Kawasaki Ninja ZX-10R Motorcycle Service Manual – PDF DOWNLOAD

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Kawasaki Ninja ZX-10R Motorcycle Service Manual – PDF DOWNLOAD

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Kawasaki Ninja ZX-10R Motorcycle Service Manual – PDF DOWNLOAD 

Language : English
Pages : 651
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Kawasaki Ninja ZX-10R Motorcycle Service Manual – PDF DOWNLOAD 

tables 1
LIST OF ABBREVIATIONS 6
COUNTRY AND AREA CODES 6
Units of Mass 22
Units of Volume 22
Units of Force 22
Units of Length 22
Units of Torque 22
Units of Pressure 22
Units of Speed 22
Units of Power 22
Periodic Inspection 25
Periodic Replacement Parts 27
Basic Torque for General Fasteners 34
Throttle Grip Free Play 38
Throttle Body Vacuum 39
Main Throttle Sensor Output Voltage 41
Idle Speed 41
Valve Clearance 45
Example: 46
Adjustment Shims 47
Clutch Lever Free Play 49
Air Pressure (when Cold) 50
Tread Depth 51
Chain Slack 52
Drive Chain 20-link Length 54
Standard Chain 54
Recommended Disc Brake Fluid 56
Pad Lining Thickness 56
Sidestand Switch Operation 64
Water and Coolant Mixture Ratio (Recommended) 72
Recommended Engine Oil 75
Standard Spark Plug 82
Sample Diagnosis Sheet 113
Engine Doesn’t Start, Starting Difficulty 115
Poor Running at Low Speed 117
Poor Running or No Power at High Speed: 120
Main Throttle Sensor Input Voltage 132
Input Voltage at ECU Connector 132
Main Throttle Sensor Input Voltage 133
Input Voltage at Sensor 133
Main Throttle Sensor Output Voltage 134
Idle Speed 134
Output Voltage at ECU 134
Throttle Sensor Output Voltage 136
Output Voltage at Sensor 136
Main Throttle Sensor Resistance 137
Inlet Air Pressure Sensor Input Voltage 138
Input Voltage at ECU 138
Inlet Air Pressure Sensor Input Voltage 139
Input Voltage at Sensor Connector 139
Inlet Air Pressure Sensor Output Voltage 139
Output Voltage at ECU 139
Inlet Air Pressure Sensor Output Voltage 140
Output Voltage at Sensor Connector 140
Inlet Air Pressure Sensor Output Voltage Connection to Adapter 141
Inlet Air Temperature Sensor Output Voltage 143
Output Voltage at ECU 143
Inlet Air Temperature Sensor Resistance 144
Water Temperature Sensor Output Voltage 146
Output Voltage at ECU 146
Atmospheric Pressure Sensor Input Voltage 148
Input Voltage at ECU 148
Atmospheric Pressure Sensor Input Voltage 149
Input Voltage at Sensor Connector 149
Atmospheric Pressure Sensor Output Voltage 149
Output Voltage 149
Atmospheric Pressure Sensor Output Voltage 150
Output Voltage at Sensor 150
Speed Sensor Input Voltage 154
Input Voltage at ECU Connector 154
Speed Sensor Input Voltage 155
Input Voltage at Sensor 155
Speed Sensor Output Voltage 156
Output Voltage at Sensor 156
Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions 157
Input Voltage at 1 ∼ 6 Gear Positions 157
Vehicle-down sensor Power Source Voltage 160
Power Source Voltage at Sensor 160
Vehicle-down sensor Output Voltage 160
Output Voltage at Sensor 160
Subthrottle Sensor Input Voltage 162
Input Voltage at ECU Connector 162
Subthrottle Sensor Input Voltage 163
Input Voltage at Sensor 163
Subthrottle Sensor Output Voltage 163
Output Voltage at ECU 163
Subthrottle Sensor Output Voltage 164
Output Voltage at Sensor 164
Subthrottle Sensor Resistance 165
Oxygen Sensor ##1 Output Voltage 166
Oxygen Sensor ##1 Output Voltage (with Plugs) 167
Oxygen Sensor ##1 Output Voltage (without Plugs) 167
Exhaust Butterfly Valve Actuator Sensor Resistance 169
Antenna Resistance 170
Amplifier Input Voltage 170
Input Voltage 170
Testing Relay 172
Stick Coil Input Voltage at ECU 173
Input Voltage at ECU 173
Subthrottle Valve Actuator Resistance 175
Subthrottle Valve Actuator Input Voltage 176
Input Voltage 176
Connections to Adapter 180
Actuator Output Voltage (Pulley Original Position) 180
Oxygen Sensor Heaters Resistance 181
Oxygen Sensor Heaters Power Source Voltage 182
Power Source Voltage at Sensor Connector 182
Oxygen Sensor ##2 Output Voltage 185
Oxygen Sensor Output Voltage (with Plugs) 186
Oxygen Sensor ##2 Output Voltage (without Plugs) 186
ECU Identification 188
ECU Grounding Inspection 189
ECU Power Source Inspection 190
Fuel Pressure 194
Fuel Pressure (idling) 195
Amount of Fuel Flow 196
Pump Operating Voltage at Pump 198
Operating Voltage at Pump Connector 198
Injector Power Source Voltage at ECU Connector 200
Power Source Voltage at ECU 200
Injector Power Source Voltage at Injector 201
Power Source Voltage at Injector Connector 201
Injector Output Voltage at ECU 201
Output Voltage at ECU 201
Injector Output Voltage at Injector 202
Output Voltage at Injector Connector 202
Injector Resistance 203
Fuel Line Maximum Pressure 204
Radiator Cap Relief Pressure 238
Thermostat Valve Opening Temperature 242
Camshaft Journal, Camshaft Cap Clearance 269
Camshaft Journal Diameter 269
Camshaft Runout 269
Cam Height 270
Cylinder Compression 271
Cylinder Head Warp 274
Valve/Valve Guide Clearance (Wobble Method) 277
Valve Seating Surface Outside Diameter 277
Valve Seating Surface Width 277
Spring Plate Free Play 307
Spring Plate Free Play 308
Clutch Plate Assembly Length (Reference) 308
Friction Plate Thickness 308
Friction and Steel Plate Warp 309
Clutch Spring Free Length 309
Oil Pressure 327
Connecting Rod Big End Bearing Insert Selection 350
Crankshaft Main Bearing Insert Selection 350
Connecting Rod Bend 362
Connecting Rod Twist 363
Connecting Rod Big End Side Clearance 363
Connecting Rod Big End Bearing Insert/Crankpin Clearance 363
Crankpin Diameter 364
Crankpin Diameter Marks 364
Connecting Rod Big End Inside Diameter Marks 365
Crankshaft Side Clearance 365
Crankshaft Runout 365
Crankshaft Main Bearing Insert/Journal Clearance 366
Crankshaft Main Journal Diameter 366
Crankshaft Main Journal Diameter Marks 366
Crankcase Main Bearing Inside Diameter Marks 367
Cylinder Inside Diameter 370
Piston Diameter 370
Piston Ring/Groove Clearance 370
Piston Ring Groove Width 371
Piston Ring Thickness 371
Piston Ring End Gap 371
Shift Fork Ear Thickness 380
Gear Groove Width 380
Shift Fork Guide Pin Diameter 380
Shift Drum Groove Width 380
Rim Runout (with tire installed) 390
Axle Runout/100 mm (3 94 in ) 390
Balance Weight 392
Link Pin Outside Diameter 408
Link Plates Outside Width 408
Rear Sprocket Warp 413
Pedal Position 422
Brake Discs Thickness 432
Disc Runout 432
Rebound Damping Force Adjustment 447
Compression Damping Force Adjustment 447
Adjuster Protrusion (from the top plug nut surface) 448
Spring Action 448
Fork Oil 452
Oil Level (fully compressed, without spring) 452
Spring Free Length 457
Rebound Damping Force Adjustment 458
Rebound Damping Force Adjustment 458
Spring Preload Setting 459
Spring Adjustment 459
Damping Force Adjustment 475
Kawasaki-recommended chargers: 531
Battery Terminal Voltage 533
Terminal Voltage: 11 5 ∼ less than 12 8 V 534
Terminal Voltage: less than 11 5 V 534
Table 1 Alternator Output Voltage 538
Table 2 Stator Coil Resistance 538
Regulator/Rectifier Resistance (Unit: kΩ) 539
Charging Voltage 540
Crankshaft Sensor Peak Voltage 544
Ignition Coil Winding Resistance 547
Primary Lead Connection 547
Stick Coil Primary Peak Voltage 548
Connections: 550
Camshaft Position Sensor Peak Voltage 550
Condition: 550
Condition: 551
Condition: 551
Starter Motor Brush Length 561
Commutator Diameter 561
Testing Relay 562
Testing Turn Signal Relay 569
Air Switching Valve Resistance 571
User Key Indicator Light and Symbol Flashes 588
Water Temperature Sensor 605
Connections 606
Gear Position Switch Resistance kΩ 610
Relay Circuit Inspection (with the battery disconnected) 611
Relay Circuit Inspection (with the battery connected) 612
Diode Circuit Inspection 612
toc 1
EMISSION CONTROL INFORMATION 7
1 7
2 7
3 7
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 8
Foreword 9
General Information 11
Before starting to perform an inspection service or carry out a 12
Battery Ground 12
Edges of Parts 12
Solvent 12
Cleaning vehicle before disassembly 12
Arrangement and Cleaning of Removed Parts 13
Storage of Removed Parts 13
Inspection 13
Replacement Parts 13
Assembly Order 13
Tightening Sequence 14
Tightening Torque 14
Force 14
Gasket, O-ring 14
Liquid Gasket, Non-permanent Locking Agent 14
Press 15
Ball Bearing and Needle Bearing 15
Oil Seal, Grease Seal 15
Circlips, Cotter Pins 15
Lubrication 16
Direction of Engine Rotation 16
Electrical Wires 16
Instrument 16
ZX1000D6F (Europe) Left Side View 17
ZX1000D6F (Europe) Right Side View 17
ZX1000D6F (United States and Canada) Left Side View 18
ZX1000D6F (United States and Canada) Right Side View 18
Frame Number 18
Engine Number 18
Prefixes for Units 22
Units of Temperature 22
Periodic Maintenance 23
The scheduled maintenance must be done in accordance with this c 25
The following tables list the tightening torque for the major fa 0
Inside Circlip Pliers: 37
Fuel System (DFI) 38
Throttle Control System Inspection 38
Engine Vacuum Synchronization Inspection 38
Special Tool – 39
Special Tool – 39
Special Tool – 40
Torque – 40
Torque – 40
Idle Speed Inspection 41
Idle Speed Adjustment 42
Fuel Hose Inspection (fuel leak, damage, installation condition) 42
Evaporative Emission Control System (California Model) 43
Evaporative Emission Control System Inspection 43
Cooling System 44
Coolant Level Inspection 44
Radiator Hose and Pipe Inspection (coolant leak, damage, install 44
Torque – 44
Engine Top End 44
Valve Clearance Inspection 44
Valve Clearance Adjustment 46
Air Suction System 48
Air Suction System Damage Inspection 48
Special Tool – 48
Clutch 49
Clutch Operation Inspection 49
Wheels/Tires 50
Air Pressure Inspection 50
Wheel/Tire Damage Inspection 50
Tire Tread Wear Inspection 50
Wheel Bearing Damage Inspection 51
Drive Train 52
Drive Chain Lubrication Condition Inspection 52
Drive Chain Slack Inspection 52
Drive Chain Slack Adjustment 53
Torque – 53
Wheel Alignment Inspection 54
Drive Chain Wear Inspection 54
Chain Guide Wear Inspection 55
Brake System 55
Brake Fluid Leak (Brake Hose and Pipe) Inspection 55
Brake Hose Damage and Installation Condition Inspection 55
Torque – 55
Brake Operation Inspection 55
Brake Fluid Level Inspection 56
Brake Pad Wear Inspection 56
Brake Light Switch Operation Inspection 56
Suspensions 57
Front Forks/Rear Shock Absorber Operation Inspection 57
Front Fork Oil Leak Inspection 58
Rear Shock Absorber Oil Leak Inspection 58
Rocker Arm Operation Inspection 58
Tie-Rod Operation Inspection 58
Steering System 59
Steering Play Inspection 59
Special Tools – 59
Steering Play Adjustment 59
Special Tool – 59
Torque – 60
Steering Stem Bearing Lubrication 60
Steering Damper Oil Leak Inspection 60
Electrical System 61
Lights and Switches Operation Inspection 61
Headlight Aiming Inspection 63
Sidestand Switch Operation Inspection 64
Engine Stop Switch Operation Inspection 65
Others 66
Chassis Parts Lubrication 66
Pivots: Lubricate with Grease 66
Points: Lubricate with Grease 66
Cables: Lubricate with Rust Inhibitor 66
Bolts, Nuts and Fasteners Tightness Inspection 67
Bolt, Nut and Fastener to be checked 68
Replacement Parts 69
Air Cleaner Element Replacement 69
Torque – 70
Fuel Hose Replacement 70
Coolant Change 71
Torque – 72
Torque – 72
Radiator Hose and O-ring Replacement 74
Torque – 74
Engine Oil Change 75
Torque – 75
Torque – 75
Oil Filter Replacement 75
Special Tool – 75
Torque – 76
Brake Hose and Pipe Replacement 76
Torque – 76
Brake Fluid Change 76
Torque – 77
Torque – 77
Master Cylinder Rubber Parts Replacement 78
Special Tool – 78
Special Tool – 78
Torque – 79
Caliper Rubber Parts Replacement 79
Torque – 80
Torque – 80
Torque – 81
Spark Plug Replacement 82
Owner’s Tool – 82
Torque – 82
Fuel System (DFI) 83
DFI System 92
Oil Pressure Gauge, 5 kgf/cm : 96
Main Throttle Sensor [A] 98
DFI System Wiring Diagram 100
Terminal Numbers of ECU Connectors 102
DFI Servicing Precautions 104
Torque – 105
The warning indicator light (LED) [A] is used for the FI indicat 106
Outline 106
Special Tool – 108
Sealant – 108
Special Tool – 109
DFI Diagnosis Flow Chart 112
Inquiries to Rider 112
NOTE 115
The warning indicator light (LED) [A] is used for the FI indicat 123
Self-diagnosis Outline 123
Self-diagnosis Procedures 124
Self-Diagnosis Flow Chart 126
Service Code Reading 127
Service Code Erasing 127
Backups 129
The main throttle sensor is a rotating variable resistor that ch 132
Main Throttle Sensor Removal/Adjustment 132
Input Voltage Inspection 132
Special Tool – 132
Special Tool – 133
Output Voltage Inspection 134
Special Tool – 134
Special Tool – 136
Resistance Inspection 137
Main Throttle Sensor Circuit 137
CAUTION 138
Removal 138
Installation 138
Input Voltage Inspection 138
Special Tool – 138
Special Tool – 139
Output Voltage Inspection 139
Special Tool – 139
Special Tool – 140
Inlet Air Pressure Sensor Circuit 140
Special Tools – 141
Removal/Installation 143
Output Voltage Inspection 143
Special Tool – 143
Sealant – 144
Sensor Resistance Inspection 144
Inlet Air Temperature Sensor Circuit 145
Removal/Installation 146
Sealant – 146
Torque – 146
Output Voltage Inspection 146
Special Tool – 146
Sealant – 147
Sensor Resistance Inspection 147
Water Temperature Sensor Circuit 147
CAUTION 148
Removal 148
Installation 148
Input Voltage Inspection 148
Special Tool – 148
Special Tool – 149
Output Voltage Inspection 149
Special Tool – 149
Special Tool – 150
Atmospheric Pressure Sensor Circuit 150
Atmospheric Pressure/Altitude Relationship 151
Crankshaft Sensor Removal/Installation 152
Crankshaft Sensor Inspection 152
Crankshaft Sensor Circuit 152
Camshaft Position Sensor Removal/Installation 153
Camshaft Position Sensor Inspection 153
Camshaft Position Sensor Circuit 153
Speed Sensor Removal/Installation 154
Input Voltage Inspection 154
Special Tool – 154
Special Tool – 155
Output Voltage Inspection 155
Special Tool – 155
Speed Sensor Circuit 156
Gear Position Switch Removal/Installation 157
Gear Position Switch Inspection 157
Input Voltage Inspection 157
Special Tool – 157
Gear Position Switch Circuit 158
This sensor has a weight [A] with two magnets inside, and sends 159
Removal 159
Installation 159
Torque – 159
Inspection 159
Special Tool – 160
Special Tool – 160
Sealant – 161
Vehicle-down Sensor Circuit 161
The subthrottle sensor is a rotating variable resistor that chan 162
Subthrottle Sensor Removal/Adjustment 162
Input Voltage Inspection 162
Special Tool – 162
Special Tool – 163
Output Voltage Inspection 163
Special Tool – 163
Special Tool – 164
Resistance Inspection 165
Subthrottle Sensor Circuit 165
Oxygen Sensor ##1 Removal/Installation 166
Oxygen Sensor ##1 Inspection 166
Special Tool – 166
Special Tool – 167
Sealant – 167
Oxygen Sensor Circuit 168
Exhaust Butterfly Valve Actuator Sensor Inspection 169
Exhaust Butterfly Valve Actuator Sensor Circuit 169
Antenna Resistance Inspection 170
Amplifier Input Voltage Inspection 170
Special Tool – 170
User Key Inspection 171
Immobilizer System Circuit 171
Fuel Pump Relay Removal 172
Fuel Pump Relay Inspection 172
Special Tool – 172
Fuel Pump Relay Circuit 172
Stick Coil ##1: Service Code 51 173
Removal/Installation 173
Input Voltage Inspection 173
Special Tool – 173
Stick Coil Circuit 174
Subthrottle Valve Actuator Removal 175
Subthrottle Valve Actuator Inspection 175
Resistance Inspection 175
Input Voltage Inspection 176
Special Tools – 176
Subthrottle Valve Actuator Circuit 177
Exhaust Butterfly Valve Actuator Removal 178
Exhaust Butterfly Valve Actuator Installation 178
Torque – 178
Torque – 179
Exhaust Butterfly Valve Actuator Inspection 179
Output Voltage Inspection 180
Special Tool – 180
Exhaust Butterfly Valve Actuator Circuit 180
Oxygen Sensor Heaters Removal/Installation 181
Oxygen Sensor Heaters Inspection 181
Special Tool – 181
Special Tool – 182
Sealant – 182
Oxygen Sensor Circuit 183
ECU Main Relay Inspection 184
Oxygen Sensor ##2 Removal/Installation 185
Oxygen Sensor ##2 Inspection 185
Special Tool – 185
Special Tool – 186
Sealant – 186
Oxygen Sensor Circuit 187
CAUTION 188
ECU Identification 188
ECU Removal 188
ECU Installation 189
ECU Power Supply Inspection 189
Special Tool – 189
ECU Power Source Circuit 191
ECU Fuse Removal 192
ECU Fuse Installation 192
ECU Fuse Inspection 192
Light (LED) Inspection 193
Warning Indicator Light (LED) (FI/Immobilizer) Circuit 193
Fuel Pressure Inspection 194
Special Tools – 194
Fuel Flow Rate Inspection 195
Special Tool – 195
Fuel Pump Removal 197
Fuel Pump Installation 197
Torque – 198
Operation Inspection 198
Operating Voltage Inspection 198
Special Tools – 198
Fuel Pump Circuit 199
Removal/Installation 200
Power Source Voltage Inspection 200
Special Tool – 200
Special Tool – 201
Output Voltage Inspection 201
Special Tool – 201
Special Tool – 202
Audible Inspection 202
Special Tool – 202
Injector Signal Test 203
Special Tool – 203
Injector Resistance Inspection 203
Injector Unit Test 204
Injector Fuel Line Inspection 204
Fuel Injector Circuit 205
Free Play Inspection 206
Free Play Adjustment 206
Cable Installation 206
Cable Lubrication 206
Idle Speed Inspection 207
Throttle Bore Cleaning 207
Synchronization Inspection 207
Synchronization Adjustment 207
Throttle Body Assy Removal 207
Throttle Body Assy Installation 209
Torque – 209
Torque – 209
Throttle Body Assy Disassembly 210
Throttle Body Assy Assembly 211
Torque – 212
Element Removal 213
Element Installation 213
Air Cleaner Element Inspection 213
Air Cleaner Housing Removal 213
Air Cleaner Housing Installation 214
Torque – 215
Air Cleaner Housing Disassembly 215
Air Cleaner Housing Assembly 215
Sealant – 215
Oil Draining 215
Air Inlet Duct Removal 216
Air Inlet Duct Installation 216
Torque – 216
Fuel Tank Removal 217
Fuel Tank Installation 219
Fuel Tank and Cap Inspection 220
Fuel Tank Cleaning 220
The Evaporative Emission Control System routes fuel vapors from 221
Parts Removal/Installation 221
Hose Inspection 221
Separator Inspection 221
Separator Operation Test 222
Canister Inspection 222
Cooling System 223
Coolant Deterioration Inspection 229
Coolant Level Inspection 229
Coolant Draining 229
Coolant Filling 229
Pressure Testing 229
Cooling System Flushing 230
Coolant Reserve Tank Removal 230
Coolant Reserve Tank Installation 231
Torque – 231
Water Pump Removal 232
Water Pump Installation 232
Torque – 233
Torque – 233
Torque – 233
Water Pump Impeller Inspection 233
Radiator and Radiator Fan Removal 234
Radiator and Radiator Fan Installation 235
Torque – 236
Torque – 236
Torque – 236
Torque – 236
Radiator Inspection 238
Radiator Cap Inspection 238
Radiator Filler Neck Inspection 239
Thermostat Removal 240
Thermostat Installation 240
Torque – 241
Torque – 241
Torque – 241
Torque – 241
Thermostat Inspection 241
Hose Installation 243
Torque – 243
Hose Inspection 243
CAUTION 244
Water Temperature Sensor Removal 244
Water Temperature Sensor Inspection 244
Engine Top End 245
Dummy Page 247
Exhaust System ZX1000D6F 252
Compression Gauge, 20 kgf/cm : 256
Air Suction Valve Removal 258
Air Suction Valve Installation 258
Torque – 258
Air Suction Valve Inspection 258
Air Switching Valve Removal 259
Air Switching Valve Installation 259
Air Switching Valve Operation Test 259
Air Switching Valve Unit Test 259
Clean Air System Hose Inspection 259
Cylinder Head Cover Removal 260
Cylinder Head Cover Installation 260
Sealant – 260
Torque – 261
Camshaft Chain Tensioner Removal 262
Camshaft Chain Tensioner Installation 263
Torque – 263
Torque – 263
Torque – 263
Camshaft Removal 264
Camshaft Installation 265
Torque – 266
Torque – 268
Torque – 268
Camshaft, Camshaft Cap Wear 269
Camshaft Runout 269
Cam Wear 270
Camshaft Chain Removal 270
Cylinder Compression Measurement 271
Special Tools – 271
Torque – 271
Cylinder Head Removal 272
Cylinder Head Installation 273
Torque – 273
Torque – 273
Torque – 273
Cylinder Head Warp 274
Valve Clearance Inspection 275
Valve Removal 275
Special Tools – 275
Valve Installation 275
Valve Guide Removal 275
Special Tool – 275
Valve Guide Installation 276
Special Tools – 276
Special Tool – 276
Valve-to-Guide Clearance Measurement (Wobble Method) 276
Valve Seat Inspection 277
Valve Seat Repair 277
Special Tools – 277
Throttle Body Assy Holder Removal 282
Throttle Body Assy Holder Installation 282
Torque – 282
WARNING 283
Muffler Body Removal 283
Muffler Body Installation 284
Torque – 284
Torque – 284
Middle and Rear Exhaust Pipe Removal 285
Middle and Rear Exhaust Pipe Installation 286
Torque – 286
Torque – 286
Torque – 286
Front Exhaust Pipe Removal 287
Front Exhaust Pipe Installation 288
Torque – 288
Exhaust Butterfly Valve Cable Removal 289
Exhaust Butterfly Valve Cable Installation 290
Torque – 290
Torque – 291
Torque – 291
Clutch 293
Clutch Holder: 297
Clutch Lever Free Play Inspection 298
Clutch Lever Free Play Adjustment 298
Cable Removal 298
Cable Installation 298
Cable Lubrication 298
Clutch Lever Installation 298
Torque – 298
Clutch Cover Removal 299
Clutch Cover Installation 299
Sealant – 299
Torque – 299
Release Shaft Removal 299
Release Shaft Installation 300
Clutch Cover Disassembly 300
Clutch Cover Assembly 301
Torque – 301
Clutch Removal 302
Special Tool – 302
Special Tool – 302
Clutch Installation 304
Torque – 304
Special Tool – 305
Torque – 305
Torque – 306
Spring Plate Free Play Measurement 307
Spring Plate Free Play Adjustment 308
Torque – 308
Clutch Plate, Wear, Damage Inspection 308
Clutch Plate Warp Inspection 309
Clutch Spring Free Length Measurement 309
Damper Cam Inspection 309
Engine Lubrication System 311
Oil Pressure Gauge, 10 kgf/cm : 317
WARNING 318
Oil Level Inspection 318
Engine Oil Change 318
Oil Filter Replacement 318
Oil Pan Removal 319
Oil Pan Installation 319
Torque – 319
Oil Pressure Relief Valve Removal 320
Oil Pressure Relief Valve Installation 320
Torque – 320
Oil Pressure Relief Valve Inspection 321
Oil Pump Removal 322
Oil Pump Installation 322
Torque – 323
Oil Pump Gear Removal 323
Special Tool – 323
Oil Pump Gear Installation 323
Special Tool – 324
Torque – 324
Oil Cooler Removal 325
Oil Cooler Installation 325
Torque – 325
Torque – 325
Oil Cooler/Oil Filter Case Removal 325
Oil Cooler/Oil Filter Case Installation 326
Torque – 326
Torque – 326
Oil Pressure Measurement 327
Special Tools – 327
Torque – 327
Oil Pressure Switch Removal 328
Oil Pressure Switch Installation 328
Sealant – 328
Torque – 328
Torque – 328
Engine Removal/Installation 329
Engine Mount Nut Wrench: 332
Engine Removal 333
Special Tool – 336
Engine Installation 336
Torque – 338
Torque – 338
Torque – 339
Special Tool – 339
Torque – 339
Torque – 339
Torque – 340
Torque – 340
Torque – 340
Torque – 340
Crankshaft/Transmission 343
Bearing Puller: 351
Crankcase Splitting 352
Crankcase Assembly 353
Sealant – 353
Torque – 354
Sealant – 355
Torque – 356
Torque – 356
Torque – 356
Torque – 357
Torque – 357
Torque – 357
Crankshaft Removal 358
Crankshaft Installation 358
Connecting Rod Removal 358
Connecting Rod Installation 359
Crankshaft/Connecting Rod Cleaning 362
Connecting Rod Bend 362
Connecting Rod Twist 363
Connecting Rod Big End Side Clearance 363
Connecting Rod Big End Bearing Insert/Crankpin Wear 363
Crankshaft Side Clearance 365
Crankshaft Runout 365
Crankshaft Main Bearing Insert/Journal Wear 366
Piston Removal 368
Special Tool – 368
Piston Installation 369
Special Tools – 370
Cylinder Wear (Upper Crankcase) 370
Piston Wear 370
Piston Ring, Piston Ring Groove Wear 370
Piston Ring Groove Width 371
Piston Ring Thickness 371
Piston Ring End Gap 371
Shift Pedal Removal 372
Shift Pedal Installation 372
Torque – 372
Torque – 372
Torque – 372
External Shift Mechanism Removal 372
Special Tool – 372
External Shift Mechanism Installation 373
Torque – 373
External Shift Mechanism Inspection 373
Torque – 373
Transmission Shaft Removal 374
Transmission Shaft Installation 374
Torque – 374
Transmission Shaft Disassembly 375
Special Tool – 375
Special Tools – 375
Transmission Shaft Assembly 375
Spacial Tool – 375
Shift Drum and Fork Removal 379
Shift Drum and Fork Installation 379
Torque – 379
Shift Drum Disassembly 379
Shift Drum Assembly 379
Torque – 379
Shift Fork Bending 380
Shift Fork/Gear Groove Wear 380
Shift Fork Guide Pin/Drum Groove Wear 380
Gear Dog and Gear Dog Hole Damage 380
Wheels/Tires 381
Bearing Driver Set: 385
Front Wheel Removal 386
Special Tools – 386
Front Wheel Installation 386
Torque – 387
Torque – 387
Rear Wheel Removal 388
Rear Wheel Installation 388
Torque – 389
Wheel Inspection 390
Special Tools – 390
Axle Inspection 390
Balance Inspection 391
Balance Adjustment 391
Balance Weight Removal 391
Balance Weight Installation 391
Air Pressure Inspection/Adjustment 393
Tire Inspection 393
Tire Removal 393
Tire Installation 393
Tire Repair 395
Hub Bearing Removal 396
Special Tools – 396
Hub Bearing Installation 396
Special Tool – 396
Special Tool – 396
Hub Bearing Inspection 396
Hub Bearing Lubrication 397
Final Drive 399
Inside Circlip Pliers: 403
Drive Chain Slack Inspection 404
Drive Chain Slack Adjustment 404
Wheel Alignment Inspection/Adjustment 404
Drive Chain Wear Inspection 404
Drive Chain Lubrication 404
Drive Chain Removal 404
Drive Chain Installation 406
Engine Sprocket Removal 409
Engine Sprocket Installation 409
Torque – 409
Torque – 410
Rear Sprocket Removal 410
Rear Sprocket Installation 410
Torque – 410
Coupling Installation 411
Coupling Bearing Removal 411
Special Tool – 411
Special Tool – 411
Coupling Bearing Installation 411
Special Tool – 411
Special Tool – 411
Special Tool – 412
Coupling Bearing Inspection 412
Coupling Bearing Lubrication 412
Coupling Damper Inspection 412
Sprocket Wear Inspection 412
Rear Sprocket Warp Inspection 413
Brakes 415
Inside Circlip Pliers: 421
Brake Lever Position Adjustment 422
Brake Pedal Position Inspection 422
Brake Pedal Position Adjustment 422
Torque – 422
Brake Pedal Removal 422
Brake Pedal Installation 423
Torque – 423
Torque – 423
Torque – 423
Front Caliper Removal 424
Rear Caliper Removal 424
Caliper Installation 424
Torque – 424
Front Caliper Disassembly 425
Front Caliper Assembly 425
Rear Caliper Disassembly 425
Rear Caliper Assembly 425
Caliper Fluid Seal Damage 425
Rear Caliper Dust Boot and Friction Boot Damage 426
Caliper Piston and Cylinder Damage 426
Rear Caliper Holder Shaft Wear 426
Front Brake Pad Removal 427
Front Brake Pad Installation 427
Torque – 427
Rear Brake Pad Removal 428
Rear Brake Pad Installation 428
Brake Pad Wear Inspection 428
Front Master Cylinder Removal 429
Front Master Cylinder Installation 429
Torque – 429
Torque – 429
Rear Master Cylinder Removal 430
Rear Master Cylinder Installation 430
Torque – 430
Front Master Cylinder Disassembly 430
Rear Master Cylinder Disassembly 430
Master Cylinder Assembly 430
Master Cylinder Inspection (Visual Inspection) 431
Brake Disc Removal 432
Brake Disc Installation 432
Torque – 432
Brake Disc Wear 432
Brake Disc Warp 432
Special Tools – 432
Brake Fluid Level Inspection 433
Brake Fluid Change 433
Brake Line Bleeding 433
Torque – 434
Torque – 435
Torque – 435
Brake Hose Removal/Installation 437
Brake Hose Inspection 437
Suspension 439
Inside Circlip Pliers: 445
Rebound Damping Force Adjustment 447
Compression Damping Force Adjustment 447
Spring Preload Adjustment 448
Front Fork Removal (each fork leg) 448
Front Fork Installation 449
Torque – 449
Torque – 449
Front Fork Oil Change 449
Special Tools – 450
Special Tool – 451
Special Tool – 452
Special Tool – 452
Special Tool – 453
Special Tools – 453
Torque – 454
Front Fork Disassembly 455
Special Tool – 455
Front Fork Assembly 455
Special Tool – 455
Torque – 455
Special Tool – 456
Inner Tube Inspection 456
Dust Seal Inspection 457
Spring Tension 457
Rebound Damping Force Adjustment 458
Compression Damping Force Adjustment 458
Spring Preload Adjustment 458
Special Tool – 458
Special Tool – 459
Rear Shock Absorber Removal 459
Special Tools – 459
Rear Shock Absorber Installation 460
Torque – 460
Rear Shock Absorber Inspection 460
Rear Shock Absorber Scrapping 460
Swingarm Removal 461
Special Tool – 461
Swingarm Installation 462
Torque – 462
Special Tool – 462
Torque – 462
Torque – 462
Swingarm Bearing Removal 463
Special Tool – 463
Special Tools – 463
Swingarm Bearing Installation 463
Special Tool – 463
Swingarm Bearing, Sleeve Inspection 464
Swingarm Pivot Lubrication 464
Chain Guide Inspection 464
Tie-Rod Removal 465
Special Tools – 465
Tie-Rod Installation 465
Torque – 465
Rocker Arm Removal 465
Special Tools – 465
Rocker Arm Installation 466
Torque – 466
Tie-Rod and Rocker Arm Bearing Removal 466
Special Tools – 466
Tie-Rod and Rocker Arm Bearing Installation 466
Special Tools – 467
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection 468
Rocker Arm/Tie-Rod Bearing Lubrication 468
Steering 469
Bearing Puller Adapter: 473
Steering Inspection 474
Steering Adjustment 474
Steering Damper Removal 475
Steering Damper Installation 475
Damping Force Adjustment 475
Steering Damper Oil Leak Inspection 475
Stem, Stem Bearing Removal 476
Special Tool – 476
Special Tool – 477
Special Tools – 477
Stem, Stem Bearing Installation 477
Special Tools – 477
Special Tools – 478
Special Tool – 478
Torque – 478
Torque – 479
Steering Stem Bearing Lubrication 480
Steering Stem Warp 480
Stem Cap Deterioration, Damage 480
Handlebar Removal 481
Handlebar Installation 481
Torque – 481
Torque – 482
Frame 483
Rear Seat Removal 490
Rear Seat Installation 490
Front Seat Removal 490
Front Seat Installation 490
Lower Fairing Removal 491
Lower Fairing Installation 491
Middle Fairing Removal 491
Middle Fairing Installation 492
Windshield Removal 492
Windshield Installation 493
Torque – 493
Upper Fairing Removal 493
Upper Fairing Disassembly 493
Upper Fairing Assembly 493
Upper Fairing Installation 493
Upper Inner Fairing Removal 494
Upper Inner Fairing Installation 494
Center Inner Fairing Removal 494
Center Inner Fairing Installation 494
Right and Left Inner Fairing Removal 495
Right and Left Inner Fairing Installation 495
Side Cover Removal 496
Side Cover Installation 496
Seat Cover Removal 497
Seat Cover Installation 498
Front Fender Removal 499
Front Fender Installation 499
Torque – 499
Rear Fender Rear Removal 499
Rear Fender Rear Installation 500
Rear Fender Front Removal 500
Rear Fender Front Installation 501
Rear Frame Removal 502
Rear Frame Installation 502
Torque – 502
Frame Inspection 502
Sidestand Removal 503
Sidestand Installation 503
Torque – 503
Torque – 503
Electrical System 505
Dummy Page 515
Hand Tester: 525
There are a number of important precautions that are musts when 526
Wiring Inspection 528
Special Tool – 528
Battery Removal 529
Battery Installation 529
Battery Activation 530
Precautions 532
1) 532
2) 532
3) 532
4) 532
Interchange 533
Charging Condition Inspection 533
Refreshing Charge 533
Alternator Cover Removal 535
Alternator Cover Installation 535
Sealant – 535
Torque – 535
Stator Coil Removal 535
Stator Coil Installation 536
Torque – 536
Sealant – 536
Torque – 536
Alternator Rotor Removal 536
Special Tools – 536
Special Tool – 536
Alternator Rotor Installation 536
Special Tools – 537
Torque – 537
Alternator Inspection 537
Special Tool – 538
Regulator/Rectifier Inspection 539
Special Tool – 539
Torque – 539
Charging Voltage Inspection 540
Special Tool – 540
Charging System Circuit 541
Crankshaft Sensor Removal 543
Crankshaft Sensor Installation 543
Torque – 543
Sealant – 543
Crankshaft Sensor Inspection 544
Special Tool – 544
Crankshaft Sensor Peak Voltage Inspection 544
Special Tools – 544
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal 544
Stick Coil (Ignition Coil together with Spark Plug Cap) Installa 546
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti 547
Stick Coil Primary Peak Voltage 547
Special Tools – 547
Spark Plug Removal 548
Spark Plug Installation 548
Spark Plug Condition Inspection 548
Camshaft Position Sensor Removal 549
Camshaft Position Sensor Installation 549
Torque – 549
Camshaft Position Sensor Inspection 549
Special Tool – 549
Camshaft Position Sensor Peak Voltage Inspection 550
Special Tool – 550
Interlock Operation Inspection 550
IC Igniter Inspection 551
Ignition System Circuit 552
Starter Idle Gear Removal 553
Starter Idle Gear Installation 553
Sealant – 554
Torque – 554
Torque – 554
Starter Clutch Removal 555
Special Tools – 555
Starter Clutch Installation 555
Special Tools – 556
Torque – 556
Starter Clutch Disassembly 556
Starter Clutch Assembly 556
Starter Clutch Inspection 556
Starter Motor Removal 557
Starter Motor Installation 558
Torque – 558
Torque – 558
Starter Motor Disassembly 558
Starter Motor Assembly 559
Torque – 559
Torque – 560
Brush Inspection 561
Commutator Cleaning and Inspection 561
Armature Inspection 561
Special Tool – 561
Brush Lead Inspection 562
Special Tool – 562
Right-hand End Cover Assembly Inspection 562
Special Tool – 562
Starter Relay Inspection 562
Special Tool – 562
Torque – 562
Electric Starter Circuit 563
This motorcycle adopt the daylight system and have a headlight r 564
Headlight Beam Horizontal Vertical Adjustment 564
Headlight Beam Vertical Adjustment 564
Headlight Bulb Replacement 564
City Light Bulb Replacement 565
Headlight Removal/Installation 565
Torque – 565
Tail/Brake Light (LED) Removal 566
Tail/Brake Light (LED) Installation 566
License Plate Light Bulb Replacement 566
Torque – 566
Headlight/Tail Light Circuit 567
Turn Signal Light Bulb Replacement 567
Torque – 569
Turn Signal Relay Inspection 569
Turn Signal Light Circuit 570
Air Switching Valve Operation Test 571
Air Switching Valve Unit Test 571
Special Tool – 571
Fan Motor Inspection 572
Radiator Fan Circuit 572
Meter Unit Removal/Installation 573
Torque – 573
Meter Unit Disassembly 573
Electronic Combination Meter Unit Inspection 574
Meter Unit Circuit 583
This motorcycle is equipped with an immobilizer system to protec 584
Operational Cautions 584
Key Registration 584
Special Tool – 585
Spare User Key Registration Flow Chart 589
Special Tool – 590
All Keys Initial Registration Flow Chart 599
Immobilizer System Parts Replacement 600
Immobilizer System Inspection 602
Immobilizer System Circuit 603
Brake Light Timing Inspection 604
Brake Light Timing Adjustment 604
Switch Inspection 604
Special Tool – 604
Rear Brake Light Switch Connections 604
Sidestand Switch Connections 604
Oil Pressure Switch Connections * 604
Water Temperature Sensor Inspection 605
Speed Sensor Removal 605
Speed Sensor Installation 606
Torque – 606
Speed Sensor Inspection 606
Fuel Reserve Switch Inspection 606
Special Tool – 606
Oxygen Sensor Removal (Europe Models) 607
Oxygen Sensor Installation (Europe Models) 608
Torque – 608
Oxygen Sensor Inspection (Europe Models) 608
Oxygen Sensor Heater Inspection (Europe Models) 608
Gear Position Switch Removal 608
Gear Position Switch Installation 609
Torque – 609
Gear Position Switch Inspection 610
Special Tool – 610
The relay box [A] has relays and diodes The relays and diodes c 611
Relay Box Removal 611
Relay Circuit Inspection 611
Diode Circuit Inspection 612
Relay Box Internal Circuit 613
30 A Main Fuse Removal 614
Fuse Box Fuse Removal 614
15 A ECU Fuse Removal 614
Fuse Installation 615
Fuse Inspection 615
Appendix 617
California Model 642
California Model 644
NOTE 646
Engine Doesn’t Start, Starting Difficulty: 646
Starter motor not rotating: 646
Starter motor rotating but engine doesn’t turn over: 646
Engine won’t turn over: 646
No fuel flow: 646
No spark; spark weak: 646
Fuel/air mixture incorrect: 646
Compression Low: 646
Poor Running at Low Speed: 646
Spark weak: 646
Fuel/air mixture incorrect: 646
Compression low: 646
Other: 647
Poor Running or No Power at High Speed: 647
Firing incorrect: 647
Fuel/air mixture incorrect: 647
Compression low: 647
Knocking: 647
Miscellaneous: 647
Overheating: 647
Firing incorrect: 647
Muffler overheating: 647
Fuel/air mixture incorrect: 647
Compression high: 647
Engine load faulty: 647
Lubrication inadequate: 648
Oil cooler incorrect: 648
Gauge incorrect: 648
Coolant incorrect: 648
Cooling system component incorrect: 648
Over Cooling: 648
Gauge incorrect: 648
Cooling system component incorrect: 648
Clutch Operation Faulty: 648
Clutch slipping: 648
Clutch not disengaging properly: 648
Gear Shifting Faulty: 648
Doesn’t go into gear; shift pedal doesn’t return: 648
Jumps out of gear: 648
Overshifts: 648
Abnormal Engine Noise: 648
Knocking: 648
Piston slap: 648
Valve noise: 648
Other noise: 648
Abnormal Drive Train Noise: 649
Clutch noise: 649
Transmission noise: 649
Drive line noise: 649
Abnormal Frame Noise: 649
Front fork noise: 649
Rear shock absorber noise: 649
Disc brake noise: 649
Other noise: 649
Oil Pressure Warning Light Goes On: 649
Exhaust Smokes Excessively: 649
White smoke: 649
Black smoke: 649
Brown smoke: 649
Handling and/or Stability Unsatisfactory: 649
Handlebar hard to turn: 649
Handlebar shakes or excessively vibrates: 649
Handlebar pulls to one side: 649
Shock absorption unsatisfactory: 649
Brake Doesn’t Hold: 650
Battery Trouble: 650
Battery discharged: 650
Battery overcharged: 650
EDDŠp2-6 pdf 0
toc 28
The following tables list the tightening torque for the major fa 0

DESCRIPTION:

Kawasaki Ninja ZX-10R Motorcycle Service Manual – PDF DOWNLOAD 

FOREWORD:

• This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance andrepair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry outmaintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
• In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures  before starting work, and then do the work carefullyin a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
• For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

S.V 17/03/2025