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Ninja ZX-12R
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki NINJA ZX-12R

   Summary of Contents for Kawasaki NINJA ZX-12R

  • Page 1 Ninja ZX-12R Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Troubleshooting...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2002 Kawasaki Heavy Industries, Ltd. Fourth Edition (1) : Mar. 5, 2004 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the...
  • Page 9 Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......Technical Information – Monocoque Frame ................1-12 Technical Information – Spark Plug ..................1-13 Technical Information – Immobilizer System (ZX1200-B3).............
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 13 GENERAL INFORMATION 1-3 Before Servicing (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing (18)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent...
  • Page 15: Model Identification

    GENERAL INFORMATION 1-5 Model Identification ZX1200-B1 Left Side View ZX1200-B1 Right Side View...
  • Page 16: General Specifications

    1-6 GENERAL INFORMATION General Specifications Items ZX1200-B1 Dimensions Overall Length 2 085 mm (82.09 in.) Overall Width 740 mm (29.13 in.) Overall Height 1 200 mm (47.24 in.) Wheelbase 1 450 mm (57.09 in.) Road Clearance 120 mm (4.72 in.) Seat Height 820 mm (32.28 in.) Dry Mass...
  • Page 17 GENERAL INFORMATION 1-7 General Specifications Items ZX1200-B1 Valve Timing: Inlet: Open 46° BTDC Close 74° ABDC Duration 300° Exhaust: Open 69° BBDC Close 45° ATDC Duration 294° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Grade API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40...
  • Page 18 1-8 GENERAL INFORMATION General Specifications Items ZX1200-B1 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 140 mm (5.51 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 12 Ah Headlight:...
  • Page 19: Technical Information - Kawasaki Low Exhaust Emission System

    GENERAL INFORMATION 1-9 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys- tem, according to each regulation of different countries.
  • Page 20 1-10 GENERAL INFORMATION Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Exhaust System (ZX1200-B1/B2) 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb Type Catalyst UK: United Kingdom Model...
  • Page 21 GENERAL INFORMATION 1-11 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Exhaust System (ZX1200-B3) 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb Type Catalyst UK: United Kingdom Model...
  • Page 22: Technical Information - Monocoque Frame

    1-12 GENERAL INFORMATION Technical Information – Monocoque Frame Why a monocoque? Like all breakthrough innovations, the choice appears quite obvious after the fact. When large-section aluminium spars are wrapped around an already wide, large-displacement in-line Four engine, the resulting package must of necessity be wide. The ZX-12R’s all-aluminium box -section monocoque chassis eliminates these perimeter spars in favor of a large box section running over the top of the engine.
  • Page 23: Technical Information - Spark Plug

    GENERAL INFORMATION 1-13 Technical Information – Spark Plug ZX1200-B1 is equipped with the Kawasaki recommended spark plug (NGK CR9EKPA). By using the Kawasaki recom- mended spark plug, the idling stability, the fuel consump- tion improvement, and the maintenance free spark plug is planed.
  • Page 24: Technical Information - Immobilizer System (zx1200-b3)

    4. FI Indicator Light 11. Junction Box 5. Immobilizer Antenna 12. Fuse Box 6. Ignition Switch 13. Immobilizer/Kawasaki Diagnostic System 7. Immobilizer Amplifier Connector Master Key (1 piece) The master key (colored red) has an inbuilt transponder, containing a master key code. These codes are unique to each key.
  • Page 25 3. Ignition Switch 11. Main Fuse 30 A 4. Meter Unit 12. Battery 12 V 12 Ah 5. FI Indicator Light 13. Immobilizer/Kawasaki Diagnostic System 6. Ignition Fuse 10 A Connector 7. ECU Fuse 15 A 14. Electronic Control Unit (ECU)
  • Page 26 1-16 GENERAL INFORMATION Technical Information – Immobilizer System (ZX1200-B3) Sequence of Operation 1. Turn ON the ignition switch, the ECU, amplifier and antenna start working, and the meter assembly FI indicator lights up. 2. The transponder excited by radio waves transmitted from the antenna receives the ciphered code from the ECU.
  • Page 27: Torque And Locking Agent

    GENERAL INFORMATION 1-17 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. M: Apply molybdenum disulfide grease.
  • Page 28 1-18 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 106 in·lb Coolant Fitting Nozzle (ZX1200-B1/B2) Coolant Drain Plug (Water Pump) 106 in·lb Coolant Drain Plug (Cylinder) 89 in·lb Radiator Fan Switch Water Temperature Sensor Water Pump Impeller Bolt 89 in·lb Water Pump Cover Bolts 106 in·lb...
  • Page 29 GENERAL INFORMATION 1-19 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Plug 1.5 or 0.15 or 13 in·lb Hand Hand or Hand -Tight -Tight -Tight Engine Oil Drain Plug Oil Filter (Cartridge Type) EO, R Oil Cooler Passage Bolt Oil Cooler Mounting Bolts Oil Pan Bolts L (1)
  • Page 30 1-20 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Clutch Shaft Bolt Starter Clutch Shaft Plate Bolt 106 in·lb Wheels/Tires Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Sprocket Nuts Air Valve Cap 0.15 0.015 1.3 in·lb...
  • Page 31 GENERAL INFORMATION 1-21 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Uni-Track: Rocker Arm Nut Tie-rod Nuts Steering Steering Stem Head Nut (ZX1200-B1/B2) Steering Stem Head Nut (ZX1200-B3) Steering Stem Nut Handlebar Bolts Handlebar Weight Bolts – – –...
  • Page 32: Special Tools And Sealant

    1-22 GENERAL INFORMATION Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Compression Gauge, 20 kgf/cm²: 57001-125 57001-221 Bearing Puller: Valve Spring Compressor Assembly: 57001-135 57001-241 Inside Circlip Pliers: Bearing Puller Adapter: 57001-143 57001-317 Outside Circlip Pliers: Bearing Driver: 57001-144 57001-382 Oil Pressure Gauge, 10 kgf/cm²: Piston Pin Puller Assembly:...
  • Page 33 GENERAL INFORMATION 1-23 Special Tools and Sealant Oil Pressure Gauge Adapter, PT 1/8: Head Pipe Outer Race Remover: 57001-1033 57001-1107 Oil Seal & Bearing Remover: Valve Seat Cutter, 45° - 35: 57001-1058 57001-1116 Head Pipe Outer Race Press Shaft: Valve Seat Cutter, 30° - 30: 57001-1075 57001-1120 Piston Ring Compressor Grip:...
  • Page 34 1-24 GENERAL INFORMATION Special Tools and Sealant Valve Seat Cutter Holder Bar: Valve Guide Reamer, 5: 57001-1128 57001-1204 Bearing Driver Set: Valve Seat Cutter Holder, 5: 57001-1129 57001-1208 Valve Seat Cutter, 45° - 30: Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1187 57001-1216 Valve Spring Compressor Adapter, 22: Jack:...
  • Page 35 GENERAL INFORMATION 1-25 Special Tools and Sealant Valve Seat Cutter, 55° - 35: Pilot Screw Adjuster, C: 57001-1247 57001-1292 Oil Filter Wrench: Flywheel Holder: 57001-1249 57001-1313 Carburetor Drain Plug Wrench, Hex 3: Piston Ring Compressor Belt, 80 57001-1269 57001-1320 Fork Piston Rod Puller, M12 × 1.25: Fork Oil Seal Driver, 43: 57001-1289 57001-1340...
  • Page 36 1-26 GENERAL INFORMATION Special Tools and Sealant Steering Stem Bearing Driver: Hand Tester: 57001-1344 57001-1394 Steering Stem Bearing Driver Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1345 57001-1405 Bearing Remover Head, 25 × 28: Throttle Sensor Setting Adapter #2: 57001-1346 57001-1408 Socket Wrench:...
  • Page 37 GENERAL INFORMATION 1-27 Special Tools and Sealant Head Pipe Outer Race Driver: Clutch Gear Setting Screw: 57001-1446 57001-1455 Head Pipe Outer Race Driver: Needle Adapter Set: 57001-1447 57001-1457 Lead Wire - Voltage Regulator Adapter: Compression Gauge Adapter, M10 × 1.0: 57001-1448 57001-1458 Lead Wire - Peak Voltage Adapter:...
  • Page 38 1-28 GENERAL INFORMATION Special Tools and Sealant Throttle Sensor Setting Adapter: Rotor Holder: 57001-1538 57001-1592 Key Registration Unit: Kawasaki Bond (Silicone Sealant): 57001-1582 56019-120 Fork Spring Compressor: Kawasaki Bond (Liquid Gasket - Black): 57001-1587 92104-1062 Pulley Holder, Grip: 57001-1591...
  • Page 39: Cable, Wire, And Hose Routing (zx1200-b1/b2)

    GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 40 1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 41 GENERAL INFORMATION 1-31 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 42 1-32 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 43 GENERAL INFORMATION 1-33 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 44 1-34 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 45 GENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 46 1-36 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 47 GENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 48 1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 49 GENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 50 1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 51 GENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 52 1-42 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 53 GENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 54 1-44 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 55 GENERAL INFORMATION 1-45 Cable, Wire, and Hose Routing (ZX1200-B1/B2)
  • Page 56: Cable, Wire, And Hose Routing (zx1200-b3)

    1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 57 GENERAL INFORMATION 1-47 Cable, Wire, and Hose Routing (ZX1200-B3) 1. Clamp 2. To Side Stand Switch 3. Insert the dampers of the ECU into the holes of the fender. 4. ECU 5. Atmospheric Pressure Sensor 6. Regulator/rectifier 7. From Regulator/rectifier 8.
  • Page 58 1-48 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 59 GENERAL INFORMATION 1-49 Cable, Wire, and Hose Routing (ZX1200-B3) 1. Front 2. About 45° 3. Viewed A 4. Clamp...
  • Page 60 1-50 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 61 GENERAL INFORMATION 1-51 Cable, Wire, and Hose Routing (ZX1200-B3) 1. Run the horn lead between the water hose and water pipe. 2. Clamp 3. Clamp the leads so that the speed sensor lead is outside. 4. Clamp the speed sensor lead, gear position switch lead and sub harness. 5.
  • Page 62 1-52 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 63 GENERAL INFORMATION 1-53 Cable, Wire, and Hose Routing (ZX1200-B3) 1. ECU Guard 2. Clamp 3. Connect the connectors of the fuel pump and fuel gauge leads. 4. To Alternator 5. Install the clamp with air cleaner cap. 6. Insert the harness into the clamps. 7.
  • Page 64 1-54 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 65 GENERAL INFORMATION 1-55 Cable, Wire, and Hose Routing (ZX1200-B3) 1. To Meter Assembly 2. Sub Harness 3. Headlight Relays 4. Band (Clamp the ignition switch lead on to the upper bracket.) 5. Clamp (Bend inside the tip of the left side clamp.) 6.
  • Page 66 1-56 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 67 GENERAL INFORMATION 1-57 Cable, Wire, and Hose Routing (ZX1200-B3) 1. Clamp the vacuum hose and fuel hose. 2. Vacuum Hose 3. Fuel Hose 4. Engine Sub Harness 5. Gear Position Switch Lead 6. Alternator Lead 7. Tube (Air Switching Valve – Canister):California Model Only 8.
  • Page 68 1-58 GENERAL INFORMATION Cable, Wire, and Hose Routing (ZX1200-B3)
  • Page 69 GENERAL INFORMATION 1-59 Cable, Wire, and Hose Routing (ZX1200-B3) 1. Air Switching Valve 2. Fan Leads 3. Run the water hose on the fan leads and fan switch lead. 4. Fan Relay (Signal) Connector 5. To Main Harness 6. Run the engine sub harness outside the lib of the head cover. 7.
  • Page 70: Unit Conversion Table

    1-60 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 micro µ...
  • Page 71 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Drive Chain Lubrication....2-28 Specifications ........Brakes..........2-28 Periodic Maintenance Procedures..Brake Hose, Connection Fuel System (DFI)......Inspection........2-28 Fuel Hose and Connection Brake Fluid Level Inspection..2-29 Inspection........
  • Page 72: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever *Odometer Reading comes ×...
  • Page 73 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever *Odometer Reading comes × 1000 km first (× 1000 mile) Refer- ence OPERATION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Engine oil - change # 6 months 2-23 •...
  • Page 74: Specifications

    2-4 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play 3 mm (0.08 0.12 in.) – – – Idle Speed 1 000 ±50 r/min (rpm) – – – Throttle Body Vacuum 26 ±1.333 kPa (195 ±10 mmHg) –...
  • Page 75: Specifications

    PERIODIC MAINTENANCE 2-5 Specifications Item Standard Service Limit Air Pressure: (when Cold) Front Up to 182 kg (401 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Rear Up to 182 kg (401 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive Drive Chain Slack...
  • Page 76: Periodic Maintenance Procedures

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 77: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Throttle Control System Inspection • Check the throttle grip free play [B]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 3 mm (0.08 0.12 in.) • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely in all steering position by the return spring.
  • Page 78: Idle Speed Inspection

    2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ In accordance with the Periodic Maintenance Chart, check the throttle bores [A] at the butterfly valves [B] and around them for carbon deposits by opening the valves. If any carbon accumulates, wipe the carbon off the throttle bores around the butterfly valves, using a lint-free cloth [C] penetrated with high-flash point solvent.
  • Page 79: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection ZX1200-B1/B2 NOTE ○ These procedures are explained on the assumption that the inlet and exhaust system of the engine are in good condition. • Remove the lower inner covers (see Frame chapter). •...
  • Page 80 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the adjusting screw [A] to synchronize the throttle valves. ○ First synchronize the left two or the right two throttle valves by means of the left and right adjusting screws. Then synchronize the left two throttle valves and the right two throttle valves using the center adjusting screw.
  • Page 81 PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] • Open and close the throttle. If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 82 2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after left and right synchronization, turn in the bypass screw [A] until it seat fully but not tightly. CAUTION Do not over tighten them. They could be damaged, requiring replacement.
  • Page 83: Air Cleaner Element Cleaning (zx1200-b1/b2)/element Replacement (zx1200-b3)

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Air Cleaner Element Cleaning (ZX1200-B1/B2)/ Element Replacement (ZX1200-B3) NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately.
  • Page 84: Evaporative Emission Control System Inspection(cal)

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures ZX1200-B1/B2 • Clean the element [A] in cleaning solvent, and then dry it with compressed air or by shaking it. • After cleaning, saturate a clean, lint-free towel with SE, SF, SG class SAE-30 oil or high-quality air filter oil, and apply the oil to the element by tapping the element outside with the towel.
  • Page 85: Cooling System

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Check the liquid/vapor separator as follows: ○ Remove: Seat (see Frame chapter) Fuel Tank Cover (see Fuel Tank Removal section in Fuel System (DFI) chapter) Supporting Rod (see Fuel Tank Removal section in Fuel System (DFI) chapter) ○...
  • Page 86 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Right Lower Inner Cover (see Frame chapter) Right Air Inlet Duct (see Fuel System (DFI) chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.
  • Page 87: Engine Top End

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (Recommended) Soft Water: Coolant: Freezing Point: – 35°C (– 31°F) Total Amount: 3.6 L (3.8 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. •...
  • Page 88: Valve Clearance Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings with Lower Inner Fairing (see Frame chapter) Crankshaft Sensor Cover (see Electrical System chap- ter) Cylinder Head Cover (see Cylinder Head Cover Re- moval section in Engine Top End chapter)
  • Page 89 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions.
  • Page 90 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 91 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 92: Clutch

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 93: Engine Lubrication System

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Support the motorcycle perpendicular to the ground after warming up the engine. • Remove the engine oil drain plug [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Change).
  • Page 94: Wheels/tires

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 95: Final Drive

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. •...
  • Page 96: Drive Chain Wear Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. • Check that the right and left notches [A] on the alignment indicators [B] point to the same marks or positions [C] on the swingarm. If they are not, adjust the chain slack and align the wheel alignment.
  • Page 97 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Rotate the rear wheel to inspect the drive chain for cracked, worn or damaged rollers [B], pins [F] and links [E, C] If there is any irregularity, replace the drive chain Drive Chain Roller Wear •...
  • Page 98: Drive Chain Lubrication

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to lighter oil because if will stay on the chain longer and provide better lubrication. •...
  • Page 99: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 100: Front Brake Pad Wear Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Change the brake fluid as follows: ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [C]. 2.
  • Page 101: Rear Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Rear Brake Pad Wear Inspection • Remove the brake pads (see Brakes chapter). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set (see Brakes chapter).
  • Page 102: Suspension

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Change ZX1200-B1/B2 • Remove the front fork (see Front Fork Removal in Sus- pension chapter). ○ Turn the spring preload adjuster [A] counterclockwise until the fully position. ○ Turn the rebound damping adjuster [C] clockwise until the fully tightened position.
  • Page 103 PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures ○ Install the holder plate [A] and lever [B] on these collars with the bolt [C]. ○ Compress the outer tube holding the front fork by using the lever [A] of the spring compressor to insert the stopper [B] into the hole [C] with the lever hole aligned with the holder hole.
  • Page 104 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Rebound Damping Adjuster Rod [D] • Drain the fork oil into a suitable container. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork. •...
  • Page 105 PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Oil Level (fully compressed, without spring) Standard: 93 ±2 mm (3.66 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge: 57001-1290 [A] ○...
  • Page 106 2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the spacer and outer tube with the fork spring com- pressor set [A] to compress it. Special Tool - Fork Spring Compressor Set: 57001-1452 • Check the O-ring [B] on the top plug and replace it with a new one if damaged.
  • Page 107 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Install the clamps [A] as shown. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D].
  • Page 108 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Screw the adjust nut [A] onto the compression shaft as shown. • Screw the locknut [B]. • Set the other side compression shaft same process. • Screw in one side nut [A] come out the piston rod nut. •...
  • Page 109 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Drain the fork oil into a suitable container. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork. • Hold the fork tube upright, press the outer tube [A] and the piston rod all the way down.
  • Page 110 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Level (fully compressed, without spring) Standard: 93 ±2 mm (3.66 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge: 57001-1290 [A] ○...
  • Page 111 PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Set the fork spring compressor on the spacer using the outer tube as a guide. Special Tool - Fork Spring Compressor: 57001-1587 NOTE ○ Set the clamps so that the cutout [A] of the upper side does not fit the hole [B] of spacer [C], pull up the outer tube [D] to hold it by the clamps, and then tighten the two bolts [E].
  • Page 112: Front Fork Oil Leak Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Screw in the top plug [A] stopped onto the piston rod. • Check the O-ring [B] on the top plug and replace it with a new one if damaged. • Holding the top plug with a wrench, tighten the piston rod nut [C] against the top plug.
  • Page 113: Unit-trak Linkage Lubrication

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Unit-trak Linkage Lubrication In order for the tie-rod and rocker arm to function safely and wear slowly, it should be lubricated in accordance with the Periodic Maintenance Chart. • For the rocker arm and tie-rod needle bearings, there are grease nipples [A] on the rocker arm and swingarm for lubrication.
  • Page 114 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001-1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the nut a fraction of a turn.
  • Page 115: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem. • Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off old grease and dirt.
  • Page 116 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends Choke Inner Cable Upper and Lower Ends Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Rear Brake Push Rod Joint Side Stand...
  • Page 117: Nut, Bolt, And Fastener Tightness

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 119 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Self-diagnosis Procedures....3-59 Specifications ........3-12 How to Read Service Codes... 3-61 Throttle Grip and Cables ....3-15 How to Erase Service Codes..3-62 Free Play Inspection ....3-15 Backups ..........
  • Page 120 3-2 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Fuel Pump Relay Removal ..3-122 Code 23) ......... 3-94 Operating Voltage Inspection..3-122 Camshaft Position Sensor Power Source Voltage Inspection 3-124 Removal/Installation....3-94 Relay Inspection ......3-125 Camshaft Position Sensor Stick Coils (#1, #2, #3, #4: Service Inspection........
  • Page 121: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View 1. Air Cleaner Elements 2. Ducts 3. Vacuum Switch Valve AO: Apply high-quality-form-air-filter oil. CAL: California Model...
  • Page 122 3-4 FUEL SYSTEM (DFI) Exploded View T1: 12 N·m (1.2 kgf·m, 106 in·lb) 8. Camshaft Position Sensor Rotor T2: 4.0 N·m (0.40 kgf·m, 35 in·lb) 9. Inlet Pressure Sensor T3: 6.0 N·m (0.60 kgf·m, 53 in·lb) 10. Crankshaft Sensor T4: 10 N·m (1.0 kgf·m, 89 in·lb) 11.
  • Page 123 FUEL SYSTEM (DFI) 3-5 Exploded View T1: 6.9 N·m (0.70 kgf·m, 61 in·lb) T2: 1.5 N·m (0.15 kgf·m, 13 in·lb) 1. Fuel Pump 2. Separator 3. Canister L: Apply a non-permanent locking agent. R: Replacement Parts S: Tighten the fasteners following the specified sequence. CAL: California Model...
  • Page 124 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 125 FUEL SYSTEM (DFI) 3-7 Exploded View 1. Air Cleaner Elements 2. Ducts 3. Air Switching Valve AO: Apply high-quality-form-air-filter oil. CAL: California Model...
  • Page 126 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 127 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Inlet Air Pressure Sensor Bolt 106 in·lb Inlet Air Temperature Sensor Bracket Nut 106 in·lb Atmospheric Pressure Sensor 106 in·lb Gear Position Switch Screws 0.40 35 in·lb Crankshaft Sensor Bolts 0.60 53 in·lb Camshaft Position Sensor Bolt...
  • Page 128 3-10 FUEL SYSTEM (DFI) Exploded View...
  • Page 129 FUEL SYSTEM (DFI) 3-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Bolts 0.70 61 in·lb Fuel Pump Bolts 0.70 61 in·lb L, S Fuel Hose Clamp Bolts 0.15 13 in·lb 4. Fuel Pump 5. Separator 6. Canister L: Apply a non-permanent locking agent.
  • Page 130: Specifications

    3-12 FUEL SYSTEM (DFI) Specifications Item Standard Throttle Grip and Cables Throttle Grip Free Play 3 mm (0.08 0.12 in.) Choke Cable Choke Cable Free Play 3 mm (0.08 0.12 in.) Digital Fuel Injection System Idle Speed 1 000 ±50 r/min (rpm) Throttle Assy: Type Four barrel type...
  • Page 131 FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Sub Throttle Valve Actuator (ZX1200-B3): Resistance about 2 4 kΩ Input Voltage about 10 14 V DC Atmospheric Pressure Sensor/Inlet Air Pressure Sensor: Input Voltage 4.75 5.25 V DC between BL/W and BR/BK lead Output Voltage 3.46 3.82 V DC at standard atmospheric pressure (see...
  • Page 132 Fork Oil Level Gauge: 57001-1290 Pilot Screw Adjuster, C: 57001-1292 Hand Tester: 57001-1394 Throttle Sensor Harness Adapter #2: 57001-1408 Fuel Pressure Gauge Adapter: 57001-1417 Needle Adapter Set: 57001-1457 Throttle Sensor Setting Adapter: 57001-1538 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 133: Free Play Inspection

    FUEL SYSTEM (DFI) 3-15 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 134: Choke Cable

    3-16 FUEL SYSTEM (DFI) Choke Cable Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free paly [B]. If the free play is incorrect, adjust the choke cable. Choke Cable Free Play Standard: 3 mm (0.08 0.12 in.)
  • Page 135: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-17 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Throttle Bore Cleaning • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Synchronization Inspection •...
  • Page 136 3-18 FUEL SYSTEM (DFI) Throttle Body Assy • Unscrew the duct bolts [A]. • Pull out the ducts [B] upward. ZX1200-B1/B2 • Remove the brackets [A] from the stoppers [B]. • Disconnect the throttle sensor connector [A]. • Pull out the vacuum hose [B] from the inlet air pressure sensor.
  • Page 137 FUEL SYSTEM (DFI) 3-19 Throttle Body Assy • Pull the throttle body assy out of the holders, and then remove it to the right side. ○ Removing the throttle body assy halfway, pull out the three vacuum hoses [A] and flatten the clamp [B] to free the throttle body from the vacuum hoses.
  • Page 138: Throttle Body Assy Installation

    3-20 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect the connector [A]. • Disconnect the injector lead connector [A]. • Pull the throttle body assy out of the holders, and then remove it to the right side. ○ Removing the throttle body assy halfway, flatten the clamp [A] to free the throttle body from the hose [B].
  • Page 139 FUEL SYSTEM (DFI) 3-21 Throttle Body Assy • Be sure the fuel hose [A] are clamped securely to prevent leaks. WARNING Fuel spilled from the fuel hoses are hazardous. • Adjust: Throttle Grip Free Play Choke Lever Free Play Idle Speed ZX1200-B3 •...
  • Page 140: Throttle Body Assy Disassembly

    3-22 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly ZX1200-B1/B2 1. Throttle Body Assy 5. Nipple Assy 2. Injector 6. Inlet Air Pressure Sensor Hose 3. Injector Connector Assy T1: 3.5 N·m (0.35 kgf·m, 31 in·lb) 4. Delivery Pipe Assy T2: 5.0 N·m (0.50 kgf·m, 44 in·lb) CAUTION Do not remove, disassemble or adjust the throttle...
  • Page 141 FUEL SYSTEM (DFI) 3-23 Throttle Body Assy • Pull out the each hose [A] from the throttle body fittings, open the clamps (2) [B] which bind the hoses, and remove the hose assy. • Remove the screws (2) [C] to pull out the injector assys (4) from the throttle body assys together with the delivery pipe [D].
  • Page 142: Throttle Body Assy Assembly

    3-24 FUEL SYSTEM (DFI) Throttle Body Assy CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • Pull out the injectors along with the delivery pipe [A]. If necessary, remove the injectors from the delivery pipe. Replace the O-rings of the indicators.
  • Page 143 FUEL SYSTEM (DFI) 3-25 Throttle Body Assy ZX1200-B3 ○ Replace the O-rings [A] with the new ones. • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. • Apply engine oil to the new O-rings of fuel pipe. •...
  • Page 144: Air Line

    3-26 FUEL SYSTEM (DFI) Air Line Element Removal • Remove: Seats (see Frame chapter) Fuel Tank Cover (see Fuel Tank Removal) Supporting Rod (see Fuel Tank Removal) • Set up the fuel tank [A] with the supporting rod [B]. CAUTION Do not insert the supporting rod into the bolt hole, or the thread of the bolt hole could be damaged.
  • Page 145: Air Inlet Duct Removal

    FUEL SYSTEM (DFI) 3-27 Air Line Air Inlet Duct Removal • Remove the lower inner cover (see Frame chapter). • Loosen the clamp screws [A]. • Slide the frame side of the duct forward first, and remove the duct [B]. Air Inlet Duct Installation •...
  • Page 146: Fuel Tank

    3-28 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 147 FUEL SYSTEM (DFI) 3-29 Fuel Tank • Pull up the front portion of the fuel tank, and then, pull out the supporting rod [A]. • Lift the front portion of the fuel tank [A] and support it with the supporting rod [B]. CAUTION Do not insert the supporting rod into the bolt hole, or the thread of the bolt hole could be damaged.
  • Page 148: Fuel Tank Installation

    3-30 FUEL SYSTEM (DFI) Fuel Tank • Remove the supporting rod, and set the fuel tank to proper position. • Remove the breather hose [A] and return hose [B]. CAUTION The fuel tank may be damaged if its bracket bolts are removed lifting the front portion of fuel tank up- ward.
  • Page 149: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-31 Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low flash point solvents to clean the tank.
  • Page 150: Dfi System

    3-32 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZX1200-B1/B2)
  • Page 151 FUEL SYSTEM (DFI) 3-33 DFI System Part Name 1. ECU (Electric Control Unit) 2. Gear Position Switch 3. Inlet Air Pressure Sensor 4. Throttle Sensor 5. Water Temperature Sensor 6. Camshaft Position Sensor 7. Crankshaft Sensor 8. Side Stand Switch 9.
  • Page 152 3-34 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Stick Coil #1 Output Signal 2. Stick Coil #2 Output Signal 3. Stick Coil #3 Output Signal 4. Injector #1 Output Signal 5. Injector #2 Output Signal 6.
  • Page 153 FUEL SYSTEM (DFI) 3-35 DFI System 35. ECU Power Source Circuit Ground to Battery 36. Crankshaft Sensor (+) Output Signal 37. Camshaft Position Sensor (+) Output Signal 38. Power Source for External Diagnosis System 39. Power Supply to ECU 40. Vehicle-down Sensor Output Signal 41.
  • Page 154 3-36 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZX1200-B3)
  • Page 155 FUEL SYSTEM (DFI) 3-37 DFI System Part Name 1. ECU (Electric Control Unit) 2. Gear Position Switch 3. Inlet Air Pressure Sensor 4. Air Switching Valve 5. Water Temperature Sensor 6. Camshaft Position Sensor 7. Crankshaft Sensor 8. Side Stand Switch 9.
  • Page 156 3-38 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors 1. Subthrottle Valve Actuator Drive Signal 2. Subthrottle Valve Actuator Drive Signal 3. Unused 4. Unused 5. Unused 6. Ignition Switch Signal 7. Main Throttle Sensor Signal 8. Inlet Air Pressure Sensor Signal 9.
  • Page 157 FUEL SYSTEM (DFI) 3-39 DFI System 36. Detect the 2nd Gear Position Signal 37. Detect the 1st Gear Position Signal 38. FI Indicator LED Light Signal 39. Tachometer Signal 40. Electric Starter Button Signal 41. Injector #4 Signal 42. Injector #3 Signal 43.
  • Page 158: Dfi Servicing Precautions

    3-40 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V battery as its power source. Do not use any other battery except for a 12 V battery as a power source.
  • Page 159 FUEL SYSTEM (DFI) 3-41 DFI Servicing Precautions ○ Install the hose clamps in the position shown, and se- curely tighten the clamp bolts to the specified torque. Check the fuel system for leaks after hose installation. Fuel Hose [A] Clamp [B] Fuel Pipe [C] Torque - Fuel Hose Clamp Bolts: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 160: Troubleshooting The Dfi System

    3-42 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 161 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector • Always check battery condition before replacing the DFI parts.
  • Page 162 3-44 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 163 FUEL SYSTEM (DFI) 3-45 Troubleshooting the DFI System • Narrow down suspicious locations by repeating the con- tinuity tests from the ECU connectors. If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages.
  • Page 164: Inquiries To Rider

    3-46 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 165 FUEL SYSTEM (DFI) 3-47 Troubleshooting the DFI System Sample Diagnosis Sheet Rider Name: Registration No. (License Plate No.): Year of Initial Registration: Model: Engine No.: Frame No.: Date Problem Occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 166 3-48 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ hesitation when acceleration. □ engine oil viscosity too high. □ brake dragging. □ engine overheating. □ clutch slipping. □ other: □ Poor Running or No choke lever pulled out fully (push it in fully). Power at High Speed □...
  • Page 167: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-49 DFI System Troubleshooting Guide DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 168 3-50 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) When flooded, don’t crank engine with throttle Starting technique faulty fully opened. No spark or spark weak: Ignition and engine stop switches not ON Turn both switches ON. Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
  • Page 169: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-51 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
  • Page 170 3-52 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 171 FUEL SYSTEM (DFI) 3-53 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 172 3-54 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Clean spark plugs and adjust plug gap (see Spark plug dirty, broken or gap maladjusted chapter 2). Too low fuel pressure Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3).
  • Page 173: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-55 DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter) Firing incorrect: Clean spark plug and adjust plug gap (see chapter Spark plug dirty, broken or maladjusted Spark plug cap trouble Inspect stick coil (see chapter 16).
  • Page 174 3-56 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 175 FUEL SYSTEM (DFI) 3-57 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 176: Self-diagnosis

    3-58 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis indicate terminal [A]. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI sys- tem and ignition system parts a faulty, and initiates fail-safe function.
  • Page 177: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-59 Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the DFI indicator LED light [A] goes on. NOTE ○ Use a fully charged battery when conducting self-diagnosis. Otherwise, the LED light blinks very slowly or doesn’t blink.
  • Page 178 3-60 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 179: How To Read Service Codes

    FUEL SYSTEM (DFI) 3-61 Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long or short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 180: How To Erase Service Codes

    3-62 FUEL SYSTEM (DFI) Self-Diagnosis How to Erase Service Codes ○ Even if the ignition SW is turned OFF, or the problem is solved, all service codes remain in the ECU. If the battery or the ECU are disconnected, all service codes will disappear in the ECU. Service Code Table Service FI Indicator LED Light...
  • Page 181 FUEL SYSTEM (DFI) 3-63 Self-Diagnosis Service FI Indicator LED Light Problems (1) Code Fuel pump relay wiring open Fuel pump relay stuck ON Ignition coil #1 malfunction, wiring open or short Ignition coil #2 malfunction, wiring open or short Ignition coil #3 malfunction, wiring open or short Ignition coil #4 malfunction, wiring open or short Subthrottle valve actuator malfunction, wiring open or short...
  • Page 182: Backups

    3-64 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal Throttle ZX1200-B1/B2: is out of the usable range, wiring short or...
  • Page 183 FUEL SYSTEM (DFI) 3-65 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the subthrottle sensor system fails (the Subthrottle Sensor Output Subthrottle signal is out of the usable range, wiring Voltage Sensor short or open), the actuator locks subthrottle 0.15 4.85 V valve at full open position.
  • Page 184 3-66 FUEL SYSTEM (DFI) Self-Diagnosis Note: (1) α – N Method: the DFI control method from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output voltage).
  • Page 185: Throttle Sensor (service Code 11) (zx1200-b1/b2)

    FUEL SYSTEM (DFI) 3-67 Throttle Sensor (Service Code 11) (ZX1200-B1/B2) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 186: Output Voltage Inspection

    3-68 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) (ZX1200-B1/B2) • Disconnect the throttle sensor connector and connect the harness adapter between the sub harness connector and throttle sensor connector. • Connect a digital meter [A] to the harness adapter leads [B].
  • Page 187 FUEL SYSTEM (DFI) 3-69 Throttle Sensor (Service Code 11) (ZX1200-B1/B2) NOTE ○ The throttle sensor is operating correctly if the following voltages are obtained: • 1.07 VDC (or slightly higher) with the throttle at the idle position. • 4.61 VDC (or slightly lower) with the throttle at the fully open position.
  • Page 188: Resistance Inspection

    3-70 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) (ZX1200-B1/B2) NOTE ○ The throttle sensor is operating correctly if the following voltages are obtained: • 1.07 VDC (or slightly higher) with the throttle at the idle position. • 4.61 VDC (or slightly lower) with the throttle at the fully open position.
  • Page 189 FUEL SYSTEM (DFI) 3-71 Throttle Sensor (Service Code 11) (ZX1200-B1/B2) →: Signal ECU [1] Throttle Sensor [4]...
  • Page 190: Main Throttle Sensor (service Code 11) (zx1200-b3)

    3-72 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (ZX1200-B3) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 191: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Main Throttle Sensor (Service Code 11) (ZX1200-B3) Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor connector (gray) [A] and connect the harness adapter [B] between these con- nectors.
  • Page 192: Resistance Inspection

    3-74 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (ZX1200-B3) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance.
  • Page 193: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-75 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal ZX1200-B1/B2 • Remove the left lower inner cover (see Frame chapter). •...
  • Page 194: Installation

    3-76 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Installation CAUTION Do not connect the throttle sensor connector to the inlet air pressure sensor, because the pressure sen- sor is broken by the opposite electrical connection. NOTE ○ The inlet air pressure sensor is the same part as the at- mospheric sensor except that the sensor has a vacuum hose and different wiring.
  • Page 195: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. • Disconnect the inlet air pressure sensor connector and connect the harness adapter between the sub harness connector and inlet air pressure sensor connector.
  • Page 196 3-78 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector (when the lead is open, the output voltage is about 1.8 V). •...
  • Page 197 FUEL SYSTEM (DFI) 3-79 Inlet Air Pressure Sensor (Service Code 12) ZX1200-B3 →: Signal ECU [1] Inlet Air Pressure Sensor [3] If you need to check the inlet air pressure sensor for vac- uum other than 76 cmHg (abs), check the output voltage as follows: •...
  • Page 198 3-80 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.0 V (digital volt meter reading) then Pv = 70 –...
  • Page 199: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-81 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank cover (see Fuel Tank Removal). •...
  • Page 200: Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...
  • Page 201 FUEL SYSTEM (DFI) 3-83 Inlet Air Temperature Sensor (Service Code 13) ZX1200-B1/B2 →: Signal ECU [1] Inlet Air Temperature Sensor [37] ZX1200-B3 →: Signal ECU [1] Inlet Air Temperature Sensor [29]...
  • Page 202: Water Temperature Sensor (service Code 14)

    Such a shock to the sensor can damage it. • Disconnect the sensor connector [A], and unscrew the water temperature sensor [B]. Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
  • Page 203 If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors ZX1200-B1/B2 →: Signal ECU [1]...
  • Page 204: Sensor Resistance Inspection

    3-86 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) ZX1200-B3 →: Signal ECU [1] Water Temperature Sensor [5] Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper- ature sensor inspection.
  • Page 205: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-87 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch off. • Remove: Seat Cover (see Frame chapter) Bolts [A] •...
  • Page 206: Output Voltage Inspection

    3-88 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the reading of input voltage is less than the standard range, check the ECU for its ground, and power supply (see this chapter). If the ground and power supply are good, replace the ECU.
  • Page 207 FUEL SYSTEM (DFI) 3-89 Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure Sensor Output Voltage Connections to ECU ZX1200-B1/B2: Meter (+) → G/W lead (terminal 45) Meter (–) → BR/BK lead (terminal 54) ZX1200-B3: Meter (+) → G/W lead (terminal 25) Meter (–) →...
  • Page 208 3-90 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) ZX1200-B1/B2 →: Signal ECU [1] Atmospheric Pressure Sensor [38] ZX1200-B3 →: Signal ECU [1] Atmospheric Pressure Sensor [14] If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○...
  • Page 209 FUEL SYSTEM (DFI) 3-91 Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section in this chapter). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output...
  • Page 210: Crankshaft Sensor (service Code 21)

    3-92 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 211 FUEL SYSTEM (DFI) 3-93 Crankshaft Sensor (Service Code 21) ZX1200-B3 ECU [1] Crankshaft Sensor [7]...
  • Page 212: Camshaft Position Sensor (service Code 23)

    3-94 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the camshaft position sensor.
  • Page 213 FUEL SYSTEM (DFI) 3-95 Camshaft Position Sensor (Service Code 23) ZX1200-B3 ECU [1] Camshaft Position Sensor [6]...
  • Page 214: Speed Sensor (service Code 24)

    3-96 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Electrical System. Speed Sensor Inspection • See the Electrical System chapter as to the Speed Sen- sor. Torque - Speed Sensor Bolt: 10 N·m (1.0 kgf·m, 89 in·lb) NOTE ○...
  • Page 215 FUEL SYSTEM (DFI) 3-97 Speed Sensor (Service Code 24) ZX1200-B1/B2 ECU [1] Meter Assembly [39] Speed Sensor [40] ZX1200-B3 ECU [1] Meter Assembly [15] Speed Sensor [16]...
  • Page 216: Gear Position Switch (service Code 25)

    3-98 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) The gear position switch detects the gear position of the neutral and running, and sends the signal to the ECU. The signal is used to determine the basic amount of the fuel injected.
  • Page 217: Gear Position Switch Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Gear Position Switch (Service Code 25) Gear Position Switch Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ECU (see this chapter). Do not disconnect the ECU connectors.
  • Page 218: Gear Position Switch Inspection

    3-100 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) If the reading is within the standard range, set up the fuel tank, and check the input voltage again at the sensor con- nector. • Connect a digital voltmeter [H] to the connector [I], with the needle adapter set.
  • Page 219 FUEL SYSTEM (DFI) 3-101 Gear Position Switch (Service Code 25) • Check the switch for continuity at the following gear posi- tions. Gear Position Tester (+) Tester (–) Neutral Light Green Lead [A] Blue/Red Lead [B] Light Blue Lead [C] Engine Ground Red Lead [D] Blue Lead [E]...
  • Page 220 3-102 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) ZX1200-B3 →: Signal Gear Position Switch [2] ECU [1]...
  • Page 221: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-103 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 222: Installation

    3-104 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Installation The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations, like leaning over in a turn, with the potential for an accident resulting in injury or death.
  • Page 223 FUEL SYSTEM (DFI) 3-105 Vehicle-down Sensor (Service Code 31) • Connect a digital volt meter [C] to the connector [B] (nat- ural, 3P) of the vehicle-down sensor [A], with the needle adapter set [D]. • Turn the ignition switch ON, and measure the power source voltage with the connector joined.
  • Page 224 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 225 FUEL SYSTEM (DFI) 3-107 Vehicle-down Sensor (Service Code 31) ZX1200-B3 →: Signal ECU Main Relay [25] Starter Relay [30] ECU [1] ECU Main Fuse 15 A [27] Main Fuse 30 A [31] Ignition Switch [17] Vehicle-down Sensor [28] Battery [33]...
  • Page 226: Subthrottle Sensor (service Code 32) (zx1200-b3)

    3-108 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (ZX1200-B3) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 227: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-109 Subthrottle Sensor (Service Code 32) (ZX1200-B3) Output Voltage Inspection • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing. • Disconnect the subthrottle sensor connector (black) [A] and connect the harness adapter [B] between these con- nectors.
  • Page 228: Resistance Inspection

    3-110 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (ZX1200-B3) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL/W lead [C] ←→...
  • Page 229: Immobilizer Amplifier (service Code 35) (zx1200-b3)

    FUEL SYSTEM (DFI) 3-111 Immobilizer Amplifier (Service Code 35) (ZX1200-B3) Antenna Resistance Inspection • Remove: Left Lower Inner Cover (see Frame chapter) • Disconnect: Antenna Lead Connector [A] • Measure the resistance of the antenna coil in the ignition switch as follows. Antenna Resistance Connections to Antenna Meter →...
  • Page 230: Blank Key Detection (service Code 36) (zx1200-b3)

    10. Starter Relay 3. Ignition Switch 11. Main Fuse 30 A 4. Meter Unit 12. Battery 5. FI Indicator Light (LED) 13. Immobilizer/Kawasaki Diagnostic 6. Ignition Fuse 10 A System Connector 7. ECU Fuse 15 A 14. ECU 8. Junction Box...
  • Page 231: Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44)

    FUEL SYSTEM (DFI) 3-113 Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) Fuel Injector #1: (Service Code 41) Fuel Injector #2: (Service Code 42) Fuel Injector #3: (Service Code 43) Fuel Injector #4: (Service Code 44) CAUTION Never drop the injector, especially on a hard sur- face.
  • Page 232 3-114 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) If the reading is normal, check the power source voltage at the injector connector [B], with a digital volt meter [A]. • Measure the power source voltage with the engine stopped, and the connector joined, with a digital meter and needle adapter set [C].
  • Page 233: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-115 Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) Output Voltage Inspection • Measure the output voltage at the ECU connector in the same way as power source voltage inspection. Note the following. Injector Output Voltage at ECU ZX1200-B1/B2: Connections for Injector #1...
  • Page 234: Audible Inspection

    3-116 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) If the output voltage is out of the standard, remove the left lower inner cover, and check the output voltage at the injector connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V).
  • Page 235: Injector Signal Test

    FUEL SYSTEM (DFI) 3-117 Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION...
  • Page 236: Injector Resistance Inspection

    3-118 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) Injector Resistance Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Disconnect the connector [B] from the injector (see Throt- tle Body Disassembly/Assembly).
  • Page 237: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-119 Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) Injector Fuel Line Inspection • Remove the throttle body assy (see this chapter). • Check the injector [A] fuel line for leakage as follows: ○...
  • Page 238 3-120 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) ZX1200-B1/B2 →: Signal Ignition Switch [17] ECU Fuse 15 A [27] ECU [1] Engine Stop Switch [19] Starter Motor [29] Fuel Injector #4 [9] Junction Box [22] Starter Relay [30] Fuel Injector #3 [10]...
  • Page 239 FUEL SYSTEM (DFI) 3-121 Fuel Injectors (#1, #2, #3, #4: Service Code 41, 42, 43, 44) ZX1200-B3 →: Signal Junction Box [22] Starter Relay [30] ECU [1] Ignition Fuse 10 A [23] Main Fuse 30 A [31] Fuel Injector #1, #2, #3, #4 [9] ECU Main Relay [25] Battery [33] Ignition Switch [17]...
  • Page 240: Fuel Pump Relay (service Code 45, 46)

    3-122 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 45, 46) Service code 45 is short or open to the fuel pump relay system. Service code 46 is stuck ON to the fuel pump relay sys- tem. Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface.
  • Page 241 FUEL SYSTEM (DFI) 3-123 Fuel Pump Relay (Service Code 45, 46) If the reading stays on 12.5 V or more, check the following. [1] Vehicle-down Sensor (see this chapter) [2] Emergency Engine Stop Voltage (ZX1200-B1/B2: Terminal 23 ←→ Ground) (ZX1200-B3: Terminal 53 ←→ Ground) [3] ECU for its Ground, and Power Supply If the reading stays on 0 V, and never shows, battery volt- age (12.5 V), check the ECU for its ground and power...
  • Page 242: Power Source Voltage Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 45, 46) Power Source Voltage Inspection NOTE ○ Confirm that the operation voltage is normal before in- specting the power source voltage. ○ Be sure the battery is fully charged. • Connect the hand tester (×...
  • Page 243: Relay Inspection

    FUEL SYSTEM (DFI) 3-125 Fuel Pump Relay (Service Code 45, 46) If the reading is good, the power source voltage is normal. Check the fuel pump relay and wiring continuity. If there is no battery voltage, check the following: ECU Fuse 15 A (see this chapter) ECU Main Relay (see this chapter) Wiring for Fuel Pump Relay Power Source Voltage Sys- Relay Inspection...
  • Page 244 3-126 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 45, 46) ZX1200-B3 →: Signal Junction Box [22] ECU Fuse 15 A [27] ECU [1] Ignition Fuse 10 A [23] Starter Relay [30] Ignition Switch [17] ECU Main Relay [25] Main Fuse 30 A [31] Engine Stop Switch [19] Fuel Pump Relay [26] Battery [33]...
  • Page 245: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-127 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 246 3-128 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) • Turn the ignition switch OFF. • Remove the ECU (see this chapter). Do not disconnect the ECU connector. • Connect a digital voltmeter [A] as shown, with the needle adapter set [B].
  • Page 247 FUEL SYSTEM (DFI) 3-129 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) If the reading is out of the standard, check the wiring (see next wiring diagram). If the reading is good, the input voltage is normal. Crank the engine, and check the peak voltage of the stick coils (see Electrical System chapter) in order to check the pri- mary coils.
  • Page 248 3-130 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) ZX1200-B3 →: Signal Engine Stop Switch [19] Starter Relay [30] ECU [1] Junction Box [22] Main Fuse 30 A [31] Stick Coil #1, #2, #3, #4, [13] Ignition Fuse 10 A [23] Battery [33] Ignition Switch [17]...
  • Page 249: Subthrottle Valve Actuator (service Code 62) (zx1200-b3)

    FUEL SYSTEM (DFI) 3-131 Subthrottle Valve Actuator (Service Code 62) (ZX1200-B3) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 250: Input Voltage Inspection

    3-132 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) (ZX1200-B3) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 251: Ecu

    FUEL SYSTEM (DFI) 3-133 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Rear Seat with Cover (see Frame chapter) Storage Box (see Frame chapter) • Pull the ECU [A] out.
  • Page 252 3-134 FUEL SYSTEM (DFI) • With the ECU connectors [A] connected, check the fol- lowing ground lead for continuity with the ignition switch OFF, using the hand tester and needle adapter set. ECU Grounding Inspection ZX1200-B1/B2: 18, 26, 27, or 35 (BK/Y) Terminal ←→ Battery (–) Terminal: 0 Ω...
  • Page 253 FUEL SYSTEM (DFI) 3-135 • Check the ECU power source voltage with the hand tester. ○ Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure. ECU Power Source Inspection ZX1200-B1/B2: Tester Connections: between 17 (W/Y) Terminal and Battery (–) Terminal between 48 (W) Terminal and Battery (–) Terminal...
  • Page 254 3-136 FUEL SYSTEM (DFI) ECU Power Source Circuit ZX1200-B1/B2 →: Current ECU Main Fuse 15 A [27] ECU [1] Starter Relay [30] Ignition Switch [17] Main Fuse 30 A [31] ECU Main Relay [25] Battery [33] ZX1200-B3 →: Current ECU Main Fuse 15 A [27] ECU [1] Starter Relay [30] Ignition Switch [17]...
  • Page 255: Dfi Power Source

    FUEL SYSTEM (DFI) 3-137 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 256: Fi Indicator Led Light

    3-138 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 257: Led Light Inspection

    FUEL SYSTEM (DFI) 3-139 FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection:...
  • Page 258 3-140 FUEL SYSTEM (DFI) FI Indicator LED Light ZX1200-B3 →: Signal Ignition Fuse 10 A [23] ECU [1] Starter Relay [30] Ignition Switch [17] Main Fuse 30 A [31] FI Indicator LED Light [21] Battery [33] Junction Box [22]...
  • Page 259: Fuel Line

    FUEL SYSTEM (DFI) 3-141 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank Cover (see Fuel Tank Removal) • Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assy.
  • Page 260: Fuel Flow Rate Inspection

    3-142 FUEL SYSTEM (DFI) Fuel Line If the fuel pressure is much higher than the specified, check the following: Fuel Return Hose for Sharp Bend, Kinking, or Clogging If the fuel pressure is much lower than specified, check the following: Fuel Line Leakage Amount of Fuel Flow (see Fuel Flow Rate Inspection) If the fuel pressure is much lower than specified, and if...
  • Page 261 FUEL SYSTEM (DFI) 3-143 Fuel Line • Prepare a measuring cylinder [A]. • Disconnect the fuel supply hose [B] from the fuel outlet pipe [C], and plug the outlet pipe with the rubber plug quickly. • Connect the fuel pressure gauge adapter [D], and the measuring cylinder as shown.
  • Page 262: In-tank Fuel Pump

    3-144 FUEL SYSTEM (DFI) In-tank Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
  • Page 263: Pump Screen Cleaning

    FUEL SYSTEM (DFI) 3-145 In-tank Fuel Pump Pump Screen Cleaning WARNING Clean the pump screw in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area. Because of the dan- ger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the pump screen.
  • Page 264: Operation Inspection

    3-146 FUEL SYSTEM (DFI) In-tank Fuel Pump • Secure the fuel level sensor connector [A], and fuel pump connector [B] on the bracket. • Install the fuel tank (see this chapter). Operation Inspection NOTE ○ Be sure the battery is fully charged. •...
  • Page 265 FUEL SYSTEM (DFI) 3-147 In-tank Fuel Pump ZX1200-B1/B2 →: Current Fuel Pump Relay [26] ECU [1] ECU Main Fuse 15 A [27] Ignition Switch [17] Starter Motor [29] Engine Stop Switch [19] Starter Relay [30] Junction Box [22] Main Fuse 30 A [31] Ignition Fuse 10 A [23] Battery [33] ECU Main Relay [25]...
  • Page 266 3-148 FUEL SYSTEM (DFI) In-tank Fuel Pump ZX1200-B3 →: Current Fuel Pump Relay [26] ECU [1] ECU Main Fuse 15 A [27] Ignition Switch [17] Starter Relay [30] Engine Stop Switch [19] Main Fuse 30 A [31] Junction Box [22] Battery [33] Ignition Fuse 10 A [23] Fuel Pump [34]...
  • Page 267: Evaporative Emission Control System

    FUEL SYSTEM (DFI) 3-149 Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 268: Separator Operation Test

    3-150 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 269 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Water Pump..........................Water Pump Removal ....................... Water Pump Installation ....................
  • Page 270: Exploded View

    4-2 COOLING SYSTEM Exploded View 1. Radiator Fan Switch T4: 25 N·m (2.5 kgf·m, 18 ft·lb) 2. Water Temperature Sensor T5: 10 N·m (1.0 kgf·m, 89 in·lb) 3. Coolant By-pass Fitting (ZX1200-B1/B2) T6: 8.0 N·m (0.80 kgf·m, 71 in·lb) 4. Drain Plug EO: Apply engine oil.
  • Page 271: Specifications

    1.25 kgf/cm², 14 18 psi) Thermostat Valve Opening Temperature 62°C (136 144°F) Valve Full Opening Lift 8 mm (0.31 in.) or more @75°C (167°F) Special Tools - Bearing Driver: 57001-382 Bearing Driver Set: 57001-1129 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 272: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 273 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 7. Radiator Fan Switch 2. Water Pump 8. Reservoir Tank 3. Thermostat 9. Radiator Cap 4. Water Temperature Sensor 10. Oil Filter 5. Radiator Fan 11. Oil Cooler 6. Radiator...
  • Page 274: Coolant

    4-6 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak.
  • Page 275: Pressure Testing

    COOLING SYSTEM 4-7 Coolant Pressure Testing • Remove: Right Lower Inner Cover (see Frame chapter) Right Air Inlet Duct (see Fuel System (DFI) chapter) • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck. NOTE ○...
  • Page 276: Water Pump

    4-8 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Lower Fairing (see Frame chapter) Cooling Pipe Bolt [A] Cooling Hose with Pipe [B] • Loosen the hose clamp [C] and pull out the cooling hose [D].
  • Page 277: Water Pump Installation

    COOLING SYSTEM 4-9 Water Pump Water Pump Installation • Check to see that the knock pins [A]. • Water pump housing [B] are in place to apply engine oil at O-ring. • Apply molybdenum disulfide oil solution to the water (oil) pump shaft [C] to the journal portion (about 10 mm (0.4 in.) [D]) of the water pump housing.
  • Page 278: Water Pump Impeller Inspection

    4-10 COOLING SYSTEM Water Pump Water Pump Impeller Inspection • Visually inspect the impeller [A]. If the surface is corroded, or if the blades [B] are dam- aged, replace the impeller. Water Pump Housing Disassembly CAUTION Do not damage the hole wall of the water pump housing.
  • Page 279: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Inspection • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit. Impeller Sealing Seat Surface [A] Rubber Seal [B] Mechanical Seal [C]...
  • Page 280: Radiator, Radiator Fan

    4-12 COOLING SYSTEM Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 281: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator, Radiator Fan • Remove: Reserve Tank Hose [A] Bypass Hose [B] Radiator Cooling Hose Clamp Bolt (loosen) [C] Radiator Cooling Hose [D] Rivet Screw [E] Radiator Mounting Bolts with Clamps Radiator [F] • Remove: Radiator Fan Mounting Bolts [A] Radiator Fans [B] CAUTION Do not touch the radiator core.
  • Page 282: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator, Radiator Fan CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular to the core sur- face.
  • Page 283: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain: Coolant (Cylinder) (see Coolant Change in the Periodic Maintenance chapter) • Remove: Lower Fairings (see Frame chapter) Fuel Hose (see Fuel System (DFI) chapter) Water Temperature Sensor Connector Cooling Hoses Starter Motor Cable Fitting Bolts [A] Cooling Hose Fitting [B] •...
  • Page 284 4-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water.
  • Page 285: Hose And Pipes

    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 286: Radiator Fan Switch, Water Temperature Sensor

    • Apply silicone sealant to the threads of the water temper- ature sensor. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the fan switch and water temperature sensor. Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb) Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18...
  • Page 287 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head........5-18 Specifications ........Cylinder Compression Clean Air System....... Measurement ......5-18 Air Suction Valve Removal... Cylinder Head Removal ....5-19 Air Suction Valve Installation..Cylinder Head Installation .... 5-20 Air Suction Valve Check....
  • Page 288: Exploded View

    5-2 ENGINE TOP END Exploded View ZX1200-B1/B2 1. Closed coil end faces downward. EO: Apply engine oil. T1: 13 N·m (1.3 kgf·m, 115 in·lb) G: Apply grease. T2: 34 N·m (3.5 kgf·m, 25 ft·lb) L: Apply a non-permanent locking agent. T3: 12 N·m (1.2 kgf·m, 106 in·lb) M: Apply molybdenum disulfide grease.
  • Page 289 ENGINE TOP END 5-3 Exploded View ZX1200-B3 1. Closed coil end faces downward. EO: Apply engine oil. T1: 13 N·m (1.3 kgf·m, 115 in·lb) G: Apply grease. T2: 34 N·m (3.5 kgf·m, 25 ft·lb) L: Apply a non-permanent locking agent. T3: 12 N·m (1.2 kgf·m, 106 in·lb) M: Apply molybdenum disulfide grease.
  • Page 290 5-4 ENGINE TOP END Exploded View 1. Muffler Cover (ZX1200-B1/B2) T4: 15 N·m (1.5 kgf·m, 11 ft·lb) 2. R marked side face up. EO: Apply engine oil. 3. RN marked side face up. G: Apply grease. 4. A marking hollow facing forward. L: Apply a non-permanent locking agent.
  • Page 291: Specifications

    ENGINE TOP END 5-5 Specifications Item Standard Service Limit Clean Air System (ZX1200-B1/B2) Vacuum Switch Valve Closing Pressure Open → Close 49 kPa (310 370 mmHg) – – – Camshafts Cam Height: Exhaust 36.643 36.757 mm 36.54 mm (1.4426 1.4471 in.) (1.439 in.) Inlet 37.043...
  • Page 292 5-6 ENGINE TOP END Specifications Item Standard Service Limit Valve Guide Inside Diameter: Exhaust 5.000 5.012 mm 5.07 mm (0.1969 0.1973 in.) (0.200 in.) Inlet 5.000 5.012 mm 5.07 mm (0.1969 0.1973 in.) (0.200 in.) Valve/valve Guide Clearance (wobble method): Exhaust 0.09 0.17 mm...
  • Page 293 Valve Seat Cutter Holder, 5.0: 57001-1208 Valve Seat Cutter, 55° - 35: 57001-1247 Fork Oil Level Gauge: 57001-1290 Piston Ring Compressor Belt, 80 91: 57001-1320 Compression Gauge Adapter, M10 × 1.0: 57001-1458 Piston Base, 1.0: 57001-1459 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 294: Clean Air System

    5-8 ENGINE TOP END Clean Air System Air Suction Valve Removal ZX1200-B1/B2 • Remove: Lower Inner Covers (see Frame chapter) Vacuum Switch Valve Hoses Throttle Cable and Choke Cable Lower Ends (for Right Side Air Suction Valve Removal) (see Fuel System (DFI) chapter) Air Suction Valve Cover Bolts [A] Clamp [B]...
  • Page 295: Vacuum Switch Valve Removal (zx1200-b1/b2)

    ENGINE TOP END 5-9 Clean Air System Vacuum Switch Valve Removal (ZX1200-B1/B2) • Remove: Lower Inner Covers (see Frame chapter) • Pull off the switch valve hoses [A] and vacuum hose [B], and remove the vacuum switch valve [C]. Vacuum Switch Valve Installation (ZX1200-B1/B2) •...
  • Page 296: Air Switching Valve Removal (zx1200-b3)

    5-10 ENGINE TOP END Clean Air System Air Switching Valve Removal (ZX1200-B3) • Remove: Lower Inner Covers (see Frame chapter) Connector [A] Air Switching Valve [B] Air Switching Valve Installation (ZX1200-B3) • Install the air switching valve so that the air duct [A] faces right side.
  • Page 297: Cylinder Head Cover

    ENGINE TOP END 5-11 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Lower Fairings with Lower Inner Fairing (see Frame chapter) Lower Inner Covers (see Frame chapter) Choke Cable Lower End (see Fuel System (DFI) chap- ter) Throttle Cable Lower Ends (see Fuel System (DFI) chap- ter) Camshaft Position Sensor Connector Switch Housing Harness Connectors...
  • Page 298 Replace the head cover gasket with a new one if dam- aged. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the washer with the metal side [A] faces upward. •...
  • Page 299: Camshaft Chain Tensioner

    ENGINE TOP END 5-13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 300: Camshaft, Camshaft Chain

    5-14 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Lower Fairings with Lower Inner Fairing (see Frame chapter) Lower Inner Covers (see Frame chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Electrical System chap- ter) •...
  • Page 301 ENGINE TOP END 5-15 Camshaft, Camshaft Chain If the camshaft position sensor rotor is removed, install it as follows. ○ Insert the pin [A] into the holes [B] in the camshaft and boss [C]. ○ Fit the projection [A] of the rotor on the camshaft recess [B].
  • Page 302: Camshaft, Camshaft Cap Wear

    5-16 ENGINE TOP END Camshaft, Camshaft Chain • Install the camshaft cap [A] and upper camshaft chain guide [B]. While pushing the camshaft chain, tighten all camshaft bolts and chain guide bolts. ○ Install the longer bolts to the #10 and #14 position shown by triangle marks.
  • Page 303: Camshaft Runout

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.
  • Page 304: Cylinder Head

    5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Lower Inner Covers (see Frame chapter) Baffle Plate (see Cylinder Head Cover Removal) Stick Coils (see Electrical System chapter) Spark Plugs (see Electrical System chapter) •...
  • Page 305: Cylinder Head Removal

    ENGINE TOP END 5-19 Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Radiator (see Cooling System chapter) Muffler (see Muffler Removal) Clutch Cable Lower End (see Clutch chapter) Engine Mounting Bolts [C] Engine Bracket Bolts [A] Engine Brackets [B] Throttle Body Assy (see Fuel System (DFI) chapter)
  • Page 306: Cylinder Head Installation

    5-20 ENGINE TOP END Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Make sure that the O-ring [A] of the oil pipe is not damage, and apply high-temperature grease to it.
  • Page 307: Cylinder Head Warp

    ENGINE TOP END 5-21 Cylinder Head Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Measure the space between the straightedge [B] and the head with a thickness gauge [A]. Cylinder Head Warp Standard: –...
  • Page 308: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Check • Refer to the Valve Clearance Inspection and Adjustment in the Periodic Maintenance chapter (2nd chapter). Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○...
  • Page 309: Valve Guide Installation

    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 150°C (248 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 310: Valve Seat Inspection

    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 311 ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 312 5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 313 ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...
  • Page 314 5-28 ENGINE TOP END Valves...
  • Page 315: Cylinder, Pistons

    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Cooling Hoses [A] Oil Pipe [B] • Remove the cylinder [C]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston rings. ○...
  • Page 316: Piston Removal

    5-30 ENGINE TOP END Cylinder, Pistons With the Special Tools • Install the two cylinder head bolts [A] diagonally in the crankcase. • Slip the piston bases [B] under the pistons to hold them level. • Compress the piston rings using the piston ring compres- sor grips [C] and piston ring compressor belts [D] with chamfered side upward.
  • Page 317: Piston Installation

    ENGINE TOP END 5-31 Cylinder, Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.
  • Page 318: Cylinder Wear

    5-32 ENGINE TOP END Cylinder, Pistons Cylinder Wear • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the two locations (total of four measure- ments) shown in the figure. If any of the cylinder inside diameter measurements ex- ceeds the service limit, replace the cylinder.
  • Page 319: Piston Ring Thickness

    ENGINE TOP END 5-33 Cylinder, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top [A] 0.87 0.89 mm (0.0343 0.0350 in.) Second [B] 0.97 0.99 mm (0.0382 0.0390 in.)
  • Page 320: Throttle Body Holder

    5-34 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Install the throttle body holders with the holes [A] upward. ○ Check to make sure that the O-ring is not damage, and apply high-temperature grease to it. • Install the clamps [B] as shown.
  • Page 321: Muffler

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • Remove: Lower Fairings with Lower Inner Fairing (see Frame chapter) Lower Inner Covers (see Frame chapter) Air Inlet Ducts (see Fuel System (DFI) chapter)
  • Page 322: Muffler Body Installation

    5-36 ENGINE TOP END Muffler Muffler Body Installation • Replace the exhaust pipe connection gasket [A] with a new one. • Insert the muffler body to the exhaust pipe end. • Tighten: Torque - Muffler Body Connection Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 323 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Clutch Lever and Cable ......................Lever Free Play Inspection ....................Lever Free Play Adjustment....................Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................Clutch Cover........................... Clutch Cover Removal ...................... Clutch Cover Installation ....................
  • Page 324: Exploded View

    6-2 CLUTCH Exploded View T1: 15 N·m (1.5 kgf·m, 11 ft·lb) T2: 7.0 N·m (0.70 kgf·m, 62 in·lb) T3: 8.8 N·m (0.90 kgf·m, 78 in·lb) T4: 135 N·m (14 kgf·m, 100 ft·lb) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb) CL: Apply cable lubricant. EO: Apply engine oil.
  • Page 325: Specifications

    Clutch Plate Assembly Length 56.8 57.6 mm (2.24 2.27 in.) – – – Clutch Spring Free Length 73.49 mm (2.893 in.) 68.5 mm (2.70 in.) Special Tools - Clutch Holder: 57001-1243 Clutch Gear Setting: 57001-1455 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 326: Clutch Lever And Cable

    6-4 CLUTCH Clutch Lever and Cable Lever Free Play Inspection • Refer to the Clutch Adjust Inspection in the Periodic Main- tenance chapter. Lever Free Play Adjustment • Refer to the Clutch Adjust Inspection in the Periodic Main- tenance chapter. Cable Removal •...
  • Page 327: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. • Be sure to install the pins [B]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 328: Release Shaft Removal

    6-6 CLUTCH Clutch Cover • Replace the cover gasket with a new one. • Apply a non-permanent locking agent to the two cover bolts [A] only. • Tighten the cover bolts. Torque - Clutch Cover Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) Release Shaft Removal •...
  • Page 329: Clutch Cover Assembly

    CLUTCH 6-7 Clutch Cover • Remove: Oil Seal [A] Needle Bearings [B] Clutch Cover Assembly • Replace the needle bearings and oil seal with new one. NOTE ○ Install the needle bearings so that the manufacturer’s mark face out. • Install the needle bearings [A] and oil seal [B] position as shown.
  • Page 330: Clutch Removal

    6-8 CLUTCH Clutch Clutch Removal • Remove: Right Lower Fairing (see Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing, pusher [C] and washer) • Remove: Friction Plates [A] Steel Plates Springs Spring Seats...
  • Page 331: Clutch Installation

    CLUTCH 6-9 Clutch Clutch Installation • Install the thrust washer [A] by facing its chamfered side [B] towards the crankcase. • Install the oil pump drive gear [A] on the clutch housing. • Align the teeth of the clutch housing gears by the gear setting [A].
  • Page 332 6-10 CLUTCH Clutch • Install the spring seats [D] [F], springs [E], friction plates [A] [C] [H] and steel plates [B] as shown. NOTE ○ The inside diameter of first and seventh friction plates are larger than the others because the spring seats and springs are equipped to decrease the judder noise as shown.
  • Page 333: Clutch Plate Assembly Inspection

    CLUTCH 6-11 Clutch • Align the mark [A] of the spring plate [B] to one of the grooves [C] of the clutch hub [D] to install the spring plate on the clutch hub. • Install the spring, and tighten the clutch spring bolts evenly.
  • Page 334: Clutch Plate, Wear, Damage Inspection

    6-12 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of the friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 335 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Cooler..........................Oil Cooler Removal......................Oil Cooler Installation......................Oil Pan............................
  • Page 336: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) or Hand EO: Apply engine oil. -Tight G: Apply grease. T2: 25 N·m (2.5 kgf·m, 18 ft·lb) L: Apply a non-permanent locking agent. T3: 10 N·m (1.0 kgf·m, 89 in·lb) MO: Apply molybdenum disulfide oil solution.
  • Page 337: Engine Oil Flow Chart

    ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart 1. Camshaft Oil Passage 13. Drive Shaft Oil Passage Hole 2. Oil Pipe 14. Output Shaft Oil Passage Hole 3. Main Oil Passage 15. Inlet Camshaft 4. Crankshaft Oil Passage 16. Exhaust Camshaft 5.
  • Page 338: Specifications

    196 kPa (2.0 kgf/cm², 28 psi) Oil Temperature 90°C (194°F) Special Tools - Outside Circlip Pliers: 57001-144 Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 339: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-5 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 340: Oil Cooler

    7-6 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Left Lower Fairing (see Frame chapter) • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) •...
  • Page 341: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-7 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler (see Engine Top End chapter) • Unscrew the oil level gauge bolts [A] and pull out the level gauge [B].
  • Page 342 7-8 ENGINE LUBRICATION SYSTEM Oil Pan • Apply grease to the O-rings on the oil pipes [C]. • Apply a non-permanent locking agent to the threads of the oil pressure relief valve [D], and tighten it. Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 343: Oil Pump, Oil Pump Drive Gear And Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pump, Oil Pump Drive Gear and Oil Pressure Relief Valve Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) •...
  • Page 344: Oil Pump Drive Gear Removal

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump, Oil Pump Drive Gear and Oil Pressure Relief Valve Oil Pump Drive Gear Removal • Remove: Clutch (see Clutch chapter) Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 345 ENGINE LUBRICATION SYSTEM 7-11 Oil Pump, Oil Pump Drive Gear and Oil Pressure Relief Valve • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 346: Oil Pressure Measurement

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairing (see Frame chapter). • Remove the oil pressure switch, and attach the gauge and adapter to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT 1/8: 57001 -1033 [B] •...
  • Page 347: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction [A] forward and upward.
  • Page 349 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 350: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View 1. Engine Mounting Bracket (ZX1200-B1) T1: 44 N·m (4.5 kgf·m, 32 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb) T3: 59 N·m (6.0 kgf·m, 44 ft·lb)
  • Page 351: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-3 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand [A]. • Squeeze the brake lever slowly and hold it with band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 352 8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator (see Cooling System chapter) Muffler (see Engine Top End chapter) Choke Cable Lower End Throttle Cable Lower Ends Air Cleaner Caps (see Fuel System (DFI) chapter) Inlet Ducts [A] (see Fuel System (DFI) chapter) •...
  • Page 353: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Installation CAUTION Do not connect the throttle sensor connector to the inlet air pressure sensor, because the pressure sen- sor is broken by the opposite electrical connection. • Before the engine installing, install the following parts. Engine Sub Harness [A] Gear Position Switch Harness [B] Alternator Leads [D]...
  • Page 354 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bracket [A] to the engine. Torque - Engine Mounting Bolts (M8) [B]: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the engine mounting bracket [C] temporarily. Engine Mounting Bracket Bolt (M12) [D] Engine Mounting Bracket Bolt (M10) [E] •...
  • Page 355 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Installation... 9-21 Specifications ........Starter Motor Clutch Disassembly 9-21 Crankcase Splitting......Starter Motor Clutch Assembly ..9-22 Crankcase Splitting ...... Starter Clutch Inspection....9-22 Crankcase Assembly ....Torque Limiter Removal ....9-23 Crankshaft and Connecting Rods..
  • Page 356: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View 1. Clamp (ZX1200-B1/B2) T8: 30 N·m (3.0 kgf·m, 22 ft·lb) T1: 5.4 N·m (0.55 kgf·m, 48 in·lb) T9: See the text. T2: 10 N·m (1.0 kgf·m, 89 in·lb) T10: 50 N·m (5.0 kgf·m, 37 ft·lb) T3: 12 N·m (1.2 kgf·m, 106 in·lb) T11: 28 N·m (2.8 kgf·m, 21 ft·lb) T4: 15 N·m (1.5 kgf·m, 11 ft·lb) T12: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 357 CRANKSHAFT/TRANSMISSION 9-3 Exploded View D: Do not apply any grease or oil. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Three Bond 1207B). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. R: Replacement Parts S: Follow the specific tightening sequence.
  • Page 358: Specifications

    9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 0.38 mm 0.58 mm (0.0051 0.0150 in.) (0.023 in.)
  • Page 359 CRANKSHAFT/TRANSMISSION 9-5 Specifications Item Standard Service Limit Crankshaft Side Clearance 0.05 0.20 mm 0.40 mm (0.0020 0.0079 in.) (0.016 in.) Crankshaft Runout TIR 0.03 mm (0.0012 in.) TIR 0.07 mm or less (0.0028 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.031 0.063 mm 0.07 mm (0.0012...
  • Page 360 7.3 mm (0.278 0.283 in.) (0.287 in.) Special Tools - Bearing Puller: 57001-135 Steering Stem Bearing Driver: 57001-137 Outside Circlip Pliers: 57001-144 Bearing Puller Adapter: 57001-317 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Silicone Sealant): 92104-1062 Three Bond 1207B...
  • Page 361: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-7 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter) External Shift Mechanism (see External Shift Mecha- nism Removal)
  • Page 362 9-8 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket to the breather plate mating surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - Three Bond 1207B • Apply a non-permanent locking agent to the threads and tighten the breather plate mounting bolts [A].
  • Page 363 CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. ○ Pile up the gasket [B] to slot portions. NOTE ○ Make the application finish within 5 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
  • Page 364 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • After tightening all crankcase bolts, check the following items. ○ Crankshaft and transmission shafts turn freely. ○ While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st. ○...
  • Page 365: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-11 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed.
  • Page 366 9-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] If the connecting rods, big end bearing inserts, or crank- shaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed.
  • Page 367: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods • Apply small amount of molybdenum disulfide oil solution to the threads [A] and seating surfaces [B] of the connect- ing rod nuts. • First, tighten the nuts to the specified torque. See the table below.
  • Page 368: Connecting Rod Twist

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • On surface plate, set the big-end arbor on V block [C]. • Measure the difference in the heights of the arbor above the surface plate over a 100 mm (3.94 in.) distance-on the arbor to determine the amount of connecting rod twist with the connecting rod held horizontally, and using a height gauge.
  • Page 369 CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 370: Crankshaft Main Bearing Insert/journal Wear

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Measure the bearing insert/journal [B] clearance with a plastigage [A]. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment.
  • Page 371: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Measure the main bearing bore diameter, and mark [B] the upper crankcase half [A] in accordance with the bore diameter. ○ Crankcase main bearing bore diameter marks are " " mark and no mark. NOTE ○...
  • Page 372: Crankshaft Runout

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.07 mm (0.0028 in.)
  • Page 373: Balancer

    CRANKSHAFT/TRANSMISSION 9-19 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove: Crankshaft Driveshaft • Unscrew the balancer shaft clamp bolt [A], and balancer shaft clamp lever bolt [B], and pull off the clamp lever [C]. • Pull the balancer shaft [D] out of the crankcase. The bal- ancer weight and gear assembly [E] come off with the needle bearings and copper washers.
  • Page 374: Balancer Damper Inspection

    9-20 CRANKSHAFT/TRANSMISSION Balancer • Position the crankshaft at #1, 4 position TDC. • Fit the lower crankcase to the upper crankcase aligning the punch mark [A] on the balancer weight with the pro- jection [B] of the lower crankcase. • Adjust the balancer gear backlash with the engine idling.
  • Page 375: Starter Motor Clutch And Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch and Torque Limiter Starter Motor Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Removal • Split the crankcase (see Crankcase Splitting). • Remove: Transmission Shafts Crankshaft •...
  • Page 376: Starter Motor Clutch Assembly

    9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter • Holding the drive gear [A] with a hand, take off the one -way clutch [B] from the gear by using the screw driver [C]. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its flange [B] fits in the holder recess [C].
  • Page 377: Torque Limiter Removal

    CRANKSHAFT/TRANSMISSION 9-23 Starter Motor Clutch and Torque Limiter Torque Limiter Removal • Remove: Starter Motor (see Electrical System chapter) Torque Limiter Cover (see Starter Motor Clutch Inspec- tion) • Using the 5 mm (0.20 in.) bolt [A], pull out the torque limiter shaft [B].
  • Page 378: Transmission

    9-24 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Bolt [C] Shift Lever • Remove the bolt [A], and shift pedal [B]. Shift Pedal Installation •...
  • Page 379: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-25 Transmission External Shift Mechanism Removal • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle, may fall over. If could cause an accident and injury.
  • Page 380: External Shift Mechanism Installation

    9-26 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Installation • Replace the circlip that was removed with a new one and install the shift mechanism arm. • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Apply a non-permanent locking agent to the bolt and tighten it.
  • Page 381: Transmission Shaft Installation

    CRANKSHAFT/TRANSMISSION 9-27 Transmission Transmission Shaft Installation • Apply engine oil to the sliding surfaces of the shafts, gears and bearings. • Check to see that the set pins [A] and set rings [B] are in place. • Install the drive shaft and output shaft into the upper crankcase half.
  • Page 382: Transmission Assembly

    9-28 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001-135 [B] Bearing Puller Adapter: 57001-317 [C] • Discard the bearing. Transmission Assembly • Apply engine oil to the ball bearing and shaft. •...
  • Page 383 CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. Circlip (small) 6. Outer Race 11. Bushing 2. Needle Bearing 7. 2nd Gear 12. 5th Gear 3. Washer (big) 8. Bushing (Spline) 13. Drive Shaft with 1st Gear 4. Washers (small) 9. Top Gear 14. Ball Bearing 5.
  • Page 384: Shift Drum And Fork Removal

    9-30 CRANKSHAFT/TRANSMISSION Transmission 1. Ball Bearing 8. Output Shaft 15. 5th Gear 2. Washer 9. 2nd Gear 16. Needle Bearing 3. Circlips 10. Bushing 17. 1st Gear 4. Steel Balls 11. Top Gear 18. Washer 5. Washer 12. 4th Gear 19.
  • Page 385: Shift Drum And Fork Installation

    CRANKSHAFT/TRANSMISSION 9-31 Transmission • Pull the shift rods [A] with the shift drum bearing holder [B] on, and take off the bearing holder and shift forks. • Pull out the shift drum [C] with the ball bearing [D]. Shift Drum and Fork Installation •...
  • Page 386: Shift Drum Assembly

    9-32 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Assembly • Be sure to install the dowel pin [A]. ○ Align the dowel pin with the hole [B] of the shift drum cam holder. • Apply a non-permanent locking agent to the threads of the shift drum cam bolt, and tighten it.
  • Page 387: Gear Dog And Gear Dog Hole Damage

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 389 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-3 Wheels (Rims) ........................10-4 Front Wheel Removal ....................... 10-4 Front Wheel Installation ....................10-4 Rear Wheel Removal......................10-6 Rear Wheel Installation..................... 10-7 Wheel Inspection ......................10-8 Axle Inspection........................10-9 Balance Inspection......................
  • Page 390: Exploded View

    10-2 WHEELS/TIRES Exploded View T1: 20 N·m (2.0 kgf·m, 15 ft·lb) T2: 125 N·m (13 kgf·m, 92 ft·lb) T3: 59 N·m (6.0 kgf·m, 44 ft·lb) T4: 0.15 N·m (0.015 kgf·m, 1.3 in·lb) G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 391: Specifications

    WHEELS/TIRES 10-3 Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial – – – 0.5 mm (0.02 in.) Radial – – – 0.8 mm (0.03 in.) Axle Runout/100 mm (3.94 in.) 0.05 mm (0.002 in.) or less 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz) or less –...
  • Page 392: Wheels (rims)

    10-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Lower Fairings (see Frame chapter) Brake Caliper Mounting Bolts [A] Refractors [B] (for the US and Canadian model) ZX1200-B1/B2 [C] ZX1200-B3 [D] • Loosen: Right Side Axle Clamp Bolts [A] Axle [B] •...
  • Page 393 WHEELS/TIRES 10-5 Wheels (Rims) • Before tightening the clamp bolts on the right fork leg, pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. NOTE ○...
  • Page 394: Rear Wheel Removal

    10-6 WHEELS/TIRES Wheels (Rims) ZX1200-B3 • Tighten the right axle clamp bolts [A] to the specified torque. ○ The tightening sequence is left, right and left side bolt to prevent from loosening the bolts. Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) NOTE ○...
  • Page 395: Rear Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) • Remove the chain [A] from the rear sprocket toward the left. • Move the rear caliper back and remove the rear caliper from the swingarm. • Remove the rear wheel. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 396: Wheel Inspection

    10-8 WHEELS/TIRES Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. • Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap- ter). • Check the rear brake. WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
  • Page 397: Axle Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 398: Balance Weight Removal

    10-10 WHEELS/TIRES Wheels (Rims) Balance Weight Removal (a) When the tire is not on the rim. • Push [A] the blade portion toward the outside with a reg- ular tip screw driver, and slip the weight off the rim flange. •...
  • Page 399 WHEELS/TIRES 10-11 Wheels (Rims) (b) Installation completed. • When required total weight exceeds 20 g (0.71 oz), install balance weight at both sides of rim flange as shown. Weight Selection Required Total Weight One Side [A] Other Side [B] 20 g (0.71 oz) 10 g (0.35 oz) 10 g (0.35 oz) 30 g (1.06 oz)
  • Page 400: Tires

    10-12 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 401: Tire Installation

    WHEELS/TIRES 10-13 Tires Tire Installation WARNING Use the same manufacturer’s tires on both front and rear wheels. • Inspect the rim and tire, and replace them if necessary. • Clean the sealing surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary.
  • Page 402 10-14 WHEELS/TIRES Tires • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). • Install the tire on the rim using a suitable commercially available tire changer.
  • Page 403: Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 404: Hub Bearings

    10-16 WHEELS/TIRES Hub Bearings Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (Out of rear hub) Grease Seals Circlip Special Tool - Inside Circlip Pliers: 57001-143 • Take the bearings [A] out of the hub. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 405 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-3 Drive Chain..........................11-4 Slack Inspection........................ 11-4 Slack Adjustment ......................11-4 Wheel Alignment Inspection Adjustment ................11-4 Drive Chain Wear Inspection .................... 11-4 Lubrication ........................11-4 Drive Chain Removal ......................11-4 Drive Chain Installation .....................
  • Page 406: Exploded View

    11-2 FINAL DRIVE Exploded View T1: 12 N·m (1.2 kgf·m, 106 in·lb) T2: 59 N·m (6.0 kgf·m, 44 ft·lb) T3: 125 N·m (13 kgf·m, 92 ft·lb) T4: 127 N·m (13 kgf·m, 94 ft·lb) G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent.
  • Page 407: Specifications

    FINAL DRIVE 11-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 35 mm (0.98 1.4 in.) – – – Rollers Distance Less than 6 mm (0.236 in.) 6.2 mm (0.244 in.) 20-link Length 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make...
  • Page 408: Drive Chain

    11-4 FINAL DRIVE Drive Chain Slack Inspection • Refer to the Drive Chain Inspection in the Periodic Main- tenance chapter. Slack Adjustment • Refer to the Drive Chain Inspection in the Periodic Main- tenance chapter. Wheel Alignment Inspection Adjustment • Refer to the Drive Chain Inspection in the Periodic Main- tenance chapter.
  • Page 409: Sprocket, Coupling

    FINAL DRIVE 11-5 Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [C] ○ Chain guide bolt [B] need not to be removed for engine sprocket cover removal. • Flatten out the bended washer [A]. •...
  • Page 410: Rear Sprocket Removal

    11-6 FINAL DRIVE Sprocket, Coupling • Install the engine sprocket cover. ○ Apply a non-permanent locking agent to the chain guide mounting bolt [A] if it is removed. Torque - Engine Sprocket Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 411: Rear Sprocket Warp Inspection

    FINAL DRIVE 11-7 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground (see Wheels/Tires chapter) so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 412: Coupling Installation

    11-8 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 [A] Coupling Installation •...
  • Page 413 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Brake Pad Lining Wear ....12-20 Specifications ........12-8 Master Cylinder ......... 12-21 Brake Pedal ........12-9 Front Master Cylinder Removal ... 12-21 Brake Lever Position Adjustment. 12-9 Front Master Cylinder Installation 12-21 Brake Pedal Position Adjustment.
  • Page 414: Exploded View

    12-2 BRAKES Exploded View ZX1200-B1/B2 T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T11: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 1.5 N·m (0.15 kgf·m, 13 in·lb) T12: 27 N·m (2.8 kgf·m, 20 ft·lb) T3: 3.0 N·m (0.30 kgf·m, 27 in·lb) T13: 30 N·m (3.0 kgf·m, 22 ft·lb) T4: 6.0 N·m (0.60 kgf·m, 52 in·lb) B: Apply brake fluid.
  • Page 415 BRAKES 12-3 Exploded View...
  • Page 416 12-4 BRAKES Exploded View ZX1200-B3...
  • Page 417 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.12 11 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Reservoir Cap Screws 0.15 13 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb...
  • Page 418 12-6 BRAKES Exploded View...
  • Page 419 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Mounting Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut Front Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Rear Caliper Assembly Bolts Brake Disc Mounting Bolts B: Apply brake fluid.
  • Page 420: Specifications

    12-8 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position – – – 5-way adjustable (to suit rider) Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 43 mm (1.7 in.) below footpeg top –...
  • Page 421: Brake Pedal

    BRAKES 12-9 Brake Pedal Brake Lever Position Adjustment The brake lever is adjustable to five positions to suit the rider. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B]. ○ The distance from the grip to the lever is maximum at Number 1 and minimum at Number 5.
  • Page 422: Brake Lever, Brake Pedal

    12-10 BRAKES Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Right Front Footpeg Holder Bolts [A] Rear Master Cylinder Mounting Bolts [B] • Remove: Cotter Pin [A] Joint Pin [B] (see Rear Master Cylinder Removal) • Remove the rear brake light switch spring [C]. •...
  • Page 423: Calipers

    BRAKES 12-11 Calipers Front Caliper Removal • Remove the reflectors (for the US and Canadian models). • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.
  • Page 424: Front Caliper Disassembly

    12-12 BRAKES Calipers Front Caliper Disassembly ZX1200-B1/B2 • Remove the pad spring and brake pads (see this chapter). • Loosen the front caliper assembly bolts [A] and front caliper banjo bolt [B] and tighten them loosely. • Remove the front caliper [C] and banjo bolt. •...
  • Page 425: Front Caliper Assembly

    BRAKES 12-13 Calipers • Remove the caliper of other side. • Loosen the caliper assembly bolts [A]. • Remove: Front Caliper (see Front Caliper Removal) Brake Pad Front Caliper Assembly Bolts O-rings • Using compressed air, remove the pistons. One way to remove the pistons is as follows.
  • Page 426: Rear Caliper Disassembly

    12-14 BRAKES Calipers • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.
  • Page 427: Rear Caliper Assembly

    BRAKES 12-15 Calipers • Remove the pistons, dust seals and fluid seals as same as front caliper disassembly. Piston Completes [A] Dust Seals [B] Fluid Seals [C] O-rings [D] Caliper Body [E] Caliper Assembly Bolts [F] Bleed Valves [G] Rubber Caps [H] WARNING To avoid serious injury, never place your fingers or palm in rear of the piston.
  • Page 428: Caliper Fluid Seal Damage

    12-16 BRAKES Calipers Caliper Fluid Seal Damage ZX1200-B1/B2 The fluid seals [C] around the pistons [A] maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. •...
  • Page 429: Caliper Dust Seal Damage

    BRAKES 12-17 Calipers Caliper Dust Seal Damage • Check that the dust seals [B] is not cracked, worn, swollen, or otherwise damaged. • If it show any damage, remove the caliper bracket and replace it. Pistons [A] Fluid Seals [C] Caliper Piston and Cylinder Damage •...
  • Page 430: Brake Pads

    12-18 BRAKES Brake Pads Front Brake Pad Removal ZX1200-B1/B2 • Unscrew the pad spring bolts [A], and remove the pad spring [B]. • Draw out the clip [A], and take off the pad pin [B]. • Remove the brake pads [C]. ZX1200-B3 •...
  • Page 431: Front Brake Pad Installation

    BRAKES 12-19 Brake Pads Front Brake Pad Installation ZX1200-B1/B2 • Push the caliper pistons in by hand as far as they will go. • Install the brake pads. • Install the pad pin and clip. The clip must be "outside" of the pads.
  • Page 432: Rear Brake Pad Installation

    12-20 BRAKES Brake Pads • Pushing either ends [A] of the pad spring lightly, take off the pad pins [B] one by one. • Remove the pad springs [C] and brake pads. Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...
  • Page 433: Master Cylinder

    BRAKES 12-21 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder [C] (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [A], and take off the master cylin- der as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 434: Rear Master Cylinder Removal

    12-22 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. •...
  • Page 435: Rear Master Cylinder Disassembly

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal). • Slide the dust cover [F] on the push rod out of place, and remove the circlip [E]. Special Tool - Inside Circlip Pliers: 57001-143 NOTE ○...
  • Page 436: Master Cylinder Inspection (visual Inspection)

    12-24 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].
  • Page 437: Brake Discs

    BRAKES 12-25 Brake Discs Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked [A] side faces out.
  • Page 438: Brake Fluid

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 439 BRAKES 12-27 Brake Fluid NOTE ○ The fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.
  • Page 440 12-28 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 441: Brake Hoses

    BRAKES 12-29 Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 443 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-4 Front Fork ..........................13-5 Rebound Damping Force Adjustment................13-5 Compression Damping Force Adjustment ................ 13-5 Spring Preload Adjustment ....................13-6 Front Fork Removal (each fork leg) .................. 13-7 Front Fork Installation .......................
  • Page 444: Exploded View

    13-2 SUSPENSION Exploded View T1: 20 N·m (2.0 kgf·m, 15 ft·lb) T2: 23 N·m (2.3 kgf·m, 17 ft·lb) T3: 28 N·m (2.8 kgf·m, 21 ft·lb) T4: 40 N·m (4.0 kgf·m, 30 ft·lb) AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
  • Page 445 SUSPENSION 13-3 Exploded View T5: 34 N·m (3.5 kgf·m, 25 ft·lb) T6: 98 N·m (10 kgf·m, 72 ft·lb) T7: 125 N·m (13 kgf·m, 92 ft·lb) T8: 59 N·m (6.0 kgf·m, 44 ft·lb) G: Apply grease.
  • Page 446: Fork Oil Seal Driver

    13-4 SUSPENSION Specifications Item Standard Front Fork (per One Unit) Fork Inner Tube Outside Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting: ZX1200-B1/B2 1 1/2 turns backward from the fully tightened position (Usable Range: 0 ←→ 3 turns) ZX1200-B3 7th click from the first click of the fully clockwise position (Usable Range: 0 ←→...
  • Page 447: Front Fork

    SUSPENSION 13-5 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to suit you best. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 1/2 turns backward from the fully tightened position (ZX1200-B1/B2).
  • Page 448: Spring Preload Adjustment

    13-6 SUSPENSION Front Fork ○ The damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Compression Damping Force Adjustment ZX1200-B1/B2 Adjuster...
  • Page 449: Front Fork Removal (each Fork Leg)

    SUSPENSION 13-7 Front Fork Front Fork Removal (each fork leg) • Remove: Front Wheel (see Wheels/Tires chapter) Front Fender (see Frame chapter) Loosen the upper fork clamp bolt [B] and fork top plug [A] beforehand if the fork leg is to be disassembled. NOTE ○...
  • Page 450: Front Fork Disassembly

    13-8 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Fork Oil Change in the Periodic Maintenance chapter). • Hold the front fork in a vise [A]. • Stop the cylinder [B] from turning by using the fork cylinder holder [C].
  • Page 451: Inner Tube Inspection

    SUSPENSION 13-9 Front Fork • Install the following parts into the inner tube [A]. Dust Seal [B] Circlip [C] Oil Seal [D] Washer [E] • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].
  • Page 452: Dust Seal Inspection

    13-10 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 453: Rear Shock Absorber

    SUSPENSION 13-11 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to suit you best. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 3 turns backward from the fully tightened position.
  • Page 454: Spring Preload Adjustment

    13-12 SUSPENSION Rear Shock Absorber Spring Preload Adjustment • Remove the rear shock absorber from the frame to mea- sure the spring length (see Rear Shock Absorber Re- moval). • Loosen the locknut [B] and turn out the adjusting nut [A] to free the spring.
  • Page 455: Rear Shock Absorber Installation

    SUSPENSION 13-13 Rear Shock Absorber • Remove: Upper Shock Absorber Nut Upper Shock Absorber Bolt [A] ○ Lift up [B] the rear fender front with a suitable bar or your hand to the arrow direction, and then pull out the absorber Bolt.
  • Page 456: Swingarm

    13-14 SUSPENSION Swingarm Swingarm Removal • Remove the lower fairings (see Frame chapter). • Remove the side stand mounting bracket (see Frame chapter). • Raise the rear wheel of the ground with the jack. Special Tool - Jack: 57001-1238 • Remove: Rear Wheel (see Wheels/Tires chapter) Chain Cover (see Final Drive chapter)
  • Page 457: Swingarm Installation

    SUSPENSION 13-15 Swingarm Swingarm Installation • Apply plenty of grease to the ball bearing, needle bearings and grease seals. • Install the collars [A]. ○ Place the right collar [A] on the stopper [B] inside the frame [C]. • Insert the pivot shaft into the frame from the right side. •...
  • Page 458: Swingarm Bearing Installation

    13-16 SUSPENSION Swingarm Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer’s marks face out. • Install the ball bearing so that the manufacturer’s marks faces out.
  • Page 459: Tie-rod, Rocker Arm

    SUSPENSION 13-17 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the lower fairings (see Frame chapter). • Remove the side stand mounting bracket (see Frame chapter). • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 •...
  • Page 460: Needle Bearing Inspection

    13-18 SUSPENSION Tie-Rod, Rocker Arm Needle Bearing Inspection If there is any doubt as to the condition of either needle bearing, replace the bearing and sleeve as a set, and/or add grease to the grease nipple. Tie-Rod, Rocker Arm Sleeve Inspection If there is visible damage, replace the sleeve and needle bearing as a set.
  • Page 461 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Specifications ......................... 14-3 Steering ..........................14-4 Steering Inspection ......................14-4 Steering Adjustment......................14-4 Steering Stem......................... 14-5 Stem, Stem Bearing Removal................... 14-5 Stem, Stem Bearing Installation..................14-6 Steering Bearing Lubrication and Inspection ..............14-9 Steering Stem Warp......................
  • Page 462: Exploded View

    14-2 STEERING Exploded View 1. ZX1200-B1/B2 T1: 3.5 N·m (0.36 kgf·m, 31 in·lb) T2: 20 N·m (2.0 kgf·m, 15 ft·lb) T3: 34 N·m (3.5 kgf·m, 25 ft·lb) T4: 54 N·m (5.5 kgf·m, 40 ft·lb) (ZX1200-B1/B2) 78 N·m (8.0 kgf·m, 57 ft·lb) (ZX1200-B3) AD: Apply adhesive.
  • Page 463: Specifications

    STEERING 14-3 Specifications Special Tools - Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Remover: 57001-1107 Jack: 57001-1238 Steering Stem Bearing Driver: 57001-1344 Steering Stem Bearing Driver Adapter: 57001-1345 Head Pipe Outer Race Driver 55: 57001-1446 Head Pipe Outer Race Driver 47: 57001-1447...
  • Page 464: Steering Inspection

    14-4 STEERING Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Inspection in the Periodic Mainte- nance chapter.
  • Page 465: Steering Stem

    STEERING 14-5 Steering Stem Stem, Stem Bearing Removal • Remove: Brake Hose Joint Cover Screws [A] Front Wheel (see Wheels/Tires chapter) Front Fork (see Suspension chapter) Steering Stem Head Nut and Washer Steering Stem Head with Handlebars • Remove the brake hose joint bolt [A]. ZX1200-B1/B2 •...
  • Page 466: Stem, Stem Bearing Installation

    14-6 STEERING Steering Stem • Pushing up the stem base, and remove the steering stem nut [A] with oil seal. Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 • Remove: Steering Stem [C] Upper Ball Bearing Inner Race • Drive out the bearing outer races [B] from the head pipe.
  • Page 467 STEERING 14-7 Steering Stem • Install the oil seal [A] on the steering stem, and drive the lower ball bearing inner race [B] applied the grease on to the stem. Special Tools - Steering Stem Bearing Driver: 57001-1344 Steering Stem Bearing Driver Adapter: 57001-1345 [D] •...
  • Page 468 14-8 STEERING Steering Stem ZX1200-B1/B2 • Install the lock washer. • Install the stem head. • Install the washer, and tighten the stem head nut with specified torque. • Install the front fork (see Suspension chapter). NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts.
  • Page 469: Steering Bearing Lubrication And Inspection

    STEERING 14-9 Steering Stem NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. ○ Tighten the two clamp bolts alternately two times to en- sure even tightening torque. Torque - Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 57 ft·lb) Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb)
  • Page 470: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Throttle Case [E] • Remove: Weight Bolts [A] Handlebar Weight [B] Fitting [C] Clip [D] •...
  • Page 471 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Lower Inner Covers (Left and Seats ..........15-5 Right) Removal ......15-10 Rear Seat Removal...... 15-5 Lower Inner Covers (Left and Rear Seat Installation....15-5 Right) Installation ...... 15-11 Rear Seat Cover Removal ... 15-5 Upper Fairing Removal ....
  • Page 472: Exploded View

    15-2 FRAME Exploded View T1: 25 N·m (2.5 kgf·m, 18 ft·lb) G: Apply grease. T2: 34 N·m (3.5 kgf·m, 25 ft·lb) L: Apply a non-permanent locking agent. T3: 49 N·m (5.0 kgf·m, 36 ft·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb) T5: 44 N·m (4.5 kgf·m, 32 ft·lb)
  • Page 473 FRAME 15-3 Exploded View 1. Key (ZX1200-B1/B2) 2. Key Option (ZX1200-B1/B2) T1: 0.40 N·m (0.040 kgf·m, 3.5 in·lb)
  • Page 474 15-4 FRAME Exploded View CA: Canadian Model US: U.S.A. Model...
  • Page 475: Seats

    FRAME 15-5 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turning the key clockwise, pulling up on the rear of the seat with seat cover [B], and pulling the seat backward. Rear Seat Installation •...
  • Page 476: Rear Seat Cover Installation

    15-6 FRAME Seats Rear Seat Cover Installation • Fit the two projections [A] of the rear seat front portion into the slots [B] in the front bracket of the seat cover. • Tighten the two screws. Front Seat Removal • Remove: Rear Seat (see Rear Seat Removal) Mounting Bolts [A]...
  • Page 477: Seat Cover

    FRAME 15-7 Seat Cover Seat Cover Removal • Remove: ○ Unscrew and pull out the rivet screws. Seats Rivet Screws [A] (Left and Right) Hook Bolts [B] • Pull the front portions [C] of the seat cover outside, and then remove the seat cover backward. •...
  • Page 478: Fairings

    15-8 FRAME Fairings Lower Fairings (Left and Right) Removal • Remove: Screws [A] Rivet Screws [B] Allen Bolts [C] • Remove the lower fairings from the upper and lower inner fairings. ○ Pull the lower inner fairing [A] forward to clear its projec- tions [B] from the grommets [C] on the lower fairings [D].
  • Page 479: Lower Inner Fairing Removal

    FRAME 15-9 Fairings Lower Inner Fairing Removal • Remove: Screws [A] • Remove: Lower Inner Fairing [A] ○ Pull the upper projection of the lower inner fairing [A] for- ward to remove the its projections [B] from the grommets [C] on the lower fairings [D]. Lower Inner Fairing Installation •...
  • Page 480: Wind Shield Removal

    15-10 FRAME Fairings Wind Shield Removal • Remove: ○ Pull off the wind shield upward after removing the screws. Screws [A] Wind Shield [B] Wind Shield Installation • Insert the tabus [A] of the shield in to the holes [B] of the upper fairing.
  • Page 481: Lower Inner Covers (left And Right) Installation

    FRAME 15-11 Fairings Lower Inner Covers (Left and Right) Installation • Lower inner covers installation is the reverse of removal. • Insert the projections [A] of the lower inner covers into the holes [B] on the ducts. Upper Fairing Removal •...
  • Page 482: Upper Fairing Disassembly

    15-12 FRAME Fairings • Pull the upper fairing assembly forward and disconnect the headlight harness connector [A]. Upper Fairing Disassembly • Remove the upper inner fairings [B] with loosening the screws [A]. • Remove: Front Turn Signal Connectors [A] Headlight Connectors [B] City Light Connector [C] Headlight Harness Bracket [D] •...
  • Page 483: Upper Fairing Assembly

    FRAME 15-13 Fairings • Remove the ducts [B] with the screws [A] taken off. • Take off the screw [A] to remove the air inlet [B]. • Remove the screw [A] to take off the plate [B] and turn signal light. Upper Fairing Assembly •...
  • Page 484: Hot Wind Cover Installation

    15-14 FRAME Fairings Hot Wind Cover Installation • Install the hot wind cover [A] following the below. Cooling Hose [B] Clutch Cable [C] Crankshaft Sensor Lead [J] ○ Put in the lower part of the cover between the ribs [G] on the crankshaft sensor cover [H].
  • Page 485: Fenders

    FRAME 15-15 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Left and Right) Screws [B] (Front Part Screws with Washers) Bolts [C] Reflector [E] (for US and Canadian Models) • Remove the front fender [D]. Front Fender Installation •...
  • Page 486: Rear Fender Front Removal

    15-16 FRAME Fenders Rear Fender Front Removal • Remove: Rear Fender Rear (see Rear Fender Rear Removal) Hose Clamps [A] Separator [B] • Remove the rear fender front. ○ Move the rear fender front backward until it stops, and then pull downward the right side of the rear fender front [A] to clear the brackets [B].
  • Page 487: Rear Frame

    FRAME 15-17 Rear Frame Rear Frame Removal • Remove: Seats (see Front and Rear Seats Removal) Rear Fender Front (see Rear Fender Front Removal) ECU (Not Disconnect, see Fuel System (DFI) chapter) • Disconnect: Atmospheric Pressure Sensor Connector Regulator/Rectifier Connectors Muffler Mounting Bolt [A] Fuel Tank Mount Bracket Bolts [B] Rear Footpeg Holder Bolts [C]...
  • Page 488: Storage Box

    15-18 FRAME Storage Box Storage Box Removal • Remove: Seats (see this chapter) Band [A] Bolts [B] Bolt [C] • Pulling up the rear part of the box backward. Storage Box Installation • Insert the front part [A] of the box into the hook [B] of the rear fender rear.
  • Page 489: Side Stand

    FRAME 15-19 Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Disconnect the side stand switch lead connectors. • Remove: Side Stand Bolt [A] Side Stand Bracket Bolts [B] Spring [C] Side Stand [D] Side Stand Switch Bolt [E] Side Stand Installation •...
  • Page 491 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-3 Stick Coil (Ignition Coil together Specifications ........16-8 with Spark Plug Cap) Inspection 16-35 Parts Location........16-10 Stick Coil Primary Peak Voltage Precautions........16-11 Inspection........16-36 Electrical Wiring......... 16-13 Spark Plug Removal ....
  • Page 492 16-2 ELECTRICAL SYSTEM Fan Relay Inspection ....16-59 Junction Box ........16-95 Meter ..........16-60 Junction Box Fuse Circuit Meter Unit Removal ..... 16-60 Inspection........16-95 Meter Unit Disassembly ....16-60 Starter Circuit/Headlight Relay Bulbs Replacement...... 16-60 Inspection........16-95 Meter Unit Inspection ....16-61 Diode Circuit Inspection ....
  • Page 493: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View 1. Crankshaft Sensor T2: 6.0 N·m (0.60 kgf·m, 53 in·lb) 2. ECU T3: 13 N·m (1.3 kgf·m, 115 in·lb) 3. Tail/Brake Lights T4: 39 N·m (4.0 kgf·m, 29 ft·lb) 4. Stick Coils T5: 12 N·m (1.2 kgf·m, 106 in·lb) 5.
  • Page 494 16-4 ELECTRICAL SYSTEM Exploded View 1. Regulator/rectifier (ZX1200-B1/B2) T4: 12 N·m (1.2 kgf·m, 106 in·lb) 2. Front Brake Light Switch T5: 15 N·m (1.5 kgf·m, 11 ft·lb) 3. Starter Relay/Main Fuse T6: 110 N·m (11 kgf·m, 81 ft·lb) 4. Starter Lockout Switch T7: 1.5 N·m (0.15 kgf·m, 13 in·lb) 5.
  • Page 496 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 497 ELECTRICAL SYSTEM 16-7 Exploded View 1. Water Temperature Sensor 2. Radiator Fan Switch 3. Junction Box 4. Side Stand Switch 5. Headlight Relays 6. Fuel Pump Relay 7. Fan Relay 8. ECU Relay 9. Gear Position Switch (ZX1200-B1/B2) 10. Turn Signal Relay 11.
  • Page 498: Specifications

    16-8 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Capacity 12 V 12 Ah Voltage 12.6 V or more Charging System Type Three-phase AC Alternator Output Voltage 120 V @4 000 r/min (rpm) Stator Coil Resistance 0.5 Ω @20°C (68°F) Charging Voltage 14.2 15.2 V...
  • Page 499 Flywheel Puller Assembly: 57001-1405 Lead Wire – Voltage Regulator Adapter: 57001-1448 Lead Wire – Peak Voltage Adapter: 57001-1449 Needle Adapter Set: 57001-1457 Key Registration Unit: 57001-1582 Pulley Holder, Grip: 57001-1591 Rotor Holder: 57001-1592 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 500: Parts Location

    16-10 ELECTRICAL SYSTEM Parts Location Starter Lockout Switch [A] Camshaft Position Sensor [B] Fuel Pump Relay [C] Radiator Fan Relay [D] Inlet Air Pressure Sensor [E] Throttle Sensor [F] Starter Motor [G] Radiator Fan Switch [H] Alternator [I] Oil Pressure Switch [J] Speed Sensor [K] Inlet Air Temperature Sensor [A] Battery [B]...
  • Page 501: Precautions

    ELECTRICAL SYSTEM 16-11 Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system.
  • Page 502 16-12 ELECTRICAL SYSTEM Precautions Male Connectors [B]...
  • Page 503: Electrical Wiring

    ELECTRICAL SYSTEM 16-13 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 504: Battery

    16-14 ELECTRICAL SYSTEM Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Con- trol Unit). Never reverse the connections of the battery, this could damage the ECU.
  • Page 505: Battery Installation

    ELECTRICAL SYSTEM 16-15 Battery • Remove: Positive (+) Cable [A] Battery [B] Battery Installation • Place the battery in the tray. NOTE ○ Put the (+) terminal side of the battery on the (+) symbol [A] and the (–) terminal side on the (–) symbol [B]. •...
  • Page 506: Electrolyte Filling

    16-16 ELECTRICAL SYSTEM Battery Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name for ZX1200-B1 B3: YTX14-BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec-...
  • Page 507 ELECTRICAL SYSTEM 16-17 Battery • Make sure air bubbles [A] are coming up from all six filler ports. ○ Leave the container this way for 5 minutes or longer. NOTE ○ If no air bubbles are coming up from a filler port, tap [B] the bottom of the container two or three times.
  • Page 508: Initial Charge

    16-18 ELECTRICAL SYSTEM Battery Initial Charge While a Sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use.
  • Page 509: Interchange

    ELECTRICAL SYSTEM 16-19 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec- tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if the sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
  • Page 510 16-20 ELECTRICAL SYSTEM Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case.
  • Page 511: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Check that knock pins [B] are in place on the crankcase.
  • Page 512: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Secure the alternator lead with a holding plate, and apply a non-permanent locking agent to the threads of the plate bolts and tighten them.
  • Page 513: Alternator Rotor Removal

    ELECTRICAL SYSTEM 16-23 Charging System Alternator Rotor Removal ZX1200-B1/B2 • Remove: Alternator Cover (see Alternator Cover Removal) • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [B]. Special Tool - Flywheel Holder: 57001-1313 ZX1200-B3 •...
  • Page 514: Alternator Inspection

    16-24 ELECTRICAL SYSTEM Charging System NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. ○ Install the rotor and tighten it with 70 N·m (7.0 kgf·m, 52 ft·lb) of torque. ○ Remove the rotor bolt.
  • Page 515: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-25 Charging System ○ Disconnect the alternator lead connectors [A]. ○ Connect the hand tester [B] as shown in the table 1. Special Tool - Hand Tester: 57001-1394 ○ Start the engine. ○ Run it at the rpm given in the table 1. ○...
  • Page 516 16-26 ELECTRICAL SYSTEM Charging System ZX1200-B3 • Remove: Seat Cover (see Frame chapter) Connector [A] (disconnect) • Remove: Lift up Fuel Tank (see Fuel System (DFI) chapter) Connectors [A] (disconnect) • Remove: Bolts [A] Regulator/rectifier [B] Rectifier Circuit Check • Check conductivity of the following pair of terminals.
  • Page 517 ELECTRICAL SYSTEM 16-27 Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 518: Regulator/rectifier Output Voltage Inspection

    16-28 ELECTRICAL SYSTEM Charging System Regulator Circuit Test: 3rd Step • Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test–1st Step". • Momentarily apply 24 V to the BR terminal by adding a 12 V battery.
  • Page 519 ELECTRICAL SYSTEM 16-29 Charging System ZX1200-B3 • Check the battery condition (see Battery section). • Remove the seat cover (see Frame chapter). • Warm up the engine to obtain actual alternator operating conditions. • Check that the ignition switch is turned off, and connect the hand tester as shown in the table.
  • Page 520 16-30 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load 7. Headlight Relay in Junction Box (US, CA, AU, and MY models)
  • Page 521: Ignition System

    ELECTRICAL SYSTEM 16-31 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 522: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply a non-permanent locking agent to the threads of the crankshaft sensor cover bolts and tighten them.
  • Page 523: Camshaft Position Sensor Removal

    ELECTRICAL SYSTEM 16-33 Ignition System • Turn the ignition switch and engine stop switch on. • Pushing the starter button, turn the engine 4 5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. •...
  • Page 524: Camshaft Position Sensor Inspection

    16-34 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Inspection • Remove: Left Lower Inner Cover (see Frame chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester to the × 10 Ω range and connect it to the yellow and black leads in the connector.
  • Page 525: Stick Coil (ignition Coil Together With Spark Plug Cap) Removal

    ELECTRICAL SYSTEM 16-35 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Removal • Remove: Inner Lower Covers (see Frame chapter) Baffle Plate • Disconnect the stick coil connectors [B]. • Pull the stick coils [A] off the spark plugs. CAUTION Do not pry the connector part of the coil while re- moving the coil.
  • Page 526: Stick Coil Primary Peak Voltage

    16-36 ELECTRICAL SYSTEM Ignition System Stick Coil Primary Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the stick coils (see Stick Coil Removal), but do not remove the spark plugs. • Measure the primary peak voltage as follows. ○...
  • Page 527: Spark Plug Installation

    ELECTRICAL SYSTEM 16-37 Ignition System Spark Plug Installation • Insert the spark plug vertically into the plug hole with the plug [A] installed in the plug wrench [B]. Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132 • Tighten the plugs. Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb) •...
  • Page 528: Ic Igniter Inspection

    16-38 ELECTRICAL SYSTEM Ignition System 2nd Check Raise the rear wheel off the ground with a stand. • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition Transmission Gear →...
  • Page 529: Ignition System Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Ignition System Inspection...
  • Page 530 16-40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit ZX1200-B1/B2 1. Ignition Switch 13. Starter Lockout Switch 2. Engine Stop Switch 14. ECU Main Relay 3. Starter Button 15. ECU Fuse 15 A 4. Spark Plugs 16. Vehicle-down Sensor 5. Stick Coils 17.
  • Page 531 ELECTRICAL SYSTEM 16-41 Ignition System ZX1200-B3 1. Ignition Switch 16. ECU (Electric Control Unit) 2. Immobilizer Antenna 17. Fuel Pump 3. Immobilizer Amplifier 18. Engine Ground 4. Engine Stop Switch 19. Battery 5. Starter Button 20. Main Fuse 30 A 6.
  • Page 532: Electric Starter System

    16-42 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Battery Compartment Cover (see Battery Removal) Terminal Nut [A] Starter Motor Cable [B] • Remove: Lower Fairing (see Frame chapter) Coolant Reserve Tank Starter Motor Mounting Bolts [A] • Pull out the starter motor [A].
  • Page 533: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-43 Electric Starter System Starter Motor Disassembly • Take off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [C]. ○ The brush plate [A] and brushes come off with the left–hand end cover [B].
  • Page 534: Brush Inspection

    16-44 ELECTRICAL SYSTEM Electric Starter System • Align the notch [A] in the brush plate with the end cover notch [B] and the mark [C] on the yoke. • Align the line [A] marked on the yoke with the through bolt hole [B].
  • Page 535: Armature Inspection

    ELECTRICAL SYSTEM 16-45 Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 536 16-46 ELECTRICAL SYSTEM Electric Starter System • Remove: Starter Cable [A] Battery Cable [B] (disconnect) Connector [C] Starter Relay [D] • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. If the relay does not work as specified, the relay is defec- tive.
  • Page 537 ELECTRICAL SYSTEM 16-47 Electric Starter System Electric Starter Circuit ZX1200-B1/B2 1. Ignition Switch 6. Ignition Fuse 10 A 10. Starter Relay 2. Engine Stop Switch 7. Starter Lockout Switch 11. Main Fuse 30 A 3. Starter Button 8. Neutral Switch (in Gear 12.
  • Page 538 16-48 ELECTRICAL SYSTEM Electric Starter System ZX1200-B3 1. Ignition Switch 7. Starter Lockout Switch 2. Engine Stop Switch 8. Side Stand Switch 3. Starter Button 9. Starter Motor 4. Junction Box 10. Starter Relay 5. Starter Circuit Relay 11. Main Fuse 30 A 6.
  • Page 539: Lighting System

    ELECTRICAL SYSTEM 16-49 Lighting System The U.S.A., Canadian, Australian, and Malaysian models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on.
  • Page 540: Headlight Bulbs (left And Right) Replacement

    16-50 ELECTRICAL SYSTEM Lighting System Headlight Bulbs (Left and Right) Replacement • Remove: Left and Right Lower Inner Covers Headlight Connectors Headlight Bulb Dust Covers Hooks [A] Headlight Bulbs [B] CAUTION When handling the quartz–halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth.
  • Page 541: Tail/brake Light Bulbs Replacement

    ELECTRICAL SYSTEM 16-51 Lighting System Tail/Brake Light Bulbs Replacement • Remove: Rear Seat (see Frame chapter) Seat Cover (see Frame chapter) • Turn the left and right sockets [A] counterclockwise, and remove the sockets and bulbs. • Push and turn the bulb [A] counterclockwise and remove •...
  • Page 542: Headlight Relays (high/low) Inspection

    16-52 ELECTRICAL SYSTEM Lighting System Headlight Relays (High/Low) Inspection • Remove: Wind Shield (see Frame chapter) Headlight Relay (High Beam) [A] • Remove: Headlight Relay (Low Beam) [A] Right Upper and Lower Inner Covers (see Frame chap- ter) • Connect the hand tester [A] and 12 V battery [B] to the headlight relay [C] as shown.
  • Page 543 ELECTRICAL SYSTEM 16-53 Lighting System Headlight/Tail Light Circuit ZX1200-B1/B2 1. High Beam Indicator Light 11. Tail Lights 2. City Light 12. Ignition Switch 3. Headlights 13. Junction Box 4. Headlight Relay (Low Beam) 14. Tail Light Fuse 10 A 5. Headlight Relay (High Beam) 15.
  • Page 544: Turn Signal Relay Inspection

    16-54 ELECTRICAL SYSTEM Lighting System ZX1200-B3 1. High Beam Indicator Light 10. Battery 2. City Light 11. Tail Lights 3. Headlights 12. Ignition Switch 4. Headlight Relay (Low Beam) 13. Junction Box 5. Headlight Relay (High Beam) 14. Tail Light Fuse 10 A 6.
  • Page 545 ELECTRICAL SYSTEM 16-55 Lighting System • Remove: Turn Signal Relay [A] • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how many times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig-...
  • Page 546 16-56 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Lights (Right and Left) 2. Front Right Turn Signal Light 3. Front Left Turn Signal Light 4. Hazard Button 5. Turn Signal Switch 6. Turn Signal Relay 7.
  • Page 547: Air Switching Valve (zx1200-b3)

    ELECTRICAL SYSTEM 16-57 Air Switching Valve (ZX1200-B3) Air Switching Valve Operation Test • Pull the air switching valve hose out of the air cleaner base. • Start the engine and run it at idle speed. • Plug [A] the air switching valve hose [B] end with your finger and feel vacuum pulsing in the hose.
  • Page 548: Radiator Fan System

    16-58 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Remove the left lower fairing (see Frame chapter). • Disconnect the connector [A] from the radiator fan switch. • Using an auxiliary lead, connect it to the terminals in the connector.
  • Page 549: Fan Relay Inspection

    ELECTRICAL SYSTEM 16-59 Radiator Fan System Fan Relay Inspection • Remove the fan relay (see Fan Relay Removal). • Connect the hand tester [A] and one 12 V battery [B] to the relay connector [C] as shown. Special Tool - Hand Tester: 57001-1394 Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] Testing Relay...
  • Page 550: Meter

    16-60 ELECTRICAL SYSTEM Meter Meter Unit Removal • Remove: Wind Shield (see Frame chapter) • Slide the dust cover [A] and remove the wiring connector [B]. • Remove: Mounting Nuts [C] Meter Unit [D] CAUTION Do not drop the meter unit. Meter Unit Disassembly •...
  • Page 551: Meter Unit Inspection

    ELECTRICAL SYSTEM 16-61 Meter Meter Unit Inspection • Remove: Meter Unit [A] (see Meter Unit Removal) CAUTION Do not drop the meter unit. [1] Tachometer Pulse [2] Fuel Level Sensor [3] Oil Pressure Warning Indicator Light (LED) Ground [4] Left Turn Signal Indicator Light (+) [5] Right Turn Signal Indicator Light (–) [6] High Beam Indicator Light (+) [7] Neutral Indicator Light (–)
  • Page 552 16-62 ELECTRICAL SYSTEM Meter Check 2: CLOCK/TRIP A and ODO/TRIP B Button Operation Check • Connect the leads in the same circuit as for the Check 1. • Check that when the CLOCK/TRIP A button [A] is pushed within two seconds, the display [B] cycles through the two modes.
  • Page 553 ELECTRICAL SYSTEM 16-63 Meter Check 3: Speedometer Check • Connect the leads in the same circuit as for the Check 1. • The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [9].
  • Page 554 16-64 ELECTRICAL SYSTEM Meter Check 6: TRIP A/TRIP B Meter Check • Connect the leads in the same circuit as for the Check 3. • Cycle the display to the TRIP A [A] or TRIP B [B] mode. • Raise the input frequency of the oscillator to quickly see the result of this inspection.
  • Page 555 ELECTRICAL SYSTEM 16-65 Meter Check 8: Coolant Temperature Gauge Inspection • Connect the leads in the same circuit as for the Check 1. • Connect a variable rheostat [A] to terminal [10] and [12] as shown. • Check that the position of segment [B] matches the resis- tance value of the variable rheostat.
  • Page 556 16-66 ELECTRICAL SYSTEM Meter Check 9: Fuel Gauge Inspection • Connect the leads in the same circuit as for the Check 1. • Connect a variable rheostat [A] to terminal [2] and [12] as shown. • Check that the number of segment [B] matches the resis- tance value of the variable rheostat.
  • Page 557 ELECTRICAL SYSTEM 16-67 Meter Check 10: LED Light Inspection • Using the auxiliary leads, connect a 12 V battery to the meter unit connector as follows. Oil Pressure Warning Indicator Light (LED) [A]: Battery Positive (+) Terminal to Terminal [14] Battery Negative (–) Terminal to Terminal [3] FI Indicator Light (LED) [B]: Battery Positive (+) Terminal to Terminal [14]...
  • Page 558 16-68 ELECTRICAL SYSTEM Meter Meter Circuit ZX1200-B1/B2 1. Meter Unit 2. High Beam Indicator Light 12 V 1.1 W 3. Left Turn Signal Indicator Light 12 V 1.1 W 4. Right Turn Signal Indicator Light 12 V 1.1 W 5. Neutral Indicator Light 12 V 1.1 W 6.
  • Page 559 ELECTRICAL SYSTEM 16-69 Meter ZX1200-B3 1. Meter Unit 2. High Beam Indicator Light 12 V 1.1 W 3. Left Turn Signal Indicator Light 12 V 1.1 W 4. Right Turn Signal Indicator Light 12 V 1.1 W 5. Neutral Indicator Light 12 V 1.1 W 6.
  • Page 560: Immobilizer System (equipped Models) (zx1200-b3)

    • Prepare a new spare user key. • Cut the key in accordance with the shape of the current user key. • Remove: Rear Seat with Cover (see Frame chapter) • Disconnect the immobilizer/Kawasaki self-diagnosis sys- tem connector [A].
  • Page 561 ELECTRICAL SYSTEM 16-71 Immobilizer System (Equipped Models) (ZX1200-B3) • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 • Insert the master key to the ignition switch and turn it ON. Verified ○ The FI indicator light [A] blinks to display the registration mode (go to the next step).
  • Page 562 16-72 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) • Insert the user key 1 to the ignition switch and turn it ON. NOTE ○ Keep the other user key away from the immobilizer an- tenna. ○ If there is any problem in the registration, the FI indicator light [A] blinks to display the collation error.
  • Page 563 ELECTRICAL SYSTEM 16-73 Immobilizer System (Equipped Models) (ZX1200-B3) • Turn the user key 1 OFF and remove off the user key 1. ○ The FI indicator light [A] blinks to display the registration mode. NOTE ○ Turn off the ignition switch and wait for the period of 15 seconds or more.
  • Page 564 The registration mode automatically ends. • FI indicator light goes off [A]. • Remove the key registration unit and connect the immo- bilizer Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○...
  • Page 565 ELECTRICAL SYSTEM 16-75 Immobilizer System (Equipped Models) (ZX1200-B3) Spare User Key Registration Flow Chart...
  • Page 566 Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Rear Seat with Cover (see Frame chapter) • Disconnect the immobilizer/Kawasaki self-diagnostic sys- tem connector. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 •...
  • Page 567 ELECTRICAL SYSTEM 16-77 Immobilizer System (Equipped Models) (ZX1200-B3) Not Verified ○ The FI indicator light [A] blinks to display the collation er- ror. Immobilizer Amplifier Failure Master Key Collation Error • Turn off and remove the new user key 1. •...
  • Page 568 16-78 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) When Registered User Key is Inserted. User Key Collation Error • The user key 1 is successfully registered in the ECU. ○ The FI indicator light [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1.
  • Page 569 ELECTRICAL SYSTEM 16-79 Immobilizer System (Equipped Models) (ZX1200-B3) ○ If there is any problem in the registration, the FI indicator light [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 570 16-80 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) • Remove the key registration unit and connect the immo- bilizer/Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis- tered user keys.
  • Page 571 ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) (ZX1200-B3) • The master key is registered in the ECU. ○ The FI indicator light [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. •...
  • Page 572 16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) User Key Collation Error • The user key 1 is registered in the ECU. ○ The FI indicator light [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.
  • Page 573 ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) (ZX1200-B3) When Registered User Key is Inserted. User Key Collation Error • The user key 2 is registered in the ECU. ○ The FI indicator light [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2.
  • Page 574 16-84 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) • Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE ○ The key registration unit is not required. ○ The key registration process is same as the electric con- trol unit replacement.
  • Page 575 ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) (ZX1200-B3) All Keys Initial Registration Flow Chart...
  • Page 576: Immobilizer System Parts Replacement

    16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) (ZX1200-B3) Immobilizer System Parts Replacement Immobilizer Antenna • Remove: Left Lower Inner Cover (see Frame chapter) • Disconnect the lead connectors [A]. • Remove: Steering Stem Head (see Steering chapter) Handlebar (see Steering chapter) •...
  • Page 577 ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) (ZX1200-B3) ECU (Electric Control Unit) Replacement (for European Model) • Remove: Rear Seat with Cover (see Frame chapter) • Remove the screws [A] and upper guard bracket [B]. • Remove: ECU [A] • Disconnect the connectors [B] and remove the under guard bracket.
  • Page 578: Immobilizer System Inspection

    Refer to the Immobilizer Amplifier and Blank Key Detec- tion section in the Fuel System (DFI) chapter. Immobilizer System Circuit 1. Immobilizer Amplifier 7. ECU Fuse 15 A 13. Immobilizer/Kawasaki 2. Immobilizer Antenna 8. Junction Box Diagnostic System Con- 3. Ignition Switch 9.
  • Page 579: Switches And Sensors

    ELECTRICAL SYSTEM 16-89 Switches and Sensors Front Brake Light Switch Inspection • Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter. Rear Brake Light Switch Check/Adjustment • Refer to the Rear Brake Light Switch Inspection/Adjust- ment in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 580: Radiator Fan Switch Inspection

    16-90 ELECTRICAL SYSTEM Switches and Sensors Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection [C] and threaded portion [C] are submerged. •...
  • Page 581: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-91 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.
  • Page 582: Speed Sensor Installation

    16-92 ELECTRICAL SYSTEM Switches and Sensors • Remove: Speed Sensor Mounting Bolt [A] Speed Sensor [B] Speed Sensor Installation • Apply grease or engine oil to the O-ring [A] on the speed sensor. • Tighten: Torque - Speed Sensor Mounting Bolt: 10 N·m (1.0 kgf·m, 89 in·lb) Speed Sensor Inspection •...
  • Page 583: Fuel Reserve Switch Inspection (1)

    ELECTRICAL SYSTEM 16-93 Switches and Sensors • Remove: Bolts [A] Fuel Level Sensor [B] • Check that the float moves up and down smoothly without binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor. Float in Full Position [A] Float in Empty Position [B] Float Arm Stoppers [C]...
  • Page 584: Fuel Reserve Switch Inspection

    16-94 ELECTRICAL SYSTEM Switches and Sensors Fuel Reserve Switch Inspection (2) • Remove: Fuel Pump (see Fuel System (DFI) chapter) • Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump connector as shown.
  • Page 585: Junction Box

    ELECTRICAL SYSTEM 16-95 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove: Fuel Tank Cover (see Fuel System (DFI) chapter) Rubber Cover Connectors Junction Box •...
  • Page 586: Diode Circuit Inspection

    16-96 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading (Ω) Tester Connection Tester Reading (Ω) *7 - 8 ∞ 9 - 11 ∞ Head- ∞ 12 - 13 ∞ *7 - 13 light Re- Starter (+) (–) (+) (–)
  • Page 587 ELECTRICAL SYSTEM 16-97 Junction Box Junction Internal Circuit (U.S.A., Canadian, Australian, Malaysian/ZX1200-B2/B3 Models) Junction Box Internal Circuit (Other than U.S.A., Canadian, Australian, and Malaysian Models) A. Fan Fuse 15 A G. Headlight Relay B. Fan Fuse 15 A H. Headlight Diodes C.
  • Page 588: Fuse

    16-98 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Battery Tray (see Battery Removal) Screw [A] Cover [B] • Disconnect the Connector [A]. • Pull out the 30 A main fuse [B] from the starter relay with a needle nose pliers. 30 A Headlight/Fan Fuse Removal •...
  • Page 589: 15 A Ecu Fuse Removal

    ELECTRICAL SYSTEM 16-99 Fuse 15 A ECU Fuse Removal • Remove: Fuel Tank Cover Plate (see Fuel System (DFI) chapter) 15 A ECU Fuse [A] Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 590 16-100 ELECTRICAL SYSTEM Wiring Diagram (U.S.A. and Canada)
  • Page 591 ELECTRICAL SYSTEM 16-101 Wiring Diagram (U.S.A. and Canada)
  • Page 592: Wiring Diagram (australia/zx1200-b2: H, Hu, Hr Models)

    16-102 ELECTRICAL SYSTEM Wiring Diagram (Australia/ZX1200-B2: H, HU, HR models)
  • Page 593 ELECTRICAL SYSTEM 16-103 Wiring Diagram (Australia/ZX1200-B2: H, HU, HR models)
  • Page 594: Wiring Diagram (malaysia)

    16-104 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
  • Page 595 ELECTRICAL SYSTEM 16-105 Wiring Diagram (Malaysia)
  • Page 596: Wiring Diagram (other Than U.s.a., Canada, Australia, And Malaysia)

    16-106 ELECTRICAL SYSTEM Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
  • Page 597 ELECTRICAL SYSTEM 16-107 Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
  • Page 598: Wiring Diagram (zx1200-b3: U.s.a., And Canada)

    16-108 ELECTRICAL SYSTEM Wiring Diagram (ZX1200-B3: U.S.A., and Canada)
  • Page 599 ELECTRICAL SYSTEM 16-109 Wiring Diagram (ZX1200-B3: U.S.A., and Canada)
  • Page 600: Wiring Diagram (zx1200-b3: Other Than U.s.a., Canada, Hong Kong, Kuwait And Malaysia)

    16-110 ELECTRICAL SYSTEM Wiring Diagram (ZX1200-B3: Other than U.S.A., Canada, Hong Kong, Kuwait and Malaysia)
  • Page 601: Wiring Diagram (zx1200-b3: Hong Kong, Kuwait)

    ELECTRICAL SYSTEM 16-111 Wiring Diagram (ZX1200-B3: Other than U.S.A., Canada, Hong Kong, Kuwait and Malaysia)
  • Page 602 16-112 ELECTRICAL SYSTEM Wiring Diagram (ZX1200-B3: Hong Kong, Kuwait)
  • Page 603 ELECTRICAL SYSTEM 16-113 Wiring Diagram (ZX1200-B3: Hong Kong, Kuwait)
  • Page 604: Wiring Diagram (zx1200-b3: Malaysia)

    16-114 ELECTRICAL SYSTEM Wiring Diagram (ZX1200-B3: Malaysia)
  • Page 605 ELECTRICAL SYSTEM 16-115 Wiring Diagram (ZX1200-B3: Malaysia)
  • Page 607 TROUBLESHOOTING 17-1 Troubleshooting Table of Contents Troubleshooting Guide ......................17-2...
  • Page 608: Troubleshooting Guide

    17-2 TROUBLESHOOTING Troubleshooting Guide NOTE Immobilizer system trouble (ZX1200-B3) ○ Refer to the Fuel System chapter for most Spark plug dirty, broken, or gap malad- of DFI trouble shooting guide. justed ○ This is not an exhaustive list, giving every Stick coil shorted or not in good contact possible cause for each problem listed.
  • Page 609: Troubleshooting

    TROUBLESHOOTING 17-3 Troubleshooting Guide Fuel pump trouble Cylinder, piston worn Throttle body assy holder loose Piston ring bad (worn, weak, broken, or Air cleaner duct loose sticking) Compression low: Piston ring/groove clearance excessive Spark plug loose Cylinder head gasket damaged Cylinder head not sufficiently tightened Cylinder head warped down...
  • Page 610: Gear Shifting Faulty

    17-4 TROUBLESHOOTING Troubleshooting Guide Air cleaner clogged Clutch friction plate installed wrong Compression high: Clutch lever play excessive Carbon built up in combustion chamber Clutch release mechanism trouble Engine load faulty: Gear Shifting Faulty: Clutch slipping Engine oil level too high Doesn’t go into gear;...
  • Page 611: Exhaust Smokes Excessively

    TROUBLESHOOTING 17-5 Troubleshooting Guide Oil Pressure Warning Light Goes On: Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con- Engine oil pump damaged nection Engine oil screen clogged Crankshaft runout excessive Engine oil filter clogged Engine mount loose Engine oil level too low Crankshaft bearing worn Engine oil viscosity too low...
  • Page 612: Battery Trouble

    17-6 TROUBLESHOOTING Troubleshooting Guide Shock absorption unsatisfactory: Brake fluid deteriorated (Too hard) Primary or secondary cup damaged in master Front fork oil excessive cylinder Front fork oil viscosity too high Master cylinder scratched inside Rear shock absorber adjustment too hard Battery Trouble: Tire air pressure too high Front fork bent...
  • Page 613 MODEL APPLICATION Year Model Beginning Frame No. □ JKAZX9B1 2A000001 or JKAZXT20ABA035001 or □ 2002 ZX1200-B1 JKAZX9B1 2A035001 or □ JKAZX9B1 2A000001 or ZXT20B-000001 □ JKAZX9B1 3A008001 or 2003 ZX1200-B2 JKAZXT20ABA041001 or ZXT20B-008001 □ JKAZX9B1 4A012001 or 2004 ZX1200-B3 JKAZXT20ABA045001 or ZXT20B-012001 □...

Comments to this Manuals

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Latest comments:
  • JB Sep 01, 2015 12:12:
    WANT TO CHECK STRIPPING OF GEARBOX
  • JB Sep 01, 2015 12:12:
    WANT TO CHECK STRIPPING OF GEARBOX