Complete service repair manual with Electrical Wiring Diagrams for Kawasaki Motorcycles ZX-6R, ZX-6RR, ZX-7R(R), ZX-9R, ZX-10, ZX-10R, ZX-12R, ZX-14, ZX600, ZX750, ZX900, ZX1000, ZX1100, ZZ-R250, ZZ-R1200, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Kawasaki Motorcycles ZX-6R, ZX-6RR, ZX-7R(R), ZX-9R, ZX-10, ZX-10R, ZX-12R, ZX-14, ZX600, ZX750, ZX900, ZX1000, ZX1100, ZZ-R250, ZZ-R1200 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Kawasaki Motorcycle Service Repair Manual '00 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '00 ZX-12R (DE).pdf
Kawasaki Motorcycle Service Repair Manual '00 ZX-12R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '02-'04 ZX-12R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '02-'05 ZZ-R1200.pdf
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (IT).pdf
Kawasaki Motorcycle Service Repair Manual '04-'05 ZZ-R250.pdf
Kawasaki Motorcycle Service Repair Manual '04 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6RR (EN).pdf
Kawasaki Motorcycle Service Repair Manual '05 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '06-'07 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '06 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '06 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '07-'08 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '07 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '08-'11 ZX-14 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '09 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '11 ZX-10R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '83-'97 ZX900-1000-1100 Ninja (EN).pdf
Kawasaki Motorcycle Service Repair Manual '84-'90 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '84 ZX-9R (DE).pdf
Kawasaki Motorcycle Service Repair Manual '85-'97 ZX600 & 750 Fours (EN).pdf
Kawasaki Motorcycle Service Repair Manual '88-'90 ZX-10 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '90-'00 ZX600 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '90 ZXR400 (DE).pdf
Kawasaki Motorcycle Service Repair Manual '93-'01 ZX-11 (EN).pdf
Kawasaki Motorcycle Service Repair Manual '94-'97 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '95-'02 ZX600 & 636 (ZX-6R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual '96-'99 ZX-7R(R) (EN).pdf
Kawasaki Motorcycle Service Repair Manual '96 ZX-7R(R) (DE).pdf
Kawasaki Motorcycle Service Repair Manual '98-'99 ZX-6R (EN).pdf
Kawasaki Motorcycle Service Repair Manual '98 ZX-9R (EN).pdf
Kawasaki Motorcycle Service Repair Manual Assembly & Preparation ZX-6R.pdf
Kawasaki Motorcycle Service Repair Manual ZXR400 (ZX400H2).pdf
Kawasaki Motorcycle ZZR250 1990 - 1996 Repair Manual Supplement.pdf
Kawasaki Motorcycle Racing Kit Manual '05 ZX-6RR.pdf
Kawasaki Motorcycle Service Parts Catalog '05 ZX-6R.pdf
Kawasaki Motorcycle Service Parts Catalog '91 GPX600R (ZX600-C4).pdf

PRODUCT DETAILS:
Total Pages: 2,122 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
Kawasaki Motorcycle Racing Kit Manual '05 ZX-6RR...3
Kawasaki Motorcycle Service Parts Catalog '05 ZX-6R...66
  AIR CLEANER...67
  AIR DUCT...68
  BRAKE PEDAL/TORQUE LINK...69
  CABLES...70
  CAMSHAFT(S)/TENSIONER...71
  CHAIN COVER...72
  CHASSIS ELECTRICAL EQUIPMENT...73
  CLUTCH...74
  COWLING...75
  COWLING LOWERS...76
  CRANKCASE...77
  CRANKCASE BOLT PATTERN...78
  CRANKSHAFT...79
  CYLINDER HEAD...80
  CYLINDER HEAD COVER...81
  CYLINDER/PISTON(S)...82
  DECALS (BLUE)...83
  DECALS (GREEN)...84
  DECALS (RED)...85
  DECALS (TITANIUM)...86
  ENGINE COVER(S)...87
  ENGINE MOUNT...88
  FOOTRESTS...89
  FRAME...90
  FRAME FITTINGS (FRONT)...91
  FRAME FITTINGS (REAR)...92
  FRONT BRAKE...93
  FRONT FENDER(S)...94
  FRONT FORK...95
  FRONT MASTER CYLINDER...96
  FRONT WHEEL...97
  FUEL EVAPORATIVE SYSTEM (CA)...98
  FUEL INJECTION...99
  FUEL PUMP...100
  FUEL TANK...101
  GEAR CHANGE DRUM/SHIFT FORK(S)...102
  GEAR CHANGE MECHANISM...103
  GENERATOR...104
  HANDLEBAR...105
  HEADLIGHT(S)...106
  IGNITION SWITCH/LOCKS/REFLECTORS...107
  IGNITION SYSTEM...108
  LABELS...109
  METER(S)...110
  MUFFLER(S)...111
  OIL COOLER...112
  OIL PAN...113
  OIL PUMP/OIL FILTER...114
  OWNER'S TOOLS...115
  PUBLICATIONS...116
  RADIATOR...117
  REAR BRAKE...118
  REAR FENDER(S)...119
  REAR MASTER CYLINDER...120
  REAR SUSPENSION...121
  REAR WHEEL/CHAIN...122
  SEAT...123
  SHOCK ABSORBER(S)...124
  SIDE COVERS...125
  STAND(S)...126
  STARTER MOTOR...127
  SWINGARM...128
  TAILLIGHT(S)...129
  THROTTLE...130
  TIRES...131
  TOP FEED INJECTER...132
  TRANSMISSION...133
  TURN SIGNALS...134
  VALVE(S)...135
  WATER PIPE...136
...
Kawasaki Motorcycle Service Repair Manual '00 ZX-12R (EN)...689
  Forward Ch-0...689
  General Info Ch-1...697
  Fuel Injection Ch-2...735
  Cooling System Ch-3...830
  Engine Top End Ch-4...850
  Clutch Ch-5...885
  Engine Lube System Ch-6...899
  Engine Removal Ch-7...913
  Crankshaft/Tranny Ch-8...919
  Wheels/Tires Ch-9...950
  Final Drive Ch-10...964
  Brakes Ch-11...975
  Suspension Ch12...996
  Steering Ch13...1017
  Electrical System Ch15...1041
  Appendix Ch16...1112
Kawasaki Motorcycle Service Repair Manual '00 ZX-6R (EN)...1123
  Cover...1123
  Table of Contents...1124
  Foreward...1129
  1- General Info...1131
  2- Fuel System...1171
  3- Cooling System...1195
  4- Engine Top End...1211
  5- Clutch...1245
  6- Engine Lube System...1255
  7- Engine Removal/ Installation...1267
  8- Crankshaft/ Transmission...1273
  9- Wheels/ Tires...1295
  10- Final Drive...1307
  11- Brakes...1317
  12- Suspension...1337
  13- Steering...1356
  14- Frame...1366
  15- Electrical System...1376
  16- Appendix...1444
Kawasaki Motorcycle Service Repair Manual '02-'04 ZX-12R (EN)...1455
  SM_ZX1200-B1B2B3_English_eBook...0
    SM_ZX1200-B1B2B3_English_eBook...0
      tables...1455
        LIST OF ABBREVIATIONS...1460
        Basic Torque for General Fasteners...1481
        Units of Mass:...1524
        Units of Volume:...1524
        Units of Force:...1524
        Units of Length:...1524
        Units of Torque:...1524
        Units of Pressure:...1524
        Units of Speed:...1524
        Units of Power:...1524
        Throttle Grip Free Play...1531
        Idle Speed...1532
        Engine Vacuum...1533
        Engine Vacuum...1535
        Main Throttle Sensor Output Voltage...1536
        Water and Coolant Mixture Ratio (Recommended)...1541
        Valve Clearance...1542
        Clutch Lever Free Play...1546
        Engine Oil...1547
        Tread Depth...1548
        Chain Slack...1549
        Rollers Distance...1551
        Drive Chain 20-link Length...1551
        Recommended Disc Brake Fluid...1553
        Pad Lining Thickness...1554
        Pad Lining Thickness...1555
        Brake Light Timing...1555
        Fork Oil...1558
        Oil Level (fully compressed, without spring)...1559
        Fork Oil...1563
        Oil Level (fully compressed, without spring)...1564
        Choke Cable Free Play...1588
        Sample Diagnosis Sheet...1619
        Engine Doesn't Start, Starting Difficulty...1621
        Poor Running at Low Speed...1623
        Poor Running or No Power at High Speed...1627
        Throttle Sensor Input Voltage...1639
        Throttle Sensor Input Voltage...1640
        Idle Speed...1640
        Throttle Sensor Output Voltage...1640
        Throttle Sensor Output Voltage...1641
        Throttle Sensor Resistance...1642
        Main Throttle Sensor Input Voltage...1644
        Wiring Connection...1644
        Idle Speed...1645
        Main Throttle Sensor Output Voltage...1645
        Wiring Connection...1645
        Main Throttle Sensor Resistance...1646
        Inlet Air Pressure Sensor Input Voltage...1648
        Inlet Air Pressure Sensor Input Voltage...1649
        Inlet Air Pressure Sensor Output Voltage...1649
        Inlet Air Pressure Sensor Output Voltage...1650
        Digital Volt Meter Connections...1651
        Inlet Air Temperature Sensor Output Voltage...1653
        Inlet Air Temperature Sensor Resistance...1654
        Water Temperature Sensor Output Voltage...1657
        Atmospheric Pressure Sensor Input Voltage...1659
        Atmospheric Pressure Sensor Input Voltage...1660
        Atmospheric Pressure Sensor Output Voltage...1661
        Atmospheric Pressure Sensor Output Voltage...1661
        Gear Position Switch Input Voltage Connections to ECU ZX1200-B1/...1671
        ZX1200-B3:...1671
        Input Voltage at ECU (Except gear position)...1671
        Input Voltage at ECU (Respective Gear Position)...1671
        Gear Position Switch Input Voltage Connection to ECU...1672
        Input Voltage at Gear Position Switch Connector (Except Gear Pos...1672
        Input Voltage at Gear Position Switch Connector (Respective Gear...1672
        Vehicle-down Sensor Power Source Voltage...1677
        Vehicle-down Sensor Output Voltage...1677
        Subthrottle Sensor Input Voltage...1680
        Wiring Connection...1680
        Main Throttle Sensor Output Voltage...1681
        Wiring Connection...1681
        Throttle Sensor Resistance...1682
        Antenna Resistance...1683
        Amplifier Input Voltage...1683
        Input Voltage...1683
        Injector Power Source Voltage at ECU...1685
        Injector Power Source Voltage at Injector...1686
        Injector Output Voltage at ECU...1687
        Injector Output Voltage at Injector...1688
        Injector Resistance...1690
        Fuel Line Maximum Pressure...1691
        Fuel Pump Relay Operating Voltage at ECU...1694
        Fuel Pump Relay Operating Voltage at Relay Connector...1695
        Relay Power Source Voltage...1696
        Fuel Pump Relay Power Source Voltage...1696
        Stick Coil Input Voltage at ECU...1700
        Subthrottle Valve Actuator Resistance...1703
        Subthrottle Valve Actuator Input Voltage...1704
        Input Voltage at Actuator...1704
        ECU Grounding Inspection...1706
        ECU Power Source Inspection...1707
        Testing Relay...1709
        FI Indicator LED Light Check...1711
        Fuel Pressure...1713
        Amount of Fuel Flow...1715
        Pump Operating Voltage at Pump...1718
        Radiator Cap Relief Pressure...1736
        Thermostat Valve Opening Temperature...1738
        Vacuum Switch Valve Closing Pressure (Open → Close)...1749
        Camshaft Journal, Camshaft Cap Clearance...1756
        Camshaft Journal Diameter...1756
        Camshaft Runout...1757
        Cam Height...1757
        Cylinder Compression...1758
        Cylinder Head Warp...1761
        Valve/Valve Guide Clearance (Wobble Method)...1763
        Valve Seating Surface Outside Diameter...1764
        Valve Seating Surface Width...1764
        Cylinder Inside Diameter...1772
        Piston Diameter...1772
        Piston Ring/Groove Clearance...1772
        Piston Ring Groove Width...1772
        Piston Ring Thickness...1773
        Piston Ring End Gap...1773
        Clutch Plate Assembly Length...1787
        Friction Plate Thickness...1788
        Friction and Steel Plate Warp...1788
        Clutch Spring Free Length...1788
        Oil Pressure...1800
        Connecting Rod Bend...1821
        Connecting Rod Twist...1822
        Connecting Rod Big End Side Clearance...1822
        Connecting Rod Big End Bearing Insert/Crankpin Clearance...1822
        Crankpin Diameter...1822
        Crankpin Diameter Marks...1823
        Connecting Rod Big End Bore Diameter Marks...1823
        Crankshaft Main Bearing Insert/Journal Clearance...1824
        Crankshaft Main Journal Diameter...1824
        Crankshaft Main Journal Diameter Marks...1824
        Crankcase Main Bearing Bore Diameter Marks...1825
        Crankshaft Side Clearance...1825
        Crankshaft Runout...1826
        Shift Fork Ear Thickness...1840
        Gear Groove Width...1840
        Shift Fork Guide Pin Diameter...1840
        Shift Drum Groove Width...1840
        Rim Runout...1850
        Axle Runout/100 mm (3.94 in.)...1851
        Balance Weight...1851
        Air Pressure (when cold)...1854
        Rear Sprocket Warp...1865
        Pedal Position [C]...1875
        Length [A]...1875
        Front Disc Thickness...1891
        Rear Disc Thickness...1891
        Disc Runout...1891
        Rebound Damping Force Adjustment ZX1200-B1/B2...1901
        ZX1200-B3...1901
        Compression Damping Force Adjustment ZX1200-B1/B2...1902
        ZX1200-B3...1902
        Adjuster Protrusion (from top)...1902
        Spring Action...1902
        Spring Free Length...1906
        Rebound Damping Force Adjustment...1907
        Compression Damping Force Adjustment...1907
        Spring Free Length...1908
        Spring Preload Setting...1908
        Spring Adjustment...1908
        Battery Terminal Voltage...1963
        Terminal Voltage: 11.5 ∼ less than 12.6 V...1963
        Terminal Voltage: less than 11.5 V...1963
        Table 1 Alternator Output Voltage...1969
        Table 2 Stator Coil Resistance...1969
        Rectifier Circuit Inspection...1970
        Regulator/Rectifier Output Voltage...1972
        Regulator/Rectifier Output Voltage...1973
        Connections...1976
        Crankshaft Sensor Peak Voltage...1977
        Connections...1978
        Camshaft Position Sensor Peak Voltage...1978
        Stick Coil Winding Resistance...1979
        Primary Lead Connection...1980
        Stick Coil Primary Peak Voltage...1980
        Connection...1981
        Condition...1981
        Interlock Operation Voltage...1981
        Condition...1982
        Condition...1982
        Starter Motor Brush Length...1988
        Commutator Diameter...1988
        Testing Relay...1990
        Testing Relay...1996
        Testing Turn Signal Relay...1999
        Air Switching Valve Resistance...2001
        Testing Relay...2003
        B1 Model...2009
        B2/B3 Model...2009
        Oil Pressure Warning Indicator Light (LED) [A]:...2011
        FI Indicator Light (LED) [B]:...2011
        User Key Indicator Flashes...2018
        Fan Switch Resistance...2034
        Water Temperature Sensor...2035
        Fuel Level Sensor Resistance...2037
        Fuse Circuit Inspection...2039
        Relay Circuit Inspection (with the battery disconnected)...2040
        Relay Circuit Inspection (with the battery connected)...2040
        Diode Circuit Inspection...2040
      toc...1455
        Read OWNER'S MANUAL before operating...1460
          EMISSION CONTROL INFORMATION...1461
            1...1461
            2...1461
            3...1461
          TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...1462
          Foreword...1463
          General Information...1465
            Before starting to service a motorcycle, careful reading of the ...1466
              Especially note the following:...1466
            ZX1200-B1 Left Side View...1469
            ZX1200-B1 Right Side View...1469
            Since the emission regulations become more severe, Kawasaki has ...1473
              Honeycomb Type Catalytic Converter...1473
            Exhaust System (ZX1200-B1/B2)...1474
            Exhaust System (ZX1200-B3)...1475
            Why a monocoque? Like all breakthrough innovations, the choice a...1476
            ZX1200-B1 is equipped with the Kawasaki recommended spark plug (...1477
            Overview...1478
              Related Parts and Function...1478
              Sequence of Operation...1480
            The following tables list the tightening torque for the major fa...1481
            Oil Pressure Gauge, 5 kgf/cm :...1486
            Prefixes for Units:...1524
            Units of Temperature:...1524
          Periodic Maintenance...1525
            The scheduled maintenance must be done in accordance with this c...1526
              Special Tools -...1529
            Fuel System (DFI)...1530
              Fuel Hose and Connection Inspection...1530
              Throttle Control System Inspection...1531
              Idle Speed Inspection...1532
              Engine Vacuum Synchronization Inspection...1533
                Special Tool -...1534
                Special Tool -...1535
              Air Cleaner Element Cleaning (ZX1200-B1/B2)/ Element Replacement...1537
              Evaporative Emission Control System Inspection (CAL)...1538
              Cooling System...1539
                Cooling Hose and Connection Inspection...1539
                  Torque -...1539
                Coolant Change...1539
                  Torque -...1540
              Engine Top End...1541
                Air Suction Valve Inspection...1541
                Valve Clearance Inspection...1542
                INLET VALVE CLEARANCE ADJUSTMENT CHART...1544
                  Example:...1544
                EXHAUST VALVE CLEARANCE ADJUSTMENT CHART...1545
                  Example:...1545
              Clutch...1546
                Clutch Adjust Inspection...1546
              Engine Lubrication System...1547
                Engine Oil Change...1547
                  Torque -...1547
                Oil Filter Replace...1547
                  Special Tool -...1547
                  Torque -...1547
              Wheels/Tires...1548
                Tire Wear Inspection...1548
              Final Drive...1549
                Drive Chain Slack Inspection...1549
                  Torque -...1549
                Drive Chain Wear Inspection...1550
                Drive Chain Lubrication...1552
              Brakes...1552
                Brake Hose, Connection Inspection...1552
                Brake Fluid Level Inspection...1553
                Brake Fluid Change...1553
                  Torque -...1554
                  Torque -...1554
                Front Brake Pad Wear Inspection...1554
                Rear Brake Pad Wear Inspection...1555
                Brake/Master Cylinder Cup and Dust Seal Replace...1555
                Caliper Piston/Dust Seal Replace...1555
                Front Brake Light Switch Inspection...1555
                Rear Brake Light Switch Inspection/Adjustment...1555
              Suspension...1556
                Front Fork Oil Change...1556
                  Special Tool -...1556
                  Special Tool -...1558
                  Special Tool -...1559
                  Special Tool -...1559
                  Special Tool -...1560
                  Torque -...1560
                  Special Tool -...1561
                  Special Tool -...1563
                  Special Tool -...1564
                  Special Tool -...1564
                  Special Tool -...1565
                  Torque -...1566
                Front Fork Oil Leak Inspection...1566
                Rear Shock Absorber Oil Leak Inspection...1566
                Swingarm Pivot Lubrication...1566
                Unit-trak Linkage Lubrication...1567
              Steering...1567
                Steering Inspection...1567
                  Special Tool -...1567
                  Special Tool -...1568
                  Torque -...1568
                  Special Tool -...1568
                  Torque -...1568
                  Torque -...1568
                Steering Stem Bearing Lubrication...1569
              Electrical System...1569
                Spark Plug Cleaning and Inspection...1569
                  Torque -...1569
              General Lubrication...1569
                Lubrication Perform...1569
                  Points: Lubricate with Grease...1570
                  Cables: Lubricate with Cable Lubricant...1570
              Nut, Bolt, and Fastener Tightness...1571
                Tightness Inspection...1571
                  Nut, Bolt and Fastener to be checked...1571
          Fuel System (DFI)...1573
            Special Tools -...1586
            Sealant -...1586
            Free Play Inspection...1587
              Free Play Adjustment...1587
              Cable Installation...1587
              Cable Lubrication...1587
            Free Play Inspection...1588
              Free Play Adjustment...1588
              Choke Cable Installation...1588
              Cable Lubrication...1588
            Idle Speed Inspection...1589
              Throttle Bore Cleaning...1589
              Synchronization Inspection...1589
              Synchronization Adjustment...1589
              Throttle Body Assy Removal...1589
                Special Tool -...1590
                Special Tool -...1591
              Throttle Body Assy Installation...1592
                Special Tool -...1592
                Special Tool -...1593
              Throttle Body Assy Disassembly...1594
              ZX1200-B1/B2...1594
                Throttle Body Assy Assembly...1596
                  Torque -...1596
                  Torque -...1596
                  Torque -...1597
            Element Removal...1598
              Element Installation...1598
              Air Cleaner Element Cleaning and Inspection...1598
              Oil Draining...1598
              Air Inlet Duct Removal...1599
              Air Inlet Duct Installation...1599
              Front Duct Removal/Installation...1599
            Fuel Tank Removal...1600
              Fuel Tank Installation...1602
                Torque -...1602
              Fuel Tank Inspection...1602
              Fuel Tank Cleaning...1603
            DFI System Wiring Diagram (ZX1200-B1/B2)...1604
            Terminal Numbers of ECU Connectors...1606
            DFI System Wiring Diagram (ZX1200-B3)...1608
            Terminal Numbers of ECU Connectors...1610
            There are a number of important precautions that should be follo...1612
              Torque -...1613
              Torque -...1613
            Outline...1614
              Special Tool -...1614
              Special Tool -...1615
              DFI Diagnosis Flow Chart...1618
              Inquiries to Rider...1618
            DFI System Troubleshooting Guide...1621
            Self-diagnosis Outline...1630
              Self-diagnosis Function...1630
              Self-diagnosis Procedures...1631
              How to Read Service Codes...1633
              How to Erase Service Codes...1634
                Footnotes...1635
              Backups...1636
            The throttle sensor is a rotating variable resistor that change ...1639
              Throttle Sensor Removal/Adjustment...1639
              Input Voltage Inspection...1639
                Special Tool -...1639
                Special Tool -...1640
              Output Voltage Inspection...1640
                Special Tool -...1640
                Special Tool -...1641
              Resistance Inspection...1642
            Main Throttle Sensor Removal/Adjustment...1644
              Input Voltage Inspection...1644
                Special Tool -...1644
              Output Voltage Inspection...1645
                Special Tool -...1645
              Resistance Inspection...1646
            CAUTION...1647
              Removal...1647
              Installation...1648
                Torque -...1648
              Input Voltage Inspection...1648
                Special Tool -...1648
                Special Tool -...1649
              Output Voltage Inspection...1649
                Special Tool -...1650
              ZX1200-B1/B2...1650
              ZX1200-B3...1651
                Special Tool -...1651
            Removal/Installation...1653
              Torque -...1653
              Output Voltage Inspection...1653
                Special Tool -...1653
              Sensor Resistance Inspection...1654
              ZX1200-B1/B2...1655
              ZX1200-B3...1655
            Removal/Installation...1656
              Torque -...1656
              Output Voltage Inspection...1656
                Special Tool -...1656
              ZX1200-B1/B2...1657
              ZX1200-B3...1658
                Sensor Resistance Inspection...1658
            CAUTION...1659
              Removal...1659
              Installation...1659
                Torque -...1659
              Input Voltage Inspection...1659
                Special Tool -...1659
                Special Tool -...1660
              Output Voltage Inspection...1660
                Special Tool -...1661
              ZX1200-B1/B2...1662
              ZX1200-B3...1662
              Atmospheric Pressure/Altitude Relationship...1663
            Start the engine and switch the diagnosis mode to Dealer 1 mode ...1664
              Crankshaft Sensor Removal/Installation...1664
              Crankshaft Sensor Inspection...1664
              ZX1200-B1/B2...1664
              ZX1200-B3...1665
            Start the engine and switch the diagnosis mode to Dealer 1 mode ...1666
              Camshaft Position Sensor Removal/Installation...1666
              Camshaft Position Sensor Inspection...1666
              ZX1200-B1/B2...1666
              ZX1200-B3...1667
            Speed Sensor Removal/Installation...1668
              Speed Sensor Inspection...1668
                Torque -...1668
                Special Tool -...1668
              ZX1200-B1/B2...1669
              ZX1200-B3...1669
            The gear position switch detects the gear position of the neutra...1670
              Gear Position Switch Removal...1670
              Gear Position Switch Installation...1670
                Torque -...1670
              Gear Position Switch Input Voltage Inspection...1671
                Special Tool -...1671
                Special Tool -...1672
              Gear Position Switch Inspection...1672
              ZX1200-B1/B2...1673
              ZX1200-B3...1674
            This sensor has a weight [A] with two magnets inside, and sends ...1675
              Removal...1675
              Installation...1676
              Inspection...1676
                Special Tool -...1677
              ZX1200-B1/B2...1678
              ZX1200-B3...1679
            Subthrottle Sensor Removal/Adjustment...1680
              Input Voltage Inspection...1680
                Special Tool -...1680
              Output Voltage Inspection...1681
                Special Tool -...1681
              Resistance Inspection...1682
            Antenna Resistance Inspection...1683
              Amplifier Input Voltage Inspection...1683
                Special Tool -...1683
            This code appears in the following conditions. ...1684
              User Key Inspection...1684
            Fuel Injector ##1: (Service Code 41)...1685
              Power Source Voltage Inspection...1685
                Special Tool -...1685
              Output Voltage Inspection...1687
              Audible Inspection...1688
              Injector Signal Test...1689
                Special Tool -...1689
              Injector Resistance Inspection...1690
                Special Tool -...1690
              Injector Unit Test...1690
              Injector Fuel Line Inspection...1691
                Torque -...1691
                Torque -...1691
              ZX1200-B1/B2...1692
              ZX1200-B3...1693
            Service code 45 is short or open to the fuel pump relay system...1694
              Fuel Pump Relay Removal...1694
              Operating Voltage Inspection...1694
                Special Tools -...1694
              Power Source Voltage Inspection...1696
                Special Tools -...1696
              Relay Inspection...1697
              ZX1200-B1/B2...1697
              ZX1200-B3...1698
            Stick Coil ##1: Ignition Coil (Service Code 51)...1699
              Removal/Installation...1699
              Input Voltage Inspection...1699
              ZX1200-B1/B2...1701
              ZX1200-B3...1702
            Subthrottle Valve Actuator Removal...1703
              Audible Inspection...1703
              Visual Inspection...1703
              Resistance Inspection...1703
                Special Tool -...1703
              Input Voltage Inspection...1704
                Recommended Tool -...1704
                Special Tool -...1704
            CAUTION...1705
              ECU Removal...1705
              ECU Installation...1705
              ECU Power Supply Inspection...1705
                Special Tools -...1706
              ZX1200-B1/B2...1706
              ZX1200-B3...1706
              ECU Power Source Circuit ZX1200-B1/B2...1708
              ZX1200-B3...1708
            ECU Fuse Removal...1709
              ECU Fuse Installation...1709
              ECU Fuse Inspection...1709
              ECU Main Relay Removal...1709
              ECU Main Relay Inspection...1709
                Special Tool -...1709
            Inspection Flow Chart...1710
              LED Light Inspection...1711
              ZX1200-B1/B2...1711
              ZX1200-B3...1712
            Fuel Pressure Inspection...1713
              Special Tools -...1713
              Torque -...1714
              Fuel Flow Rate Inspection...1714
                Special Tool -...1715
            Fuel Pump Removal...1716
              Pump Screen Cleaning...1717
              Fuel Pump Installation...1717
                Torque -...1717
              Operation Inspection...1718
              Operating Voltage Inspection...1718
                Special Tools -...1718
              ZX1200-B1/B2...1719
              ZX1200-B3...1720
            The Evaporative Emission Control System routes fuel vapors from ...1721
              Parts Removal/Installation...1721
              Hose Inspection...1721
              Separator Inspection...1721
              Separator Operation Test...1722
              Canister Inspection (California Model Only)...1722
          Cooling System...1723
            Special Tools -...1725
            Sealant -...1725
            Permanent type antifreeze is used as a coolant to protect the co...1726
            Coolant Deterioration Inspection...1728
              Coolant Level Inspection...1728
              Coolant Draining...1728
              Coolant Filling...1728
              Pressure Testing...1729
              Cooling System Flushing...1729
            Water Pump Removal...1730
              Water Pump Installation...1731
                Torque -...1731
                Torque -...1731
              Water Pump Impeller Disassembly/Assembly...1731
                Torque -...1731
              Water Pump Inspection...1731
              Water Pump Impeller Inspection...1732
              Water Pump Housing Disassembly...1732
              Water Pump Housing Assembly...1732
                Special Tool -...1732
                Special Tool -...1732
              Mechanical Seal Inspection...1733
            Radiator and Radiator Fan Removal...1734
              Radiator and Radiator Fan Installation...1735
              Radiator Inspection...1735
              Radiator Cap Inspection...1736
            Thermostat Removal...1737
              Thermostat Installation...1737
                Torque -...1737
              Thermostat Inspection...1737
            Hose Installation...1739
              Torque -...1739
              Hose Inspection...1739
            Radiator Fan Switch, Water Temperature Sensor Removal...1740
              Radiator Fan Switch, Water Temperature Sensor Installation...1740
                Sealant -...1740
                Torque -...1740
              Radiator Fan Switch, Water Temperature Sensor Inspection...1740
          Engine Top End...1741
            ZX1200-B1/B2...1742
            ZX1200-B3...1743
              Special Tools -...1747
              Sealant -...1747
            Air Suction Valve Removal...1748
              Air Suction Valve Installation...1748
                Torque -...1748
                Torque -...1748
              Air Suction Valve Check...1748
              Vacuum Switch Valve Removal (ZX1200-B1/B2)...1749
              Vacuum Switch Valve Installation (ZX1200-B1/B2)...1749
              Vacuum Switch Valve Test (ZX1200-B1/B2)...1749
                Special Tool -...1749
              Air Switching Valve Removal (ZX1200-B3)...1750
              Air Switching Valve Installation (ZX1200-B3)...1750
              Air Switching Valve Operation Test (ZX1200-B3)...1750
              Air Switching Valve Unit Test (ZX1200-B3)...1750
              Clean Air System Hose Inspection...1750
            Cylinder Head Cover Removal...1751
              Cylinder Head Cover Installation...1751
                Sealant -...1752
                Torque -...1752
            Camshaft Chain Tensioner Removal...1753
              Camshaft Chain Tensioner Installation...1753
                Torque -...1753
            Camshaft Removal...1754
              Camshaft Installation...1754
                Torque -...1755
                Torque -...1756
              Camshaft, Camshaft Cap Wear...1756
                Torque -...1756
              Camshaft Runout...1757
              Cam Wear...1757
              Camshaft Chain Removal...1757
            Cylinder Compression Measurement...1758
              Special Tools -...1758
              Torque -...1758
              Cylinder Head Removal...1759
              Cylinder Head Installation...1760...
              Brake Hose Inspection...1895
          Suspension...1897
            Special Tools -...1900
            Rebound Damping Force Adjustment...1901
              Compression Damping Force Adjustment...1901
              Spring Preload Adjustment...1902
              Front Fork Removal (each fork leg)...1903
              Front Fork Installation...1903
                Torque -...1903
                Torque -...1903
              Fork Oil Change...1903
              Front Fork Disassembly...1904
                Special Tool -...1904
              Front Fork Assembly...1904
                Special Tool -...1904
                Torque -...1904
                Special Tool -...1905
              Inner Tube Inspection...1905
              Dust Seal Inspection...1906
              Spring Tension...1906
            Rebound Damping Force Adjustment...1907
              Compression Damping Force Adjustment...1907
              Spring Preload Adjustment...1908
                Special Tool -...1908
                Special Tool -...1908
              Rear Shock Absorber Removal...1908
                Special Tool -...1908
              Rear Shock Absorber Installation...1909
                Torque -...1909
              Rear Shock Absorber Scrapping...1909
            Swingarm Removal...1910
              Special Tool -...1910
              Special Tool -...1910
              Swingarm Installation...1911
                Torque -...1911
                Torque -...1911
                Torque -...1911
              Swingarm Bearing Removal...1911
                Special Tool -...1911
                Special Tool -...1911
              Swingarm Bearing Installation...1912
                Special Tool -...1912
              Swingarm Bearing, Sleeve Inspection...1912
              Swingarm Pivot Lubrication...1912
              Chain Slider Inspection...1912
            Tie-Rod Removal...1913
              Special Tool -...1913
              Tie-Rod Installation...1913
                Torque -...1913
              Rocker Arm Removal...1913
                Special Tool -...1913
              Rocker Arm Installation...1913
                Torque -...1913
              Needle Bearing Inspection...1914
              Tie-Rod, Rocker Arm Sleeve Inspection...1914
              Uni-track Linkage Lubrication...1914
          Steering...1915
            Special Tools -...1917
            Steering Inspection...1918
              Steering Adjustment...1918
            Stem, Stem Bearing Removal...1919
              Special Tool -...1919
              Special Tool -...1919
              Special Tool -...1920
              Special Tool -...1920
              Stem, Stem Bearing Installation...1920
                Special Tools -...1920
                Special Tools -...1921
                Special Tool -...1921
                Torque -...1921
                Torque -...1922
                Torque -...1923
              Steering Bearing Lubrication and Inspection...1923
              Steering Stem Warp...1923
            Handlebar Removal...1924
              Handlebar Installation...1924
                Torque -...1924
                Torque -...1924
          Frame...1925
            Rear Seat Removal...1929
              Rear Seat Installation...1929
              Rear Seat Cover Removal...1929
              Rear Seat Cover Installation...1930
              Front Seat Removal...1930
              Front Seat Installation...1930
            Seat Cover Removal...1931
              Seat Cover Installation...1931
            Lower Fairings (Left and Right) Removal...1932
              Lower Fairings (Left and Right) Installation...1932
              Lower Inner Fairing Removal...1933
              Lower Inner Fairing Installation...1933
              Upper Inner Fairings (Left and Right) Removal...1933
              Upper Inner Fairings (Left and Right) Installation...1933
              Wind Shield Removal...1934
              Wind Shield Installation...1934
                Torque -...1934
              Upper Inner Covers (Left and Right) Removal...1934
              Upper Inner Covers (Left and Right) Installation...1934
              Lower Inner Covers (Left and Right) Removal...1934
              Lower Inner Covers (Left and Right) Installation...1935
              Upper Fairing Removal...1935
              Upper Fairing Disassembly...1936
              Upper Fairing Assembly...1937
              Hot Wind Cover Installation...1938
            Front Fender Removal...1939
              Front Fender Installation...1939
              Rear Fender Rear Removal...1939
              Rear Fender Rear Installation...1939
              Rear Fender Front Removal...1940
              Rear Fender Front Installation...1940
            Rear Frame Removal...1941
              Rear Frame Installation...1941
                Torque -...1941
              Frame Inspection...1941
            Storage Box Removal...1942
              Storage Box Installation...1942
            Side Stand Removal...1943
              Side Stand Installation...1943
                Torque -...1943
                Torque -...1943
          Electrical System...1945
            Special Tools -...1953
            Sealant -...1953
            Starter Lockout Switch [A]...1954
            There are a number of important precautions that should be follo...1955
            Wiring Inspection...1957
              Special Tool -...1957
            Battery Removal...1958
              Battery Installation...1959
              Electrolyte Filling...1960
              Initial Charge...1962
              Precautions...1962
                1)...1962
                2)...1962
                3)...1962
                4)...1962
              Interchange...1963
                Charging Condition Inspection...1963
                Refreshing Charge...1963
            Alternator Cover Removal...1965
              Alternator Cover Installation...1965
                Sealant -...1965
                Torque -...1965
              Stator Coil Removal...1965
              Stator Coil Installation...1966
                Torque -...1966
                Sealant -...1966
                Torque -...1966
                Torque -...1966
              Alternator Rotor Removal...1967
                Special Tool -...1967
                Special Tools -...1967
                Special Tool -...1967
              Alternator Rotor Installation...1967
                Special Tool -...1968
                Special Tool -...1968
                Torque -...1968
              Alternator Inspection...1968
                Special Tool -...1969
              Regulator/Rectifier Inspection...1969
              Regulator/Rectifier Output Voltage Inspection...1972
                Special Tools -...1972
                Special Tool -...1973
              Charging System Circuit...1974
            WARNING...1975
              Crankshaft Sensor Removal...1975
              Crankshaft Sensor Installation...1976
                Torque -...1976
                Sealant -...1976
                Torque -...1976
              Crankshaft Sensor Inspection...1976
                Special Tool -...1976
              Crankshaft Sensor Peak Voltage Inspection...1976
                Special Tool -...1976
                Recommended Tool -...1976
              Camshaft Position Sensor Removal...1977
              Camshaft Position Sensor Installation...1977
                Torque -...1977
              Camshaft Position Sensor Inspection...1978
                Special Tool -...1978
              Camshaft Position Sensor Peak Voltage Inspection...1978
                Special Tool -...1978
                Recommended Tool -...1978
              Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...1979
              Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...1979
              Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...1979
              Stick Coil Primary Peak Voltage Inspection...1980
                Recommended Tool -...1980
                Special Tools -...1980
              Spark Plug Removal...1980
                Owner's Tool -...1980
              Spark Plug Installation...1981
                Owner's Tool -...1981
                Torque -...1981
              Spark Plug Cleaning and Inspection...1981
              Spark Plug Gap Inspection...1981
              Interlock Operation Inspection...1981
              IC Igniter Inspection...1982
              Ignition System Inspection...1983
              Ignition System Circuit ZX1200-B1/B2...1984
              ZX1200-B3...1985
            Starter Motor Removal...1986
              Starter Motor Installation...1986
                Torque -...1986
              Starter Motor Disassembly...1987
              Starter Motor Assembly...1987
              Brush Inspection...1988
              Commutator Cleaning and Inspection...1988
              Armature Inspection...1989
              Brush Lead Inspection...1989
              Brush Plate and Terminal Bolt Inspection...1989
              Starter Relay Inspection...1989
              Electric Starter Circuit ZX1200-B1/B2...1991
              ZX1200-B3...1992
            The U.S.A., Canadian, Australian, and Malaysian models adopt the...1993
              Headlight Beam Horizontal/Vertical Adjustment...1993
              Headlight Bulbs (Left and Right) Replacement...1994
              City Light Bulb Replacement...1994
              Tail/Brake Light Bulbs Replacement...1995
              Tail/Brake Light Lens Assembly Replacement...1995
                Torque -...1995
              Headlight Relays (High/Low) Inspection...1996
              Headlight/Tail Light Circuit ZX1200-B1/B2...1997
              ZX1200-B3...1998
                Turn Signal Relay Inspection...1998
              Turn Signal Light Circuit...2000
            Air Switching Valve Operation Test...2001
              Air Switching Valve Unit Test...2001
                Special Tool -...2001
            Fan System Circuit Inspection...2002
              Fan Motors Inspection...2002
              Fan Relay Removal...2002
              Fan Relay Inspection...2003
                Special Tool -...2003
              Radiator Fan Circuit...2003
            Meter Unit Removal...2004
              Meter Unit Disassembly...2004
              Bulbs Replacement...2004
              Meter Unit Inspection...2005
              Meter Circuit ZX1200-B1/B2...2012
              ZX1200-B3...2013
            This motorcycle is equipped with an immobilizer system to protec...2014
              Operational Cautions...2014
                Key Registration...2014
                  Special Tool -...2015
              Spare User Key Registration Flow Chart...2019
                Special Tool -...2020
              All Keys Initial Registration Flow Chart...2029
                Immobilizer System Parts Replacement...2030
                Immobilizer System Inspection...2032
              Immobilizer System Circuit...2032
            Front Brake Light Switch Inspection...2033
              Rear Brake Light Switch Check/Adjustment...2033
              Switch Inspection...2033
                Special Tool -...2033
              Rear Brake Light Switch Connections...2033
              Side Stand Switch Connections...2033
              Gear Position Switch Connections...2033
              Engine Oil Pressure Switch Connections*...2033
              Radiator Fan Switch Inspection...2034
              Water Temperature Sensor Inspection...2035
              Speed Sensor Removal...2035
              Speed Sensor Installation...2036
                Torque -...2036
              Speed Sensor Inspection...2036
                Special Tool -...2036
              Fuel Level Sensor Inspection...2036
                Special Tool -...2037
                Torque -...2037
              Fuel Reserve Switch Inspection (1)...2037
                Special Tool -...2037
              Fuel Reserve Switch Inspection (2)...2038
            The junction box [A] has fuses [B], relays, and diodes. The rela...2039
              Junction Box Fuse Circuit Inspection...2039
              Starter Circuit/Headlight Relay Inspection...2039
              Diode Circuit Inspection...2040
              Junction Box Internal Circuit (U.S.A., Canadian, Australian, and...2041
              Junction Box Internal Circuit (Other than U.S.A., Canadian, Aust...2041
            30 A Main Fuse Removal...2042
              30 A Headlight/Fan Fuse Removal...2042
              Junction Box Fuse Removal...2042
              15 A ECU Fuse Removal...2043
              Fuse Installation...2043
              Fuse Inspection...2043
          Troubleshooting...2061
            NOTE...2062
              Engine Doesn't Start, Starting Difficulty:...2062
                Starter motor not rotating:...2062
                Starter motor rotating but engine doesn't turn over:...2062
                Engine won't turn over:...2062
                No fuel flow:...2062
                Engine flooded:...2062
                No spark; spark weak:...2062
                Fuel/air mixture incorrect:...2062
                Compression Low:...2062
              Poor Running at Low Speed:...2062
                Spark weak:...2062
                Fuel/air mixture incorrect:...2062
                Compression low:...2063
                Other:...2063
              Poor Running or No Power at High Speed:...2063
                Firing incorrect:...2063
                Fuel/air mixture incorrect:...2063
                Compression low:...2063
                Knocking:...2063
                Miscellaneous:...2063
              Overheating:...2063
                Firing incorrect:...2063
                Muffler overheating:...2063
                Fuel/air mixture incorrect:...2063
                Compression high:...2064
                Engine load faulty:...2064
                Lubrication inadequate:...2064
                Gauge incorrect:...2064
                Coolant incorrect:...2064
                Cooling system component incorrect:...2064
              Over Cooling:...2064
                Gauge incorrect:...2064
                Cooling system component incorrect:...2064
              Clutch Operation Faulty:...2064
                Clutch slipping:...2064
                Clutch not disengaging properly:...2064
              Gear Shifting Faulty:...2064
                Doesn't go into gear; shift pedal doesn't return:...2064
                Jumps out of gear:...2064
                Overshifts:...2064
              Abnormal Engine Noise:...2064
                Knocking:...2064
                Piston slap:...2064
                Valve noise:...2064
                Other noise:...2064
              Abnormal Drive Train Noise:...2065
                Clutch noise:...2065
                Transmission noise:...2065
                Drive line noise:...2065
              Abnormal Frame Noise:...2065
                Front fork noise:...2065
                Rear shock absorber noise:...2065
                Disc brake noise:...2065
                Other noise:...2065
              Oil Pressure Warning Light Goes On:...2065
              Exhaust Smokes Excessively:...2065
                White smoke:...2065
                Black smoke:...2065
                Brown smoke:...2065
              Handling and/or Stability Unsatisfactory:...2065
                Handlebar hard to turn:...2065
                Handlebar shakes or excessively vibrates:...2065
                Handlebar pulls to one side:...2065
                Shock absorption unsatisfactory:...2066
              Brake Doesn't Hold:...2066
              Battery Trouble:...2066
                Battery discharged:...2066
                Battery overcharged:...2066
Kawasaki Motorcycle Service Repair Manual '02-'05 ZZ-R1200...2068
  Index...2068
  Section 1 - General Information...2069
  Section 2 - Periodic Maintenance...2079
  Section 3 - Fuel System...2125
  Section 4 - Cooling System...2162
  Section 5 - Engine Top End...2180
  Section 6 - Clutch...2219
  Section 7 - Engine Lubrication System...2234
  Section 8 - Engine Removal / Installation...2256
  Section 9 - Crankshaft/Transmission...2267
  Section 10 - Wheels / Tires...2305
  Section 11 - Final Drive...2325
  Section 12 - Brakes...2338
  Section 13 - Suspension...2365
  Section 14 - Steering...2386
  Section 15 - Frame...2397
  Section 16 - Electrical System...2417
  Section 17 - Appendix...2518
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (EN)...2560
  General Information...2563
  Periodic Maintenance...2586
  Fuel System...2632
  Cooling System...2748
  Engine Top...2770
  Clutch...2806
  Engine Lubrication System...2822
  Engine Removal / Installation...2837
  Crankshaft / Transmission...2846
  Wheels / Tires...2876
  Final Drive...2893
  Brakes...2904
  Suspension...2926
  Steering...2952
  Frame...2962
  Electrical System...2978
  Appendix...3058
Kawasaki Motorcycle Service Repair Manual '03 ZX-6R(R) (IT)...3074
Kawasaki Motorcycle Service Repair Manual '04 ZX-10R (EN)...3630
Kawasaki Motorcycle Service Repair Manual '04-'05 ZZ-R250...4225
Kawasaki Motorcycle Service Repair Manual '05 ZX-6R (EN)...4573
  KAWASAKI ZX636-C1 SERVICE MANUAL...0
    Tables...4573
      LIST OF ABBREVIATIONS...4578
      Units of Mass...4594
      Units of Volume...4594
      Units of Force...4594
      Units of Length...4594
      Units of Torque...4594
      Units of Pressure...4594
      Units of Speed...4594
      Units of Power...4594
      Periodic Inspection...4597
      Periodic Replacement Parts...4599
      Periodic Inspection...4600
      Periodic Replacement Parts...4602
      Basic Torque for General Fasteners...4608
      Throttle Grip Free Play...4612
      Engine Vacuum...4613
      Main Throttle Sensor Output Voltage...4615
      Idle Speed...4616
      Valve Clearance...4619
      Clutch Lever Free Play...4623
      Air Pressure (when Cold)...4624
      Tread Depth...4625
      Chain Slack...4626
      Drive Chain 20-link Length...4628
      Standard Chain...4628
      Recommended Disc Brake Fluid...4630
      Pad Lining Thickness...4630
      Side Stand Switch Operation...4639
      Water and Coolant Mixture Ratio (Recommended)...4647
      Recommended Engine Oil...4649
      Terminal Names...4676
      Sample Diagnosis Sheet...4684
      Engine Doesn't Start, Starting Difficulty...4686
      Poor Running at Low Speed...4688
      Poor Running or No Power at High Speed:...4691
      Service Code Table...4697
      Main Throttle Sensor Input Voltage...4701
      Input Voltage at ECU Connector...4701
      Main Throttle Sensor Input Voltage...4702
      Input Voltage at Sensor...4702
      Main Throttle Sensor Output Voltage...4702
      Idle Speed...4702
      Output Voltage at ECU...4702
      Throttle Sensor Output Voltage...4703
      Output Voltage at Sensor...4703
      Main Throttle Sensor Resistance...4704
      Inlet Air Pressure Sensor Input Voltage...4705
      Input Voltage at ECU...4705
      Inlet Air Pressure Sensor Input Voltage...4706
      Input Voltage at Sensor Connector...4706
      Inlet Air Pressure Sensor Output Voltage...4706
      Output Voltage at ECU...4706
      Inlet Air Pressure Sensor Output Voltage...4707
      Output Voltage at Sensor Connector...4707
      Inlet Air Pressure Sensor Output Voltage Connection to Sensor...4708
      Inlet Air Temperature Sensor Output Voltage...4710
      Output Voltage at ECU...4710
      Inlet Air Temperature Sensor Resistance...4711
      Water Temperature Sensor Output Voltage...4713
      Output Voltage at ECU...4713
      Atmospheric Pressure Sensor Input Voltage...4715
      Input Voltage at ECU...4715
      Atmospheric Pressure Sensor Input Voltage...4716
      Input Voltage at Sensor Connector...4716
      Atmospheric Pressure Sensor Output Voltage...4716
      Output Voltage...4716
      Atmospheric Pressure Sensor Output Voltage...4717
      Output Voltage at Sensor...4717
      Speed Sensor Input Voltage...4721
      Input Voltage at Sensor...4721
      Speed Sensor Output Voltage...4722
      Output Voltage at Sensor ...4722
      Vehicle-down Sensor Power Source Voltage...4724
      Power Source Voltage at Sensor...4724
      Vehicle-down Sensor Output Voltage...4724
      Output Voltage at Sensor...4724
      Subthrottle Sensor Input Voltage...4726
      Input Voltage at ECU Connector...4726
      Subthrottle Sensor Input Voltage...4727
      Input Voltage at Sensor...4727
      Subthrottle Sensor Output Voltage...4727
      Output Voltage at ECU...4727
      Subthrottle Sensor Output Voltage...4728
      Output Voltage at Sensor...4728
      Subthrottle Sensor Resistance...4729
      Exhaust Butterfly Valve Actuator Sensor Resistance...4730
      Antenna Resistance...4731
      Amplifier Input Voltage...4731
      Input Voltage...4731
      Stick Coil Input Voltage at ECU...4734
      Input Voltage at ECU...4734
      Subthrottle Valve Actuator Resistance...4736
      Subthrottle Valve Actuator Input Voltage...4737
      Input Voltage at Sensor...4737
      Connections...4740
      Actuator Output Voltage (Pulley Original Position)...4740
      ECU Identification...4741
      ECU Grounding Inspection...4742
      ECU Power Source Inspection...4743
      FI Indicator Light (LED) Check...4745
      Fuel Pressure...4746
      Fuel Pressure (Idling)...4747
      Amount of Fuel Flow...4748
      Pump Operating Voltage at Pump...4750
      Operating Voltage at Pump Connector...4750
      Primary Fuel Injector Resistance...4753
      Secondary Fuel Injector Resistance...4754
      Primary Fuel Injector Power Source Voltage...4755
      Secondary Fuel Injector Power Source Voltage...4755
      Power Source Voltage at Injector Connector...4755
      Primary Fuel Injector Output Voltage...4755
      Secondary Fuel Injector Output Voltage...4756
      Output Voltage at Injector Connector...4756
      Fuel Line Maximum Pressure...4757
      Radiator Cap Relief Pressure...4793
      Thermostat Valve Opening Temperature...4797
      Vacuum Switch Valve Closing Pressure (Open → Close)...4812
      Camshaft Journal, Camshaft Cap Clearance...4818
      Camshaft Journal Diameter...4818
      Camshaft Runout...4818
      Cam Height...4819
      Cylinder Compression...4820
      Cylinder Head Warp...4822
      Valve/Valve Guide Clearance (Wobble Method)...4825
      Valve Seating Surface Outside Diameter...4825
      Valve Seating Surface Width...4825
      Cylinder Inside Diameter...4832
      Piston Diameter...4832
      Piston Ring/Groove Clearance...4833
      Piston Ring Groove Width...4833
      Piston Ring Thickness...4833
      Piston Ring End Gap...4834
      Clutch Housing Gear Selection when Replacing Clutch Housing Gear...4855
      Spring Plate Free Play ...4858
      Clutch Plate Assembly Length...4859
      Friction Plate Thickness...4859
      Friction and Steel Plate Warp...4859
      Clutch Spring Free Length...4860
      Oil Pressure...4875
      Connecting Rod Big End Bearing Insert Selection...4893
      Crankshaft Main Bearing Insert Selection...4893
      Crankshaft Selection when Replacing Crankshaft...4899
      Connecting Rod Bend...4904
      Connecting Rod Twist...4904
      Connecting Rod Big End Side Clearance...4904
      Connecting Rod Big End Bearing Insert/Crankpin Clearance...4905
      Crankpin Diameter...4905
      Crankpin Diameter Marks...4905
      Connecting Rod Big End Inside Diameter Marks...4906
      Crankshaft Side Clearance...4906
      Crankshaft Runout...4907
      Crankshaft Main Bearing Insert/Journal Clearance...4907
      Crankshaft Main Journal Diameter...4907
      Crankshaft Main Journal Diameter Marks...4907
      Crankcase Main Bearing Inside Diameter Marks...4908
      Shift Fork Ear Thickness...4916
      Gear Groove Width...4916
      Shift Fork Guide Pin Diameter...4916
      Shift Drum Groove Width...4916
      Rim Runout...4926
      Axle Runout/100 mm (3.94 in.)...4926
      Balance Weight...4928
      Link Pin Outside Diameter...4943
      Link Plates Outside Width...4943
      Rear Sprocket Warp...4948
      Pedal Position...4956
      Brake Discs Thickness...4966
      Disc Runout...4966
      Rebound Damping Force Adjustment...4981
      Compression Damping Force Adjustment...4981
      Adjuster Protrusion (from top)...4982
      Spring Action...4982
      Fork Oil...4985
      Oil Level (fully compressed, without spring)...4986
      Spring Free Length...4989
      Rebound Damping Force Adjustment...4990
      Rebound Damping Force Adjustment...4990
      Spring Preload Setting...4991
      Spring Adjustment...4991
      Kawasaki-recommended chargers...5059
      Battery Terminal Voltage...5061
      Terminal Voltage: 11.5 ∼ less than 12.8 V...5062
      Terminal Voltage: less than 11.5 V...5062
      Table 1 Alternator Output Voltage...5066
      Table 2 Stator Coil Resistance...5066
      Charging Voltage...5069
      Crankshaft Sensor Peak Voltage...5075
      Ignition Coil Winding Resistance...5076
      Primary Lead Connection...5077
      Stick Coil Primary Peak Voltage...5077
      Connections:...5079
      Camshaft Position Sensor Peak Voltage...5079
      Condition...5080
      Condition...5080
      Condition...5080
      Starter Motor Brush Length...5084
      Commutator Diameter...5085
      Testing Relay...5086
      Testing Turn Signal Relay...5093
      Testing Turn Signal Relay...5094
      User Key Indicator Flashes...5112
      Water Temperature Sensor...5129
      Connections...5130
      Relay Circuit Inspection (with the battery disconnected)...5131
      Relay Circuit Inspection (with the battery connected)...5132
      Diode Circuit Inspection...5132
    Table Of Contents...4573
      Read OWNER'S MANUAL before operating...4578
        EMISSION CONTROL INFORMATION...4579
          1...4579
          2...4579
          3...4579
        TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...4580
        Foreword...4581
        General Information...4583
          Before starting to perform an inspection service or carry out a ...4584
            Battery Ground...4584
            Edges of Parts...4584
            Solvent...4584
            Cleaning vehicle before disassembly...4584
            Arrangement and Cleaning of Removed Parts...4585
            Storage of Removed Parts...4585
            Inspection...4585
            Replacement Parts...4585
            Assembly Order...4585
            Tightening Sequence...4586
            Tightening Torque...4586
            Force...4586
            Gasket, O-ring...4586
            Liquid Gasket, Non-permanent Locking Agent...4586
            Press...4587
            Ball Bearing and Needle Bearing...4587
            Oil Seal, Grease Seal...4587
            Circlips, Cotter Pins...4587
            Lubrication...4588
            Direction of Engine Rotation...4588
            Electrical Wires...4588
          ZX636-C1 (Europe) Left Side View...4589
          ZX636-C1 (Europe) Right Side View...4589
          ZX636-C1 (US and Canada) Left Side View...4590
          ZX636-C1 (US and Canada) Right Side View...4590
          Prefixes for Units...4594
          Units of Temperature...4594
        Periodic Maintenance...4595
          The scheduled maintenance must be done in accordance with this c...4597
          The scheduled maintenance must be done in accordance with this c...4600
          The following tables list the tightening torque for the major fa...4603
          Inside Circlip Pliers:...4611
          Fuel System (DFI)...4612
            Throttle Control System Inspection...4612
            Engine Vacuum Synchronization Inspection...4612
              Special Tool -...4613
              Special Tool -...4614
            Idle Speed Inspection...4616
            Idle Speed Adjustment...4616
            Fuel Hose Damage and Installation Condition Inspection...4616
            Evaporative Emission Control System (California Model)...4617
              Evaporative Emission Control System Inspection...4617
            Cooling System...4618
              Coolant Level Inspection...4618
              Radiator Hose Damage and Installation Condition Inspection...4618
                Torque -...4618
            Engine Top End...4619
              Valve Clearance Inspection...4619
              Valve Clearance Adjustment...4620
              VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE...4621
              VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE...4622
            Air Suction System...4623
              Air Suction System Damage Inspection...4623
            Clutch...4623
              Clutch Operation Inspection ...4623
            Wheels/Tires...4624
              Air Pressure Inspection...4624
              Wheel/Tire Damage Inspection...4624
              Tire Tread Wear Inspection ...4624
              Wheel Bearing Damage Inspection...4625
            Drive Train...4626
              Drive Chain Lubrication Condition Inspection...4626
              Drive Chain Slack Inspection...4626
              Drive Chain Slack Adjustment...4627
                Torque -...4627
              Wheel Alignment Inspection...4628
              Drive Chain Wear Inspection...4628
              Chain Guide Wear Inspection...4629
            Brake System...4629
              Brake Fluid Leak (Brake Hose and Pipe) Inspection...4629
              Brake Hose Damage and Installation Condition Inspection...4629
                Torque -...4629
              Brake Operation Inspection...4629
              Brake Fluid Level Inspection...4630
              Brake Pad Wear Inspection...4630
              Brake Light Switch Operation Inspection...4630
            Suspensions...4631
              Front Forks/Rear Shock Absorber Operation Inspection...4631
              Front Fork Oil Leak Inspection...4632
              Rear Shock Absorber Oil Leak Inspection...4632
              Rocker Arm Operation Inspection...4632
              Tie-Rod Operation Inspection...4632
            Steering System...4633
              Steering Play Inspection...4633
                Special Tools -...4633
              Steering Play Adjustment...4633
                Special Tool -...4633
                Torque -...4634
              Steering Stem Bearing Lubrication...4634
            Electrical System...4634
              Spark Plug Clean and Gap Inspection...4634
              Lights and Switches Operation Inspection...4636
              Headlight Aiming Inspection...4638
              Side Stand Switch Operation Inspection...4639
              Engine Stop Switch Operation Inspection...4640
            Others...4641
              Chassis Parts Lubrication ...4641
                Pivots: Lubricate with Grease...4641
                Points: Lubricate with Grease...4641
                Cables: Lubricate with Rust Inhibitor...4641
              Bolts, Nuts and Fasteners Tightness Inspection...4642
                Bolt, Nut and Fastener to be checked...4643
            Replacement Parts...4644
              Air Cleaner Element Replacement...4644
              Fuel Hose Replacement...4644
              Coolant Change...4646
                Torque -...4646
              Radiator Hose and O-ring Replacement...4648
              Engine Oil Change...4649
                Torque -...4649
              Oil Filter Replacement...4649
                Special Tool -...4649
                Torque -...4649
              Brake Hose and Pipe Replacement...4650
                Torque -...4650
              Brake Fluid Change...4650
                Torque -...4651
                Torque -...4651
              Master Cylinder Rubber Parts Replacement...4652
                Special Tool -...4652
                Special Tool -...4652
                Silicone Grease -...4653
                Torque -...4653
              Caliper Rubber Parts Replacement...4653
                Torque -...4654
                Torque -...4654
                Torque -...4655
              Spark Plug Replacement...4656
                Owner's Tool -...4656
                Torque -...4656
        Fuel System (DFI)...4657
          Dummy Page...4659
          Oil Pressure Gauge, 5 kgf/cm :...4668
          Subthrottle Sensor [A]...4670
          DFI System...4672
          DFI System Wiring Diagram...4674
          Terminal Numbers of ECU Connectors...4676
          There are a number of important precautions that should be follo...4677
            Torque -...4678
          Outline...4679
            Special Tool -...4679
            Sealant -...4680
            Special Tool -...4680
            DFI Diagnosis Flow Chart...4683
            Inquiries to Rider...4683
          NOTE...4686
          Self-diagnosis Outline...4694
            Self-diagnosis Procedures...4694
            Service Code Clearing Procedures...4695
              Service Code Reading...4697
              Service Code Erasing...4697
            Backups...4699
          The main throttle sensor is a rotating variable resistor that ch...4701
            Main Throttle Sensor Removal/Adjustment...4701
            Input Voltage Inspection...4701
              Special Tool -...4701
              Special Tool -...4702
            Output Voltage Inspection...4702
              Special Tool -...4702
              Special Tool -...4703
            Resistance Inspection...4704
          CAUTION...4705
            Removal...4705
            Installation...4705
            Input Voltage Inspection...4705
              Special Tool -...4705
              Special Tool -...4706
            Output Voltage Inspection...4706
              Special Tool -...4707
              Special Tools -...4708
          Removal/Installation...4710
            Output Voltage Inspection...4710
              Special Tool -...4710
              Sealant -...4711
            Sensor Resistance Inspection...4711
          Removal/Installation...4713
            Sealant -...4713
            Torque -...4713
            Output Voltage Inspection...4713
              Special Tool -...4713
              Sealant -...4714
            Sensor Resistance Inspection...4714
          CAUTION...4715
            Removal...4715
            Installation...4715
            Input Voltage Inspection...4715
              Special Tool -...4715
              Special Tool -...4716
            Output Voltage Inspection...4716
              Special Tool -...4717
            Atmospheric Pressure/Altitude Relationship...4718
          Crankshaft Sensor Removal/Installation...4719
            Crankshaft Sensor Inspection...4719
          Camshaft Position Sensor Removal/Installation...4720
            Camshaft Position Sensor Inspection...4720
          Speed Sensor Removal/Installation...4721
            Speed Sensor Inspection...4721
            Input Voltage Inspection...4721
              Special Tool -...4721
            Output Voltage Inspection...4721
              Special Tool -...4722
          This sensor has a weight [A] with two magnets inside, and sends ...4723
            Removal...4723
            Installation...4723
            Inspection...4723
              Special Tool -...4724
              Sealant -...4725
          Subthrottle Sensor Removal/Adjustment...4726
            Input Voltage Inspection...4726
              Special Tool -...4726
              Special Tool -...4727
            Output Voltage Inspection...4727
              Special Tool -...4727
              Special Tool -...4728
            Resistance Inspection...4729
          Exhaust Butterfly Valve Actuator Sensor Inspection...4730
          Antenna Resistance Inspection...4731
            Amplifier Input Voltage Inspection...4731
              Special Tool -...4731
          This code appears in the following conditions. ...4732
            User Key Inspection...4732
          Stick Coil ##1: Service Code 51...4734
            Removal/Installation...4734
            Input Voltage Inspection...4734
          Subthrottle Valve Actuator Removal...4736
            Subthrottle Valve Actuator Inspection...4736
            Resistance Inspection...4736
            Input Voltage Inspection...4737
              Special Tools -...4737
          Exhaust Butterfly Valve Actuator Removal...4738
            Exhaust Butterfly Valve Actuator Installation...4738
              Torque -...4738
              Torque -...4739
            Exhaust Butterfly Valve Actuator Inspection...4739
            Output Voltage Inspection...4740
              Special Tool -...4740
          CAUTION...4741
            ECU Identification...4741
            ECU Removal...4741
            ECU Installation...4742
            ECU Power Supply Inspection...4742
              Special Tool -...4742
            ECU Power Source Circuit...4743
          ECU Fuse Removal...4744
            ECU Fuse Installation...4744
            ECU Fuse Inspection...4744
          Light (LED) Inspection...4745
          Fuel Pressure Inspection...4746
            Special Tools -...4746
            Fuel Flow Rate Inspection...4747
          Fuel Pump Removal...4749
            Fuel Pump Installation...4749
              Torque -...4750
            Operation Inspection...4750
            Operating Voltage Inspection...4750
              Special Tools -...4750
          CAUTION...4752
            Audible Inspection...4752
            Injector Signal Test...4752
              Special Tool -...4753
            Injector Resistance Inspection...4753
              Special Tool -...4753
              Special Tool -...4754
            Injector Unit Test...4754
            Injector Voltage Inspection...4755
              Special Tool -...4755
              Special Tool -...4755
            Injector Fuel Line Inspection...4757
          Free Play Inspection...4759
            Free Play Adjustment...4759
            Cable Installation...4759
            Cable Lubrication...4759
          Idle Speed Inspection...4760
            Throttle Bore Cleaning...4760
            Synchronization Inspection...4760
            Synchronization Adjustment...4760
            Throttle Body Assy Removal...4760
            Throttle Body Assy Installation...4762
              Torque -...4762
            Throttle Body Assy Disassembly...4762
              Throttle Body Assy Assembly...4763
                Torque -...4763
          Nozzle Assy Removal...4764
            Nozzle Assy Installation...4764
              Torque -...4764
            Nozzle Assy Disassembly...4764
            Nozzle Assy Assembly...4765
              Torque -...4766
              Torque -...4766
          Element Removal...4767
            Element Installation...4767
            Air Cleaner Element Inspection...4767
            Air Cleaner Housing Removal...4767
            Air Cleaner Housing Installation...4768
              Torque -...4768
            Air Cleaner Housing Disassembly...4769
            Air Cleaner Housing Assembly...4769
            Oil Draining...4769
            Air Inlet Duct Removal...4769
            Air Inlet Duct Installation...4769
          Fuel Tank Removal...4770
            Fuel Tank Installation...4772
            Fuel Tank and Cap Inspection...4773
            Fuel Tank Cleaning...4773
          The Evaporative Emission Control System routes fuel vapors from ...4774
            Parts Removal/Installation...4774
            Hose Inspection...4774
            Separator Inspection...4774
            Separator Operation Test...4775
            Canister Inspection ...4775
        Cooling System...4777
          Bearing Driver, 32:...4781
          Coolant Deterioration Inspection...4784
            Coolant Level Inspection...4784
            Coolant Draining...4784
            Coolant Filling...4784
            Pressure Testing...4784
            Cooling System Flushing...4785
            Coolant Reserve Tank Removal...4785
            Coolant Reserve Tank Installation...4785
              Torque -...4785
          Water Pump Removal...4786
            Water Pump Installation...4786
            Water Pump Impeller Disassembly/Assembly...4786
              Torque -...4786
              Water Pump Impeller Inspection...4786
              Water Pump Housing Disassembly...4786
              Water Pump Housing Assembly...4787
                Special Tool -...4787
                Special Tool -...4787
              Mechanical Seal Inspection...4787
          Radiator and Radiator Fan Removal...4788
            Radiator and Radiator Fan Installation...4789
              Torque -...4792
              Torque -...4792
            Radiator Inspection...4793
            Radiator Cap Inspection...4793
            Radiator Filler Neck Inspection...4794
          Thermostat Removal...4795
            Thermostat Installation...4795
              Torque -...4796
            Thermostat Inspection...4796
          Hose Installation...4798
            Torque -...4798
            Hose Inspection...4798
          CAUTION...4799
            Water Temperature Sensor Removal...4799
            Water Temperature Sensor Inspection...4799
        Engine Top End...4801
          Exhaust System...4805
          Compression Gauge, 20 kgf/cm :...4809
          Air Suction Valve Removal...4811
            Air Suction Valve Installation...4811
              Torque -...4811
            Air Suction Valve Inspection...4811
            Vacuum Switch Valve Removal...4811
            Vacuum Switch Valve Installation...4812
            Vacuum Switch Valve Test...4812
              Special Tool -...4812
            Clean Air System Hose Inspection...4812
          Cylinder Head Cover Removal...4813
            Cylinder Head Cover Installation...4813
              Sealant -...4813
              Torque -...4814
          Camshaft Chain Tensioner Removal...4815
            Camshaft Chain Tensioner Installation...4815
              Torque -...4815
              Torque -...4815
          Camshaft Removal...4816
            Camshaft Installation...4816
              Torque -...4817
              Torque -...4817
            Camshaft, Camshaft Cap Wear...4818
              Torque -...4818
            Camshaft Runout...4818
            Cam Wear...4819
            Camshaft Chain Removal...4819
          Cylinder Compression Measurement...4820
            Special Tools -...4820
            Torque -...4820
            Cylinder Head Removal...4821
            Cylinder Head Installation...4821
              Torque -...4822
              Torque -...4822
              Torque -...4822
            Cylinder Head Warp...4822
          Valve Clearance Inspection...4823
            Valve Clearance Adjustment...4823
            Valve Removal...4823
              Special Tools -...4823
            Valve Installation...4823
            Valve Guide Removal...4823
              Special Tool -...4823
            Valve Guide Installation...4824
              Special Tools -...4824
              Special Tool -...4824
            Valve-to-Guide Clearance Measurement (Wobble Method)...4824
            Valve Seat Inspection...4825
            Valve Seat Repair...4825
              Special Tools -...4825
          Cylinder Removal...4830
            Cylinder Installation...4830
            Piston Removal...4831
              Special Tool -...4831
            Piston Installation...4831
            Cylinder Wear...4832
            Piston Wear...4832
            Piston Ring, Piston Ring Groove Wear...4833
            Piston Ring Groove Width...4833
            Piston Ring Thickness...4833
            Piston Ring End Gap...4834
          Throttle Body Holder Installation...4835
            Torque -...4835
          WARNING...4836
            Muffler Body Removal...4836
            Muffler Body Installation...4838
              Torque -...4838
            Exhaust Pipe Removal...4839
            Exhaust Pipe Installation...4840
              Torque -...4840
            Exhaust Butterfly Valve Cable Removal...4841
            Exhaust Butterfly Valve Cable Installation...4841
              Torque -...4842
              Torque -...4842
              Torque -...4842
        Clutch...4845
          Clutch Holder:...4849
          Clutch Lever Free Play Inspection...4850
            Clutch Lever Free Play Adjustment...4850
            Cable Removal...4850
            Cable Installation...4850
            Cable Lubrication...4850
            Clutch Lever Installation...4850
              Torque -...4850
          Clutch Cover Removal...4851
            Clutch Cover Installation...4851
              Sealant -...4851
              Torque -...4851
            Release Shaft Removal...4851
            Release Shaft Installation...4852
            Clutch Cover Disassembly...4852
            Clutch Cover Assembly...4852
          Clutch Removal...4853
            Special Tool -...4853
            Clutch Installation...4854
              Special Tool -...4857
              Torque -...4857
              Torque -...4857
            Spring Plate Free Play Measurement...4858
            Spring Plate Play Adjustment...4859
              Torque -...4859
            Clutch Plate, Wear, Damage Inspection...4859
            Clutch Plate Warp Inspection...4859
            Clutch Spring Free Length Measurement...4860
            Damper Cam Inspection...4860
        Engine Lubrication System...4861
          Outside Circlip Pliers:...4865
          WARNING...4868
            Oil Level Inspection...4868
            Engine Oil Change...4868
            Oil Filter Replacement...4868
          Oil Pan Removal...4869
            Oil Pan Installation...4869
              Torque -...4869
              Torque -...4869
          Oil Pressure Relief Valve Removal...4870
            Oil Pressure Relief Valve Installation...4870
            Oil Pressure Relief Valve Inspection...4870
          Oil Pump Removal...4871
            Oil Pump Installation...4871
              Torque -...4872
              Torque -...4872
              Torque -...4872
            Oil Pump Drive Gear Removal...4872
              Special Tool -...4872
            Oil Pump Drive Gear Installation...4873
            Special Tool -...4873
          Oil Cooler Removal...4874
            Oil Cooler Installation...4874
              Torque -...4874
              Torque -...4874
          Oil Pressure Measurement...4875
            Special Tools -...4875
            Torque -...4875
          Oil Pressure Switch Removal...4876
            Oil Pressure Switch Installation...4876
              Sealant -...4876
              Torque -...4876
              Torque -...4876
        Engine Removal/Installation...4877
          Engine Mount Nut Wrench:...4880
          Engine Removal...4881
            Special Tool -...4882
            Engine Installation...4883
              Torque -...4884
              Special Tool -...4884
              Torque -...4884
        Crankshaft/Transmission...4887
          Bearing Puller:...4894
          Crankcase Splitting...4895
            Crankcase Assembly...4896
              Sealant -...4896
              Torque -...4896
              Torque -...4896
              Sealant -...4897
              Torque -...4898
              Torque -...4898
              Torque -...4898
              Torque -...4898
              Torque -...4898
          Crankshaft Removal...4899
            Crankshaft Installation...4899
            Connecting Rod Removal...4900
            Connecting Rod Installation...4900
            Crankshaft/Connecting Rod Cleaning...4904
            Connecting Rod Bend...4904
            Connecting Rod Twist...4904
            Connecting Rod Big End Side Clearance...4904
            Connecting Rod Big End Bearing Insert/Crankpin Wear...4905
            Crankshaft Side Clearance...4906
            Crankshaft Runout...4907
            Crankshaft Main Bearing Insert/Journal Wear...4907
          Shift Pedal Removal...4909
            Shift Pedal Installation...4909
              Torque -...4909
              Torque -...4909
              Torque -...4909
            External Shift Mechanism Removal...4910
            External Shift Mechanism Installation...4910
              Torque -...4910
            External Shift Mechanism Inspection...4910
              Torque -...4910
            Transmission Shaft Removal...4911
            Transmission Shaft Installation...4911
            Transmission Shaft Disassembly...4911
              Special Tool -...4911
              Special Tools -...4912
            Transmission Shaft Assembly...4912
              Special Tool -...4912
            Shift Drum and Fork Removal...4915
            Shift Drum and Fork Installation...4915
              Torque -...4915
            Shift Drum Disassembly...4915
            Shift Drum Assembly...4915
              Torque -...4915
            Shift Fork Bending...4915
            Shift Fork/Gear Groove Wear...4916
            Shift Fork Guide Pin/Drum Groove Wear...4916
            Gear Dog and Gear Dog Hole Damage...4916
        Wheels/Tires...4917
          Bearing Driver Set:...4921
          Front Wheel Removal...4922
            Special Tools -...4922
            Front Wheel Installation...4922
              Torque -...4923
              Torque -...4923
            Rear Wheel Removal...4923
            Rear Wheel Installation...4924
              Torque -...4925
            Wheel Inspection...4926
              Special Tools -...4926
            Axle Inspection...4926
            Balance Inspection...4927
            Balance Adjustment...4927
            Balance Weight Removal...4927
            Balance Weight Installation...4927
          Air Pressure Inspection/Adjustment...4929
            Tire Inspection...4929
            Tire Removal...4929
            Tire Installation...4929
            Tire Repair...4931
          Hub Bearing Removal...4932
            Special Tools -...4932
            Hub Bearing Installation...4932
              Special Tool -...4932
              Special Tool -...4932
            Hub Bearing Inspection...4932
            Hub Bearing Lubrication...4933
        Final Drive...4935
          Inside Circlip Pliers:...4939
          Drive Chain Slack Inspection...4940
            Drive Chain Slack Adjustment...4940
            Wheel Alignment Inspection/Adjustment...4940
            Drive Chain Wear Inspection...4940
            Drive Chain Lubrication...4940
            Drive Chain Removal...4940
            Drive Chain Installation...4941
          Engine Sprocket Removal...4944
            Engine Sprocket Installation...4944
              Torque -...4944
              Torque -...4945
            Rear Sprocket Removal...4945
            Rear Sprocket Installation...4945
              Torque -...4945
            Coupling Installation...4945
            Coupling Bearing Removal...4946
              Special Tool -...4946
              Special Tool -...4946
            Coupling Bearing Installation...4946
              Special Tool -...4946
              Special Tool -...4946
              Special Tool -...4946
            Coupling Bearing Inspection...4947
            Coupling Bearing Lubrication...4947
            Coupling Damper Inspection...4947
            Sprocket Wear Inspection...4947
            Rear Sprocket Warp Inspection...4948
        Brakes...4949
          Inside Circlip Pliers:...4955
          Brake Lever Position Adjustment...4956
            Brake Pedal Position Inspection ...4956
            Brake Pedal Position Adjustment ...4956
              Torque -...4956
            Brake Pedal Removal...4956
            Brake Pedal Installation...4957
              Torque -...4957
              Torque -...4957
              Torque -...4957
          Front Caliper Removal...4958
            Rear Caliper Removal...4958
            Caliper Installation...4958
              Torque -...4958
            Front Caliper Disassembly...4959
            Front Caliper Assembly...4959
            Rear Caliper Disassembly...4959
            Rear Caliper Assembly...4959
            Caliper Fluid Seal Damage...4959
            Rear Caliper Dust Boot and Friction Boot Damage...4960
            Caliper Piston and Cylinder Damage...4960
            Rear Caliper Holder Shaft Wear...4960
          Front Brake Pad Removal...4961
            Front Brake Pad Installation...4961
              Torque -...4961
            Rear Brake Pad Removal ...4962
            Rear Brake Pad Installation...4962
            Brake Pad Wear Inspection...4962
          Front Master Cylinder Removal...4963
            Front Master Cylinder Installation...4963
              Torque -...4963
              Torque -...4963
            Rear Master Cylinder Removal...4964
            Rear Master Cylinder Installation...4964
              Torque -...4964
            Front Master Cylinder Disassembly...4964
            Rear Master Cylinder Disassembly...4964
            Master Cylinder Assembly...4964
            Master Cylinder Inspection (Visual Inspection)...4964
          Brake Disc Removal...4966
            Brake Disc Installation...4966
              Torque -...4966
            Brake Disc Wear...4966
            Brake Disc Warp...4966
              Special Tools -...4966
          Brake Fluid Level Inspection...4967
            Brake Fluid Change...4967
            Brake Line Bleeding...4967
              Torque -...4968
              Torque -...4969
          Brake Hose Removal/Installation...4971
            Brake Hose Inspection...4971
        Suspension...4973
          Inside Circlip Pliers:...4979
          Rebound Damping Force Adjustment...4981
            Compression Damping Force Adjustment...4981
            Spring Preload Adjustment...4982
            Front Fork Removal (Each Fork Leg)...4982
            Front Fork Installation...4983
              Torque -...4983
              Torque -...4983
            Front Fork Oil Change...4983
              Special Tools -...4983
              Special Tool -...4985
              Special Tool -...4985
              Special Tool -...4986
              Special Tool -...4986
              Special Tools -...4986
              Torque -...4987
            Front Fork Disassembly...4987
              Special Tool -...4987
            Front Fork Assembly...4988
              Special Tool -...4988
              Torque -...4988
              Special Tool -...4988
            Inner Tube Inspection...4988
            Dust Seal Inspection...4989
            Spring Tension...4989
          Rebound Damping Force Adjustment...4990
            Compression Damping Force Adjustment...4990
            Spring Preload Adjustment...4990
              Special Tools -...4990
              Special Tools -...4991
            Rear Shock Absorber Removal...4991
              Special Tools -...4991
            Rear Shock Absorber Installation...4992
              Torque -...4992
            Rear Shock Absorber Inspection...4992
            Rear Shock Absorber Scrapping...4992
          Swingarm Removal...4993
            Special Tool -...4994
            Swingarm Installation...4994
              Torque -...4994
              Special Tool -...4995
              Torque -...4995
              Torque -...4995
            Swingarm Bearing Removal...4995
              Special Tool -...4995
              Special Tool -...4995
            Swingarm Bearing Installation...4996
              Special Tools -...4996
            Swingarm Bearing, Sleeve Inspection...4996
            Chain Guide Inspection...4997
          Tie-Rod Removal...4998
            Special Tools -...4998
            Tie-Rod Installation...4998
              Torque -...4998
            Rocker Arm Removal...4998
              Special Tools -...4998
            Rocker Arm Installation...4999
              Torque -...4999
            Tie-Rod and Rocker Arm Bearing Removal...4999
              Special Tools -...4999
            Tie-Rod and Rocker Arm Bearing Installation...4999
              Special Tools -...5000
            Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...5001
            Rocker Arm/Tie-Rod Bearing Lubrication...5001
        Steering...5003
          Bearing Puller Adapter:...5006
          Steering Inspection...5007
            Steering Adjustment...5007
          Stem, Stem Bearing Removal...5008
            Special Tool -...5008
            Special Tool -...5008
            Special Tools -...5009
            Stem, Stem Bearing Installation...5009
              Special Tools -...5009
              Special Tools -...5009
              Special Tool -...5010
              Torque -...5010
              Torque -...5011
            Steering Stem Bearing Lubrication...5011
            Steering Stem Warp...5011
            Stem Cap Deterioration, Damage...5011
          Handlebar Removal...5012
            Handlebar Installation...5012
              Torque -...5012
              Torque -...5013
        Frame...5015
          Rear Seat Removal...5022
            Rear Seat Installation...5022
            Front Seat Removal...5022
            Front Seat Installation...5022
          Lower Fairing Removal...5023
            Lower Fairing Installation...5023
            Center Fairing Removal...5023
            Center Fairing Installation...5024
            Windshield Removal...5024
            Windshield Installation...5024
              Torque -...5024
            Upper Fairing Removal...5024
            Upper Fairing Disassembly...5025
              Upper Fairing Assembly...5025
              Upper Fairing Installation...5026
                Torque -...5026
              Upper Inner Fairing Removal...5026
              Upper Inner Fairing Installation...5026
              Center Inner Fairing Removal...5026
              Center Inner Fairing Installation...5026
              Right and Left Inner Fairing Removal...5027
              Right and Left Inner Fairing Installation...5027
          Left Side Cover Removal...5028
            Left Side Cover Installation...5028
            Right Side Cover Removal...5028
            Right Side Cover Installation...5028
          Seat Cover Removal...5029
            Seat Cover Installation...5029
          Front Fender Removal...5030
            Front Fender Installation...5030
              Torque -...5030
            Flap and Rear Fender Rear Removal...5030
            Flap and Rear Fender Rear Installation...5031
            Rear Fender Front Removal...5032
            Rear Fender Front Installation...5032
          Rear Frame Removal...5033
            Rear Frame Installation...5033
              Torque -...5033
            Frame Inspection...5033
          Side Stand Removal...5034
            Side Stand Installation...5034
              Torque -...5034
              Torque -...5034
        Electrical System...5035
          Flywheel Holder:...5053
          There are a number of important precautions that are musts when ...5054
          Wiring Inspection...5056
            Special Tool -...5056
          Battery Removal...5057
            Battery Installation...5057
            Battery Activation...5057
            Precautions...5060
              1)...5060
              2)...5060
              3)...5060
              4)...5060
            Interchange...5060
              Charging Condition Inspection...5061
              Refreshing Charge...5061
          Alternator Cover Removal...5063
            Alternator Cover Installation...5063
              Sealant -...5063
              Torque -...5063
            Stator Coil Removal...5063
            Stator Coil Installation...5064
              Torque -...5064
              Sealant -...5064
              Torque -...5064
            Alternator Rotor Removal...5064
              Special Tool -...5064
              Special Tool -...5064
            Alternator Rotor Installation...5064
              Special Tool -...5065
              Torque -...5065
            Alternator Inspection...5066
              Special Tool -...5066
            Regulator/Rectifier Removal...5067
            Regulator/Rectifier Inspection...5067
            Charging Voltage Inspection...5069
              Special Tool -...5069
            Charging System Circuit...5070
          Starter Motor Clutch Removal/Inspection...5071
            Starter Motor Clutch Inspection...5071
            Starter Motor Clutch Disassembly...5071
            Starter Motor Clutch Assembly...5071
              Torque -...5071
            Crankshaft Sensor Removal...5073
            Crankshaft Sensor Installation...5074
              Torque -...5074
              Sealant -...5074
              Torque -...5074
            Crankshaft Sensor Inspection...5074
              Special Tool -...5074
            Crankshaft Sensor Peak Voltage...5074
              Special Tools -...5075
            Timing Rotor Removal...5075
              Special Tool -...5075
            Timing Rotor Installation...5075
              Torque -...5075
              Special Tool -...5075
            Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...5075
            Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...5076
            Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...5076
            Stick Coil Primary Peak Voltage...5077
              Special Tools -...5077
            Spark Plug Removal...5077
            Spark Plug Installation...5078
            Spark Plug Clean and Inspection...5078
            Spark Plug Gap Inspection...5078
            Camshaft Position Sensor Removal...5078
            Camshaft Position Sensor Installation...5078
              Torque -...5078
            Camshaft Position Sensor Inspection...5078
              Special Tool -...5079
            Camshaft Position Sensor Peak Voltage Inspection...5079
              Special Tool -...5079
            Interlock Operation Inspection...5080
            IC Igniter Inspection...5081
            Ignition System Circuit...5082
          Starter Motor Removal...5083
            Starter Motor Installation...5083
              Torque -...5083
            Starter Motor Disassembly...5083
            Starter Motor Assembly...5083
            Brush Inspection...5084
            Commutator Cleaning and Inspection...5085
            Armature Inspection...5085
              Special Tool -...5085
            Brush Lead Inspection...5085
              Special Tool -...5085
            Right-hand End Cover Assembly Inspection...5086
              Special Tool -...5086
            Starter Relay Inspection...5086
              Special Tool -...5086
            Electric Starter Circuit...5087
          This motorcycle adopt the daylight system and have a headlight r...5088
            Headlight Beam Horizontal Adjustment...5088
            Headlight Beam Vertical Adjustment...5088
            Headlight Bulb Replacement...5088
            City Light Bulb Replacement...5089
            Headlight Removal/Installation...5089
            Tail/Brake Light (LED) Removal...5090
            Tail/Brake Light (LED) Installation...5090
            License Plate Light Bulb Replacement...5090
            Headlight/Tail Light Circuit...5091
              Turn Signal Light Bulb Replacement...5092
              Turn Signal Relay Inspection...5093
            Turn Signal Light Circuit...5095
          Fan Motor Inspection...5096
            Radiator Fan Circuit...5097
          Meter Unit Removal...5098
            Meter Unit Disassembly...5098
            Electronic Combination Meter Assembly Inspection...5099
              Special Tool -...5099
              Special Tool -...5104
            Meter Circuit...5107
          This motorcycle is equipped with an immobilizer system to protec...5108
            Operational Cautions...5108
              Key Registration...5108
                Special Tool -...5109
            Spare User Key Registration Flow Chart...5113
              Special Tool -...5114
            All Keys Initial Registration Flow Chart...5123
              Immobilizer System Parts Replacement...5124
              Immobilizer System Inspection...5126
            Immobilizer System Circuit...5126
          Brake Light Timing Inspection...5127
            Brake Light Timing Adjustment...5127
            Neutral Switch Replacement...5127
              Torque -...5127
            Switch Inspection...5128
              Special Tool -...5128
            Rear Brake Light Switch Connections...5128
            Side Stand Switch Connections...5128
            Neutral Switch Connections...5128
            Oil Pressure Switch Connections *...5128
            Water Temperature Sensor Inspection...5129
            Speed Sensor Removal...5129
            Speed Sensor Installation...5129
              Torque -...5129
            Speed Sensor Inspection...5130
              Special Tool -...5130
            Fuel Reserve Switch Inspection...5130
              Special Tool -...5130
          The relay box [A] has relays and diodes. The relays and diodes c...5131
            Relay Box Removal...5131
            Relay Circuit Inspection...5131
            Diode Circuit Inspection...5132
            Relay Box Internal Circuit...5133
          30 A Main Fuse Removal...5134
            Fuse Box Fuse Removal...5134
            15 A ECU Fuse Removal...5134
            Fuse Installation...5135
            Fuse Inspection...5135
        Appendix...5137
          California Model...5162
          NOTE...5164
            Engine Doesn't Start, Starting Difficulty:...5164
              Starter motor not rotating:...5164
              Starter motor rotating but engine doesn't turn over:...5164
              Engine won't turn over:...5164
              No fuel flow:...5164
              No spark; spark weak:...5164
              Fuel/air mixture incorrect:...5164
              Compression Low:...5164
            Poor Running at Low Speed:...5164
              Spark weak:...5164
              Fuel/air mixture incorrect:...5164
              Compression low:...5164
              Other:...5165
            Poor Running or No Power at High Speed:...5165
              Firing incorrect:...5165
              Fuel/air mixture incorrect:...5165
              Compression low:...5165
              Knocking:...5165
              Miscellaneous:...5165
            Overheating:...5165
              Firing incorrect:...5165
              Muffler overheating:...5165
              Fuel/air mixture incorrect:...5165
              Compression high:...5165
              Engine load faulty:...5165
              Lubrication inadequate:...5166
              Oil cooler incorrect:...5166
              Gauge incorrect:...5166
              Coolant incorrect:...5166
              Cooling system component incorrect:...5166
            Over Cooling:...5166
              Gauge incorrect:...5166
              Cooling system component incorrect:...5166
            Clutch Operation Faulty:...5166
              Clutch slipping:...5166
              Clutch not disengaging properly:...5166
            Gear Shifting Faulty:...5166
              Doesn't go into gear; shift pedal doesn't return:...5166
              Jumps out of gear:...5166
              Overshifts:...5166
            Abnormal Engine Noise:...5166
              Knocking:...5166
              Piston slap:...5166
              Valve noise:...5166
              Other noise:...5166
            Abnormal Drive Train Noise:...5167
              Clutch noise:...5167
              Transmission noise:...5167
              Drive line noise:...5167
            Abnormal Frame Noise:...5167
              Front fork noise:...5167
              Rear shock absorber noise:...5167
              Disc brake noise:...5167
              Other noise:...5167
            Oil Pressure Warning Light Goes On:...5167
            Exhaust Smokes Excessively:...5167
              White smoke:...5167
              Black smoke:...5167
              Brown smoke:...5167
            Handling and/or Stability Unsatisfactory:...5167
              Handlebar hard to turn:...5167
              Handlebar shakes or excessively vibrates:...5167
              Handlebar pulls to one side:...5167
              Shock absorption unsatisfactory:...5167
            Brake Doesn't Hold:...5168
            Battery Trouble:...5168
              Battery discharged:...5168
              Battery overcharged:...5168
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6R (EN)...5170
  tables...0
    LIST OF ABBREVIATIONS...5173
    Units of Mass...5190
    Units of Volume...5190
    Units of Force...5190
    Units of Length...5190
    Units of Torque...5190
    Units of Pressure...5190
    Units of Speed...5190
    Units of Power...5190
    Periodic Inspection...5194
    Periodic Replacement Parts...5196
    Periodic Inspection...5197
    Periodic Replacement Parts...5199
    Basic Torque for General Fasteners...5205
    Throttle Grip Free Play...5209
    Engine Vacuum...5210
    Main Throttle Sensor Output Voltage...5212
    Idle Speed...5213
    Valve Clearance...5216
    Clutch Lever Free Play...5220
    Air Pressure (when Cold)...5221
    Tread Depth...5222
    Chain Slack...5223
    Drive Chain 20-link Length...5225
    Standard Chain...5225
    Recommended Disc Brake Fluid...5227
    Pad Lining Thickness...5227
    Side Stand Switch Operation...5236
    Water and Coolant Mixture Ratio (Recommended)...5244
    Recommended Engine Oil...5246
    Terminal Names...5273
    Sample Diagnosis Sheet...5281
    Engine Doesn't Start, Starting Difficulty...5283
    Poor Running at Low Speed...5285
    Poor Running or No Power at High Speed:...5288
    Service Code Table...5294
    Main Throttle Sensor Input Voltage...5298
    Input Voltage at ECU Connector...5298
    Main Throttle Sensor Input Voltage...5299
    Input Voltage at Sensor...5299
    Main Throttle Sensor Output Voltage...5299
    Idle Speed...5299
    Output Voltage at ECU...5299
    Throttle Sensor Output Voltage...5300
    Output Voltage at Sensor...5300
    Main Throttle Sensor Resistance...5301
    Inlet Air Pressure Sensor Input Voltage...5302
    Input Voltage at ECU...5302
    Inlet Air Pressure Sensor Input Voltage...5303
    Input Voltage at Sensor Connector...5303
    Inlet Air Pressure Sensor Output Voltage...5303
    Output Voltage at ECU...5303
    Inlet Air Pressure Sensor Output Voltage...5304
    Output Voltage at Sensor Connector...5304
    Inlet Air Pressure Sensor Output Voltage Connection to Sensor...5305
    Inlet Air Temperature Sensor Output Voltage...5307
    Output Voltage at ECU...5307
    Inlet Air Temperature Sensor Resistance...5308
    Water Temperature Sensor Output Voltage...5310
    Output Voltage at ECU...5310
    Atmospheric Pressure Sensor Input Voltage...5312
    Input Voltage at ECU...5312
    Atmospheric Pressure Sensor Input Voltage...5313
    Input Voltage at Sensor Connector...5313
    Atmospheric Pressure Sensor Output Voltage...5313
    Output Voltage...5313
    Atmospheric Pressure Sensor Output Voltage...5314
    Output Voltage at Sensor...5314
    Speed Sensor Input Voltage...5318
    Input Voltage at Sensor...5318
    Speed Sensor Output Voltage...5319
    Output Voltage at Sensor ...5319
    Vehicle-down Sensor Power Source Voltage...5321
    Power Source Voltage at Sensor...5321
    Vehicle-down Sensor Output Voltage...5321
    Output Voltage at Sensor...5321
    Subthrottle Sensor Input Voltage...5323
    Input Voltage at ECU Connector...5323
    Subthrottle Sensor Input Voltage...5324
    Input Voltage at Sensor...5324
    Subthrottle Sensor Output Voltage...5324
    Output Voltage at ECU...5324
    Subthrottle Sensor Output Voltage...5325
    Output Voltage at Sensor...5325
    Subthrottle Sensor Resistance...5326
    Exhaust Butterfly Valve Actuator Sensor Resistance...5327
    Antenna Resistance...5328
    Amplifier Input Voltage...5328
    Input Voltage...5328
    Stick Coil Input Voltage at ECU...5331
    Input Voltage at ECU...5331
    Subthrottle Valve Actuator Resistance...5333
    Subthrottle Valve Actuator Input Voltage...5334
    Input Voltage at Sensor...5334
    Connections...5337
    Actuator Output Voltage (Pulley Original Position)...5337
    ECU Identification...5338
    ECU Grounding Inspection...5339
    ECU Power Source Inspection...5340
    FI Indicator Light (LED) Check...5342
    Fuel Pressure...5343
    Fuel Pressure (Idling)...5344
    Amount of Fuel Flow...5345
    Pump Operating Voltage at Pump...5347
    Operating Voltage at Pump Connector...5347
    Primary Fuel Injector Resistance...5350
    Secondary Fuel Injector Resistance...5351
    Primary Fuel Injector Power Source Voltage...5352
    Secondary Fuel Injector Power Source Voltage...5352
    Power Source Voltage at Injector Connector...5352
    Primary Fuel Injector Output Voltage...5352
    Secondary Fuel Injector Output Voltage...5353
    Output Voltage at Injector Connector...5353
    Fuel Line Maximum Pressure...5354
    Radiator Cap Relief Pressure...5390
    Thermostat Valve Opening Temperature...5394
    Vacuum Switch Valve Closing Pressure (Open → Close)...5409
    Camshaft Journal, Camshaft Cap Clearance...5416
    Camshaft Journal Diameter...5416
    Camshaft Runout...5416
    Cam Height...5417
    Cylinder Compression...5418
    Cylinder Head Warp...5420
    Valve/Valve Guide Clearance (Wobble Method)...5423
    Valve Seating Surface Outside Diameter...5423
    Valve Seating Surface Width...5423
    Cylinder Inside Diameter...5430
    Piston Diameter...5430
    Piston Ring/Groove Clearance...5431
    Piston Ring Groove Width...5431
    Piston Ring Thickness...5431
    Piston Ring End Gap...5432
    Clutch Housing Gear Selection when Replacing Clutch Housing Gear...5452
    Spring Plate Free Play ...5455
    Clutch Plate Assembly Length...5456
    Friction Plate Thickness...5456
    Friction and Steel Plate Warp...5456
    Clutch Spring Free Length...5457
    Oil Pressure...5472
    Connecting Rod Big End Bearing Insert Selection...5490
    Crankshaft Main Bearing Insert Selection...5490
    Crankshaft Selection when Replacing Crankshaft...5496
    Connecting Rod Bend...5501
    Connecting Rod Twist...5501
    Connecting Rod Big End Side Clearance...5501
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...5502
    Crankpin Diameter...5502
    Crankpin Diameter Marks...5502
    Connecting Rod Big End Inside Diameter Marks...5503
    Crankshaft Side Clearance...5503
    Crankshaft Runout...5504
    Crankshaft Main Bearing Insert/Journal Clearance...5504
    Crankshaft Main Journal Diameter...5504
    Crankshaft Main Journal Diameter Marks...5504
    Crankcase Main Bearing Inside Diameter Marks...5505
    Shift Fork Ear Thickness...5513
    Gear Groove Width...5513
    Shift Fork Guide Pin Diameter...5513
    Shift Drum Groove Width...5513
    Rim Runout (with tire installed)...5523
    Axle Runout/100 mm (3.94 in.)...5523
    Balance Weight...5525
    Link Pin Outside Diameter...5540
    Link Plates Outside Width...5540
    Rear Sprocket Warp...5545
    Pedal Position...5553
    Brake Discs Thickness...5563
    Disc Runout...5563
    Rebound Damping Force Adjustment...5578
    Compression Damping Force Adjustment...5578
    Adjuster Protrusion (from top)...5579
    Spring Action...5579
    Fork Oil...5582
    Oil Level (fully compressed, without spring)...5583
    Spring Free Length...5587
    Rebound Damping Force Adjustment...5588
    Rebound Damping Force Adjustment...5588
    Spring Preload Setting...5589
    Spring Adjustment...5589
    Kawasaki-recommended chargers...5656
    Battery Terminal Voltage...5658
    Terminal Voltage: 11.5 ∼ less than 12.8 V...5659
    Terminal Voltage: less than 11.5 V...5659
    Table 1 Alternator Output Voltage...5663
    Table 2 Stator Coil Resistance...5663
    Charging Voltage...5666
    Crankshaft Sensor Peak Voltage...5672
    Ignition Coil Winding Resistance...5673
    Primary Lead Connection...5674
    Stick Coil Primary Peak Voltage...5674
    Connections:...5676
    Camshaft Position Sensor Peak Voltage...5676
    Condition...5677
    Condition...5677
    Condition...5677
    Starter Motor Brush Length...5681
    Commutator Diameter...5682
    Testing Relay...5683
    Testing Turn Signal Relay...5690
    Testing Turn Signal Relay...5691
    User Key Indicator Flashes...5709
    Water Temperature Sensor...5726
    Connections...5727
    Relay Circuit Inspection (with the battery disconnected)...5728
    Relay Circuit Inspection (with the battery connected)...5729
    Relay Circuit Inspection (with the battery disconnected)...5729
    Relay Circuit Inspection (with the battery connected)...5729
    Diode Circuit Inspection...5730
    Diode Circuit Inspection...5730
  toc...0
    Read OWNER'S MANUAL before operating...5173
      EMISSION CONTROL INFORMATION...5174
        1...5174
        2...5174
        3...5174
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...5175
      Foreword...5176
      General Information...5178
        Before starting to perform an inspection service or carry out a ...5179
          Battery Ground...5179
          Edges of Parts...5179
          Solvent...5179
          Cleaning vehicle before disassembly...5179
          Arrangement and Cleaning of Removed Parts...5180
          Storage of Removed Parts...5180
          Inspection...5180
          Replacement Parts...5180
          Assembly Order...5180
          Tightening Sequence...5181
          Tightening Torque...5181
          Force...5181
          Gasket, O-ring...5181
          Liquid Gasket, Non-permanent Locking Agent...5181
          Press...5182
          Ball Bearing and Needle Bearing...5182
          Oil Seal, Grease Seal...5182
          Circlips, Cotter Pins...5182
          Lubrication...5183
          Direction of Engine Rotation...5183
          Electrical Wires...5183
          Instrument...5183
        ZX636-C1 ∼ (Europe) Left Side View...5184
        ZX636-C1 ∼ (Europe) Right Side View...5184
        ZX636-C1 ∼ (US and Canada) Left Side View...5185
        ZX636-C1 ∼  (US and Canada) Right Side View...5185
        ZX636D6F (US and Canada) Left Side View...5186
        ZX636D6F (US and Canada) Right Side View...5186
        Prefixes for Units...5190
        Units of Temperature...5190
      Periodic Maintenance...5192
        The scheduled maintenance must be done in accordance with this c...5194
        The scheduled maintenance must be done in accordance with this c...5197
        The following tables list the tightening torque for the major fa...5200
        Inside Circlip Pliers:...5208
        Fuel System (DFI)...5209
          Throttle Control System Inspection...5209
          Engine Vacuum Synchronization Inspection...5209
            Special Tool -...5210
            Special Tool -...5211
          Idle Speed Inspection...5213
          Idle Speed Adjustment...5213
          Fuel Hose Damage and Installation Condition Inspection...5213
          Evaporative Emission Control System (California Model)...5214
            Evaporative Emission Control System Inspection...5214
          Cooling System...5215
            Coolant Level Inspection...5215
            Radiator Hose Damage and Installation Condition Inspection...5215
              Torque -...5215
          Engine Top End...5216
            Valve Clearance Inspection...5216
            Valve Clearance Adjustment...5217
            VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE...5218
            VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE...5219
          Air Suction System...5220
            Air Suction System Damage Inspection...5220
          Clutch...5220
            Clutch Operation Inspection ...5220
          Wheels/Tires...5221
            Air Pressure Inspection...5221
            Wheel/Tire Damage Inspection...5221
            Tire Tread Wear Inspection ...5221
            Wheel Bearing Damage Inspection...5222
          Drive Train...5223
            Drive Chain Lubrication Condition Inspection...5223
            Drive Chain Slack Inspection...5223
            Drive Chain Slack Adjustment...5224
              Torque -...5224
            Wheel Alignment Inspection...5225
            Drive Chain Wear Inspection...5225
            Chain Guide Wear Inspection...5226
          Brake System...5226
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...5226
            Brake Hose Damage and Installation Condition Inspection...5226
              Torque -...5226
            Brake Operation Inspection...5226
            Brake Fluid Level Inspection...5227
            Brake Pad Wear Inspection...5227
            Brake Light Switch Operation Inspection...5227
          Suspensions...5228
            Front Forks/Rear Shock Absorber Operation Inspection...5228
            Front Fork Oil Leak Inspection...5229
            Rear Shock Absorber Oil Leak Inspection...5229
            Rocker Arm Operation Inspection...5229
            Tie-Rod Operation Inspection...5229
          Steering System...5230
            Steering Play Inspection...5230
              Special Tools -...5230
            Steering Play Adjustment...5230
              Special Tool -...5230
              Torque -...5231
            Steering Stem Bearing Lubrication...5231
          Electrical System...5231
            Spark Plug Clean and Gap Inspection...5231
            Lights and Switches Operation Inspection...5233
            Headlight Aiming Inspection...5235
            Side Stand Switch Operation Inspection...5236
            Engine Stop Switch Operation Inspection...5237
          Others...5238
            Chassis Parts Lubrication ...5238
              Pivots: Lubricate with Grease...5238
              Points: Lubricate with Grease...5238
              Cables: Lubricate with Rust Inhibitor...5238
            Bolts, Nuts and Fasteners Tightness Inspection...5239
              Bolt, Nut and Fastener to be checked...5240
          Replacement Parts...5241
            Air Cleaner Element Replacement...5241
            Fuel Hose Replacement...5241
            Coolant Change...5243
              Torque -...5243
            Radiator Hose and O-ring Replacement...5245
            Engine Oil Change...5246
              Torque -...5246
            Oil Filter Replacement...5246
              Special Tool -...5246
              Torque -...5246
            Brake Hose and Pipe Replacement...5247
              Torque -...5247
            Brake Fluid Change...5247
              Torque -...5248
              Torque -...5248
            Master Cylinder Rubber Parts Replacement...5249
              Special Tool -...5249
              Special Tool -...5249
              Silicone Grease -...5250
              Torque -...5250
            Caliper Rubber Parts Replacement...5250
              Torque -...5251
              Torque -...5251
              Torque -...5252
            Spark Plug Replacement...5253
              Owner's Tool -...5253
              Torque -...5253
      Fuel System (DFI)...5254
        Dummy Page...5256
        Oil Pressure Gauge, 5 kgf/cm :...5265
        Subthrottle Sensor [A]...5267
        DFI System...5269
        DFI System Wiring Diagram...5271
        Terminal Numbers of ECU Connectors...5273
        There are a number of important precautions that should be follo...5274
          Torque -...5275
        Outline...5276
          Special Tool -...5276
          Sealant -...5277
          Special Tool -...5277
          DFI Diagnosis Flow Chart...5280
          Inquiries to Rider...5280
        NOTE...5283
        Self-diagnosis Outline...5291
          Self-diagnosis Procedures...5291
          Service Code Clearing Procedures...5292
            Service Code Reading...5294
            Service Code Erasing...5294
          Backups...5296
        The main throttle sensor is a rotating variable resistor that ch...5298
          Main Throttle Sensor Removal/Adjustment...5298
          Input Voltage Inspection...5298
            Special Tool -...5298
            Special Tool -...5299
          Output Voltage Inspection...5299
            Special Tool -...5299
            Special Tool -...5300
          Resistance Inspection...5301
        CAUTION...5302
          Removal...5302
          Installation...5302
          Input Voltage Inspection...5302
            Special Tool -...5302
            Special Tool -...5303
          Output Voltage Inspection...5303
            Special Tool -...5304
            Special Tools -...5305
        Removal/Installation...5307
          Output Voltage Inspection...5307
            Special Tool -...5307
            Sealant -...5308
          Sensor Resistance Inspection...5308
        Removal/Installation...5310
          Sealant -...5310
          Torque -...5310
          Output Voltage Inspection...5310
            Special Tool -...5310
            Sealant -...5311
          Sensor Resistance Inspection...5311
        CAUTION...5312
          Removal...5312
          Installation...5312
          Input Voltage Inspection...5312
            Special Tool -...5312
            Special Tool -...5313
          Output Voltage Inspection...5313
            Special Tool -...5314
          Atmospheric Pressure/Altitude Relationship...5315
        Crankshaft Sensor Removal/Installation...5316
          Crankshaft Sensor Inspection...5316
        Camshaft Position Sensor Removal/Installation...5317
          Camshaft Position Sensor Inspection...5317
        Speed Sensor Removal/Installation...5318
          Speed Sensor Inspection...5318
          Input Voltage Inspection...5318
            Special Tool -...5318
          Output Voltage Inspection...5318
            Special Tool -...5319
        This sensor has a weight [A] with two magnets inside, and sends ...5320
          Removal...5320
          Installation...5320
          Inspection...5320
            Special Tool -...5321
            Sealant -...5322
        Subthrottle Sensor Removal/Adjustment...5323
          Input Voltage Inspection...5323
            Special Tool -...5323
            Special Tool -...5324
          Output Voltage Inspection...5324
            Special Tool -...5324
            Special Tool -...5325
          Resistance Inspection...5326
        Exhaust Butterfly Valve Actuator Sensor Inspection...5327
        Antenna Resistance Inspection...5328
          Amplifier Input Voltage Inspection...5328
            Special Tool -...5328
        This code appears in the following conditions. ...5329
          User Key Inspection...5329
        Stick Coil ##1: Service Code 51...5331
          Removal/Installation...5331
          Input Voltage Inspection...5331
        Subthrottle Valve Actuator Removal...5333
          Subthrottle Valve Actuator Inspection...5333
          Resistance Inspection...5333
          Input Voltage Inspection...5334
            Special Tools -...5334
        Exhaust Butterfly Valve Actuator Removal...5335
          Exhaust Butterfly Valve Actuator Installation...5335
            Torque -...5335
            Torque -...5336
          Exhaust Butterfly Valve Actuator Inspection...5336
          Output Voltage Inspection...5337
            Special Tool -...5337
        CAUTION...5338
          ECU Identification...5338
          ECU Removal...5338
          ECU Installation...5339
          ECU Power Supply Inspection...5339
            Special Tool -...5339
          ECU Power Source Circuit...5340
        ECU Fuse Removal...5341
          ECU Fuse Installation...5341
          ECU Fuse Inspection...5341
        Light (LED) Inspection...5342
        Fuel Pressure Inspection...5343
          Special Tools -...5343
          Fuel Flow Rate Inspection...5344
        Fuel Pump Removal...5346
          Fuel Pump Installation...5346
            Torque -...5347
          Operation Inspection...5347
          Operating Voltage Inspection...5347
            Special Tools -...5347
        CAUTION...5349
          Audible Inspection...5349
          Injector Signal Test...5349
            Special Tool -...5350
          Injector Resistance Inspection...5350
            Special Tool -...5350
            Special Tool -...5351
          Injector Unit Test...5351
          Injector Voltage Inspection...5352
            Special Tool -...5352
            Special Tool -...5352
          Injector Fuel Line Inspection...5354
        Free Play Inspection...5356
          Free Play Adjustment...5356
          Cable Installation...5356
          Cable Lubrication...5356
        Idle Speed Inspection...5357
          Throttle Bore Cleaning...5357
          Synchronization Inspection...5357
          Synchronization Adjustment...5357
          Throttle Body Assy Removal...5357
          Throttle Body Assy Installation...5359
            Torque -...5359
          Throttle Body Assy Disassembly...5359
            Throttle Body Assy Assembly...5360
              Torque -...5360
        Nozzle Assy Removal...5361
          Nozzle Assy Installation...5361
            Torque -...5361
          Nozzle Assy Disassembly...5361
          Nozzle Assy Assembly...5362
            Torque -...5363
            Torque -...5363
        Element Removal...5364
          Element Installation...5364
          Air Cleaner Element Inspection...5364
          Air Cleaner Housing Removal...5364
          Air Cleaner Housing Installation...5365
            Torque -...5365
          Air Cleaner Housing Disassembly...5366
          Air Cleaner Housing Assembly...5366
          Oil Draining...5366
          Air Inlet Duct Removal...5366
          Air Inlet Duct Installation...5366
        Fuel Tank Removal...5367
          Fuel Tank Installation...5369
          Fuel Tank and Cap Inspection...5370
          Fuel Tank Cleaning...5370
        The Evaporative Emission Control System routes fuel vapors from ...5371
          Parts Removal/Installation...5371
          Hose Inspection...5371
          Separator Inspection...5371
          Separator Operation Test...5372
          Canister Inspection ...5372
      Cooling System...5374
        Bearing Driver, 32:...5378
        Coolant Deterioration Inspection...5381
          Coolant Level Inspection...5381
          Coolant Draining...5381
          Coolant Filling...5381
          Pressure Testing...5381
          Cooling System Flushing...5382
          Coolant Reserve Tank Removal...5382
          Coolant Reserve Tank Installation...5382
            Torque -...5382
        Water Pump Removal...5383
          Water Pump Installation...5383
          Water Pump Impeller Disassembly/Assembly...5383
            Torque -...5383
            Water Pump Impeller Inspection...5383
            Water Pump Housing Disassembly...5383
            Water Pump Housing Assembly...5384
              Special Tool -...5384
              Special Tool -...5384
            Mechanical Seal Inspection...5384
        Radiator and Radiator Fan Removal...5385
          Radiator and Radiator Fan Installation...5386
            Torque -...5389
            Torque -...5389
          Radiator Inspection...5390
          Radiator Cap Inspection...5390
          Radiator Filler Neck Inspection...5391
        Thermostat Removal...5392
          Thermostat Installation...5392
            Torque -...5393
          Thermostat Inspection...5393
        Hose Installation...5395
          Torque -...5395
          Hose Inspection...5395
        CAUTION...5396
          Water Temperature Sensor Removal...5396
          Water Temperature Sensor Inspection...5396
      Engine Top End...5398
        Exhaust System...5402
        Compression Gauge, 20 kgf/cm :...5406
        Air Suction Valve Removal...5408
          Air Suction Valve Installation...5408
            Torque -...5408
          Air Suction Valve Inspection...5408
          Vacuum Switch Valve Removal...5409
          Vacuum Switch Valve Installation...5409
          Vacuum Switch Valve Test...5409
            Special Tool -...5409
          Clean Air System Hose Inspection...5410
        Cylinder Head Cover Removal...5411
          Cylinder Head Cover Installation...5411
            Sealant -...5411
            Torque -...5412
        Camshaft Chain Tensioner Removal...5413
          Camshaft Chain Tensioner Installation...5413
            Torque -...5413
            Torque -...5413
        Camshaft Removal...5414
          Camshaft Installation...5414
            Torque -...5415
            Torque -...5415
          Camshaft, Camshaft Cap Wear...5416
            Torque -...5416
          Camshaft Runout...5416
          Cam Wear...5417
          Camshaft Chain Removal...5417
        Cylinder Compression Measurement...5418
          Special Tools -...5418
          Torque -...5418
          Cylinder Head Removal...5419
          Cylinder Head Installation...5419
            Torque -...5420
            Torque -...5420
            Torque -...5420
          Cylinder Head Warp...5420
        Valve Clearance Inspection...5421
          Valve Clearance Adjustment...5421
          Valve Removal...5421
            Special Tools -...5421
          Valve Installation...5421
          Valve Guide Removal...5421
            Special Tool -...5421
          Valve Guide Installation...5422
            Special Tools -...5422
            Special Tool -...5422
          Valve-to-Guide Clearance Measurement (Wobble Method)...5422
          Valve Seat Inspection...5423
          Valve Seat Repair...5423
            Special Tools -...5423
        Cylinder Removal...5428
          Cylinder Installation...5428
          Piston Removal...5429
            Special Tool -...5429
          Piston Installation...5429
          Cylinder Wear...5430
          Piston Wear...5430
          Piston Ring, Piston Ring Groove Wear...5431
          Piston Ring Groove Width...5431
          Piston Ring Thickness...5431
          Piston Ring End Gap...5432
        Throttle Body Holder Installation...5433
          Torque -...5433
        WARNING...5434
          Muffler Body Removal...5434
          Muffler Body Installation...5436
            Torque -...5436
          Exhaust Pipe Removal...5437
          Exhaust Pipe Installation...5438
            Torque -...5438
          Exhaust Butterfly Valve Cable Removal...5439
          Exhaust Butterfly Valve Cable Installation...5439
            Torque -...5440
            Torque -...5440
            Torque -...5440
      Clutch...5442
        Clutch Holder:...5446
        Clutch Lever Free Play Inspection...5447
          Clutch Lever Free Play Adjustment...5447
          Cable Removal...5447
          Cable Installation...5447
          Cable Lubrication...5447
          Clutch Lever Installation...5447
            Torque -...5447
        Clutch Cover Removal...5448
          Clutch Cover Installation...5448
            Sealant -...5448
            Torque -...5448
          Release Shaft Removal...5448
          Release Shaft Installation...5449
          Clutch Cover Disassembly...5449
          Clutch Cover Assembly...5449
        Clutch Removal...5450
          Special Tool -...5450
          Clutch Installation...5451
            Special Tool -...5454
            Torque -...5454
            Torque -...5454
          Spring Plate Free Play Measurement...5455
          Spring Plate Play Adjustment...5456
            Torque -...5456
          Clutch Plate, Wear, Damage Inspection...5456
          Clutch Plate Warp Inspection...5456
          Clutch Spring Free Length Measurement...5457
          Damper Cam Inspection...5457
      Engine Lubrication System...5458
        Outside Circlip Pliers:...5462
        WARNING...5465
          Oil Level Inspection...5465
          Engine Oil Change...5465
          Oil Filter Replacement...5465
        Oil Pan Removal...5466
          Oil Pan Installation...5466
            Torque -...5466
            Torque -...5466
        Oil Pressure Relief Valve Removal...5467
          Oil Pressure Relief Valve Installation...5467
          Oil Pressure Relief Valve Inspection...5467
        Oil Pump Removal...5468
          Oil Pump Installation...5468
            Torque -...5469
            Torque -...5469
            Torque -...5469
          Oil Pump Drive Gear Removal...5469
            Special Tool -...5469
          Oil Pump Drive Gear Installation...5470
          Special Tool -...5470
        Oil Cooler Removal...5471
          Oil Cooler Installation...5471
            Torque -...5471
            Torque -...5471
        Oil Pressure Measurement...5472
          Special Tools -...5472
          Torque -...5472
        Oil Pressure Switch Removal...5473
          Oil Pressure Switch Installation...5473
            Sealant -...5473
            Torque -...5473
            Torque -...5473
      Engine Removal/Installation...5474
        Engine Mount Nut Wrench:...5477
        Engine Removal...5478
          Special Tool -...5479
          Engine Installation...5480
            Torque -...5481
            Special Tool -...5481
            Torque -...5481
      Crankshaft/Transmission...5484
        Bearing Puller:...5491
        Crankcase Splitting...5492
          Crankcase Assembly...5493
            Sealant -...5493
            Torque -...5493
            Torque -...5493
            Sealant -...5494
            Torque -...5495
            Torque -...5495
            Torque -...5495
            Torque -...5495
            Torque -...5495
        Crankshaft Removal...5496
          Crankshaft Installation...5496
          Connecting Rod Removal...5497
          Connecting Rod Installation...5497
          Crankshaft/Connecting Rod Cleaning...5501
          Connecting Rod Bend...5501
          Connecting Rod Twist...5501
          Connecting Rod Big End Side Clearance...5501
          Connecting Rod Big End Bearing Insert/Crankpin Wear...5502
          Crankshaft Side Clearance...5503
          Crankshaft Runout...5504
          Crankshaft Main Bearing Insert/Journal Wear...5504
        Shift Pedal Removal...5506
          Shift Pedal Installation...5506
            Torque -...5506
            Torque -...5506
            Torque -...5506
          External Shift Mechanism Removal...5507
          External Shift Mechanism Installation...5507
            Torque -...5507
          External Shift Mechanism Inspection...5507
            Torque -...5507
          Transmission Shaft Removal...5508
          Transmission Shaft Installation...5508
          Transmission Shaft Disassembly...5508
            Special Tool -...5508
            Special Tools -...5509
          Transmission Shaft Assembly...5509
            Special Tool -...5509
          Shift Drum and Fork Removal...5512
          Shift Drum and Fork Installation...5512
            Torque -...5512
          Shift Drum Disassembly...5512
          Shift Drum Assembly...5512
            Torque -...5512
          Shift Fork Bending...5512
          Shift Fork/Gear Groove Wear...5513
          Shift Fork Guide Pin/Drum Groove Wear...5513
          Gear Dog and Gear Dog Hole Damage...5513
      Wheels/Tires...5514
        Bearing Driver Set:...5518
        Front Wheel Removal...5519
          Special Tools -...5519
          Front Wheel Installation...5519
            Torque -...5520
            Torque -...5520
          Rear Wheel Removal...5520
          Rear Wheel Installation...5521
            Torque -...5522
          Wheel Inspection...5523
            Special Tools -...5523
          Axle Inspection...5523
          Balance Inspection...5524
          Balance Adjustment...5524
          Balance Weight Removal...5524
          Balance Weight Installation...5524
        Air Pressure Inspection/Adjustment...5526
          Tire Inspection...5526
          Tire Removal...5526
          Tire Installation...5526
          Tire Repair...5528
        Hub Bearing Removal...5529
          Special Tools -...5529
          Hub Bearing Installation...5529
            Special Tool -...5529
            Special Tool -...5529
          Hub Bearing Inspection...5529
          Hub Bearing Lubrication...5530
      Final Drive...5532
        Inside Circlip Pliers:...5536
        Drive Chain Slack Inspection...5537
          Drive Chain Slack Adjustment...5537
          Wheel Alignment Inspection/Adjustment...5537
          Drive Chain Wear Inspection...5537
          Drive Chain Lubrication...5537
          Drive Chain Removal...5537
          Drive Chain Installation...5538
        Engine Sprocket Removal...5541
          Engine Sprocket Installation...5541
            Torque -...5541
            Torque -...5542
          Rear Sprocket Removal...5542
          Rear Sprocket Installation...5542
            Torque -...5542
          Coupling Installation...5542
          Coupling Bearing Removal...5543
            Special Tool -...5543
            Special Tool -...5543
          Coupling Bearing Installation...5543
            Special Tool -...5543
            Special Tool -...5543
            Special Tool -...5543
          Coupling Bearing Inspection...5544
          Coupling Bearing Lubrication...5544
          Coupling Damper Inspection...5544
          Sprocket Wear Inspection...5544
          Rear Sprocket Warp Inspection...5545
      Brakes...5546
        Inside Circlip Pliers:...5552
        Brake Lever Position Adjustment...5553
          Brake Pedal Position Inspection ...5553
          Brake Pedal Position Adjustment ...5553
            Torque -...5553
          Brake Pedal Removal...5553
          Brake Pedal Installation...5554
            Torque -...5554
            Torque -...5554
            Torque -...5554
        Front Caliper Removal...5555
          Rear Caliper Removal...5555
          Caliper Installation...5555
            Torque -...5555
          Front Caliper Disassembly...5556
          Front Caliper Assembly...5556
          Rear Caliper Disassembly...5556
          Rear Caliper Assembly...5556
          Caliper Fluid Seal Damage...5556
          Rear Caliper Dust Boot and Friction Boot Damage...5557
          Caliper Piston and Cylinder Damage...5557
          Rear Caliper Holder Shaft Wear...5557
        Front Brake Pad Removal...5558
          Front Brake Pad Installation...5558
            Torque -...5558
          Rear Brake Pad Removal ...5559
          Rear Brake Pad Installation...5559
          Brake Pad Wear Inspection...5559
        Front Master Cylinder Removal...5560
          Front Master Cylinder Installation...5560
            Torque -...5560
            Torque -...5560
          Rear Master Cylinder Removal...5561
          Rear Master Cylinder Installation...5561
            Torque -...5561
          Front Master Cylinder Disassembly...5561
          Rear Master Cylinder Disassembly...5561
          Master Cylinder Assembly...5561
          Master Cylinder Inspection (Visual Inspection)...5561
        Brake Disc Removal...5563
          Brake Disc Installation...5563
            Torque -...5563
          Brake Disc Wear...5563
          Brake Disc Warp...5563
            Special Tools -...5563
        Brake Fluid Level Inspection...5564
          Brake Fluid Change...5564
          Brake Line Bleeding...5564
            Torque -...5565
            Torque -...5566
        Brake Hose Removal/Installation...5568
          Brake Hose Inspection...5568
      Suspension...5570
        Inside Circlip Pliers:...5576
        Rebound Damping Force Adjustment...5578
          Compression Damping Force Adjustment...5578
          Spring Preload Adjustment...5579
          Front Fork Removal (Each Fork Leg)...5579
          Front Fork Installation...5580
            Torque -...5580
            Torque -...5580
          Front Fork Oil Change...5580
            Special Tools -...5580
            Special Tool -...5582
            Special Tool -...5583
            Special Tool -...5583
            Special Tool -...5583
            Special Tools -...5584
            Torque -...5584
          Front Fork Disassembly...5584
            Special Tool -...5584
          Front Fork Assembly...5585
            Special Tool -...5585
            Torque -...5585
            Special Tool -...5586
          Inner Tube Inspection...5586
          Dust Seal Inspection...5586
          Spring Tension...5587
        Rebound Damping Force Adjustment...5588
          Compression Damping Force Adjustment...5588
          Spring Preload Adjustment...5588
            Special Tools -...5588
            Special Tools -...5589
          Rear Shock Absorber Removal...5589
            Special Tools -...5589
          Rear Shock Absorber Installation...5590
            Torque -...5590
          Rear Shock Absorber Inspection...5590
          Rear Shock Absorber Scrapping...5590
        Swingarm Removal...5591
          Special Tool -...5592
          Swingarm Installation...5592
            Torque -...5592
            Special Tool -...5593
            Torque -...5593
            Torque -...5593
          Swingarm Bearing Removal...5593
            Special Tool -...5593
            Special Tool -...5593
          Swingarm Bearing Installation...5594
            Special Tools -...5594
          Swingarm Bearing, Sleeve Inspection...5594
          Chain Guide Inspection...5595
        Tie-Rod Removal...5596
          Special Tools -...5596
          Tie-Rod Installation...5596
            Torque -...5596
          Rocker Arm Removal...5596
            Special Tools -...5596
          Rocker Arm Installation...5597
            Torque -...5597
          Tie-Rod and Rocker Arm Bearing Removal...5597
            Special Tools -...5597
          Tie-Rod and Rocker Arm Bearing Installation...5597
            Special Tools -...5598
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...5599
          Rocker Arm/Tie-Rod Bearing Lubrication...5599
      Steering...5600
        Bearing Puller Adapter:...5603
        Steering Inspection...5604
          Steering Adjustment...5604
        Stem, Stem Bearing Removal...5605
          Special Tool -...5605
          Special Tool -...5605
          Special Tools -...5606
          Stem, Stem Bearing Installation...5606
            Special Tools -...5606
            Special Tools -...5606
            Special Tool -...5607
            Torque -...5607
            Torque -...5608
          Steering Stem Bearing Lubrication...5608
          Steering Stem Warp...5608
          Stem Cap Deterioration, Damage...5608
        Handlebar Removal...5609
          Handlebar Installation...5609
            Torque -...5609
            Torque -...5610
      Frame...5612
        Rear Seat Removal...5619
          Rear Seat Installation...5619
          Front Seat Removal...5619
          Front Seat Installation...5619
        Lower Fairing Removal...5620
          Lower Fairing Installation...5620
          Center Fairing Removal...5620
          Center Fairing Installation...5621
          Windshield Removal...5621
          Windshield Installation...5621
            Torque -...5621
          Upper Fairing Removal...5621
          Upper Fairing Disassembly...5622
            Upper Fairing Assembly...5622
            Upper Fairing Installation...5623
              Torque -...5623
            Upper Inner Fairing Removal...5623
            Upper Inner Fairing Installation...5623
            Center Inner Fairing Removal...5623
            Center Inner Fairing Installation...5623
            Right and Left Inner Fairing Removal...5624
            Right and Left Inner Fairing Installation...5624
        Left Side Cover Removal...5625
          Left Side Cover Installation...5625
          Right Side Cover Removal...5625
          Right Side Cover Installation...5625
        Seat Cover Removal...5626
          Seat Cover Installation...5626
        Front Fender Removal...5627
          Front Fender Installation...5627
            Torque -...5627
          Flap and Rear Fender Rear Removal...5627
          Flap and Rear Fender Rear Installation...5628
          Rear Fender Front Removal...5629
          Rear Fender Front Installation...5629
        Rear Frame Removal...5630
          Rear Frame Installation...5630
            Torque -...5630
          Frame Inspection...5630
        Side Stand Removal...5631
          Side Stand Installation...5631
            Torque -...5631
            Torque -...5631
      Electrical System...5632
        Flywheel Holder:...5650
        There are a number of important precautions that are musts when ...5651
        Wiring Inspection...5653
          Special Tool -...5653
        Battery Removal...5654
          Battery Installation...5654
          Battery Activation...5654
          Precautions...5657
            1)...5657
            2)...5657
            3)...5657
            4)...5657
          Interchange...5657
            Charging Condition Inspection...5658
            Refreshing Charge...5658
        Alternator Cover Removal...5660
          Alternator Cover Installation...5660
            Sealant -...5660
            Torque -...5660
          Stator Coil Removal...5660
          Stator Coil Installation...5661
            Torque -...5661
            Sealant -...5661
            Torque -...5661
          Alternator Rotor Removal...5661
            Special Tool -...5661
            Special Tool -...5661
          Alternator Rotor Installation...5661
            Special Tool -...5662
            Torque -...5662
          Alternator Inspection...5663
            Special Tool -...5663
          Regulator/Rectifier Removal...5664
          Regulator/Rectifier Inspection...5664
          Charging Voltage Inspection...5666
            Special Tool -...5666
          Charging System Circuit...5667
        Starter Motor Clutch Removal/Installation...5668
          Starter Motor Clutch Inspection...5668
          Starter Motor Clutch Disassembly...5668
          Starter Motor Clutch Assembly...5668
            Torque -...5668
          Crankshaft Sensor Removal...5670
          Crankshaft Sensor Installation...5671
            Torque -...5671
            Sealant -...5671
            Torque -...5671
          Crankshaft Sensor Inspection...5671
            Special Tool -...5671
          Crankshaft Sensor Peak Voltage...5671
            Special Tools -...5672
          Timing Rotor Removal...5672
            Special Tool -...5672
          Timing Rotor Installation...5672
            Torque -...5672
            Special Tool -...5672
          Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...5672
          Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...5673
          Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...5673
          Stick Coil Primary Peak Voltage...5674
            Special Tools -...5674
          Spark Plug Removal...5674
          Spark Plug Installation...5675
          Spark Plug Clean and Inspection...5675
          Spark Plug Gap Inspection...5675
          Camshaft Position Sensor Removal...5675
          Camshaft Position Sensor Installation...5675
            Torque -...5675
          Camshaft Position Sensor Inspection...5675
            Special Tool -...5676
          Camshaft Position Sensor Peak Voltage Inspection...5676
            Special Tools -...5676
          Interlock Operation Inspection...5677
          IC Igniter Inspection...5678
          Ignition System Circuit...5679
        Starter Motor Removal...5680
          Starter Motor Installation...5680
            Torque -...5680
          Starter Motor Disassembly...5680
          Starter Motor Assembly...5680
          Brush Inspection...5681
          Commutator Cleaning and Inspection...5682
          Armature Inspection...5682
            Special Tool -...5682
          Brush Lead Inspection...5682
            Special Tool -...5682
          Right-hand End Cover Assembly Inspection...5683
            Special Tool -...5683
          Starter Relay Inspection...5683
            Special Tool -...5683
          Electric Starter Circuit...5684
        This motorcycle adopt the daylight system and have a headlight r...5685
          Headlight Beam Horizontal Adjustment...5685
          Headlight Beam Vertical Adjustment...5685
          Headlight Bulb Replacement...5685
          City Light Bulb Replacement...5686
          Headlight Removal/Installation...5686
          Tail/Brake Light (LED) Removal...5687
          Tail/Brake Light (LED) Installation...5687
          License Plate Light Bulb Replacement...5687
          Headlight/Tail Light Circuit...5688
            Turn Signal Light Bulb Replacement...5689
            Turn Signal Relay Inspection...5690
          Turn Signal Light Circuit...5692
        Fan Motor Inspection...5693
          Radiator Fan Circuit...5694
        Meter Unit Removal...5695
          Meter Unit Disassembly...5695
          Electronic Combination Meter Assembly Inspection...5696
            Special Tool -...5696
            Special Tool -...5701
          Meter Circuit...5704
        This motorcycle is equipped with an immobilizer system to protec...5705
          Operational Cautions...5705
            Key Registration...5705
              Special Tool -...5706
          Spare User Key Registration Flow Chart...5710
            Special Tool -...5711
          All Keys Initial Registration Flow Chart...5720
            Immobilizer System Parts Replacement...5721
            Immobilizer System Inspection...5723
          Immobilizer System Circuit...5723
        Brake Light Timing Inspection...5724
          Brake Light Timing Adjustment...5724
          Neutral Switch Replacement...5724
            Torque -...5724
          Switch Inspection...5725
            Special Tool -...5725
          Rear Brake Light Switch Connections...5725
          Side Stand Switch Connections...5725
          Neutral Switch Connections...5725
          Oil Pressure Switch Connections *...5725
          Water Temperature Sensor Inspection...5726
          Speed Sensor Removal...5726
          Speed Sensor Installation...5726
            Torque -...5726
          Speed Sensor Inspection...5727
            Special Tool -...5727
          Fuel Reserve Switch Inspection...5727
            Special Tool -...5727
        The relay box [A] has relays and diodes. The relays and diodes c...5728
          Relay Box Removal...5728
          Relay Circuit Inspection...5728
          Diode Circuit Inspection...5730
          Relay Box Internal Circuit (ZX636-C1 Models of ZX636CE000001 thr...5730
          Relay Box Internal Circuit (After ZX636CE013061 of ZX636C Models...5731
        30 A Main Fuse Removal...5732
          Fuse Box Fuse Removal...5732
          15 A ECU Fuse Removal...5732
          Fuse Installation...5733
          Fuse Inspection...5733
      Appendix...5734
        California Model...5759
        NOTE...5761
          Engine Doesn't Start, Starting Difficulty:...5761
            Starter motor not rotating:...5761
            Starter motor rotating but engine doesn't turn over:...5761
            Engine won't turn over:...5761
            No fuel flow:...5761
            No spark; spark weak:...5761
            Fuel/air mixture incorrect:...5761
            Compression Low:...5761
          Poor Running at Low Speed:...5761
            Spark weak:...5761
            Fuel/air mixture incorrect:...5761
            Compression low:...5761
            Other:...5762
          Poor Running or No Power at High Speed:...5762
            Firing incorrect:...5762
            Fuel/air mixture incorrect:...5762
            Compression low:...5762
            Knocking:...5762
            Miscellaneous:...5762
          Overheating:...5762
            Firing incorrect:...5762
            Muffler overheating:...5762
            Fuel/air mixture incorrect:...5762
            Compression high:...5762
            Engine load faulty:...5762
            Lubrication inadequate:...5763
            Oil cooler incorrect:...5763
            Gauge incorrect:...5763
            Coolant incorrect:...5763
            Cooling system component incorrect:...5763
          Over Cooling:...5763
            Gauge incorrect:...5763
            Cooling system component incorrect:...5763
          Clutch Operation Faulty:...5763
            Clutch slipping:...5763
            Clutch not disengaging properly:...5763
          Gear Shifting Faulty:...5763
            Doesn't go into gear; shift pedal doesn't return:...5763
            Jumps out of gear:...5763
            Overshifts:...5763
          Abnormal Engine Noise:...5763
            Knocking:...5763
            Piston slap:...5763
            Valve noise:...5763
            Other noise:...5763
          Abnormal Drive Train Noise:...5764
            Clutch noise:...5764
            Transmission noise:...5764
            Drive line noise:...5764
          Abnormal Frame Noise:...5764
            Front fork noise:...5764
            Rear shock absorber noise:...5764
            Disc brake noise:...5764
            Other noise:...5764
          Oil Pressure Warning Light Goes On:...5764
          Exhaust Smokes Excessively:...5764
            White smoke:...5764
            Black smoke:...5764
            Brown smoke:...5764
          Handling and/or Stability Unsatisfactory:...5764
            Handlebar hard to turn:...5764
            Handlebar shakes or excessively vibrates:...5764
            Handlebar pulls to one side:...5764
            Shock absorption unsatisfactory:...5764
          Brake Doesn't Hold:...5765
          Battery Trouble:...5765
            Battery discharged:...5765
            Battery overcharged:...5765
Kawasaki Motorcycle Service Repair Manual '05-'06 ZX-6RR (EN)...5767
  tables...0
    LIST OF ABBREVIATIONS...5770
    Units of Mass...5786
    Units of Volume...5786
    Units of Force...5786
    Units of Length...5786
    Units of Torque...5786
    Units of Pressure...5786
    Units of Speed...5786
    Units of Power...5786
    Periodic Inspection...5789
    Periodic Replacement Parts...5791
    Periodic Inspection...5792
    Periodic Replacement Parts...5794
    Basic Torque for General Fasteners...5800
    Throttle Grip Free Play...5804
    Engine Vacuum...5805
    Example:...5805
    Main Throttle Sensor Output Voltage...5807
    Idle Speed...5807
    Valve Clearance...5810
    Example:...5812
    Adjustment Shims...5813
    Clutch Lever Free Play...5814
    Air Pressure (when Cold)...5815
    Tread Depth...5816
    Chain Slack...5818
    Drive Chain 20-link Length...5820
    Standard Chain...5820
    Recommended Disc Brake Fluid...5822
    Pad Lining Thickness...5822
    Side Stand Switch Operation...5830
    Water and Coolant Mixture Ratio (Recommended)...5837
    Recommended Engine Oil...5839
    Terminal Names...5866
    Sample Diagnosis Sheet...5873
    Engine Doesn't Start, Starting Difficulty...5875
    Poor Running at Low Speed...5877
    Poor Running or No Power at High Speed:...5880
    Service Code Table...5886
    Main Throttle Sensor Input Voltage...5890
    Input Voltage at ECU Connector...5890
    Main Throttle Sensor Input Voltage...5891
    Input Voltage at Sensor...5891
    Main Throttle Sensor Output Voltage...5891
    Idle Speed...5891
    Output Voltage at ECU...5891
    Main Throttle Sensor Output Voltage...5892
    Output Voltage at Sensor...5892
    Main Throttle Sensor Resistance...5893
    Inlet Air Pressure Sensor Input Voltage...5894
    Input Voltage at ECU...5894
    Inlet Air Pressure Sensor Input Voltage...5895
    Input Voltage at Sensor Connector...5895
    Inlet Air Pressure Sensor Output Voltage...5895
    Output Voltage at ECU...5895
    Inlet Air Pressure Sensor Output Voltage...5896
    Output Voltage at Sensor Connector...5896
    Inlet Air Pressure Sensor Output Voltage Connection to Sensor...5897
    Inlet Air Temperature Sensor Output Voltage...5899
    Output Voltage at ECU...5899
    Inlet Air Temperature Sensor Resistance...5900
    Water Temperature Sensor Output Voltage...5902
    Output Voltage at ECU...5902
    Atmospheric Pressure Sensor Input Voltage...5904
    Input Voltage at ECU...5904
    Atmospheric Pressure Sensor Input Voltage...5905
    Input Voltage at Sensor Connector...5905
    Atmospheric Pressure Sensor Output Voltage...5905
    Output Voltage...5905
    Atmospheric Pressure Sensor Output Voltage...5906
    Output Voltage at Sensor...5906
    Speed Sensor Input Voltage...5910
    Input Voltage at Sensor...5910
    Speed Sensor Output Voltage...5911
    Output Voltage at Sensor ...5911
    Vehicle-down Sensor Input Voltage...5913
    Power Source Voltage at Sensor...5913
    Vehicle-down Sensor Output Voltage...5913
    Output Voltage at Sensor...5913
    Subthrottle Sensor Input Voltage...5915
    Input Voltage at ECU Connector...5915
    Subthrottle Sensor Input Voltage...5916
    Input Voltage at Sensor...5916
    Subthrottle Sensor Output Voltage...5916
    Output Voltage at ECU...5916
    Subthrottle Sensor Output Voltage...5917
    Output Voltage at Sensor...5917
    Subthrottle Sensor Resistance...5918
    Exhaust Butterfly Valve Actuator Sensor Resistance...5919
    Stick Coil Input Voltage at ECU...5920
    Input Voltage at ECU...5920
    Subthrottle Valve Actuator Resistance...5922
    Subthrottle Valve Actuator Input Voltage...5923
    Input Voltage at Sensor...5923
    Connections...5926
    Actuator Output Voltage (Pulley Original Position)...5926
    ECU Grounding Inspection...5928
    ECU Power Source Inspection...5928
    FI Indicator Light (LED) Check...5931
    Fuel Pressure...5932
    Fuel Pressure (Idling)...5933
    Amount of Fuel Flow...5934
    Pump Operating Voltage at Pump...5936
    Operating Voltage at Pump Connector...5936
    Primary Fuel Injector Resistance...5939
    Secondary Fuel Injector Resistance...5940
    Primary Fuel Injector Power Source Voltage...5940
    Secondary Fuel Injector Power Source Voltage...5940
    Power Source Voltage at Fuel Injector Connector...5940
    Primary Fuel Injector Output Voltage...5941
    Secondary Fuel Injector Output Voltage...5941
    Output Voltage at Fuel Injector Connector...5941
    Fuel Line Maximum Pressure...5942
    Radiator Cap Relief Pressure...5977
    Thermostat Valve Opening Temperature...5979
    Vacuum Switch Valve Closing Pressure (Open → Close)...5994
    Camshaft Journal, Camshaft Cap Clearance...6001
    Camshaft Journal Diameter...6001
    Camshaft Runout...6001
    Cam Height...6002
    Cylinder Compression...6003
    Cylinder Head Warp...6005
    Valve/Valve Guide Clearance (Wobble Method)...6008
    Valve Seating Surface Outside Diameter...6008
    Valve Seating Surface Width...6008
    Cylinder Inside Diameter...6015
    Piston Diameter...6015
    Piston Ring/Groove Clearance...6016
    Piston Ring Groove Width...6016
    Piston Ring Thickness...6016
    Piston Ring End Gap...6017
    Spring Plate Free Play ...6039
    Clutch Plate Assembly Length...6039
    Friction Plate Thickness...6040
    Friction and Steel Plate Warp...6040
    Clutch Spring Free Length...6040
    Oil Pressure...6056
    Connecting Rod Big End Bearing Insert Selection...6073
    Crankshaft Main Bearing Insert Selection...6073
    Connecting Rod Bend...6083
    Connecting Rod Twist...6083
    Connecting Rod Big End Side Clearance...6083
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...6084
    Crankpin Diameter...6084
    Crankpin Diameter Marks...6084
    Connecting Rod Big End Inside Diameter Marks...6085
    Crankshaft Side Clearance...6085
    Crankshaft Runout...6086
    Crankshaft Main Bearing Insert/Journal Clearance...6086
    Crankshaft Main Journal Diameter...6086
    Crankshaft Main Journal Diameter Marks...6086
    Crankcase Main Bearing Inside Diameter Marks...6087
    Shift Fork Ear Thickness...6095
    Gear Groove Width...6095
    Shift Fork Guide Pin Diameter...6095
    Shift Drum Groove Width...6095
    Rim Runout (with tire installed)...6106
    Axle Runout/100 mm (3.94 in.)...6106
    Balance Weight...6107
    Link Pin Outside Diameter...6123
    Link Plates Outside Width...6123
    Rear Sprocket Warp...6128
    Pedal Position...6136
    Brake Discs Thickness...6146
    Disc Runout...6146
    Rebound Damping Force Adjustment...6161
    Compression Damping Force Adjustment...6161
    Adjuster Protrusion (from top)...6162
    Spring Action...6162
    Fork Oil...6165
    Oil Level (fully compressed, without spring)...6166
    Spring Free Length...6169
    Rebound Damping Force Adjustment...6170
    Compression Damping Force Adjustment...6170
    Compression Damping Force Adjustment...6171
    Spring Preload Setting...6172
    Spring Adjustment...6172
    Kawasaki-recommended chargers...6237
    Battery Terminal Voltage...6239
    Terminal Voltage: 11.5 ∼ less than 12.8 V...6239
    Terminal Voltage: less than 11.5 V...6239
    Table 1 Alternator Output Voltage...6244
    Table 2 Stator Coil Resistance...6244
    Charging Voltage...6247
    Crankshaft Sensor Peak Voltage...6253
    Ignition Coil Winding Resistance...6254
    Primary Lead Connection...6255
    Stick Coil Primary Peak Voltage...6255
    Connections:...6257
    Camshaft Position Sensor Peak Voltage...6257
    Condition...6258
    Condition...6258
    Condition...6258
    Starter Motor Brush Length...6262
    Commutator Diameter...6263
    Testing Relay...6264
    Testing Turn Signal Relay...6271
    Testing Turn Signal Relay...6272
    Water Temperature Sensor...6286
    Connections...6287
    Relay Circuit Inspection (with the battery disconnected)...6288
    Relay Circuit Inspection (with the battery connected)...6289
    Diode Circuit Inspection...6289
  toc...0
    Read OWNER'S MANUAL before operating...5770
      EMISSION CONTROL INFORMATION...5771
        1...5771
        2...5771
        3...5771
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...5772
      Foreword...5773
      General Information...5775
        Before starting to perform an inspection service or carry out a ...5776
          Battery Ground...5776
          Edges of Parts...5776
          Solvent...5776
          Cleaning vehicle before disassembly...5776
          Arrangement and Cleaning of Removed Parts...5777
          Storage of Removed Parts...5777
          Inspection...5777
          Replacement Parts...5777
          Assembly Order...5777
          Tightening Sequence...5778
          Tightening Torque...5778
          Force...5778
          Gasket, O-ring...5778
          Liquid Gasket, Non-permanent Locking Agent...5778
          Press...5779
          Ball Bearing and Needle Bearing...5779
          Oil Seal, Grease Seal...5779
          Circlips, Cotter Pins...5779
          Lubrication...5780
          Direction of Engine Rotation...5780
          Electrical Leads...5780
          Instrument...5780
        ZX600-N1 (Europe) Left Side View...5781
        ZX600-N1 (Europe) Right Side View...5781
        ZX600-N1 (US and Canada) Left Side View...5782
        ZX600-N1 (US and Canada) Right Side View...5782
        Prefixes for Units...5786
        Units of Temperature...5786
      Periodic Maintenance...5787
        The scheduled maintenance must be done in accordance with this c...5789
        The scheduled maintenance must be done in accordance with this c...5792
        The following tables list the tightening torque for the major fa...5795
        Inside Circlip Pliers:...5803
        Fuel System (DFI)...5804
          Throttle Control System Inspection...5804
          Engine Vacuum Synchronization Inspection...5804
            Special Tool -...5805
            Special Tool -...5805
          Idle Speed Inspection...5807
          Idle Speed Adjustment...5808
          Fuel Hose Damage and Installation Condition Inspection...5808
          Evaporative Emission Control System Inspection (California Model...5808
          Cooling System...5809
            Coolant Level Inspection...5809
            Water Hose Damage and Installation Condition Inspection...5810
              Torque -...5810
          Engine Top End...5810
            Valve Clearance Inspection...5810
            Valve Clearance Adjustment...5811
            Air Suction System Damage Inspection...5814
          Clutch...5814
            Clutch Operation Inspection ...5814
          Wheels/Tires...5815
            Air Pressure Inspection...5815
            Wheel/Tire Damage Inspection...5816
            Tire Tread Wear Inspection ...5816
            Wheel Bearing Damage Inspection...5817
          Final Drive...5817
            Drive Chain Lubrication Condition Inspection...5817
            Drive Chain Slack Inspection...5818
            Drive Chain Slack Adjustment...5819
              Torque -...5819
            Wheel Alignment Inspection...5820
            Drive Chain Wear Inspection...5820
            Chain Guide Wear Inspection...5821
          Brakes...5821
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...5821
            Brake Hose Damage and Installation Condition Inspection...5821
              Torque -...5821
            Brake Operation Inspection...5821
            Brake Fluid Level Inspection...5822
            Brake Pad Wear Inspection...5822
            Brake Light Switch Operation Inspection...5823
          Suspension...5823
            Front Forks/Rear Shock Absorber Operation Inspection...5823
            Front Fork Oil Leak Inspection...5824
            Rear Shock Absorber Oil Leak Inspection...5824
            Rocker Arm Operation Inspection...5824
            Tie-Rod Operation Inspection...5824
          Steering...5825
            Steering Play Inspection...5825
              Special Tools -...5825
            Steering Play Adjustment...5825
              Special Tool -...5825
              Torque -...5826
            Steering Stem Bearing Lubrication...5826
          Electrical System...5826
            Spark Plug Clean and Gap Inspection...5826
            Lights and Switches Operation Inspection...5827
            Headlight Aiming Inspection...5829
            Side Stand Switch Operation Inspection...5830
            Engine Stop Switch Operation Inspection...5831
          Others...5832
            Chassis Parts Lubrication ...5832
              Pivots: Lubricate with Grease...5832
              Points: Lubricate with Grease...5832
              Cables: Lubricate with Rust Inhibitor...5832
            Bolts, Nuts and Fasteners Tightness Inspection...5833
              Bolt, Nut and Fastener to be checked...5833
          Replacement Parts...5834
            Air Cleaner Element Replacement...5834
            Fuel Hose Replacement...5834
            Coolant Change...5836
              Torque -...5836
            Radiator Hose and O-ring Replacement...5838
              Engine Oil Change...5839
                Torque -...5839
              Oil Filter Replacement...5839
                Special Tool -...5839
                Torque -...5839
              Brake Hose and Pipe Replacement...5840
                Torque -...5840
              Brake Fluid Change...5840
                Torque -...5841
                Torque -...5841
              Master Cylinder Rubber Parts Replacement...5842
                Special Tool -...5842
                Special Tool -...5842
                Torque -...5843
              Caliper Rubber Parts Replacement...5843
                Torque -...5844
              Spark Plug Replacement...5846
                Owner's Tool -...5846
                Torque -...5846
      Fuel System (DFI)...5847
        Dummy Page...5849
        Oil Pressure Gauge, 5 kgf/cm 2:...5858
        Subthrottle Sensor [A]...5860
        DFI System...5862
        DFI System Wiring Diagram...5864
        Terminal Numbers of ECU Connectors...5866
        There are a number of important precautions that should be follo...5867
          Torque -...5867
        Outline...5868
          Special Tool -...5868
          Sealant -...5869
          Special Tool -...5869
          DFI Diagnosis Flow Chart...5872
          Inquiries to Rider...5872
        NOTE...5875
        Self-diagnosis Outline...5883
          Self-diagnosis Procedures...5883
          Service Code Clearing Procedures...5884
            Service Code Reading...5886
            Service Code Erasing...5886
          Backups...5888
        The main throttle sensor is a rotating variable resistor that ch...5890
          Main Throttle Sensor Removal/Adjustment...5890
          Main Throttle Sensor Input Voltage Inspection...5890
            Special Tool -...5890
            Special Tool -...5891
          Main Throttle Sensor Output Voltage Inspection...5891
            Special Tool -...5891
            Special Tool -...5892
          Main Throttle Sensor Resistance Inspection...5893
        CAUTION...5894
          Inlet Air Pressure Sensor Removal...5894
          Inlet Air Pressure Sensor Installation...5894
          Inlet Air Pressure Sensor Input Voltage Inspection...5894
            Special Tool -...5894
            Special Tool -...5895
          Inlet Air Temperature Sensor Output Voltage Inspection...5895
            Special Tool -...5896
            Special Tools -...5897
        Inlet Air Temperature Sensor Removal/Installation...5899
          Inlet Air Temperature Sensor Output Voltage Inspection...5899
            Special Tool -...5899
            Sealant -...5900
          Inlet Air Temperature Sensor Resistance Inspection...5900
        Water Temperature Sensor Removal/Installation...5902
          Sealant -...5902
          Torque -...5902
          Water Temperature Sensor Output Voltage Inspection...5902
            Special Tool -...5902
            Sealant -...5903
          Water Temperature Sensor Resistance Inspection...5903
        CAUTION...5904
          Atmospheric Pressure Sensor Removal...5904
          Atmospheric Pressure Sensor Installation...5904
          Atmospheric Pressure Sensor Input Voltage Inspection...5904
            Special Tool -...5904
            Special Tool -...5905
          Atmospheric Pressure Sensor Output Voltage Inspection...5905
            Special Tool -...5906
          Atmospheric Pressure/Altitude Relationship...5907
        Crankshaft Sensor Removal/Installation...5908
          Crankshaft Sensor Inspection...5908
        Camshaft Position Sensor Removal/Installation...5909
          Camshaft Position Sensor Inspection...5909
        Speed Sensor Removal/Installation...5910
          Speed Sensor Inspection...5910
          Speed Sensor Input Voltage Inspection...5910
            Special Tool -...5910
          Speed Sensor Output Voltage Inspection...5910
            Special Tool -...5911
        This sensor has a weight [A] with two magnets inside, and sends ...5912
          Vehicle-down Sensor Removal...5912
          Vehicle-down Sensor Installation...5912
          Vehicle-down Sensor Inspection...5912
            Special Tool -...5913
            Sealant -...5914
        Subthrottle Sensor Removal/Adjustment...5915
          Subthrottle Sensor Input Voltage Inspection...5915
            Special Tool -...5915
            Special Tool -...5916
          Subthrottle Sensor Output Voltage Inspection...5916
            Special Tool -...5916
            Special Tool -...5917
          Subthrottle Sensor Resistance Inspection...5918
        Exhaust Butterfly Valve Actuator Sensor Inspection...5919
        Stick Coil ##1: Service Code 51...5920
          Stick Coils Removal/Installation...5920
          Stick Coils Input Voltage Inspection...5920
        Subthrottle Valve Actuator Removal...5922
          Subthrottle Valve Actuator Inspection...5922
          Subthrottle Valve Actuator Resistance Inspection...5922
          Subthrottle Valve Actuator Input Voltage Inspection...5923
            Special Tools -...5923
        Exhaust Butterfly Valve Actuator Removal...5924
          Exhaust Butterfly Valve Actuator Installation...5924
            Torque -...5924
            Torque -...5925
          Exhaust Butterfly Valve Actuator Inspection...5925
          Exhaust Butterfly Valve Actuator Output Voltage Inspection...5926
            Special Tool -...5926
        CAUTION...5927
          ECU Removal...5927
          ECU Installation...5927
          ECU Power Supply Inspection...5928
            Special Tool -...5928
          ECU Power Source Circuit...5929
        ECU Fuse Removal...5930
          ECU Fuse Installation...5930
          ECU Fuse Inspection...5930
        Light (LED) Inspection...5931
        Fuel Pressure Inspection...5932
          Special Tools -...5932
          Fuel Flow Rate Inspection...5933
        Fuel Pump Removal...5935
          Fuel Pump Installation...5935
            Torque -...5936
          Fuel Pump Operation Inspection...5936
          Fuel Pump Operating Voltage Inspection...5936
            Special Tools -...5936
        CAUTION...5938
          Fuel Injector Audible Inspection...5938
          Fuel Injector Signal Test...5938
            Special Tool -...5939
          Fuel Injector Resistance Inspection...5939
            Special Tool -...5939
            Special Tool -...5939
          Fuel Injector Unit Test...5940
          Fuel Injector Voltage Inspection...5940
            Special Tool -...5940
            Special Tool -...5941
          Fuel Injector Fuel Line Inspection...5942
        Throttle Grip Free Play Inspection...5944
          Throttle Grip Free Play Adjustment...5944
          Cable Installation...5944
          Cable Lubrication...5944
        Idle Speed Inspection...5945
          Throttle Bore Cleaning...5945
          Synchronization Inspection...5945
          Synchronization Adjustment...5945
          Throttle Body Assy Removal...5945
          Throttle Body Assy Installation...5946
            Torque -...5947
          Throttle Body Assy Disassembly...5947
            Throttle Body Assy Assembly...5948
              Torque -...5948
        Nozzle Assy Removal...5949
          Nozzle Assy Installation...5949
            Torque -...5949
          Nozzle Assy Disassembly...5949
          Nozzle Assy Assembly...5950
            Torque -...5951
            Torque -...5951
        Air Cleaner Element Removal...5952
          Air Cleaner Element Installation...5952
          Air Cleaner Element Inspection...5952
          Air Cleaner Housing Removal...5952
          Air Cleaner Housing Installation...5953
            Torque -...5953
          Air Cleaner Housing Disassembly...5954
          Air Cleaner Housing Assembly...5954
            Adhesive -...5954
            Adhesive -...5954
          Oil Draining...5954
          Air Inlet Duct Removal...5954
          Air Inlet Duct Installation...5954
        Fuel Tank Removal...5955
          Fuel Tank Installation...5957
          Fuel Tank and Cap Inspection...5958
          Fuel Tank Cleaning...5958
        The Evaporative Emission Control System routes fuel vapors from ...5959
          Parts Removal/Installation...5959
          Hose Inspection...5959
          Separator Inspection...5959
          Separator Operation Test...5960
          Canister Inspection ...5960
      Cooling System...5961
        Bearing Driver, 32:...5965
        Coolant Deterioration Inspection...5968
          Coolant Level Inspection...5968
          Coolant Draining...5968
          Coolant Filling...5968
          Pressure Testing...5968
          Cooling System Flushing...5969
          Coolant Reserve Tank Removal...5969
          Coolant Reserve Tank Installation...5969
            Torque -...5969
        Water Pump Removal...5970
          Water Pump Installation...5970
          Water Pump Impeller Disassembly/Assembly...5970
            Torque -...5970
            Water Pump Impeller Inspection...5970
            Water Pump Housing Disassembly...5970
            Water Pump Housing Assembly...5971
              Special Tool -...5971
              Special Tool -...5971
            Mechanical Seal Inspection...5971
        Radiator and Radiator Fan Removal...5972
          Radiator and Radiator Fan Installation...5973
          Torque -...5976
          Torque -...5976
            Radiator Inspection...5976
            Radiator Cap Inspection...5977
            Radiator Filler Neck Inspection...5977
        Thermostat Removal...5978
          Thermostat Installation...5978
          Torque -...5978
            Thermostat Inspection...5979
        Hose Installation...5980
          Torque -...5980
          Hose Inspection...5980
        CAUTION...5981
          Water Temperature Sensor Removal...5981
            Torque -...5981
          Water Temperature Sensor Inspection...5981
      Engine Top End...5983
        Exhaust System...5987
        Compression Gauge, 20 kgf/cm 2:...5991
        Air Suction Valve Removal...5993
          Air Suction Valve Installation...5993
            Torque -...5993
          Air Suction Valve Inspection...5993
          Vacuum Switch Valve Removal...5994
          Vacuum Switch Valve Installation...5994
          Vacuum Switch Valve Test...5994
            Special Tool -...5994
          Clean Air System Hose Inspection...5995
        Cylinder Head Cover Removal...5996
          Cylinder Head Cover Installation...5996
            Sealant -...5996
            Torque -...5997
        Camshaft Chain Tensioner Removal...5998
          Camshaft Chain Tensioner Installation...5998
            Torque -...5998
            Torque -...5998
        Camshaft Removal...5999
          Camshaft Installation...5999
            Torque -...6000
            Torque -...6000
          Camshaft, Camshaft Cap Wear Inspection...6001
            Torque -...6001
          Camshaft Runout Inspection...6001
          Cam Wear Inspection...6002
          Camshaft Chain Removal...6002
        Cylinder Compression Measurement...6003
          Special Tools -...6003
          Torque -...6003
          Cylinder Head Removal...6004
          Cylinder Head Installation...6004
            Torque -...6005
            Torque -...6005
            Torque -...6005
          Cylinder Head Warp Inspection...6005
        Valve Clearance Inspection...6006
          Valve Clearance Adjustment...6006
          Valve Removal...6006
            Special Tools -...6006
          Valve Installation...6006
          Valve Guide Removal...6006
            Special Tool -...6006
          Valve Guide Installation...6007
            Special Tools -...6007
            Special Tool -...6007
          Valve/Valve Guide Clearance Measurement (Wobble Method)...6007
          Valve Seat Inspection...6008
          Valve Seat Repair...6008
            Special Tools -...6008
        Cylinder Removal...6013
          Cylinder Installation...6013
          Piston Removal...6014
            Special Tool -...6014
          Piston Installation...6014
          Cylinder Wear Inspection...6015
          Piston Wear Inspection...6015
          Piston Ring, Piston Ring Groove Wear Inspection...6016
          Piston Ring Groove Width Inspection...6016
          Piston Ring Thickness Inspection...6016
          Piston Ring End Gap Inspection...6017
        Throttle Body Holder Installation...6018
          Torque -...6018
        Muffler Body Removal...6019
          Muffler Body Installation...6020
            Torque -...6020
              Exhaust Pipe Manifold Removal...6021
          Exhaust Pipe Manifold Installation...6022
            Torque -...6022
              Exhaust Butterfly Valve Cable Removal...6023
              Exhaust Butterfly Valve Cable Installation...6023
                Torque -...6024
            Torque -...6024
            Torque -...6024
      Clutch...6027
        Clutch Holder:...6031
        Clutch Lever Free Play Inspection...6032
          Clutch Lever Free Play Adjustment...6032
          Cable Removal...6032
          Cable Installation...6032
          Cable Lubrication...6032
          Clutch Lever Installation...6032
            Torque -...6032
        Clutch Cover Removal...6033
          Clutch Cover Installation...6033
            Sealant -...6033
            Torque -...6033
          Release Shaft Removal...6033
          Release Shaft Installation...6034
          Clutch Cover Disassembly...6034
          Clutch Cover Assembly...6034
        Clutch Removal...6035
          Special Tool -...6035
          Clutch Installation...6035
            Special Tool -...6037
            Torque -...6037
            Torque -...6038
          Spring Plate Free Play Measurement...6038
          Spring Plate Play Adjustment...6039
            Torque -...6039
          Clutch Plate, Wear, Damage Inspection...6040
          Clutch Plate Warp Inspection...6040
          Clutch Spring Free Length Measurement...6040
          Damper Cam Inspection...6040
      Engine Lubrication System...6041
        Outside Circlip Pliers:...6045
        WARNING...6048
          Oil Level Inspection...6048
          Engine Oil Change...6048
          Oil Filter Replacement...6048
        Oil Pan Removal...6049
          Oil Pan Installation...6049
            Torque -...6049
            Torque -...6050
        Oil Pressure Relief Valve Removal...6051
          Oil Pressure Relief Valve Installation...6051
          Oil Pressure Relief Valve Inspection...6051
        Oil Pump Removal...6052
          Oil Pump Installation...6052
            Torque -...6053
            Torque -...6053
            Torque -...6053
          Oil Pump Drive Gear Removal...6053
            Special Tool -...6053
          Oil Pump Drive Gear Installation...6054
          Special Tool -...6054
        Oil Cooler Removal...6055
          Oil Cooler Installation...6055
            Torque -...6055
            Torque -...6055
        Oil Pressure Measurement...6056
          Special Tools -...6056
          Torque -...6056
        Oil Pressure Switch Removal...6057
          Oil Pressure Switch Installation...6057
            Sealant -...6057
            Torque -...6057
            Torque -...6057
      Engine Removal/Installation...6059
        Engine Mount Nut Wrench:...6062
        Engine Removal...6063
          Special Tool -...6064
          Engine Installation...6065
          Torque -...6065
          Torque -...6065
          Torque -...6065
          Torque -...6065
          Special Tool -...6065
          Torque -...6065
      Crankshaft/Transmission...6067
        Bearing Puller:...6074
        Crankcase Splitting...6075
          Crankcase Assembly...6076
            Sealant -...6076
            Torque -...6076
            Torque -...6076
          Sealant -...6077
            Torque -...6078
            Torque -...6078
            Torque -...6078
            Torque -...6078
            Torque -...6078
        Crankshaft Removal...6079
          Crankshaft Installation...6079
          Connecting Rod Removal...6079
          Connecting Rod Installation...6079
          Crankshaft/Connecting Rod Cleaning...6083
          Connecting Rod Bend Inspection...6083
          Connecting Rod Twist Inspection...6083
          Connecting Rod Big End Side Clearance Inspection...6083
          Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection...6084
          Crankshaft Side Clearance Inspection...6085
          Crankshaft Runout Inspection...6086
          Crankshaft Main Bearing Insert/Journal Wear Inspection...6086
        Shift Pedal Removal...6088
          Shift Pedal Installation...6088
            Torque -...6088
            Torque -...6088
            Torque -...6088
          External Shift Mechanism Removal...6089
          External Shift Mechanism Installation...6089
            Torque -...6089
          External Shift Mechanism Inspection...6089
            Torque -...6089
          Transmission Shaft Removal...6090
          Transmission Shaft Installation...6090
          Transmission Shaft Disassembly...6090
            Special Tool -...6090
            Special Tools -...6091
          Transmission Shaft Assembly...6091
            Special Tool -...6091
          Shift Drum and Fork Removal...6094
          Shift Drum and Fork Installation...6094
            Torque -...6094
          Shift Drum Disassembly...6094
          Shift Drum Assembly...6094
            Torque -...6094
          Shift Fork Bending...6094
          Shift Fork/Gear Groove Wear Inspection...6095
          Shift Fork Guide Pin/Drum Groove Wear Inspection...6095
          Gear Dog and Gear Dog Hole Damage Inspection...6095
      Wheels/Tires...6097
        Bearing Driver Set:...6101
        Front Wheel Removal...6102
          Special Tools -...6102
          Front Wheel Installation...6102
            Torque -...6103
            Torque -...6103
          Rear Wheel Removal...6103
          Rear Wheel Installation...6104
            Torque -...6105
          Wheel Inspection...6105
            Special Tools -...6105
          Axle Inspection...6106
          Balance Inspection...6106
          Balance Adjustment...6107
          Balance Weight Removal...6107
          Balance Weight Installation...6107
        Air Pressure Inspection/Adjustment...6109
          Tire Inspection...6109
          Tire Removal...6109
          Tire Installation...6109
          Tire Repair...6111
        Hub Bearing Removal...6112
          Special Tools -...6112
          Hub Bearing Installation...6112
            Special Tool -...6112
            Special Tool -...6112
          Hub Bearing Inspection...6112
          Hub Bearing Lubrication...6113
      Final Drive...6115
        Inside Circlip Pliers:...6119
        Drive Chain Slack Inspection...6120
          Drive Chain Slack Adjustment...6120
          Wheel Alignment Inspection/Adjustment...6120
          Drive Chain Wear Inspection...6120
          Drive Chain Lubrication...6120
          Drive Chain Removal...6120
          Drive Chain Installation...6121
        Engine Sprocket Removal...6124
          Engine Sprocket Installation...6124
            Torque -...6124
            Torque -...6125
          Rear Sprocket Removal...6125
          Rear Sprocket Installation...6125
            Torque -...6125
            Torque -...6125
          Coupling Installation...6125
          Coupling Bearing Removal...6126
            Special Tool -...6126
            Special Tool -...6126
          Coupling Bearing Installation...6126
            Special Tool -...6126
            Special Tool -...6126
            Special Tool -...6126
          Coupling Bearing Inspection...6127
          Coupling Bearing Lubrication...6127
          Coupling Damper Inspection...6127
          Sprocket Wear Inspection...6127
          Rear Sprocket Warp Inspection...6128
      Brakes...6129
        Inside Circlip Pliers:...6135
        Brake Lever Position Adjustment...6136
          Brake Pedal Position Inspection ...6136
          Brake Pedal Position Adjustment ...6136
            Torque -...6136
          Brake Pedal Removal...6136
          Brake Pedal Installation...6137
            Torque -...6137
            Torque -...6137
            Torque -...6137
        Front Caliper Removal...6138
          Rear Caliper Removal...6138
          Caliper Installation...6138
            Torque -...6138
          Front Caliper Disassembly ...6139
          Front Caliper Assembly...6139
          Rear Caliper Disassembly...6139
          Rear Caliper Assembly...6139
          Caliper Fluid Seal Damage Inspection...6139
          Rear Caliper Dust Boot and Rubber Boot Damage Inspection...6140
          Caliper Piston and Cylinder Damage Inspection...6140
          Rear Caliper Holder Shaft Wear Inspection...6140
        Front Brake Pad Removal...6141
          Front Brake Pad Installation...6141
            Torque -...6141
          Rear Brake Pad Removal ...6142
          Rear Brake Pad Installation...6142
          Brake Pad Wear Inspection...6142
        Front Master Cylinder Removal...6143
          Front Master Cylinder Installation...6143
            Torque -...6143
            Torque -...6143
          Rear Master Cylinder Removal...6144
          Rear Master Cylinder Installation...6144
            Torque -...6144
          Front Master Cylinder Disassembly...6144
          Rear Master Cylinder Disassembly...6144
          Master Cylinder Assembly...6144
          Master Cylinder Inspection (Visual Inspection)...6144
        Brake Disc Removal...6146
          Brake Disc Installation...6146
            Torque -...6146
          Brake Disc Wear Inspection...6146
          Brake Disc Warp Inspection...6146
            Special Tools -...6146
        Brake Fluid Level Inspection...6147
          Brake Fluid Change...6147
          Brake Line Bleeding...6147
            Torque -...6148
            Torque -...6149
        Brake Hose Removal/Installation...6151
          Brake Hose Inspection...6151
      Suspension...6153
        Inside Circlip Pliers:...6159
        Rebound Damping Force Adjustment...6161
          Compression Damping Force Adjustment...6161
          Spring Preload Adjustment...6162
          Front Fork Removal (Each Fork Leg)...6162
          Front Fork Installation...6163
            Torque -...6163
            Torque -...6163
          Front Fork Oil Change...6163
            Special Tools -...6163
            Special Tool -...6165
            Special Tool -...6165
            Special Tool -...6166
            Special Tool -...6166
            Special Tools -...6166
            Torque -...6167
          Front Fork Disassembly...6167
            Special Tool -...6167
          Front Fork Assembly...6168
            Special Tool -...6168
            Torque -...6168
            Special Tool -...6168
          Inner Tube Inspection...6168
          Dust Seal Inspection...6169
          Spring Tension Inspection...6169
        Rebound Damping Force Adjustment...6170
          Compression Damping Force Adjustment...6170
          Spring Preload Adjustment...6171
            Special Tools -...6171
          Rear Shock Absorber Removal...6172
            Special Tools -...6172
          Rear Shock Absorber Installation...6172
            Torque -...6172
          Rear Shock Absorber Inspection...6173
          Rear Shock Absorber Scrapping...6173
        Swingarm Removal...6174
          Special Tool -...6175
          Swingarm Installation...6175
            Torque -...6175
            Special Tool -...6176
            Torque -...6176
            Torque -...6176
          Swingarm Bearing Removal...6176
            Special Tool -...6176
            Special Tool -...6176
          Swingarm Bearing Installation...6177
            Special Tools -...6177
          Swingarm Bearing, Sleeve Inspection...6177
          Chain Guide Inspection...6178
        Tie-Rod Removal...6179
          Special Tools -...6179
          Tie-Rod Installation...6179
            Torque -...6179
          Rocker Arm Removal...6179
            Special Tools -...6179
          Rocker Arm Installation...6180
            Torque -...6180
          Tie-Rod and Rocker Arm Bearing Removal...6180
            Special Tools -...6180
              Tie-Rod and Rocker Arm Bearing Installation...6180
                Special Tools -...6181
              Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...6182
              Rocker Arm/Tie-Rod Bearing Lubrication...6182
      Steering...6183
        Bearing Puller Adapter:...6186
        Steering Inspection...6187
          Steering Adjustment...6187
        Steering Stem, Steering Stem Bearing Removal...6188
          Special Tool -...6188
          Special Tool -...6188
          Special Tools -...6189
          Steering Stem, Steering Stem Bearing Installation...6189
            Special Tools -...6189
            Special Tools -...6189
            Special Tool -...6190
            Torque -...6190
            Torque -...6191
          Steering Stem Bearing Lubrication...6191
          Steering Stem Warp Inspection...6191
          Steering Stem Cap Deterioration, Damage Inspection...6191
        Handlebar Removal...6192
          Handlebar Installation...6192
            Torque -...6192
            Torque -...6193
      Frame...6195
        Rear Seat Removal...6202
          Rear Seat Installation...6202
          Front Seat Removal...6202
          Front Seat Installation...6202
        Lower Fairing Removal...6203
          Lower Fairing Installation...6203
          Center Fairing Removal...6203
          Center Fairing Installation...6204
          Windshield Removal...6204
          Windshield Installation...6204
            Torque -...6204
          Upper Fairing Removal...6204
          Upper Fairing Disassembly...6205
            Upper Fairing Assembly...6205
            Upper Fairing Installation...6206
              Torque -...6206
            Upper Inner Fairing Removal...6206
            Upper Inner Fairing Installation...6206
            Center Inner Fairing Removal...6206
            Center Inner Fairing Installation...6206
            Right and Left Inner Fairing Removal...6207
            Right and Left Inner Fairing Installation...6207
        Left Side Cover Removal...6208
          Left Side Cover Installation...6208
          Right Side Cover Removal...6208
          Right Side Cover Installation...6208
        Seat Cover Removal...6209
          Seat Cover Installation...6209
        Front Fender Removal...6210
          Front Fender Installation...6210
            Torque -...6210
          Flap and Rear Fender Rear Removal...6210
          Flap and Rear Fender Rear Installation...6211
          Rear Fender Front Removal...6212
          Rear Fender Front Installation...6212
        Rear Frame Removal...6213
          Rear Frame Installation...6213
            Torque -...6213
          Frame Inspection...6213
        Side Stand Removal...6214
          Side Stand Installation...6214
            Torque -...6214
            Torque -...6214
      Electrical System...6215
        Flywheel Holder:...6231
        There are a number of important precautions that are musts when ...6232
        Wiring Inspection...6234
          Special Tool -...6234
        Battery Removal...6235
          Battery Installation...6235
          Battery Activation...6235
          Precautions...6238
            1)...6238
            2)...6238
            3)...6238
            4)...6238
          Interchange...6238
            Charging Condition Inspection...6239
            Refreshing Charge...6239
        Alternator Cover Removal...6241
          Alternator Cover Installation...6241
            Sealant -...6241
            Torque -...6241
          Stator Coil Removal...6241
          Stator Coil Installation...6241
            Torque -...6241
            Sealant -...6241
            Torque -...6242
          Alternator Rotor Removal...6242
            Special Tool -...6242
            Special Tool -...6242
          Alternator Rotor Installation...6242
            Special Tool -...6243
            Torque -...6243
          Alternator Inspection...6243
            Special Tool -...6244
          Regulator/Rectifier Removal...6245
          Regulator/Rectifier Inspection...6245
          Charging Voltage Inspection...6247
            Special Tool -...6247
          Charging System Circuit...6248
        Starter Motor Clutch Removal/Installation...6249
          Starter Motor Clutch Inspection...6249
          Starter Motor Clutch Disassembly...6249
          Starter Motor Clutch Assembly...6249
            Torque -...6249
          Crankshaft Sensor Removal...6251
          Crankshaft Sensor Installation...6252
            Torque -...6252
            Sealant -...6252
            Torque -...6252
          Crankshaft Sensor Inspection...6252
            Special Tool -...6252
          Crankshaft Sensor Peak Voltage Inspection...6252
            Special Tools -...6253
          Timing Rotor Removal...6253
            Special Tool -...6253
          Timing Rotor Installation...6253
            Torque -...6253
            Special Tool -...6253
          Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...6253
          Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...6254
          Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...6254
          Stick Coil Primary Peak Voltage Inspection...6255
            Special Tools -...6255
          Spark Plug Removal...6255
          Spark Plug Installation...6255
          Spark Plug Clean and Inspection...6256
          Spark Plug Gap Inspection...6256
          Camshaft Position Sensor Removal...6256
          Camshaft Position Sensor Installation...6256
            Torque -...6256
          Camshaft Position Sensor Inspection...6256
            Special Tool -...6257
          Camshaft Position Sensor Peak Voltage Inspection...6257
            Special Tools -...6257
          Interlock Operation Inspection...6258
          IC Igniter Inspection...6259
          Ignition System Circuit...6260
        Starter Motor Removal...6261
          Starter Motor Installation...6261
            Torque -...6261
          Starter Motor Disassembly...6261
          Starter Motor Assembly...6261
          Brush Inspection...6262
          Commutator Cleaning and Inspection...6263
          Armature Inspection...6263
            Special Tool -...6263
          Brush Lead Inspection...6263
            Special Tool -...6263
          Right-hand End Cover Assembly Inspection...6264
            Special Tool -...6264
          Starter Relay Inspection...6264
            Special Tool -...6264
          Electric Starter Circuit...6265
        This motorcycle adopt the daylight system and have a headlight r...6266
          Headlight Beam Horizontal Adjustment...6266
          Headlight Beam Vertical Adjustment...6266
          Headlight Bulb Replacement...6266
          City Light Bulb Replacement (Europe Models)...6267
          Headlight Removal/Installation...6267
          Tail/Brake Light (LED) Removal...6268
          Tail/Brake Light (LED) Installation...6268
          License Plate Light Bulb Replacement...6268
          Headlight/Tail Light Circuit...6269
            Turn Signal Light Bulb Replacement...6269
            Turn Signal Relay Inspection...6271
          Turn Signal Light Circuit...6273
        Fan Motor Inspection...6274
          Radiator Fan Circuit...6274
        Meter Unit Removal...6275
          Meter Unit Disassembly...6275
          Electronic Combination Meter Unit Inspection...6276
            Special Tool -...6276
            Special Tool -...6281
          Meter Circuit...6283
        Brake Light Timing Inspection...6284
          Brake Light Timing Adjustment...6284
          Neutral Switch Replacement...6284
            Torque -...6284
          Switch Inspection...6285
            Special Tool -...6285
          Rear Brake Light Switch Connections...6285
          Side Stand Switch Connections...6285
          Neutral Switch Connections...6285
          Oil Pressure Switch Connections *...6285
          Water Temperature Sensor Inspection...6286
          Speed Sensor Removal...6286
          Speed Sensor Installation...6286
            Torque -...6286
          Speed Sensor Inspection...6287
            Special Tool -...6287
          Fuel Reserve Switch Inspection...6287
            Special Tool -...6287
        The relay box [A] has relays and diodes. The relays and diodes c...6288
          Relay Box Removal...6288
          Relay Circuit Inspection...6288
          Diode Circuit Inspection...6289
          Relay Box Internal Circuit...6289
        30 A Main Fuse Removal...6291
          Fuse Box Fuse Removal...6291
          15 A ECU Fuse Removal...6291
          Fuse Installation...6292
          Fuse Inspection...6292
      Appendix...6293
        California Model Only...6320
        NOTE...6322
          Engine Doesn't Start, Starting Difficulty:...6322
            Starter motor not rotating:...6322
            Starter motor rotating but engine doesn't turn over:...6322
            Engine won't turn over:...6322
            No fuel flow:...6322
            No spark; spark weak:...6322
            Fuel/air mixture incorrect:...6322
            Compression Low:...6322
          Poor Running at Low Speed:...6322
            Spark weak:...6322
            Fuel/air mixture incorrect:...6322
            Compression low:...6322
            Other:...6323
          Poor Running or No Power at High Speed:...6323
            Firing incorrect:...6323
            Fuel/air mixture incorrect:...6323
            Compression low:...6323
            Knocking:...6323
            Miscellaneous:...6323
          Overheating:...6323
            Firing incorrect:...6323
            Muffler overheating:...6323
            Fuel/air mixture incorrect:...6323
            Compression high:...6323
            Engine load faulty:...6323
            Lubrication inadequate:...6323
            Oil cooler incorrect:...6324
            Gauge incorrect:...6324
            Coolant incorrect:...6324
            Cooling system component incorrect:...6324
          Over Cooling:...6324
            Gauge incorrect:...6324
            Cooling system component incorrect:...6324
          Clutch Operation Faulty:...6324
            Clutch slipping:...6324
            Clutch not disengaging properly:...6324
          Gear Shifting Faulty:...6324
            Doesn't go into gear; shift pedal doesn't return:...6324
            Jumps out of gear:...6324
            Overshifts:...6324
          Abnormal Engine Noise:...6324
            Knocking:...6324
            Piston slap:...6324
            Valve noise:...6324
            Other noise:...6324
          Abnormal Drive Train Noise:...6325
            Clutch noise:...6325
            Transmission noise:...6325
            Drive line noise:...6325
          Abnormal Frame Noise:...6325
            Front fork noise:...6325
            Rear shock absorber noise:...6325
            Disc brake noise:...6325
            Other noise:...6325
          Oil Pressure Warning Light Goes On:...6325
          Exhaust Smokes Excessively:...6325
            White smoke:...6325
            Black smoke:...6325
            Brown smoke:...6325
          Handling and/or Stability Unsatisfactory:...6325
            Handlebar hard to turn:...6325
            Handlebar shakes or excessively vibrates:...6325
            Handlebar pulls to one side:...6325
            Shock absorption unsatisfactory:...6325
          Brake Doesn't Hold:...6325
          Battery Trouble:...6326
            Battery discharged:...6326
            Battery overcharged:...6326
Kawasaki Motorcycle Service Repair Manual '06 ZX-10R (EN)...6328
  tables...6328
    LIST OF ABBREVIATIONS...6333
    COUNTRY AND AREA CODES...6333
    Units of Mass...6349
    Units of Volume...6349
    Units of Force...6349
    Units of Length...6349
    Units of Torque...6349
    Units of Pressure...6349
    Units of Speed...6349
    Units of Power...6349
    Periodic Inspection...6352
    Periodic Replacement Parts...6354
    Basic Torque for General Fasteners...6361
    Throttle Grip Free Play...6365
    Throttle Body Vacuum...6366
    Main Throttle Sensor Output Voltage...6368
    Idle Speed...6368
    Valve Clearance...6372
    Example:...6373
    Adjustment Shims...6374
    Clutch Lever Free Play...6376
    Air Pressure (when Cold)...6377
    Tread Depth...6378
    Chain Slack...6379
    Drive Chain 20-link Length...6381
    Standard Chain...6381
    Recommended Disc Brake Fluid...6383
    Pad Lining Thickness...6383
    Sidestand Switch Operation...6391
    Water and Coolant Mixture Ratio (Recommended)...6399
    Recommended Engine Oil...6402
    Standard Spark Plug...6409
    Sample Diagnosis Sheet...6440
    Engine Doesn't Start, Starting Difficulty...6442
    Poor Running at Low Speed...6444
    Poor Running or No Power at High Speed:...6447
    Main Throttle Sensor Input Voltage...6459
    Input Voltage at ECU Connector...6459
    Main Throttle Sensor Input Voltage...6460
    Input Voltage at Sensor...6460
    Main Throttle Sensor Output Voltage...6461
    Idle Speed...6461
    Output Voltage at ECU...6461
    Throttle Sensor Output Voltage...6463
    Output Voltage at Sensor...6463
    Main Throttle Sensor Resistance...6464
    Inlet Air Pressure Sensor Input Voltage...6465
    Input Voltage at ECU...6465
    Inlet Air Pressure Sensor Input Voltage...6466
    Input Voltage at Sensor Connector...6466
    Inlet Air Pressure Sensor Output Voltage...6466
    Output Voltage at ECU...6466
    Inlet Air Pressure Sensor Output Voltage...6467
    Output Voltage at Sensor Connector...6467
    Inlet Air Pressure Sensor Output Voltage Connection to Adapter...6468
    Inlet Air Temperature Sensor Output Voltage...6470
    Output Voltage at ECU...6470
    Inlet Air Temperature Sensor Resistance...6471
    Water Temperature Sensor Output Voltage...6473
    Output Voltage at ECU...6473
    Atmospheric Pressure Sensor Input Voltage...6475
    Input Voltage at ECU...6475
    Atmospheric Pressure Sensor Input Voltage...6476
    Input Voltage at Sensor Connector...6476
    Atmospheric Pressure Sensor Output Voltage...6476
    Output Voltage...6476
    Atmospheric Pressure Sensor Output Voltage...6477
    Output Voltage at Sensor...6477
    Speed Sensor Input Voltage...6481
    Input Voltage at ECU Connector...6481
    Speed Sensor Input Voltage...6482
    Input Voltage at Sensor...6482
    Speed Sensor Output Voltage...6483
    Output Voltage at Sensor ...6483
    Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions...6484
    Input Voltage at 1 ∼ 6 Gear Positions...6484
    Vehicle-down sensor Power Source Voltage...6487
    Power Source Voltage at Sensor...6487
    Vehicle-down sensor Output Voltage...6487
    Output Voltage at Sensor...6487
    Subthrottle Sensor Input Voltage...6489
    Input Voltage at ECU Connector...6489
    Subthrottle Sensor Input Voltage...6490
    Input Voltage at Sensor...6490
    Subthrottle Sensor Output Voltage...6490
    Output Voltage at ECU...6490
    Subthrottle Sensor Output Voltage...6491
    Output Voltage at Sensor...6491
    Subthrottle Sensor Resistance...6492
    Oxygen Sensor ##1 Output Voltage...6493
    Oxygen Sensor ##1 Output Voltage (with Plugs)...6494
    Oxygen Sensor ##1 Output Voltage (without Plugs)...6494
    Exhaust Butterfly Valve Actuator Sensor Resistance...6496
    Antenna Resistance...6497
    Amplifier Input Voltage...6497
    Input Voltage...6497
    Testing Relay...6499
    Stick Coil Input Voltage at ECU...6500
    Input Voltage at ECU...6500
    Subthrottle Valve Actuator Resistance...6502
    Subthrottle Valve Actuator Input Voltage...6503
    Input Voltage...6503
    Connections to Adapter...6507
    Actuator Output Voltage (Pulley Original Position)...6507
    Oxygen Sensor Heaters Resistance...6508
    Oxygen Sensor Heaters Power Source Voltage...6509
    Power Source Voltage at Sensor Connector...6509
    Oxygen Sensor ##2 Output Voltage...6512
    Oxygen Sensor Output Voltage (with Plugs)...6513
    Oxygen Sensor ##2 Output Voltage (without Plugs)...6513
    ECU Identification...6515
    ECU Grounding Inspection...6516
    ECU Power Source Inspection...6517
    Fuel Pressure...6521
    Fuel Pressure (idling)...6522
    Amount of Fuel Flow...6523
    Pump Operating Voltage at Pump...6525
    Operating Voltage at Pump Connector...6525
    Injector Power Source Voltage at ECU Connector...6527
    Power Source Voltage at ECU...6527
    Injector Power Source Voltage at Injector...6528
    Power Source Voltage at Injector Connector...6528
    Injector Output Voltage at ECU...6528
    Output Voltage at ECU...6528
    Injector Output Voltage at Injector...6529
    Output Voltage at Injector Connector...6529
    Injector Resistance...6530
    Fuel Line Maximum Pressure...6531
    Radiator Cap Relief Pressure...6565
    Thermostat Valve Opening Temperature...6569
    Camshaft Journal, Camshaft Cap Clearance...6596
    Camshaft Journal Diameter...6596
    Camshaft Runout...6596
    Cam Height...6597
    Cylinder Compression...6598
    Cylinder Head Warp...6601
    Valve/Valve Guide Clearance (Wobble Method)...6604
    Valve Seating Surface Outside Diameter...6604
    Valve Seating Surface Width...6604
    Spring Plate Free Play ...6634
    Spring Plate Free Play...6635
    Clutch Plate Assembly Length (Reference)...6635
    Friction Plate Thickness...6635
    Friction and Steel Plate Warp...6636
    Clutch Spring Free Length...6636
    Oil Pressure...6654
    Connecting Rod Big End Bearing Insert Selection...6677
    Crankshaft Main Bearing Insert Selection...6677
    Connecting Rod Bend...6689
    Connecting Rod Twist...6690
    Connecting Rod Big End Side Clearance...6690
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...6690
    Crankpin Diameter...6691
    Crankpin Diameter Marks...6691
    Connecting Rod Big End Inside Diameter Marks...6692
    Crankshaft Side Clearance...6692
    Crankshaft Runout...6692
    Crankshaft Main Bearing Insert/Journal Clearance...6693
    Crankshaft Main Journal Diameter...6693
    Crankshaft Main Journal Diameter Marks...6693
    Crankcase Main Bearing Inside Diameter Marks...6694
    Cylinder Inside Diameter...6697
    Piston Diameter...6697
    Piston Ring/Groove Clearance...6697
    Piston Ring Groove Width...6698
    Piston Ring Thickness...6698
    Piston Ring End Gap...6698
    Shift Fork Ear Thickness...6707
    Gear Groove Width...6707
    Shift Fork Guide Pin Diameter...6707
    Shift Drum Groove Width...6707
    Rim Runout (with tire installed)...6717
    Axle Runout/100 mm (3.94 in.)...6717
    Balance Weight...6719
    Link Pin Outside Diameter...6735
    Link Plates Outside Width...6735
    Rear Sprocket Warp...6740
    Pedal Position...6749
    Brake Discs Thickness...6759
    Disc Runout...6759
    Rebound Damping Force Adjustment...6774
    Compression Damping Force Adjustment...6774
    Adjuster Protrusion (from the top plug nut surface)...6775
    Spring Action...6775
    Fork Oil...6779
    Oil Level (fully compressed, without spring)...6779
    Spring Free Length...6784
    Rebound Damping Force Adjustment...6785
    Rebound Damping Force Adjustment...6785
    Spring Preload Setting...6786
    Spring Adjustment...6786
    Damping Force Adjustment...6802
    Kawasaki-recommended chargers:...6858
    Battery Terminal Voltage...6860
    Terminal Voltage: 11.5 ∼ less than 12.8 V...6861
    Terminal Voltage: less than 11.5 V...6861
    Table 1 Alternator Output Voltage...6865
    Table 2 Stator Coil Resistance...6865
    Regulator/Rectifier Resistance (Unit: kΩ)...6866
    Charging Voltage...6867
    Crankshaft Sensor Peak Voltage...6871
    Ignition Coil Winding Resistance...6874
    Primary Lead Connection...6874
    Stick Coil Primary Peak Voltage...6875
    Connections:...6877
    Camshaft Position Sensor Peak Voltage...6877
    Condition:...6877
    Condition:...6878
    Condition:...6878
    Starter Motor Brush Length...6888
    Commutator Diameter...6888
    Testing Relay...6889
    Testing Turn Signal Relay...6896
    Air Switching Valve Resistance...6898
    User Key Indicator Light and Symbol Flashes...6915
    Water Temperature Sensor...6932
    Connections...6933
    Gear Position Switch Resistance kΩ...6937
    Relay Circuit Inspection (with the battery disconnected)...6938
    Relay Circuit Inspection (with the battery connected)...6939
    Diode Circuit Inspection...6939
  toc...6328
    EMISSION CONTROL INFORMATION...6334
      1...6334
      2...6334
      3...6334
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...6335
      Foreword...6336
      General Information...6338
        Before starting to perform an inspection service or carry out a ...6339
          Battery Ground...6339
          Edges of Parts...6339
          Solvent...6339
          Cleaning vehicle before disassembly...6339
          Arrangement and Cleaning of Removed Parts...6340
          Storage of Removed Parts...6340
          Inspection...6340
          Replacement Parts...6340
          Assembly Order...6340
          Tightening Sequence...6341
          Tightening Torque...6341
          Force...6341
          Gasket, O-ring...6341
          Liquid Gasket, Non-permanent Locking Agent...6341
          Press...6342
          Ball Bearing and Needle Bearing...6342
          Oil Seal, Grease Seal...6342
          Circlips, Cotter Pins...6342
          Lubrication...6343
          Direction of Engine Rotation...6343
          Electrical Wires...6343
          Instrument...6343
        ZX1000D6F (Europe) Left Side View...6344
        ZX1000D6F (Europe) Right Side View...6344
        ZX1000D6F (United States and Canada) Left Side View...6345
        ZX1000D6F (United States and Canada) Right Side View...6345
        Frame Number...6345
        Engine Number...6345
        Prefixes for Units...6349
        Units of Temperature...6349
      Periodic Maintenance...6350
        The scheduled maintenance must be done in accordance with this c...6352
        Inside Circlip Pliers:...6364
        Fuel System (DFI)...6365
          Throttle Control System Inspection...6365
          Engine Vacuum Synchronization Inspection...6365
            Special Tool -...6366
            Special Tool -...6366
            Special Tool -...6367
            Torque -...6367
            Torque -...6367
          Idle Speed Inspection...6368
          Idle Speed Adjustment...6369
          Fuel Hose Inspection (fuel leak, damage, installation condition)...6369
          Evaporative Emission Control System (California Model)...6370
            Evaporative Emission Control System Inspection...6370
          Cooling System...6371
            Coolant Level Inspection...6371
            Radiator Hose and Pipe Inspection (coolant leak, damage, install...6371
              Torque -...6371
          Engine Top End...6371
            Valve Clearance Inspection...6371
            Valve Clearance Adjustment...6373
          Air Suction System...6375
            Air Suction System Damage Inspection...6375
              Special Tool -...6375
          Clutch...6376
            Clutch Operation Inspection ...6376
          Wheels/Tires...6377
            Air Pressure Inspection...6377
            Wheel/Tire Damage Inspection...6377
            Tire Tread Wear Inspection ...6377
            Wheel Bearing Damage Inspection...6378
          Drive Train...6379
            Drive Chain Lubrication Condition Inspection...6379
            Drive Chain Slack Inspection...6379
            Drive Chain Slack Adjustment...6380
              Torque -...6380
            Wheel Alignment Inspection...6381
            Drive Chain Wear Inspection...6381
            Chain Guide Wear Inspection...6382
          Brake System...6382
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...6382
            Brake Hose Damage and Installation Condition Inspection...6382
              Torque -...6382
            Brake Operation Inspection...6382
            Brake Fluid Level Inspection...6383
            Brake Pad Wear Inspection...6383
            Brake Light Switch Operation Inspection...6383
          Suspensions...6384
            Front Forks/Rear Shock Absorber Operation Inspection...6384
            Front Fork Oil Leak Inspection...6385
            Rear Shock Absorber Oil Leak Inspection...6385
            Rocker Arm Operation Inspection...6385
            Tie-Rod Operation Inspection...6385
          Steering System...6386
            Steering Play Inspection...6386
              Special Tools -...6386
            Steering Play Adjustment...6386
              Special Tool -...6386
              Torque -...6387
            Steering Stem Bearing Lubrication...6387
            Steering Damper Oil Leak Inspection...6387
          Electrical System...6388
            Lights and Switches Operation Inspection...6388
            Headlight Aiming Inspection...6390
            Sidestand Switch Operation Inspection...6391
            Engine Stop Switch Operation Inspection...6392
          Others...6393
            Chassis Parts Lubrication ...6393
              Pivots: Lubricate with Grease...6393
              Points: Lubricate with Grease...6393
              Cables: Lubricate with Rust Inhibitor...6393
            Bolts, Nuts and Fasteners Tightness Inspection...6394
              Bolt, Nut and Fastener to be checked...6395
          Replacement Parts...6396
            Air Cleaner Element Replacement...6396
              Torque -...6397
            Fuel Hose Replacement...6397
            Coolant Change...6398
              Torque -...6399
              Torque -...6399
            Radiator Hose and O-ring Replacement...6401
              Torque -...6401
            Engine Oil Change...6402
              Torque -...6402
              Torque -...6402
            Oil Filter Replacement...6402
              Special Tool -...6402
              Torque -...6403
            Brake Hose and Pipe Replacement...6403
              Torque -...6403
            Brake Fluid Change...6403
              Torque -...6404
              Torque -...6404
            Master Cylinder Rubber Parts Replacement...6405
              Special Tool -...6405
              Special Tool -...6405
              Torque -...6406
            Caliper Rubber Parts Replacement...6406
              Torque -...6407
              Torque -...6407
              Torque -...6408
            Spark Plug Replacement...6409
              Owner's Tool -...6409
              Torque -...6409
      Fuel System (DFI)...6410
        DFI System...6419
        Oil Pressure Gauge, 5 kgf/cm :...6423
        Main Throttle Sensor [A]...6425
        DFI System Wiring Diagram...6427
        Terminal Numbers of ECU Connectors...6429
        DFI Servicing Precautions...6431
          Torque -...6432
        The warning indicator light (LED) [A] is used for the FI indicat...6433
          Outline...6433
            Special Tool -...6435
            Sealant -...6435
            Special Tool -...6436
            DFI Diagnosis Flow Chart...6439
          Inquiries to Rider...6439
        NOTE...6442
        The warning indicator light (LED) [A] is used for the FI indicat...6450
          Self-diagnosis Outline...6450
          Self-diagnosis Procedures...6451
          Self-Diagnosis Flow Chart...6453
            Service Code Reading...6454
            Service Code Erasing...6454
          Backups...6456
        The main throttle sensor is a rotating variable resistor that ch...6459
          Main Throttle Sensor Removal/Adjustment...6459
          Input Voltage Inspection...6459
            Special Tool -...6459
            Special Tool -...6460
          Output Voltage Inspection...6461
            Special Tool -...6461
            Special Tool -...6463
          Resistance Inspection...6464
          Main Throttle Sensor Circuit...6464
        CAUTION...6465
          Removal...6465
          Installation...6465
          Input Voltage Inspection...6465
            Special Tool -...6465
            Special Tool -...6466
          Output Voltage Inspection...6466
            Special Tool -...6466
            Special Tool -...6467
          Inlet Air Pressure Sensor Circuit...6467
            Special Tools -...6468
        Removal/Installation...6470
          Output Voltage Inspection...6470
            Special Tool -...6470
            Sealant -...6471
          Sensor Resistance Inspection...6471
          Inlet Air Temperature Sensor Circuit...6472
        Removal/Installation...6473
          Sealant -...6473
          Torque -...6473
          Output Voltage Inspection...6473
            Special Tool -...6473
            Sealant -...6474
          Sensor Resistance Inspection...6474
          Water Temperature Sensor Circuit...6474
        CAUTION...6475
          Removal...6475
          Installation...6475
          Input Voltage Inspection...6475
            Special Tool -...6475
            Special Tool -...6476
          Output Voltage Inspection...6476
            Special Tool -...6476
            Special Tool -...6477
          Atmospheric Pressure Sensor Circuit...6477
          Atmospheric Pressure/Altitude Relationship...6478
        Crankshaft Sensor Removal/Installation...6479
          Crankshaft Sensor Inspection...6479
          Crankshaft Sensor Circuit...6479
        Camshaft Position Sensor Removal/Installation...6480
          Camshaft Position Sensor Inspection...6480
          Camshaft Position Sensor Circuit...6480
        Speed Sensor Removal/Installation...6481
          Input Voltage Inspection...6481
            Special Tool -...6481
            Special Tool -...6482
          Output Voltage Inspection...6482
            Special Tool -...6482
          Speed Sensor Circuit...6483
        Gear Position Switch Removal/Installation...6484
          Gear Position Switch Inspection...6484
          Input Voltage Inspection...6484
            Special Tool -...6484
          Gear Position Switch Circuit...6485
        This sensor has a weight [A] with two magnets inside, and sends ...6486
          Removal...6486
          Installation...6486
            Torque -...6486
          Inspection...6486
            Special Tool -...6487
            Special Tool -...6487
            Sealant -...6488
          Vehicle-down Sensor Circuit...6488
        The subthrottle sensor is a rotating variable resistor that chan...6489
          Subthrottle Sensor Removal/Adjustment...6489
          Input Voltage Inspection...6489
            Special Tool -...6489
            Special Tool -...6490
          Output Voltage Inspection...6490
            Special Tool -...6490
            Special Tool -...6491
          Resistance Inspection...6492
          Subthrottle Sensor Circuit...6492
        Oxygen Sensor ##1 Removal/Installation...6493
          Oxygen Sensor ##1 Inspection...6493
            Special Tool -...6493
            Special Tool -...6494
            Sealant -...6494
          Oxygen Sensor Circuit...6495
        Exhaust Butterfly Valve Actuator Sensor Inspection...6496
          Exhaust Butterfly Valve Actuator Sensor Circuit...6496
        Antenna Resistance Inspection...6497
          Amplifier Input Voltage Inspection...6497
            Special Tool -...6497
          User Key Inspection...6498
          Immobilizer System Circuit...6498
        Fuel Pump Relay Removal...6499
          Fuel Pump Relay Inspection...6499
            Special Tool -...6499
          Fuel Pump Relay Circuit...6499
        Stick Coil ##1: Service Code 51...6500
          Removal/Installation...6500
          Input Voltage Inspection...6500
            Special Tool -...6500
          Stick Coil Circuit...6501
        Subthrottle Valve Actuator Removal...6502
          Subthrottle Valve Actuator Inspection...6502
          Resistance Inspection...6502
          Input Voltage Inspection...6503
            Special Tools -...6503
          Subthrottle Valve Actuator Circuit...6504
        Exhaust Butterfly Valve Actuator Removal...6505
          Exhaust Butterfly Valve Actuator Installation...6505
            Torque -...6505
            Torque -...6506
          Exhaust Butterfly Valve Actuator Inspection...6506
          Output Voltage Inspection...6507
            Special Tool -...6507
          Exhaust Butterfly Valve Actuator Circuit...6507
        Oxygen Sensor Heaters Removal/Installation...6508
          Oxygen Sensor Heaters Inspection ...6508
            Special Tool -...6508
            Special Tool -...6509
            Sealant -...6509
          Oxygen Sensor Circuit...6510
        ECU Main Relay Inspection...6511
        Oxygen Sensor ##2 Removal/Installation...6512
          Oxygen Sensor ##2 Inspection...6512
            Special Tool -...6512
            Special Tool -...6513
            Sealant -...6513
          Oxygen Sensor Circuit...6514
        CAUTION...6515
          ECU Identification...6515
          ECU Removal...6515
          ECU Installation...6516
          ECU Power Supply Inspection...6516
            Special Tool -...6516
          ECU Power Source Circuit...6518
        ECU Fuse Removal...6519
          ECU Fuse Installation...6519
          ECU Fuse Inspection...6519
        Light (LED) Inspection...6520
          Warning Indicator Light (LED) (FI/Immobilizer) Circuit...6520
        Fuel Pressure Inspection...6521
          Special Tools -...6521
          Fuel Flow Rate Inspection...6522
            Special Tool -...6522
        Fuel Pump Removal...6524
          Fuel Pump Installation...6524
            Torque -...6525
          Operation Inspection...6525
          Operating Voltage Inspection...6525
            Special Tools -...6525
          Fuel Pump Circuit...6526
        Removal/Installation...6527
          Power Source Voltage Inspection...6527
            Special Tool -...6527
            Special Tool -...6528
          Output Voltage Inspection...6528
            Special Tool -...6528
            Special Tool -...6529
          Audible Inspection...6529
            Special Tool -...6529
          Injector Signal Test...6530
            Special Tool -...6530
          Injector Resistance Inspection...6530
          Injector Unit Test...6531
          Injector Fuel Line Inspection...6531
          Fuel Injector Circuit...6532
        Free Play Inspection...6533
          Free Play Adjustment...6533
          Cable Installation...6533
          Cable Lubrication...6533
        Idle Speed Inspection...6534
          Throttle Bore Cleaning...6534
          Synchronization Inspection...6534
          Synchronization Adjustment...6534
          Throttle Body Assy Removal...6534
          Throttle Body Assy Installation...6536
            Torque -...6536
            Torque -...6536
          Throttle Body Assy Disassembly...6537
            Throttle Body Assy Assembly...6538
              Torque -...6539
        Element Removal...6540
          Element Installation...6540
          Air Cleaner Element Inspection...6540
          Air Cleaner Housing Removal...6540
          Air Cleaner Housing Installation...6541
            Torque -...6542
          Air Cleaner Housing Disassembly...6542
          Air Cleaner Housing Assembly...6542
            Sealant -...6542
          Oil Draining...6542
          Air Inlet Duct Removal...6543
          Air Inlet Duct Installation...6543
            Torque -...6543
        Fuel Tank Removal...6544
          Fuel Tank Installation...6546
          Fuel Tank and Cap Inspection...6547
          Fuel Tank Cleaning...6547
        The Evaporative Emission Control System routes fuel vapors from ...6548
          Parts Removal/Installation...6548
          Hose Inspection...6548
          Separator Inspection...6548
          Separator Operation Test...6549
          Canister Inspection...6549
      Cooling System...6550
        Coolant Deterioration Inspection...6556
          Coolant Level Inspection...6556
          Coolant Draining...6556
          Coolant Filling...6556
          Pressure Testing...6556
          Cooling System Flushing...6557
          Coolant Reserve Tank Removal...6557
          Coolant Reserve Tank Installation...6558
            Torque -...6558
        Water Pump Removal...6559
          Water Pump Installation...6559
            Torque -...6560
            Torque -...6560
            Torque -...6560
          Water Pump Impeller Inspection...6560
        Radiator and Radiator Fan Removal...6561
          Radiator and Radiator Fan Installation...6562
            Torque -...6563
            Torque -...6563
            Torque -...6563
            Torque -...6563
          Radiator Inspection...6565
          Radiator Cap Inspection...6565
          Radiator Filler Neck Inspection...6566
        Thermostat Removal...6567
          Thermostat Installation...6567
            Torque -...6568
            Torque -...6568
            Torque -...6568
            Torque -...6568
          Thermostat Inspection...6568
        Hose Installation...6570
          Torque -...6570
          Hose Inspection...6570
        CAUTION...6571
          Water Temperature Sensor Removal...6571
          Water Temperature Sensor Inspection...6571
      Engine Top End...6572
        Dummy Page...6574
        Exhaust System ZX1000D6F...6579
        Compression Gauge, 20 kgf/cm :...6583
        Air Suction Valve Removal...6585
          Air Suction Valve Installation...6585
            Torque -...6585
          Air Suction Valve Inspection...6585
          Air Switching Valve Removal...6586
          Air Switching Valve Installation...6586
          Air Switching Valve Operation Test...6586
          Air Switching Valve Unit Test...6586
          Clean Air System Hose Inspection...6586
        Cylinder Head Cover Removal...6587
          Cylinder Head Cover Installation...6587
            Sealant -...6587
            Torque -...6588
        Camshaft Chain Tensioner Removal...6589
          Camshaft Chain Tensioner Installation...6590
            Torque -...6590
            Torque -...6590
            Torque -...6590
        Camshaft Removal...6591
          Camshaft Installation...6592
            Torque -...6593
            Torque -...6595
            Torque -...6595
          Camshaft, Camshaft Cap Wear...6596
          Camshaft Runout...6596
          Cam Wear...6597
          Camshaft Chain Removal...6597
        Cylinder Compression Measurement...6598
          Special Tools -...6598
          Torque -...6598
          Cylinder Head Removal...6599
          Cylinder Head Installation...6600
            Torque -...6600
            Torque -...6600
            Torque -...6600
          Cylinder Head Warp...6601
        Valve Clearance Inspection...6602
          Valve Removal...6602
            Special Tools -...6602
          Valve Installation...6602
          Valve Guide Removal...6602
            Special Tool -...6602
          Valve Guide Installation...6603
            Special Tools -...6603
            Special Tool -...6603
          Valve-to-Guide Clearance Measurement (Wobble Method)...6603
          Valve Seat Inspection...6604
          Valve Seat Repair...6604
            Special Tools -...6604
        Throttle Body Assy Holder Removal...6609
          Throttle Body Assy Holder Installation...6609
            Torque -...6609
        WARNING...6610
          Muffler Body Removal...6610
          Muffler Body Installation...6611
            Torque -...6611
            Torque -...6611
          Middle and Rear Exhaust Pipe Removal...6612
          Middle and Rear Exhaust Pipe Installation...6613
            Torque -...6613
            Torque -...6613
            Torque -...6613
          Front Exhaust Pipe Removal...6614
          Front Exhaust Pipe Installation...6615
            Torque -...6615
          Exhaust Butterfly Valve Cable Removal...6616
          Exhaust Butterfly Valve Cable Installation...6617
            Torque -...6617
            Torque -...6618
            Torque -...6618
      Clutch...6620
        Clutch Holder:...6624
        Clutch Lever Free Play Inspection...6625
          Clutch Lever Free Play Adjustment...6625
          Cable Removal...6625
          Cable Installation...6625
          Cable Lubrication...6625
          Clutch Lever Installation...6625
            Torque -...6625
        Clutch Cover Removal...6626
          Clutch Cover Installation...6626
            Sealant -...6626
            Torque -...6626
          Release Shaft Removal...6626
          Release Shaft Installation...6627
          Clutch Cover Disassembly...6627
          Clutch Cover Assembly...6628
            Torque -...6628
        Clutch Removal...6629
          Special Tool -...6629
          Special Tool -...6629
          Clutch Installation...6631
            Torque -...6631
            Special Tool -...6632
            Torque -...6632
            Torque -...6633
            Spring Plate Free Play Measurement...6634
            Spring Plate Free Play Adjustment...6635
              Torque -...6635
            Clutch Plate, Wear, Damage Inspection...6635
            Clutch Plate Warp Inspection...6636
            Clutch Spring Free Length Measurement...6636
            Damper Cam Inspection...6636
      Engine Lubrication System...6638
        Oil Pressure Gauge, 10 kgf/cm :...6644
        WARNING...6645
          Oil Level Inspection...6645
          Engine Oil Change...6645
          Oil Filter Replacement...6645
        Oil Pan Removal...6646
          Oil Pan Installation...6646
            Torque -...6646
        Oil Pressure Relief Valve Removal...6647
          Oil Pressure Relief Valve Installation...6647
            Torque -...6647
          Oil Pressure Relief Valve Inspection...6648
        Oil Pump Removal...6649
          Oil Pump Installation...6649
            Torque -...6650
          Oil Pump Gear Removal...6650
            Special Tool -...6650
          Oil Pump Gear Installation...6650
            Special Tool -...6651
            Torque -...6651
        Oil Cooler Removal...6652
          Oil Cooler Installation...6652
            Torque -...6652
            Torque -...6652
          Oil Cooler/Oil Filter Case Removal...6652
          Oil Cooler/Oil Filter Case Installation...6653
            Torque -...6653
            Torque -...6653
        Oil Pressure Measurement...6654
          Special Tools -...6654
          Torque -...6654
        Oil Pressure Switch Removal...6655
          Oil Pressure Switch Installation...6655
            Sealant -...6655
            Torque -...6655
            Torque -...6655
      Engine Removal/Installation...6656
        Engine Mount Nut Wrench:...6659
        Engine Removal...6660
          Special Tool -...6663
          Engine Installation...6663
            Torque -...6665
            Torque -...6665
            Torque -...6666
            Special Tool -...6666
            Torque -...6666
            Torque -...6666
            Torque -...6667
            Torque -...6667
            Torque -...6667
            Torque -...6667
      Crankshaft/Transmission...6670
        Bearing Puller:...6678
        Crankcase Splitting...6679
          Crankcase Assembly...6680
            Sealant -...6680
            Torque -...6681
            Sealant -...6682
            Torque -...6683
            Torque -...6683
            Torque -...6683
            Torque -...6684
            Torque -...6684
            Torque -...6684
        Crankshaft Removal...6685
          Crankshaft Installation...6685
            Connecting Rod Removal...6685
            Connecting Rod Installation...6686
            Crankshaft/Connecting Rod Cleaning...6689
            Connecting Rod Bend...6689
            Connecting Rod Twist...6690
            Connecting Rod Big End Side Clearance...6690
            Connecting Rod Big End Bearing Insert/Crankpin Wear...6690
            Crankshaft Side Clearance...6692
            Crankshaft Runout...6692
            Crankshaft Main Bearing Insert/Journal Wear...6693
        Piston Removal...6695
          Special Tool -...6695
          Piston Installation...6696
            Special Tools -...6697
          Cylinder Wear (Upper Crankcase)...6697
          Piston Wear...6697
          Piston Ring, Piston Ring Groove Wear...6697
          Piston Ring Groove Width...6698
          Piston Ring Thickness...6698
          Piston Ring End Gap...6698
        Shift Pedal Removal...6699
          Shift Pedal Installation...6699
            Torque -...6699
            Torque -...6699
            Torque -...6699
          External Shift Mechanism Removal...6699
            Special Tool -...6699
          External Shift Mechanism Installation...6700
            Torque -...6700
          External Shift Mechanism Inspection...6700
            Torque -...6700
          Transmission Shaft Removal...6701
          Transmission Shaft Installation...6701
            Torque -...6701
          Transmission Shaft Disassembly...6702
            Special Tool -...6702
            Special Tools -...6702
          Transmission Shaft Assembly...6702
            Spacial Tool -...6702
          Shift Drum and Fork Removal...6706
          Shift Drum and Fork Installation...6706
            Torque -...6706
          Shift Drum Disassembly...6706
          Shift Drum Assembly...6706
            Torque -...6706
          Shift Fork Bending...6707
          Shift Fork/Gear Groove Wear...6707
          Shift Fork Guide Pin/Drum Groove Wear...6707
          Gear Dog and Gear Dog Hole Damage...6707
      Wheels/Tires...6708
        Bearing Driver Set:...6712
        Front Wheel Removal...6713
          Special Tools -...6713
          Front Wheel Installation...6713
            Torque -...6714
            Torque -...6714
          Rear Wheel Removal...6715
          Rear Wheel Installation...6715
            Torque -...6716
          Wheel Inspection...6717
            Special Tools -...6717
          Axle Inspection...6717
          Balance Inspection...6718
          Balance Adjustment...6718
          Balance Weight Removal...6718
          Balance Weight Installation...6718
        Air Pressure Inspection/Adjustment...6720
          Tire Inspection...6720
          Tire Removal...6720
          Tire Installation...6720
          Tire Repair...6722
        Hub Bearing Removal...6723
          Special Tools -...6723
          Hub Bearing Installation...6723
            Special Tool -...6723
            Special Tool -...6723
          Hub Bearing Inspection...6723
          Hub Bearing Lubrication...6724
      Final Drive...6726
        Inside Circlip Pliers:...6730
        Drive Chain Slack Inspection...6731
          Drive Chain Slack Adjustment...6731
          Wheel Alignment Inspection/Adjustment...6731
          Drive Chain Wear Inspection...6731
          Drive Chain Lubrication...6731
          Drive Chain Removal...6731
          Drive Chain Installation...6733
        Engine Sprocket Removal...6736
          Engine Sprocket Installation...6736
            Torque -...6736
            Torque -...6737
          Rear Sprocket Removal...6737
          Rear Sprocket Installation...6737
            Torque -...6737
          Coupling Installation...6738
          Coupling Bearing Removal...6738
            Special Tool -...6738
            Special Tool -...6738
          Coupling Bearing Installation...6738
            Special Tool -...6738
            Special Tool -...6738
            Special Tool -...6739
          Coupling Bearing Inspection...6739
          Coupling Bearing Lubrication...6739
          Coupling Damper Inspection...6739
          Sprocket Wear Inspection...6739
          Rear Sprocket Warp Inspection...6740
      Brakes...6742
        Inside Circlip Pliers:...6748
        Brake Lever Position Adjustment...6749
          Brake Pedal Position Inspection ...6749
          Brake Pedal Position Adjustment ...6749
            Torque -...6749
          Brake Pedal Removal...6749
          Brake Pedal Installation...6750
            Torque -...6750
            Torque -...6750
            Torque -...6750
        Front Caliper Removal...6751
          Rear Caliper Removal...6751
          Caliper Installation...6751
            Torque -...6751
          Front Caliper Disassembly...6752
          Front Caliper Assembly...6752
          Rear Caliper Disassembly...6752
          Rear Caliper Assembly...6752
          Caliper Fluid Seal Damage...6752
          Rear Caliper Dust Boot and Friction Boot Damage...6753
          Caliper Piston and Cylinder Damage...6753
          Rear Caliper Holder Shaft Wear...6753
        Front Brake Pad Removal...6754
          Front Brake Pad Installation...6754
            Torque -...6754
          Rear Brake Pad Removal ...6755
          Rear Brake Pad Installation...6755
          Brake Pad Wear Inspection...6755
        Front Master Cylinder Removal...6756
          Front Master Cylinder Installation...6756
            Torque -...6756
            Torque -...6756
          Rear Master Cylinder Removal...6757
          Rear Master Cylinder Installation...6757
            Torque -...6757
          Front Master Cylinder Disassembly...6757
          Rear Master Cylinder Disassembly...6757
          Master Cylinder Assembly...6757
          Master Cylinder Inspection (Visual Inspection)...6758
        Brake Disc Removal...6759
          Brake Disc Installation...6759
            Torque -...6759
          Brake Disc Wear...6759
          Brake Disc Warp...6759
            Special Tools -...6759
        Brake Fluid Level Inspection...6760
          Brake Fluid Change...6760
          Brake Line Bleeding...6760
            Torque -...6761
            Torque -...6762
            Torque -...6762
        Brake Hose Removal/Installation...6764
          Brake Hose Inspection...6764
      Suspension...6766
        Inside Circlip Pliers:...6772
        Rebound Damping Force Adjustment...6774
          Compression Damping Force Adjustment...6774
          Spring Preload Adjustment...6775
          Front Fork Removal (each fork leg)...6775
          Front Fork Installation...6776
            Torque -...6776
            Torque -...6776
          Front Fork Oil Change...6776
            Special Tools -...6777
            Special Tool -...6778
            Special Tool -...6779
            Special Tool -...6779
            Special Tool -...6780
            Special Tools -...6780
            Torque -...6781
          Front Fork Disassembly...6782
            Special Tool -...6782
          Front Fork Assembly...6782
            Special Tool -...6782
            Torque -...6782
            Special Tool -...6783
          Inner Tube Inspection...6783
          Dust Seal Inspection...6784
          Spring Tension...6784
        Rebound Damping Force Adjustment...6785
          Compression Damping Force Adjustment...6785
          Spring Preload Adjustment...6785
            Special Tool -...6785
            Special Tool -...6786
          Rear Shock Absorber Removal...6786
            Special Tools -...6786
          Rear Shock Absorber Installation...6787
            Torque -...6787
          Rear Shock Absorber Inspection...6787
          Rear Shock Absorber Scrapping...6787
        Swingarm Removal...6788
          Special Tool -...6788
          Swingarm Installation...6789
            Torque -...6789
            Special Tool -...6789
            Torque -...6789
            Torque -...6789
          Swingarm Bearing Removal...6790
            Special Tool -...6790
            Special Tools -...6790
          Swingarm Bearing Installation...6790
            Special Tool -...6790
          Swingarm Bearing, Sleeve Inspection...6791
          Swingarm Pivot Lubrication...6791
          Chain Guide Inspection...6791
        Tie-Rod Removal...6792
          Special Tools -...6792
          Tie-Rod Installation...6792
            Torque -...6792
          Rocker Arm Removal...6792
            Special Tools -...6792
          Rocker Arm Installation...6793
            Torque -...6793
          Tie-Rod and Rocker Arm Bearing Removal...6793
            Special Tools -...6793
          Tie-Rod and Rocker Arm Bearing Installation...6793
            Special Tools -...6794
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...6795
          Rocker Arm/Tie-Rod Bearing Lubrication...6795
      Steering...6796
        Bearing Puller Adapter:...6800
        Steering Inspection...6801
          Steering Adjustment...6801
        Steering Damper Removal...6802
          Steering Damper Installation...6802
          Damping Force Adjustment...6802
          Steering Damper Oil Leak Inspection...6802
        Stem, Stem Bearing Removal...6803
          Special Tool -...6803
          Special Tool -...6804
          Special Tools -...6804
          Stem, Stem Bearing Installation...6804
            Special Tools -...6804
            Special Tools -...6805
            Special Tool -...6805
            Torque -...6805
            Torque -...6806
          Steering Stem Bearing Lubrication...6807
          Steering Stem Warp...6807
          Stem Cap Deterioration, Damage...6807
        Handlebar Removal...6808
          Handlebar Installation...6808
            Torque -...6808
            Torque -...6809
      Frame...6810
        Rear Seat Removal...6817
          Rear Seat Installation...6817
          Front Seat Removal...6817
          Front Seat Installation...6817
        Lower Fairing Removal...6818
          Lower Fairing Installation...6818
          Middle Fairing Removal...6818
          Middle Fairing Installation...6819
          Windshield Removal...6819
          Windshield Installation...6820
            Torque -...6820
          Upper Fairing Removal...6820
          Upper Fairing Disassembly...6820
            Upper Fairing Assembly...6820
            Upper Fairing Installation...6820
            Upper Inner Fairing Removal...6821
            Upper Inner Fairing Installation...6821
            Center Inner Fairing Removal...6821
            Center Inner Fairing Installation...6821
            Right and Left Inner Fairing Removal...6822
            Right and Left Inner Fairing Installation...6822
        Side Cover Removal...6823
          Side Cover Installation...6823
        Seat Cover Removal...6824
          Seat Cover Installation...6825
        Front Fender Removal...6826
          Front Fender Installation...6826
            Torque -...6826
          Rear Fender Rear Removal...6826
          Rear Fender Rear Installation...6827
          Rear Fender Front Removal...6827
          Rear Fender Front Installation...6828
        Rear Frame Removal...6829
          Rear Frame Installation...6829
            Torque -...6829
          Frame Inspection...6829
        Sidestand Removal...6830
          Sidestand Installation...6830
            Torque -...6830
            Torque -...6830
      Electrical System...6832
        Dummy Page...6842
        Hand Tester:...6852
        There are a number of important precautions that are musts when ...6853
        Wiring Inspection...6855
          Special Tool -...6855
        Battery Removal...6856
          Battery Installation...6856
          Battery Activation...6857
          Precautions...6859
            1)...6859
            2)...6859
            3)...6859
            4)...6859
          Interchange...6860
            Charging Condition Inspection...6860
            Refreshing Charge...6860
        Alternator Cover Removal...6862
          Alternator Cover Installation...6862
            Sealant -...6862
            Torque -...6862
          Stator Coil Removal...6862
          Stator Coil Installation...6863
            Torque -...6863
            Sealant -...6863
            Torque -...6863
          Alternator Rotor Removal...6863
            Special Tools -...6863
            Special Tool -...6863
          Alternator Rotor Installation...6863
            Special Tools -...6864
            Torque -...6864
          Alternator Inspection...6864
            Special Tool -...6865
          Regulator/Rectifier Inspection...6866
            Special Tool -...6866
            Torque -...6866
          Charging Voltage Inspection...6867
            Special Tool -...6867
          Charging System Circuit...6868
            Crankshaft Sensor Removal...6870
            Crankshaft Sensor Installation...6870
              Torque -...6870
              Sealant -...6870
            Crankshaft Sensor Inspection...6871
              Special Tool -...6871
            Crankshaft Sensor Peak Voltage Inspection...6871
              Special Tools -...6871
            Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...6871
            Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...6873
            Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...6874
            Stick Coil Primary Peak Voltage...6874
              Special Tools -...6874
            Spark Plug Removal...6875
            Spark Plug Installation...6875
            Spark Plug Condition Inspection...6875
            Camshaft Position Sensor Removal...6876
            Camshaft Position Sensor Installation...6876
              Torque -...6876
            Camshaft Position Sensor Inspection...6876
              Special Tool -...6876
            Camshaft Position Sensor Peak Voltage Inspection...6877
              Special Tool -...6877
            Interlock Operation Inspection...6877
            IC Igniter Inspection...6878
          Ignition System Circuit...6879
        Starter Idle Gear Removal...6880
          Starter Idle Gear Installation...6880
            Sealant -...6881
            Torque -...6881
            Torque -...6881
          Starter Clutch Removal...6882
            Special Tools -...6882
          Starter Clutch Installation ...6882
            Special Tools -...6883
            Torque -...6883
          Starter Clutch Disassembly...6883
          Starter Clutch Assembly...6883
          Starter Clutch Inspection...6883
          Starter Motor Removal...6884
          Starter Motor Installation...6885
            Torque -...6885
            Torque -...6885
          Starter Motor Disassembly...6885
          Starter Motor Assembly...6886
            Torque -...6886
            Torque -...6887
          Brush Inspection...6888
          Commutator Cleaning and Inspection...6888
          Armature Inspection...6888
            Special Tool -...6888
          Brush Lead Inspection...6889
            Special Tool -...6889
          Right-hand End Cover Assembly Inspection...6889
            Special Tool -...6889
          Starter Relay Inspection...6889
            Special Tool -...6889
            Torque -...6889
          Electric Starter Circuit...6890
        This motorcycle adopt the daylight system and have a headlight r...6891
          Headlight Beam Horizontal Vertical Adjustment...6891
          Headlight Beam Vertical Adjustment...6891
          Headlight Bulb Replacement...6891
          City Light Bulb Replacement...6892
          Headlight Removal/Installation...6892
            Torque -...6892
          Tail/Brake Light (LED) Removal...6893
          Tail/Brake Light (LED) Installation...6893
          License Plate Light Bulb Replacement...6893
            Torque -...6893
          Headlight/Tail Light Circuit...6894
            Turn Signal Light Bulb Replacement...6894
              Torque -...6896
            Turn Signal Relay Inspection...6896
          Turn Signal Light Circuit...6897
        Air Switching Valve Operation Test...6898
          Air Switching Valve Unit Test...6898
            Special Tool -...6898
        Fan Motor Inspection...6899
          Radiator Fan Circuit...6899
        Meter Unit Removal/Installation...6900
          Torque -...6900
          Meter Unit Disassembly...6900
          Electronic Combination Meter Unit Inspection...6901
          Meter Unit Circuit...6910
        This motorcycle is equipped with an immobilizer system to protec...6911
          Operational Cautions...6911
            Key Registration...6911
              Special Tool -...6912
          Spare User Key Registration Flow Chart...6916
            Special Tool -...6917
          All Keys Initial Registration Flow Chart...6926
            Immobilizer System Parts Replacement...6927
            Immobilizer System Inspection...6929
          Immobilizer System Circuit...6930
        Brake Light Timing Inspection...6931
          Brake Light Timing Adjustment...6931
          Switch Inspection...6931
            Special Tool -...6931
          Rear Brake Light Switch Connections...6931
          Sidestand Switch Connections...6931
          Oil Pressure Switch Connections *...6931
          Water Temperature Sensor Inspection...6932
          Speed Sensor Removal...6932
          Speed Sensor Installation...6933
            Torque -...6933
          Speed Sensor Inspection...6933
          Fuel Reserve Switch Inspection...6933
            Special Tool -...6933
          Oxygen Sensor Removal (Europe Models)...6934
          Oxygen Sensor Installation (Europe Models)...6935
            Torque -...6935
          Oxygen Sensor Inspection (Europe Models)...6935
          Oxygen Sensor Heater Inspection (Europe Models)...6935
          Gear Position Switch Removal...6935
          Gear Position Switch Installation...6936
            Torque -...6936
          Gear Position Switch Inspection...6937
            Special Tool -...6937
        The relay box [A] has relays and diodes. The relays and diodes c...6938
          Relay Box Removal...6938
          Relay Circuit Inspection...6938
          Diode Circuit Inspection...6939
          Relay Box Internal Circuit...6940
        30 A Main Fuse Removal...6941
          Fuse Box Fuse Removal...6941
          15 A ECU Fuse Removal...6941
          Fuse Installation...6942
          Fuse Inspection...6942
      Appendix...6944
        California Model...6969
        California Model...6971
        NOTE...6973
          Engine Doesn't Start, Starting Difficulty:...6973
            Starter motor not rotating:...6973
            Starter motor rotating but engine doesn't turn over:...6973
            Engine won't turn over:...6973
            No fuel flow:...6973
            No spark; spark weak:...6973
            Fuel/air mixture incorrect:...6973
            Compression Low:...6973
          Poor Running at Low Speed:...6973
            Spark weak:...6973
            Fuel/air mixture incorrect:...6973
            Compression low:...6973
            Other:...6974
          Poor Running or No Power at High Speed:...6974
            Firing incorrect:...6974
            Fuel/air mixture incorrect:...6974
            Compression low:...6974
            Knocking:...6974
            Miscellaneous:...6974
          Overheating:...6974
            Firing incorrect:...6974
            Muffler overheating:...6974
            Fuel/air mixture incorrect:...6974
            Compression high:...6974
            Engine load faulty:...6974
            Lubrication inadequate:...6975
            Oil cooler incorrect:...6975
            Gauge incorrect:...6975
            Coolant incorrect:...6975
            Cooling system component incorrect:...6975
          Over Cooling:...6975
            Gauge incorrect:...6975
            Cooling system component incorrect:...6975
          Clutch Operation Faulty:...6975
            Clutch slipping:...6975
            Clutch not disengaging properly:...6975
          Gear Shifting Faulty:...6975
            Doesn't go into gear; shift pedal doesn't return:...6975
            Jumps out of gear:...6975
            Overshifts:...6975
          Abnormal Engine Noise:...6975
            Knocking:...6975
            Piston slap:...6975
            Valve noise:...6975
            Other noise:...6975
          Abnormal Drive Train Noise:...6976
            Clutch noise:...6976
            Transmission noise:...6976
            Drive line noise:...6976
          Abnormal Frame Noise:...6976
            Front fork noise:...6976
            Rear shock absorber noise:...6976
            Disc brake noise:...6976
            Other noise:...6976
          Oil Pressure Warning Light Goes On:...6976
          Exhaust Smokes Excessively:...6976
            White smoke:...6976
            Black smoke:...6976
            Brown smoke:...6976
          Handling and/or Stability Unsatisfactory:...6976
            Handlebar hard to turn:...6976
            Handlebar shakes or excessively vibrates:...6976
            Handlebar pulls to one side:...6976
            Shock absorption unsatisfactory:...6976
          Brake Doesn't Hold:...6977
          Battery Trouble:...6977
            Battery discharged:...6977
            Battery overcharged:...6977
  EDDŠp2-6.pdf...0
    toc...6355
Kawasaki Motorcycle Service Repair Manual '06 ZX-14 (EN)...6979
  ZZR1400_'ABS'_&_ZX-14_(ZX1400-A6F_&_B6F)_SM_2006_.pdf...0
    ZZR1400_'ABS'_&_ZX-14_(ZX1400-A6F_&_B6F)_SM_2006_.pdf...0
      Cover...6979
      Quick Reference Guide...6981
      1.General Information...6989
        Before starting to perform an inspection service or carry out a ...6990
          Battery Ground...6990
          Edges of Parts...6990
          Solvent...6990
          Cleaning vehicle before disassembly...6990
          Arrangement and Cleaning of Removed Parts...6991
          Storage of Removed Parts...6991
          Inspection...6991
          Replacement Parts...6991
          Assembly Order...6991
          Tightening Sequence...6992
          Tightening Torque...6992
          Force...6992
          Gasket, O-ring...6992
          Liquid Gasket, Non-permanent Locking Agent...6992
          Press...6993
          Ball Bearing and Needle Bearing...6993
          Oil Seal, Grease Seal...6993
          Circlips, Cotter Pins...6993
          Lubrication...6994
          Direction of Engine Rotation...6994
          Electrical Wires...6994
          Instrument...6994
        ZX1400A6F (Europe) Left Side View...6995
        ZX1400A6F (Europe) Right Side View...6995
        Frame Number...6995
        Engine Number...6995
        ZX1400A6F (United States and Canada) Left Side View...6996
        ZX1400A6F (United States and Canada) Right Side View...6996
        ZX1400A6F (Malaysia) Left Side View...6997
        ZX1400A6F (Malaysia) Right Side View...6997
        ZX1400B6F (Europe) Left Side View...6998
        ZX1400B6F (Europe) Right Side View...6998
        ZX1400B6F (Malaysia) Left Side View...6999
        ZX1400B6F (Malaysia) Right Side View...6999
        Overview...7003
          Structure and Function...7004
          System failure and maintenance...7005
        Prefixes for Units...7006
        Units of Temperature...7006
      2.Periodic Maintenance...7007
        The scheduled maintenance must be done in accordance with this c...7009
        The following tables list the tightening torque for the major fa...7012
        Inside Circlip Pliers:...7020
        Fuel System (DFI)...7021
          Throttle Control System Inspection...7021
          Engine Vacuum Synchronization Inspection...7021
            Special Tool -...7022
            Special Tool -...7023
            Special Tool -...7023
            Torque -...7024
            Torque -...7024
          Idle Speed Inspection...7025
          Idle Speed Adjustment...7025
          Fuel Hose Inspection (fuel leak, damage, installation condition)...7025
          Cooling System...7026
            Coolant Level Inspection...7026
            Radiator Hose and Pipe Inspection...7026
              Torque -...7026
          Evaporative Emission Control System (California Model)...7027
            Evaporative Emission Control System Inspection...7027
          Air Suction System...7027
            Air Suction System Damage Inspection...7027
          Engine Top End...7028
            Valve Clearance Inspection...7028
            EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART...7031
            INLET- VALVE CLEARANCE ADJUSTMENT CHART...7032
          Clutch and Drive Train...7033
            Clutch Operation Inspection ...7033
            Clutch Fluid Level Inspection...7033
            Clutch Fluid Leak Inspection...7034
            Clutch Hose and Pipe Damage and Installation Condition Inspectio...7034
              Torque -...7034
          Wheels/Tires...7035
            Air Pressure Inspection...7035
            Wheel/Tire Damage Inspection...7035
            Tire Tread Wear Inspection ...7035
            Wheel Bearing Damage Inspection...7036
          Drive Train...7036
            Drive Chain Lubrication Condition Inspection...7036
            Drive Chain Slack Inspection...7037
            Drive Chain Slack Adjustment...7037
              Torque -...7037
            Wheel Alignment Inspection...7038
            Drive Chain Wear Inspection...7038
            Chain Guide Wear Inspection...7039
          Brake System...7040
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...7040
            Brake Hose and Pipe Damage and Installation Condition Inspection...7041
              Torque -...7041
            Brake Operation Inspection...7041
            Brake Fluid Level Inspection...7041
            Brake Pad Wear Inspection...7042
            Brake Light Switch Operation Inspection...7043
          Suspensions...7043
            Front Forks/Rear Shock Absorber Operation Inspection...7043
            Front Fork Oil Leak Inspection...7044
            Rear Shock Absorber Oil Leak Inspection...7044
            Rocker Arm Operation Inspection...7044
            Tie-Rod Operation Inspection...7044
          Steering System...7045
            Steering Play Inspection...7045
              Special Tools -...7045
            Steering Play Adjustment...7045
              Special Tool -...7046
              Torque -...7046
            Steering Stem Bearing Lubrication...7046
          Electrical System...7047
            Lights and Switches Operation Inspection...7047
            Headlight Aiming Inspection...7050
            Sidestand Switch Operation Inspection...7051
            Engine Stop Switch Operation Inspection...7052
          Others...7052
            Chassis Parts Lubrication ...7052
              Pivots: Lubricate with Grease...7052
              Points: Lubricate with Grease...7052
              Cables: Lubricate with Rust Inhibitor...7053
            Bolts, Nuts and Fasteners Tightness Inspection...7053
              Bolt, Nut and Fastener to be checked...7054
          Replacement Parts...7054
            Air Cleaner Element Replacement...7054
              Torque -...7055
            Fuel Hose Replacement...7055
            Coolant Change...7057
              Torque -...7057
            Radiator Hose and O-ring Replacement...7059
            Engine Oil Change...7059
              Torque -...7059
            Oil Filter Replacement...7060
              Special Tool -...7060
              Torque -...7060
            Brake Hose and Pipe Replacement...7061
              Torque -...7062
            Brake Fluid Change...7063
              Torque -...7064
              Torque -...7064
            Master Cylinder Rubber Parts Replacement...7064
              Special Tool -...7064
              Special Tool -...7064
              Torque -...7065
            Caliper Rubber Parts Replacement...7065
              Torque -...7066
              Torque -...7066
            Rear Caliper Assembly...7068
              Torque -...7068
              Torque -...7069
            Clutch Hose and Pipe Replacement...7069
              Torque -...7069
            Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacemen...7070
              Special Tool -...7070
              Torque -...7070
            Clutch Fluid Change...7072
              Torque -...7072
            Spark Plug Replacement...7072
              Torque -...7073
      3.Fuel System (DFI)...7075
        DFI System...7084
        Terminal Numbers of ECU Connectors...7088
        Main Throttle Sensor [A]...7090
        Oil Pressure Gauge, 5 kgf/cm :...7094
        DFI Servicing Precautions...7096
          Torque -...7097
        Outline...7098
          Special Tool -...7100
          Sealant -...7100
          Special Tool -...7101
          DFI Diagnosis Flow Chart...7103
          Inquiries to Rider...7103
        NOTE...7106
        Self-diagnosis Outline...7111
          Self-diagnosis Procedures...7112
          Self-Diagnosis Flow Chart...7114
            Service Code Reading...7115
            Service Code Erasing...7115
          Backups...7117
        The main throttle sensor is a rotating variable resistor that ch...7119
          Main Throttle Sensor Removal/Adjustment...7119
          Input Voltage Inspection...7119
            Special Tool -...7119
            Special Tool -...7120
          Output Voltage Inspection...7121
            Special Tool -...7121
            Special Tool -...7123
          Resistance Inspection...7124
          Main Throttle Sensor Circuit...7124
        CAUTION...7125
          Removal...7125
          Installation...7125
          Input Voltage Inspection...7126
            Special Tool -...7126
            Special Tool -...7126
          Output Voltage Inspection...7127
            Special Tool -...7127
            Special Tool -...7127
          Inlet Air Pressure Sensor Circuit...7128
            Special Tools -...7129
        Removal/Installation...7131
          Output Voltage Inspection...7131
            Special Tool -...7131
          Sensor Resistance Inspection...7132
          Inlet Air Temperature Sensor Circuit...7133
        Removal/Installation...7134
          Torque -...7134
          Output Voltage Inspection...7134
            Special Tool -...7134
          Sensor Resistance Inspection...7135
          Water Temperature Sensor Circuit...7135
        CAUTION...7136
          Removal...7136
          Installation...7136
          Input Voltage Inspection...7136
            Special Tool -...7136
            Special Tool -...7137
          Output Voltage Inspection...7137
            Special Tool -...7137
            Special Tool -...7138
          Atmospheric Pressure Sensor Circuit...7138
          Atmospheric Pressure/Altitude Relationship...7139
        Crankshaft Sensor Removal/Installation...7140
          Crankshaft Sensor Inspection...7140
          Crankshaft Sensor Circuit...7140
        Camshaft Position Sensor Removal/Installation...7141
          Camshaft Position Sensor Inspection...7141
          Camshaft Position Sensor Circuit...7141
        Speed Sensor Removal/Installation...7142
          Speed Sensor Inspection...7142
          Input Voltage Inspection...7142
            Special Tool -...7142
          Output Voltage Inspection...7143
            Special Tool -...7143
        Gear Position Switch Removal/Installation...7145
          Gear Position Switch Inspection...7145
          Input Voltage Inspection...7145
            Special Tool -...7145
          Gear Position Switch Circuit...7146
        This sensor has a weight [A] with two magnets inside, and sends ...7147
          Removal...7147
          Installation...7147
            Torque -...7147
          Inspection...7148
            Special Tool -...7148
            Special Tool -...7149
          Vehicle-down Sensor Circuit...7149
        The subthrottle sensor is a rotating variable resistor that chan...7150
          Subthrottle Sensor Removal/Adjustment...7150
          Input Voltage Inspection...7150
            Special Tool -...7150
            Special Tool -...7151
          Output Voltage Inspection...7152
            Special Tool -...7152
            Special Tool -...7153
          Resistance Inspection...7154
          Subthrottle Sensor Circuit...7154
        Antenna Resistance Inspection...7155
          Amplifier Input Voltage Inspection...7155
            Special Tool -...7155
          User Key Inspection...7156
          Immobilizer System Circuit...7156
        Fuel Pump Relay Removal...7157
          Fuel Pump Relay Inspection...7157
            Special Tool -...7157
          Fuel Pump Relay Circuit...7158
        Stick Coil ##1: Service Code 51...7159
          Removal/Installation...7159
          Input Voltage Inspection...7159
            Special Tool -...7159
          Stick Coil Circuit...7160
        Subthrottle Valve Actuator Removal...7161
          Subthrottle Valve Actuator Inspection...7161
          Resistance Inspection...7161
          Input Voltage Inspection...7162
            Special Tools -...7162
          Subthrottle Valve Actuator Circuit...7163
        ECU Main Relay Inspection...7164
        CAUTION...7165
          ECU Identification...7165
          ECU Removal...7165
          ECU Installation...7166
          ECU Power Supply Inspection...7167
            Special Tool -...7167
          ECU Power Source Circuit...7169
            CAN Communication Line Resistance Inspection...7169
          CAN Communication Line Circuit...7170
        ECU Fuse Removal...7171
          ECU Fuse Installation...7171
          ECU Fuse Inspection...7171
        Light (LED) Inspection...7172
          Warning Indicator Light (LED) Circuit...7172
        Fuel Pressure Inspection...7173
          Special Tools -...7173
          Fuel Flow Rate Inspection...7174
            Special Tool -...7174
        Fuel Pump Removal...7177
          Fuel Pump Installation...7177
            Torque -...7178
          Operation Inspection...7178
          Operating Voltage Inspection...7178
            Special Tools -...7178
          Fuel Pump Circuit...7179
        Removal/Installation...7180
          Power Source Voltage Inspection...7180
            Special Tool -...7180
            Special Tool -...7181
          Output Voltage Inspection...7181
            Special Tool -...7181
            Special Tool -...7182
          Audible Inspection...7182
          Injector Signal Test...7183
            Special Tool -...7183
          Injector Resistance Inspection...7183
          Injector Unit Test...7184
          Injector Fuel Line Inspection...7184
          Fuel Injector Circuit...7185
        Free Play Inspection...7186
          Free Play Adjustment...7186
          Cable Installation...7186
          Cable Lubrication...7186
        Idle Speed Inspection...7187
          Throttle Bore Cleaning...7187
          Synchronization Inspection...7187
          Synchronization Adjustment...7187
          Throttle Body Assy Removal...7187
          Throttle Body Assy Installation...7190
            Torque -...7190
            Torque -...7191
            Torque -...7191
          Throttle Body Assy Disassembly...7192
            Throttle Body Assy Assembly...7193
              Torque -...7194
        Element Removal...7195
          Element Installation...7195
          Air Cleaner Element Inspection...7195
          Air Cleaner Element Holder Removal...7195
          Air Cleaner Element Holder Installation...7195
            Torque -...7195
          Oil Draining...7196
          Rear Air Inlet Duct Removal...7196
          Rear Air Inlet Duct Installation...7196
            Torque -...7196
            Torque -...7197
          Front and Middle Air Inlet Duct Removal...7197
          Front and Middle Air Inlet Duct Installation...7197
            Torque -...7198
            Torque -...7198
            Torque -...7198
        Fuel Tank Removal...7199
          Fuel Tank Installation...7201
          Fuel Tank and Cap Inspection...7203
          Fuel Tank Cleaning...7203
        The Evaporative Emission Control System routes fuel vapors from ...7204
          Parts Removal/Installation...7204
          Hose Inspection...7204
          Separator Inspection...7204
          Separator Operation Test...7205
          Canister Inspection...7205
      4.Cooling System...7207
        Coolant Deterioration Inspection...7213
          Coolant Level Inspection...7213
          Coolant Draining...7213
          Coolant Filling...7213
          Pressure Testing...7213
          Cooling System Flushing...7214
          Coolant Reserve Tank Removal/Installation...7214
        Water Pump Removal...7215
          Water Pump Installation...7215
            Torque -...7216
          Water Pump Impeller Inspection...7216
        Radiator and Radiator Fan Removal...7217
          Radiator and Radiator Fan Installation...7218
          Radiator Inspection...7218
          Radiator Cap Inspection...7219
          Radiator Filler Neck Inspection...7219
        Thermostat Removal...7220
          Thermostat Installation...7220
            Torque -...7220
          Thermostat Inspection...7220
        Hose Installation...7222
          Torque -...7222
          Hose Inspection...7222
        CAUTION...7223
          Water Temperature Sensor Removal...7223
          Water Temperature Sensor Inspection...7223
      5.Engine Top End...7225
        Compression Gauge, 20 kgf/cm :...7233
        Air Suction Valve Removal...7235
          Air Suction Valve Installation...7235
            Torque -...7235
          Air Suction Valve Inspection...7236
          Air Switching Valve Removal...7236
          Air Switching Valve Installation...7236
          Air Switching Valve Operation Test...7236
          Air Switching Valve Unit Test...7236
          Clean Air System Hose Inspection...7236
        Cylinder Head Cover Removal...7237
          Cylinder Head Cover Installation...7237
            Sealant -...7237
            Torque -...7238
        Camshaft Chain Tensioner Removal...7239
          Camshaft Chain Tensioner Installation...7239
            Torque -...7239
        Camshaft Removal...7241
          Camshaft Installation...7241
            Torque -...7241
            Torque -...7244
          Camshaft, Camshaft Cap Wear...7244
            Torque -...7244
          Camshaft Runout...7245
          Cam Wear...7245
          Camshaft Chain Removal...7245
          Camshaft Chain Installation...7246
            Torque -...7246
        Cylinder Compression Measurement...7247
          Owner's Tool -...7247
          Special Tools -...7247
          Torque -...7247
          Cylinder Head Removal...7248
          Cylinder Head Installation...7248
            Torque -...7249
            Torque -...7249
            Torque -...7249
            Torque -...7249
          Cylinder Head Warp...7249
        Valve Clearance Inspection...7250
          Valve Removal...7250
            Special Tools -...7250
          Valve Installation...7250
          Valve Guide Removal...7250
            Special Tool -...7250
          Valve Guide Installation...7251
            Special Tools -...7251
            Special Tool -...7251
          Valve-to-Guide Clearance Measurement (Wobble Method)...7252
          Valve Seat Inspection...7253
          Valve Seat Repair...7253
            Special Tools -...7253
        Throttle Body Holder Installation...7258
          Torque -...7258
        WARNING...7259
          Muffler Body Removal/Installation...7259
            Torque -...7260
          Exhaust Pipe Removal...7260
          Exhaust Pipe Installation...7260
            Torque -...7260
      6.Clutch...7261
        Inside Circlip Pliers:...7265
        Clutch Lever Adjustment...7266
          Clutch Master Cylinder Removal...7266
          Clutch Master Cylinder Installation ...7266
            Torque -...7267
            Torque -...7267
          Clutch Master Cylinder Disassembly ...7267
          Clutch Master Cylinder Assembly...7267
          Clutch Master Cylinder Inspection...7267
            Special Tool -...7267
        Clutch Slave Cylinder Removal...7268
          Clutch Slave Cylinder Installation...7269
            Torque -...7269
          Clutch Slave Cylinder Disassembly ...7269
          Clutch Slave Cylinder Assembly...7269
        Clutch Fluid Level Inspection...7270
          Clutch Fluid Change...7270
          Bleeding the Clutch Line...7270
            Torque -...7271
            Torque -...7271
          Clutch Hose Removal/Installation...7271
          Clutch Hose and Connection Inspection...7271
        Clutch Cover Removal...7272
          Clutch Cover Installation...7272
            Sealant -...7272
            Torque -...7272
        Clutch Removal...7273
          Special Tool -...7273
          Special Tool -...7273
          Clutch Installation...7274
            Special Tool -...7274
            Special Tool -...7274
            Torque -...7274
            Torque -...7275
          Clutch Plate Assembly Inspection...7276
            Torque -...7276
          Clutch Plate Assembly Adjustment...7276
            Torque -...7276
          Clutch Plate, Wear, Damage Inspection...7277
          Clutch Plate Warp Inspection...7277
          Clutch Spring Free Length Measurement...7277
      7.Engine Lubrication System...7279
        Oil Pressure Gauge, 10 kgf/cm :...7285
        WARNING...7286
          Oil Level Inspection...7286
          Engine Oil Change...7286
          Oil Filter Replacement...7286
        Oil Pan Removal...7287
          Oil Pan Installation...7287
            Torque -...7287
            Torque -...7288
        Oil Pressure Relief Valve Removal...7289
          Oil Pressure Relief Valve Installation...7289
          Oil Pressure Relief Valve Inspection...7289
        Oil Pump Removal...7290
          Oil Pump Installation...7290
            Torque -...7291
        Oil Cooler Removal...7292
          Oil Cooler Installation...7292
            Torque -...7292
            Torque -...7292
        Oil Pressure Measurement...7293
          Special Tools -...7293
          Torque -...7293
        Oil Pressure Switch Removal...7294
          Oil Pressure Switch Installation...7294
            Sealant -...7294
            Torque -...7294
            Torque -...7294
      8.Engine Removal/Installation...7295
        Engine Removal...7298
          Engine Installation...7300
            Torque -...7303
            Torque -...7304
            Torque -...7304
      9.Crankshaft/Transmission...7307
        Bearing Puller:...7315
        Crankcase Splitting...7316
          Crankcase Assembly...7317
            Torque -...7317
            Sealant -...7318
            Torque -...7319
            Torque -...7319
            Torque -...7320
        Crankshaft Removal...7321
          Crankshaft Installation...7321
          Connecting Rod Removal...7322
          Connecting Rod Installation...7322
          Crankshaft/Connecting Rod Cleaning...7325
          Connecting Rod Bend...7325
          Connecting Rod Twist...7326
          Connecting Rod Big End Side Clearance...7326
          Connecting Rod Big End Bearing Insert/Crankpin Wear...7326
          Crankshaft Side Clearance...7328
          Crankshaft Runout...7329
          Crankshaft Main Bearing Insert/Journal Wear...7329
        Piston Removal...7332
          Special Tool -...7332
          Piston Installation...7333
            Special Tools -...7334
          Cylinder Wear (Upper Crankcase)...7334
          Piston Wear...7334
          Piston Ring, Piston Ring Groove Wear...7334
          Piston Ring Groove Width...7335
          Piston Ring Thickness...7335
          Piston Ring End Gap...7335
        Front Balancer Removal...7336
          Front Balancer Installation...7336
            Torque -...7337
            Torque -...7337
          Rear Balancer Removal...7337
          Rear Balancer Installation...7338
            Torque -...7339
            Torque -...7339
          Balancer Adjustment...7340
            Torque -...7340
          Balancer Damper Inspection...7340
        Starter Motor Clutch Removal...7341
          Starter Motor Clutch Installation...7341
            Torque -...7341
            Torque -...7341
          Starter Motor Clutch Disassembly...7341
          Starter Motor Clutch Assembly...7342
          Starter Clutch Inspection...7342
          Torque Limiter Removal...7342
          Torque Limiter Installation...7343
            Torque -...7343
        Shift Pedal Removal...7344
          Shift Pedal Installation...7344
          External Shift Mechanism Removal...7344
          External Shift Mechanism Installation...7345
            Torque -...7345
          External Shift Mechanism Inspection...7345
            Torque -...7345
          Transmission Shaft Removal...7345
          Transmission Shaft Installation...7346
            Torque -...7346
          Transmission Shaft Disassembly...7346
            Special Tools -...7347
          Transmission Shaft Assembly...7347
          Shift Drum and Fork Removal...7350
          Shift Drum and Fork Installation...7350
            Torque -...7350
          Shift Drum Disassembly...7350
          Shift Drum Assembly...7350
            Torque -...7350
          Shift Fork Bending...7351
          Shift Fork/Gear Groove Wear...7351
          Shift Fork Guide Pin/Drum Groove Wear...7351
          Gear Dog and Gear Dog Hole Damage...7351
      10.Wheels/Tires...7353
        Bearing Driver Set:...7357
        Front Wheel Removal...7358
          Special Tools -...7358
          Front Wheel Installation...7358
            Torque -...7359
            Torque -...7359
          Rear Wheel Removal...7359
          Rear Wheel Installation...7360
            Torque -...7360
          Wheel Inspection...7362
            Special Tools -...7362
          Axle Inspection...7362
          Balance Inspection...7363
          Balance Adjustment...7363
          Balance Weight Removal...7363
          Balance Weight Installation...7364
        Air Pressure Inspection/Adjustment...7366
          Tire Inspection...7366
          Tire Removal...7366
          Tire Installation...7366
          Tire Repair...7368
        Hub Bearing Removal...7369
          Special Tools -...7369
          Hub Bearing Installation...7369
            Special Tool -...7369
            Special Tool -...7369
          Hub Bearing Inspection...7369
          Hub Bearing Lubrication...7370
      11.Final Drive...7371
        Inside Circlip Pliers:...7375
        Drive Chain Slack Inspection...7376
          Drive Chain Slack Adjustment...7376
          Wheel Alignment Inspection/Adjustment...7376
          Drive Chain Wear Inspection...7376
          Drive Chain Lubrication...7376
          Drive Chain Removal...7376
          Drive Chain Installation...7376
        Engine Sprocket Removal...7377
          Engine Sprocket Installation...7377
            Torque -...7377
            Torque -...7377
            Torque -...7378
          Rear Sprocket Removal...7378
          Rear Sprocket Installation...7378
            Torque -...7378
          Coupling Installation...7378
          Coupling Bearing Removal...7379
            Special Tool -...7379
            Special Tool -...7379
          Coupling Bearing Installation...7379
            Special Tool -...7379
            Special Tool -...7379
            Special Tool -...7379
          Coupling Bearing Inspection...7380
          Coupling Bearing Lubrication...7380
          Coupling Damper Inspection...7380
          Sprocket Wear Inspection...7380
          Rear Sprocket Warp Inspection...7381
      12.Brakes...7383
        Dummy Page...7385
        ZX1400A Models...7386
        ZX1400B Models...7390
        Inside Circlip Pliers:...7395
        Brake Lever Position Adjustment...7396
          Brake Pedal Position Inspection ...7396
          Brake Pedal Position Adjustment ...7396
            Torque -...7396
          Brake Pedal Removal...7396
          Brake Pedal Installation...7397
            Torque -...7397
            Torque -...7397
            Torque -...7397
        Front Caliper Removal...7398
          Rear Caliper Removal...7398
          Caliper Installation...7399
            Torque -...7399
          Front Caliper Disassembly...7399
          Front Caliper Assembly...7399
          Rear Caliper Disassembly...7399
          Rear Caliper Assembly...7399
          Caliper Fluid Seal Damage...7400
          Caliper Dust Seal Damage...7400
          Caliper Piston and Cylinder Damage...7401
        Front Brake Pad Removal...7402
          Front Brake Pad Installation...7402
            Torque -...7402
          Rear Brake Pad Removal ...7403
          Rear Brake Pad Installation...7403
            Torque -...7403
          Brake Pad Wear Inspection...7403
        Front Master Cylinder Removal...7404
          Front Master Cylinder Installation...7404
            Torque -...7404
            Torque -...7404
          Rear Master Cylinder Removal...7404
          Rear Master Cylinder Installation...7405
            Torque -...7405
          Front Master Cylinder Disassembly...7405
          Rear Master Cylinder Disassembly...7405
          Master Cylinder Assembly...7405
          Master Cylinder Inspection (Visual Inspection)...7405
        Brake Disc Removal...7407
          Brake Disc Installation...7407
            Torque -...7407
          Brake Disc Wear...7407
          Brake Disc Warp...7407
            Special Tools -...7407
        Brake Fluid Level Inspection...7408
          Brake Fluid Change...7408
          Brake Line Bleeding...7408
            Torque -...7409
            Torque -...7410
            Torque -...7410
        Brake Hose and Pipe Removal/Installation...7412
          Brake Hose and Pipe Inspection...7412
        Parts Location...7413
        ABS System Wiring Diagram...7414
        Terminal Names...7415
          ABS Servicing Precautions...7416
          ABS Troubleshooting Outline...7418
            Special Tool -...7418
            Special Tool -...7419
          ABS Diagnosis Flow Chart...7420
          Inquiries to Rider...7421
          Pre-Diagnosis Inspection 1...7422
          Pre-Diagnosis Inspection 2...7423
          Self-diagnosis Outline...7423
            Self-diagnosis Procedures...7423
            Service Code Clearing Procedures...7424
          Self-diagnosis Flow Chart...7426
          How to Read Service Codes...7427
          How to Erase Service Codes...7427
            ABS Indicator Light (LED) Inspection...7429
            ABS Indicator Light (LED) is Unlit (When the Ignition Switch tur...7429
              Special Tool -...7429
            ABS Indicator Light (LED) Lights (When the Motorcycle is Running...7430
              Special Tool -...7430
            Solenoid Valve Inspection (Service Code 13,14,17,18)...7430
            ABS Solenoid Valve Relay Inspection (Service Code 19)...7430
              Special Tool -...7431
            Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)...7432
            ABS Pump Motor Relay Inspection (Service Code 35)...7432
              Special Tool -...7433
            Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)...7433
            Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)...7434
            Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)...7435
            Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)...7436
            Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)...7436
              Special Tool -...7437
            Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)...7437
              Special Tool -...7438
            ECU Inspection (Service Code 55)...7438
            ABS Hydraulic Unit Removal...7438
            ABS Hydraulic Unit Installation...7440
              Torque -...7440
            ABS Hydraulic Unit Inspection...7441
            Front Wheel Rotation Sensor Removal...7441
            Front Wheel Rotation Sensor Installation...7441
            Rear Wheel Rotation Sensor Removal...7442
            Rear Wheel Rotation Sensor Installation...7442
            Wheel Rotation Sensor Inspection...7443
            Wheel Rotation Sensor Air Gap Inspection...7443
            Wheel Rotation Sensor Rotor Inspection...7444
            ABS Solenoid Valve Relay Fuse (20 A) Removal...7444
            ABS Motor Relay Fuse (30 A) Removal...7444
            ABS ECU Fuse (10 A) Removal...7444
            Fuse Installation...7445
            Fuse Inspection...7445
      13.Suspension...7447
        Inside Circlip Pliers:...7453
        Rebound Damping Force Adjustment...7455
          Compression Damping Force Adjustment...7455
          Spring Preload Adjustment...7456
          Front Fork Removal (Each Fork Leg)...7456
          Front Fork Installation...7457
            Torque -...7457
            Torque -...7457
          Front Fork Oil Change...7457
            Special Tools -...7457
            Special Tool -...7459
            Special Tool -...7460
            Special Tool -...7460
            Special Tool -...7460
            Special Tools -...7461
            Torque -...7461
          Front Fork Disassembly...7462
            Special Tool -...7462
          Front Fork Assembly...7462
            Special Tool -...7462
            Torque -...7462
            Special Tool -...7463
          Inner Tube Inspection...7463
          Dust Seal Inspection...7464
          Spring Tension...7464
        Rebound Damping Force Adjustment...7465
          Compression Damping Force Adjustment...7465
          Spring Preload Adjustment...7465
            Special Tool -...7465
            Special Tool -...7466
          Rear Shock Absorber Removal...7466
            Special Tools -...7466
          Rear Shock Absorber Installation...7467
            Torque -...7467
          Rear Shock Absorber Inspection...7467
          Rear Shock Absorber Scrapping...7468
        Swingarm Removal...7469
          Special Tool -...7469
          Swingarm Installation...7470
            Torque -...7470
            Special Tool -...7470
            Torque -...7470
            Torque -...7470
          Swingarm Bearing Removal...7471
            Special Tool -...7471
            Special Tool -...7471
          Swingarm Bearing Installation...7471
            Special Tools -...7471
          Swingarm Bearing, Sleeve Inspection...7472
          Chain Guide Inspection...7473
        Tie-Rod Removal...7474
          Special Tools -...7474
          Tie-Rod Installation...7474
            Torque -...7474
          Rocker Arm Removal...7474
            Special Tools -...7474
          Rocker Arm Installation...7475
            Torque -...7475
          Tie-Rod and Rocker Arm Bearing Removal...7475
            Special Tools -...7475
          Tie-Rod and Rocker Arm Bearing Installation...7475
            Special Tools -...7476
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...7477
          Rocker Arm/Tie-Rod Bearing Lubrication...7477
      14.Steering...7479
        Head Pipe Outer Race Press Shaft:...7482
        Steering Inspection...7483
          Steering Adjustment...7483
        Stem, Stem Bearing Removal...7484
          Special Tool -...7484
          Special Tool -...7484
          Stem, Stem Bearing Installation...7485
            Special Tools -...7485
            Special Tools -...7485
            Special Tool -...7486
            Torque -...7486
            Torque -...7487
          Steering Stem Bearing Lubrication...7487
          Steering Stem Warp...7487
          Stem Cap Deterioration, Damage...7487
        Handlebar Removal...7488
          Handlebar Installation...7488
            Torque -...7488
            Torque -...7489
            Torque -...7489
      15.Frame...7491
        Seat Removal...7500
          Seat Installation...7500
        Lower Fairing Removal...7501
          Lower Fairing Installation...7501
          Fairing Cover Removal...7501
          Middle Fairing Removal...7501
          Middle Fairing Installation...7502
          Windshield Removal...7502
          Windshield Installation...7503
            Torque -...7503
          Upper Fairing Removal...7503
          Upper Fairing Disassembly...7503
            Upper Fairing Assembly...7503
            Upper Fairing Installation...7504
            Inner Cover Removal...7504
            Inner Cover Installation...7504
            Upper Inner Fairing Removal...7504
            Upper Inner Fairing Installation...7505
            Upper Fairing Bracket Removal...7505
            Upper Fairing Bracket Installation...7505
            Inner Fairing Removal...7505
            Inner Fairing Installation...7505
            Rear Fairing Removal...7505
            Rear Fairing Installation...7505
        Seat Cover Removal...7506
          Seat Cover Installation...7506
            Torque -...7507
        Front Fender Removal...7508
          Front Fender Installation...7508
          Flap and Rear Fender Removal...7508
          Flap and Rear Fender Installation...7509
            Torque -...7509
        Rear Frame Removal...7510
          Rear Frame Installation...7510
            Torque -...7510
          Frame Inspection...7510
        Center Stand Removal (Equipped Models)...7511
          Center Stand Installation (Equipped Models)...7511
            Torque -...7511
          Sidestand Removal...7511
          Sidestand Installation...7511
            Torque -...7511
            Torque -...7511
      16.Electrical System...7513
        Hand Tester:...7531
        There are a number of important precautions that are musts when ...7533
        Wiring Inspection...7534
          Special Tool -...7534
        Battery Removal...7535
          Battery Installation...7536
          Battery Activation...7536
          Precautions...7539
            1)...7539
            2)...7539
            3)...7539
            4)...7539
          Interchange...7539
            Charging Condition Inspection...7539
            Refreshing Charge...7540
        Alternator Cover Removal...7541
          Alternator Cover Installation...7541
            Sealant -...7541
            Torque -...7541
          Stator Coil Removal...7541
          Stator Coil Installation...7542
            Torque -...7542
            Sealant -...7542
            Torque -...7542
          Alternator Rotor Removal...7542
            Special Tools -...7542
            Special Tool -...7542
          Alternator Rotor Installation...7542
            Special Tools -...7543
            Torque -...7543
          Alternator Inspection...7543
            Special Tool -...7544
          Regulator/Rectifier Inspection...7545
            Special Tool -...7545
            Torque -...7545
          Charging Voltage Inspection...7546
            Special Tool -...7546
          Charging System Circuit...7547
            Crankshaft Sensor Removal...7549
            Crankshaft Sensor Installation...7550
              Torque -...7550
              Sealant -...7550
              Torque -...7550
            Crankshaft Sensor Inspection...7550
              Special Tool -...7550
            Crankshaft Sensor Peak Voltage Inspection...7550
              Special Tools -...7551
            Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...7551
            Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...7551
            Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...7552
            Stick Coil Primary Peak Voltage...7552
              Special Tools -...7552
            Spark Plug Removal...7553
            Spark Plug Installation...7553
            Spark Plug Condition Inspection...7553
            Camshaft Position Sensor Removal...7554
            Camshaft Position Sensor Installation...7554
              Torque -...7554
            Camshaft Position Sensor Inspection...7554
              Special Tool -...7554
            Camshaft Position Sensor Peak Voltage Inspection...7555
              Special Tools -...7555
            Interlock Operation Inspection...7555
            IC Igniter Inspection...7556
          Ignition System Circuit...7557
        Starter Motor Removal...7558
          Starter Motor Installation...7558
            Torque -...7558
            Torque -...7558
          Starter Motor Disassembly...7559
          Starter Motor Assembly...7559
            Torque -...7559
            Torque -...7560
          Brush Inspection...7560
          Commutator Cleaning and Inspection...7561
          Armature Inspection...7561
            Special Tool -...7561
          Brush Lead Inspection...7561
            Special Tool -...7561
          Right-hand End Cover Assembly Inspection...7562
            Special Tool -...7562
          Starter Relay Inspection...7562
            Special Tool -...7562
            Torque -...7562
          Electric Starter Circuit...7563
        This motorcycle adopt the daylight system and have a headlight r...7564
          Headlight Beam Horizontal Vertical Adjustment...7564
          Headlight Beam Vertical Adjustment...7564
          Headlight Bulb Replacement...7564
          City Light Bulb Replacement...7565
          Headlight Removal/Installation...7565
            Torque -...7565
          Headlight Relay Inspection...7566
            Special Tool -...7566
          Tail/Brake Light (LED) Removal...7566
          Tail/Brake Light (LED) Installation...7567
            Torque -...7567
          License Plate Light Bulb Replacement...7567
            Torque -...7567
          Headlight/Tail Light Circuit...7568
            Turn Signal Light Bulb Replacement...7568
            Turn Signal Relay Inspection...7570
          Turn Signal Light Circuit...7571
        Air Switching Valve Operation Test...7572
          Air Switching Valve Unit Test...7572
            Special Tool -...7572
        Fan Motor Inspection...7573
          Radiator Fan Circuit...7573
        Meter Unit Removal...7574
          Meter Unit Installation...7574
          Meter Unit Disassembly...7575
          Meter Unit Inspection...7575
            Special Tool -...7576
            Special Tool -...7586
            Special Tool -...7587
          Meter Unit Circuit...7591
        This motorcycle is equipped with an immobilizer system to protec...7592
          Operational Cautions...7592
            Key Registration...7592
              Special Tool -...7592
          Spare User Key Registration Flow Chart...7597
            Special Tool -...7598
          All Keys Initial Registration Flow Chart...7607
            Immobilizer System Parts Replacement...7608
            ECU (Electric Control Unit) Replacement (for Immobilizer Models)...7609
            Immobilizer System Inspection...7610
          Immobilizer System Circuit...7611
        Brake Light Timing Inspection...7612
          Brake Light Timing Adjustment...7612
          Switch Inspection...7612
            Special Tool -...7612
          Rear Brake Light Switch Connections...7612
          Sidestand Switch Connections...7612
          Oil Pressure Switch Connections *...7612
          Water Temperature Sensor Inspection...7613
          Speed Sensor Removal...7613
          Speed Sensor Installation...7613
            Torque -...7613
          Speed Sensor Inspection...7614
            Special Tool -...7614
          Fuel Level Sensor Inspection...7614
            Special Tools -...7614
            Torque -...7615
          Fuel Reserve Switch Inspection...7615
            Special Tool -...7615
          Gear Position Switch Removal...7616
          Gear Position Switch Installation...7617
            Torque -...7617
          Gear Position Switch Inspection...7617
            Special Tool -...7617
        The relay box [A] has relays and diodes. The relays and diodes c...7618
          Relay Box Removal...7618
          Relay Circuit Inspection...7618
          Diode Circuit Inspection...7619
          Relay Box Internal Circuit...7620
        30 A Main Fuse Removal...7621
          Fuse Box Fuse Removal...7621
          15 A ECU Fuse Removal...7622
          Fuse Installation...7622
          Fuse Inspection...7623
      17.Appendix...7625
        ZX1400B Models...7650
        ZX1400B Models...7660
        ZX1400B Models...7662
        ZX1400B Models...7664
        ZX1400B Models...7666
        ZX1400B Models...7668
        ZX1400B Models...7670
        ZX1400B Models...7672
        California Model...7674
        NOTE...7676
          Engine Doesn't Start, Starting Difficulty:...7676
            Starter motor not rotating:...7676
            Starter motor rotating but engine doesn't turn over:...7676
            Engine won't turn over:...7676
            No fuel flow:...7676
            No spark; spark weak:...7676
            Fuel/air mixture incorrect:...7676
            Compression Low:...7676
          Poor Running at Low Speed:...7676
            Spark weak:...7676
            Fuel/air mixture incorrect:...7676
            Compression low:...7677
            Run-on (dieseling):...7677
            Other:...7677
          Poor Running or No Power at High Speed:...7677
            Firing incorrect:...7677
            Fuel/air mixture incorrect:...7677
            Compression low:...7677
            Knocking:...7677
            Miscellaneous:...7677
          Overheating:...7677
            Firing incorrect:...7677
            Muffler overheating:...7677
            Fuel/air mixture incorrect:...7677
            Compression high:...7678
            Engine load faulty:...7678
            Lubrication inadequate:...7678
            Oil cooler incorrect:...7678
            Gauge incorrect:...7678
            Coolant incorrect:...7678
            Cooling system component incorrect:...7678
          Over Cooling:...7678
            Gauge incorrect:...7678
            Cooling system component incorrect:...7678
          Clutch Operation Faulty:...7678
            Clutch slipping:...7678
            Clutch not disengaging properly:...7678
          Gear Shifting Faulty:...7678
            Doesn't go into gear; shift pedal doesn't return:...7678
            Jumps out of gear:...7678
            Overshifts:...7678
          Abnormal Engine Noise:...7678
            Knocking:...7678
            Piston slap:...7678
            Valve noise:...7678
            Other noise:...7678
          Abnormal Drive Train Noise:...7679
            Clutch noise:...7679
            Transmission noise:...7679
            Drive line noise:...7679
          Abnormal Frame Noise:...7679
            Front fork noise:...7679
            Rear shock absorber noise:...7679
            Disc brake noise:...7679
            Other noise:...7679
          Oil Pressure Warning Light Goes On:...7679
          Exhaust Smokes Excessively:...7679
            White smoke:...7679
            Black smoke:...7679
            Brown smoke:...7679
          Handling and/or Stability Unsatisfactory:...7679
            Handlebar hard to turn:...7679
            Handlebar shakes or excessively vibrates:...7679
            Handlebar pulls to one side:...7679
            Shock absorption unsatisfactory:...7679
          Brake Doesn't Hold:...7680
          Battery Trouble:...7680
            Battery discharged:...7680
            Battery overcharged:...7680
Kawasaki Motorcycle Service Repair Manual '06-'07 ZX-14 (EN)...7682
  tables...0
    LIST OF ABBREVIATIONS...7685
    COUNTRY AND AREA CODES...7685
    Units of Mass...7707
    Units of Volume...7707
    Units of Force...7707
    Units of Length...7707
    Units of Torque...7707
    Units of Pressure...7707
    Units of Speed...7707
    Units of Power...7707
    Periodic Inspection...7710
    Periodic Replacement Parts...7712
    Basic Torque for General Fasteners...7718
    Throttle Grip Free Play...7722
    Throttle Body Vacuum...7723
    Main Throttle Sensor Output Voltage...7725
    Idle Speed...7726
    Valve Clearance...7729
    Adjustment Shims...7731
    Air Pressure (when Cold)...7736
    Tread Depth...7736
    Chain Slack...7738
    Drive Chain 20-link Length...7739
    Standard Chain...7740
    Recommended Disc Brake Fluid...7743
    Pad Lining Thickness...7743
    Sidestand Switch Operation...7752
    Water and Coolant Mixture Ratio (Recommended)...7759
    Recommended Engine Oil...7761
    Standard Spark Plug...7774
    Sample Diagnosis Sheet...7805
    Engine Won't Turn Over...7807
    Poor Running at Low Speed...7807
    Poor Running or No Power at High Speed:...7810
    Main Throttle Sensor Input Voltage...7820
    Input Voltage at ECU Connector...7820
    Main Throttle Sensor Input Voltage...7821
    Input Voltage at Sensor...7821
    Main Throttle Sensor Output Voltage...7822
    Idle Speed...7822
    Output Voltage at ECU...7822
    Throttle Sensor Output Voltage...7824
    Output Voltage at Sensor...7824
    Main Throttle Sensor Resistance...7825
    Inlet Air Pressure Sensor Input Voltage...7827
    Input Voltage at ECU...7827
    Inlet Air Pressure Sensor Input Voltage...7827
    Input Voltage at Sensor Connector...7827
    Inlet Air Pressure Sensor Output Voltage...7828
    Output Voltage at ECU...7828
    Inlet Air Pressure Sensor Output Voltage...7828
    Output Voltage at Sensor Connector...7828
    Inlet Air Pressure Sensor Output Voltage Connection to Adapter...7830
    Inlet Air Temperature Sensor Output Voltage...7832
    Output Voltage at ECU...7832
    Inlet Air Temperature Sensor Resistance...7833
    Water Temperature Sensor Output Voltage...7835
    Output Voltage at ECU...7835
    Atmospheric Pressure Sensor Input Voltage...7837
    Input Voltage at ECU...7837
    Atmospheric Pressure Sensor Input Voltage...7838
    Input Voltage at Sensor Connector...7838
    Atmospheric Pressure Sensor Output Voltage...7838
    Output Voltage...7838
    Atmospheric Pressure Sensor Output Voltage...7839
    Output Voltage at Sensor...7839
    Speed Sensor Input Voltage...7843
    Input Voltage...7843
    Speed Sensor Output Voltage...7844
    Output Voltage at Sensor ...7844
    Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions...7846
    Input Voltage at 1 ∼ 6 Gear Positions...7846
    Vehicle-down sensor Power Source Voltage...7849
    Power Source Voltage at Sensor...7849
    Vehicle-down sensor Output Voltage...7850
    Output Voltage at Sensor...7850
    Subthrottle Sensor Input Voltage...7851
    Input Voltage at ECU Connector...7851
    Subthrottle Sensor Input Voltage...7852
    Input Voltage at Sensor...7852
    Subthrottle Sensor Output Voltage...7853
    Output Voltage at ECU...7853
    Subthrottle Sensor Output Voltage...7854
    Output Voltage at Sensor...7854
    Subthrottle Sensor Resistance...7855
    Antenna Resistance...7856
    Amplifier Input Voltage...7856
    Input Voltage...7856
    Testing Relay...7858
    Stick Coil Input Voltage at ECU...7860
    Input Voltage at ECU...7860
    Subthrottle Valve Actuator Resistance...7862
    Subthrottle Valve Actuator Input Voltage...7863
    Input Voltage...7863
    ECU Identification...7866
    ECU Grounding Inspection...7868
    ECU Power Source Inspection...7869
    Fuel Pressure...7873
    Fuel Pressure (idling)...7874
    Amount of Fuel Flow...7876
    Pump Operating Voltage at Pump...7878
    Operating Voltage at Pump Connector...7878
    Injector Power Source Voltage at ECU Connector...7880
    Power Source Voltage at ECU...7880
    Injector Power Source Voltage at Injector...7881
    Power Source Voltage at Injector Connector...7881
    Injector Output Voltage at ECU...7881
    Output Voltage at ECU...7881
    Injector Output Voltage at Injector...7882
    Output Voltage at Injector Connector...7882
    Injector Resistance...7883
    Fuel Line Maximum Pressure...7884
    Radiator Cap Relief Pressure...7920
    Thermostat Valve Opening Temperature...7922
    Camshaft Journal, Camshaft Cap Clearance...7945
    Camshaft Journal Diameter...7946
    Camshaft Runout...7946
    Cam Height...7946
    Cylinder Compression...7948
    Cylinder Head Warp...7950
    Valve/Valve Guide Clearance (Wobble Method)...7953
    Valve Seating Surface Outside Diameter...7954
    Valve Seating Surface Width...7954
    Clutch Plate Assembly Length...7978
    Friction Plate Thickness (13088-0030, 13088-0031)...7979
    Friction Plate Thickness (13088-0032)...7979
    Friction and Steel Plate Warp...7979
    Friction Plate Warp (only 13088-0030)...7979
    Clutch Spring Free Length...7979
    Oil Pressure...7994
    Connecting Rod Big End Bearing Insert Selection...8015
    Crankshaft Main Bearing Insert Selection...8015
    Connecting Rod Bend...8026
    Connecting Rod Twist...8027
    Connecting Rod Big End Side Clearance...8027
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...8027
    Crankpin Diameter...8028
    Crankpin Diameter Marks...8028
    Connecting Rod Big End Inside Diameter Marks...8028
    Crankshaft Side Clearance...8029
    Crankshaft ##3 Main Journal Width...8030
    Crankshaft Runout...8030
    Crankshaft Main Bearing Insert/Journal Clearance...8031
    Crankshaft Main Journal Diameter...8031
    Crankshaft Main Journal Diameter Marks...8031
    Crankcase Main Bearing Inside Diameter Marks...8031
    Cylinder Inside Diameter...8035
    Piston Diameter...8035
    Piston Ring/Groove Clearance...8035
    Piston Ring Groove Width...8036
    Piston Ring Thickness...8036
    Piston Ring End Gap...8036
    Shift Fork Ear Thickness...8052
    Gear Groove Width...8052
    Shift Fork Guide Pin Diameter...8052
    Shift Drum Groove Width...8052
    Rim Runout (with tire installed)...8063
    Axle Runout/100 mm (3.94 in.)...8063
    Balance Weight...8065
    Rear Sprocket Warp (Runout)...8082
    Pedal Position...8097
    Brake Discs Thickness...8108
    Disc Runout...8108
    Sample Diagnosis Sheet...8122
    Service Code Table...8129
    Terminal Voltage...8130
    Battery Terminal Voltage...8132
    Battery Terminal Voltage...8134
    Air Gap...8135
    Air Gap...8136
    Battery Terminal Voltage...8138
    Battery Terminal Voltage...8139
    Air Gap...8145
    Rebound Damping Force Adjustment...8156
    Compression Damping Force Adjustment...8156
    Adjuster Protrusion (from top)...8157
    Spring Action...8157
    Fork Oil...8160
    Oil Level (fully compressed, without spring)...8161
    Spring Free Length...8165
    Rebound Damping Force Adjustment...8166
    Rebound Damping Force Adjustment...8166
    Spring Preload Setting...8167
    Spring Adjustment...8167
    Kawasaki-recommended chargers:...8245
    Battery Terminal Voltage...8247
    Terminal Voltage: 11.5 ∼ less than 12.6 V...8247
    Terminal Voltage: less than 11.5 V...8247
    Table 1 Alternator Output Voltage...8251
    Table 2 Stator Coil Resistance at 20°C (68°F)...8251
    Regulator/Rectifier Resistance (Unit: kΩ)...8252
    Charging Voltage...8253
    Connections:...8258
    Crankshaft Sensor Peak Voltage...8258
    Stick Coil Winding Resistance...8259
    Primary Lead Connection...8259
    Stick Coil Primary Peak Voltage...8260
    Connections:...8262
    Camshaft Position Sensor Peak Voltage...8262
    Condition:...8262
    Condition:...8263
    Condition:...8263
    Starter Motor Brush Length...8267
    Commutator Diameter...8268
    Testing Relay...8269
    Testing Relay...8273
    Testing Turn Signal Relay...8277
    Air Switching Valve Resistance...8279
    CAN Communication Line Resistance (at Meter Unit)...8283
    Connections:...8293
    Speed Sensor Supply Voltage...8293
    Connections:...8294
    User Key Indicator Light Flashes...8302
    Water Temperature Sensor...8320
    Fuel Level Sensor Resistance...8321
    Connections...8322
    Gear Position Switch Resistance kΩ...8324
    Relay Circuit Inspection (with the battery disconnected)...8325
    Relay Circuit Inspection (with the battery connected)...8326
    Diode Circuit Inspection...8326
  toc...0
    EMISSION CONTROL INFORMATION...7686
      1...7686
      2...7686
      3...7686
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...7687
      Foreword...7688
      General Information...7690
        Before starting to perform an inspection service or carry out a ...7691
          Battery Ground...7691
          Edges of Parts...7691
          Solvent...7691
          Cleaning vehicle before disassembly...7691
          Arrangement and Cleaning of Removed Parts...7692
          Storage of Removed Parts...7692
          Inspection...7692
          Replacement Parts...7692
          Assembly Order...7692
          Tightening Sequence...7693
          Tightening Torque...7693
          Force...7693
          Gasket, O-ring...7693
          Liquid Gasket, Non-permanent Locking Agent...7693
          Press...7694
          Ball Bearing and Needle Bearing...7694
          Oil Seal, Grease Seal...7694
          Circlips, Cotter Pins...7694
          Lubrication...7695
          Direction of Engine Rotation...7695
          Electrical Leads...7695
          Instrument...7695
        ZX1400A6F (Europe) Left Side View...7696
        ZX1400A6F (Europe) Right Side View...7696
        Frame Number...7696
        Engine Number...7696
        ZX1400A6F (United States and Canada) Left Side View...7697
        ZX1400A6F (United States and Canada) Right Side View...7697
        ZX1400A6F (Malaysia) Left Side View...7698
        ZX1400A6F (Malaysia) Right Side View...7698
        ZX1400B6F (Europe) Left Side View...7699
        ZX1400B6F (Europe) Right Side View...7699
        ZX1400B6F (Malaysia) Left Side View...7700
        ZX1400B6F (Malaysia) Right Side View...7700
        Overview...7704
          Structure and Function...7705
          System maintenance...7706
        Prefixes for Units...7707
        Units of Temperature...7707
      Periodic Maintenance...7708
        The scheduled maintenance must be done in accordance with this c...7710
        The following tables list the tightening torque for the major fa...7713
        Inside Circlip Pliers:...7721
        Fuel System (DFI)...7722
          Throttle Control System Inspection...7722
          Engine Vacuum Synchronization Inspection...7722
            Special Tool -...7723
            Special Tool -...7724
            Special Tool -...7724
            Torque -...7725
            Torque -...7725
          Idle Speed Inspection...7726
          Idle Speed Adjustment...7726
          Fuel Hose Inspection (fuel leak, damage, installation condition)...7726
          Evaporative Emission Control System (CAL) Inspection...7727
          Cooling System...7728
            Coolant Level Inspection...7728
            Water Hose and Pipe Inspection...7728
              Torque -...7728
          Engine Top End...7729
            Valve Clearance Inspection...7729
            EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART...7732
            INLET- VALVE CLEARANCE ADJUSTMENT CHART...7733
              Air Suction System Damage Inspection...7734
          Clutch...7734
            Clutch Operation Inspection ...7734
            Clutch Fluid Level Inspection...7735
            Clutch Fluid Leak Inspection...7735
            Clutch Hose and Pipe Damage and Installation Condition Inspectio...7735
              Torque -...7735
          Wheels/Tires...7736
            Air Pressure Inspection...7736
            Wheel/Tire Damage Inspection...7736
            Tire Tread Wear Inspection ...7736
            Wheel Bearing Damage Inspection...7737
          Final Drive...7737
            Drive Chain Lubrication Condition Inspection...7737
            Drive Chain Slack Inspection...7738
            Drive Chain Slack Adjustment...7738
              Torque -...7738
            Wheel Alignment Inspection...7739
            Drive Chain Wear Inspection...7739
            Drive Chain Guide Wear Inspection...7740
          Brakes...7741
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...7741
            Brake Hose and Pipe Damage and Installation Condition Inspection...7742
              Torque -...7742
            Brake Operation Inspection...7742
            Brake Fluid Level Inspection...7742
            Brake Pad Wear Inspection...7743
            Brake Light Switch Operation Inspection...7744
          Suspension...7744
            Front Forks/Rear Shock Absorber Operation Inspection...7744
            Front Fork Oil Leak Inspection...7745
            Rear Shock Absorber Oil Leak Inspection...7745
            Rocker Arm Operation Inspection...7745
            Tie-Rod Operation Inspection...7745
          Steering...7746
            Steering Play Inspection...7746
              Special Tools -...7746
            Steering Play Adjustment...7746
              Special Tool -...7747
              Torque -...7747
            Steering Stem Bearing Lubrication...7747
          Electrical System...7748
            Lights and Switches Operation Inspection...7748
            Headlight Aiming Inspection...7751
            Sidestand Switch Operation Inspection...7752
            Engine Stop Switch Operation Inspection...7753
          Others...7753
            Chassis Parts Lubrication and Cable Inspection...7753
              Pivots: Lubricate with Grease...7753
              Points: Lubricate with Grease...7753
              Points: Lubricate with Engine Oil...7753
              Cables: Lubricate with Rust Inhibitor...7754
            Bolts, Nuts and Fasteners Tightness Inspection...7754
              Bolt, Nut and Fastener to be checked...7755
          Replacement Parts...7755
            Air Cleaner Element Replacement...7755
              Torque -...7756
            Fuel Hose Replacement...7756
            Coolant Change...7758
              Torque -...7758
            Radiator Hose and O-ring Replacement...7760
            Engine Oil Change...7760
              Torque -...7760
            Oil Filter Replacement...7761
              Special Tool -...7761
              Torque -...7761
            Brake Hose and Pipe Replacement...7762
              Torque -...7763
            Brake Fluid Change...7764
              Torque -...7765
              Torque -...7765
            Master Cylinder Rubber Parts Replacement...7765
              Special Tool -...7765
              Special Tool -...7765
              Torque -...7766
            Caliper Rubber Parts Replacement...7766
              Torque -...7767
              Torque -...7767
            Rear Caliper Assembly...7769
              Torque -...7769
              Torque -...7770
            Clutch Hose and Pipe Replacement...7770
              Torque -...7770
            Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacemen...7771
              Special Tool -...7771
              Torque -...7771
            Clutch Fluid Change...7773
              Torque -...7773
            Spark Plug Replacement...7773
              Torque -...7774
      Fuel System (DFI)...7776
        DFI System...7785
        Terminal Numbers of ECU Connectors...7789
        Main Throttle Sensor [A]...7791
        Oil Pressure Gauge, 5 kgf/cm :...7795
        DFI Servicing Precautions...7797
          Torque -...7798
        Outline...7799
          Special Tool -...7801
          Sealant -...7801
          Special Tool -...7802
          DFI Diagnosis Flow Chart...7804
          Inquiries to Rider...7804
        NOTE...7807
        Self-diagnosis Outline...7812
          Self-diagnosis Procedures...7813
          Self-Diagnosis Flow Chart...7815
            Service Code Reading...7816
            Service Code Erasing...7816
          Backups...7818
        The main throttle sensor is a rotating variable resistor that ch...7820
          Main Throttle Sensor Removal/Adjustment...7820
          Input Voltage Inspection...7820
            Special Tool -...7820
            Special Tool -...7821
          Output Voltage Inspection...7822
            Special Tool -...7822
            Special Tool -...7824
          Resistance Inspection...7825
          Main Throttle Sensor Circuit...7825
        CAUTION...7826
          Removal...7826
          Installation...7826
          Input Voltage Inspection...7827
            Special Tool -...7827
            Special Tool -...7827
          Output Voltage Inspection...7828
            Special Tool -...7828
            Special Tool -...7828
          Inlet Air Pressure Sensor Circuit...7829
            Special Tools -...7830
        Removal/Installation...7832
          Output Voltage Inspection...7832
            Special Tool -...7832
          Sensor Resistance Inspection...7833
          Inlet Air Temperature Sensor Circuit...7834
        Removal/Installation...7835
          Torque -...7835
          Output Voltage Inspection...7835
            Special Tool -...7835
          Sensor Resistance Inspection...7836
          Water Temperature Sensor Circuit...7836
        CAUTION...7837
          Removal...7837
          Installation...7837
          Input Voltage Inspection...7837
            Special Tool -...7837
            Special Tool -...7838
          Output Voltage Inspection...7838
            Special Tool -...7838
            Special Tool -...7839
          Atmospheric Pressure Sensor Circuit...7839
          Atmospheric Pressure/Altitude Relationship...7840
        Crankshaft Sensor Removal/Installation...7841
          Crankshaft Sensor Inspection...7841
          Crankshaft Sensor Circuit...7841
        Camshaft Position Sensor Removal/Installation...7842
          Camshaft Position Sensor Inspection...7842
          Camshaft Position Sensor Circuit...7842
        Speed Sensor Removal/Installation...7843
          Speed Sensor Inspection...7843
          Input Voltage Inspection...7843
            Special Tool -...7843
          Output Voltage Inspection...7844
            Special Tool -...7844
        Gear Position Switch Removal/Installation...7846
          Gear Position Switch Inspection...7846
          Input Voltage Inspection...7846
            Special Tool -...7846
          Gear Position Switch Circuit...7847
        This sensor has a weight [A] with two magnets inside, and sends ...7848
          Removal...7848
          Installation...7848
            Torque -...7848
          Inspection...7849
            Special Tool -...7849
            Special Tool -...7850
          Vehicle-down Sensor Circuit...7850
        The subthrottle sensor is a rotating variable resistor that chan...7851
          Subthrottle Sensor Removal/Adjustment...7851
          Input Voltage Inspection...7851
            Special Tool -...7851
            Special Tool -...7852
          Output Voltage Inspection...7853
            Special Tool -...7853
            Special Tool -...7854
          Resistance Inspection...7855
          Subthrottle Sensor Circuit...7855
        Antenna Resistance Inspection...7856
          Amplifier Input Voltage Inspection...7856
            Special Tool -...7856
          User Key Inspection...7857
          Immobilizer System Circuit...7857
        Fuel Pump Relay Removal...7858
          Fuel Pump Relay Inspection...7858
            Special Tool -...7858
          Fuel Pump Relay Circuit...7859
        Stick Coil ##1: Service Code 51...7860
          Removal/Installation...7860
          Input Voltage Inspection...7860
            Special Tool -...7860
          Stick Coil Circuit...7861
        Subthrottle Valve Actuator Removal...7862
          Subthrottle Valve Actuator Inspection...7862
          Resistance Inspection...7862
          Input Voltage Inspection...7863
            Special Tools -...7863
          Subthrottle Valve Actuator Circuit...7864
        ECU Main Relay Inspection...7865
        CAUTION...7866
          ECU Identification...7866
          ECU Removal...7866
          ECU Installation...7867
          ECU Power Supply Inspection...7868
            Special Tool -...7868
          ECU Power Source Circuit...7870
            CAN Communication Line Resistance Inspection...7870
          CAN Communication Line Circuit...7871
        Light (LED) Inspection...7872
          Warning Indicator Light (LED) Circuit...7872
        Fuel Pressure Inspection...7873
          Special Tools -...7873
          Fuel Flow Rate Inspection...7874
            Special Tool -...7874
        Fuel Pump Removal...7877
          Fuel Pump Installation...7877
            Torque -...7878
          Operation Inspection...7878
          Operating Voltage Inspection...7878
            Special Tools -...7878
          Fuel Pump Circuit...7879
        Removal/Installation...7880
          Power Source Voltage Inspection...7880
            Special Tool -...7880
            Special Tool -...7881
          Output Voltage Inspection...7881
            Special Tool -...7881
            Special Tool -...7882
          Audible Inspection...7882
          Injector Signal Test...7883
            Special Tool -...7883
          Injector Resistance Inspection...7883
          Injector Unit Test...7884
          Injector Fuel Line Inspection...7884
          Fuel Injector Circuit...7885
        Free Play Inspection...7886
          Free Play Adjustment...7886
          Cable Installation...7886
          Cable Lubrication...7886
        Idle Speed Inspection...7887
          Throttle Bore Cleaning...7887
          Synchronization Inspection...7887
          Synchronization Adjustment...7887
          Throttle Body Assy Removal...7887
          Throttle Body Assy Installation...7890
            Torque -...7890
            Torque -...7891
            Torque -...7891
          Throttle Body Assy Disassembly...7892
            Throttle Body Assy Assembly...7893
              Torque -...7894
        Element Removal...7895
          Element Installation...7895
          Air Cleaner Element Inspection...7895
          Air Cleaner Element Holder Removal...7895
          Air Cleaner Element Holder Installation...7895
            Torque -...7895
          Oil Draining...7896
          Rear Air Inlet Duct Removal...7896
          Rear Air Inlet Duct Installation...7896
            Torque -...7896
            Torque -...7897
          Front and Middle Air Inlet Duct Removal...7897
          Front and Middle Air Inlet Duct Installation...7897
            Torque -...7898
            Torque -...7898
            Torque -...7898
        Fuel Tank Removal...7899
          Fuel Tank Installation...7901
          Fuel Tank and Cap Inspection...7903
          Fuel Tank Cleaning...7903
        The Evaporative Emission Control System routes fuel vapors from ...7904
          Parts Removal/Installation...7904
          Hose Inspection...7904
          Separator Inspection...7904
          Separator Operation Test...7905
          Canister Inspection...7905
      Cooling System...7908
        Coolant Deterioration Inspection...7914
          Coolant Level Inspection...7914
          Coolant Draining...7914
          Coolant Filling...7914
          Pressure Testing...7914
          Cooling System Flushing...7915
          Coolant Reserve Tank Removal/Installation...7915
        Water Pump Removal...7916
          Water Pump Installation...7916
            Torque -...7917
          Water Pump Impeller Inspection...7917
        Radiator and Radiator Fan Removal...7918
          Radiator and Radiator Fan Installation...7919
            Torque -...7919
          Radiator Inspection...7919
          Radiator Cap Inspection...7920
          Radiator Filler Neck Inspection...7920
        Thermostat Removal...7921
          Thermostat Installation...7921
            Torque -...7921
          Thermostat Inspection...7921
        Hose Installation...7923
          Torque -...7923
          Hose Inspection...7923
        CAUTION...7924
          Water Temperature Sensor Removal...7924
          Water Temperature Sensor Inspection...7924
      Engine Top End...7926
        Compression Gauge, 20 kgf/cm :...7934
        Air Suction Valve Removal...7936
          Air Suction Valve Installation...7936
            Torque -...7936
          Air Suction Valve Inspection...7937
          Air Switching Valve Removal...7937
          Air Switching Valve Installation...7937
          Air Switching Valve Operation Test...7937
          Air Switching Valve Unit Test...7937
          Clean Air System Hose Inspection...7937
        Cylinder Head Cover Removal...7938
          Cylinder Head Cover Installation...7938
            Sealant -...7938
            Torque -...7939
        Camshaft Chain Tensioner Removal...7940
          Camshaft Chain Tensioner Installation...7940
            Torque -...7940
        Camshaft Removal...7942
          Camshaft Installation...7942
            Torque -...7942
            Torque -...7945
          Camshaft, Camshaft Cap Wear...7945
            Torque -...7945
          Camshaft Runout...7946
          Cam Wear...7946
          Camshaft Chain Removal...7946
          Camshaft Chain Installation...7947
            Torque -...7947
        Cylinder Compression Measurement...7948
          Owner's Tool -...7948
          Special Tools -...7948
          Torque -...7948
          Cylinder Head Removal...7949
          Cylinder Head Installation...7949
            Torque -...7950
            Torque -...7950
            Torque -...7950
            Torque -...7950
          Cylinder Head Warp Inspection...7950
        Valve Clearance Inspection...7951
          Valve Removal...7951
            Special Tools -...7951
          Valve Installation...7951
          Valve Guide Removal...7951
            Special Tool -...7951
          Valve Guide Installation...7952
            Special Tools -...7952
            Special Tool -...7952
          Valve-to-Guide Clearance Measurement (Wobble Method)...7953
          Valve Seat Inspection...7954
          Valve Seat Repair...7954
            Special Tools -...7954
        Throttle Body Holder Installation...7959
          Torque -...7959
        WARNING...7960
          Muffler Body Removal/Installation...7960
            Torque -...7961
          Exhaust Pipe Removal...7961
          Exhaust Pipe Installation...7961
            Torque -...7961
      Clutch...7962
        Inside Circlip Pliers:...7966
        Clutch Lever Adjustment...7967
          Clutch Master Cylinder Removal...7967
          Clutch Master Cylinder Installation ...7967
            Torque -...7968
            Torque -...7968
          Clutch Master Cylinder Disassembly ...7968
          Clutch Master Cylinder Assembly...7968
          Clutch Master Cylinder Inspection...7968
            Special Tool -...7968
        Clutch Slave Cylinder Removal...7969
          Clutch Slave Cylinder Installation...7970
            Torque -...7970
            Torque -...7970
          Clutch Slave Cylinder Disassembly ...7970
          Clutch Slave Cylinder Assembly...7970
        Clutch Fluid Level Inspection...7971
          Clutch Fluid Change...7971
          Bleeding the Clutch Line...7971
            Torque -...7972
            Torque -...7972
            Torque -...7973
          Clutch Hose Removal/Installation...7973
          Clutch Hose and Connection Inspection...7973
        Clutch Cover Removal...7974
          Clutch Cover Installation...7974
            Sealant -...7974
            Torque -...7974
        Clutch Removal...7975
          Special Tool -...7975
          Special Tool -...7975
          Clutch Installation...7976
            Special Tool -...7976
            Special Tool -...7976
            Torque -...7976
            Torque -...7977
          Clutch Plate Assembly Inspection...7978
            Torque -...7978
          Clutch Plate Assembly Adjustment...7978
            Torque -...7978
          Clutch Plate, Wear, Damage Inspection...7979
          Clutch Plate Warp Inspection...7979
          Clutch Spring Free Length Measurement...7979
      Engine Lubrication System...7980
        Oil Pressure Gauge, 10 kgf/cm :...7986
        WARNING...7987
          Oil Level Inspection...7987
          Engine Oil Change...7987
          Oil Filter Replacement...7987
        Oil Pan Removal...7988
          Special Tool -...7988
          Oil Pan Installation...7988
            Torque -...7988
            Torque -...7989
        Oil Pressure Relief Valve Removal...7990
          Oil Pressure Relief Valve Installation...7990
          Oil Pressure Relief Valve Inspection...7990
        Oil Pump Removal...7991
          Oil Pump Installation...7991
            Torque -...7992
        Oil Cooler Removal...7993
          Oil Cooler Installation...7993
            Torque -...7993
            Torque -...7993
        Oil Pressure Measurement...7994
          Special Tools -...7994
          Torque -...7994
        Oil Pressure Switch Removal...7995
          Oil Pressure Switch Installation...7995
            Sealant -...7995
            Torque -...7995
            Torque -...7995
      Engine Removal/Installation...7996
        Engine Removal...7999
          Engine Installation...8001
            Torque -...8004
            Torque -...8005
            Torque -...8005
      Crankshaft/Transmission...8008
        Bearing Puller:...8016
        Crankcase Splitting...8017
          Crankcase Assembly...8018
            Torque -...8018
            Sealant -...8019
            Torque -...8020
            Torque -...8020
            Torque -...8021
        Crankshaft Removal...8022
          Crankshaft Installation...8022
          Connecting Rod Removal...8023
          Connecting Rod Installation...8023
          Crankshaft/Connecting Rod Cleaning...8026
          Connecting Rod Bend Inspection...8026
          Connecting Rod Twist Inspection...8027
          Connecting Rod Big End Side Clearance Inspection...8027
          Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection...8027
          Crankshaft Side Clearance Inspection...8029
          Crankshaft Runout Inspection...8030
          Crankshaft Main Bearing Insert/Journal Wear Inspection...8030
        Piston Removal...8033
          Special Tool -...8033
          Piston Installation...8034
            Special Tools -...8035
          Cylinder Wear (Upper Crankcase) Inspection...8035
          Piston Wear Inspection...8035
          Piston Ring, Piston Ring Groove Wear Inspection...8035
          Piston Ring Groove Width Inspection...8036
          Piston Ring Thickness Inspection...8036
          Piston Ring End Gap Inspection...8036
        Front Balancer Removal...8037
          Front Balancer Installation...8037
            Torque -...8038
            Torque -...8038
          Rear Balancer Removal...8038
          Rear Balancer Installation...8039
            Torque -...8040
            Torque -...8040
          Balancer Adjustment...8041
            Torque -...8041
          Balancer Damper Inspection...8041
        Starter Motor Clutch Removal...8042
          Starter Motor Clutch Installation...8042
            Torque -...8042
            Torque -...8042
          Starter Motor Clutch Disassembly...8042
          Starter Motor Clutch Assembly...8043
          Starter Clutch Inspection...8043
          Torque Limiter Removal...8043
          Torque Limiter Installation...8044
            Torque -...8044
        Shift Pedal Removal...8045
          Shift Pedal Installation...8045
            Torque -...8045
          External Shift Mechanism Removal...8045
          External Shift Mechanism Installation...8046
            Torque -...8046
          External Shift Mechanism Inspection...8046
            Torque -...8046
          Transmission Shaft Removal...8046
          Transmission Shaft Installation...8047
            Torque -...8047
          Transmission Shaft Disassembly...8048
            Special Tools -...8048
          Transmission Shaft Assembly...8048
          Shift Drum and Fork Removal...8051
          Shift Drum and Fork Installation...8051
            Torque -...8051
          Shift Drum Disassembly...8051
          Shift Drum Assembly...8051
            Torque -...8051
          Shift Fork Bending Inspection...8052
          Shift Fork/Gear Groove Wear Inspection...8052
          Shift Fork Guide Pin/Drum Groove Wear Inspection...8052
          Gear Dog and Gear Dog Hole Damage Inspection...8052
      Wheels/Tires...8054
        Bearing Driver Set:...8058
        Front Wheel Removal...8059
          Special Tools -...8059
          Front Wheel Installation...8059
            Torque -...8060
            Torque -...8060
          Rear Wheel Removal...8060
          Rear Wheel Installation...8061
            Torque -...8061
          Wheel Inspection...8063
            Special Tools -...8063
          Axle Inspection...8063
          Balance Inspection...8064
          Balance Adjustment...8064
          Balance Weight Removal...8064
          Balance Weight Installation...8065
        Air Pressure Inspection/Adjustment...8067
          Tire Inspection...8067
          Tire Removal...8067
          Tire Installation...8067
          Tire Repair...8069
        Hub Bearing Removal...8070
          Special Tools -...8070
          Hub Bearing Installation...8070
            Special Tool -...8070
            Special Tool -...8070
          Hub Bearing Inspection...8070
          Hub Bearing Lubrication...8071
      Final Drive...8072
        Inside Circlip Pliers:...8076
        Drive Chain Slack Inspection...8077
          Drive Chain Slack Adjustment...8077
          Wheel Alignment Inspection/Adjustment...8077
          Drive Chain Wear Inspection...8077
          Drive Chain Lubrication...8077
          Drive Chain Removal...8077
          Drive Chain Installation...8077
        Engine Sprocket Removal...8078
          Engine Sprocket Installation...8078
            Torque -...8078
            Torque -...8078
            Torque -...8079
          Rear Sprocket Removal...8079
          Rear Sprocket Installation...8079
            Torque -...8079
            Torque -...8079
          Coupling Installation...8079
          Coupling Bearing Removal...8080
            Special Tool -...8080
            Special Tool -...8080
          Coupling Bearing Installation...8080
            Special Tool -...8080
            Special Tool -...8080
            Special Tool -...8080
          Coupling Bearing Inspection...8081
          Coupling Bearing Lubrication...8081
          Coupling Damper Inspection...8081
          Sprocket Wear Inspection...8081
          Rear Sprocket Warp (Runout) Inspection...8082
      Brakes...8084
        Dummy Page...8086
        ZX1400A Models...8087
        ZX1400A Models...8089
        ZX1400B Models...8091
        ZX1400B Models...8093
        Inside Circlip Pliers:...8096
        Brake Lever Position Adjustment...8097
          Brake Pedal Position Inspection ...8097
          Brake Pedal Position Adjustment ...8097
            Torque -...8097
          Brake Pedal Removal...8097
          Brake Pedal Installation...8098
            Torque -...8098
            Torque -...8098
            Torque -...8098
        Front Caliper Removal...8099
          Rear Caliper Removal...8099
          Caliper Installation...8100
            Torque -...8100
          Front Caliper Disassembly...8100
          Front Caliper Assembly...8100
          Rear Caliper Disassembly...8100
          Rear Caliper Assembly...8100
          Caliper Fluid Seal Damage Inspection...8101
          Caliper Dust Seal Damage Inspection...8101
          Caliper Piston and Cylinder Damage Inspection...8102
        Front Brake Pad Removal...8103
          Front Brake Pad Installation...8103
            Torque -...8103
          Rear Brake Pad Removal ...8104
          Rear Brake Pad Installation...8104
            Torque -...8104
          Brake Pad Wear Inspection...8104
        Front Master Cylinder Removal...8105
          Front Master Cylinder Installation...8105
            Torque -...8105
            Torque -...8105
          Rear Master Cylinder Removal...8105
          Rear Master Cylinder Installation...8106
            Torque -...8106
          Front Master Cylinder Disassembly...8106
          Rear Master Cylinder Disassembly...8106
          Master Cylinder Assembly...8106
          Master Cylinder Inspection (Visual Inspection)...8106
        Brake Disc Removal...8108
          Brake Disc Installation...8108
            Torque -...8108
          Brake Disc Wear Inspection...8108
          Brake Disc Warp Inspection...8108
            Special Tools -...8108
        Brake Fluid Level Inspection...8109
          Brake Fluid Change...8109
          Brake Line Bleeding...8109
            Torque -...8110
            Torque -...8111
            Torque -...8111
        Brake Hose and Pipe Removal/Installation...8113
          Brake Hose and Pipe Inspection...8113
        Parts Location...8114
        ABS System Wiring Diagram...8115
        Terminal Names...8116
          ABS Servicing Precautions...8117
          ABS Troubleshooting Outline...8119
            Special Tool -...8119
            Special Tool -...8120
          ABS Diagnosis Flow Chart...8121
          Inquiries to Rider...8122
          Pre-Diagnosis Inspection 1...8123
          Pre-Diagnosis Inspection 2...8124
          Self-diagnosis Outline...8124
            Self-diagnosis Procedures...8124
            Service Code Clearing Procedures...8125
          Self-diagnosis Flow Chart...8127
          How to Read Service Codes...8128
          How to Erase Service Codes...8128
            ABS Indicator Light (LED) Inspection...8130
            ABS Indicator Light (LED) is Unlit (When the Ignition Switch tur...8130
              Special Tool -...8130
            ABS Indicator Light (LED) Lights (When the Motorcycle is Running...8131
              Special Tool -...8131
            Solenoid Valve Inspection (Service Code 13,14,17,18)...8131
            ABS Solenoid Valve Relay Inspection (Service Code 19)...8131
              Special Tool -...8132
            Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)...8133
            ABS Pump Motor Relay Inspection (Service Code 35)...8133
              Special Tool -...8134
            Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)...8135
            Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)...8135
            Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)...8136
            Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)...8137
            Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)...8138
              Special Tool -...8138
            Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)...8139
              Special Tool -...8139
            ECU Inspection (Service Code 55)...8140
            ABS Hydraulic Unit Removal...8140
            ABS Hydraulic Unit Installation...8141
              Torque -...8142
            ABS Hydraulic Unit Inspection...8142
            Front Wheel Rotation Sensor Removal...8142
            Front Wheel Rotation Sensor Installation...8143
            Rear Wheel Rotation Sensor Removal...8143
            Rear Wheel Rotation Sensor Installation...8144
            Wheel Rotation Sensor Inspection...8144
            Wheel Rotation Sensor Air Gap Inspection...8145
            Wheel Rotation Sensor Rotor Inspection...8145
            ABS Solenoid Valve Relay Fuse (20 A) Removal...8146
            ABS Motor Relay Fuse (30 A) Removal...8146
            ABS ECU Fuse (10 A) Removal...8146
            Fuse Installation...8146
            Fuse Inspection...8146
      Suspension...8148
        Inside Circlip Pliers:...8154
        Rebound Damping Force Adjustment...8156
          Compression Damping Force Adjustment...8156
          Spring Preload Adjustment...8157
          Front Fork Removal (Each Fork Leg)...8157
          Front Fork Installation...8158
            Torque -...8158
            Torque -...8158
          Front Fork Oil Change...8158
            Special Tools -...8158
            Special Tool -...8160
            Special Tool -...8161
            Special Tool -...8161
            Special Tool -...8161
            Special Tools -...8162
            Torque -...8162
          Front Fork Disassembly...8163
            Special Tool -...8163
          Front Fork Assembly...8163
            Special Tool -...8163
            Torque -...8163
            Special Tool -...8164
          Inner Tube Inspection...8164
          Dust Seal Inspection...8165
          Spring Tension...8165
        Rebound Damping Force Adjustment...8166
          Compression Damping Force Adjustment...8166
          Spring Preload Adjustment...8166
            Special Tool -...8166
            Special Tool -...8167
          Rear Shock Absorber Removal...8167
            Special Tools -...8167
          Rear Shock Absorber Installation...8168
            Torque -...8168
          Rear Shock Absorber Inspection...8168
          Rear Shock Absorber Scrapping...8169
        Swingarm Removal...8170
          Special Tool -...8170
          Swingarm Installation...8171
            Torque -...8171
            Special Tool -...8171
            Torque -...8171
            Torque -...8171
          Swingarm Bearing Removal...8172
            Special Tool -...8172
            Special Tool -...8172
          Swingarm Bearing Installation...8172
            Special Tools -...8172
          Swingarm Bearing, Sleeve Inspection...8173
          Chain Guide Inspection...8174
        Tie-Rod Removal...8175
          Special Tools -...8175
          Tie-Rod Installation...8175
            Torque -...8175
          Rocker Arm Removal...8175
            Special Tools -...8175
          Rocker Arm Installation...8176
            Torque -...8176
          Tie-Rod and Rocker Arm Bearing Removal...8176
            Special Tools -...8176
          Tie-Rod and Rocker Arm Bearing Installation...8176
            Special Tools -...8177
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...8178
          Rocker Arm/Tie-Rod Bearing Lubrication...8178
      Steering...8180
        Head Pipe Outer Race Press Shaft:...8183
        Steering Inspection...8184
          Steering Adjustment...8184
        Stem, Stem Bearing Removal...8185
          Special Tool -...8185
          Special Tool -...8185
          Stem, Stem Bearing Installation...8186
            Special Tools -...8186
            Special Tools -...8186
            Special Tool -...8187
            Torque -...8187
            Torque -...8188
          Steering Stem Bearing Lubrication...8188
          Steering Stem Warp Inspection...8188
          Stem Cap Deterioration, Damage Inspection...8188
        Handlebar Removal...8189
          Handlebar Installation...8189
            Torque -...8189
            Torque -...8190
            Torque -...8190
      Frame...8192
        Seat Removal...8201
          Seat Installation...8201
        Lower Fairing Removal...8202
          Lower Fairing Installation...8202
          Fairing Cover Removal...8202
          Middle Fairing Removal...8202
          Middle Fairing Installation...8203
          Windshield Removal...8203
          Windshield Installation...8204
            Torque -...8204
          Upper Fairing Removal...8204
          Upper Fairing Disassembly...8204
            Upper Fairing Assembly...8204
            Upper Fairing Installation...8205
            Inner Cover Removal...8205
            Inner Cover Installation...8205
            Upper Inner Fairing Removal...8205
            Upper Inner Fairing Installation...8206
            Upper Fairing Bracket Removal...8206
            Upper Fairing Bracket Installation...8206
            Inner Fairing Removal...8206
            Inner Fairing Installation...8206
            Rear Fairing Removal...8206
            Rear Fairing Installation...8206
        Seat Cover Removal...8207
          Seat Cover Installation...8207
            Torque -...8208
        Front Fender Removal...8209
          Front Fender Installation...8209
          Flap and Rear Fender Removal...8209
          Flap and Rear Fender Installation...8210
            Torque -...8210
        Rear Frame Removal...8211
          Rear Frame Installation...8211
            Torque -...8211
          Frame Inspection...8211
        Center Stand Removal (Equipped Models)...8212
          Center Stand Installation (Equipped Models)...8212
            Torque -...8212
          Sidestand Removal...8212
          Sidestand Installation...8212
            Torque -...8212
            Torque -...8212
      Electrical System...8214
        Hand Tester:...8238
        There are a number of important precautions that are musts when ...8240
        Wiring Inspection...8241
          Special Tool -...8241
        Battery Removal...8242
          Battery Installation...8243
          Battery Activation...8243
          Precautions...8246
            1)...8246
            2)...8246
            3)...8246
            4)...8246
          Interchange...8246
            Charging Condition Inspection...8246
            Refreshing Charge...8247
        Alternator Cover Removal...8248
          Alternator Cover Installation...8248
            Sealant -...8248
            Torque -...8248
          Stator Coil Removal...8248
          Stator Coil Installation...8249
            Torque -...8249
            Sealant -...8249
            Torque -...8249
          Alternator Rotor Removal...8249
            Special Tools -...8249
            Special Tool -...8249
          Alternator Rotor Installation...8249
            Special Tools -...8250
            Torque -...8250
          Alternator Inspection...8250
            Special Tool -...8251
          Regulator/Rectifier Inspection...8252
            Special Tool -...8252
            Torque -...8252
          Charging Voltage Inspection...8253
            Special Tool -...8253
          Charging System Circuit...8254
            Crankshaft Sensor Removal...8256
            Crankshaft Sensor Installation...8257
              Torque -...8257
              Sealant -...8257
              Torque -...8257
            Crankshaft Sensor Inspection...8257
              Special Tool -...8257
            Crankshaft Sensor Peak Voltage Inspection...8257
              Special Tools -...8258
            Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...8258
            Stick Coil (Ignition Coil together with Spark Plug Cap) Installa...8258
            Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti...8259
            Stick Coil Primary Peak Voltage...8259
              Special Tools -...8259
            Spark Plug Removal...8260
            Spark Plug Installation...8260
            Spark Plug Condition Inspection...8260
            Camshaft Position Sensor Removal...8260
            Camshaft Position Sensor Installation...8261
              Torque -...8261
            Camshaft Position Sensor Inspection...8261
              Special Tool -...8261
            Camshaft Position Sensor Peak Voltage Inspection...8262
              Special Tools -...8262
            Interlock Operation Inspection...8262
            IC Igniter Inspection...8263
          Ignition System Circuit...8264
        Starter Motor Removal...8265
          Starter Motor Installation...8265
            Torque -...8265
            Torque -...8265
          Starter Motor Disassembly...8266
          Starter Motor Assembly...8266
            Torque -...8266
            Torque -...8267
          Brush Inspection...8267
          Commutator Cleaning and Inspection...8268
          Armature Inspection...8268
            Special Tool -...8268
          Brush Lead Inspection...8268
            Special Tool -...8268
          Right-hand End Cover Assembly Inspection...8269
            Special Tool -...8269
          Starter Relay Inspection...8269
            Special Tool -...8269
            Torque -...8269
          Electric Starter Circuit...8270
        This motorcycle adopt the daylight system and have a headlight r...8271
          Headlight Beam Horizontal Vertical Adjustment...8271
          Headlight Beam Vertical Adjustment...8271
          Headlight Bulb Replacement...8271
          City Light Bulb Replacement...8272
          Headlight Removal/Installation...8272
            Torque -...8272
          Headlight Relay Inspection...8273
            Special Tool -...8273
          Tail/Brake Light (LED) Removal...8273
          Tail/Brake Light (LED) Installation...8274
            Torque -...8274
          License Plate Light Bulb Replacement...8274
            Torque -...8274
          Headlight/Tail Light Circuit...8275
            Turn Signal Light Bulb Replacement...8275
            Turn Signal Relay Inspection...8277
          Turn Signal Light Circuit...8278
        Air Switching Valve Operation Test...8279
          Air Switching Valve Unit Test...8279
            Special Tool -...8279
        Fan Motor Inspection...8280
          Radiator Fan Circuit...8280
        Meter Unit Removal...8281
          Meter Unit Installation...8281
          Meter Unit Disassembly...8282
          Meter Unit Inspection...8282
            Special Tool -...8283
            Special Tool -...8293
            Special Tool -...8294
          Meter Unit Circuit...8298
        This motorcycle is equipped with an immobilizer system to protec...8299
          Operational Cautions...8299
            Key Registration...8299
              Special Tool -...8299
          Spare User Key Registration Flow Chart...8304
            Special Tool -...8305
          All Keys Initial Registration Flow Chart...8314
            Immobilizer System Parts Replacement...8315
            ECU (Electric Control Unit) Replacement (for Immobilizer Models)...8316
            Immobilizer System Inspection...8317
          Immobilizer System Circuit...8318
        Brake Light Timing Inspection...8319
          Brake Light Timing Adjustment...8319
          Switch Inspection...8319
            Special Tool -...8319
          Rear Brake Light Switch Connections...8319
          Sidestand Switch Connections...8319
          Oil Pressure Switch Connections *...8319
          Water Temperature Sensor Inspection...8320
          Speed Sensor Removal...8320
          Speed Sensor Installation...8320
            Torque -...8320
          Speed Sensor Inspection...8321
            Special Tool -...8321
          Fuel Level Sensor Inspection...8321
            Special Tools -...8321
            Torque -...8322
          Fuel Reserve Switch Inspection...8322
            Special Tool -...8322
          Gear Position Switch Removal...8323
          Gear Position Switch Installation...8324
            Torque -...8324
          Gear Position Switch Inspection...8324
            Special Tool -...8324
        The relay box [A] has relays and diodes. The relays and diodes c...8325
          Relay Box Removal...8325
          Relay Circuit Inspection...8325
          Diode Circuit Inspection...8326
          Relay Box Internal Circuit...8327
        30 A Main Fuse Removal...8328
          Fuse Box Fuse Removal...8328
          15 A ECU Fuse Removal...8329
          Fuse Installation...8329
          Fuse Inspection...8330
      Appendix...8332
        ZX1400B Models...8357
        ZX1400B Models...8367
        ZX1400B Models...8369
        ZX1400B Models...8371
        ZX1400B Models...8373
        ZX1400B Models...8375
        ZX1400B Models...8377
        ZX1400B Models...8379
        California Model...8381
        NOTE...8383
          Engine Doesn't Start, Starting Difficulty:...8383
            Starter motor not rotating:...8383
            Starter motor rotating but engine doesn't turn over:...8383
            Engine won't turn over:...8383
            No fuel flow:...8383
            No spark; spark weak:...8383
            Fuel/air mixture incorrect:...8383
            Compression Low:...8383
          Poor Running at Low Speed:...8383
            Spark weak:...8383
            Fuel/air mixture incorrect:...8383
            Compression low:...8384
            Run-on (dieseling):...8384
            Other:...8384
          Poor Running or No Power at High Speed:...8384
            Firing incorrect:...8384
            Fuel/air mixture incorrect:...8384
            Compression low:...8384
            Knocking:...8384
            Miscellaneous:...8384
          Overheating:...8384
            Firing incorrect:...8384
            Muffler overheating:...8384
            Fuel/air mixture incorrect:...8384
            Compression high:...8385
            Engine load faulty:...8385
            Lubrication inadequate:...8385
            Oil cooler incorrect:...8385
            Gauge incorrect:...8385
            Coolant incorrect:...8385
            Cooling system component incorrect:...8385
          Over Cooling:...8385
            Gauge incorrect:...8385
            Cooling system component incorrect:...8385
          Clutch Operation Faulty:...8385
            Clutch slipping:...8385
            Clutch not disengaging properly:...8385
          Gear Shifting Faulty:...8385
            Doesn't go into gear; shift pedal doesn't return:...8385
            Jumps out of gear:...8385
            Overshifts:...8385
          Abnormal Engine Noise:...8385
            Knocking:...8385
            Piston slap:...8385
            Valve noise:...8385
            Other noise:...8385
          Abnormal Drive Train Noise:...8386
            Clutch noise:...8386
            Transmission noise:...8386
            Drive line noise:...8386
          Abnormal Frame Noise:...8386
            Front fork noise:...8386
            Rear shock absorber noise:...8386
            Disc brake noise:...8386
            Other noise:...8386
          Oil Pressure Warning Light Goes On:...8386
          Exhaust Smokes Excessively:...8386
            White smoke:...8386
            Black smoke:...8386
            Brown smoke:...8386
          Handling and/or Stability Unsatisfactory:...8386
            Handlebar hard to turn:...8386
            Handlebar shakes or excessively vibrates:...8386
            Handlebar pulls to one side:...8386
            Shock absorption unsatisfactory:...8386
          Brake Doesn't Hold:...8387
          Battery Trouble:...8387
            Battery discharged:...8387
            Battery overcharged:...8387
Kawasaki Motorcycle Service Repair Manual '07 ZX-6R (EN)...8389
  tables...0
    LIST OF ABBREVIATIONS...8392
    COUNTRY AND AREA CODES...8392
    Units of Mass...8408
    Units of Volume...8408
    Units of Force...8408
    Units of Length...8408
    Units of Torque...8408
    Units of Pressure...8408
    Units of Speed...8408
    Units of Power...8408
    Periodic Inspection...8411
    Periodic Replacement Parts...8413
    Basic Torque for General Fasteners...8419
    Throttle Grip Free Play...8423
    Idle Speed...8424
    Engine Vacuum...8424
    Main Throttle Sensor Output Voltage...8426
    Idle Speed...8426
    Valve Clearance...8429
    Example:...8430
    Adjustment Shims...8431
    Clutch Lever Free Play...8434
    Air Pressure (when Cold)...8435
    Tread Depth...8435
    Chain Slack...8437
    Drive Chain 20-link Length...8439
    Standard Chain...8439
    Recommended Disc Brake Fluid...8441
    Pad Lining Thickness...8442
    Side Stand Switch Operation...8449
    Water and Coolant Mixture Ratio (Recommended)...8459
    Recommended Engine Oil...8461
    Standard Spark Plug...8468
    Terminal Names...8488
    Sample Diagnosis Sheet...8496
    Engine Won't Turn Over...8498
    Poor Running at Low Speed...8498
    Poor Running or No Power at High Speed:...8501
    Main Throttle Sensor Input Voltage...8511
    Input Voltage at ECU Connector...8511
    Main Throttle Sensor Input Voltage...8512
    Input Voltage at Sensor...8512
    Main Throttle Sensor Output Voltage...8512
    Idle Speed...8512
    Output Voltage at ECU...8512
    Main Throttle Sensor Output Voltage...8513
    Output Voltage at Sensor...8513
    Main Throttle Sensor Resistance...8513
    Inlet Air Pressure Sensor Input Voltage...8515
    Input Voltage at ECU...8515
    Inlet Air Pressure Sensor Input Voltage...8516
    Input Voltage at Sensor Connector...8516
    Inlet Air Pressure Sensor Output Voltage...8516
    Output Voltage at ECU...8516
    Inlet Air Pressure Sensor Output Voltage...8517
    Output Voltage at Sensor Connector...8517
    Inlet Air Pressure Sensor Output Voltage Connection to Sensor...8518
    Inlet Air Temperature Sensor Output Voltage...8520
    Output Voltage at ECU...8520
    Inlet Air Temperature Sensor Resistance...8521
    Water Temperature Sensor Output Voltage...8522
    Output Voltage at ECU...8522
    Atmospheric Pressure Sensor Input Voltage...8524
    Input Voltage at ECU...8524
    Atmospheric Pressure Sensor Input Voltage...8525
    Input Voltage at Sensor Connector...8525
    Atmospheric Pressure Sensor Output Voltage...8525
    Output Voltage...8525
    Atmospheric Pressure Sensor Output Voltage...8526
    Output Voltage at Sensor...8526
    Speed Sensor Input Voltage...8530
    Input Voltage at Sensor...8530
    Speed Sensor Output Voltage...8531
    Output Voltage at Sensor ...8531
    Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions...8532
    Input Voltage at 1 ∼ 6 Gear Positions...8532
    Vehicle-down Sensor Power Source Voltage...8535
    Power Source Voltage at Sensor...8535
    Vehicle-down Sensor Output Voltage...8536
    Output Voltage at Sensor...8536
    Subthrottle Sensor Input Voltage...8538
    Input Voltage at ECU Connector...8538
    Subthrottle Sensor Input Voltage...8539
    Input Voltage at Sensor...8539
    Subthrottle Sensor Output Voltage...8539
    Output Voltage at ECU...8539
    Subthrottle Sensor Output Voltage...8540
    Output Voltage at Sensor...8540
    Subthrottle Sensor Resistance...8541
    Oxygen Sensor Output Voltage...8542
    Oxygen Sensor Output Voltage (with Plugs)...8542
    Oxygen Sensor Output Voltage (without Plugs)...8543
    Exhaust Butterfly Valve Actuator Sensor Input Voltage...8544
    Input Voltage at Actuator...8544
    Wiring Connections...8544
    Exhaust Butterfly Valve Actuator Sensor Output Voltage...8545
    Output Voltage at Actuator...8545
    Wiring Connections...8545
    Exhaust Butterfly Valve Actuator Sensor Resistance...8546
    Antenna Resistance...8547
    Amplifier Input Voltage...8547
    Input Voltage...8547
    Wiring Connections...8550
    Stick Coil Input Voltage at ECU...8551
    Input Voltage at ECU...8551
    Subthrottle Valve Actuator Resistance...8555
    Subthrottle Valve Actuator Input Voltage...8556
    Input Voltage at Sensor...8556
    Connections...8559
    Actuator Output Voltage (Pulley Original Position)...8559
    Oxygen Sensor Resistance...8562
    Oxygen Sensor Heaters Power Source Voltage...8562
    Power Source Voltage at Sensor Connector...8562
    Oxygen Sensor Output Voltage...8564
    Oxygen Sensor Output Voltage (with Plugs)...8564
    Oxygen Sensor Output Voltage (without Plugs)...8565
    ECU Identification...8566
    ECU Grounding Inspection...8567
    ECU Power Source Inspection...8568
    Fuel Pressure...8571
    Fuel Pressure (Idling)...8572
    Amount of Fuel Flow...8573
    Pump Operating Voltage at Pump...8575
    Operating Voltage at Pump Connector...8575
    Testing Relay...8577
    Secondary Fuel Injector Resistance...8579
    Primary Injector Resistance...8579
    Secondary Fuel Injector Power Source Voltage...8580
    Primary Fuel Injector Power Source Voltage...8580
    Power Source Voltage at Injector Connector...8580
    Secondary Fuel Injector Output Voltage...8581
    Primary Fuel Injector Output Voltage...8581
    Output Voltage at Injector Connector...8581
    Fuel Line Maximum Pressure...8582
    Radiator Cap Relief Pressure...8618
    Thermostat Valve Opening Temperature...8621
    Camshaft Journal, Camshaft Cap Clearance...8645
    Camshaft Journal Diameter...8646
    Camshaft Runout...8646
    Cam Height...8646
    Cylinder Compression...8647
    Cylinder Head Warp...8649
    Valve/Valve Guide Clearance (Wobble Method)...8652
    Valve Seating Surface Outside Diameter...8653
    Valve Seating Surface Width...8653
    Spring Plate Free Play ...8682
    Spring Plate Free Play...8682
    Clutch Plate Assembly Length (Reference)...8683
    Friction Plate Thickness...8683
    Friction and Steel Plate Warp...8683
    Clutch Spring Free Length...8684
    Oil Pressure...8704
    Connecting Rod Big End Bearing Insert Selection...8726
    Crankshaft Main Bearing Insert Selection (Engine No. ∼ ZX600PE...8726
    Crankshaft Main Bearing Insert Selection (Engine No. ZX600PE0085...8726
    Connecting Rod Bend...8740
    Connecting Rod Twist...8740
    Connecting Rod Big End Side Clearance...8740
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...8741
    Crankpin Diameter...8741
    Crankpin Diameter Marks...8741
    Connecting Rod Big End Inside Diameter Marks...8742
    Crankshaft Side Clearance...8742
    Crankshaft ##3 Main Journal Width...8742
    Crankshaft Runout...8743
    Crankshaft Main Bearing Insert/Journal Clearance...8743
    Crankshaft Main Journal Diameter...8743
    Crankshaft Main Journal Diameter Marks...8743
    Crankcase Main Bearing Inside Diameter Marks...8744
    (Engine No. ∼ ZX600PE008560)...8744
    (Engine No. ZX600PE008561 ∼)...8744
    Cylinder Inside Diameter...8747
    Piston Diameter...8747
    Piston Ring/Groove Clearance...8747
    Piston Ring Groove Width...8748
    Piston Ring Thickness...8748
    Piston Ring End Gap...8748
    Shift Fork Ear Thickness...8764
    Gear Groove Width...8764
    Shift Fork Guide Pin Diameter...8764
    Shift Drum Groove Width...8764
    Rim Runout (with tire installed)...8774
    Axle Runout/100 mm (3.94 in.)...8774
    Balance Weight...8776
    Link Pin Outside Diameter...8791
    Link Plates Outside Width...8791
    Rear Sprocket Warp...8796
    Pedal Position...8804
    Brake Discs Thickness...8814
    Disc Runout...8814
    Rebound Damping Force Adjustment...8829
    Spring Action...8829
    Compression Damping Force Adjustment...8830
    Fork Oil...8832
    Oil Level (fully compressed, without spring)...8833
    Spring Free Length...8838
    Rebound Damping Force Adjustment...8839
    Spring Preload Setting...8840
    Spring Adjustment...8840
    Kawasaki-recommended chargers...8912
    Battery Terminal Voltage...8914
    Terminal Voltage: 11.5 ∼ less than 12.8 V...8915
    Terminal Voltage: less than 11.5 V...8915
    Table 1 Alternator Output Voltage...8918
    Table 2 Stator Coil Resistance...8919
    Regulator/Rectifier Resistance (Unit: kΩ)...8920
    Charging Voltage...8921
    Crankshaft Sensor Peak Voltage...8926
    Ignition Coil Winding Resistance...8927
    Primary Lead Connection...8927
    Stick Coil Primary Peak Voltage...8928
    Connections:...8930
    Camshaft Position Sensor Peak Voltage...8930
    Condition...8931
    Condition...8931
    Condition...8931
    Starter Motor Brush Length...8936
    Commutator Diameter...8936
    Testing Relay...8938
    Testing Turn Signal Relay...8947
    Testing Turn Signal Relay...8947
    Air Switching Valve Resistance...8949
    LCD segment actions for 1.5 seconds...8953
    Electric Source Voltage...8958
    User Key Indicator Flashes...8973
    Immobilizer Relational Parts Replacement Chart...8988
    Gear Position Switch Resistance kΩ...8992
    Water Temperature Sensor...8994
    Connections...8996
    Relay Circuit Inspection (with the battery disconnected)...8999
    Relay Circuit Inspection (with the battery connected)...8999
    Diode Circuit Inspection...8999
  toc...0
    EMISSION CONTROL INFORMATION...8393
      1...8393
      2...8393
      3...8393
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...8394
      Foreword...8395
      General Information...8397
        Before starting to perform an inspection service or carry out a ...8398
          Battery Ground...8398
          Edges of Parts...8398
          Solvent...8398
          Cleaning vehicle before disassembly...8398
          Arrangement and Cleaning of Removed Parts...8399
          Storage of Removed Parts...8399
          Inspection...8399
          Replacement Parts...8399
          Assembly Order...8399
          Tightening Sequence...8400
          Tightening Torque...8400
          Force...8400
          Gasket, O-ring...8400
          Liquid Gasket, Non-permanent Locking Agent...8400
          Press...8401
          Ball Bearing and Needle Bearing...8401
          Oil Seal, Grease Seal...8401
          Circlips, Cotter Pins...8401
          Lubrication...8402
          Direction of Engine Rotation...8402
          Electrical Wires...8402
          Instrument...8402
        ZX600P7F (Europe) Left Side View...8403
        ZX600P7F (Europe) Right Side View...8403
        ZX600P7F (US and Canada) Left Side View...8404
        ZX600P7F (US and Canada) Right Side View...8404
        Prefixes for Units...8408
        Units of Temperature...8408
      Periodic Maintenance...8409
        The scheduled maintenance must be done in accordance with this c...8411
        The following tables list the tightening torque for the major fa...8414
        Inside Circlip Pliers:...8422
        Fuel System (DFI)...8423
          Throttle Control System Inspection...8423
          Engine Vacuum Synchronization Inspection...8423
            Special Tool -...8424
            Special Tool -...8424
            Special Tool -...8425
            Special Tool -...8426
          Idle Speed Inspection...8426
          Idle Speed Adjustment...8427
          Fuel Hose Inspection (fuel leak, damage, installation condition)...8427
          Evaporative Emission Control System (California Model)...8427
            Evaporative Emission Control System Inspection...8427
          Engine Top End...8428
            Valve Clearance Inspection...8428
            Valve Clearance Adjustment...8430
          Air Suction System...8432
            Air Suction System Damage Inspection...8432
          Cooling System...8433
            Coolant Level Inspection...8433
            Radiator Hose Damage and Installation Condition Inspection...8433
              Torque -...8433
          Clutch...8434
            Clutch Operation Inspection ...8434
          Wheels/Tires...8435
            Air Pressure Inspection...8435
            Wheel/Tire Damage Inspection...8435
            Tire Tread Wear Inspection ...8435
            Wheel Bearing Damage Inspection...8436
          Drive Train...8437
            Drive Chain Lubrication Condition Inspection...8437
            Drive Chain Slack Inspection...8437
            Drive Chain Slack Adjustment...8438
              Torque -...8438
            Wheel Alignment Inspection...8439
            Drive Chain Wear Inspection...8439
            Chain Guide Wear Inspection...8440
          Brake System...8440
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...8440
            Brake Hose Damage and Installation Condition Inspection...8440
              Torque -...8440
            Brake Operation Inspection...8441
            Brake Fluid Level Inspection...8441
            Brake Pad Wear Inspection...8442
            Brake Light Switch Operation Inspection...8442
          Suspensions...8443
            Front Forks/Rear Shock Absorber Operation Inspection...8443
            Front Fork Oil Leak Inspection...8443
            Rear Shock Absorber Oil Leak Inspection...8444
            Rocker Arm Operation Inspection...8444
            Tie-Rod Operation Inspection...8444
          Steering System...8444
            Steering Play Inspection...8444
              Special Tools -...8444
            Steering Play Adjustment...8445
              Special Tool -...8445
              Torque -...8445
            Steering Stem Bearing Lubrication...8446
            Lights and Switches Operation Inspection...8446
            Headlight Aiming Inspection...8448
            Side Stand Switch Operation Inspection...8449
            Engine Stop Switch Operation Inspection...8450
          Others...8451
            Chassis Parts Lubrication ...8451
              Pivots: Lubricate with Grease...8451
              Points: Lubricate with Grease...8451
              Cables: Lubricate with Rust Inhibitor...8451
            Bolts, Nuts and Fasteners Tightness Inspection...8452
              Bolt, Nut and Fastener to be checked...8453
          Replacement Parts...8454
            Air Cleaner Element Replacement...8454
              Torque -...8455
            Fuel Hose Replacement...8455
              Torque -...8457
            Coolant Change...8458
              Torque -...8458
            Radiator Hose and O-ring Replacement...8460
              Torque -...8460
            Engine Oil Change...8461
              Torque -...8461
            Oil Filter Replacement...8461
              Special Tool -...8461
              Torque -...8461
            Brake Hose and Pipe Replacement...8462
              Torque -...8462
            Brake Fluid Change...8462
              Torque -...8463
              Torque -...8463
            Master Cylinder Rubber Parts Replacement...8464
              Special Tool -...8464
              Special Tool -...8464
              Silicone Grease -...8465
              Torque -...8465
            Caliper Rubber Parts Replacement...8465
              Torque -...8466
              Torque -...8466
              Torque -...8467
            Spark Plug Replacement...8468
              Owner's Tool -...8468
              Torque -...8468
      Fuel System (DFI)...8469
        Oil Pressure Gauge, 5 kgf/cm :...8480
        Inlet Air Pressure Sensor [A]...8482
        DFI System...8484
        DFI System Wiring Diagram...8486
        Terminal Numbers of ECU Connectors...8488
        There are a number of important precautions that should be follo...8489
          Torque -...8490
        The warning indicator light (LED) [A] is used for the FI indicat...8491
          Outline...8491
            Special Tool -...8493
            Sealant -...8493
          DFI Diagnosis Flow Chart...8495
          Inquiries to Rider...8495
        NOTE...8498
        The warning indicator light (LED) [A] is used for the FI indicat...8503
          Self-diagnosis Outline...8503
          Self-diagnosis Procedures...8504
          Self-Diagnosis Flow Chart...8505
            Service Code Reading...8506
            Service Code Erasing...8506
          Backups...8508
        The main throttle sensor is a rotating variable resistor that ch...8511
          Main Throttle Sensor Removal/Adjustment...8511
          Main Throttle Sensor Input Voltage Inspection...8511
            Special Tool -...8511
            Special Tool -...8512
          Main Throttle Sensor Output Voltage Inspection...8512
            Special Tool -...8512
            Special Tool -...8513
          Main Throttle Sensor Resistance Inspection...8513
          Main Throttle Sensor Circuit...8514
        CAUTION...8515
          Inlet Air Pressure Sensor Removal...8515
          Inlet Air Pressure Sensor Installation...8515
          Inlet Air Pressure Sensor Input Voltage Inspection...8515
            Special Tool -...8515
            Special Tool -...8516
          Inlet Air Pressure Sensor Output Voltage Inspection...8516
            Special Tool -...8517
          Inlet Air Pressure Sensor Circuit...8517
            Special Tools -...8518
        Inlet Air Temperature Sensor Removal/Installation...8520
          Inlet Air Temperature Sensor Output Voltage Inspection...8520
            Special Tool -...8520
            Sealant -...8521
          Inlet Air Temperature Sensor Resistance Inspection...8521
          Inlet Air Temperature Sensor Circuit...8521
        Water Temperature Sensor Removal/Installation...8522
          Sealant -...8522
          Torque -...8522
          Water Temperature Sensor Output Voltage Inspection...8522
            Special Tool -...8522
            Sealant -...8523
          Water Temperature Sensor Circuit...8523
            Water Temperature Sensor Resistance Inspection...8523
        CAUTION...8524
          Atmospheric Pressure Sensor Removal...8524
          Atmospheric Pressure Sensor Installation...8524
          Atmospheric Pressure Sensor Input Voltage Inspection...8524
            Special Tool -...8524
            Special Tool -...8525
          Atmospheric Pressure Sensor Output Voltage Inspection...8525
            Special Tool -...8526
          Atmospheric Pressure Sensor Circuit...8526
          Atmospheric Pressure/Altitude Relationship...8527
        Crankshaft Sensor Removal/Installation...8528
          Crankshaft Sensor Inspection...8528
          Crankshaft Sensor Circuit...8528
        Camshaft Position Sensor Removal/Installation...8529
          Camshaft Position Sensor Inspection...8529
          Camshaft Position Sensor Circuit...8529
        Speed Sensor Removal/Installation...8530
          Speed Sensor Inspection...8530
          Speed Sensor Input Voltage Inspection...8530
            Special Tool -...8530
          Speed Sensor Output Voltage Inspection...8530
            Special Tool -...8531
          Speed Sensor Circuit...8531
        Gear Position Switch Removal/Installation...8532
          Gear Position Switch Inspection...8532
          Gear Position Switch Input Voltage Inspection...8532
            Special Tool -...8532
          Gear Position Switch Circuit...8533
        This sensor has a weight [A] with two magnets inside, and sends ...8534
          Vehicle-down Sensor Removal...8534
          Vehicle-down Sensor Installation...8534
            Torque -...8534
          Vehicle-down Sensor Inspection...8535
            Special Tool -...8535
            Special Tool -...8536
            Sealant -...8536
          Vehicle-down Sensor Circuit...8537
        Subthrottle Sensor Removal/Adjustment...8538
          Subthrottle Sensor Input Voltage Inspection...8538
            Special Tool -...8538
            Special Tool -...8539
          Subthrottle Sensor Output Voltage Inspection...8539
            Special Tool -...8539
            Special Tool -...8540
          Resistance Inspection...8541
          Subthrottle Sensor Circuit...8541
        Oxygen Sensor ##1: Service Code 33...8542
          Oxygen Sensor Removal/Installation...8542
          Oxygen Sensor Inspection...8542
            Special Tool -...8542
            Sealant -...8543
          Oxygen Sensor Circuit...8543
        Exhaust Butterfly Valve Actuator Sensor Removal/Installation...8544
          Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...8544
            Special Tool -...8544
          Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio...8545
            Special Tool -...8545
          Exhaust Butterfly Valve Actuator Sensor Inspection...8546
          Exhaust Butterfly Valve Actuator Sensor Circuit...8546
        Antenna Resistance Inspection...8547
          Amplifier Input Voltage Inspection...8547
            Special Tool -...8547
        This code appears in the following conditions. ...8548
          User Key Inspection...8548
          Immobilizer System Circuit...8549
        ECU Communication Line Inspection...8550
          ECU Communication Line Circuit...8550
        Stick Coil ##1: Service Code 51...8551
          Stick Coil Removal/Installation...8551
          Stick Coil Input Voltage Inspection...8551
            Special Tool -...8551
          Stick Coil Circuit...8552
        Radiator Fan Relay Removal/Installation...8553
          Radiator Fan Relay Inspection...8553
          Radiator Fan Relay Circuit...8554
        Subthrottle Valve Actuator Removal...8555
          Subthrottle Valve Actuator Inspection...8555
          Subthrottle Valve Actuator Resistance Inspection...8555
          Subthrottle Valve Actuator Input Voltage Inspection...8556
            Special Tools -...8556
          Subthrottle Valve Actuator Circuit...8556
        Exhaust Butterfly Valve Actuator Removal...8557
          Exhaust Butterfly Valve Actuator Installation...8557
            Torque -...8558
            Torque -...8558
          Exhaust Butterfly Valve Actuator Inspection...8559
          Exhaust Butterfly Valve Actuator Output Voltage Inspection...8559
            Special Tool -...8559
          Exhaust Butterfly Valve Actuator Circuit...8560
        Air Switching Valve Removal/Installation...8561
          Air Switching Valve Inspection...8561
          Air Switching Valve Circuit (Other than Europe Models)...8561
        Oxygen Sensor Heater Removal/Installation...8562
          Oxygen Sensor Heater Inspection ...8562
            Special Tool -...8562
            Special Tool -...8562
            Sealant -...8563
          Oxygen Sensor Circuit...8563
        Oxygen Sensor ##1: Service Code 94...8564
          Oxygen Sensor Removal/Installation...8564
          Oxygen Sensor Inspection...8564
            Special Tool -...8564
            Sealant -...8565
          Oxygen Sensor Circuit...8565
        CAUTION...8566
          ECU Identification...8566
          ECU Removal...8566
          ECU Installation...8567
          ECU Power Supply Inspection...8567
            Special Tool -...8567
          ECU Power Source Circuit...8568
        ECU Fuse Removal...8569
          ECU Fuse Installation...8569
          ECU Fuse Inspection...8569
        Warning Indicator Light (LED) Inspection...8570
          Warning Indicator Light (LED) (FI/Immobilizer) Circuit...8570
        Fuel Pressure Inspection...8571
          Special Tools -...8571
          Fuel Flow Rate Inspection...8572
            Special Tool -...8573
        Fuel Pump Removal...8574
          Fuel Pump Installation...8574
            Torque -...8575
          Fuel Pump Operation Inspection...8575
          Fuel Pump Operating Voltage Inspection...8575
            Special Tools -...8575
          Fuel Pump Circuit...8576
        Fuel Pump Relay Removal...8577
          Fuel Pump Relay Inspection...8577
            Special Tool -...8577
        CAUTION...8578
          Audible Inspection...8578
          Injector Signal Test...8578
            Special Tool -...8579
          Injector Resistance Inspection...8579
            Special Tool -...8579
          Injector Unit Test...8580
          Injector Voltage Inspection...8580
            Special Tool -...8580
            Special Tool -...8580
          Injector Fuel Line Inspection...8582
          Fuel Injector Circuit...8583
        Free Play Inspection...8584
          Free Play Adjustment...8584
          Cable Installation...8584
          Cable Lubrication...8584
        Idle Speed Inspection...8585
          Synchronization Inspection...8585
          Synchronization Adjustment...8585
          Throttle Body Assy Removal...8585
            Special Tool -...8585
          Throttle Body Assy Installation...8586
            Torque -...8586
            Torque -...8586
          Throttle Body Assy Disassembly...8587
            Throttle Body Assy Assembly...8588
              Torque -...8588
        Nozzle Assy Removal...8589
          Nozzle Assy Installation...8589
            Torque -...8589
          Nozzle Assy Disassembly...8590
          Nozzle Assy Assembly...8590
            Torque -...8591
            Torque -...8591
        Air Cleaner Element Removal...8592
          Air Cleaner Element Installation...8592
          Air Cleaner Element Inspection...8592
          Air Cleaner Housing Removal...8592
          Air Cleaner Housing Installation...8593
            Torque -...8593
          Air Cleaner Housing Disassembly...8594
          Air Cleaner Housing Assembly...8594
            Torque -...8594
          Oil Draining...8595
        Fuel Tank Removal...8596
          Fuel Tank Installation...8598
          Fuel Tank and Cap Inspection...8598
          Fuel Tank Cleaning...8599
        The Evaporative Emission Control System routes fuel vapors from ...8600
          Parts Removal/Installation...8600
          Hose Inspection...8600
          Separator Inspection...8600
          Separator Operation Test...8601
          Canister Inspection ...8601
      Cooling System...8603
        Bearing Driver, 32:...8607
        Coolant Deterioration Inspection...8610
          Coolant Level Inspection...8610
          Coolant Draining...8610
          Coolant Filling...8610
          Pressure Testing...8610
          Cooling System Flushing...8611
          Coolant Reserve Tank Removal...8611
          Coolant Reserve Tank Installation...8612
            Torque -...8612
        Water Pump Removal...8613
          Water Pump Installation...8613
          Water Pump Impeller Disassembly/Assembly...8613
            Torque -...8613
          Water Pump Impeller Inspection...8613
          Water Pump Housing Disassembly...8613
          Water Pump Housing Assembly...8614
            Special Tool -...8614
            Special Tool -...8614
          Mechanical Seal Inspection...8614
        Radiator and Radiator Fan Removal...8615
          Radiator and Radiator Fan Installation...8616
            Torque -...8617
            Torque -...8617
            Torque -...8617
            Torque -...8617
          Radiator Inspection...8618
          Radiator Cap Inspection...8618
          Radiator Filler Neck Inspection...8619
        Thermostat Removal...8620
          Thermostat Installation...8620
            Torque -...8620
            Torque -...8621
          Thermostat Inspection...8621
        Hose Installation...8622
          Torque -...8622
          Hose Inspection...8622
        Water Temperature Sensor Removal...8623
          Water Temperature Sensor Inspection...8623
      Engine Top End...8625
        Compression Gauge, 20 kgf/cm :...8633
        Air Suction Valve Removal...8635
          Air Suction Valve Installation...8635
            Torque -...8635
          Air Suction Valve Inspection...8635
          Air Switching Valve Removal...8636
          Air Switching Valve Installation...8636
          Air Switching Valve Operation Test...8636
          Air Switching Valve Unit Test...8636
          Clean Air System Hose Inspection...8636
        Cylinder Head Cover Removal...8637
          Cylinder Head Cover Installation...8637
            Sealant -...8637
            Torque -...8638
            Torque -...8638
        Camshaft Chain Tensioner Removal...8639
          Camshaft Chain Tensioner Installation...8639
            Torque -...8639
            Torque -...8639
        Camshaft Removal...8640
        Camshaft Installation...8642
          Torque -...8642
          Torque -...8645
          Camshaft, Camshaft Cap Wear...8645
            Torque -...8645
          Camshaft Runout...8646
          Cam Wear...8646
          Camshaft Chain Removal...8646
        Cylinder Compression Measurement...8647
          Special Tools -...8647
          Torque -...8647
          Cylinder Head Removal...8648
          Cylinder Head Installation...8648
            Torque -...8649
            Torque -...8649
            Torque -...8649
          Cylinder Head Warp...8649
        Valve Clearance Inspection...8650
          Valve Clearance Adjustment...8650
          Valve Removal...8650
            Special Tools -...8650
          Valve Installation...8650
          Valve Guide Removal...8651
            Special Tool -...8651
          Valve Guide Installation...8651
            Special Tools -...8651
            Special Tool -...8651
          Valve-to-Guide Clearance Measurement (Wobble Method)...8652
          Valve Seat Inspection...8653
          Valve Seat Repair...8653
            Special Tools -...8653
        Throttle Body Assy Holder Removal...8658
          Throttle Body Assy Holder Installation...8658
            Torque -...8658
        WARNING...8659
          Muffler Body Removal...8659
          Muffler Body Installation...8660
            Torque -...8660
            Torque -...8660
              Rear Exhaust Pipe Removal...8661
              Rear Exhaust Pipe Installation...8662
                Torque -...8662
              Front Exhaust Pipe Removal...8663
              Front Exhaust Pipe Installation...8664
                Torque -...8664
              Exhaust Butterfly Valve Cable Removal...8665
          Exhaust Butterfly Valve Cable Installation...8666
            Torque -...8666
            Torque -...8666
            Torque -...8667
            Torque -...8668
      Clutch...8669
        Clutch Holder:...8673
        Clutch Lever Free Play Inspection...8674
          Clutch Lever Free Play Adjustment...8674
          Cable Removal...8674
          Cable Installation...8674
          Cable Lubrication...8674
          Clutch Lever Installation...8674
            Torque -...8674
        Clutch Cover Removal...8675
          Clutch Cover Installation...8675
            Sealant -...8675
            Torque -...8675
          Release Shaft Removal...8675
          Release Shaft Installation...8676
          Clutch Cover Disassembly...8676
          Clutch Cover Assembly...8677
            Torque -...8677
        Clutch Removal...8678
          Special Tool -...8678
          Clutch Installation...8678
            Special Tool -...8680
            Torque -...8680
            Torque -...8681
          Spring Plate Free Play Measurement...8681
          Spring Plate Free Play Adjustment...8682
            Torque -...8683
          Clutch Plate, Wear, Damage Inspection...8683
          Clutch Plate Warp Inspection...8683
          Clutch Spring Free Length Measurement...8684
          Damper Cam Inspection...8684
      Engine Lubrication System...8685
        Outside Circlip Pliers:...8689
        WARNING...8692
          Oil Level Inspection...8692
          Engine Oil Change...8692
          Oil Filter Replacement...8692
        Oil Pan Removal...8693
          Oil Pan Installation...8693
            Torque -...8694
        Oil Pressure Relief Valve Removal...8695
          Oil Pressure Relief Valve Installation...8695
            Torque -...8695
          Oil Pressure Relief Valve Inspection...8696
        Oil Pump Removal...8697
          Oil Pump Installation...8698
            Torque -...8698
            Torque -...8698
            Torque -...8698
            Torque -...8699
          Oil Pump Gear Removal...8699
          Oil Pump Gear Installation...8699
            Torque -...8699
          Oil Pump Gear Shaft Removal...8700
            Special Tool -...8700
          Oil Pump Gear Shaft Installation...8700
            Special Tool -...8700
        Oil Cooler Removal...8701
          Oil Cooler Installation...8701
            Torque -...8701
            Torque -...8701
          Oil Cooler/Oil Filter Case Removal...8702
          Oil Cooler/Oil Filter Case Installation...8703
            Torque -...8703
            Torque -...8703
            Torque -...8703
        Oil Pressure Measurement...8704
          Special Tools -...8704
          Torque -...8704
        Oil Pressure Switch Removal...8705
          Oil Pressure Switch Installation...8705
            Sealant -...8705
            Torque -...8705
            Torque -...8705
      Engine Removal/Installation...8707
        Engine Mount Nut Wrench:...8710
        Engine Removal...8711
          Special Tool -...8713
          Engine Installation...8714
            Torque -...8715
            Torque -...8716
            Torque -...8716
            Torque -...8716
            Special Tool -...8716
            Torque -...8716
            Torque -...8716
      Crankshaft/Transmission...8719
        Outside Circlip Pliers:...8727
        Crankcase Splitting...8728
          Crankcase Assembly...8729
            Torque -...8729
            Special Tool -...8730
            Torque -...8730
            Torque -...8730
            Torque -...8730
            Torque -...8731
            Sealant -...8732
            Torque -...8733
            Torque -...8733
            Torque -...8733
        Crankshaft Removal...8734
          Crankshaft Installation...8734
          Connecting Rod Removal...8736
          Connecting Rod Installation...8736
          Crankshaft/Connecting Rod Cleaning...8740
          Connecting Rod Bend...8740
          Connecting Rod Twist...8740
          Connecting Rod Big End Side Clearance...8740
          Connecting Rod Big End Bearing Insert/Crankpin Wear...8741
          Crankshaft Side Clearance...8742
          Crankshaft Runout...8743
          Crankshaft Main Bearing Insert/Journal Wear...8743
        Piston Removal...8745
          Special Tool -...8745
          Piston Installation...8746
            Special Tools -...8747
          Cylinder Wear (Upper Crankcase)...8747
          Piston Wear...8747
          Piston Ring, Piston Ring Groove Wear...8747
          Piston Ring Groove Width...8748
          Piston Ring Thickness...8748
          Piston Ring End Gap...8748
        Starter Idle Gear Removal...8749
          Starter Idle Gear Installation...8749
            Sealant -...8750
            Torque -...8750
            Torque -...8750
          Starter Clutch Removal...8751
            Special Tools -...8751
          Starter Clutch Installation ...8751
            Special Tools -...8751
            Torque -...8751
          Starter Clutch Disassembly...8751
          Starter Clutch Assembly...8752
          Starter Clutch Inspection...8752
        Shift Pedal Removal...8754
          Shift Pedal Installation...8754
            Torque -...8754
            Torque -...8754
            Torque -...8754
          External Shift Mechanism Removal...8754
            Special Tool -...8754
          External Shift Mechanism Installation...8755
            Torque -...8755
            Special Tool -...8755
          External Shift Mechanism Inspection...8755
            Torque -...8756
          Transmission Assy Removal...8756
          Transmission Assy Disassembly...8756
          Transmission Assy Assembly...8757
            Special Tool -...8757
            Torque -...8757
            Torque -...8757
            Torque -...8757
          Transmission Assy Installation...8758
            Torque -...8758
          Transmission Shaft Removal...8759
          Transmission Shaft Installation...8759
          Transmission Shaft Disassembly...8760
            Special Tool -...8760
          Transmission Shaft Assembly...8760
          Shift Drum and Fork Removal...8763
          Shift Drum and Fork Installation...8763
          Shift Drum Disassembly...8763
          Shift Drum Assembly...8763
            Torque -...8763
          Shift Fork Bending...8763
          Shift Fork/Gear Groove Wear...8764
          Shift Fork Guide Pin/Drum Groove Wear...8764
          Gear Dog and Gear Dog Hole Damage...8764
      Wheels/Tires...8765
        Bearing Driver Set:...8769
        Front Wheel Removal...8770
          Special Tools -...8770
          Front Wheel Installation...8770
            Torque -...8771
            Torque -...8771
          Rear Wheel Removal...8771
          Rear Wheel Installation...8772
            Torque -...8773
          Wheel Inspection...8774
            Special Tools -...8774
          Axle Inspection...8774
          Balance Inspection...8775
          Balance Adjustment...8775
          Balance Weight Removal...8775
          Balance Weight Installation...8775
        Air Pressure Inspection/Adjustment...8777
          Tire Inspection...8777
          Tire Removal...8777
          Tire Installation...8777
          Tire Repair...8779
        Hub Bearing Removal...8780
          Special Tools -...8780
          Hub Bearing Installation...8780
            Special Tool -...8780
            Special Tool -...8780
          Hub Bearing Inspection...8780
          Hub Bearing Lubrication...8781
      Final Drive...8783
        Inside Circlip Pliers:...8787
        Drive Chain Slack Inspection...8788
          Drive Chain Slack Adjustment...8788
          Wheel Alignment Inspection/Adjustment...8788
          Drive Chain Wear Inspection...8788
          Drive Chain Lubrication...8788
          Drive Chain Removal...8788
          Drive Chain Installation...8789
        Engine Sprocket Removal...8792
          Engine Sprocket Installation...8792
            Torque -...8792
            Torque -...8793
          Rear Sprocket Removal...8793
          Rear Sprocket Installation...8793
            Torque -...8793
          Coupling Installation...8794
          Coupling Bearing Removal...8794
            Special Tool -...8794
            Special Tool -...8794
          Coupling Bearing Installation...8794
            Special Tool -...8794
            Special Tool -...8794
            Special Tool -...8795
          Coupling Bearing Inspection...8795
          Coupling Bearing Lubrication...8795
          Coupling Damper Inspection...8795
          Sprocket Wear Inspection...8795
          Rear Sprocket Warp Inspection...8796
      Brakes...8797
        Inside Circlip Pliers:...8803
        Brake Lever Position Adjustment...8804
          Brake Pedal Position Inspection ...8804
          Brake Pedal Position Adjustment ...8804
            Torque -...8804
          Brake Pedal Removal...8804
          Brake Pedal Installation...8805
            Torque -...8805
            Torque -...8805
            Torque -...8805
        Front Caliper Removal...8806
          Rear Caliper Removal...8806
          Caliper Installation...8806
            Torque -...8806
          Front Caliper Disassembly...8807
          Front Caliper Assembly...8807
          Rear Caliper Disassembly...8807
          Rear Caliper Assembly...8807
          Caliper Fluid Seal Damage...8807
          Rear Caliper Dust Boot and Friction Boot Damage...8808
          Caliper Piston and Cylinder Damage...8808
          Rear Caliper Holder Shaft Wear...8808
        Front Brake Pad Removal...8809
          Front Brake Pad Installation...8809
            Torque -...8809
          Rear Brake Pad Removal ...8809
          Rear Brake Pad Installation...8810
          Brake Pad Wear Inspection...8810
        Front Master Cylinder Removal...8811
          Front Master Cylinder Installation...8811
            Torque -...8811
            Torque -...8811
          Rear Master Cylinder Removal...8812
          Rear Master Cylinder Installation...8812
            Torque -...8812
          Front Master Cylinder Disassembly...8812
          Rear Master Cylinder Disassembly...8812
          Master Cylinder Inspection (Visual Inspection)...8812
          Master Cylinder Assembly...8813
        Brake Disc Removal...8814
          Brake Disc Installation...8814
            Torque -...8814
          Brake Disc Wear...8814
          Brake Disc Warp...8814
            Special Tools -...8814
        Brake Fluid Level Inspection...8815
          Brake Fluid Change...8815
          Brake Line Bleeding...8815
            Torque -...8816
            Torque -...8817
            Torque -...8817
        Brake Hose Removal/Installation...8819
          Brake Hose Inspection...8819
      Suspension...8821
        Inside Circlip Pliers:...8827
        Rebound Damping Force Adjustment...8829
          Spring Preload Adjustment...8829
          Compression Damping Force Adjustment...8830
          Front Fork Removal (Each Fork Leg)...8830
          Front Fork Installation...8831
            Torque -...8831
            Torque -...8831
          Front Fork Oil Change...8831
            Special Tool -...8831
            Special Tool -...8832
            Special Tool -...8832
            Special Tool -...8833
            Special Tool -...8833
            Special Tool -...8834
            Special Tool -...8834
            Special Tool -...8834
            Torque -...8835
          Front Fork Disassembly...8835
          Front Fork Assembly...8836
            Special Tool -...8837
            Special Tool -...8837
            Torque -...8837
          Inner Tube Inspection...8837
          Dust Seal Inspection...8838
          Spring Tension...8838
        Rebound Damping Force Adjustment...8839
          Compression Damping Force Adjustment...8839
          Spring Preload Adjustment...8840
            Special Tool -...8840
            Special Tools -...8840
          Rear Shock Absorber Removal...8841
            Special Tools -...8841
          Rear Shock Absorber Installation...8841
            Torque -...8841
          Rear Shock Absorber Inspection...8841
          Rear Shock Absorber Scrapping...8842
        Swingarm Removal...8843
          Special Tool -...8843
          Swingarm Installation...8844
            Torque -...8844
            Special Tool -...8844
            Torque -...8844
            Torque -...8845
          Swingarm Bearing Removal...8845
            Special Tool -...8845
            Special Tool -...8845
          Swingarm Bearing Installation...8845
            Special Tools -...8845
          Swingarm Bearing, Sleeve Inspection...8846
          Chain Guide Inspection...8846
        Tie-Rod Removal...8847
          Special Tools -...8847
          Tie-Rod Installation...8847
            Torque -...8847
          Rocker Arm Removal...8847
            Special Tools -...8848
          Rocker Arm Installation...8848
            Torque -...8848
          Tie-Rod and Rocker Arm Bearing Removal...8849
            Special Tool -...8849
          Tie-Rod and Rocker Arm Bearing Installation...8849
            Special Tools -...8850
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...8851
          Rocker Arm/Tie-Rod Bearing Lubrication...8851
      Steering...8853
        Bearing Puller:...8856
        Steering Inspection...8857
          Steering Adjustment...8857
        Stem, Stem Bearing Removal...8858
          Special Tool -...8858
          Special Tool -...8858
          Special Tools -...8859
          Stem, Stem Bearing Installation...8859
            Special Tools -...8859
            Special Tools -...8859
            Special Tool -...8860
            Torque -...8860
            Torque -...8861
          Steering Stem Bearing Lubrication...8861
          Steering Stem Warp...8861
          Stem Cap Deterioration, Damage...8861
        Handlebar Removal...8862
          Handlebar Installation...8863
            Torque -...8863
            Torque -...8863
      Frame...8865
        Rear Seat Removal...8872
          Rear Seat Installation...8872
          Front Seat Removal...8872
          Front Seat Installation...8872
        Lower Fairing Removal...8873
          Lower Fairing Installation...8873
          Middle Fairing Removal...8873
          Windshield Removal...8875
          Windshield Installation...8875
            Torque -...8875
          Upper Fairing Disassembly...8876
          Upper Fairing Assembly...8876
          Upper Fairing Installation...8876
          Inner Cover Removal...8876
          Inner Cover Installation...8877
          Center Inner Fairing Removal...8877
          Center Inner Fairing Installation...8877
          Lower Inner Fairing Removal...8877
          Lower Inner Fairing Installation...8878
        Left Side Cover Removal...8879
          Left Side Cover Installation...8879
          Right Side Cover Removal...8879
          Right Side Cover Installation...8879
        Seat Cover Removal...8880
          Seat Cover Installation...8880
        Heat Insulation Plate Removal...8881
          Heat Insulation Plate Installation...8881
          Heat Insulation Rubber Plate Pemoval...8881
          Heat Insulation Rubber Plate Installation...8882
        Front Fender Removal...8883
          Front Fender Installation...8883
            Torque -...8883
          Flap and Rear Fender Removal...8883
          Flap and Rear Fender Installation...8886
        Rear Frame Removal...8887
          Rear Frame Installation...8887
            Torque -...8887
          Frame Inspection...8887
        Sidestand Removal...8888
          Sidestand Installation...8888
            Torque -...8888
            Torque -...8888
      Electrical System...8889
        Hand Tester:...8907
        There are a number of important precautions that are musts when ...8908
        Wiring Inspection...8909
          Special Tool -...8909
        Battery Removal...8910
          Battery Installation...8910
          Battery Activation...8910
          Precautions...8913
            1)...8913
            2)...8913
            3)...8913
            4)...8913
          Interchange...8913
            Charging Condition Inspection...8914
            Refreshing Charge...8914
        Alternator Cover Removal...8916
          Alternator Cover Installation...8916
            Sealant -...8916
            Torque -...8916
          Stator Coil Removal...8916
          Stator Coil Installation...8917
            Torque -...8917
            Sealant -...8917
            Torque -...8917
          Alternator Rotor Removal...8917
            Special Tools -...8917
            Special Tool -...8917
          Alternator Rotor Installation...8917
            Special Tools -...8917
            Special Tool -...8918
            Special Tools -...8918
            Torque -...8918
          Alternator Inspection...8918
            Special Tool -...8919
          Regulator/Rectifier Removal...8919
          Regulator/Rectifier Inspection...8920
            Special Tool -...8920
            Torque -...8920
          Charging Voltage Inspection...8921
            Special Tool -...8921
          Charging System Circuit...8922
            Crankshaft Sensor Removal...8924
            Crankshaft Sensor Installation...8924
              Torque -...8924
              Sealant -...8924
            Crankshaft Sensor Inspection...8925
              Special Tool -...8925
            Crankshaft Sensor Peak Voltage...8925
              Special Tools -...8926
            Stick Coil Removal...8926
            Stick Coil Installation...8926
            Stick Coil Inspection...8927
            Stick Coil Primary Peak Voltage...8927
              Special Tools -...8927
            Spark Plug Removal...8928
            Spark Plug Installation...8928
            Spark Plug Clean and Inspection...8928
            Camshaft Position Sensor Removal...8929
            Camshaft Position Sensor Installation...8929
              Torque -...8929
            Camshaft Position Sensor Inspection...8929
              Special Tool -...8930
            Camshaft Position Sensor Peak Voltage Inspection...8930
              Special Tools -...8930
            Interlock Operation Inspection...8931
            IC Igniter Inspection...8932
          Ignition System Circuit...8933
        Starter Motor Removal...8934
          Starter Motor Installation...8934
            Torque -...8934
          Starter Motor Disassembly...8935
          Starter Motor Assembly...8935
          Brush Inspection...8936
          Commutator Cleaning and Inspection...8936
          Armature Inspection...8937
            Special Tool -...8937
          Brush Lead Inspection...8937
            Special Tool -...8937
          Right-hand End Cover Assembly Inspection...8937
            Special Tool -...8937
          Starter Relay Inspection...8937
            Special Tool -...8938
          Electric Starter Circuit...8939
        This motorcycle adopt the daylight system and have a headlight r...8940
          Headlight Beam Horizontal Adjustment...8940
          Headlight Beam Vertical Adjustment...8940
          Headlight Bulb Replacement...8940
          City Light Bulb Replacement...8941
          Headlight Removal/Installation...8941
          Tail/Brake Light (LED) Removal...8941
          Tail/Brake Light (LED) Installation...8942
          License Plate Light Bulb Replacement...8942
          Headlight/Tail Light Circuit...8943
            Turn Signal Light Bulb Replacement...8943
            Turn Signal Light Removal...8945
            Turn Signal Relay Inspection...8946
          Turn Signal Light Circuit...8948
        Air Switching Valve Operation Test...8949
          Air Switching Valve Unit Test...8949
            Special Tool -...8949
        Fan Motor Inspection...8950
          Radiator Fan Circuit...8950
        Meter Unit Removal...8951
          Meter Unit Disassembly...8951
          Electronic Combination Meter Unit Inspection...8952
          Fuel Level Sensor Line Self-Diagnosis Mode Inspection...8968
          Meter Circuit...8969
        This motorcycle is equipped with an immobilizer system to protec...8970
          Operational Cautions...8970
            Key Registration...8970
              Special Tool -...8970
          Spare User Key Registration Flow Chart...8975
            Special Tool -...8976
          All Keys Initial Registration Flow Chart...8985
            Immobilizer System Parts Replacement...8986
            Immobilizer System Inspection...8988
          Immobilizer System Circuit...8989
        Brake Light Timing Inspection...8990
          Brake Light Timing Adjustment...8990
          Gear Position Switch Removal...8990
          Gear Position Switch Installation...8991
            Torque -...8991
          Gear Position Switch Inspection...8992
            Special Tool -...8992
          Switch Inspection...8993
            Special Tool -...8993
          Rear Brake Light Switch Connections...8993
          Side Stand Switch Connections...8993
          Oil Pressure Switch Connections *...8993
          Water Temperature Sensor Inspection...8994
          Speed Sensor Removal...8994
          Speed Sensor Installation...8995
            Torque -...8995
          Speed Sensor Inspection...8995
            Special Tool -...8995
          Fuel Reserve Switch Inspection...8996
          Oxygen Sensor Removal (Equipped Models)...8996
          Oxygen Sensor Installation (Equipped Models)...8997
            Torque -...8997
          Oxygen Sensor Inspection (Equipped Models)...8997
        The relay box [A] has relays and diodes. The relays and diodes c...8998
          Relay Box Removal...8998
          Relay Circuit Inspection...8998
          Diode Circuit Inspection...8999
          Relay Box Internal Circuit...9000
        30 A Main Fuse Removal...9001
          Fuse Box Fuse Removal...9001
          10 A ECU Fuse Removal...9001
          Fuse Installation...9002
          Fuse Inspection...9002
      Appendix...9003
        California Model...9029
        California Model...9030
        NOTE...9032
          Engine Doesn't Start, Starting Difficulty:...9032
            Starter motor not rotating:...9032
            Starter motor rotating but engine doesn't turn over:...9032
            Engine won't turn over:...9032
            No fuel flow:...9032
            No spark; spark weak:...9032
            Fuel/air mixture incorrect:...9032
            Compression Low:...9032
          Poor Running at Low Speed:...9032
            Spark weak:...9032
            Fuel/air mixture incorrect:...9032
            Compression low:...9033
            Run-on (dieseling):...9033
            Other:...9033
          Poor Running or No Power at High Speed:...9033
            Firing incorrect:...9033
            Fuel/air mixture incorrect:...9033
            Compression low:...9033
            Knocking:...9033
            Miscellaneous:...9033
          Overheating:...9033
            Firing incorrect:...9033
            Muffler overheating:...9033
            Fuel/air mixture incorrect:...9033
            Compression high:...9034
            Engine load faulty:...9034
            Lubrication inadequate:...9034
            Oil cooler incorrect:...9034
            Water temperature meter incorrect:...9034
            Coolant incorrect:...9034
            Cooling system component incorrect:...9034
          Over Cooling:...9034
            Water temperature meter incorrect:...9034
            Cooling system component incorrect:...9034
          Clutch Operation Faulty:...9034
            Clutch slipping:...9034
            Clutch not disengaging properly:...9034
          Gear Shifting Faulty:...9034
            Doesn't go into gear; shift pedal doesn't return:...9034
            Jumps out of gear:...9034
            Overshifts:...9034
          Abnormal Engine Noise:...9034
            Knocking:...9034
            Piston slap:...9034
            Valve noise:...9034
            Other noise:...9034
          Abnormal Drive Train Noise:...9035
            Clutch noise:...9035
            Transmission noise:...9035
            Drive line noise:...9035
          Abnormal Frame Noise:...9035
            Front fork noise:...9035
            Rear shock absorber noise:...9035
            Disc brake noise:...9035
            Other noise:...9035
          Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:...9035
          Exhaust Smokes Excessively:...9035
            White smoke:...9035
            Black smoke:...9035
            Brown smoke:...9035
          Handling and/or Stability Unsatisfactory:...9035
            Handlebar hard to turn:...9035
            Handlebar shakes or excessively vibrates:...9035
            Handlebar pulls to one side:...9035
            Shock absorption unsatisfactory:...9035
          Brake Doesn't Hold:...9036
          Battery Trouble:...9036
            Battery discharged:...9036
            Battery overcharged:...9036
Kawasaki Motorcycle Service Repair Manual '07-'08 ZX-6R (EN)...9038
  tables...0
    LIST OF ABBREVIATIONS...9041
    COUNTRY AND AREA CODES...9041
    Units of Mass...9057
    Units of Volume...9057
    Units of Force...9057
    Units of Length...9057
    Units of Torque...9057
    Units of Pressure...9057
    Units of Speed...9057
    Units of Power...9057
    Periodic Inspection...9060
    Periodic Replacement Parts...9062
    Basic Torque for General Fasteners...9068
    Throttle Grip Free Play...9072
    Idle Speed...9073
    Engine Vacuum...9073
    Main Throttle Sensor Output Voltage...9075
    Idle Speed...9075
    Valve Clearance...9078
    Example:...9079
    Adjustment Shims...9080
    Clutch Lever Free Play...9083
    Air Pressure (when Cold)...9084
    Tread Depth...9084
    Chain Slack...9086
    Drive Chain 20-link Length...9088
    Standard Chain...9088
    Recommended Disc Brake Fluid...9090
    Pad Lining Thickness...9091
    Side Stand Switch Operation...9098
    Water and Coolant Mixture Ratio (Recommended)...9107
    Recommended Engine Oil...9109
    Standard Spark Plug...9116
    Terminal Names...9137
    Sample Diagnosis Sheet...9145
    Engine Won't Turn Over...9147
    Poor Running at Low Speed...9147
    Poor Running or No Power at High Speed:...9150
    Main Throttle Sensor Input Voltage...9160
    Input Voltage at ECU Connector...9160
    Main Throttle Sensor Input Voltage...9161
    Input Voltage at Sensor...9161
    Main Throttle Sensor Output Voltage...9161
    Idle Speed...9161
    Output Voltage at ECU...9161
    Main Throttle Sensor Output Voltage...9162
    Output Voltage at Sensor...9162
    Main Throttle Sensor Resistance...9162
    Inlet Air Pressure Sensor Input Voltage...9164
    Input Voltage at ECU...9164
    Inlet Air Pressure Sensor Input Voltage...9165
    Input Voltage at Sensor Connector...9165
    Inlet Air Pressure Sensor Output Voltage...9165
    Output Voltage at ECU...9165
    Inlet Air Pressure Sensor Output Voltage...9166
    Output Voltage at Sensor Connector...9166
    Inlet Air Pressure Sensor Output Voltage Connection to Sensor...9167
    Inlet Air Temperature Sensor Output Voltage...9169
    Output Voltage at ECU...9169
    Inlet Air Temperature Sensor Resistance...9170
    Water Temperature Sensor Output Voltage...9171
    Output Voltage at ECU...9171
    Atmospheric Pressure Sensor Input Voltage...9173
    Input Voltage at ECU...9173
    Atmospheric Pressure Sensor Input Voltage...9174
    Input Voltage at Sensor Connector...9174
    Atmospheric Pressure Sensor Output Voltage...9174
    Output Voltage...9174
    Atmospheric Pressure Sensor Output Voltage...9175
    Output Voltage at Sensor...9175
    Speed Sensor Input Voltage...9179
    Input Voltage at Sensor...9179
    Speed Sensor Output Voltage...9180
    Output Voltage at Sensor ...9180
    Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions...9181
    Input Voltage at 1 ∼ 6 Gear Positions...9181
    Vehicle-down Sensor Power Source Voltage...9184
    Power Source Voltage at Sensor...9184
    Vehicle-down Sensor Output Voltage...9185
    Output Voltage at Sensor...9185
    Subthrottle Sensor Input Voltage...9187
    Input Voltage at ECU Connector...9187
    Subthrottle Sensor Input Voltage...9188
    Input Voltage at Sensor...9188
    Subthrottle Sensor Output Voltage...9188
    Output Voltage at ECU...9188
    Subthrottle Sensor Output Voltage...9189
    Output Voltage at Sensor...9189
    Subthrottle Sensor Resistance...9190
    Oxygen Sensor Output Voltage...9191
    Oxygen Sensor Output Voltage (with Plugs)...9191
    Oxygen Sensor Output Voltage (without Plugs)...9192
    Exhaust Butterfly Valve Actuator Sensor Input Voltage...9193
    Input Voltage at Actuator...9193
    Wiring Connections...9193
    Exhaust Butterfly Valve Actuator Sensor Output Voltage...9194
    Output Voltage at Actuator...9194
    Wiring Connections...9194
    Exhaust Butterfly Valve Actuator Sensor Resistance...9195
    Antenna Resistance...9196
    Amplifier Input Voltage...9196
    Input Voltage...9196
    Wiring Connections...9199
    Stick Coil Input Voltage at ECU...9200
    Input Voltage at ECU...9200
    Subthrottle Valve Actuator Resistance...9204
    Subthrottle Valve Actuator Input Voltage...9205
    Input Voltage at Sensor...9205
    Connections...9208
    Actuator Output Voltage (Pulley Original Position)...9208
    Oxygen Sensor Resistance...9211
    Oxygen Sensor Heaters Power Source Voltage...9211
    Power Source Voltage at Sensor Connector...9211
    Oxygen Sensor Output Voltage...9213
    Oxygen Sensor Output Voltage (with Plugs)...9213
    Oxygen Sensor Output Voltage (without Plugs)...9214
    ECU Identification...9215
    ECU Grounding Inspection...9216
    ECU Power Source Inspection...9217
    Fuel Pressure (Idling)...9221
    Amount of Fuel Flow...9222
    Pump Operating Voltage at Pump...9224
    Operating Voltage at Pump Connector...9224
    Testing Relay...9226
    Secondary Fuel Injector Resistance...9228
    Primary Injector Resistance...9228
    Secondary Fuel Injector Power Source Voltage...9229
    Primary Fuel Injector Power Source Voltage...9229
    Power Source Voltage at Injector Connector...9229
    Secondary Fuel Injector Output Voltage...9230
    Primary Fuel Injector Output Voltage...9230
    Output Voltage at Injector Connector...9230
    Fuel Line Maximum Pressure...9231
    Radiator Cap Relief Pressure...9267
    Thermostat Valve Opening Temperature...9270
    Camshaft Journal, Camshaft Cap Clearance...9294
    Camshaft Journal Diameter...9295
    Camshaft Runout...9295
    Cam Height...9295
    Cylinder Compression...9296
    Cylinder Head Warp...9298
    Valve/Valve Guide Clearance (Wobble Method)...9301
    Valve Seating Surface Outside Diameter...9302
    Valve Seating Surface Width...9302
    Spring Plate Free Play ...9331
    Spring Plate Free Play...9331
    Clutch Plate Assembly Length (Reference)...9332
    Friction Plate Thickness...9332
    Friction and Steel Plate Warp...9332
    Clutch Spring Free Length...9333
    Oil Pressure...9353
    Connecting Rod Big End Bearing Insert Selection...9375
    Crankshaft Main Bearing Insert Selection (Engine No. ∼ ZX600PE...9375
    Crankshaft Main Bearing Insert Selection (Engine No. ZX600PE0085...9375
    Connecting Rod Bend...9389
    Connecting Rod Twist...9389
    Connecting Rod Big End Side Clearance...9389
    Connecting Rod Big End Bearing Insert/Crankpin Clearance...9390
    Crankpin Diameter...9390
    Crankpin Diameter Marks...9390
    Connecting Rod Big End Inside Diameter Marks...9391
    Crankshaft Side Clearance...9391
    Crankshaft ##3 Main Journal Width...9391
    Crankshaft Runout...9392
    Crankshaft Main Bearing Insert/Journal Clearance...9392
    Crankshaft Main Journal Diameter...9392
    Crankshaft Main Journal Diameter Marks...9392
    Crankcase Main Bearing Inside Diameter Marks...9393
    (Engine No. ∼ ZX600PE008560)...9393
    (Engine No. ZX600PE008561 ∼)...9393
    Cylinder Inside Diameter...9396
    Piston Diameter...9396
    Piston Ring/Groove Clearance...9396
    Piston Ring Groove Width...9397
    Piston Ring Thickness...9397
    Piston Ring End Gap...9397
    Shift Fork Ear Thickness...9413
    Gear Groove Width...9413
    Shift Fork Guide Pin Diameter...9413
    Shift Drum Groove Width...9413
    Rim Runout (with tire installed)...9423
    Axle Runout/100 mm (3.94 in.)...9423
    Balance Weight...9425
    Link Pin Outside Diameter...9440
    Link Plates Outside Width...9440
    Rear Sprocket Warp...9445
    Pedal Position...9453
    Brake Discs Thickness...9463
    Disc Runout...9463
    Rebound Damping Force Adjustment...9478
    Spring Action...9478
    Compression Damping Force Adjustment...9479
    Fork Oil...9481
    Oil Level (fully compressed, without spring)...9482
    Spring Free Length...9487
    Rebound Damping Force Adjustment...9488
    Spring Preload Setting...9489
    Spring Adjustment...9489
    Kawasaki-recommended chargers...9571
    Battery Terminal Voltage...9573
    Terminal Voltage: 11.5 ∼ less than 12.8 V...9574
    Terminal Voltage: less than 11.5 V...9574
    Table 1 Alternator Output Voltage...9577
    Table 2 Stator Coil Resistance...9578
    Regulator/Rectifier Resistance (Unit: kΩ)...9579
    Charging Voltage...9580
    Crankshaft Sensor Peak Voltage...9585
    Ignition Coil Winding Resistance...9586
    Primary Lead Connection...9586
    Stick Coil Primary Peak Voltage...9587
    Connections:...9589
    Camshaft Position Sensor Peak Voltage...9589
    Condition...9590
    Condition...9590
    Condition...9590
    Starter Motor Brush Length...9595
    Commutator Diameter...9595
    Testing Relay...9597
    Testing Turn Signal Relay...9606
    Testing Turn Signal Relay...9606
    Air Switching Valve Resistance...9608
    LCD segment actions for 1.5 seconds...9613
    Electric Source Voltage...9618
    User Key Indicator Flashes...9633
    Immobilizer Relational Parts Replacement Chart...9648
    Gear Position Switch Resistance kΩ...9652
    Water Temperature Sensor...9654
    Connections...9656
    Relay Circuit Inspection (with the battery disconnected)...9659
    Relay Circuit Inspection (with the battery connected)...9659
    Diode Circuit Inspection...9659
  toc...0
    EMISSION CONTROL INFORMATION...9042
      1...9042
      2...9042
      3...9042
      TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED...9043
      Foreword...9044
      General Information...9046
        Before starting to perform an inspection service or carry out a ...9047
          Battery Ground...9047
          Edges of Parts...9047
          Solvent...9047
          Cleaning vehicle before disassembly...9047
          Arrangement and Cleaning of Removed Parts...9048
          Storage of Removed Parts...9048
          Inspection...9048
          Replacement Parts...9048
          Assembly Order...9048
          Tightening Sequence...9049
          Tightening Torque...9049
          Force...9049
          Gasket, O-ring...9049
          Liquid Gasket, Non-permanent Locking Agent...9049
          Press...9050
          Ball Bearing and Needle Bearing...9050
          Oil Seal, Grease Seal...9050
          Circlips, Cotter Pins...9050
          Lubrication...9051
          Direction of Engine Rotation...9051
          Electrical Wires...9051
          Instrument...9051
        ZX600P7F (Europe) Left Side View...9052
        ZX600P7F (Europe) Right Side View...9052
        Frame Number...9052
        Engine Number...9052
        ZX600P7F (US and Canada) Left Side View...9053
        ZX600P7F (US and Canada) Right Side View...9053
        Prefixes for Units...9057
        Units of Temperature...9057
      Periodic Maintenance...9058
        The scheduled maintenance must be done in accordance with this c...9060
        The following tables list the tightening torque for the major fa...9063
        Inside Circlip Pliers:...9071
        Fuel System (DFI)...9072
          Throttle Control System Inspection...9072
          Engine Vacuum Synchronization Inspection...9072
            Special Tool -...9073
            Special Tool -...9073
            Special Tool -...9074
            Special Tool -...9075
          Idle Speed Inspection...9075
          Idle Speed Adjustment...9076
          Fuel Hose Inspection (fuel leak, damage, installation condition)...9076
          Evaporative Emission Control System Inspection (California Mode...9076
          Engine Top End...9077
            Valve Clearance Inspection...9077
            Valve Clearance Adjustment...9079
            Air Suction System Damage Inspection...9081
          Cooling System...9082
            Coolant Level Inspection...9082
            Radiator Hose Damage and Installation Condition Inspection...9082
              Torque -...9082
          Clutch...9083
            Clutch Operation Inspection ...9083
          Wheels/Tires...9084
            Air Pressure Inspection...9084
            Wheel/Tire Damage Inspection...9084
            Tire Tread Wear Inspection ...9084
            Wheel Bearing Damage Inspection...9085
          Final Drive...9086
            Drive Chain Lubrication Condition Inspection...9086
            Drive Chain Slack Inspection...9086
            Drive Chain Slack Adjustment...9087
              Torque -...9087
            Wheel Alignment Inspection...9088
            Drive Chain Wear Inspection...9088
            Chain Guide Wear Inspection...9089
          Brakes...9089
            Brake Fluid Leak (Brake Hose and Pipe) Inspection...9089
            Brake Hose Damage and Installation Condition Inspection...9089
              Torque -...9089
            Brake Operation Inspection...9090
            Brake Fluid Level Inspection...9090
            Brake Pad Wear Inspection...9091
            Brake Light Switch Operation Inspection...9091
          Suspensions...9092
            Front Forks/Rear Shock Absorber Operation Inspection...9092
            Front Fork Oil Leak Inspection...9092
            Rear Shock Absorber Oil Leak Inspection...9093
            Rocker Arm Operation Inspection...9093
            Tie-Rod Operation Inspection...9093
          Steering System...9093
            Steering Play Inspection...9093
              Special Tools -...9093
            Steering Play Adjustment...9094
              Special Tool -...9094
              Torque -...9094
            Steering Stem Bearing Lubrication...9095
            Lights and Switches Operation Inspection...9095
            Headlight Aiming Inspection...9097
            Side Stand Switch Operation Inspection...9098
            Engine Stop Switch Operation Inspection...9099
          Others...9100
            Chassis Parts Lubrication ...9100
              Pivots: Lubricate with Grease...9100
              Points: Lubricate with Grease...9100
              Cables: Lubricate with Rust Inhibitor...9100
            Bolts, Nuts and Fasteners Tightness Inspection...9101
              Bolt, Nut and Fastener to be checked...9101
          Replacement Parts...9102
            Air Cleaner Element Replacement...9102
              Torque -...9103
            Fuel Hose Replacement...9103
              Torque -...9105
            Coolant Change...9106
              Torque -...9106
            Radiator Hose and O-ring Replacement...9108
              Torque -...9108
            Engine Oil Change...9109
              Torque -...9109
            Oil Filter Replacement...9109
              Special Tool -...9109
              Torque -...9109
            Brake Hose and Pipe Replacement...9110
              Torque -...9110
            Brake Fluid Change...9110
              Torque -...9111
              Torque -...9111
            Master Cylinder Rubber Parts Replacement...9112
              Special Tool -...9112
              Special Tool -...9112
              Silicone Grease -...9113
              Torque -...9113
            Caliper Rubber Parts Replacement...9113
              Torque -...9114
              Torque -...9114
              Torque -...9115
            Spark Plug Replacement...9116
              Owner's Tool -...9116
              Torque -...9116
      Fuel System (DFI)...9118
        Oil Pressure Gauge, 5 kgf/cm :...9129
        Inlet Air Pressure Sensor [A]...9131
        DFI System...9133
        DFI System Wiring Diagram...9135
        Terminal Numbers of ECU Connectors...9137
        There are a number of important precautions that should be follo...9138
          Torque -...9139
        The warning indicator light (LED) [A] is used for the FI indicat...9140
          Outline...9140
            Special Tool -...9142
            Sealant -...9142
          DFI Diagnosis Flow Chart...9144
          Inquiries to Rider...9144
        NOTE...9147
        The warning indicator light (LED) [A] is used for the FI indicat...9152
          Self-diagnosis Outline...9152
          Self-diagnosis Procedures...9153
          Self-Diagnosis Flow Chart...9154
            Service Code Reading...9155
            Service Code Erasing...9155
          Backups...9157
        The main throttle sensor is a rotating variable resistor that ch...9160
          Main Throttle Sensor Removal/Adjustment...9160
          Main Throttle Sensor Input Voltage Inspection...9160
            Special Tool -...9160
            Special Tool -...9161
          Main Throttle Sensor Output Voltage Inspection...9161
            Special Tool -...9161
            Special Tool -...9162
          Main Throttle Sensor Resistance Inspection...9162
          Main Throttle Sensor Circuit...9163
        CAUTION...9164
          Inlet Air Pressure Sensor Removal...9164
          Inlet Air Pressure Sensor Installation...9164
          Inlet Air Pressure Sensor Input Voltage Inspection...9164
            Special Tool -...9164
            Special Tool -...9165
          Inlet Air Pressure Sensor Output Voltage Inspection...9165
            Special Tool -...9166
          Inlet Air Pressure Sensor Circuit...9166
            Special Tools -...9167
        Inlet Air Temperature Sensor Removal/Installation...9169
          Inlet Air Temperature Sensor Output Voltage Inspection...9169
            Special Tool -...9169
            Sealant -...9170
          Inlet Air Temperature Sensor Resistance Inspection...9170
          Inlet Air Temperature Sensor Circuit...9170
        Water Temperature Sensor Removal/Installation...9171
          Sealant -...9171
          Torque -...9171
          Water Temperature Sensor Output Voltage Inspection...9171
            Special Tool -...9171
            Sealant -...9172
          Water Temperature Sensor Circuit...9172
            Water Temperature Sensor Resistance Inspection...9172
        CAUTION...9173
          Atmospheric Pressure Sensor Removal...9173
          Atmospheric Pressure Sensor Installation...9173
          Atmospheric Pressure Sensor Input Voltage Inspection...9173
            Special Tool -...9173
            Special Tool -...9174
          Atmospheric Pressure Sensor Output Voltage Inspection...9174
            Special Tool -...9175
          Atmospheric Pressure Sensor Circuit...9175
          Atmospheric Pressure/Altitude Relationship...9176
        Crankshaft Sensor Removal/Installation...9177
          Crankshaft Sensor Inspection...9177
          Crankshaft Sensor Circuit...9177
        Camshaft Position Sensor Removal/Installation...9178
          Camshaft Position Sensor Inspection...9178
          Camshaft Position Sensor Circuit...9178
        Speed Sensor Removal/Installation...9179
          Speed Sensor Inspection...9179
          Speed Sensor Input Voltage Inspection...9179
            Special Tool -...9179
          Speed Sensor Output Voltage Inspection...9179
            Special Tool -...9180
          Speed Sensor Circuit...9180
        Gear Position Switch Removal/Installation...9181
          Gear Position Switch Inspection...9181
          Gear Position Switch Input Voltage Inspection...9181
            Special Tool -...9181
          Gear Position Switch Circuit...9182
        This sensor has a weight [A] with two magnets inside, and sends ...9183
          Vehicle-down Sensor Removal...9183
          Vehicle-down Sensor Installation...9183
            Torque -...9183
          Vehicle-down Sensor Inspection...9184
            Special Tool -...9184
            Special Tool -...9185
            Sealant -...9185
          Vehicle-down Sensor Circuit...9186
        Subthrottle Sensor Removal/Adjustment...9187
          Subthrottle Sensor Input Voltage Inspection...9187
            Special Tool -...9187
            Special Tool -...9188
          Subthrottle Sensor Output Voltage Inspection...9188
            Special Tool -...9188
            Special Tool -...9189
          Resistance Inspection...9190
          Subthrottle Sensor Circuit...9190
        Oxygen Sensor ##1: Service Code 33...9191
          Oxygen Sensor Removal/Installation...9191
          Oxygen Sensor Inspection...9191
            Special Tool -...9191
            Sealant -...9192
          Oxygen Sensor Circuit...9192
        Exhaust Butterfly Valve Actuator Sensor Removal/Installation...9193
          Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...9193
            Special Tool -...9193
          Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio...9194
            Special Tool -...9194
          Exhaust Butterfly Valve Actuator Sensor Inspection...9195
          Exhaust Butterfly Valve Actuator Sensor Circuit...9195
        Antenna Resistance Inspection...9196
          Amplifier Input Voltage Inspection...9196
            Special Tool -...9196
        This code appears in the following conditions. ...9197
          User Key Inspection...9197
          Immobilizer System Circuit...9198
        ECU Communication Line Inspection...9199
          ECU Communication Line Circuit...9199
        Stick Coil ##1: Service Code 51...9200
          Stick Coil Removal/Installation...9200
          Stick Coil Input Voltage Inspection...9200
            Special Tool -...9200
          Stick Coil Circuit...9201
        Radiator Fan Relay Removal/Installation...9202
          Radiator Fan Relay Inspection...9202
          Radiator Fan Relay Circuit...9203
        Subthrottle Valve Actuator Removal...9204
          Subthrottle Valve Actuator Inspection...9204
          Subthrottle Valve Actuator Resistance Inspection...9204
          Subthrottle Valve Actuator Input Voltage Inspection...9205
            Special Tools -...9205
          Subthrottle Valve Actuator Circuit...9205
        Exhaust Butterfly Valve Actuator Removal...9206
          Exhaust Butterfly Valve Actuator Installation...9206
            Torque -...9206
            Torque -...9207
          Exhaust Butterfly Valve Actuator Inspection...9208
          Exhaust Butterfly Valve Actuator Output Voltage Inspection...9208
            Special Tool -...9208
          Exhaust Butterfly Valve Actuator Circuit...9209
        Air Switching Valve Removal/Installation...9210
          Air Switching Valve Inspection...9210
          Air Switching Valve Circuit (Other than Europe Models)...9210
        Oxygen Sensor Heater Removal/Installation...9211
          Oxygen Sensor Heater Inspection ...9211
            Special Tool -...9211
            Special Tool -...9211
            Sealant -...9212
          Oxygen Sensor Circuit...9212
        Oxygen Sensor ##1: Service Code 94...9213
          Oxygen Sensor Removal/Installation...9213
          Oxygen Sensor Inspection...9213
            Special Tool -...9213
            Sealant -...9214
          Oxygen Sensor Circuit...9214
        CAUTION...9215
          ECU Identification...9215
          ECU Removal...9215
          ECU Installation...9216
          ECU Power Supply Inspection...9216
            Special Tool -...9216
          ECU Power Source Circuit...9217
        ECU Fuse Removal...9218
          ECU Fuse Installation...9218
          ECU Fuse Inspection...9218
        Warning Indicator Light (LED) Inspection...9219
          Warning Indicator Light (LED) (FI/Immobilizer) Circuit...9219
        Fuel Pressure Inspection...9220
          Special Tools -...9220
          Fuel Flow Rate Inspection...9221
            Special Tool -...9222
        Fuel Pump Removal...9223
          Fuel Pump Installation...9223
            Torque -...9224
          Fuel Pump Operation Inspection...9224
          Fuel Pump Operating Voltage Inspection...9224
            Special Tools -...9224
          Fuel Pump Circuit...9225
        Fuel Pump Relay Removal...9226
          Fuel Pump Relay Inspection...9226
            Special Tool -...9226
        CAUTION...9227
          Audible Inspection...9227
          Injector Signal Test...9227
            Special Tool -...9228
          Injector Resistance Inspection...9228
            Special Tool -...9228
          Injector Unit Test...9229
          Injector Voltage Inspection...9229
            Special Tool -...9229
            Special Tool -...9229
          Injector Fuel Line Inspection...9231
          Fuel Injector Circuit...9232
        Free Play Inspection...9233
          Free Play Adjustment...9233
          Cable Installation...9233
          Cable Lubrication...9233
        Idle Speed Inspection...9234
          Synchronization Inspection...9234
          Synchronization Adjustment...9234
          Throttle Body Assy Removal...9234
            Special Tool -...9234
          Throttle Body Assy Installation...9235
            Torque -...9235
            Torque -...9235
          Throttle Body Assy Disassembly...9236
            Throttle Body Assy Assembly...9237
              Torque -...9237
        Nozzle Assy Removal...9238
          Nozzle Assy Installation...9238
            Torque -...9238
          Nozzle Assy Disassembly...9239
          Nozzle Assy Assembly...9239
            Torque -...9240
            Torque -...9240
        Air Cleaner Element Removal...9241
          Air Cleaner Element Installation...9241
          Air Cleaner Element Inspection...9241
          Air Cleaner Housing Removal...9241
          Air Cleaner Housing Installation...9242
            Torque -...9242
          Air Cleaner Housing Disassembly...9243
          Air Cleaner Housing Assembly...9243
            Torque -...9243
          Oil Draining...9244
        Fuel Tank Removal...9245
          Fuel Tank Installation...9247
          Fuel Tank and Cap Inspection...9247
          Fuel Tank Cleaning...9248
        The Evaporative Emission Control System routes fuel vapors from ...9249
          Parts Removal/Installation...9249
          Hose Inspection...9249
          Separator Inspection...9249
          Separator Operation Test...9250
          Canister Inspection ...9250
      Cooling System...9252
        Bearing Driver, 32:...9256
        Coolant Deterioration Inspection...9259
          Coolant Level Inspection...9259
          Coolant Draining...9259
          Coolant Filling...9259
          Pressure Testing...9259
          Cooling System Flushing...9260
          Coolant Reserve Tank Removal...9260
          Coolant Reserve Tank Installation...9261
            Torque -...9261
        Water Pump Removal...9262
          Water Pump Installation...9262
          Water Pump Impeller Disassembly/Assembly...9262
            Torque -...9262
          Water Pump Impeller Inspection...9262
          Water Pump Housing Disassembly...9262
          Water Pump Housing Assembly...9263
            Special Tool -...9263
            Special Tool -...9263
          Mechanical Seal Inspection...9263
        Radiator and Radiator Fan Removal...9264
          Radiator and Radiator Fan Installation...9265
            Torque -...9266
            Torque -...9266
            Torque -...9266
            Torque -...9266
          Radiator Inspection...9267
          Radiator Cap Inspection...9267
          Radiator Filler Neck Inspection...9268
        Thermostat Removal...9269
          Thermostat Installation...9269
            Torque -...9269
            Torque -...9270
          Thermostat Inspection...9270
        Hose Installation...9271
          Torque -...9271
          Hose Inspection...9271
        Water Temperature Sensor Removal...9272
          Water Temperature Sensor Inspection...9272
      Engine Top End...9274
        Compression Gauge, 20 kgf/cm :...9282
        Air Suction Valve Removal...9284
          Air Suction Valve Installation...9284
            Torque -...9284
          Air Suction Valve Inspection...9284
          Air Switching Valve Removal...9285
          Air Switching Valve Installation...9285
          Air Switching Valve Operation Test...9285
          Air Switching Valve Unit Test...9285
          Clean Air System Hose Inspection...9285
        Cylinder Head Cover Removal...9286
          Cylinder Head Cover Installation...9286
            Sealant -...9286
            Torque -...9287
            Torque -...9287
        Camshaft Chain Tensioner Removal...9288
          Camshaft Chain Tensioner Installation...9288
            Torque -...9288
            Torque -...9288
        Camshaft Removal...9289
        Camshaft Installation...9291
          Torque -...9291
          Torque -...9294
          Camshaft, Camshaft Cap Wear...9294
            Torque -...9294
          Camshaft Runout...9295
          Cam Wear...9295
          Camshaft Chain Removal...9295
        Cylinder Compression Measurement...9296
          Special Tools -...9296
          Torque -...9296
          Cylinder Head Removal...9297
          Cylinder Head Installation...9297
            Torque -...9298
            Torque -...9298
            Torque -...9298
          Cylinder Head Warp...9298
        Valve Clearance Inspection...9299
          Valve Clearance Adjustment...9299
          Valve Removal...9299
            Special Tools -...9299
          Valve Installation...9299
          Valve Guide Removal...9300
            Special Tool -...9300
          Valve Guide Installation...9300
            Special Tools -...9300
            Special Tool -...9300
          Valve-to-Guide Clearance Measurement (Wobble Method)...9301
          Valve Seat Inspection...9302
          Valve Seat Repair...9302
            Special Tools -...9302
        Throttle Body Assy Holder Removal...9307
          Throttle Body Assy Holder Installation...9307
            Torque -...9307
        WARNING...9308
          Muffler Body Removal...9308
          Muffler Body Installation...9309
            Torque -...9309
            Torque -...9309
              Rear Exhaust Pipe Removal...9310
              Rear Exhaust Pipe Installation...9311
                Torque -...9311
              Front Exhaust Pipe Removal...9312
              Front Exhaust Pipe Installation...9313
                Torque -...9313
              Exhaust Butterfly Valve Cable Removal...9314
          Exhaust Butterfly Valve Cable Installation...9315
            Torque -...9315
            Torque -...9315
            Torque -...9316
            Torque -...9317
      Clutch...9318
        Clutch Holder:...9322
        Clutch Lever Free Play Inspection...9323
          Clutch Lever Free Play Adjustment...9323
          Cable Removal...9323
          Cable Installation...9323
          Cable Lubrication...9323
          Clutch Lever Installation...9323
            Torque -...9323
        Clutch Cover Removal...9324
          Clutch Cover Installation...9324
            Sealant -...9324
            Torque -...9324
          Release Shaft Removal...9324
          Release Shaft Installation...9325
          Clutch Cover Disassembly...9325
          Clutch Cover Assembly...9326
            Torque -...9326
        Clutch Removal...9327
          Special Tool -...9327
          Clutch Installation...9327
            Special Tool -...9329
            Torque -...9329
            Torque -...9330
          Spring Plate Free Play Measurement...9330
          Spring Plate Free Play Adjustment...9331
            Torque -...9332
          Clutch Plate, Wear, Damage Inspection...9332
          Clutch Plate Warp Inspection...9332
          Clutch Spring Free Length Measurement...9333
          Damper Cam Inspection...9333
      Engine Lubrication System...9334
        Outside Circlip Pliers:...9338
        WARNING...9341
          Oil Level Inspection...9341
          Engine Oil Change...9341
          Oil Filter Replacement...9341
        Oil Pan Removal...9342
          Oil Pan Installation...9342
            Torque -...9343
        Oil Pressure Relief Valve Removal...9344
          Oil Pressure Relief Valve Installation...9344
            Torque -...9344
          Oil Pressure Relief Valve Inspection...9345
        Oil Pump Removal...9346
          Oil Pump Installation...9347
            Torque -...9347
            Torque -...9347
            Torque -...9347
            Torque -...9348
          Oil Pump Gear Removal...9348
          Oil Pump Gear Installation...9348
            Torque -...9348
          Oil Pump Gear Shaft Removal...9349
            Special Tool -...9349
          Oil Pump Gear Shaft Installation...9349
            Special Tool -...9349
        Oil Cooler Removal...9350
          Oil Cooler Installation...9350
            Torque -...9350
            Torque -...9350
          Oil Cooler/Oil Filter Case Removal...9351
          Oil Cooler/Oil Filter Case Installation...9352
            Torque -...9352
            Torque -...9352
            Torque -...9352
        Oil Pressure Measurement...9353
          Special Tools -...9353
          Torque -...9353
        Oil Pressure Switch Removal...9354
          Oil Pressure Switch Installation...9354
            Sealant -...9354
            Torque -...9354
            Torque -...9354
      Engine Removal/Installation...9356
        Engine Mount Nut Wrench:...9359
        Engine Removal...9360
          Special Tool -...9362
          Engine Installation...9363
            Torque -...9364
            Torque -...9365
            Torque -...9365
            Torque -...9365
            Special Tool -...9365
            Torque -...9365
            Torque -...9365
      Crankshaft/Transmission...9368
        Outside Circlip Pliers:...9376
        Crankcase Splitting...9377
          Crankcase Assembly...9378
            Torque -...9378
            Special Tool -...9379
            Torque -...9379
            Torque -...9379
            Torque -...9379
            Torque -...9380
            Sealant -...9381
            Torque -...9382
            Torque -...9382
            Torque -...9382
        Crankshaft Removal...9383
          Crankshaft Installation...9383
          Connecting Rod Removal...9385
          Connecting Rod Installation...9385
          Crankshaft/Connecting Rod Cleaning...9389
          Connecting Rod Bend...9389
          Connecting Rod Twist...9389
          Connecting Rod Big End Side Clearance...9389
          Connecting Rod Big End Bearing Insert/Crankpin Wear...9390
          Crankshaft Side Clearance...9391
          Crankshaft Runout...9392
          Crankshaft Main Bearing Insert/Journal Wear...9392
        Piston Removal...9394
          Special Tool -...9394
          Piston Installation...9395
            Special Tools -...9396
          Cylinder Wear (Upper Crankcase)...9396
          Piston Wear...9396
          Piston Ring, Piston Ring Groove Wear...9396
          Piston Ring Groove Width...9397
          Piston Ring Thickness...9397
          Piston Ring End Gap...9397
        Starter Idle Gear Removal...9398
          Starter Idle Gear Installation...9398
            Sealant -...9399
            Torque -...9399
            Torque -...9399
          Starter Clutch Removal...9400
            Special Tools -...9400
          Starter Clutch Installation ...9400
            Special Tools -...9400
            Torque -...9400
          Starter Clutch Disassembly...9400
          Starter Clutch Assembly...9401
          Starter Clutch Inspection...9401
        Shift Pedal Removal...9403
          Shift Pedal Installation...9403
            Torque -...9403
            Torque -...9403
            Torque -...9403
          External Shift Mechanism Removal...9403
            Special Tool -...9403
          External Shift Mechanism Installation...9404
            Torque -...9404
            Special Tool -...9404
          External Shift Mechanism Inspection...9404
            Torque -...9405
          Transmission Assy Removal...9405
          Transmission Assy Disassembly...9405
          Transmission Assy Assembly...9406
            Special Tool -...9406
            Torque -...9406
            Torque -...9406
            Torque -...9406
          Transmission Assy Installation...9407
            Torque -...9407
          Transmission Shaft Removal...9408
          Transmission Shaft Installation...9408
          Transmission Shaft Disassembly...9409
            Special Tool -...9409
          Transmission Shaft Assembly...9409
          Shift Drum and Fork Removal...9412
          Shift Drum and Fork Installation...9412
          Shift Drum Disassembly...9412
          Shift Drum Assembly...9412
            Torque -...9412
          Shift Fork Bending...9412
          Shift Fork/Gear Groove Wear...9413
          Shift Fork Guide Pin/Drum Groove Wear...9413
          Gear Dog and Gear Dog Hole Damage...9413
      Wheels/Tires...9414
        Bearing Driver Set:...9418
        Front Wheel Removal...9419
          Special Tools -...9419
          Front Wheel Installation...9419
            Torque -...9420
            Torque -...9420
          Rear Wheel Removal...9420
          Rear Wheel Installation...9421
            Torque -...9422
          Wheel Inspection...9423
            Special Tools -...9423
          Axle Inspection...9423
          Balance Inspection...9424
          Balance Adjustment...9424
          Balance Weight Removal...9424
          Balance Weight Installation...9424
        Air Pressure Inspection/Adjustment...9426
          Tire Inspection...9426
          Tire Removal...9426
          Tire Installation...9426
          Tire Repair...9428
        Hub Bearing Removal...9429
          Special Tools -...9429
          Hub Bearing Installation...9429
            Special Tool -...9429
            Special Tool -...9429
          Hub Bearing Inspection...9429
          Hub Bearing Lubrication...9430
      Final Drive...9432
        Inside Circlip Pliers:...9436
        Drive Chain Slack Inspection...9437
          Drive Chain Slack Adjustment...9437
          Wheel Alignment Inspection/Adjustment...9437
          Drive Chain Wear Inspection...9437
          Drive Chain Lubrication...9437
          Drive Chain Removal...9437
          Drive Chain Installation...9438
        Engine Sprocket Removal...9441
          Engine Sprocket Installation...9441
            Torque -...9441
            Torque -...9442
          Rear Sprocket Removal...9442
          Rear Sprocket Installation...9442
            Torque -...9442
          Coupling Installation...9443
          Coupling Bearing Removal...9443
            Special Tool -...9443
            Special Tool -...9443
          Coupling Bearing Installation...9443
            Special Tool -...9443
            Special Tool -...9443
            Special Tool -...9444
          Coupling Bearing Inspection...9444
          Coupling Bearing Lubrication...9444
          Coupling Damper Inspection...9444
          Sprocket Wear Inspection...9444
          Rear Sprocket Warp Inspection...9445
      Brakes...9446
        Inside Circlip Pliers:...9452
        Brake Lever Position Adjustment...9453
          Brake Pedal Position Inspection ...9453
          Brake Pedal Position Adjustment ...9453
            Torque -...9453
          Brake Pedal Removal...9453
          Brake Pedal Installation...9454
            Torque -...9454
            Torque -...9454
            Torque -...9454
        Front Caliper Removal...9455
          Rear Caliper Removal...9455
          Caliper Installation...9455
            Torque -...9455
          Front Caliper Disassembly...9456
          Front Caliper Assembly...9456
          Rear Caliper Disassembly...9456
          Rear Caliper Assembly...9456
          Caliper Fluid Seal Damage...9456
          Rear Caliper Dust Boot and Friction Boot Damage...9457
          Caliper Piston and Cylinder Damage...9457
          Rear Caliper Holder Shaft Wear...9457
        Front Brake Pad Removal...9458
          Front Brake Pad Installation...9458
            Torque -...9458
          Rear Brake Pad Removal ...9458
          Rear Brake Pad Installation...9459
          Brake Pad Wear Inspection...9459
        Front Master Cylinder Removal...9460
          Front Master Cylinder Installation...9460
            Torque -...9460
            Torque -...9460
          Rear Master Cylinder Removal...9461
          Rear Master Cylinder Installation...9461
            Torque -...9461
          Front Master Cylinder Disassembly...9461
          Rear Master Cylinder Disassembly...9461
          Master Cylinder Inspection (Visual Inspection)...9461
          Master Cylinder Assembly...9462
        Brake Disc Removal...9463
          Brake Disc Installation...9463
            Torque -...9463
          Brake Disc Wear...9463
          Brake Disc Warp...9463
            Special Tools -...9463
        Brake Fluid Level Inspection...9464
          Brake Fluid Change...9464
          Brake Line Bleeding...9464
            Torque -...9465
            Torque -...9466
            Torque -...9466
        Brake Hose Removal/Installation...9468
          Brake Hose Inspection...9468
      Suspension...9470
        Inside Circlip Pliers:...9476
        Rebound Damping Force Adjustment...9478
          Spring Preload Adjustment...9478
          Compression Damping Force Adjustment...9479
          Front Fork Removal (Each Fork Leg)...9479
          Front Fork Installation...9480
            Torque -...9480
            Torque -...9480
          Front Fork Oil Change...9480
            Special Tool -...9480
            Special Tool -...9481
            Special Tool -...9481
            Special Tool -...9482
            Special Tool -...9482
            Special Tool -...9483
            Special Tool -...9483
            Special Tool -...9483
            Torque -...9484
          Front Fork Disassembly...9484
          Front Fork Assembly...9485
            Special Tool -...9486
            Special Tool -...9486
            Torque -...9486
          Inner Tube Inspection...9486
          Dust Seal Inspection...9487
          Spring Tension...9487
        Rebound Damping Force Adjustment...9488
          Compression Damping Force Adjustment...9488
          Spring Preload Adjustment...9489
            Special Tool -...9489
            Special Tools -...9489
          Rear Shock Absorber Removal...9490
            Special Tools -...9490
          Rear Shock Absorber Installation...9490
            Torque -...9490
          Rear Shock Absorber Inspection...9490
          Rear Shock Absorber Scrapping...9491
        Swingarm Removal...9492
          Special Tool -...9492
          Swingarm Installation...9493
            Torque -...9493
            Special Tool -...9493
            Torque -...9493
            Torque -...9494
          Swingarm Bearing Removal...9494
            Special Tool -...9494
            Special Tool -...9494
          Swingarm Bearing Installation...9494
            Special Tools -...9494
          Swingarm Bearing, Sleeve Inspection...9495
          Chain Guide Inspection...9495
        Tie-Rod Removal...9496
          Special Tools -...9496
          Tie-Rod Installation...9496
            Torque -...9496
          Rocker Arm Removal...9496
            Special Tools -...9497
          Rocker Arm Installation...9497
            Torque -...9497
          Tie-Rod and Rocker Arm Bearing Removal...9498
            Special Tool -...9498
          Tie-Rod and Rocker Arm Bearing Installation...9498
            Special Tools -...9499
          Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...9500
          Rocker Arm/Tie-Rod Bearing Lubrication...9500
      Steering...9502
        Bearing Puller:...9505
        Steering Inspection...9506
          Steering Adjustment...9506
        Stem, Stem Bearing Removal...9507
          Special Tool -...9507
          Special Tool -...9507
          Special Tools -...9508
          Stem, Stem Bearing Installation...9508
            Special Tools -...9508
            Special Tools -...9508
            Special Tool -...9509
            Torque -...9509
            Torque -...9510
          Steering Stem Bearing Lubrication...9510
          Steering Stem Warp...9510
          Stem Cap Deterioration, Damage...9510
        Handlebar Removal...9511
          Handlebar Installation...9512
            Torque -...9512
            Torque -...9512
      Frame...9514
        Rear Seat Removal...9521
          Rear Seat Installation...9521
          Front Seat Removal...9521
          Front Seat Installation...9521
        Lower Fairing Removal...9522
          Lower Fairing Installation...9522
          Middle Fairing Removal...9522
          Windshield Removal...9524
          Windshield Installation...9524
            Torque -...9524
          Upper Fairing Disassembly...9525
          Upper Fairing Assembly...9525
          Upper Fairing Installation...9525
          Inner Cover Removal...9525
          Inner Cover Installation...9526
          Center Inner Fairing Removal...9526
          Center Inner Fairing Installation...9526
          Lower Inner Fairing Removal...9526
          Lower Inner Fairing Installation...9527
        Left Side Cover Removal...9528
          Left Side Cover Installation...9528
          Right Side Cover Removal...9528
          Right Side Cover Installation...9528
        Seat Cover Removal...9529
          Seat Cover Installation...9529
        Heat Insulation Plate Removal...9530
          Heat Insulation Plate Installation...9530
          Heat Insulation Rubber Plate Pemoval...9530
          Heat Insulation Rubber Plate Installation...9531
        Front Fender Removal...9532
          Front Fender Installation...9532
            Torque -...9532
          Flap and Rear Fender Removal...9532
          Flap and Rear Fender Installation...9536
            Torque -...9536
            Torque -...9536
        Rear Frame Removal...9537
          Rear Frame Installation...9537
            Torque -...9537
          Frame Inspection...9537
        Sidestand Removal...9538
          Sidestand Installation...9538
            Torque -...9538
            Torque -...9538
      Electrical System...9540
        Hand Tester:...9566
        There are a number of important precautions that are musts when ...9567
        Wiring Inspection...9568
          Special Tool -...9568
        Battery Removal...9569
          Battery Installation...9569
          Battery Activation...9569
          Precautions...9572
            1)...9572
            2)...9572
            3)...9572
            4)...9572
          Interchange...9572
            Charging Condition Inspection...9573
            Refreshing Charge...9573
        Alternator Cover Removal...9575
          Alternator Cover Installation...9575
            Sealant -...9575
            Torque -...9575
          Stator Coil Removal...9575
          Stator Coil Installation...9576
            Torque -...9576
            Sealant -...9576
            Torque -...9576
          Alternator Rotor Removal...9576
            Special Tools -...9576
            Special Tool -...9576
          Alternator Rotor Installation...9576
            Special Tools -...9576
            Special Tool -...9577
            Special Tools -...9577
            Torque -...9577
          Alternator Inspection...9577
            Special Tool -...9578
          Regulator/Rectifier Removal...9578
          Regulator/Rectifier Inspection...9579
            Special Tool -...9579
            Torque -...9579
          Charging Voltage Inspection...9580
            Special Tool -...9580
          Charging System Circuit...9581
            Crankshaft Sensor Removal...9583
            Crankshaft Sensor Installation...9583
              Torque -...9583
              Sealant -...9583
            Crankshaft Sensor Inspection...9584
              Special Tool -...9584
            Crankshaft Sensor Peak Voltage...9584
              Special Tools -...9585
            Stick Coil Removal...9585
            Stick Coil Installation...9585
            Stick Coil Inspection...9586
            Stick Coil Primary Peak Voltage...9586
              Special Tools -...9586
            Spark Plug Removal...9587
            Spark Plug Installation...9587
            Spark Plug Clean and Inspection...9587
            Camshaft Position Sensor Removal...9588
            Camshaft Position Sensor Installation...9588
              Torque -...9588
            Camshaft Position Sensor Inspection...9588
              Special Tool -...9589
            Camshaft Position Sensor Peak Voltage Inspection...9589
              Special Tools -...9589
            Interlock Operation Inspection...9590
            IC Igniter Inspection...9591
          Ignition System Circuit...9592
        Starter Motor Removal...9593
          Starter Motor Installation...9593
            Torque -...9593
          Starter Motor Disassembly...9594
          Starter Motor Assembly...9594
          Brush Inspection...9595
          Commutator Cleaning and Inspection...9595
          Armature Inspection...9596
            Special Tool -...9596
          Brush Lead Inspection...9596
            Special Tool -...9596
          Right-hand End Cover Assembly Inspection...9596
            Special Tool -...9596
          Starter Relay Inspection...9596
            Special Tool -...9597
          Electric Starter Circuit...9598
        This motorcycle adopt the daylight system and have a headlight r...9599
          Headlight Beam Horizontal Adjustment...9599
          Headlight Beam Vertical Adjustment...9599
          Headlight Bulb Replacement...9599
          City Light Bulb Replacement...9600
          Headlight Removal/Installation...9600
          Tail/Brake Light (LED) Removal...9600
          Tail/Brake Light (LED) Installation...9601
          License Plate Light Bulb Replacement...9601
          Headlight/Tail Light Circuit...9602
            Turn Signal Light Bulb Replacement...9602
            Turn Signal Light Removal...9604
            Turn Signal Relay Inspection...9605
          Turn Signal Light Circuit...9607
        Air Switching Valve Operation Test...9608
          Air Switching Valve Unit Test...9608
            Special Tool -...9608
        Fan Motor Inspection...9609
          Radiator Fan Circuit ZX600P7F...9609
          Radiator Fan Circuit ZX600P8F...9610
        Meter Unit Removal...9611
          Meter Unit Disassembly...9611
          Electronic Unit (Combination Meter) Inspection...9612
          Fuel Level Sensor Line Self-Diagnosis Mode Inspection...9628
          Meter Circuit...9629
        This motorcycle is equipped with an immobilizer system to protec...9630
          Operational Cautions...9630
            Key Registration...9630
              Special Tool -...9630
          Spare User Key Registration Flow Chart...9635
            Special Tool -...9636
          All Keys Initial Registration Flow Chart...9645
            Immobilizer System Parts Replacement...9646
            Immobilizer System Inspection...9648
          Immobilizer System Circuit...9649
        Brake Light Timing Inspection...9650
          Brake Light Timing Adjustment...9650
          Gear Position Switch Removal...9650
          Gear Position Switch Installation...9651
            Torque -...9651
          Gear Position Switch Inspection...9652
            Special Tool -...9652
          Switch Inspection...9653
            Special Tool -...9653
          Rear Brake Light Switch Connections...9653
          Side Stand Switch Connections...9653
          Oil Pressure Switch Connections *...9653
          Water Temperature Sensor Inspection...9654
          Speed Sensor Removal...9654
          Speed Sensor Installation...9655
            Torque -...9655
          Speed Sensor Inspection...9655
            Special Tool -...9655
          Fuel Reserve Switch Inspection...9656
          Oxygen Sensor Removal (Equipped Models)...9656
          Oxygen Sensor Installation (Equipped Models)...9657
            Torque -...9657
          Oxygen Sensor Inspection (Equipped Models)...9657
        The relay box [A] has relays and diodes. The relays and diodes c...9658
          Relay Box Removal...9658
          Relay Circuit Inspection...9658
          Diode Circuit Inspection...9659
          Relay Box Internal Circuit...9660
        30 A Main Fuse Removal...9661
          Fuse Box Fuse Removal...9661
          10 A ECU Fuse Removal...9661
          Fuse Installation...9662
          Fuse Inspection...9662
      Appendix...9664
        California Model...9690
        California Model...9691
        NOTE...9693
          Engine Doesn't Start, Starting Difficulty:...9693
            Starter motor not rotating:...9693
            Starter motor rotating but engine doesn't turn over:...9693
            Engine won't turn over:...9693
            No fuel flow:...9693
            No spark; spark weak:...9693
            Fuel/air mixture incorrect:...9693
            Compression Low:...9693
          Poor Running at Low Speed:...9693
            Spark weak:...9693
            Fuel/air mixture incorrect:...9693
            Compression low:...9694
            Run-on (dieseling):...9694
            Other:...9694
          Poor Running or No Power at High Speed:...9694
            Firing incorrect:...9694
            Fuel/air mixture incorrect:...9694
            Compression low:...9694
            Knocking:...9694
            Miscellaneous:...9694
          Overheating:...9694
            Firing incorrect:...9694
            Muffler overheating:...9694
            Fuel/air mixture incorrect:...9694
            Compression high:...9695
            Engine load faulty:...9695
            Lubrication inadequate:...9695
            Oil cooler incorrect:...9695
            Water temperature meter incorrect:...9695
            Coolant incorrect:...9695
            Cooling system component incorrect:...9695
          Over Cooling:...9695
            Water temperature meter incorrect:...9695
            Cooling system component incorrect:...9695
          Clutch Operation Faulty:...9695
            Clutch slipping:...9695
            Clutch not disengaging properly:...9695
          Gear Shifting Faulty:...9695
            Doesn't go into gear; shift pedal doesn't return:...9695
            Jumps out of gear:...9695
            Overshifts:...9695
          Abnormal Engine Noise:...9695
            Knocking:...9695
            Piston slap:...9695
            Valve noise:...9695
            Other noise:...9695
          Abnormal Drive Train Noise:...9696
            Clutch noise:...9696
            Transmission noise:...9696
            Drive line noise:...9696
          Abnormal Frame Noise:...9696
            Front fork noise:...9696
            Rear shock absorber noise:...9696
            Disc brake noise:...9696
            Other noise:...9696
          Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:...9696
          Exhaust Smokes Excessively:...9696
            White smoke:...9696
            Black smoke:...9696
            Brown smoke:...9696
          Handling and/or Stability Unsatisfactory:...9696
            Handlebar hard to turn:...9696
            Handlebar shakes or excessively vibrates:...9696
            Handlebar pulls to one side:...9696
            Shock absorption unsatisfactory:...9696
          Brake Doesn't Hold:...9697
          Battery Trouble:...9697
            Battery discharged:...9697
            Battery overcharged:...9697
Kawasaki Motorcycle Service Repair Manual '08-'11 ZX-14 (EN)...9699
  General Information...9707
    Before Servicing...9708
    Model Identification...9713
    General Specifications...9716
    Unit Conversion Table...9719
  Periodic Maintenance...9721
    Periodic Maintenance Chart...9723
    Torque and Locking Agent...9727
    Specifications...9734
    Special Tools and Sealant...9736
    Periodic Maintenance Procedures...9737
      Fuel System (DFI)...9737
        Throttle Control System Inspection...9737
        Engine Vacuum Synchronization Inspection...9737
        Idle Speed Inspection...9741
        Idle Speed Adjustment...9741
        Fuel Hose Inspection (fuel leak, damage, installation condition)...9741
        Evaporative Emission Control System Inspection (CAL, SEA and TH Models) ...9742
      Cooling System...9743
        Coolant Level Inspection...9743
        Radiator Hose and Pipe Inspection...9744
      Engine Top End...9744
        Valve Clearance Inspection...9744
        Valve Clearance Adjustment...9746
        Air Suction System Damage Inspection...9749
      Clutch...9749
        Clutch Operation Inspection ...9749
        Clutch Fluid Level Inspection...9750
        Clutch Fluid Leak Inspection...9750
        Clutch Hose and Pipe Damage and Installation Condition Inspection...9750
      Wheels/Tires...9751
        Air Pressure Inspection...9751
        Wheel/Tire Damage Inspection...9751
        Tire Tread Wear Inspection ...9751
        Wheel Bearing Damage Inspection...9752
      Final Drive...9753
        Drive Chain Lubrication Condition Inspection...9753
        Drive Chain Slack Inspection...9753
        Drive Chain Slack Adjustment...9754
        Wheel Alignment Inspection...9755
        Drive Chain Wear Inspection...9755
        Drive Chain Guide Wear Inspection...9756
      Brakes...9756
        Brake Fluid Leak (Brake Hose and Pipe) Inspection...9756
        Brake Hose and Pipe Damage and Installation Condition Inspection...9757
        Brake Operation Inspection...9757
        Brake Fluid Level Inspection...9757
        Brake Pad Wear Inspection...9758
        Brake Light Switch Operation Inspection...9759
      Suspension...9759
        Front Forks/Rear Shock Absorber Operation Inspection...9759
        Front Fork Oil Leak Inspection...9760
        Rear Shock Absorber Oil Leak Inspection...9760
        Rocker Arm Operation Inspection...9760
        Tie-Rod Operation Inspection...9760
      Steering...9761
        Steering Play Inspection...9761
        Steering Play Adjustment...9761
        Steering Stem Bearing Lubrication...9762
      Electrical System...9763
        Lights and Switches Operation Inspection...9763
        Headlight Aiming Inspection...9766
        Sidestand Switch Operation Inspection...9767
        Engine Stop Switch Operation Inspection...9768
      Others...9768
        Chassis Parts Lubrication ...9768
        Bolts, Nuts and Fasteners Tightness Inspection...9769
      Replacement Parts...9770
        Air Cleaner Element Replacement...9770
        Fuel Hose Replacement...9772
        Coolant Change...9773
        Radiator Hose and O-ring Replacement...9775
        Clutch Hose Replacement...9776
        Clutch Fluid Change...9777
        Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement...9778
        Engine Oil Change...9779
        Oil Filter Replacement...9780
        Brake Hose Replacement...9781
        Brake Fluid Change...9783
        Master Cylinder Rubber Parts Replacement...9784
        Caliper Rubber Parts Replacement...9785
        Spark Plug Replacement...9789
  Fuel System (DFI)...9791
    Exploded View...9794
    DFI System...9800
    DFI Parts Location...9806
    Specifications...9808
    Special Tools and Sealant...9810
    DFI Servicing Precautions...9812
      DFI Servicing Precautions...9812
    Troubleshooting the DFI System...9814
      Outline...9814
      Inquiries to Rider...9819
    DFI System Troubleshooting Guide...9822
    Self-Diagnosis...9827
      Self-diagnosis Outline...9827
      Self-diagnosis Procedures...9828
        Service Code Reading...9831
        Service Code Erasing...9831
      Backups...9833
    Main Throttle Sensor (Service Code 11)...9835
      Main Throttle Sensor Removal/Adjustment...9835
      Main Throttle Sensor Input Voltage Inspection...9835
      Main Throttle Sensor Output Voltage Inspection...9837
      Main Throttle Sensor Resistance Inspection...9840
    Inlet Air Pressure Sensor (Service Code 12)...9841
      Inlet Air Pressure Sensor Removal...9841
      Inlet Air Pressure Sensor Installation...9841
      Inlet Air Pressure Sensor Input Voltage Inspection...9842
      Inlet Air Pressure Sensor Output Voltage Inspection...9843
    Inlet Air Temperature Sensor (Service Code 13)...9847
      Inlet Air Temperature Sensor Removal/Installation...9847
      Inlet Air Temperature Sensor Output Voltage Inspection...9847
      Inlet Air Temperature Sensor Resistance Inspection...9848
    Water Temperature Sensor (Service Code 14)...9850
      Water Temperature Sensor Removal/Installation...9850
      Water Temperature Sensor Output Voltage Inspection...9850
      Water Temperature Sensor Resistance Inspection...9851
    Atmospheric Pressure Sensor (Service Code 15)...9852
      Atmospheric Pressure Sensor Removal...9852
      Atmospheric Pressure Sensor Installation...9852
      Atmospheric Pressure Sensor Input Voltage Inspection...9852
      Atmospheric Pressure Sensor Output Voltage Inspection...9853
    Crankshaft Sensor (Service Code 21)...9856
      Crankshaft Sensor Removal/Installation...9856
      Crankshaft Sensor Inspection...9856
    Camshaft Position Sensor (Service Code 23)...9857
      Camshaft Position Sensor Removal/Installation...9857
      Camshaft Position Sensor Inspection...9857
    Speed Sensor (Service Code 24)...9858
      Speed Sensor Removal/Installation...9858
      Speed Sensor Inspection...9858
      Speed Sensor Input Voltage Inspection...9858
      Speed Sensor Output Voltage Inspection...9859
    Gear Position Switch (Service Code 25)...9861
      Gear Position Switch Removal/Installation...9861
      Gear Position Switch Inspection...9861
      Gear Position Switch Input Voltage Inspection...9861
    Vehicle-down Sensor (Service Code 31)...9863
      Vehicle-down Sensor Removal...9863
      Vehicle-down Sensor Installation...9863
      Vehicle-down Sensor Inspection...9864
    Subthrottle Sensor (Service Code 32)...9866
      Subthrottle Sensor Removal/Adjustment...9866
      Subthrottle Sensor Input Voltage Inspection...9866
      Subthrottle Sensor Output Voltage Inspection...9868
      Subthrottle Sensor Resistance Inspection...9870
    Oxygen Sensor - not activated (Service Code 33) (Equipped Models)...9871
      Oxygen Sensor Removal/Installation...9871
      Oxygen Sensor Inspection...9871
    Immobilizer Amplifier (Service Code 35) (Equipped Models)...9873
      Antenna Resistance Inspection...9873
      Amplifier Input Voltage Inspection...9873
    Blank Key Detection (Service Code 36) (Equipped Models)...9874
      User Key Inspection...9874
    Fuel Pump Relay (Service Code 46)...9875
      Fuel Pump Relay Removal...9875
      Fuel Pump Relay Inspection...9875
    Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)...9877
      Stick Coil Removal/Installation...9877
      Stick Coil Input Voltage Inspection...9877
    Subthrottle Valve Actuator (Service Code 62)...9879
      Subthrottle Valve Actuator Removal...9879
      Subthrottle Valve Actuator Inspection...9879
      Subthrottle Valve Actuator Resistance Inspection...9879
      Subthrottle Valve Actuator Input Voltage Inspection...9880
    Oxygen Sensor Heater (Service Code 67) (Equipped Models)...9882
      Oxygen Sensor Heater Removal/Installation...9882
      Oxygen Sensor Heater Inspection ...9882
    ECU Main Relay (Service Code 75)...9885
      ECU Main Relay Inspection...9885
    ECU...9886
      ECU Identification...9886
      ECU Removal...9886
      ECU Installation...9888
      ECU Power Supply Inspection...9889
      CAN Communication Line Resistance Inspection...9890
    Warning Indicator Light (LED)...9892
      Light (LED) Inspection...9892
    Fuel Line...9893
      Fuel Pressure Inspection...9893
      Fuel Flow Rate Inspection...9894
    Fuel Pump...9897
      Fuel Pump Removal...9897
      Fuel Pump Installation...9897
      Fuel Pump Operation Inspection...9898
      Fuel Pump Operating Voltage Inspection...9898
    Fuel Injectors...9900
      Fuel Injectors Removal/Installation...9900
      Fuel Injectors Power Source Voltage Inspection...9900
      Fuel Injector Output Voltage Inspection...9901
      Fuel Injector Audible Inspection...9902
      Fuel Injector Signal Test...9903
      Fuel Injector Resistance Inspection...9904
      Fuel Injector Unit Test...9904
      Fuel Injector Fuel Line Inspection...9905
    Throttle Grip and Cables...9907
      Free Play Inspection...9907
      Free Play Adjustment...9907
      Cable Installation...9907
      Cable Lubrication...9907
    Throttle Body Assy...9908
      Idle Speed Inspection/Adjustment...9908
      Throttle Bore Cleaning...9908
      Synchronization Inspection/Adjustment...9908
      Throttle Body Assy Removal...9908
      Throttle Body Assy Installation...9911
      Throttle Body Assy Disassembly...9913
      Throttle Body Assy Assembly...9914
    Air Line...9916
      Air Cleaner Element Removal...9916
      Air Cleaner Element Installation...9916
      Air Cleaner Element Inspection...9916
      Air Cleaner Element Holder Removal...9916
      Air Cleaner Element Holder Installation...9916
      Air Cleaner Oil Draining...9917
      Rear Air Inlet Duct Removal...9917
      Rear Air Inlet Duct Installation...9917
      Front and Middle Air Inlet Duct Removal...9918
      Front and Middle Air Inlet Duct Installation...9918
    Fuel Tank...9920
      Fuel Tank Removal...9920
      Fuel Tank Installation...9923
      Fuel Tank Inspection...9924
      Fuel Tank Cleaning...9925
    Evaporative Emission Control System (CAL, SEA and TH Models)...9926
      Parts Removal/Installation...9926
      Hose Inspection...9926
      Separator Inspection...9926
      Separator Operation Test...9927
      Canister Inspection...9927
  Cooling System...9929
    Exploded View...9930
    Coolant Flow Chart...9932
    Specifications...9934
    Coolant...9935
      Coolant Deterioration Inspection...9935
      Coolant Level Inspection...9935
      Coolant Draining...9935
      Coolant Filling...9935
      Pressure Testing...9935
      Cooling System Flushing...9936
      Coolant Reserve Tank Removal/Installation...9936
    Water Pump...9937
      Water Pump Removal...9937
      Water Pump Installation...9937
      Water Pump Impeller Inspection...9938
    Radiator...9939
      Radiator and Radiator Fan Removal...9939
      Radiator and Radiator Fan Installation...9940
      Radiator Inspection...9940
      Radiator Cap Inspection...9941
      Radiator Filler Neck Inspection...9941
    Thermostat...9942
      Thermostat Removal...9942
      Thermostat Installation...9942
      Thermostat Inspection...9942
    Hoses and Pipes...9944
      Hose Installation...9944
      Hose Inspection...9944
    Water Temperature Sensor...9945
      Water Temperature Sensor Removal...9945
      Water Temperature Sensor Inspection...9945
  Engine Top End...9947
    Exploded View...9948
    Exhaust System...9952
    Specifications...9954
    Special Tools and Sealant...9955
    Clean Air System...9957
      Air Suction Valve Removal...9957
      Air Suction Valve Installation...9957
      Air Suction Valve Inspection...9958
      Air Switching Valve Removal...9958
      Air Switching Valve Installation...9958
      Air Switching Valve Operation Test...9958
      Air Switching Valve Unit Test...9958
      Clean Air System Hose Inspection...9959
    Cylinder Head Cover...9960
      Cylinder Head Cover Removal...9960
      Cylinder Head Cover Installation...9960
    Camshaft Chain Tensioner...9962
      Camshaft Chain Tensioner Removal...9962
      Camshaft Chain Tensioner Installation...9962
    Camshaft, Camshaft Chain...9963
      Camshaft Removal...9963
      Camshaft Installation...9963
      Camshaft, Camshaft Cap Wear...9966
      Camshaft Runout...9967
      Cam Wear...9967
      Camshaft Chain Removal...9967
      Camshaft Chain Installation...9968
    Cylinder Head...9969
      Cylinder Compression Measurement...9969
      Cylinder Head Removal...9970
      Cylinder Head Installation...9970
      Cylinder Head Warp Inspection...9971
    Valves...9972
      Valve Clearance Inspection...9972
      Valve Clearance Adjustment...9972
      Valve Removal...9972
      Valve Installation...9972
      Valve Guide Removal...9972
      Valve Guide Installation...9973
      Valve-to-Guide Clearance Measurement (Wobble Method)...9974
      Valve Seat Inspection...9975
      Valve Seat Repair...9975
    Throttle Body Holder...9980
      Throttle Body Holder Installation...9980
    Muffler...9981
      Muffler Body Removal/Installation...9981
      Exhaust Pipe Removal...9982
      Exhaust Pipe Installation...9982
  Clutch...9983
    Exploded View...9984
    Specifications...9986
    Special Tools and Sealant...9987
    Clutch Master Cylinder...9988
      Clutch Lever Position Adjustment...9988
      Clutch Master Cylinder Removal...9988
      Clutch Master Cylinder Installation ...9988
      Clutch Master Cylinder Disassembly ...9989
      Clutch Master Cylinder Assembly...9989
      Clutch Master Cylinder Inspection...9989
    Clutch Slave Cylinder...9990
      Clutch Slave Cylinder Removal...9990
      Clutch Slave Cylinder Installation...9991
      Clutch Slave Cylinder Disassembly ...9991
      Clutch Slave Cylinder Assembly...9991
    Clutch Fluid...9992
      Clutch Fluid Level Inspection...9992
      Clutch Fluid Change...9992
      Bleeding the Clutch Line...9992
      Clutch Hose Removal/Installation...9994
      Clutch Hose Inspection...9994
    Clutch Cover...9995
      Clutch Cover Removal...9995
      Clutch Cover Installation...9995
    Clutch...9996
      Clutch Removal...9996
      Clutch Installation...9996
      Clutch Plate Assembly Inspection...9998
      Clutch Plate Assembly Adjustment...9999
      Clutch Plate, Wear, Damage Inspection...9999
      Clutch Plate Warp Inspection...9999
      Clutch Spring Free Length Measurement...10000
  Engine Lubrication System...10001
    Exploded View...10002
    Engine Oil Flow Chart...10004
    Specifications...10006
    Special Tools and Sealant...10007
    Engine Oil and Oil Filter...10008
      Oil Level Inspection...10008
      Engine Oil Change...10008
      Oil Filter Replacement...10008
    Oil Pan...10009
      Oil Pan Removal...10009
      Oil Pan Installation...10009
    Oil Pressure Relief Valve...10011
      Oil Pressure Relief Valve Removal...10011
      Oil Pressure Relief Valve Installation...10011
      Oil Pressure Relief Valve Inspection...10011
    Oil Pump...10012
      Oil Pump Removal...10012
      Oil Pump Installation...10012
    Oil Cooler...10014
      Oil Cooler Removal...10014
      Oil Cooler Installation...10014
    Oil Pressure Measurement...10015
      Oil Pressure Measurement...10015
    Oil Pressure Switch...10016
      Oil Pressure Switch Removal...10016
      Oil Pressure Switch Installation...10016
  Engine Removal/Installation...10017
    Exploded View...10018
    Engine Removal/Installation...10020
      Engine Removal...10020
      Engine Installation...10022
  Crankshaft/Transmission...10029
    Exploded View...10030
    Specifications...10034
    Special Tools and Sealants...10037
    Crankcase Splitting...10038
      Crankcase Splitting...10038
      Crankcase Assembly...10039
    Crankshaft and Connecting Rods...10043
      Crankshaft Removal...10043
      Crankshaft Installation...10043
      Connecting Rod Removal...10044
      Connecting Rod Installation...10044
      Crankshaft/Connecting Rod Cleaning...10047
      Connecting Rod Bend Inspection...10048
      Connecting Rod Twist Inspection...10048
      Connecting Rod Big End Side Clearance Inspection...10048
      Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection...10049
      Crankshaft Side Clearance Inspection...10050
      Crankshaft Runout Inspection...10051
      Crankshaft Main Bearing Insert/Journal Wear Inspection...10051
    Pistons...10054
      Piston Removal...10054
      Piston Installation...10055
      Cylinder Wear (Upper Crankcase) Inspection...10056
      Piston Wear Inspection...10056
      Piston Ring, Piston Ring Groove Wear Inspection...10056
      Piston Ring Groove Width Inspection...10057
      Piston Ring Thickness Inspection...10057
      Piston Ring End Gap Inspection...10057
    Balancer...10058
      Front Balancer Removal...10058
      Front Balancer Installation...10058
      Rear Balancer Removal...10059
      Rear Balancer Installation...10060
      Balancer Adjustment...10062
      Balancer Damper Inspection...10062
    Starter Motor Clutch and Torque Limiter...10063
      Starter Motor Clutch Removal...10063
      Starter Motor Clutch Installation...10063
      Starter Motor Clutch Disassembly...10063
      Starter Motor Clutch Assembly...10064
      Starter Clutch Inspection...10064
      Torque Limiter Removal...10064
      Torque Limiter Installation...10065
    Transmission...10066
      Shift Pedal Removal...10066
      Shift Pedal Installation...10066
      External Shift Mechanism Removal...10066
      External Shift Mechanism Installation...10067
      External Shift Mechanism Inspection...10067
      Transmission Shaft Removal...10067
      Transmission Shaft Installation...10068
      Transmission Shaft Disassembly...10069
      Transmission Shaft Assembly...10069
      Shift Drum and Fork Removal...10072
      Shift Drum and Fork Installation...10072
      Shift Drum Disassembly...10072
      Shift Drum Assembly...10072
      Shift Fork Bending Inspection...10073
      Shift Fork/Gear Groove Wear Inspection...10073
      Shift Fork Guide Pin/Drum Groove Wear Inspection...10073
      Gear Dog and Gear Dog Hole Damage Inspection...10073
  Wheels/Tires...10075
    Exploded View...10076
    Specifications...10078
    Special Tools...10079
    Wheels (Rims)...10080
      Front Wheel Removal...10080
      Front Wheel Installation...10080
      Rear Wheel Removal...10081
      Rear Wheel Installation...10082
      Wheel Inspection...10084
      Axle Inspection...10084
      Balance Inspection...10085
      Balance Adjustment...10085
      Balance Weight Removal...10085
      Balance Weight Installation...10086
    Tires...10088
      Air Pressure Inspection/Adjustment...10088
      Tire Inspection...10088
      Tire Removal...10088
      Tire Installation...10088
      Tire Repair...10090
    Hub Bearing...10091
      Hub Bearing Removal...10091
      Hub Bearing Installation...10091
      Hub Bearing Inspection...10091
      Hub Bearing Lubrication...10092
  Final Drive...10093
    Exploded View ...10094
    Specifications ...10096
    Special Tools...10097
    Drive Chain...10098
      Drive Chain Slack Inspection...10098
      Drive Chain Slack Adjustment...10098
      Wheel Alignment Inspection/Adjustment...10098
      Drive Chain Wear Inspection...10098
      Drive Chain Lubrication...10098
      Drive Chain Removal...10098
      Drive Chain Installation...10098
    Sprocket, Coupling...10099
      Engine Sprocket Removal...10099
      Engine Sprocket Installation...10099
      Rear Sprocket Removal...10100
      Rear Sprocket Installation...10100
      Coupling Installation...10100
      Coupling Bearing Removal...10101
      Coupling Bearing Installation...10101
      Coupling Bearing Inspection...10102
      Coupling Bearing Lubrication...10102
      Coupling Damper Inspection...10102
      Sprocket Wear Inspection...10102
      Rear Sprocket Warp Inspection...10102
  Brakes...10103
    Exploded View ...10106
    Specifications ...10114
    Special Tools...10115
    Brake Lever, Brake Pedal...10116
      Brake Lever Position Adjustment...10116
      Brake Pedal Position Inspection ...10116
      Brake Pedal Position Adjustment ...10116
      Brake Pedal Removal...10116
      Brake Pedal Installation...10117
    Calipers...10118
      Front Caliper Removal...10118
      Rear Caliper Removal...10118
      Caliper Installation...10119
      Front Caliper Disassembly...10119
      Front Caliper Assembly...10119
      Rear Caliper Disassembly...10119
      Rear Caliper Assembly...10119
      Caliper Fluid Seal Damage Inspection...10120
      Caliper Dust Seal Damage Inspection...10120
      Caliper Piston and Cylinder Damage Inspection...10121
    Brake Pads...10122
      Front Brake Pad Removal...10122
      Front Brake Pad Installation...10122
      Rear Brake Pad Removal ...10123
      Rear Brake Pad Installation...10123
      Brake Pad Wear Inspection...10123
    Master Cylinder...10124
      Front Master Cylinder Removal...10124
      Front Master Cylinder Installation...10124
      Rear Master Cylinder Removal...10124
      Rear Master Cylinder Installation...10125
      Front Master Cylinder Disassembly...10125
      Rear Master Cylinder Disassembly...10125
      Master Cylinder Assembly...10125
      Master Cylinder Inspection (Visual Inspection)...10125
    Brake Disc...10126
      Brake Disc Removal...10126
      Brake Disc Installation...10126
      Brake Disc Wear Inspection...10126
      Brake Disc Warp Inspection...10126
    Brake Fluid...10127
      Brake Fluid Level Inspection...10127
      Brake Fluid Change...10127
      Brake Line Bleeding...10127
    Brake Hose...10131
      Brake Hose and Pipe Removal/Installation...10131
      Brake Hose and Pipe Inspection...10131
    Anti-Lock Brake System (Equipped Models)...10132
      ABS Servicing Precautions...10136
      ABS Troubleshooting Outline...10138
      Inquiries to Rider...10141
      Self-diagnosis Outline...10143
      Self-diagnosis Procedures...10143
      Service Code Clearing Procedures...10144
      How to Read Service Codes...10147
      How to Erase Service Codes...10147
      ABS Indicator Light (LED) Inspection...10149
      ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)...10149
      ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code)...10150
      Solenoid Valve Inspection (Service Code 13,14,17,18)...10150
      ABS Solenoid Valve Relay Inspection (Service Code 19)...10150
      Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)...10152
      ABS Pump Motor Relay Inspection (Service Code 35)...10152
      Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)...10154
      Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)...10154
         Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)...10155
      Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)...10156
      Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)...10157
      Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)...10158
      ECU Inspection (Service Code 55)...10159
      ABS Hydraulic Unit Removal...10159
      ABS Hydraulic Unit Installation...10160
      ABS Hydraulic Unit Inspection...10161
      Front Wheel Rotation Sensor Removal...10161
      Front Wheel Rotation Sensor Installation...10162
      Rear Wheel Rotation Sensor Removal...10162
      Rear Wheel Rotation Sensor Installation...10163
      Wheel Rotation Sensor Inspection...10163
      Wheel Rotation Sensor Air Gap Inspection...10164
      Wheel Rotation Sensor Rotor Inspection...10164
      ABS Solenoid Valve Relay Fuse (20 A) Removal...10165
      ABS Motor Relay Fuse (30 A) Removal...10165
      ABS ECU Fuse (10 A) Removal...10165
      Fuse Installation...10165
      Fuse Inspection...10165
  Suspension...10167
    Exploded View...10168
    Specifications...10172
    Special Tools...10173
    Front Fork...10175
      Rebound Damping Force Adjustment...10175
      Compression Damping Force Adjustment...10175
      Spring Preload Adjustment...10176
      Front Fork Removal (Each Fork Leg)...10176
      Front Fork Installation...10177
      Front Fork Oil Change...10177
      Front Fork Disassembly...10182
      Front Fork Assembly...10183
      Inner Tube, Outer Tube Inspection...10184
      Dust Seal Inspection...10184
      Spring Tension Inspection...10184
    Rear Shock Absorber...10185
      Rebound Damping Force Adjustment...10185
      Compression Damping Force Adjustment...10185
      Spring Preload Adjustment...10185
      Rear Shock Absorber Removal...10186
      Rear Shock Absorber Installation...10187
      Rear Shock Absorber Inspection...10187
      Rear Shock Absorber Scrapping...10188
    Swingarm...10189
      Swingarm Removal...10189
      Swingarm Installation...10190
      Swingarm Bearing Removal...10191
      Swingarm Bearing Installation...10191
      Swingarm Bearing, Sleeve Inspection...10192
      Swingarm Bearing Lubrication...10193
      Chain Guide Inspection...10193
    Tie-Rod, Rocker Arm...10194
      Tie-Rod Removal...10194
      Tie-Rod Installation...10194
      Rocker Arm Removal...10194
      Rocker Arm Installation...10195
      Tie-Rod and Rocker Arm Bearing Removal...10195
      Tie-Rod and Rocker Arm Bearing Installation...10195
      Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...10197
      Rocker Arm/Tie-Rod Bearing Lubrication...10197
  Steering...10199
    Exploded View...10200
    Special Tools...10202
    Steering...10203
      Steering Inspection...10203
      Steering Adjustment...10203
    Steering Stem...10204
      Stem, Stem Bearing Removal...10204
      Stem, Stem Bearing Installation...10205
      Steering Stem Bearing Lubrication...10207
      Steering Stem Warp Inspection...10207
      Stem Cap Deterioration, Damage Inspection...10207
    Handlebar...10208
      Handlebar Removal...10208
      Handlebar Installation...10208
  Frame...10211
    Exploded View...10212
    Seat...10220
      Seat Removal...10220
      Seat Installation...10220
    Fairings...10221
      Lower Fairing Removal...10221
      Lower Fairing Installation...10221
      Fairing Cover Removal...10221
      Fairing Cover Installation...10221
      Middle Fairing Removal...10221
      Middle Fairing Installation...10222
      Windshield Removal...10222
      Windshield Installation...10223
      Upper Fairing Removal...10223
      Upper Fairing Disassembly...10223
      Upper Fairing Assembly...10223
      Upper Fairing Installation...10224
      Inner Cover Removal...10224
      Inner Cover Installation...10224
      Upper Inner Fairing Removal...10224
      Upper Inner Fairing Installation...10225
      Upper Fairing Bracket Removal...10225
      Upper Fairing Bracket Installation...10225
      Inner Fairing Removal...10225
      Inner Fairing Installation...10225
      Rear Fairing Removal...10225
      Rear Fairing Installation...10225
    Seat Cover...10226
      Seat Cover Removal...10226
      Seat Cover Installation...10226
    Fenders...10228
      Front Fender Removal...10228
      Front Fender Installation...10228
      Flap and Rear Fender Removal...10228
      Flap and Rear Fender Installation...10229
    Frame...10230
      Rear Frame Removal...10230
      Rear Frame Installation...10230
      Frame Inspection...10230
    Center Stand, Sidestand...10231
      Center Stand Removal (Equipped Models)...10231
      Center Stand Installation (Equipped Models)...10231
      Sidestand Removal...10231
      Sidestand Installation...10231
  Electrical System...10233
    Exploded View...10236
    Specifications...10242
    Special Tools and Sealant...10243
    Parts Location...10245
    Wiring Diagram (ZX1400C8F ∼ C9F CA, CAL and US Models)...10248
    Wiring Diagram (ZX1400C8F ∼ C9F AU and MY Models)...10250
    Wiring Diagram (ZX1400C8F ∼ C9F Other than CA, CAL, US, AU and MY Models)...10252
    Wiring Diagram (ZX1400D8F ∼ D9F ABS Equipped Models: MY Model)...10254
    Wiring Diagram (ZX1400D8F ∼ D9F ABS Equipped Models: Other than MY Model)...10256
    Wiring Diagram (ZX1400CAF ∼ CBF CA, CAL and US Models)...10258
    Wiring Diagram (ZX1400CAF ∼ CBF AU and MY Models)...10260
    Wiring Diagram (ZX1400CAF ∼ CBF Other than CA, CAL, US, AU and MY Models)...10262
    Wiring Diagram (ZX1400DAF ∼ DBF ABS Equipped Models: MY Model)...10264
    Wiring Diagram (ZX1400DAF ∼ DBF ABS Equipped Models: Other than MY Model)...10266
    Precautions...10268
    Electrical Wiring...10269
      Wiring Inspection...10269
    Battery...10270
      Battery Removal...10270
      Battery Installation...10271
      Battery Activation...10271
      Precautions...10274
      Interchange...10274
      Charging Condition Inspection...10274
      Refreshing Charge...10275
    Charging System...10276
      Alternator Cover Removal...10276
      Alternator Cover Installation...10276
      Stator Coil Removal...10276
      Stator Coil Installation...10277
      Alternator Rotor Removal...10277
      Alternator Rotor Installation...10277
      Alternator Inspection...10278
      Regulator/Rectifier Inspection...10280
      Charging Voltage Inspection...10281
    Ignition System...10283
      Crankshaft Sensor Removal...10283
      Crankshaft Sensor Installation...10284
      Crankshaft Sensor Inspection...10284
      Crankshaft Sensor Peak Voltage Inspection...10284
      Timing Rotor Removal...10285
      Timing Rotor Installation...10285
      Camshaft Position Sensor Removal...10285
      Camshaft Position Sensor Installation...10286
      Camshaft Position Sensor Inspection...10286
      Camshaft Position Sensor Peak Voltage Inspection...10287
      Stick Coil Removal...10287
      Stick Coil Installation...10288
      Stick Coil Inspection...10288
      Stick Coil Primary Peak Voltage...10289
      Spark Plug Removal...10289
      Spark Plug Installation...10289
      Spark Plug Condition Inspection...10290
      Interlock Operation Inspection...10290
      IC Igniter Inspection...10291
    Electric Starter System...10294
      Starter Motor Removal...10294
      Starter Motor Installation...10294
      Starter Motor Disassembly...10295
      Starter Motor Assembly...10295
      Brush Inspection...10297
      Commutator Cleaning and Inspection...10297
      Armature Inspection...10297
      Brush Lead Inspection...10298
      Right-hand End Cover Assembly Inspection...10298
      Starter Relay Inspection...10298
    Lighting System...10300
      Headlight Beam Horizontal Adjustment...10300
      Headlight Beam Vertical Adjustment...10300
      Headlight Bulb Replacement...10300
      City Light Bulb Replacement...10301
      Headlight Removal/Installation...10301
      Headlight Relay Inspection...10302
      Tail/Brake Light (LED) Removal...10302
      Tail/Brake Light (LED) Installation...10303
      License Plate Light Bulb Replacement...10303
      Turn Signal Light Bulb Replacement...10304
      Turn Signal Relay Inspection...10306
    Air Switching Valve...10308
      Air Switching Valve Operation Test...10308
      Air Switching Valve Unit Test...10308
    Radiator Fan System...10310
      Fan Motor Inspection...10310
    Meter, Gauge, Indicator Unit...10311
      Meter Unit Removal...10311
      Meter Unit Installation...10311
      Meter Unit Disassembly...10312
      Meter Unit Inspection...10312
    Immobilizer System (Equipped Models), ZX1400C8F ∼ CAF/D8F ∼ DAF Models...10329
      Operational Cautions...10329
      Key Registration...10329
      Immobilizer System Parts Replacement...10345
      ECU Replacement...10345
    Immobilizer System (Equipped Models), ZX1400CBF/DBF Models...10347
      Operational Cautions...10347
      Key Registration...10347
      Immobilizer System Parts Replacement...10365
      ECU Replacement...10365
    Immobilizer System (Equipped Models)...10367
      Immobilizer System Inspection...10367
    Switches and Sensors...10368
      Brake Light Timing Inspection...10368
      Brake Light Timing Adjustment...10368
      Switch Inspection...10368
      Water Temperature Sensor Inspection...10369
      Speed Sensor Removal...10369
      Speed Sensor Installation...10369
      Speed Sensor Inspection...10370
      Oxygen Sensor Removal (Equipped Models)...10370
      Oxygen Sensor Installation (Equipped Models)...10370
      Oxygen Sensor Inspection (Equipped Models)...10370
      Fuel Level Sensor Inspection...10371
      Fuel Reserve Switch Inspection...10372
      Gear Position Switch Removal...10373
      Gear Position Switch Installation...10374
      Gear Position Switch Inspection...10374
    Relay Box...10375
      Relay Box Removal...10375
      Relay Circuit Inspection...10375
      Diode Circuit Inspection...10376
    Fuse...10378
      30 A Main Fuse Removal...10378
      Fuse Box Fuse Removal...10378
      15 A ECU Fuse Removal...10379
      Fuse Installation...10379
      Fuse Inspection...10380
  Appendix...10381
    Cable, Wire, and Hose Routing...10382
    Troubleshooting Guide...10440
Kawasaki Motorcycle Service Repair Manual '09 ZX-6R (EN)...10446
  General Information...10456
    Before Servicing...10457
    Model Identification...10462
    General Specifications...10464
    Unit Conversion Table...10467
  Periodic Maintenance...10468
    Periodic Maintenance Chart...10470
    Torque and Locking Agent...10473
    Specifications...10480
    Special Tools...10482
    Periodic Maintenance Procedures...10483
      Fuel System (DFI)...10483
        Throttle Control System Inspection...10483
        Engine Vacuum Synchronization Inspection...10483
        Idle Speed Inspection...10487
        Idle Speed Adjustment...10487
        Fuel Hose Inspection (fuel leak, damage, installation condition)...10487
      Evaporative Emission Control System Inspection (CAL, SEA and TH Models)...10488
      Cooling System...10489
        Coolant Level Inspection...10489
        Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)...10490
      Engine Top End...10490
        Valve Clearance Inspection...10490
        Valve Clearance Adjustment...10491
      Air Suction System Damage Inspection...10494
      Clutch...10495
        Clutch Operation Inspection ...10495
      Wheels/Tires...10496
        Air Pressure Inspection...10496
        Wheel/Tire Damage Inspection...10496
        Tire Tread Wear Inspection ...10496
        Wheel Bearing Damage Inspection...10497
      Final Drive...10498
        Drive Chain Lubrication Condition Inspection...10498
        Drive Chain Slack Inspection...10498
        Drive Chain Slack Adjustment...10499
        Wheel Alignment Inspection...10500
        Drive Chain Wear Inspection...10500
        Chain Guide Wear Inspection...10501
      Brakes...10501
        Brake Fluid Leak (Brake Hose and Pipe) Inspection...10501
        Brake Hose and Pipe Damage and Installation Condition Inspection...10501
        Brake Fluid Level Inspection...10502
        Brake Pad Wear Inspection...10503
        Brake Operation Inspection...10503
        Brake Light Switch Operation Inspection...10503
      Suspension...10504
        Front Forks/Rear Shock Absorber Operation Inspection...10504
        Front Fork Oil Leak Inspection...10504
        Rear Shock Absorber Oil Leak Inspection...10505
        Rocker Arm Operation Inspection...10505
        Tie-Rod Operation Inspection...10505
      Steering...10505
        Steering Play Inspection...10505
        Steering Play Adjustment...10506
        Steering Stem Bearing Lubrication...10507
        Steering Damper Oil Leak Inspection...10507
      Electrical System...10508
        Lights and Switches Operation Inspection...10508
        Headlight Aiming Inspection...10510
        Sidestand Switch Operation Inspection...10511
        Engine Stop Switch Operation Inspection...10512
      Others...10513
        Chassis Parts Lubrication ...10513
        Bolts, Nuts and Fasteners Tightness Inspection...10514
      Replacement Parts...10515
        Air Cleaner Element Replacement...10515
        Fuel Hose Replacement...10515
        Coolant Change...10518
        Radiator Hose and O-ring Replacement...10521
        Engine Oil Change...10522
        Oil Filter Replacement...10523
        Brake Hose and Pipe Replacement...10524
        Brake Fluid Change...10524
        Master Cylinder Rubber Parts Replacement...10526
        Caliper Rubber Parts Replacement...10527
        Spark Plug Replacement...10530
  Fuel System (DFI)...10532
    Exploded View...10535
    DFI System...10541
    DFI Parts Location...10547
    Specifications...10550
    Special Tools and Sealant...10552
    DFI Servicing Precautions...10554
      DFI Servicing Precautions...10554
    Troubleshooting the DFI System...10556
      Outline...10556
      Inquiries to Rider...10560
    DFI System Troubleshooting Guide...10563
    Self-Diagnosis...10568
      Self-diagnosis Outline...10568
      Self-diagnosis Procedures...10569
        Service Code Reading...10572
        Service Code Erasing...10572
      Backups...10574
    Main Throttle Sensor (Service Code 11)...10577
      Main Throttle Sensor Removal/Adjustment...10577
      Main Throttle Sensor Input Voltage Inspection...10577
      Main Throttle Sensor Output Voltage Inspection...10578
      Main Throttle Sensor Resistance Inspection...10579
    Inlet Air Pressure Sensor #1 (Service Code 12)...10580
      Inlet Air Pressure Sensor #1 Removal...10580
      Inlet Air Pressure Sensor #1 Installation...10580
      Inlet Air Pressure Sensor #1 Input Voltage Inspection...10580
      Inlet Air Pressure Sensor #1 Output Voltage Inspection...10581
    Inlet Air Temperature Sensor (Service Code 13)...10586
      Inlet Air Temperature Sensor Removal/Installation...10586
      Inlet Air Temperature Sensor Output Voltage Inspection...10586
      Inlet Air Temperature Sensor Resistance Inspection...10587
    Water Temperature Sensor (Service Code 14)...10589
      Water Temperature Sensor Removal/Installation...10589
      Water Temperature Sensor Output Voltage Inspection...10589
      Water Temperature Sensor Resistance Inspection...10590
    Inlet Air Pressure Sensor #2 (Service Code 16)...10591
      Inlet Air Pressure Sensor #2 Removal...10591
      Inlet Air Pressure Sensor #2 Installation...10591
      Inlet Air Pressure Sensor #2 Input Voltage Inspection...10591
      Inlet Air Pressure Sensor #2 Output Voltage Inspection...10592
    Crankshaft Sensor (Service Code 21)...10596
      Crankshaft Sensor Removal/Installation...10596
      Crankshaft Sensor Resistance Inspection...10596
      Crankshaft Sensor Peak Voltage Inspection...10596
    Speed Sensor (Service Code 24)...10598
      Speed Sensor Removal/Installation...10598
      Speed Sensor Inspection...10598
      Speed Sensor Input Voltage Inspection...10598
      Speed Sensor Output Voltage Inspection...10599
    Gear Position Switch (Service Code 25)...10601
      Gear Position Switch Removal/Installation...10601
      Gear Position Switch Resistance Inspection...10601
      Gear Position Switch Output Voltage Inspection...10601
    Vehicle-down Sensor (Service Code 31)...10603
      Vehicle-down Sensor Removal...10603
      Vehicle-down Sensor Installation...10603
      Vehicle-down Sensor Input Voltage Inspection...10604
      Vehicle-down Sensor Output Voltage Inspection...10605
    Subthrottle Sensor (Service Code 32)...10607
      Subthrottle Sensor Removal/Adjustment...10607
      Subthrottle Sensor Input Voltage Inspection...10607
      Subthrottle Sensor Output Voltage Inspection...10608
      Subthrottle Sensor Resistance Inspection...10609
    Oxygen Sensor - not activated (Service Code 33 (Equipped Models))...10610
      Oxygen Sensor Removal/Installation...10610
      Oxygen Sensor Inspection...10610
    Exhaust Butterfly Valve Actuator Sensor (Service Code 34)...10613
      Exhaust Butterfly Valve Actuator Sensor Removal/Installation...10613
      Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...10613
      Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection...10614
      Exhaust Butterfly Valve Actuator Sensor Resistance Inspection...10615
    Immobilizer Amplifier (Service Code 35 (Equipped Models))...10616
      Antenna Resistance Inspection...10616
      Amplifier Input Voltage Inspection...10616
    Blank Key Detection (Service Code 36 (Equipped Models))...10617
      User Key Inspection...10617
    ECU Communication Error (Service Code 39)...10619
      ECU Communication Line Inspection...10619
    Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)...10620
      Stick Coil Removal/Installation...10620
      Stick Coil Primary Winding Resistance Inspection...10620
      Stick Coil Input Voltage Inspection...10620
    Radiator Fan Relay (Service Code 56)...10622
      Radiator Fan Relay Removal/Installation...10622
      Radiator Fan Relay Inspection...10622
    Subthrottle Valve Actuator (Service Code 62)...10624
      Subthrottle Valve Actuator Removal...10624
      Subthrottle Valve Actuator Inspection...10624
      Subthrottle Valve Actuator Resistance Inspection...10624
      Subthrottle Valve Actuator Input Voltage Inspection...10625
    Exhaust Butterfly Valve Actuator (Service Code 63)...10627
      Exhaust Butterfly Valve Actuator Removal...10627
      Exhaust Butterfly Valve Actuator Installation...10627
      Exhaust Butterfly Valve Actuator Inspection...10629
      Exhaust Butterfly Valve Actuator Resistance Inspection...10629
    Air Switching Valve (Service Code 64)...10631
      Air Switching Valve Removal/Installation...10631
      Air Switching Valve Inspection...10631
    Oxygen Sensor Heater (Service Code 67 (Equipped Models))...10632
      Oxygen Sensor Heater Removal/Installation...10632
      Oxygen Sensor Heater Resistance Inspection...10632
      Oxygen Sensor Heater Power Source Voltage Inspection...10633
    Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models))...10635
      Oxygen Sensor Removal/Installation...10635
      Oxygen Sensor Inspection...10635
    Warning Indicator Light (LED)...10638
      Light (LED) Inspection...10638
    ECU...10639
      ECU Identification...10639
      ECU Removal...10639
      ECU Installation...10640
      ECU Power Supply Inspection...10640
    DFI Power Source...10643
      ECU Fuse Removal...10643
      ECU Fuse Installation...10643
      ECU Fuse Inspection...10643
      ECU Main Relay Removal/Installation...10643
      ECU Main Relay Inspection...10643
    Fuel Line...10644
      Fuel Pressure Inspection...10644
      Fuel Flow Rate Inspection...10645
    Fuel Pump...10647
      Fuel Pump Removal...10647
      Fuel Pump Installation...10648
      Fuel Pump Operation Inspection...10648
      Fuel Pump Operating Voltage Inspection...10649
      Pressure Regulator Removal...10650
      Fuel Filter Cleaning...10650
    Fuel Injectors...10651
      Primary Fuel Injector Removal/Installation...10651
      Secondary Fuel Injector Removal/Installation...10651
      Fuel Injector Audible Inspection...10651
      Fuel Injector Resistance Inspection...10652
      Fuel Injector Power Source Voltage Inspection...10653
      Fuel Injector Output Voltage Inspection...10655
      Fuel Injector Fuel Line Inspection...10657
    Throttle Grip and Cables...10659
      Free Play Inspection...10659
      Free Play Adjustment...10659
      Cable Installation...10659
      Cable Lubrication...10659
    Throttle Body Assy...10660
      Idle Speed Inspection/Adjustment...10660
      Synchronization Inspection/Adjustment...10660
      Throttle Body Assy Removal...10660
      Throttle Body Assy Installation...10661
      Throttle Body Assy Disassembly...10662
      Throttle Body Assy Assembly...10663
    Nozzle Assy...10664
      Nozzle Assy Removal...10664
      Nozzle Assy Installation...10664
      Nozzle Assy Disassembly...10665
      Nozzle Assy Assembly...10665
    Air Cleaner...10667
      Air Cleaner Element Removal/Installation...10667
      Air Cleaner Element Inspection...10667
      Air Cleaner Oil Draining...10667
      Air Cleaner Housing Removal...10667
      Air Cleaner Housing Installation...10669
      Air Cleaner Housing Disassembly...10669
      Air Cleaner Housing Assembly...10670
    Air Line...10671
      Air Inlet Duct Removal...10671
      Air Inlet Duct Installation...10671
    Fuel Tank...10672
      Fuel Tank Removal...10672
      Fuel Tank Installation...10674
      Fuel Tank Inspection...10676
      Fuel Tank Cleaning...10676
    Evaporative Emission Control System (CAL, SEA and TH Models)...10677
      Parts Removal/Installation...10677
      Hose Inspection...10677
      Separator Inspection...10677
      Separator Operation Test...10678
      Canister Inspection ...10678
  Cooling System...10680
    Exploded View...10681
    Coolant Flow Chart...10683
    Specifications...10685
    Special Tools...10686
    Coolant...10687
      Coolant Deterioration Inspection...10687
      Coolant Level Inspection...10687
      Coolant Draining...10687
      Coolant Filling...10687
      Pressure Testing...10687
      Cooling System Flushing...10688
      Coolant Reserve Tank Removal...10688
      Coolant Reserve Tank Installation...10688
    Water Pump...10689
      Water Pump Removal...10689
      Water Pump Installation...10689
      Water Pump Inspection...10689
      Water Pump Impeller Disassembly/Assembly...10689
      Water Pump Impeller Inspection...10689
      Water Pump Housing Disassembly...10689
      Water Pump Housing Assembly...10690
      Mechanical Seal Inspection...10690
    Radiator...10691
      Radiator and Radiator Fan Removal...10691
      Radiator and Radiator Fan Installation...10692
      Radiator Inspection...10692
      Radiator Cap Inspection...10693
      Radiator Filler Neck Inspection...10693
    Thermostat...10694
      Thermostat Removal...10694
      Thermostat Installation...10694
      Thermostat Inspection...10694
    Hoses and Pipes...10696
      Hose Installation...10696
      Hose Inspection...10696
    Water Temperature Sensor...10697
      Water Temperature Sensor Removal/Installation...10697
      Water Temperature Sensor Inspection...10697
  Engine Top End...10698
    Exploded View...10699
    Exhaust System Identification...10703
    Specifications...10705
    Special Tools and Sealant...10706
    Clean Air System...10708
      Air Suction Valve Removal...10708
      Air Suction Valve Installation...10708
      Air Suction Valve Inspection...10709
      Air Switching Valve Removal...10709
      Air Switching Valve Installation...10709
      Air Switching Valve Operation Test...10710
      Air Switching Valve Unit Test...10710
      Clean Air System Hose Inspection...10710
    Cylinder Head Cover...10711
      Cylinder Head Cover Removal...10711
      Cylinder Head Cover Installation...10711
    Camshaft Chain Tensioner...10713
      Camshaft Chain Tensioner Removal...10713
      Camshaft Chain Tensioner Installation...10714
    Camshaft, Camshaft Chain...10715
      Camshaft Removal...10715
      Camshaft Installation...10716
      Camshaft, Camshaft Cap Wear Inspection...10720
      Camshaft Runout Inspection...10721
      Cam Wear Inspection...10721
      Camshaft Chain Removal...10721
    Cylinder Head...10722
      Cylinder Compression Measurement...10722
      Cylinder Head Removal...10723
      Cylinder Head Installation...10724
      Cylinder Head Warp Inspection...10725
    Valves...10726
      Valve Clearance Inspection...10726
      Valve Removal...10726
      Valve Installation...10726
      Valve Guide Removal...10726
      Valve Guide Installation...10726
      Valve-to-Guide Clearance Measurement (Wobble Method)...10727
      Valve Seat Inspection...10728
      Valve Seat Repair...10728
    Throttle Body Assy Holder...10733
      Throttle Body Assy Holder Removal...10733
      Throttle Body Assy Holder Installation...10733
    Muffler...10734
      Muffler Body Removal...10734
      Muffler Body Installation...10735
      Premuffler Chamber Removal...10736
      Premuffler Chamber Installation...10737
      Exhaust Pipe Removal...10738
      Exhaust Pipe Installation...10739
      Exhaust Butterfly Valve Cable Removal...10740
      Exhaust Butterfly Valve Cable Installation...10741
  Clutch...10744
    Exploded View...10745
    Specifications...10747
    Special Tool and Sealant...10748
    Clutch Lever and Cable...10749
      Clutch Lever Free Play Inspection...10749
      Clutch Lever Free Play Adjustment...10749
      Cable Removal...10749
      Cable Installation...10749
      Cable Lubrication...10749
      Clutch Lever Installation...10749
    Clutch Cover...10750
      Clutch Cover Removal...10750
      Clutch Cover Installation...10750
      Release Shaft Removal...10751
      Release Shaft Installation...10751
      Clutch Cover Disassembly...10751
      Clutch Cover Assembly...10752
    Clutch...10754
      Clutch Removal...10754
      Clutch Installation...10755
      Spring Plate Free Play Measurement...10758
      Spring Plate Free Play Adjustment...10759
      Clutch Plate, Wear, Damage Inspection...10760
      Clutch Plate Warp Inspection...10760
      Clutch Spring Free Length Measurement...10761
      Clutch Housing Finger Inspection...10761
      Clutch Housing Spline Inspection...10761
      Damper Cam Inspection...10761
  Engine Lubrication System...10762
    Exploded View...10763
    Engine Oil Flow Chart...10765
    Specifications...10767
    Special Tools and Sealant...10768
    Engine Oil and Oil Filter...10769
      Oil Level Inspection...10769
      Engine Oil Change...10769
      Oil Filter Replacement...10769
    Oil Pan...10770
      Oil Pan Removal...10770
      Oil Pan Installation...10770
    Oil Pressure Relief Valve...10771
      Oil Pressure Relief Valve Removal...10771
      Oil Pressure Relief Valve Installation...10771
      Oil Pressure Relief Valve Inspection...10772
    Oil Pump...10773
      Oil Pump Removal...10773
      Oil Pump Installation...10774
      Oil Pump Drive Gear Removal...10775
      Oil Pump Drive Gear Installation...10775
      Oil Pump Drive Gear Shaft Removal...10775
      Oil Pump Drive Gear Shaft Installation...10776
    Oil Cooler...10777
      Oil Cooler Removal...10777
      Oil Cooler Installation...10777
      Oil Cooler/Oil Filter Case Removal...10777
      Oil Cooler/Oil Filter Case Installation...10778
    Oil Pressure Measurement...10780
      Oil Pressure Measurement...10780
    Oil Pressure Switch...10781
      Oil Pressure Switch Removal...10781
      Oil Pressure Switch Installation...10781
  Engine Removal/Installation...10782
    Exploded View...10783
    Special Tool...10785
    Engine Removal/Installation...10786
      Engine Removal...10786
      Engine Installation...10789
  Crankshaft/Transmission...10792
    Exploded View...10793
    Specifications...10797
    Special Tools and Sealants...10800
    Crankcase...10802
      Crankcase Splitting...10802
      Crankcase Assembly...10803
    Crankshaft and Connecting Rods...10808
      Crankshaft Removal...10808
      Crankshaft Installation...10808
      Connecting Rod Removal...10809
      Connecting Rod Installation...10810
      Crankshaft/Connecting Rod Cleaning...10813
      Connecting Rod Bend Inspection...10813
      Connecting Rod Twist Inspection...10814
      Connecting Rod Big End Side Clearance Inspection...10814
      Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection...10814
      Crankshaft Side Clearance Inspection...10816
      Crankshaft Runout Inspection...10816
      Crankshaft Main Bearing Insert/Journal Wear Inspection...10817
    Pistons...10819
      Piston Removal...10819
      Piston Installation...10820
      Cylinder (Upper Crankcase) Wear Inspection...10821
      Piston Wear Inspection...10821
      Piston Ring, Piston Ring Groove Wear Inspection...10821
      Piston Ring Groove Width Inspection...10822
      Piston Ring Thickness Inspection...10822
      Piston Ring End Gap Inspection...10822
    Starter Idle Gear and Starter Clutch...10823
      Starter Idle Gear Removal...10823
      Starter Idle Gear Installation...10823
      Starter Clutch Removal...10825
      Starter Clutch Installation ...10825
      Starter Clutch Disassembly...10825
      Starter Clutch Assembly...10826
      Starter Clutch Inspection...10826
    Transmission...10828
      Transmission Assy Removal...10828
      Transmission Assy Disassembly...10828
      Transmission Assy Assembly...10828
      Transmission Assy Installation...10830
      Transmission Shaft Removal...10831
      Transmission Shaft Installation...10831
      Transmission Shaft Disassembly...10831
      Transmission Shaft Assembly...10831
      Shift Drum and Fork Removal...10835
      Shift Drum and Fork Installation...10835
      Shift Drum Disassembly...10835
      Shift Drum Assembly...10835
      Shift Fork Bending Inspection...10835
      Shift Fork/Gear Groove Wear Inspection...10835
      Shift Fork Guide Pin/Drum Groove Wear Inspection...10836
      Gear Dog and Gear Dog Hole Damage Inspection...10836
    External Shift Mechanism...10837
      Shift Pedal Removal...10837
      Shift Pedal Installation...10837
      External Shift Mechanism Removal...10838
      External Shift Mechanism Installation...10838
      External Shift Mechanism Inspection...10839
  Wheels/Tires...10840
    Exploded View...10841
    Specifications...10843
    Special Tools...10844
    Wheels (Rims)...10845
      Front Wheel Removal...10845
      Front Wheel Installation...10846
      Rear Wheel Removal...10847
      Rear Wheel Installation...10847
      Wheel Inspection...10849
      Axle Inspection...10849
      Balance Inspection...10850
      Balance Adjustment...10850
      Balance Weight Removal...10850
      Balance Weight Installation...10850
    Tires...10852
      Air Pressure Inspection/Adjustment...10852
      Tire Inspection...10852
      Tire Removal...10852
      Tire Installation...10852
      Tire Repair...10854
    Hub Bearing...10855
      Hub Bearing Removal...10855
      Hub Bearing Installation...10855
      Hub Bearing Inspection...10855
      Hub Bearing Lubrication...10856
  Final Drive...10858
    Exploded View ...10859
    Specifications ...10861
    Special Tools...10862
    Drive Chain...10863
      Drive Chain Slack Inspection...10863
      Drive Chain Slack Adjustment...10863
      Wheel Alignment Inspection/Adjustment...10863
      Drive Chain Wear Inspection...10863
      Drive Chain Lubrication...10863
      Drive Chain Guide Wear Inspection...10863
      Drive Chain Removal...10863
    Sprocket, Coupling...10867
      Engine Sprocket Removal...10867
      Engine Sprocket Installation...10867
      Rear Sprocket Removal...10868
      Rear Sprocket Installation...10869
      Coupling Installation...10869
      Coupling Bearing Removal...10869
      Coupling Bearing Installation...10870
      Coupling Bearing Inspection...10870
      Coupling Bearing Lubrication...10870
      Coupling Damper Inspection...10870
      Sprocket Wear Inspection...10871
      Rear Sprocket Warp Inspection...10871
  Brakes...10872
    Exploded View ...10873
    Specifications ...10877
    Special Tools...10878
    Brake Lever, Brake Pedal...10879
      Brake Lever Position Adjustment...10879
      Brake Pedal Position Inspection ...10879
      Brake Pedal Position Adjustment ...10879
      Brake Pedal Removal...10879
      Brake Pedal Installation...10880
    Calipers...10882
      Front Caliper Removal...10882
      Rear Caliper Removal...10882
      Caliper Installation...10883
      Front Caliper Disassembly...10883
      Front Caliper Assembly...10883
      Rear Caliper Disassembly...10883
      Rear Caliper Assembly...10883
      Caliper Fluid Seal Damage Inspection...10884
      Caliper Dust Seal Damage Inspection...10884
      Rear Caliper Dust Boot and Friction Boot Damage Inspection...10884
      Caliper Piston and Cylinder Damage Inspection...10885
      Rear Caliper Holder Shaft Wear Inspection...10885
    Brake Pads...10886
      Front Brake Pad Removal...10886
      Front Brake Pad Installation...10886
      Rear Brake Pad Removal ...10887
      Rear Brake Pad Installation...10887
      Brake Pad Wear Inspection...10887
    Master Cylinder...10888
      Front Master Cylinder Removal...10888
      Front Master Cylinder Installation...10888
      Rear Master Cylinder Removal...10889
      Rear Master Cylinder Installation...10890
      Front Master Cylinder Disassembly...10890
      Rear Master Cylinder Disassembly...10891
      Master Cylinder Assembly...10891
      Master Cylinder Inspection (Visual Inspection)...10891
    Brake Disc...10892
      Brake Disc Removal...10892
      Brake Disc Installation...10892
      Brake Disc Wear Inspection...10892
      Brake Disc Warp Inspection...10893
    Brake Fluid...10894
      Brake Fluid Level Inspection...10894
      Brake Fluid Change...10894
      Brake Line Bleeding...10894
    Brake Hose...10899
      Brake Hose Removal/Installation...10899
      Brake Hose Inspection...10899
  Suspension...10900
    Exploded View...10901
    Specifications...10905
    Special Tools...10906
    Front Fork...10908
      Rebound Damping Force Adjustment...10908
      Compression Damping Force Adjustment...10908
      Spring Preload Adjustment...10909
      Front Fork Removal (Each Fork Leg)...10909
      Front Fork Installation (Each Fork Leg)...10910
      Front Fork Oil Change...10910
      Front Fork Disassembly...10913
      Front Fork Assembly...10914
      Inner Tube Inspection...10915
      Dust Seal Inspection...10915
      Spring Tension Inspection...10915
    Rear Shock Absorber...10916
      Rebound Damping Force Adjustment...10916
      Compression Damping Force Adjustment...10916
      Spring Preload Adjustment...10917
      Rear Shock Absorber Removal...10918
      Rear Shock Absorber Installation...10919
      Rear Shock Absorber Inspection...10919
      Rear Shock Absorber Scrapping...10919
    Swingarm...10920
      Swingarm Removal...10920
      Swingarm Installation...10920
      Swingarm Bearing Removal...10921
      Swingarm Bearing Installation...10922
      Swingarm Bearing, Sleeve Inspection...10923
      Swingarm Bearing Lubrication...10923
    Tie-Rod, Rocker Arm...10924
      Tie-Rod Removal...10924
      Tie-Rod Installation...10924
      Rocker Arm Removal...10924
      Rocker Arm Installation...10925
      Tie-Rod and Rocker Arm Bearing Removal...10925
      Tie-Rod and Rocker Arm Bearing Installation...10926
      Tie-Rod/Rocker Arm Bearing, Sleeve Inspection...10927
      Tie-Rod/Rocker Arm Bearing Lubrication...10927
  Steering...10928
    Exploded View...10929
    Specifications...10931
    Special Tools...10932
    Steering...10933
      Steering Inspection...10933
      Steering Adjustment...10933
    Steering Damper...10934
      Damping Force Adjustment...10934
      Steering Damper Removal...10934
      Steering Damper Installation...10934
      Steering Damper Oil Leak Inspection...10934
    Steering Stem...10935
      Stem, Stem Bearing Removal...10935
      Stem, Stem Bearing Installation...10936
      Steering Stem Bearing Lubrication...10938
      Steering Stem Warp Inspection...10938
      Stem Cap Deterioration, Damage Inspection...10938
    Handlebar...10939
      Handlebar Removal...10939
      Handlebar Installation...10940
  Frame...10942
    Exploded View...10943
    Seats...10949
      Front Seat Removal...10949
      Front Seat Installation...10949
      Rear Seat Removal...10949
      Rear Seat Installation...10949
    Fairings...10950
      Lower Fairing Removal...10950
      Lower Fairing Installation...10950
      Lower Inner Fairing Removal...10950
      Lower Inner Fairing Installation...10951
      Upper Fairing Assembly Removal...10951
      Upper Fairing Assembly Installation...10952
      Center Fairing Removal...10952
      Center Fairing Installation...10953
      Upper Fairing Removal...10953
      Upper Fairing Installation...10953
      Upper Center Fairing Removal...10953
      Upper Center Fairing Installation...10954
      Upper Inner Fairing Removal...10954
      Upper Inner Fairing Installation...10954
      Center Inner Fairing Removal...10955
      Center Inner Fairing Installation...10955
      Inner Fairing Removal...10955
      Inner Fairing Installation...10955
      Fairing Cover Removal...10956
      Fairing Cover Installation...10956
    Side Covers...10957
      Side Cover Removal...10957
      Side Cover Installation...10957
    Seat Covers...10958
      Seat Cover Removal...10958
      Seat Cover Installation...10959
      Upper Seat Cover Removal (Only on Ninja ZX-6R MONSTER ENERGY® Model)...10960
      Upper Seat Cover Installation (Only on Ninja ZX-6R MONSTER ENERGY® Model)...10960
    Fenders...10961
      Front Fender Removal...10961
      Front Fender Installation...10961
      Flap and Rear Fender Removal...10961
      Flap and Rear Fender Installation...10962
    Frame...10963
      Rear Frame Rear Removal...10963
      Rear Frame Rear Installation...10963
      Rear Frame Front Removal...10963
      Rear Frame Front Installation...10963
      Frame Inspection...10963
    Windshield...10964
      Windshield Removal...10964
      Windshield Installation...10964
    Guard...10965
      Mud Guard Removal...10965
      Mud Guard Installation...10965
    Sidestand...10966
      Sidestand Removal...10966
      Sidestand Installation...10966
  Electrical System...10968
    Exploded View...10971
    Specifications...10977
    Special Tools and Sealant...10978
    Parts Location...10979
    Wiring Diagram (US, CAL and CA Models)...10981
    Wiring Diagram (Other than US, CAL and CA Models)...10983
    Precautions...10985
    Electrical Wiring...10986
      Wiring Inspection...10986
    Battery...10987
      Battery Removal...10987
      Battery Installation...10987
      Battery Activation...10987
      Precautions...10991
      Interchange...10991
      Charging Condition Inspection...10991
      Refreshing Charge...10992
    Charging System...10993
      Alternator Cover Removal...10993
      Alternator Cover Installation...10993
      Stator Coil Removal...10993
      Stator Coil Installation...10994
      Alternator Rotor Removal...10994
      Alternator Rotor Installation...10994
      Charging Voltage Inspection...10996
      Alternator Inspection...10996
      Regulator/Rectifier Inspection...10998
    Ignition System...11000
      Crankshaft Sensor Removal...11000
      Crankshaft Sensor Installation...11000
      Crankshaft Sensor Inspection...11001
      Crankshaft Sensor Peak Voltage Inspection...11001
      Stick Coil Removal...11002
      Stick Coil Installation...11002
      Stick Coil Inspection...11002
      Stick Coil Primary Peak Voltage Inspection...11003
      Spark Plug Removal...11003
      Spark Plug Installation...11003
      Spark Plug Condition Inspection...11004
      Interlock Operation Inspection...11004
      IC Igniter Inspection...11005
    Electric Starter System...11008
      Starter Motor Removal...11008
      Starter Motor Installation...11008
      Starter Motor Disassembly...11009
      Starter Motor Assembly...11009
      Brush Inspection...11010
      Commutator Cleaning and Inspection...11011
      Armature Inspection...11011
      Brush Lead Inspection...11011
      Right-hand End Cover Assembly Inspection...11012
      Starter Relay Inspection...11012
    Lighting System...11014
      Headlight Beam Horizontal Adjustment...11014
      Headlight Beam Vertical Adjustment...11014
      Headlight Bulb Replacement...11014
      City Light Bulb Replacement...11015
      Headlight Removal/Installation...11015
      Tail/Brake Light (LED) Removal/Installation...11016
      License Plate Light Bulb Replacement...11016
      Turn Signal Light Bulb Replacement...11018
      Turn Signal Relay Inspection...11019
    Air Switching Valve...11022
      Air Switching Valve Operation Test...11022
      Air Switching Valve Unit Test...11022
    Radiator Fan System...11024
      Fan Motor Inspection...11024
    Meter, Gauge, Indicator Unit...11025
      Meter Unit Removal/Installation...11025
      Meter Unit Disassembly...11025
      Electronic Unit (Combination Meter) Inspection...11026
    Immobilizer System (Equipped Models)...11037
      Operational Cautions...11037
      Key Registration...11037
      Immobilizer System Parts Replacement...11053
      Immobilizer System Inspection...11054
    Switches and Sensors...11056
      Brake Light Timing Inspection...11056
      Brake Light Timing Adjustment...11056
      Switch Inspection...11056
      Water Temperature Sensor Inspection...11057
      Speed Sensor Removal...11057
      Speed Sensor Installation...11058
      Speed Sensor Inspection...11058
      Fuel Reserve Switch Inspection...11058
      Oxygen Sensor Removal (Equipped Models)...11059
      Oxygen Sensor Installation (Equipped Models)...11060
      Oxygen Sensor Inspection (Equipped Models)...11060
      Oxygen Sensor Heater Inspection (Equipped Models)...11060
      Gear Position Switch Removal...11060
      Gear Position Switch Installation...11061
      Gear Position Switch Inspection...11061
    Relay Box...11063
      Relay Box Removal...11063
      Relay Circuit Inspection...11063
      Diode Circuit Inspection...11064
    Fuse...11065
      30 A Main Fuse Removal...11065
      Fuse Box Fuse Removal...11065
      10 A ECU Fuse Removal...11065
      Fuse Installation...11066
      Fuse Inspection...11066
  Appendix...11068
    Cable, Wire, and Hose Routing...11069
    Troubleshooting Guide...11115
Kawasaki Motorcycle Service Repair Manual '11 ZX-10R (EN)...11121
  General Information...11129
    Before Servicing...11130
    Model Identification...11135
    General Specifications...11139
    Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC)...11142
    Technical Information-Power Mode...11145
    Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)...11147
    Unit Conversion Table...11151
  Periodic Maintenance...11153
    Periodic Maintenance Chart...11155
    Torque and Locking Agent...11158
    Specifications...11164
    Special Tools...11166
    Periodic Maintenance Procedures...11167
      Fuel System (DFI)...11167
        Throttle Control System Inspection...11167
        Engine Vacuum Synchronization Inspection...11167
        Idle Speed Inspection...11171
        Idle Speed Adjustment...11172
        Fuel Hose Inspection (fuel leak, damage, installation condition)...11172
        Evaporative Emission Control System Inspection (CAL and SEA Models)...11173
      Cooling System...11174
        Coolant Level Inspection...11174
        Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)...11174
      Engine Top End...11175
        Valve Clearance Inspection...11175
        Valve Clearance Adjustment...11176
      Air Suction System Damage Inspection...11178
      Clutch...11179
        Clutch Operation Inspection ...11179
      Wheels/Tires...11180
        Tire Air Pressure Inspection...11180
        Wheel/Tire Damage Inspection...11180
        Tire Tread Wear Inspection ...11181
        Wheel Bearing Damage Inspection...11181
      Final Drive...11182
        Drive Chain Lubrication Condition Inspection...11182
        Drive Chain Slack Inspection...11183
        Drive Chain Slack Adjustment...11183
        Wheel Alignment Inspection...11184
        Drive Chain Wear Inspection...11184
        Chain Guide Wear Inspection...11185
      Brakes...11185
        Brake Fluid Leak (Brake Hose and Pipe) Inspection...11185
        Brake Hose and Pipe Damage and Installation Condition Inspection...11186
        Brake Fluid Level Inspection...11186
        Brake Pad Wear Inspection...11187
        Brake Operation Inspection...11187
        Brake Light Switch Operation Inspection...11187
      Suspension...11188
        Front Forks/Rear Shock Absorber Operation Inspection...11188
        Front Fork Oil Leak Inspection...11189
        Rear Shock Absorber Oil Leak Inspection...11189
        Rocker Arm Operation Inspection...11189
        Tie-Rod Operation Inspection...11189
      Steering...11190
        Steering Play Inspection...11190
        Steering Play Adjustment...11190
        Steering Stem Bearing Lubrication...11191
        Steering Damper Oil Leak Inspection...11192
      Electrical System...11193
        Lights and Switches Operation Inspection...11193
        Headlight Aiming Inspection...11195
        Headlight Aiming Adjustment...11195
        Sidestand Switch Operation Inspection...11196
        Engine Stop Switch Operation Inspection...11197
      Others...11198
        Chassis Parts Lubrication ...11198
        Bolts, Nuts and Fasteners Tightness Inspection...11199
      Replacement Parts...11201
        Air Cleaner Element Replacement...11201
        Fuel Hose Replacement...11201
        Coolant Change...11204
        Radiator Hose and O-ring Replacement...11206
        Engine Oil Change...11207
        Oil Filter Replacement...11208
        Brake Hose and Pipe Replacement...11209
        Brake Fluid Change...11212
        Master Cylinder Rubber Parts Replacement...11213
        Caliper Rubber Parts Replacement...11215
        Spark Plug Replacement...11219
  Fuel System (DFI)...11221
    Exploded View...11223
    DFI System...11230
    DFI Parts Location...11240
    Specifications...11243
    Special Tools and Sealant...11244
    DFI Servicing Precautions...11245
      DFI Servicing Precautions...11245
    Troubleshooting the DFI System...11247
      Outline...11247
      Inquiries to Rider...11251
    DFI System Troubleshooting Guide...11254
    Warning Indicator Light (LED)...11259
      Light (LED) Inspection...11259
    ECU...11260
      ECU Identification...11260
      ECU Removal...11260
      ECU Installation...11260
      ECU Power Supply Inspection...11261
    CAN Communication Line...11264
      CAN Communication Line Resistance Inspection...11264
    DFI Power Source...11266
      ECU Fuse Removal...11266
      ECU Fuse Installation...11266
      ECU Fuse Inspection...11266
      ECU Main Relay Removal/Installation...11266
      ECU Main Relay Inspection...11266
    Fuel Line...11267
      Fuel Pressure Inspection...11267
      Fuel Flow Rate Inspection...11268
    Fuel Pump...11270
      Fuel Pump Removal...11270
      Fuel Pump Installation...11271
      Fuel Pump Operation Inspection...11271
      Fuel Pump Operating Voltage Inspection...11271
      Pressure Regulator Removal...11272
      Fuel Filter Cleaning...11273
    Fuel Injectors...11274
      Primary Fuel Injector Removal/Installation...11274
      Secondary Fuel Injector Removal/Installation...11274
      Fuel Injector Audible Inspection...11274
      Fuel Injector Resistance Inspection...11275
      Fuel Injector Power Source Voltage Inspection...11276
      Fuel Injector Output Voltage Inspection...11278
      Fuel Injector Fuel Line Inspection...11280
    Throttle Grip and Cables...11282
      Free Play Inspection...11282
      Free Play Adjustment...11282
      Cable Installation...11282
      Cable Lubrication...11282
    Throttle Body Assy...11283
      Idle Speed Inspection...11283
      Synchronization Inspection/Adjustment...11283
      Throttle Body Assy Removal...11283
      Throttle Body Assy Installation...11284
      Throttle Body Assy Disassembly...11285
      Throttle Body Assy Assembly...11286
    Nozzle Assy...11288
      Nozzle Assy Removal...11288
      Nozzle Assy Installation...11288
      Nozzle Assy Disassembly...11288
      Nozzle Assy Assembly...11289
    Air Cleaner...11290
      Air Cleaner Element Removal/Installation...11290
      Air Cleaner Element Inspection...11290
      Air Cleaner Oil Draining...11290
      Air Cleaner Housing Removal...11290
      Air Cleaner Housing Installation...11291
      Air Cleaner Housing Disassembly...11292
      Air Cleaner Housing Assembly...11292
    Air Line...11294
      Air Intake Duct Removal...11294
      Air Intake Duct Installation...11294
      Air Intake Duct Disassembly...11294
      Air Intake Duct Assembly...11295
      Air Intake Duct Disassembly (Other than US, CA and CAL Models)...11295
      Air Intake Duct Assembly (Other than US, CA and CAL Models)...11296
      Air Intake Solenoid Valve Removal (Other than US, CA and CAL Models)...11297
      Air Intake Solenoid Valve Installation (Other than US, CA and CAL Models)...11297
      Air Intake Solenoid Valve Unit Test (Other than US, CA and CAL Models)...11297
      Vacuum Chamber Removal (Other than US, CA and CAL Models)...11298
      Vacuum Chamber Installation (Other than US, CA and CAL Models)...11298
    Fuel Tank...11299
      Fuel Tank Removal...11299
      Fuel Tank Installation...11302
      Fuel Tank and Cap Inspection...11304
      Fuel Tank Cleaning...11304
    Evaporative Emission Control System (CAL and SEA Models)...11305
      Parts Removal/Installation...11305
      Hose Inspection...11305
      Separator Inspection...11305
      Separator Operation Test...11306
      Canister Inspection ...11307
  Cooling System...11309
    Exploded View...11310
    Coolant Flow Chart...11312
    Specifications...11314
    Special Tools...11315
    Coolant...11316
      Coolant Deterioration Inspection...11316
      Coolant Level Inspection...11316
      Coolant Draining...11316
      Coolant Filling...11316
      Pressure Testing...11316
      Cooling System Flushing...11317
      Coolant Reserve Tank Removal...11317
      Coolant Reserve Tank Installation...11317
    Water Pump...11318
      Water Pump Removal...11318
      Water Pump Installation...11318
      Water Pump Inspection...11318
      Water Pump Impeller Disassembly/Assembly...11318
      Water Pump Impeller Inspection...11318
      Water Pump Housing Disassembly...11318
      Water Pump Housing Assembly...11319
      Mechanical Seal Inspection...11319
    Radiator...11320
      Radiator and Radiator Fan Removal...11320
      Radiator and Radiator Fan Installation...11321
      Radiator Inspection...11321
      Radiator Cap Inspection...11322
      Radiator Filler Neck Inspection...11322
    Thermostat...11323
      Thermostat Removal...11323
      Thermostat Installation...11323
      Thermostat Inspection...11324
    Hoses and Pipes...11325
      Hose Installation...11325
      Hose Inspection...11325
    Water Temperature Sensor...11326
      Water Temperature Sensor Removal/Installation...11326
      Water Temperature Sensor Inspection...11326
  Engine Top End...11327
    Exploded View...11328
    Exhaust System Identification...11332
    Specifications...11334
    Special Tools and Sealant...11335
    Clean Air System...11337
      Air Suction Valve Removal...11337
      Air Suction Valve Installation...11337
      Air Suction Valve Inspection...11338
      Air Switching Valve Removal...11338
      Air Switching Valve Installation...11338
      Air Switching Valve Operation Test...11339
      Air Switching Valve Unit Test...11339
      Clean Air System Hose Inspection...11339
    Cylinder Head Cover...11340
      Cylinder Head Cover Removal...11340
      Cylinder Head Cover Installation...11340
    Camshaft Chain Tensioner...11342
      Camshaft Chain Tensioner Removal...11342
      Camshaft Chain Tensioner Installation...11343
    Camshaft, Camshaft Chain...11344
      Camshaft Removal...11344
      Camshaft Installation...11345
      Camshaft, Camshaft Cap Wear Inspection...11347
      Camshaft Runout Inspection...11348
      Cam Wear Inspection...11348
      Camshaft Chain Removal...11348
      Camshaft Chain Installation...11349
    Cylinder Head...11350
      Cylinder Compression Measurement...11350
      Cylinder Head Removal...11350
      Cylinder Head Installation...11351
      Cylinder Head Warp Inspection...11352
    Valves...11353
      Valve Clearance Inspection...11353
      Valve Removal...11353
      Valve Installation...11353
      Valve Guide Removal...11353
      Valve Guide Installation...11354
      Valve-to-Guide Clearance Measurement (Wobble Method)...11354
      Valve Seat Inspection...11355
      Valve Seat Repair...11355
    Throttle Body Assy Holder...11360
      Throttle Body Assy Holder Removal...11360
      Throttle Body Assy Holder Installation...11360
    Muffler...11361
      Muffler Body Removal...11361
      Muffler Body Installation...11361
      Premuffler Chamber Removal...11362
      Premuffler Chamber Installation...11363
      Exhaust Pipe Removal...11364
      Exhaust Pipe Installation...11364
      Exhaust Butterfly Valve Cable Removal...11365
      Exhaust Butterfly Valve Cable Installation...11367
  Clutch...11369
    Exploded View...11370
    Specifications...11372
    Special Tool and Sealant...11373
    Clutch Lever and Cable...11374
      Clutch Lever Free Play Inspection...11374
      Clutch Lever Free Play Adjustment...11374
      Cable Removal...11374
      Cable Installation...11374
      Cable Lubrication...11374
      Clutch Lever Installation...11374
    Clutch Cover...11375
      Clutch Cover Removal...11375
      Clutch Cover Installation...11375
      Release Shaft Removal...11376
      Release Shaft Installation...11376
      Clutch Cover Disassembly...11376
      Clutch Cover Assembly...11377
    Clutch...11378
      Clutch Removal...11378
      Clutch Installation...11379
      Spring Plate Free Play Measurement...11382
      Spring Plate Free Play Adjustment...11383
      Clutch Plate, Wear, Damage Inspection...11384
      Clutch Plate Warp Inspection...11384
      Clutch Spring Free Length Measurement...11385
      Clutch Housing Finger Inspection...11385
      Clutch Housing Spline Inspection...11385
      Damper Cam Inspection...11385
  Engine Lubrication System...11387
    Exploded View...11388
    Engine Oil Flow Chart...11390
    Specifications...11391
    Special Tools and Sealant...11392
    Engine Oil and Oil Filter...11393
      Oil Level Inspection...11393
      Engine Oil Change...11393
      Oil Filter Replacement...11393
    Oil Pan...11394
      Oil Pan Removal...11394
      Oil Pan Installation...11394
    Oil Pressure Relief Valve...11396
      Oil Pressure Relief Valve Removal...11396
      Oil Pressure Relief Valve Installation...11396
      Oil Pressure Relief Valve Inspection...11396
    Oil Pump...11397
      Oil Pump Removal...11397
      Oil Pump Installation...11397
      Oil Pump Drive Gear Removal/Installation...11398
      Oil Pump Drive Gear Installation...11399
      Oil Pump Drive Gear Shaft Removal...11399
      Oil Pump Drive Gear Shaft Installation...11399
    Oil Cooler...11400
      Oil Cooler Removal...11400
      Oil Cooler Installation...11400
    Oil Pressure Measurement...11401
      Oil Pressure Measurement...11401
    Oil Pressure Switch...11402
      Oil Pressure Switch Removal...11402
      Oil Pressure Switch Installation...11402
  Engine Removal/Installation...11403
    Exploded View...11404
    Special Tool...11406
    Engine Removal/Installation...11407
      Engine Removal...11407
      Engine Installation...11410
  Crankshaft/Transmission...11413
    Exploded View...11414
    Specifications...11418
    Special Tools and Sealants...11421
    Crankcase...11422
      Crankcase Splitting...11422
      Crankcase Assembly...11423
    Crankshaft and Connecting Rods...11429
      Crankshaft Removal...11429
      Crankshaft Installation...11429
      Connecting Rod Removal...11430
      Connecting Rod Installation...11430
      Crankshaft/Connecting Rod Cleaning...11433
      Connecting Rod Bend Inspection...11434
      Connecting Rod Twist Inspection...11434
      Connecting Rod Big End Side Clearance Inspection...11434
      Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection...11435
      Crankshaft Side Clearance Inspection...11436
      Crankshaft Runout Inspection...11437
      Crankshaft Main Bearing Insert/Journal Wear Inspection...11437
    Pistons...11439
      Piston Removal...11439
      Piston Installation...11440
      Cylinder (Upper Crankcase) Wear Inspection...11441
      Piston Wear Inspection...11441
      Piston Ring, Piston Ring Groove Wear Inspection...11442
      Piston Ring Groove Width Inspection...11442
      Piston Ring Thickness Inspection...11442
      Piston Ring End Gap Inspection...11443
    Balancer...11444
      Balancer Removal...11444
      Balancer Assemble...11444
      Balancer Installation...11445
      Balancer Adjustment...11445
      Balancer Damper Inspection...11445
    Torque Limiter...11446
      Torque Limiter Removal...11446
      Torque Limiter Installation...11446
    Starter Clutch...11448
      Starter Clutch Removal...11448
      Starter Clutch Installation...11448
      Starter Clutch Disassembly...11448
      Starter Clutch Assembly...11449
      Starter Clutch Inspection...11449
    Transmission...11450
      Transmission Assy Removal...11450
      Transmission Assy Disassembly...11450
      Transmission Assy Assembly...11451
      Transmission Assy Installation...11452
      Transmission Shaft Removal...11453
      Transmission Shaft Installation...11453
      Transmission Shaft Disassembly...11453
      Transmission Shaft Assembly...11453
      Shift Drum and Fork Removal...11456
      Shift Drum and Fork Installation...11456
      Shift Drum Disassembly...11456
      Shift Drum Assembly...11456
      Shift Fork Bending Inspection...11456
      Shift Fork/Gear Groove Wear Inspection...11456
      Shift Fork Guide Pin/Drum Groove Wear Inspection...11457
      Gear Dog and Gear Dog Hole Damage Inspection...11457
    External Shift Mechanism...11458
      Shift Pedal Removal...11458
      Shift Pedal Installation...11458
      External Shift Mechanism Removal...11459
      External Shift Mechanism Installation...11459
      External Shift Mechanism Inspection...11461
  Wheels/Tires...11463
    Exploded View...11464
    Specifications...11466
    Special Tools...11467
    Wheels (Rims)...11468
      Front Wheel Removal...11468
      Front Wheel Installation...11469
      Rear Wheel Removal...11470
      Rear Wheel Installation...11470
      Wheel Inspection...11472
      Axle Inspection...11472
      Balance Inspection...11473
      Balance Adjustment...11473
      Balance Weight Removal...11473
      Balance Weight Installation...11474
    Tires...11475
      Air Pressure Inspection/Adjustment...11475
      Tire Inspection...11475
      Tire Removal...11475
      Tire Installation...11475
      Tire Repair...11477
    Hub Bearing...11478
      Hub Bearing Removal...11478
      Hub Bearing Installation...11478
      Hub Bearing Inspection...11478
      Hub Bearing Lubrication...11479
  Final Drive...11481
    Exploded View ...11482
    Specifications ...11484
    Special Tools...11485
    Drive Chain...11486
      Drive Chain Slack Inspection...11486
      Drive Chain Slack Adjustment...11486
      Wheel Alignment Inspection/Adjustment...11486
      Drive Chain Wear Inspection...11486
      Drive Chain Lubrication...11486
      Drive Chain Guide Wear Inspection...11486
      Drive Chain Removal...11486
    Sprocket, Coupling...11490
      Engine Sprocket Removal...11490
      Engine Sprocket Installation...11490
      Rear Sprocket Removal...11491
      Rear Sprocket Installation...11491
      Coupling Installation...11491
      Coupling Bearing Removal...11492
      Coupling Bearing Installation...11492
      Coupling Bearing Inspection...11493
      Coupling Bearing Lubrication...11493
      Coupling Damper Inspection...11493
      Sprocket Wear Inspection...11493
      Rear Sprocket Warp Inspection...11493
  Brakes...11495
    Exploded View ...11496
    Specifications ...11504
    Special Tools...11505
    Brake Lever, Brake Pedal...11506
      Brake Lever Position Adjustment...11506
      Brake Pedal Position Inspection ...11506
      Brake Pedal Position Adjustment ...11506
      Brake Pedal Removal...11506
      Brake Pedal Installation...11507
    Calipers...11509
      Front Caliper Removal...11509
      Rear Caliper Removal...11509
      Caliper Installation...11510
      Front Caliper Disassembly...11510
      Front Caliper Assembly...11510
      Rear Caliper Disassembly...11510
      Rear Caliper Assembly...11510
      Caliper Fluid Seal Damage...11511
      Rear Caliper Dust Boot and Friction Boot Damage...11511
      Caliper Piston and Cylinder Damage...11511
      Rear Caliper Holder Shaft Wear...11512
    Brake Pads...11513
      Front Brake Pad Removal...11513
      Front Brake Pad Installation...11513
      Rear Brake Pad Removal ...11513
      Rear Brake Pad Installation...11514
      Brake Pad Wear Inspection...11514
    Master Cylinder...11515
      Front Master Cylinder Removal...11515
      Front Master Cylinder Installation...11515
      Rear Master Cylinder Removal...11516
      Rear Master Cylinder Installation...11517
      Front Master Cylinder Disassembly...11517
      Rear Master Cylinder Disassembly...11517
      Master Cylinder Assembly...11517
      Master Cylinder Inspection (Visual Inspection)...11518
    Brake Disc...11519
      Brake Disc Removal...11519
      Brake Disc Installation...11519
      Brake Disc Wear Inspection...11519
      Brake Disc Warp Inspection...11520
    Brake Fluid...11521
      Brake Fluid Level Inspection...11521
      Brake Fluid Change...11521
      Brake Line Bleeding...11521
    Brake Hose...11525
      Brake Hose Removal/Installation...11525
      Brake Hose Inspection...11525
    KIBS (Equipped Models)...11526
      Parts Location...11526
      KIBS Servicing Precautions...11529
      KIBS Troubleshooting Outline...11531
      Inquiries to Rider...11534
      Self-diagnosis Outline...11536
      ABS and KIBS Indicator Lights (LED) Inspection...11537
      KIBS Hydraulic Unit Removal...11537
      KIBS Hydraulic Unit Installation...11539
      KIBS Hydraulic Unit Inspection...11539
      Front Wheel Rotation Sensor Removal...11540
      Front Wheel Rotation Sensor Installation...11540
      Rear Wheel Rotation Sensor Removal...11541
      Rear Wheel Rotation Sensor Installation...11541
      Wheel Rotation Sensor Inspection...11542
      Wheel Rotation Sensor Air Gap Inspection...11542
      Wheel Rotation Sensor Rotor Inspection...11542
      KIBS Solenoid Valve Relay Fuse (20 A) Removal...11543
      KIBS Motor Relay Fuse (30 A) Removal...11543
      Fuse Installation...11543
      Fuse Inspection...11543
  Suspension...11545
    Exploded View...11546
    Specifications...11550
    Special Tools...11551
    Front Fork...11553
      Rebound Damping Force Adjustment...11553
      Compression Damping Force Adjustment...11553
      Spring Preload Adjustment...11554
      Front Fork Removal (Each Fork Leg)...11554
      Front Fork Installation (Each Fork Leg)...11555
      Front Fork Oil Change...11556
      Front Fork Disassembly...11560
      Front Fork Assembly...11560
      Inner Tube Inspection...11561
      Dust Seal Inspection...11562
      Spring Tension Inspection...11562
    Rear Shock Absorber...11563
      Rebound Damping Force Adjustment...11563
      Compression Damping Force Adjustment...11563
      Spring Preload Adjustment...11564
      Rear Shock Absorber Removal...11565
      Rear Shock Absorber Installation...11566
      Rear Shock Absorber Inspection...11566
      Rear Shock Absorber Scrapping...11566
    Swingarm...11567
      Swingarm Removal...11567
      Swingarm Installation...11568
      Swingarm Bearing Removal...11569
      Swingarm Bearing Installation...11569
      Swingarm Bearing, Sleeve Inspection...11570
      Swingarm Bearing Lubrication...11571
    Tie-Rod, Rocker Arm...11572
      Tie-Rod Removal...11572
      Tie-Rod Installation...11572
      Rocker Arm Removal...11572
      Rocker Arm Installation...11573
      Tie-Rod and Rocker Arm Bearing Removal...11573
      Tie-Rod and Rocker Arm Bearing Installation...11574
      Rocker Arm/Tie-Rod Bearing, Sleeve Inspection...11575
      Rocker Arm/Tie-Rod Bearing Lubrication...11575
  Steering...11577
    Exploded View...11578
    Specifications...11580
    Special Tools...11581
    Steering...11582
      Steering Inspection...11582
      Steering Adjustment...11582
    Steering Damper...11583
      Damping Force Adjustment...11583
      Steering Damper Removal...11583
      Steering Damper Installation...11583
      Steering Damper Oil Leak Inspection...11583
    Steering Stem...11584
      Stem, Stem Bearing Removal...11584
      Stem, Stem Bearing Installation...11585
      Steering Stem Bearing Lubrication...11587
      Steering Stem Warp Inspection...11587
      Stem Cap Deterioration, Damage Inspection...11587
    Handlebar...11588
      Handlebar Removal...11588
      Handlebar Installation...11589
  Frame...11591
    Exploded View...11592
    Seats...11598
      Front Seat Removal...11598
      Front Seat Installation...11598
      Rear Seat Removal...11598
      Rear Seat Installation...11598
    Fairings...11599
      Lower Fairing Removal...11599
      Lower Fairing Installation...11599
      Upper Fairing Assembly Removal...11599
      Upper Fairing Assembly Installation...11600
      Upper Fairing Assembly Disassembly...11601
      Upper Inner Fairing Removal...11601
      Upper Inner Fairing Installation...11601
      Center Inner Fairing Removal...11601
      Center Inner Fairing Installation...11602
    Seat Covers...11603
      Seat Cover Removal...11603
      Seat Cover Installation...11603
    Fenders...11604
      Front Fender Removal...11604
      Front Fender Installation...11604
      Flap and Rear Fender Rear Removal...11604
      Flap and Rear Fender Rear Installation...11605
      Rear Fender Front Removal...11606
      Rear Fender Front Installation...11606
    Frame...11607
      Rear Frame Rear Removal...11607
      Rear Frame Rear Installation...11607
      Rear Frame Front Removal...11607
      Rear Frame Front Installation...11607
      Frame Inspection...11607
    Windshield...11608
      Windshield Removal...11608
      Windshield Installation...11608
    Guard...11609
      Mud Guard Removal...11609
      Mud Guard Installation...11609
    Sidestand...11610
      Sidestand Removal...11610
      Sidestand Installation...11610
    Footpeg...11611
      Footpeg Height Adjustment...11611
  Electrical System...11613
    Exploded View...11616
    Specifications...11622
    Special Tools and Sealant...11623
    Parts Location...11624
    Wiring Diagram (US, CA and CAL without KIBS Models)...11627
    Wiring Diagram (US, CA and CAL with KIBS Models)...11630
    Wiring Diagram (Other than US, CA and CAL without KIBS Models)...11632
    Wiring Diagram (Other than US, CA and CAL with KIBS Models)...11634
    Precautions...11636
    Electrical Wiring...11637
      Wiring Inspection...11637
    Battery...11638
      Battery Removal...11638
      Battery Installation...11638
      Precautions...11638
      Interchange...11639
      Charging Condition Inspection...11639
      Refreshing Charge...11640
    Charging System...11642
      Alternator Cover Removal...11642
      Alternator Cover Installation...11642
      Stator Coil Removal...11642
      Stator Coil Installation...11643
      Alternator Rotor Removal...11643
      Alternator Rotor Installation...11643
      Charging Voltage Inspection...11645
      Alternator Inspection...11645
      Regulator/Rectifier Inspection...11647
    Ignition System...11649
      Crankshaft Sensor Removal...11649
      Crankshaft Sensor Installation...11650
      Crankshaft Sensor Inspection...11650
      Crankshaft Sensor Peak Voltage Inspection...11651
      Stick Coil Removal...11651
      Stick Coil Installation...11652
      Stick Coil Inspection...11652
      Stick Coil Primary Peak Voltage Inspection...11653
      Spark Plug Removal...11653
      Spark Plug Installation...11653
      Spark Plug Condition Inspection...11654
      Interlock Operation Inspection...11654
      IC Igniter Inspection...11655
    Electric Starter System...11658
      Starter Motor Removal...11658
      Starter Motor Installation...11658
      Starter Motor Disassembly...11659
      Starter Motor Assembly...11659
      Brush Inspection...11661
      Commutator Cleaning and Inspection...11661
      Armature Inspection...11661
      Brush Lead Inspection...11662
      Right-hand End Cover Inspection...11662
      Starter Relay Inspection...11662
    Lighting System...11664
      Headlight Beam Horizontal Adjustment...11664
      Headlight Beam Vertical Adjustment...11664
      Headlight Bulb Replacement...11664
      Headlight Removal/Installation...11665
      City Light (LED) Removal/Installation...11665
      Tail/Brake Light (LED) Removal/Installation...11665
      License Plate Light Bulb Replacement...11666
      Rear Turn Signal Light Bulb Replacement...11668
      Turn Signal Relay Inspection...11669
    Air Switching Valve...11672
      Air Switching Valve Operation Test...11672
      Air Switching Valve Unit Test...11672
    Air Intake Solenoid Valve...11674
      Air Intake Solenoid Valve Operation Test...11674
      Air Intake Solenoid Valve Unit Test...11674
    Radiator Fan System...11676
      Fan Motor Inspection...11676
    Meter, Gauge, Indicator Unit...11677
      Meter Unit Removal/Installation...11677
      Meter Unit Disassembly...11677
      Meter Operation Inspection...11678
      Meter System Inspection...11681
      Meter Unit Inspection...11683
    Immobilizer System (Equipped Models)...11689
      Operational Cautions...11689
      Key Registration...11689
      Immobilizer System Parts Replacement...11707
      Immobilizer System Inspection...11708
    Switches and Sensors...11710
      Brake Light Timing Inspection...11710
      Brake Light Timing Adjustment...11710
      Switch Inspection...11710
      Water Temperature Sensor Inspection...11711
      Fuel Reserve Switch Inspection...11711
      Oxygen Sensor Removal (Equipped Models)...11712
      Oxygen Sensor Installation (Equipped Models)...11712
      Oxygen Sensor Inspection (Equipped Models)...11713
      Oxygen Sensor Heater Inspection (Equipped Models)...11713
      Gear Position Switch Removal...11713
      Gear Position Switch Installation...11713
      Gear Position Switch Inspection...11714
    Relay Box...11715
      Relay Box Removal...11715
      Relay Circuit Inspection...11715
      Diode Circuit Inspection...11716
    Fuse...11717
      30 A Main/15 A ECU Fuse Removal...11717
      Fuse Box Fuse Removal...11717
      Fuse Installation...11718
      Fuse Inspection...11718
  Self-Diagnosis System...11719
    Specifications...11722
    Special Tools...11724
    Self-Diagnosis...11725
      Self-Diagnosis Outline...11725
      Self-Diagnosis Procedures...11726
      Self-Diagnosis Flow Chart...11728
      Service Code Reading...11729
      Service Code Erasing...11729
      Backups...11731
    Main Throttle Sensor (Service Code 11)...11734
      Main Throttle Sensor Removal/Adjustment...11734
      Main Throttle Sensor Input Voltage Inspection...11734
      Main Throttle Sensor Resistance Inspection...11735
      Main Throttle Sensor Output Voltage Inspection...11736
    Intake Air Pressure Sensor #1 (Service Code 12)...11739
      Intake Air Pressure Sensor #1 Removal...11739
      Intake Air Pressure Sensor #1 Installation...11739
      Intake Air Pressure Sensor #1 Input Voltage Inspection...11740
      Intake Air Pressure Sensor #1 Output Voltage Inspection...11741
    Intake Air Temperature Sensor (Service Code 13)...11745
      Intake Air Temperature Sensor Removal...11745
      Intake Air Temperature Sensor Installation...11745
      Intake Air Temperature Sensor Output Voltage Inspection...11746
      Intake Air Temperature Sensor Resistance Inspection...11747
    Water Temperature Sensor (Service Code 14)...11748
      Water Temperature Sensor Removal/Installation...11748
      Water Temperature Sensor Output Voltage Inspection...11748
      Water Temperature Sensor Resistance Inspection...11749
    Intake Air Pressure Sensor #2 (Service Code 16)...11750
      Intake Air Pressure Sensor #2 Removal...11750
      Intake Air Pressure Sensor #2 Installation...11750
      Intake Air Pressure Sensor #2 Input Voltage Inspection...11751
      Intake Air Pressure Sensor #2 Output Voltage Inspection...11752
    Crankshaft Sensor (Service Code 21)...11754
      Crankshaft Sensor Removal/Installation...11754
      Crankshaft Sensor Resistance Inspection...11754
      Crankshaft Sensor Peak Voltage Inspection...11754
    Rear Wheel Rotation Sensor Signal (Service Code 24)...11756
      Rear Wheel Rotation Sensor Signal Inspection...11756
    Gear Position Switch (Service Code 25)...11759
      Gear Position Switch Removal/Installation...11759
      Gear Position Switch Resistance Inspection...11759
      Gear Position Switch Output Voltage Inspection...11759
    Front Wheel Rotation Sensor Signal (Service Code 27)...11761
      Front Wheel Rotation Sensor Signal Inspection...11761
    Vehicle-down Sensor (Service Code 31)...11764
      Vehicle-down Sensor Removal...11764
      Vehicle-down Sensor Installation...11764
      Vehicle-down Sensor Input Voltage Inspection...11765
      Vehicle-down Sensor Output Voltage Inspection...11766
    Subthrottle Sensor (Service Code 32)...11768
      Subthrottle Sensor Removal/Adjustment...11768
      Subthrottle Sensor Input Voltage Inspection...11768
      Subthrottle Sensor Output Voltage Inspection...11769
      Subthrottle Sensor Resistance Inspection...11771
    Oxygen Sensor - not activated (Service Code 33, Equipped Models)...11772
      Oxygen Sensor Removal/Installation...11772
      Oxygen Sensor Inspection...11772
    Exhaust Butterfly Valve Actuator Sensor (Service Code 34)...11776
      Exhaust Butterfly Valve Actuator Sensor Removal/Installation...11776
      Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...11776
      Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection...11777
      Exhaust Butterfly Valve Actuator Sensor Resistance Inspection...11778
    Immobilizer Amplifier (Service Code 35, Equipped Models)...11779
      Antenna Resistance Inspection...11779
      Amplifier Input Voltage Inspection...11779
    Blank Key Detection (Service Code 36, Equipped Models)...11780
      User Key Inspection...11780
    ECU Communication Error (Service Code 39)...11781
      ECU Communication Line Inspection...11781
    Fuel Pump Relay (Service Code 46)...11783
      Fuel Pump Relay Removal/Installation...11783
      Fuel Pump Relay Inspection...11783
    Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54)...11784
      Stick Coil Removal/Installation...11784
      Stick Coil Primary Winding Resistance Inspection...11784
      Stick Coil Input Voltage Inspection...11784
    Radiator Fan Relay (Service Code 56)...11786
      Radiator Fan Relay Removal/Installation...11786
      Radiator Fan Relay Inspection...11786
    Subthrottle Valve Actuator (Service Code 62)...11787
      Subthrottle Valve Actuator Removal...11787
      Subthrottle Valve Actuator Inspection...11787
      Subthrottle Valve Actuator Resistance Inspection...11787
      Subthrottle Valve Actuator Input Voltage Inspection...11788
    Exhaust Butterfly Valve Actuator (Service Code 63)...11790
      Exhaust Butterfly Valve Actuator Removal...11790
      Exhaust Butterfly Valve Actuator Installation...11791
      Exhaust Butterfly Valve Actuator Inspection...11792
      Exhaust Butterfly Valve Actuator Resistance Inspection...11792
    Air Switching Valve (Service Code 64)...11794
      Air Switching Valve Removal/Installation...11794
      Air Switching Valve Inspection...11794
    Oxygen Sensor Heater (Service Code 67, Equipped Models)...11795
      Oxygen Sensor Heater Removal/Installation...11795
      Oxygen Sensor Heater Resistance Inspection...11795
      Oxygen Sensor Heater Power Source Voltage Inspection...11796
    KIBS Hydraulic Unit Communication Error (Service Code 1b, KIBS Equipped Models)...11798
      KIBS Hydraulic Unit Communication Line Inspection...11798
    Idle Speed Control Valve Actuator (Service Code 1C)...11800
      Idle Speed Control Valve Actuator Removal...11800
      Idle Speed Control Valve Actuator Installation...11800
      Idle Speed Control Valve Actuator Resistance Inspection...11800
      Idle Speed Control Valve Actuator Input Voltage Inspection...11801
    Air Intake Solenoid Valve (Service Code 2d, Equipped Models)...11803
      Air Intake Solenoid Valve Removal/Installation...11803
      Air Intake Solenoid Valve Inspection...11803
    KIBS Service Codes (KIBS Equipped Models)...11804
      Solenoid Valve Inspection (Service Code b 13, b 14, b 17, b 18)...11804
      KIBS Solenoid Valve Relay Inspection (Service Code b 19)...11804
      Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code b 25)...11804
      KIBS Motor Relay Inspection (Service Code b 35)...11804
      Front Wheel Rotation Sensor Signal Abnormal (Service Code b 42)...11805
      Front Wheel Rotation Sensor Wiring Inspection (Service Code b 43)...11806
      Rear Wheel Rotation Sensor Signal Abnormal (Service Code b 44)...11806
      Rear Wheel Rotation Sensor Wiring Inspection (Service Code b 45)...11807
      Power Supply Voltage Inspection (Low-Voltage) (Service Code b 52)...11807
      Power Supply Voltage Inspection (Over-Voltage) (Service Code b 53)...11808
      ECU Inspection (Service Code b 55)...11808
      CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code b 57) CAN Communication (Reception) Monitor Inspection (Service Code b 58)...11808
      Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code b 83)...11809
      Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code b 84)...11809
      Fluid Pressure Sensor Supply Voltage Inspection (Service Code b 89)...11809
  Appendix...11811
    Cable, Wire, and Hose Routing...11812
    Troubleshooting Guide...11852
Kawasaki Motorcycle Service Repair Manual '83-'97 ZX900-1000-1100 Ninja (EN)...11858
Kawasaki Motorcycle Service Repair Manual '84 ZX-9R (DE)...12097
Kawasaki Motorcycle Service Repair Manual '84-'90 ZX-9R (EN)...12339
Kawasaki Motorcycle Service Repair Manual '85-'97 ZX600 & 750 Fours (EN)...12633
Kawasaki Motorcycle Service Repair Manual '88-'90 ZX-10 (EN)...12898
  ZX10 Front Cover '88-'90...12898
  Model Application...12899
  Quick Reference...12900
  Title page...12901
  Foreward...12905
  1 General Information...12907
    Model Identification...12910
    Specifications...12911
    Periodic Maintenance Chart...12914
    Cable,Wire and Hose Routing...12920
  2 Fuel System...12927
    Carburetors...12932
    Fuel pump and Filter...12937
  3 Cooling System...12941
    Water pump...12946
    Thermostat...12949
  4 Engine Top End...12951
    Cylinder Head Cover...12958
    Cylinder Head...12962
    Valves...12964
    Cylinder, Piston...12971
    Carburetor Holder...12973
  5 Clutch...12975
  6 Engine Lubrication System...12987
    Engine oil and filter...12992
  7 Engine Removal/Installation...12999
  8 Crankshaft/Transmission...13003
    Crankcase splitting...13008
...
Kawasaki Motorcycle ZZR250 1990 - 1996 Repair Manual Supplement...16184
  Front_Cover...16184
  Model_Application...16185
  Quick_Reference_Guide...16186
  General_Information_1...16191
  Fuel_System_2...16203
  Cooling_System_3...16211
  Engine_Top_End_4...16215
  Clutch_5...16223
  Engine_Lubrication_System_6...16227
  Engine_Removal/Installation_7...16230
  Crankshaft/Transmission_8...16233
  Wheels/Tires_9...16239
  Final_Drive_10...16247
  Brakes_11...16253
  Suspension_12...16258
  Steering_13...16268
  Frame_14...16271
  Electrical_System_15...16279
  Appendix_16...16306
  Back_Cover...16308