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Ninja ZX-10R
Ninja ZX-10R ABS
Assembly & Preparation


Table of Contents

   Summary of Contents for Kawasaki Ninja ZX-10R

  • Page 1 Ninja ZX-10R Ninja ZX-10R ABS Motorcycle Assembly & Preparation Manual...
  • Page 2 Recharge the Battery First! The 2011 Ninja ZX-10R comes with a pre-filled, pre-charged sealed battery, eliminating the need for dealers to prepare the battery by filling it with electrolyte. However, the battery must be charged upon initial receipt of each unit since it may...
  • Page 3 Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual ex- plains step by step procedures of the following NOTICE items for all Kawasaki Ninja ZX-10R and Ninja NOTICE is used to address practices not ZX-10R ABS. related to personal injury.
  • Page 4: Table Of Contents

    Table of Contents Uncrating ..................Opening Crate ................Parts Check ................. Assembly ..................Windshield................... Rider’s Seat Bolt................Brake Disc Cleaning ..............Preparation ................... Battery Service ................Front Brake Fluid................. Rear Brake Fluid ................. Clutch Lever and Cable ............... Drive Chain.................. Steering Damper .................
  • Page 5: Uncrating

    UNCRATING 3 Uncrating Opening Crate WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrat- ing to prevent injury. A. Straps B. Battery Cardboard Box •...
  • Page 6 4 UNCRATING A. Front Axle Holding Nut (D = 14) A. Lower Support Bracket B. Front Support Bracket (Left) B. Rubber Washer (D = 11.5 × 30) C. Bolt (D = 8, L = 12) D. Rubber Washers (D = 14.5) •...
  • Page 7: Parts Check

    UNCRATING 5 Parts Check • Open the parts cardboard box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. Part Name Remarks Plastic Washer...
  • Page 8: Assembly

    (D = 5, L = 16) on the Battery Service upper fairing. Charged Battery Service The 2011 Ninja ZX-10R comes with a pre -filled, pre-charged sealed battery, eliminating the need for dealers to prepare the battery by filling it with electrolyte. However, the battery...
  • Page 9 0.9 A × 5 ∼ Standard Charge 10 hours 10 hours • Use a recommended battery charger, follow- ing the manufacturer’s instructions. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO 2 Yuasa MB-2040/2060 Christie C10122S • If the recommended chargers are not avail- able, use equivalent one.
  • Page 10: Battery Installation

    8 PREPARATION ○ NOTE The battery manufacturing date is printed on ○ battery top. Determine the condition of the battery 30 min- utes after completion of the charge by mea- Example) suring the terminal voltage according to the table below. Day Month Year Mfg.
  • Page 11 PREPARATION 9 For models equipped with KIBS: A. Socket Bolts (D = 5, L = 16) B. Seat Cover A. Battery (YTZ10S) B. Band (L = 164) • Remove the rider’s seat. C. (+) Cable NOTICE D. (–) Cable Be sure the correct battery is installed in E.
  • Page 12: Front Brake Fluid

    10 PREPARATION A. Rider’s Seat A. Socket Bolts (D = 5, L = 16) B. Tabs B. Seat Cover C. Slots • Insert the tab on the rear of the passenger’s • seat into the slot in the frame. Secure the rider’s seat with two flange bolts •...
  • Page 13 PREPARATION 11 A. Reservoir A. Front Brake Fluid Reservoir B. Cap B. Upper Level Line C. Clockwise C. Lower Level Line D. 1/6 turn D. Cap Stopper Screw • If the fluid level in the reservoir is lower than NOTICE the lower level line, check for fluid leaks in the Brake fluid quickly ruins painted sur- front brake lines and fill the reservoir.
  • Page 14: Rear Brake Fluid

    12 PREPARATION • • Pump the brake lever a few times until it Repeat the previous step one more time for becomes hard and then, holding the lever the other front disc brake. • squeezed, quickly open (turn counterclock- When air bleeding is finished, check that the wise) and close the bleed valve.
  • Page 15 PREPARATION 13 • NOTICE Attach a clear plastic hose to the bleed valve on the rear brake caliper and run the other Brake fluid quickly ruins painted sur- end of the hose into a container. faces. Wipe up any spilled fluid immedi- •...
  • Page 16: Clutch Lever And Cable

    14 PREPARATION Clutch Lever and Cable Drive Chain Clutch Lever Free Play Inspection Drive Chain Slack and Wheel Alignment • Inspection Check that the clutch lever has the specified • amount of free play as shown in the figure. Set the motorcycle up on its side stand. •...
  • Page 17 PREPARATION 15 • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. • Install a new cotter pin. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise up to the next alignment.
  • Page 18: Steering Damper

    Damping Adjustment Standard Setting Position: This motorcycle is equipped with the steer- 6 turns in from the fully seated position ing damper unit. Kawasaki recommends that (turned fully counterclockwise) this steering damping adjuster is at the standard setting during everyday riding.
  • Page 19: Rear Shock Absorber

    PREPARATION 17 Rebound Damping Adjuster: Compression Damping Adjustment • • Turn the rebound damping adjuster clockwise Check the position of the compression damp- all the way, then turn it counterclockwise to ing adjuster on the gas reservoir at the left the standard setting position.
  • Page 20: Tire Air Pressures

    18 PREPARATION For US, Canada and Brazil Models Tire Air Pressures Fuel Type Unleaded Gasoline • (RON + MON) To prevent flat-spotting during shipment, the Antiknock Minimum tires are over-inflated before crating. Adjust Index Octane the pressures to the specified values in the Rating front and rear, and make sure to tighten the caps securely.
  • Page 21 PREPARATION 19 • Reinstall the right fairing and cover in reverse order of removal. NOTE ○ Insert the tabs on the right fairing and cover into the slots of the upper fairing. A. Right Fairing and Cover B. Bolts (D = 5, L = 16) and Plastic Washers C.
  • Page 22: Engine Oil (4-stroke)

    20 PREPARATION Engine Oil (4-stroke) Engine Oil Level Inspection NOTE ○ This vehicle’s engine is filled with 10W-40 oil from the factory. DO NOT DRAIN and refill the crankcase before use. Check oil level and drain plug tightness. Engine Oil Drain Plug Torque: 29 N·m (3.0 kgf·m, 21 ft·lb) A.
  • Page 23: Throttle Grip And Cable

    PREPARATION 21 Throttle Grip and Cable Throttle Grip Free Play Inspection • Inspect the throttle grip free play. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) •...
  • Page 24: Headlight Aim

    22 PREPARATION A. Rear Brake Light Switch A. Inside Adjuster B. Adjusting Nut B. Outside Adjuster C. Lights sooner C. Screwdriver D. Lights later For US and Canadian models: E. Viewed from behind the bracket NOTE ○ NOTICE On high beam, the brightest point should be slightly below horizontal.
  • Page 25: Digital Meter

    PREPARATION 23 Check the Display Mode: The display mode can alternate between the Digital Meter "Normal mode" and the "Race mode" in the dig- ital meter. Check the Display Unit Setting in the The "Race mode" gives priority to reading the Digital Meter: gear position rather than the speedometer read- The display unit setting can alternate between...
  • Page 26 24 PREPARATION • Push and hold the upper button until the mode has been shifted. Check if the Shift-Up Indicator is “OFF”: The shift-up indicator can be used in closed course competition. Do not use the shift-up in- dicator during everyday riding. The shift-up indicator has three modes, light off, fast blinking or slow blinking.
  • Page 27 PREPARATION 25 This page intentionally left blank.
  • Page 28: Fastener Check

    26 PREPARATION Fastener Check • The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place.
  • Page 29 PREPARATION 27 Torque Fastener Remarks N·m kgf·m ft·lb Frame/Steering Handlebar mounting bolt (Left and Right) Brake Front caliper bleed valve (Left and Right) 0.80 69 in·lb Front caliper mounting bolt (Left and Right) Front master cylinder clamp bolt 97 in·lb Front master cylinder bleed valve 0.55 48 in·lb...
  • Page 30: Standard Torque Table

    28 PREPARATION Electrical System: Standard Torque Table Headlight - check high and low beams. This table relating tightening torque to thread Taillight - check operation. diameter, lists the basic torque for bolts and Brake Light - check operation. nuts. Use this table for only the bolts and nuts Turn Signal Lights - check operation.
  • Page 32 MODEL APPLICATION Year Model Name 2011 ZX1000JBF Ninja ZX-10R 2011 ZX1000KBF Ninja ZX-10R, Ninja ZX-10R ABS Part No. 99931-1521-02...

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