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Kawasaki Ninja ZX-10R Service Manual

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Table of Contents
Ninja ZX-10R
Ninja ZX-10R ABS
Motorcycle
Service Manual

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Table of Contents
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  Summary of Contents for Kawasaki Ninja ZX-10R

  • Page 1 Ninja ZX-10R Ninja ZX-10R ABS Motorcycle Service Manual...
  • Page 3: General Information

    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 Self-Diagnosis System...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6: Country And Area Codes

    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 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 vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    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 Specifications......................1-11 Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) ......1-14 Technical Information-Power Mode ..................1-17 Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) ............................. 1-19 Technical Information - Electronic Steering Damper (ESD/ZX1000JD/KD models) ....1-23 Unit Conversion Table ......................
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX1000JB (US and CA Models) Left Side View ZX1000JB (US and CA Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX1000JB (EUR Models) Left Side View ZX1000JB (EUR Models) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZX1000KB (US and CA Models) Left Side View ZX1000KB (US and CA Models) Right Side View...
  • Page 20 1-10 GENERAL INFORMATION Model Identification ZX1000KB (EUR Models) Left Side View ZX1000KB (EUR Models) Right Side View Frame Number Engine Number...
  • Page 21: General Specifications

    GENERAL INFORMATION 1-11 General Specifications ZX1000JB ∼ JD/KB ∼ KD Items Dimensions Overall Length 2 075 mm (81.69 in.) Overall Width 715 mm (28.1 in.) Overall Height 1 115 mm (43.90 in.) Wheelbase 1 425 mm (56.10 in.) Road Clearance 135 mm (5.31 in.) Seat Height 813 mm (32.0 in.)
  • Page 22 1-12 GENERAL INFORMATION General Specifications ZX1000JB ∼ JD/KB ∼ KD Items Valve Timing: Intake: Open 36° (BTDC) Close 80° (ABDC) Duration 296° Exhaust: Open 74° (BBDC) Close 39° (ATDC) Duration 293° Lubrication System Forced lubrication (wet sump with oil cooler) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2...
  • Page 23 GENERAL INFORMATION 1-13 General Specifications ZX1000JB ∼ JD/KB ∼ KD Items Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm (horizontal back-link) Wheel Travel 140 mm (5.51 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment...
  • Page 24: Technical Information-Sport-Kawasaki Traction Control System (S-Ktrc)

    1-14 GENERAL INFORMATION Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) Overview S-KTRC is a highly sophisticated system based on MotoGP racing technology. Unlike the KTRC system used on the GTR1400 ABS (Concours 14 ABS in N. America), which is designed to offer rider reassurance when traversing slippery surfaces, S-KTRC, is designed to maximize forward motion, allowing riding at the edge of traction.
  • Page 25 The wheel rotation sensor converts front and rear wheel rotation speed to a pulse signal and transmits it to the FI ECU. As for the KIBS (Kawasaki Intelligent anti-lock Brake Sys- tem) equipped model, a pulse signal is transmitted via the KIBS ECU.
  • Page 26 1-16 GENERAL INFORMATION Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC) 6. Multifunction Meter The multifunction meter receives a mode-switching signal and displays the mode [A], and transmits it to the FI ECU by the CAN system. When a failure occurs in the system, the multifunction me- ter displays the warning indication by blinking the warning indicator light (yellow LED) [B] and mode indicator symbol.
  • Page 27: Technical Information-Power Mode

    GENERAL INFORMATION 1-17 Technical Information-Power Mode The rider can choose from three engine power modes to suit their preferences and road conditions. The FI ECU controls the engine power by adjusting fuel injection, air intake, and ignition timing. It enables three-mode selection: Full Power (Mode F), Middle Power (Mode M), and Low Power (Mode In addition, combining each mode with each S-KTRC setting allows the rider to have more choices to be able to interact with various conditions.
  • Page 28 1-18 GENERAL INFORMATION Technical Information-Power Mode Mode F: The highest engine power output is achieved. The rider can use the full power of the engine. Mode M: The throttle response is less sharp compared to mode F. Depending on the throttle application, full power can be accessed temporarily.
  • Page 29: Technical Information-Kawasaki Intelligent Anti-Lock Brake System (Kibs/Zx1000K Model Only)

    (KIBS/ZX1000K model only) Overview Kawasaki Intelligent anti-lock Brake System (KIBS) offers enhanced braking stability (ABS perfor- mance equivalent to the current model) to supersport models, which pitch more than most motorcycles and also offers high-precision front and rear brake pressure control (high-precision ABS) for sport rid- ing.
  • Page 30 1-20 GENERAL INFORMATION Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) 3. KIBS Hydraulic Unit The KIBS hydraulic unit consists of the hydraulic unit and KIBS ECU and has the front caliper hydraulic pressure sen- sor built-in. When receiving a signal from the KIBS ECU, the hydraulic unit increases or decreases the front and rear brake hy- draulic pressure.
  • Page 31 GENERAL INFORMATION 1-21 Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) KIBS Control 1. ABS performance equivalent to the current model (enhanced braking stability) By monitoring front caliper hydraulic pressure, KIBS regulates pressure increases reducing the ten- dency of the rear to lift. Before the ABS system fully reacts, KIBS system prevents the pressure from increasing too quickly thus suppressing rear lift.
  • Page 32 1-22 GENERAL INFORMATION Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only) 3. Rear brake control enhancement during engine braking By recognizing rear wheel slip due to engine brake force during aggressive throttle operation, and at high rpm or downshifting, the KIBS system prevents unnecessary ABS intervention to the rear wheel...
  • Page 33: Technical Information - Electronic Steering Damper (Esd/Zx1000Jd/Kd Models)

    1) Overview This model has an Electronic Steering Damper (ESD) [A]. Unlike conventional manual adjustment method of Kawasaki, damping characteristics are adjusted by the electronic control unit. 2) Purpose Designed to offer increased stability at high speed without interfering with light and nimble steering at low speed.
  • Page 34 1-24 GENERAL INFORMATION Technical Information - Electronic Steering Damper (ESD/ZX1000JD/KD models) 5) Related Parts Meter [A] Electronic Steering Damper (ESD) [B]...
  • Page 35 GENERAL INFORMATION 1-25 Technical Information - Electronic Steering Damper (ESD/ZX1000JD/KD models) ESD ECU [A] FI ECU [B] Rear Wheel Rotation Sensor [A] 6) Meter Added an indicator “ESD” warning symbol [A] in the in- struments. The yellow warning indicator light [B] and ESD warning symbol go on whenever there is a malfunction in the ESD system.
  • Page 36: Unit Conversion Table

    1-26 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 N·m ×...
  • Page 37 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Co