Turn Signal Relay Inspection

e Remove:
Seats
Tum Signal Relay [A)
e Connect one 12 V battery and tum signal lights as indicated in the (E_,pc TWo lights -coo • r cud )
figure, and count how many timea the lights flash for one minute. A
Tum Signal Relay (A]
Tum Signal Ughts [8]
12 V 8an81Y [C]
*II the lights do not flash as specified, replace the turn signal relay. ® ®
TNIIng Tum Signal Relay (Oermeny Model)
-
Loed
The Number
of Tum W8118Qe(W) Flaohiov timee (C/m' )
Signal Ughts
1 21 - 23 More then 150
2 42 - 46
3 63-69 76 - 95
4 64 - 92
('): Cycle(s} per minute
Teeling T"m Signal Reley (Other l'llln Oennony Model) (~lo: Two lltlhts are con.-ed.)
Loed A
The Number
of Turn Wattage(W) Flashiov timee (c/m')
Signal Lights
1 21 Light stayt on
® ®
2 42 75 - 95
( '): Cycle(s) per minute
Tum Signal Relay [A]
Turn Signal Lights [8]
12V 8a1181Y (C]
ICill
__<r..,c~
.... .."'
--
~0~ .......
GY
GY
(US.CH) (/)
BK/Y -iJ<r-
-iJ<r- BK/Y ..J.CV
C ~
~:t~t:~======~=B~Y~B~Y:@
,....
..,
....... GY
(us. eN)
•
@
-
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,....
.......
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CN: Canada
FG: Germany
US: United St111M
1. Tum Signal Indicator Ught 5. Turn Signal Fuae 1OA 9. Tum Signal Switch
2. Front Right Tum Signal Ught 6. Junction Box 10. Ignition Switch
3. Front Left Tum Signal Light 7. Rear Right Tum Signal Light 11. Main Fuae 30A
4. Turn Signal Relay 8. Rear Left Turn Signal Light 12. Bllttery
Fuel Pump
O The fuel pump (A] openotea when the S1alter button ie pushed oo or
tho engine is running.
O When fuel level in the ftoet dlember is low, the fuel pump opontes to
supply fuel into the float chamber. When the fuel raechee a certain
level, the fuel presaure rlaee, and tho fuel pump stope.
Rsmovsl/ lnstallstion
• Refer to the fuel system chepter.
Fuel Pump Relay Inspection

• Remove the seats.
e Teke off the fuel pump relay [A).
e Set the hand tester to the x t kO range and make the measurements
shown in the tsble.
Special Tool - H8ACI T - r: 57001·1394
* If the teoter readings ere not at specified, replace the fuel pump relay.
An--
* li tho teoter reedings ere normal, chock the fuel pump operetioo.
U.. only Hand T - 57001·1* lof 1111-.

then.,. K a - IWidT_mooy.,_d...,wll-lngo.
lla..,_ora.-wllllalarge c~bdlll'yleUMd,.,.pump
relay wiH be damaged.
F\lel Pump Relay Internal R•letanoe

1
Range Teater (+) Lead Connection
X 1 kfl 1 2 3 4
. 1 - 00 00 00
-) 2 00 - 00 00
3 00 10- 100 - 00
4 00 20-200 1- 5 -
( - )" : Tester (-) Lead Connac1lon
Fuel Pump Operations/Inspection

e Remove the fuel pump whh the fuel filter (see Fuel System c hapter).
• Prepare a container filled with kerosene.
• Prepare the rubber hosee, end connect them to the pump lininga.
e Connect the suitable P<-.re gauge to the outlet hOM aalhown.
Fuel Pump [A) Kerosene[F)

Pressure Gauge [ B) 2 -Pin Coonac1or [G)
Outlet Hose [C) Battery [ H]
Inlet Hose [OJ Auxiliary Leads [I)
Fuse Filter [ E)
e Connect the pump leeds to the battery using auxifilltY wiree 81 shown.
* II me pump operet88. checlt the pump relay.
* tf the pump cto.. not opet8l8, the pump is defec1i\le.
* tf the pump opao atel and the pump relay is nonnal, clole the outlet
hOM while ope<ating the fuel pump.
e When me pump &tops, read the pressure gauge.
* "the p,_ure gauge reading is out of the specified p..-ure. the pump
Is defective.
Fuel Pump PrMeure
Sllonderd : 11 - 11 kPe
(0.11 - 0.18 kg/em•, 1.8 - 2.3 psi)
ZXJOO.B1, 82
ICJI
r•
.. ~
cfu
0
1. IC Ignite< 6. Starter Lockout Switch 11. Mein Fuee30A

2. Fuel Pump Relay 7. Fuel Pump 12. Starter Reley
3. Junction Box 8. Starter Button 13. Battety
4. Startat Circuit Relay 9. Engine Stop Switch
5. Ignition FuM 1 OA 10. Ignition Switch
ELECTRICAL SYSTEM 15· 45
Radiator Fan System
Fan Systsm Ci-cuit Inspection

e Oiaconnect lhe leads from the radiator fan switch [A].
e Using an auxiliary wire [B), connect lhe radiator fan switch leeds.
* If the fan rotates. inspect the fan switch.
*If the fan does not rotate, Inspect the following.
Leads and Connectors
Main Fuse and Fan Fuse
Fan Motor
Fan Motor Inspection

e Remove:
Right Inner Fairing
Air Intake Duct Clamp
• Bend open the air intake duct.
• Disconnect the 2 -pln connector In the fan motor leads.
• Using two auxiliary w irlle, supply battery powfl< to the fan motor.
2 - Pin Connector [A] B8ttery [ B)
*If the fan does not rotate, the tan motor is defective and must be
~
Roodllllor Fan Circuit

lCIJ
CD
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BK-flr-8K/Y
8 L-\.J,J- 8 L /W
2P
8L/W
8L/8K-...a
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1 . Radiator Fan 3. Junction Box 5. Main Fuse 30A
2. Radiator Fan Switch 4. Fan Fuse 10A 6. Battery
Meters. Gauges
R8mOVBI
• Remove !he following.
UPP« Fairing ( - Frame chapter)
~ Cable Upper End [A]
Wiring Conn«:~ono
e Rernoveme meter unit by taking off me moun1ing nuta [B).
P...,. .,.m...r or ga~~ge eo that the ' - le up. • • m - 00' o•ua•

It left upelde down 00' oldeweys for any length ol lime, It will
mdunctlon.
MetBf, Gsug8 Dis8$$8111b/y

e Remove the meter unit <-this chapter) .
e unecrew the- knob screw [A) .
e Tekeoffllleoov.< (B) by removing thesaews (C).
• Remow the screws [A] for removal of each unit.

Fuel Level Geuge end Water Temperature Gauge (B)
Tachomet.,. [C)
Speedomet8f [OJ
Bulb R6f)l8c8ment
e To remove the w~ -base type bulb, pull [A) the bulb out of me
lOCket
Dei not turn the bulb. Pull !he bulb out 1o p - dem-lo the bulb.
Do not UH bull r•led for gre...r w•ttage th•n tile •peclfled v•l,.,
Meter. Gsug8 ASS8111bly

e lnmll each teed on the original position shown.
R/8L. 81(/Y LANidl (A) W/Y Lead [OJ LG. BR LANidl [G)
8K/Y LANidl [B] BR Leads [ E) G. GY LANidl [H)
Y/W Leed (C) 81( Lead [F] BR. R/BL Leads [I)
Water Temperature Gauge Inspection

eRemove:
Right lower Fairing
• Prepare an auxiliary wire, and check t he Ojleration of the w ater
temperature gauge [ A] .
Gauge O.,.ratlon Teet

lgnlllon SWitch Poaltlon: ON
Wire Location: Water 18mperalure Mneor female COlo lector
(dleconnected)
R•u..: Gauge ahould reed C when Mneor lead Ia -nad (A].
Gauge ahould reed H when Mneor lead lagroundad [B) tD
engine.
Do nal ground tile wiring longer than -•AfY· Aller the hand
-lngo to llle H poelllon, atop lhe teat. Otherwise tile gauge could
bedamegad.
* If the gauge readings are correct. the water temperature sensor is bad.
*If these readings are not correct the trouble is with the gauge and/or
wiring.
e Check the water temperature gauge circuit wiring (see Wiring
Inspection).
e lf all w iring and componen1S other than the water temperature gauge
unit check out good, the gauge is defectiw.
Walllr Temperature Gauge CircuM
. - - - - - - - BK /Y
JP
~@
BR ~ BR/R
BK/Y -t..1,.J- BK/Y
Y/ W - - - - .
~
gp I I
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Y/W
"'
a>
®
BK /Y - - - - - l
1. Ignition Switch 4. Junction Box 7. Main Fuse 30A

2 . Water Temperature Gauge 5. Ignition Fuse 1 OA 8. Battery
3. Water Temperature Sensor 6. Starter Relay
ELECT RICAL SYSTEM 15· 49
Fuel Gauge Operation Inspection

e Removethe fuel tank (see Fuel Sys1em chapter).
• Pull off the fuel level sensor connector(W /Y, BI(JY) [A] .
e Prepare auxiliary wire (8] , and check the operation o f the gauge.
Fuel Gauge Operation Check

Ignition Switch Poaltlon : OH
Wino Location : F<omale 21'1n aenaor connector
(dleconnecled)
Reaul..: Gauge thould read E _,connector wlrea are opened.
Gauge should reed F when connector wires are ahofted.
Do not ahort-eln:ull the leada.. W1Mn lhe hand awingo 1o lhe •p-
poaltlon, alop short-circuiting. Othe rwiM a good gauge could be
damaged.
* II the gauge readings are correct, the fuel level sensor is maladjusted.
If these readings are not obtained, the trouble is with the gauge and/ or
wiring.
e Check the fuel gauge circuit wiring (see Wiring Inspection) .
* II all wiring and components other than the fuel gauge u nit check out
good, the u nit is defective.
Fuel Gauge Circuli
<D
,_ ,_ >--Z::oc:
........... w
............ "" ... BR/W
=""
1* ~ ® &P
...........
>- ..
...... ......
@s:t r:
..... "" 'jlI
,_ >-
............
I
I BK/Y ------o<l-- 8 K/Y +
I
@
I
1. Fuel level Sensor 4. Ignition Fuse 1OA 7. M ain Fuse 30A
2. Fuel Gauge 5. Ignition Switch 8. Battery
3. Junction Box 6. Starter Relay
Switches and Sensors
Front Brake Light Switch Inspection
eTurn on the ignition switch.
eTho brake light should go on when tho front brake is applied.
*If it does not replace the switch.
Rear Brake Light Switch Adjustment

• Check the operation of the roar brake light switch by depressing tho
btake.podal [A]. The btakolight should go on after about 10 mm of
pedal travel [B) .
*If it does no~ adjust the brake light switch.

eTurn the adjusting nut to adjust the switch.
Switch Body [A] Light sooner [C) .
Adjusting Nut [B) Light later [ D).
To avoid damaging the elecCrlcel connecllone lnelde the -"""· be

aure that the twitch body - noiiUm during edjuatrnent.
Radiator Fan Switch Inspection

• Remove tho loft lower fairing.
• Drain the coolant (see Cooling System chapter).
e Remove the fan switch from the radiator.
esuspend the switch [A) in a container of coolant so that the 8
temperature-sensing projection and threaded portion are submerged.
eSuspend an accurate thonnomotor [ B] in the coolant.
NOTE
o The switch and thermometer must not touch tho conllliner sides or
I
bottom.
• Place the container over a source of hoot and gradually raise the
temperature of the coolant while stirring the coolant gently.
• Using the hand tester (special tool), moosure tho internal resistance of
the switch across the terminals at the temperatures shown in the table.
*If the hand tester does not show the specified values, replace the
switch.
Fen Swllch Raslotance
0 Rising temperature:
From OFF to ON et 93 - 103'C (199- 21TF)
0 Falling temperature:
From ON to OFF at 91 - 95' C (196 - 203' F)
ON: Less than 0.5 0
OFF: More than 1 MO
Water Temperature Sensor Inspection

• Drain the coolant (see Cooling System chapter).
e Remove:
Right Lower Fairing
Water Temperature Sensor [A)
e Suspend the sensor [A) in a container of coolant so that the

temperature-sensing projection and threaded portion are submerged.
e Suspend an accurate thermometer [B) in the coolant.
NOTE
0 The sensor and th8m!ometer must not touch the conl8iner side or
bottom.
e Piace the container over a source of heat and gradually raise the
temperature of the coolant while stirring the coolant gently.
• Using the hand tester, measure the internal resistance of the sensor
across the terminal and the body at the temperatures shown in the
table.
B
*If the hand tester does not show the specified values, replace the
sensor.
Water Temperalunt Sensor

so-c {178.F): 47 - 67 o
100'C (212.F): 26 - 30 0
Fuel Level Sensor Inspection

eRemove the fuel tank (see Fuel System chapter) .
• Remove the fuel level sensor from the fuel tank.
eCheck that the float moves up and down smoothly without binding.
It should go down under its own weight.
*If the float does not move smoothly, replace the sensor.
Float in Full Position [A) Float Arm Stoppers [C)
Float in Empty Position [B)
eUsing the hand tester, measure the resistance across the terminals in
the fuel level sensor lead connector (A).
Special Tool - Hend T-r: 57001-1394
*"the tester readings are not as specified, or do not change smoothly
according as the float moves up and down, replace the sensor.
FuelleveiSensorR~nco
Stendanl: FuM -Ilion: 1 - 5 0
Emply -llton: 103 - 117 0
Junction Box
The junction box [AJ has fuses ( B] . relays, and diodel. The relays
end d~ can not be IWI'IlCIWd.
Junction B ox Fuss Circuit Inspection

e Remove the INII.
• Remove the juncdon box.
• Pull off lhe connectors from the junction boJC.
• Make aure ell connector terminals are clean end tight end none of
lhem haw been bent
* Clean lhe d illY terminals, and straighten slighdy-benttermlnels.
• Check conductMty of lhe numbered terminals with lhe hand - ·
* II m.- doee not read as specified. replace the junction boJC.
"'-e Clrculllr11~ I cllon
Teeter Connection Testar Reading (0) Tester Connection Tester Reeding (0)
1 - lA 0 1A - 8 00
1- 2 0 2 - 8 00
3A - 4 0 3A -8 00
6- 6 0 6 - 2 00
6 - 10 0 6- 3A 00
6 -7 0 17- 3A 00
6 - 17 0
Sttllter Circuit/ HBBdlight Relay Inspection

• Remove lhe junction box.
e Check conductivity of the following numbered terminal• by connect-
ing the hand teeter and one 12 V battery to the junction box as ahown.
* II the teeter doea not read as specified, replace the junction box.
ReillY Circuit lnapecllon (WIIh lie bettary dltconnec1ed)
Tester Con nection Tester Reading (0) Tester Connection Tester Reading (0)
.7 - 8 00 9 - 11 00
Headlight .7 - 13 00 Sterter Circuit 12 - 13 00
Relay ..
( ) (- )
. 13 - 9 Not oo ••
Relay (~) (-)
13 - 11 00
(+) (-)
12- 11 Not oo ••
("): us, Canada, end Australia Models only
(.. ): The actual reading variea w ith the hand taster uaad.
( +): Apply tester positive lead.
(-): Apply tester negative lead.
Battery Tester
Tester
Connection Reading
Connection
(+) (- ) (0)
Headlight Relay "9 - 13 "7 - 8 0
( +) (- )
Starter Circuit Relay 11 - 12 13 - 11 Not IX) • •
("): US, Canad<~, and Australia Models only

(" "): The actual reading variee with the hand testet used.
( +): Apply tester positive lead.
(-): Apply tester negative lead.
Diode Circuit Inspection

• Remove the junction box.
e Check conductivity of the following pairs of terminals.
Diode CircuM Inspection
TeoterConnection 1 " 13·8, "13·9, 12- 11,12-14, 16-14, 18-14

•: US, Canad<~. and Australia Models only
* The resistance should be low In one direction and more than tan times
as much in the other direction. If any diode shows low or high In both
directions, the diode is defective and the junction box muS1 be
replaced.
NOTE
0 The M:tuel meter ret/ding v~ with ~ meter us«/ Mid ~
individual diodes. but g.ne.-.1/y spsaking, ~ lower ret/ding shou/<1
be from zero to OM helf the •c.'-.
I•
15- 64 ELECTRICAL SYSTEM
(CU
r-
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® @·~·~
Juncllon Box lnlernal Circuli (oe- lh8n US, c.n8Cia, and Aua1ralla)
reu
- -
fll ®
-
.... r _,_
.. 111)(1!)0 7)
A. Acceasory Fuse 1 OA E. Ignition Fuse 1 OA I. Starter Diode

B. Fen Fuse 1OA F. Headlight Fuse 1 OA J. Starter Circuit Relay
C. Tum Signal Fuse 1 OA G. Headlight Relay K. Interlock Diodes
D. Horn Fuse 1 OA H. Headlight Diodes L. Taillight Fuse 1OA
Fuse
304 Main Fuse Removal

e Remove:
Seats
e Pull out the main fuse (A] from the starter relay with needle nose
pliers.
Junction Box Fuss Removal

e Rernove:
Seats
e Unlock the hook to lift up tho lid (A].
e Pull the fuses (B] straight out of the junction box whh needle nose
pliers.
Fuse Installation
e lf a fuse fails during operation. inspect the electrical system to
determine the cause, and then replace it with a new fuse of proper
amperage.
e lnstall tho junction box fu- on the original position as apecified on
tho lid .
Fuss Inspection
e Romovothe fuse (see Fuse Removal) .
e lnspoct the fuse element
* If it is blown out replace the fuse. Before replacing a blown fuse,
always ched< the ampeqge In the affected circuit. If the amperage is
equal to or greater than lhe fuse rating, check lhe w iring and related
components for a short circuit.
Housing [A] Tem~inals[C)
Fuse Element [B] Blown Element [0]
CAUTION
When Nf)laclng a tu.., be ...,. the , _ fuse malciMie the epeclfted
l
tuse rating lor that clrcuiL lnalllllatlon ole fuee wl" • higher rating
mey cau. . da""'G• 10 wiring and components.
APPENDIX 16-1
Appendix
Table of Contents
Additional Considerations for Racing ......................................................................16-2

Carburetor: ............................................................................................................16-2
Spark Plug:............................................................................................................16-2
Spark Plug lnspaction ......................................................................................16-3
Troubleshooting Guide .............................................................................................16-4
Engine Doesn't Start.. Starting Difficulty: .............................................................16-4
Poor Running at Low Speed: ...............................................................................16-4
Poor Running or No Power at High Speed: ........................................................16-5
Ovettteating: ..........................................................................................................16-5
Over Cooling: ........................................................................................................16-6
Clutch Operation Faulty:....................................•...................................•..............16-6
Gear Shifting Fautty: .............................................................................................16-6
Abnormal Engine Noise: .......................................................................................16 -6
Abnonnal Drive Train Noise: ................................................................................16-6
Abnormal Frame Noise: ........................................................................................16-6
Oil Pressure Warning Light Goes On : ..................................................................16-6
Exhaust Smokes Excessively: ...............................................................................16- 6
Handling and/or Stability Unsatisfactory: ............................................................16- 7
Brake Doesn't Hold :..............................................................................................16- 7
Battery Troubie:.....................................................................................................16- 7
General lubrication ...................................................................................................16-8
lt.lbrication ........................................................................................................16 -8
Nut. Bolt. and Fastener nghmess ............................................................................16-9
Tightness Inspection ........................................................................................16-9
Unit Conversion Table ............................................................................................16-1 0
Prefixes for Units:................................................................................................16 -1 0
Units of Mass: .......................................... _.,, ......................................................16-1 0
Units of Volume: .................................................................................................16-1 0
Units of Force: ....................................................................................................16-1 0
Units of length: ..................................................................................................16 -1 0
Units of T01que: ..................................................................................................16 -1 0
Units of Pressure:................................................................................................16-1 0
Uniis of Speed: ...................................................................................................16-1 0
Units of Power: ...................................................................................................16-1 0
Units of Temperature: .........................................................................................16-10
16-2 APPENDIX
Additional Considerations for Racing
This motorcycle has been manufactured for use in a reasonable and
prudent manner and as a vehicle only. However, some may wish to
subject this motorcycle to abnormal operation, such as would be
experienced under racing conditions. KAWASAKI STRONGLY
RECOMM ENDS THAT ALL RIDERS RIDE SAFELY AND OBEY ALL
LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE
AND ITS OPERATION.
Racing should be done under supervised conditions, and recognized
sanctioning bodies should be contacted for further details. For those
who desire to participate in competitive racing or related use, the
following technical information may prove useful. However, please note
the following important notes.
e You are entirely responsible for the use of your motorcycle under
abnormal conditions such as racing, and Kawasaki shall not be liable
for any darT]ages which might arise from such use.
• Kawasaki's Limited Motorcycle Warranty and Limited Emission
Control Systems Warranty specifically exclude motorcycles which are
used in competition or related uses. Please reed the warranty carefully.
e Motorcycle racing is a very sophisticated sport.· subject to many
variables. The following Information is theoretical only, and Kawasaki
shall not be liable for any damages which might arise from alterations
utilizing this information.
e When the motorcycle is operated on public reeds, it must be in its
original state in order to ensure safety and compliance with applicable
regulations. ·
Carbureto r:
Sometimes an alteration may be desirable for improved performance
under special conditions w hen proper mixture is not obtained after the
carburetor has been properly adjusted, and all parts cleaned and found
to be functioning property.
If the engine still exhibits symptoms of overly rich or lean carburetion
after all maintenance and adjustments are comactiy performed, the main
jet can ba replaced with a smaller or larger one-. A smaller numbered jet
gives a leaner mixture and a larger numbered jet a richer mixture.
Spark Plug:
The spark plug ignites the fuel and air mixture in the combustion
chamber. To do this effectively and at the proper time, the comact spark
plug must be used, and the spark plug must be kept clean and the gap
adjusted. ·
Tests have shown the plug listed in the "General Information• chapter
to be the best plug for general use.
Since spark plug requirements change with the ignition and
carburetion adjustments and with riding conditions, whether or not a
spark plug of the correct heat range is used should be determined by
removing and inspecting the plug.
A Terminal·
s, Insulator
C. Cement
D. Gasket
E. Center Electrode
F. Gap (0.7 - 0.8 mm)
G. Reach
H. Side Electrode
APPENDIX 16-3
When e plug of the correct heat range is being used, the electrodes
w ill stay hot enough to keep all the carbon burned off, but cool enough Spark Plug Condillon
to keep from damaging the engine and me plug itself. This temperatUre
is about 400 - soo-c (750 - 1 ,450'F) end can be Judged by noting the
condition end color of the ceramic insulator around the center electrode.
If the ceramic is clean end of a light brown color, the plug is operating
at the right temperature.
A spark plug for higher operating temperaturee is used for racing.
Such a plug is designed for better oooling effiCiency 10 that it will not
ovafieet and thus is often called a •co~ plug. If a spark plug with too
cool a neat range is used - that is, a "cold" plug that cools itself too wall
- the plug will stay too cool to bum off the carbon, and the carbon will carbon fouling
collect on the electrodaa and the ceramic Insulator.
The carbon on the electrodes conducts electricity, and can short the
cente< electrode to ground by etther coating the ceramic insulator or
bridging across the gap. Such a short will P<Wet't an effective spark.
Carbon build -up on the plug can alao cause other troubles. It can heat
up red -hot and cause preignition and knocking, which may eventually
bum a hole in the top of the piston.
Spark Plug Inspection

• Remove the spark plug and inspect tha eetamic lnaulator.
*Whether or not the right temperature plug is being used can be aacer-
tained by noting the condition of the ceramic lnaulator around the Oil fouling
etec1rode. A light brown color indicatel the conect plug is being UMd.
If the ceramic is blac:ll. it indicatelthat the plug ia firing at too low a
temperature, so me next notter type should be UMd instead. If the
ceramic is white, tha plug is operating at too high a temperature and
it should be replaced with the next colder type.
I the-"' plug lo repiKed wltll a type-·._ the atanclarcl plug,

make cenaln ... replacement plug hao ......... thread pltcll -
r...h (Iangiii ol ..,.aded portion) end lila uma type alactroda
(regular type or projacsad type) 11 the atandarcl plug.
I the plug raech II too "'-1, cartoon wiQ build "" on the plug - Norm~l operation
llwelcllln .,. cylinder head, caualng ov-..lng and making ~ ..,.,
dllllcuh to lnMrt the oorrect ~ plug llllr.
I Ill• raadlloloo long, cartoon will build up on lila axpoeed spark plug
11rHdl cauolng OVIfflaadng, pralgnhon, end poaolbly bumlng I hole
In ... pilton lop. In addhlon, • may be lmpoaol>lalo , _.... plug
wltllouS damaglng.,. cy- head.
Slandard Sport< Plug Threads

Dlamelar: 10 mm
Pilch: 1.0 mm
Reach: 11mm Overhuting
NOTE
0 The hut range of the spark plug functions /Ike e thermostat lor the
engine. Using the wrong type of SfJ8tk plug can mske tho engine Too short Corrccc ru ch
run too hot (FNultlng in engine dlltnBge} or too cold (with poor
,.,_misfiring, lind SUII/111(1).
16-4 APPENDIX
Troubleshooting Guide
NOTE Compression Low:

Spark plug loose
o This is not en exheustiv• list. giving every possible Cylinder head not sufficiendy tightened down
ceuse for Hch problem /Jst«J. It Is mHnt limply as • No valve clearance
rough guide to assist th•IIOubluhootlng for some of Cylinder, piston w om
the more common diHiculrM. Piston ring bad (wom, weak. broken. or sticking)
Piston ring/ groove clearance ex011101ive
Engine Doesn' t Start. Starting Difficulty: Cylinder head gasket damaged
Starter motor not rotating: Cylinder heed warped
Sta<lef lockout or neulr8l twitch lrOUble Valve spring broken Of weak
Starter motor lrOUble Valve not saating property (valve ben~ wom. or
eaneov voltage 1ow C8lbon accumulation on the _ ,ing surtaoa)
Starter re1avs not contaCting or operwting
Staner button not contaCting
Wiring open or ahorted Poor Running at Low Speed:
Ignition switch trouble
Engine stop switch tJOUble
Spart< -•k:
Batteov voltage low
Fuse blown Sperle plug dirty, broken, or maladjusted
Starter motor rotating but engine doeen't turn Sparlt plug cap or high tension w iring troubte
over: Spark plug cap shonad or not in good contact
Staner clutch trouble Sparlt plug incorrect
Engine won't turn over: IC igniter trouble
Valve seizure Pickup coil trouble
Rocker arm saizure Ignition coil trouble
Cylinder, piston seizure Fuel/air mixture incorrect:
Crankshaft seizure Pilot screw maladjusted
Connecting rod small end ~eizure Pilot j~ or air p881age clogged
Connecting rod big end 1elzure Air bleed pipe bleed holes clogged
Transmi81ion gear or bearing seizure Pilot passage clogged
camshaft seizure Air cleaner clogged. poorly sealed, or missing
Alternator shaft bearing saizure Staner plunger stuck open
No fuel flow: Fuel level in carburetor float bowl too high or too
No fuel in tank low
Fuel pump trouble Fuel tank air vent obstructed
Fuel tank air vent obltructed Carburetor holder loose
Fuel filter clogged Air cleaner duct loose
Fuel tap clogged Air clean,.. 0 -ring damaged
Fuel line clogged Compression low:
Float valve clogged Spark plug loose
Engine flooded: Cylinder head not suffiCiently tightafled down
Fuel level In carburecO< float bowl too high No valve clearance
Float valve wom Of stuck open Cylinder. piston wom
Starting technique faulty Piston ring bad (wom, weak. broken, 0< sticking)
(When flooded, crank the engtne w ith the throttle Piston ring/ groove clearance excessive
fully opened to allow more aor to reach the engi ne.) Cy1ind,.. head warped
No spartc .,art< - k: Cylinder head gasket damaged
8atteoy voltage low Valve spring broken 0< waak
Spark plug dirty, broken. or maladjusted Valve not seating property (valve bent wom, or
Spark plug cap or high tenlion w iring lrOUble carbon accumulation on the seating surface)
Spalit plug cap shorted 0< not in good contact Other:
Spalit plug incorrea IC ignitar trouble
IC igniter trouble Carburetors not synchronizing
Neutral, starter lockou~ or lide stand switch lrOUble Carburetor vacuum piston doesn't slide 11moothlv
Pickup coil trouble Carburetor vacuum piston diaphragm damage
Ignition coil trouble Engine oil viscosity too high
Ignition or engine stop switch ahoned D rive train trouble
Wiring shorted or open Brake dragging
Fuse blown Air suction valve trouble
Fuel/ air mixture Incorrect: Vacuum switch valva trouble
Pilot screw and/or idle adjusting screw maled)usted
Pilot jet. or air passage clogged
Air cleaner clogged, poortv sealed, or mining
Stoner jet clogged
APPENDIX 16-6
Poor Running or No Power at High S~: IC ignite< trouble

Firing lncorr~: Fuel/ air mixture incorrect:
Spark plug dirty, broken, or maladjustBd Main jet clogged or wrong size
Spark plug cap 0< high tension wiring trouble Fuel lewl in carburetor float bowl too low
Spark plug cap shorted or not In good contact Carburetor holder loose
Spark p lug incoiT8Ct Air cleaner duct loose
IC igniter trouble Air cleaner poorly sealed, or missing
Pickup coil trouble Alr cleaner 0-ring damaged
Ignition coil trouble Alr cleaner clogged
Fuel/elr mixture lncorr~: Compression high:
Starter plunger stud< open Carbon built up in combustion chamber
Main jet clogged 0< wrong alze Engine load feulty:
Jet needle 0< needle jet WO<n Clutdlslipping
Air jet clogged Engine oil level too high
Fuel level in carburetor floet bowl too high 0< too Engine oil viscosity too high
tow Oriw train trouble
Bleed holes of needle jet holder or needle jet Brake dragging
clogged Lubrication Inadequate:
Air cleaner clogged, poorly sealed, or missing Engine oil level too low
Air cleaner duct looae Engine oil poor quality or Incorrect
Air cleaner 0-ring damaged 011 cooter lncor....:t:
Weter or tore;gn matter in fuel Oil cooler clogged
Catburetor holder looee Gauge incorr~:
Fuel tank air va11 obatructed Water ternpeqt\Jra gauge broken
Fuel tap clogged , Water temperatura senaor broken
Fuel line clogged Coolant incorrect:
Fuel pump trouble COolant level too low
Compression low: COolant deteriorated
- Spark plug loose Cooling aystem component Incorrect:
Cylinder head not sufficiently tightened down Radiator clogged
No valw clearance Thermostat troubl<l
Cylinder, piston wom Radiator cap trouble
Piston ring bad (wom, weak, broken. 0< sticking) Radiator fan switch trouble
Piston ring/ groove ct-ance elCC8SSMI Fan motor broken
Cylinder head gasket dameged Fan blade damegad
Cylinder head warped Water pump not tuming
Valva spring broken or weak Water pump impeller damaged
Valva not seating properly (valve bant. wom, or Over Cooling:
carbon accumulation on the seating surface.) Gauge incorrect:
Knocking: Water temperature gauge broken
Carbon built up in combusdon chamber Water temperatura sensor broken
Fuel poor quality or Incorrect Cooling system component Incorrect:
Spark plug incorrect Radiator fan switch trouble
IC igniter trouble Thermostat trouble
M iscetlaneous:
Thronle valve won' t fully open
Carburetor vacuum piSton doe.n't slide smoothly Clutch Operation Faulty:
Carburetor vacuum p1ston d iaphragm damaged Clutch slipping:
Brake dragging Friction plate worn or warped
Clutch slipping Steel plate wom or warped
Overheating
Clutch spring broken or weak
Engine oillewl too high
Clutch hub or housing unevenly wom
Engine oil viscosity too high Clutch not disengaging properly:
Drive lnlin troubl<l Clutch plate warped or too rough
Alr suction valw trouble Cl utch spring com~ion un8V9n
Vacuum switch valve trouble Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Overheating:
Firing incorrect:
Spall( plug dirty, broken, or maladjusted
Spall( plug incorrect
16-6 APPENDIX
Clutch housing frozen on drive shaft Primary gear worn or chipped

Clutch hub nut loose Camshaft chain tensioner trouble
Clutch hub spline damaged Camshaft chain, sprocket. guide worn
Clutch friction plate installed wrong Air suctlo~ valve damaged
Clutch fluid leakage Vacuum switch valve damaged
Clutch fluid deteriorated Alternator shaft coupling rubber damper damaged
Clutch master cylinder primary or secondary cup Alternator shaft chain tensioner trouble
damaged Alternator shaft chain, sprocket, guide worn
Clutch master cylinder scratched inside
Abnormal Drive Train Noise:

Gear Shifting Faulty: Clutch noise:
Doesn't go into gear; shift pedal doesn't return: Clutch rubber damper weak or damaged
Clutch not disengaging Clutch housing/lriction plate clearance excessive
Shift fori< bent or seized Clutch housing gear wom
Gear stuck on the shaft Transmission noise:
Gear positioning 191/er binding Bearings worn
Neutral positioning lever binding Transmission gears wom or chipped
Shift return spring weak or broken Metal chips jammed in gear teeth
Shift return spring pin loose Engine oil insufficient
Shift mechanism arm spring broken Drive chain noise:
Shift mechanism arm broken Drive chain adjusted improperly
Shift pawl broken Drive chain worn
Jumps out of gear: Rear and/or engine sprocket worn
Shift fork worn, bent Chain lubrication insufficient
Gear groove worn Rear wheel misaligned
Gear dogs and/or dog holes worn Abnormal Frame Noise:
Shift drum groove worn Front fork noise:
Gear positioning lever spring weak or broken Oil insufficient or too thin
Shift fork pin worn Spring weak or broken
Drive shaft output shaft, and/or gear splines wom Rear shock absorber noise:
Overshlfts: Shock absorber damaged
Gear positioning lever spring weak or broken Disc brake noise:
Shift mechanism arm spring broken Pad installed incorrectly
Pad surface glazed
Disc warped
Abnormal Engine Noise: Caliper trouble
Knocking : Other noise:
IC igniter trouble Bracket. nut bolt etc. not properly mounted or
Carbon built up in combustion chamber tightened
Fuel poor quality or incorrect
Spar!< plug incorrect
Overheating Oil Pressure Warning Light Goes On:
Piston slap: Engine oil.pump damaged
Cylinder/piston clearance excessive Engine oil screen clogged
Cylinder, piston wom Engine oil level too low
Connecting rod bent Engine oil viscosity too low
Piston pin, piston pin hole worn Camshaft bearings wom
Valve noise: Crankshaft bearings worn
Valve clearance incorrect Oil pressure switch damaged
Valve spring broken or weak Wiring faulty
Camshaft bearing wom Relief valve stuck open
Other noise: 0-ring at the oil passage in the crankcase damaged
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Exhaust Smokes Excessively:
Piston ring wom, broken, or stuck
White smoke:
Piston seizure, damage
Piston oil ring worn
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing wom
APPENDIX 16-7
Cylinder worn Brake fluid deteriorated

Valve oil seal ~ Primary or seoondary cup damaged in meltar
Valve guide wom cy1inder
Engine oil level too high Master cy1inder acretched Inside
Black smoke:
Air cleaner clogged
Main jet too larva or !allan off Battery Trouble:
Starter plunger stuck open llatlery dlochergecl:
Fuel level in carburetorfloat bowl too high Battaty faulty (e.g.. plates SYiphated, shorted
Brown smoke: through sedimentation, electrolyte insufficient)
Main jel too small Battery leads making poor contact
Fuel level in carbuiiMor float bowl too low load 8l<t:811Sive (e.g .. bulb of eJ<Ce!iSive wattage)
Air cleaner duct looM Ignition switch trouble
Air cl-.er 0 - ring demaged Alternator trouble
Air cleaner poorly ...led or missing Wiring faulty
-ry """"'hargecl:
Alternator trouble
Handling and/or Stability Unsati.s factory: Battery faulty
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Ste.ing stem locknut too tight
Ste«ing stem bearing damaged
Ste«ing stem bearing lubncatlon i nadequate
Ste«ing stem bent
Tire air pressure too low
Handlebar shakes or exc-ively vibrates:
Tirewom
Swing arm pivot bearings wom
Rim warped, or not balanced
Wheel bearing wom
Handlebar clamp looae
S~ng stem heed nut loose
Handlebar pulls to one aide:
Frame bent
Wheel misalignment
Swing arm bent or twisted
Steering maladjusted
Front foil< bent
Right and left front foil< olllavel uneven
Shock absorption unaatidectory:
(Too hard)
Front fork oil excesaive
Front fork oil viscosity too high
R- shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front foil< oil insufficient end/or leaking
Front foil< oil viscosity too low
Rear shock adjustment too soft
Front fort<. rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn't Hold:

Air in the brake line
Peel or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
16-8 APPENDIX
General Lubrication
Lubtication
• Before lubricating each part, clean off any rusty spots with rust remover
and wipe off any grease, oil, dirt or grime.
• Lub!icate me points listed befow with indicated lubricant.
NOTE
0 WhtmevBI' the vehicle hss bHn optNated undtN wet or rsiny condi-
tions. or BSpecial/y aft!JI' using a high-pr8SSure water spray. pBrform
the geners/lubricstion.
Pivots: Lubricate with Motor 011.
Clutch Lever
Brake Lever
Brake Pedal
Side Stand
Rear Brake Rod Joint
Points: Lubricate with Grease.
Thronle Inner Cable Lower Ends
Choke Inner Cable Lower End
Speedometer Inner Cable•
("): Grease the lower part of the inner cable sparingly.
Cablee: Lubricate with Rust Inhibiter.

Choke Cable
Thronle Cables
Special Tool - Pr-ure Cable Luber: K5601t-021 [A)
APPENDIX 16-9
Nut, Bolt. and Fastener Tightness
Tightness Inspection
eCheck the tightness of the bolts and nuts listed here. Also, check to
see that each cotter pin is in place and in good condition.
NOTE
OFor the engine fasteners, check the tightness of them when the
engine is cold (at room tempBmture).
*Iffollowing
there are loose fasteners, retorque them to the specified torque
the specified tightening sequence. Refer to the appropriate
chapter for torque specifications. If torque specifications are not in the
appropriate chapter, see the Standard Torque Table. For each fastener,
first loosen it by 1/2 turn, then tighten it.
*II cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Front Axle Nut
Front Axle Clamp Bolts
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Front Master Cylinder Clamp Bolts
Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Front Fender Mounting Bolts
Rear Shock Absorber Mounting Bolts
Swingann Pivot Shaft Nut
Uni-Trak Link Nuts
Steering:
Stem Head Nut
Handlebar Mounting Bolts
Engine:
Engine Mounting Bolts
Cylinder Head Bolts
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Muffler Connecting Clamp Bolt
Clutch Master Cylinder Clamp Bolts
Clutch Lever Pivot Nut
Others:
Side Stand Bolt
Footpeg Mounting Bolts
Down Tube Mounting Bolts
Footpeg Bracket Mounting Bolts
16-10 APPENDIX
Unit Conversion Table
Prefixes for Units: Units of Length:

km X 0.6214 mile
Prefix Symbol Power
m X 3.281 = ft
mega M X 1 000 000 mm X 0.03937 = in
kilo k X 1 000
centi c X 0.01
milli m x0.001
micro j.l X 0.000001
Units of Torque:
N-m X 0.1020 = . kg-m
N-m X 0.7376 = ft-lb
N-m X 8.851 in-lb
Units of Mass: kg-m X 9.807
- N-m
kg
g
X
X
2.205
0.03527
-
= lb
oz
kg-m
kg-m
X
X
7.233
86.89
=
=
ft-lb
in-lb
Units of Volume:
Units of Pressure:
-
L X 0.2642 e gal (US)
L X 0.2200 = gal (imp) kPa X 0.01020 kg/em'
L X 1.057 qt (US) kPa X 0.1450 = psi
= kPa
-
L X 0.8799 qt (imp) X 0.7501 em Hg
L
L
mL
X
X
X
2.113
1.816
0.03381
e
=
pint (US)
pint (imp)
oz (US)
kg/em'
kg/em'
X
X
98.07
14.22
-
=
kPa
psi
em Hg X 1.333 = kPa
mL
mL
X
X
0.02816
0.06102
- oz (imp)
cuin
Units of Speed:
Units of Force: km/h X 0.6214 = mph
N X 0.1020 = kg
N X 0.2248 = lb
Units of Power:
kg
kg
X
X
9.807
2.205
=
=
N
lb kW
kW
X
X
1.360
1.341
-
=
PS
HP
PS X 0.7355 = kW
PS X 0.9863 ~
HP
Units of Temperature:
9(.C+40)
·r s( •r••o)
- 40 = - -40 = ·c
5 9
·r ·r
176
-.w - 20! !
140 160
·c -17. 8 26.7 •e. 9 116 138

·c
APPENDIX 16-11
Periodic Maintenance Chart (ZX900-83 other than US. CN)
The scheduled maintenance must be done in accordance with this chart to keep the motoroycle in good
Nnning condition. The initial maintenance I• vitally important and mu.t not be neglected.
FREQUENCY Whichever +I "ODOMETER READING
OPERATION
Spark plug - clean and gap t
,_1W1tlff
•
Evety
........ ~"'()
~:"\ ~....
() " ' () ()
()()!:>~ ()() ~ ()
.., ~ ro ~<::>_::~
• • •
()
() .§>
..,'b$' $
•
.. ..' .......' ......
..... ' () ()
() !:> () !:> () ! )
.§> () .§>
,.,o~ ,.,ro,~
• •
()
()
()
Valve clearance - check t

• • •
Air Suction valve - check t
• • • • • •
Air cleaner element - clean t #
Throttle grip play - check t
•
•
•
•• •
•
ldl• apeed - check t
Carburetor synchronization - check t
• •
• •• •
•
Engine oil - change # 6 months
• • • • • • •
Oil ftltet - replace
Drive chain wear - check t #
•• • •• • •• •
• •
Brake pad wear - check t #
• • • • • •
Brake light switch - check t
Steering - check t
• • • •
• • • •
•• •• ••
Front fork o il - change 2 vears
•
Rear shock absorber oil leak - check t
• • •
Front fork oil leak - check t
• • •
Tire wear - check t
• • • • • •
Swlngarm pivot. uni -trak linkage - lubricate
• • •
General lubtication - perform
Nuts, bolts, and fasteners tightness - check t
•
•
•
•• •
•
Drive chain - lubricate # 600km
• • • • • •
Drive chain slack - check t #
Breke fluid level - check t
1000km
month
•• •• •• •• •
•
• •
• •
Clutch fluid level - check t month
• • • • • • •
Rediator hoses. connection - check t
•
Brake fluid - change
Brake mastet cylinder cup and dust
2vears •
4years
seal - replace
Coolant - change
Caliper piston seal and dust seal - replace
2 years
4years
•
Steering stem bearing - lubricate 2 years
•
Clutch fluid - change
Clutch master cylinder cup and seal - replace
2 years
4 years
• .
Clutch slave cylinder piston seal - replace 4years
# : Serv~ce more frequently when op&fatlng on severe condotoons... dusty. wet. muddy, hogh speed, or frequent
starting/ stopping.
: For higher odometer readings, repeat at the frequency interval established here.
t : Replace, add. adjust. clean. or torque If necessary.
SUPPLEMENT - 1997 MODEL 17-1
This "Supplement - 1997 Model" chapter is designed to be used in conjuction with the front part of this
manual (up to page 16· 11 ). The maintenance and repair procedures described in this chapter are only those that
are unique to the 1997 ZX900· 84 model. Most service operations for these models remain identical to those
described in front of this chapter.
Complete and proper servicing of the 1997 ZX900· 84 model, therefore requires mechanics to read both this
chapter and the text in front of this chapter.
Supplement - 1997 Model

Table of Contents
General Information ..................................................................................................17 -2

Model Identification ............................................................................................17· 2
General Specifications .........................................................................................17-3
Wheels/Tires ..............................................................................................................17· 6
Specification ........................................................................................................17-6
Suspension ................................................................................................................17.7
Specifications.......................................................................................................17. 7
Frame .........................................................................................................................17-8
Exploded View,....................................................................................................17· 8
Electirical System ...........................................................................................-. .......17 -10
Wiring Diagram .......................................................................................................17-1 0
17-2 SUPPLEMENT - 1997 MODEL
General Information
Model Identification
ZX900-84 (European Model)
ZX900-B4 (US and Canadian Models)

General Specifications
Items ZX900-B4
Dimensions:
Overall length 2 085 mm. (FG)(GR)(NR)(SD)(ST) 2 195 mm.
(IT) 2105 mm
Overall width 725mm
Overall height 1 165 mm
Wheelbase 1 440mm
Road clearance 125 mm
Seat height 800mm
Dry mass 218 kg. (CA) 219 kg
Curb mass: Front 125 kg
Rear 120 kg, (CA) 121 kg
Fuel tank capacity 20 L
Performance:
M inimum turning radius 3.5m
Engine:
Type 4-atroke. DOHC, 4-cylinder
Cooling sys1em Liquid-cooled
Sore end stroke 73.0 x 53.7 mm
Displacement 899 ml
Compression ratio 11 .5, (FR)(ST)1 0.1
Maximum horsepower 102 kW (139 PS) @10 500 r/min (rpm).
(AR) 74 kW (100 PS) @10 000 r/min (rpm)(OI N),
(FR) 75.1 kW (102 PS) @9 800 r/min(rpm) (UTAC's norm),
(SO) 63 kW (86 PS) @ 10 000 r/min.
(ST) 45 kW (61 PS) @6 000 r/min (rpm),
(FG) 72kW (98 PS) @1 000 r/min (rpm)(OIN).
(US) ---
Maximum torque 96 N·m(9.8 kg·m, 70.9 ft-lb) @9 000 r/min(rpm).
(FG) 77 N-m (7.9 kg-m, 57.0 ft· ib) @7 000 r/min (rpm) (DIN).
(AR) 78 N-m (8.0 kg·m, 57.0 ft·lb) @7 000 r/min (rpm) (DIN),
(50) 74 N-m (7.6 kg·m, 55.0 ft·lb) @7 000 r/min (rpm)
(ST) 72 N-m (7.3 k.g-m, 52.8 ft·lb) @5 500 r/min (rpm),
(FR)(US) ---
Carburetion syslem Carburetors. Keihin CVKD 40 • 4
Starting system Electric starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced (digital igniter)
Ignition timing From 10' BTDC @1 100 r/min (rpm) to
(CA) From 10' BTDC @1 300 r/min (rpm)
to 45' BTDC @5 800 r/min (rpm).
(ST) From 5' BTOC @1 300 r/min (rpm) to
17-4 SUPPLEM ENT - 1997 MODEL
Items ZX900-B4
Spark plug NGK CR9EK or NO U27ETR

Cylinder numbering method Left to right. 1-2-3-4
Firing order 1- 2-4-3
Valve timing:
Inlet
Open 39" BTDC. (FR)(ST) 20• BTDC
Close 59• ABDC, (FR)(ST) so· ABDC
Duration 288·. (FR)(ST) 250"
Exhaust
Open 65" BBDC. (FR)(ST) so• BBDC
Close 35" ATDC. (FR)(ST) 20• ATDC
Duration 280", (FR)(ST) 2SO•
Lubrication system Forced lubrication (wet sump with cooler)
Engine oil:
Grade SE. SF or SG class
Viscosity SAE1 OW-40. 10W- 50, 20W- 40, or 20W-50
Capacity 4.0 L
Drive Train:
Primary reduction system:
Type Gear
Reduction ratio 1.S34 (89/S8)
Clutch type Wet multi disc
Transmission:
Type 6 -speed. constant mesh. return shift
Gear ratios:
1st 2.857 ( 40/14)
(E)(FG)(IT)(NL)(AR)(GR)(NR)(SP)(UK) 2.785 (39/14)
2nd 2.055 (37/ 18)
3rd 1.6So (33/20)
4th 1.391 (32/.23)
5th 1.222 (33/27)
6tti' 1 .103 (32/ 29)
Final drive system:
Type Chain drive
Reduction ratio 2.750 (44/16}
Overall drive ratio 4.656 @Top gear
SUPPLEMENT- 1997 MODEL 17-5
Items ZX900-B4
Frame:
Type Tubular, double cradle
Caster {rake angle) 24•
Trail 93mm
Front tire:
Type Tubeless
Size 120/70 ZR17 (68W)
Rear tire:
Type Tubeless
Size 180/ 55 ZR17 (73W)
Front suspension:
Type Telescopic fork
Wheel travel 110mm
Rear suspension:
Type Swingarm (uni · trak)
Wheel travel 135mm
Brake type:
Front Dual disc
Rear Single disc
Electrical Equipment:
Battery 12V10Ah
Headlight:
Type Semi-sealed beam
Bulb 12V55/55W (quartz·halogen) ,
(AS)(CA)(CN)(UK)(US) 12 V 60/ 55 W
(quartz-halogen)
Tail/brake light 12 v 5/ 21 w. 2.
(CA)( CN )(US) 12 V 8/ 27W • 2
Alternator:
Type Three-phase AC
Rated output 30.7 AI 14 V @5 200 r/ min ( rpm)
Specifications are subject to change without notice, and may not apply to every country.
(AR) : Austrian Model (SO) : Swedish Model

(AS) : Australian Model {SP) : Spanish Model
{CA) Califomia Model (ST) : Swiss Modlel
{CN) Canadian Model (UK): U.K. Model
{E) European Model (US): U.S. Model
(FG) German Model
(FA) French Model
(GR) Greek Model
{IT) Italian Model
{ NL) Dutch Model
{NR) Norwegian Model
17-6 SUPPLEMENT- 1997 MODEL
Wheels/Tires
Specification
Tires:
Tires:
Front DUNLOP D204FU 120/70 ZR17 (58W) ---
Rear DUNLOP D204L 180/55 ZR17 (73W) ---
Air Pressure:
(when cold)
Front Up to 165 kg (364 lb) load: ---
250 kPa (2.5 kg/em'. 36 psi)
Rear Up to 165 kg (364 lb) load:
260 kPa (2.9 kg/em'. 41 psi)
---
Tread depth :
Front 4.4mm 1 mm
Rear 5.4mm Up to 130 km/h
(80 mph): 2 mm
Over 1 30 km/h
(80 mph): 3 mm
Replacement Make, Type Air Pressure Size

tires Front BRIDGESTONE. BATILAX BT-50F J
BRIDGESTONE. BATILAX BT-64F
BRIDGESTONE. BATILAX BT-50F
SS-TYPE3
BRIDGESTONE. BATILAX BT56F
BRIDGESTONE. BATILAX BT57F Up 10 165 kg (364 lb) load:
DUNLOP. D203FG 250 kPa (2.5 kg/em'. 36 psi)
DUNLOP. C: D204 FJ 1zonozR11
DUNLOP. D204F
PIRELLI. MTR 01
PIRELLI. MTR 03
METZELER. ME 21 FRONT
METZELER. ME Z2 FRONT
MICHELIN, AB9X
MICHELIN, TX11
MICHELIN, TX15 Up to 165 kg (3641b) load:
MICHELIN, MACADAM 90X 260 kPa (2.9 kg/em'. 41 psi)
Rear BRIDGESTONE, BATILAX BT-50R J 180/50 ZR17
BRIDGESTONE. BATILAX BT-54R
BRIDGESTONE. BATILAX BT-50R 190/50 ZR17
SS-TYPE3
BRIDGESTONE. BATILAX 8T56R
BRIDGESTONE. BATILAX 8T57R 180/60ZR17
DUNLOP. D203G
DUNLOP. D204L Up to 165 kg (364 lb) load:
DUNLOP, D204 260 kPa (2.9 kg/ em' 41 psi) 190/50ZR17
PIRELLI, MTR 02
PIRELLI. MTR 04
METZELER, ME Z1
METZELER, ME Z2 160/50ZR17
MICHELIN, M89X
MICHELIN, TX23
MICHELIN. TX25
MICHELIN, MACADAM 90X
Suspension
Specifications
Item Standard
Front Fork (per one unit):
F()fl( inner tube diameter 41 41 mm
Fori< spring preload setting Adjuster protrusion is 15 mm (6 Mari<s)
(Usable Range: 5 - 20 mm)
Air Pressure A tmospheric pressure (Non -adjustable)
Rebound damper setting 6th click from the first click of the fully clockwise position
(Usable Range: 1 <--+ 12 - 13 clicks)
Compression damper setting 5th click from the forst click of the fully clockwise position
(Usable Range: 1 ........ 7 - 9 clicks)
F()fl( oil viscosity KAYABA01 (SAESW)
Fori< oil capacity 457 ± 4 ml (completely dry) ,
approx. 395 ml (when changing oil),
390 ml (when changing oil)
Fori< oil level Fully compressed, without fori< spring. below from
outer tube top
90t2mm
Fo.X spring free length 387.4 mm (Service limit 380 mm)
Rear Shock Absorber:
Rebound damper sat No. 2 of 4 positions
Compression damper set 12th click
from the first click of the fully clockwise position
( Usable Range: 1 ........ 16 - 22 clicks)
Spring setting position
Standard Spring length 212 mm
Usable range Spring length 212 mm to 206 mm
(weaker to stronger)
Spring Free Length
Standard 226mm
Gas pressure 9SO kPa (1 0 kg/em•. 142 psi. Non· adjustable)
17-8 SUPPLEM ENT -1997 M O D EL
Frame
Exploded View
L·· Apply
lock.a non- permanent
0: lng agent.
Apply oil.
~
Tl . 0~ ~
~ ~
•' ' 0::.. •
/1 _., ' 1•
T1:44Nm(
T2: 34 N:m (~·~ ~g-m. 33 ttllb)
'
I
17-10 SUPPLEMENT -1997 MODEL
ELECTRICAL SYSTEM
ZX900- B4 Wiring Diagram (IT and NL)
tonltlon
SYI tell
•••
Col
Neutra l Jnatoator Lt ont
uu . ..
TIChOfMttr l. IOht
t2Vt. TWU
liChMeUr
sotec:toeettr llonr
UVI. TWi l
cooltAt r .... r aturt

S.Utl
Fut l aauot
cootent Tt NOt r aturt/

,Uti GIUOI Lltht llYt.TW
Hl on ,,_. 1nc:t1cator
L IQI'It U VJ. 4W
Turn Sl onat lnc:t lc t tor
Ll oht UV3.4W
011 Prtaaurt werntno
L I Of'lt UV3. '*"
City Lltf'lt
uvsw
Lt tl IOht
HU.CU
<Ht on
uu sw
l ti M)
~ ~ ~ --
Sldt
stlllel
5wltc
front lltht TUrn Slonal
Lltht U.VUW ~ c -co-
~11/"f-<:0- 1 1/"f
'' =======iJ Ltft Ht ndlt•er fW i tChll
•~ worn li.U ton
a. Turn Slent l Sw ii:Ch
]4 Dl_ .r SWI ten
•. starter Loc•out svttcn
s.,ata lno Iutton
front Ltft Turn Sltntl
LIOM UVUV ~ ~
~ 11/f-<:0-11/"f
Q • =======:t-_J Horn
11'12. 5A
SUPPLEMENT- 1997 MODEL 17-11
.. ..., .,.,.
I ten
SDart PIUOS .......
,
Relu lloht ~----.,.-,...,,.----=---..,
(I) <Z> ~ (J) \lunct I on sox
;w
Fuel , 1ten
t.Horn Fuse tOA
Starter 2. lonltton Fuse 104
Circuit
3. Telllloht Fuse tOA
m
Iller
4.Headll o~t Fuse tOA
S.Fe:n Fuse 1DA
r $ . ACC trust 104
=- =~ I
·-
7. Turn Sl ona l
Fuse t OA
~l oht
Turn
~~
lonlt lon S lonat
COlla RelaY
=-·- ~w
;:;:: - -- ~.: ~
~
-.:
Ill I~
lTn
~ ~-
~~,~~
~
•w•
II
_......
.!,
---
II
~ .:~ .
II,!. T
'-
w 0 --
-- IT I
I
_:::::.
r--tY--QO-
r--ll/l-cJq-il/T
c;@ Turn s I ona,l
Rear Rl ..
G ..,
'- LIOht 1 2Y21W
ante
LIOht
ll~~ 11L 12V5/ 2lWX2
tl/l 11/T
II 1 ::lJ]:tc/l
1 ~License Plate
1-tk/T Lloht t zvsw
'--lk/T-0<)-U~ ltor LO tt
II c ---CJc:J- c Turn Sl onal
L loht 12V2tw
I I'
-
~
;:;-
.=
l ~- I
~
n
••'
~ --
w
--
~
w
~
~
~
'••
>~
::'9
·H_ ~-
.y.:;•
..... •o •
b~ • ----;:::t.....; ~
----
§'-o~ a-
- -
~.sor~n
Side Neutral Oil
Stand SWItch Pressure
swttoh At urnator SWitCh
(tiOSI·IUU)C
I
MODEL APPLICATION
Veer Moc:t.l Beginning !'Tame No.
1994 ZX900-B1 JKAZX2B1 ORA000001. or
ZX900B-000001 ·
1996 ZX900· B2 JKAZX2B1 OSA018001, or
ZX900B· 018001
1996 ZX900· B3 JKAZX2B1 OTA028001 , or
ZX900B·028001
1997 ZX900- B4 JKAZX2B1 OVA038001. or
ZX900B ·038001
0 : This digit in the frame number changes from one
machine to another•
.-c Kawasaki
KAWASAKI HEAVY INDUSTRIES, LTD.
C.on1umer Products Group
Part No. 99924-1171 -04 Prlntod In J-

•

Kawasaki ZX-9R (B1-B4 1994-1997) Service Manual

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Kawasaki ZX-9R (B1-B4 1994-1997) Service Manual

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Kawasaki Ninja ZX-9R

This quick reference guide will assist you in

Before Servicing ..........................................................................................................1-2

Eapecially no te the f o llo w ing:

(12) Oil Seal and Grease Seal

Name of Wire Color

(18) Replacement Parts

ZX900-B1 (US end Cenede Models) Lett Side View:

ZX900-B1 (US end Cenade Modele) Right Side View:

ZX90()..81 (Europe Model) left Side View:

ZX900-81 (Europe Model) Right Side VIew:

Items ZX900- B1 ZX900-B2 ZX900-B3

Items ZX900- B1 ZX900- B2 ZX900- B3

Spark plug NGK CR9EK or NO U27ETR +- +-

Close 35• ATOC. (FR)(ST} 20" ATOC +- +-

6-speed. constant mesh, return shift

Whichever .. I 1000METER READING

' ~~ ~~~6()~ ~~~ ~()~ ~()~~()~

(II) Main Feeturw

Pb .. 1/2 Ot .... (PbO)

(IV) RBing the Batte<y with Electrolyte

Be lift 10 UH lhe dedicated -rolytoo contal,_ lor eo<rect

e Tske the eleciJOiyte container out of the vinyl bag.

• Be certain that all the electrolyte has flowed out

o.- you "lnalllllecl ... atrtp ol - - filling ... INttlery, never

Condition requiring lnMial ctoorge Cloorglng method

3) When you do not use !ht motorcycle IO< monthl

(VII) ~lity with Ordinary Battery

Technica l Information - Engine Lubricat ion System

To cool the oil, a liquid-cooled oil coole< [ A) is employed, which

First having almost me same cooling capability, the liquid-cooled oil

Liquid-cooled Oil Cooler [A)

1M ...,;.dry sump system is designed to reduce oil stirring loss by

Technical Information - Swingarm

A Swongarm Pi110t Locknut D. Sleeve G. Swingarm Pivot Nut

Fastener Torque Remarks

Fastener Tor que Remark s

Fastener Torque Remarks

Fastener Torque Remarka

Fastener Torque Remarks

Outside Circlip Pliers: 67001 · 144 Hand Tester. 57001-1394

Bearing Ori\/Of Set: 57001-1129 Clutch Holder: 57001 -1243

Steering Stom Bearing Driver. 57001 •1 344

Sodcet Wrench: 57001.1347 Pilot Screw AdjuS1er Driver: 57001 · 1373

Vacuum Gauge Bolt Washer: 92022· 304

Sperle Plug Wrench, 16mm: 9211 0·1154

VSQJum Gauge Bolt: 92150· 1161

Pressure Cable Luber: k6601 9· 021

Position the white !ape here.

Strap (Right Handlebar Switch"Loads and

Position the connectors

the headlight ~:kel~~~~jj~~~~~~~!~~~ij~~i~~~=

I. Main Hameu 4. Upper Fairing 7 . Meter Unit

Run th e hose between the radiator tank and

Front 1. Left Handlebar Switch

Run the fuel hose through the

(Main Hamess and Bracket)

Run the brake hose inside lhe leh

1. Right Front Foli< 4. Front Brake Reservoir 7. Rear Brake Caliper

Run the choke cable on the leftside of the

Run the throttle cables over the ---r..__

The clamp screw points downward.

1. Ignition Coil #1, #4 5. Choke Cable 9. Brake Hose

Face the Hange of the collar toward

' ~6()~ ~~~ ~()~ ~()~~()~

the headlight ~:keljj~!~iji~=