![Kawasaki NINJA ZX12R (2000) [2/434] Ninja zx 12r](/img/pdf.png)
Kawasaki NINJA ZX12R (2000) [2/434] Ninja zx 12r
![Kawasaki NINJA ZX12R (2000) [2/434] Ninja zx 12r](/views2/1121156/page2/bg2.png)
Содержание
- Forward ch 0 1
- Kawasaki 2
- Motorcycle 2
- Ninja zx 12r 2
- Service manual 2
- Quick reference guide 3
- List of abbreviations 4
- Read owner s manual before operating 4
- Emission control information 5
- Tampering with noise control system prohibited 6
- A warning 7
- Caution 7
- Foreword 7
- How to use this manual 7
- Kawasaki 8
- Model application 8
- Part no 99924 1253 01 8
- General info ch 1 9
- General information 9
- General information 1 1 9
- Table of contents 9
- 2 general information 10
- Before servicing 10
- Before servicing 11
- General information 1 3 11
- Wire cross section name of wire color 11
- Wire strands 11
- Yellow 11
- Yellow red 11
- 4 general information 12
- Model identification 12
- General information 1 5 13
- General specifications 13
- 6 general information 14
- General specifications 14
- General information 1 7 15
- Periodic maintenance chart 15
- 8 general information 16
- Honeycomb type catalytic converter 16
- Technical information kleen kawasaki low exhaust emission system 16
- General information 1 9 17
- Technical information kleen kawasaki low exhaust emission system 17
- 10 general information 18
- Technical information monocoque frame 18
- Caution 19
- Feature 19
- General information 1 11 19
- Specification 19
- Technical information spark plug 19
- 12 general information 20
- Basic torque for general fasteners 20
- Torque and locking agent 20
- General information 1 13 21
- Torque and locking agent 21
- 14 general information 22
- Torque and locking agent 22
- General information 1 15 23
- Torque and locking agent 23
- 16 general information 24
- Special tools and sealant 24
- General information 1 17 25
- Special tools and sealant 25
- 18 general information 26
- Special tools and sealant 26
- General information 1 19 27
- Special tools and sealant 27
- _________ i 27
- 20 general information 28
- Special tools and sealant 28
- General information 1 21 29
- Special tools and sealant 29
- General information 1 23 31
- Caution of inlet air pressure 33
- General information 1 25 33
- Sensor i nstai i at i on 33
- 26 general information 34
- Cable wire and hose routing 34
- Viewed from right side 34
- Cable wire and hose routing 35
- General information 1 27 35
- General information 1 29 37
- O m cr 0 37
- General information 1 31 39
- General information 1 33 41
- California model 45
- General information 1 37 45
- Digital fuel injection dfi system 47
- Digital fuel injection dfi system 2 1 47
- Fuel injection ch 2 47
- Table of contents 47
- 2 digital fuel injection dfi system 48
- Digital fuel injection dfi system 2 3 49
- Exploded view 49
- 4 digital fuel injection dfi system 50
- Exploded view 50
- Digital fuel injection dfi system 2 5 51
- Exploded view 51
- 6 digital fuel injection dfi system 52
- Specifications 52
- Specifications 53
- ________________________ digital fuel injection dfi system 2 7 53
- 8 digital fuel injection dfi system 54
- Throttle grip and cables 54
- Warning 54
- Digital fuel injection dfi system 2 9 55
- Fast idle cable 55
- Warning 55
- 10 digital fuel injection dfi system 56
- A warning 56
- Throttle body assy 56
- Caution 57
- Throttle body assy 57
- _______________________ eg g fuel injection ph system 2 11 57
- 12 digital fuel injection dfi system 58
- Caution 58
- Throttle body assy 58
- Warning 58
- Digital fuel injection dfi system 2 13 59
- Throttle body assy 59
- Warning 59
- 14 digital fuel injection dfi system 60
- Caution 60
- Throttle body assy 60
- Warning 60
- Air line 61
- Caution 61
- Digital fuel injection dfi system 2 15 61
- Warning 61
- 16 digital fuel injection dfi system 62
- A warning 62
- Air line 62
- A warning 63
- Caution 63
- Digital fuel injection dfi system 2 17 63
- Fuel tank 63
- 18 digital fuel injection dfi system 64
- Caution 64
- Fuel tank 64
- Warning 64
- Digital fuel injection dfi system 2 19 65
- Fuel tank 65
- 20 digital fuel injection dfi system 66
- Caution 66
- Fuel tank 66
- Warning 66
- Dfi system 69
- Digital fuel injection dfi system 2 23 69
- 24 digital fuel injection dfi system 70
- Dfi system 70
- Terminal names 70
- Terminal numbers of ecu connectors 70
- Dfi servicing precautions 71
- Digital fuel injection dfi system 2 25 71
- 26 digital fuel injection dfi system 72
- Dfi servicing precautions 72
- Caution 73
- Digital fuel injection dfi system 2 27 73
- Outline 73
- Troubleshooting the dfi system 73
- 28 digital fuel injection dfi system 74
- Troubleshooting the dfi system 74
- Digital fuel injection dfi system 2 29 75
- Troubleshooting the dfi system 75
- 30 digital fuel injection dfi system 76
- Troubleshooting the dfi system 76
- Digital fuel injection dfi system 2 31 77
- 32 digital fuel injection df1 system 78
- Inquiries to rider 78
- Troubleshooting the dfi system 78
- Digital fuel injection dfi system 2 33 79
- Troubleshooting the dfi system 79
- 34 digital fuel injection dfi system 80
- Problem chart 80
- Troubleshooting the dfi system 80
- Digital fuel injection dfi system 2 35 81
- Troubleshooting the dfi system 81
- 36 digital fuel injection dfi system 82
- Troubleshooting the dfi system 82
- Caution 83
- Digital fuel injection dfi system 2 37 83
- 38 digital fuel injection dfi system 84
- Battery c in the frame 84
- Check the ecu power source voltage with the hand tester o position the terminal in accordance with terminal numbers of ecu 84
- Connectors in this chapter figure 84
- Ecu the ecu itself cannot be checked or serviced 84
- Harness and repair or replace them if necessary 84
- If no continuity check the connector the engine ground wire or main 84
- If the inspection checks good the ecu is damaged replace the 84
- If the tester does not read as specified check the following 84
- Power source wiring see wiring diagram below ecu fuse 15 a see dfi power source section ecu main relay see dfi power source section ignition fuse 10 a see electrical system chapter main fuse 30 a see electrical system chapter 84
- Wire for continuity with the ignition sw off using the hand tester 84
- With the ecu connectors a connected check the following ground 84
- Digital fuel injection dfi system 2 39 85
- Ecu power source circuit 85
- 40 digital fuel injection dfi system 86
- Caution 86
- Dfi power source 86
- Digital fuel injection dfi system 2 41 87
- 42 digital fuel injection dfi system 88
- Fl indicator led light 88
- Digital fuel injection dfi system 2 43 89
- Fuel line 89
- 44 digital fuel injection dfi system 90
- Fuel line 90
- Warning 90
- Caution 91
- Digital fuel injection dfi system 2 45 91
- In tank fuel pump 91
- Warning 91
- 46 digital fuel injection dfi system 92
- In tank fuel pump 92
- Warning 92
- Digital fuel injection dfi system 2 47 93
- In tank fuel pump 93
- 48 digital fuel injection dfi system 94
- In tank fuel pump 94
- Digital fuel injection dfi system 2 49 95
- Self diagnosis _________________________________ 95
- Self diagnosis function 95
- Self diagnosis outline 95
- 50 digital fuel injection dfi system 96
- Self diagnosis 96
- Self diagnosis procedures 96
- Digital fuel injection dfi system 2 51 97
- 52 digital fuel injection dfi system 98
- How to read fault codes 98
- Self diagnosis 98
- How to erase fault codes 99
- Jtwljmm 99
- Jw1tlt1ji 99
- Nnnnjlfl 99
- Nnnnjwlr 99
- Nnnnn_m 99
- Nnnnnjwui 99
- Nnrinrum 99
- Nntltljwuwl 99
- Nruwmji 99
- Rnnruwi 99
- Self diagnosis ________________________________________________________ __________ 99
- ______________ digital fuel injection dfi system 2 53 99
- 54 digital fuel injection dfi system 100
- Backups 100
- Self diagnosis 100
- Digital fuel injection dfi system 2 55 101
- Self diagnosis 101
- 56 digital fuel injection dfi system 102
- Caution 102
- Throttle sensor fault code 11 102
- Throttle sensor fault code 11 103
- _______________________ digstal fuel injection dfi system 2 57 103
- 58 digital fuel injection dfi system 104
- Throttle sensor fault code 11 104
- Caution 105
- Inlet air pressure sensor fault code 12 105
- _______________________ digital fuel 8njecti0n dfi system 2 59 105
- 60 digital fuel injection dfi system 106
- Inlet air pressure sensor fault code 12 106
- Inlet air pressure sensor fault code 12 107
- ______________________ digital fuel injection dfi system 2 61 107
- 62 digital fuel injection dfi system 108
- Inlet air pressure sensor fault code 12 108
- Digital fuel injection dfi system 2 63 109
- Inlet air pressure sensor fault code 12 109
- 64 digital fuel injection dfi system 110
- Caution 110
- Inlet air temperature sensor fault code 13 110
- Inlet air temperature sensor fault code 13 111
- _______________________ digital fuel injection dfi system 2 65 111
- 66 digital fuel injection dfi system 112
- Caution 112
- Water temperature sensor fault code 14 112
- Water temperature sensor fault code 14 113
- _______________________ digital fuel injection dfi system 2 67 113
- 68 digital fuel injection dfi system 114
- Atmospheric pressure sensor fault code 15 114
- Caution 114
- Atmospheric pressure sensor fault code 15 115
- _______________________ digital fuel injection dfi system 2 69 115
- 70 digital fuel injection dfi system 116
- Atmospheric pressure sensor fault code 15 116
- Atmospheric pressure altitude relationship 117
- Atmospheric pressure sensor fault code 15 117
- I i i i i i i i i i i i i i i 117
- _______________________ digital fuel injection dfi system 2 71 117
- 72 digital fuel injection dfi system 118
- Crankshaft sensor fault code 21 118
- Cam sensor fault code 23 119
- Digital fuel injection dfi system 2 73 119
- 74 digital fuel injection dfi system 120
- Gear position switch fault code 25 120
- Adapter set 121
- Be sure the battery is fully charged 121
- Connect a digital voltmeter a to the connector using the needle 121
- Connectors 121
- Connectors joined 121
- Gear position switch fault code 25 121
- Gear position switch input voltage inspection 121
- If the reading of input voltage is out of the standard range check 121
- O mesure the input voltage with the engine stopped and with the 121
- The ecu for its ground and power supply see this chapter if the ground and power supply are good replace the ecu 121
- Turn the ignition switch off remove the ecu see this chapter do not disconnect the ecu 121
- Turn the ignition switch on 121
- _______________________ digital fuel injection dfi system 2 75 121
- 76 digital fuel injection dfi system 122
- Adapter set 122
- Check the input voltage again at the sensor connector 122
- Connect a digital voltmeter h to the connector i using the needle 122
- Connector joined 122
- Gear position switch fault code 25 122
- Gear position switch input voltage connection to ecu 122
- Gear position switch inspection set up the fuel tank disconnect the gear position switch connector a 122
- Gear position tester tester 122
- If the reading is good the input voltage is normal check the gear 122
- If the reading is out of the standard range check the wiring see 122
- If the reading is within the standard range set up the fuel tank and 122
- Input voltage at gear position switch connector except gear position 122
- Input voltage at gear position switch connector respective gear position 122
- Measure the input voltage with the engine stopped and with the 122
- Other than neutral less than 5 v 122
- Position switch 122
- Special tool needle adapter set 57001 1457 122
- Standard 0 v 122
- Standard neutral battery voltage 12 v or more 122
- Tha i gpitiiw smtej q m 122
- Turn the ignition switch off remove the needle adapter set 122
- Wiring diagram in this section 122
- Check the switch for continuity at the following gear positions 123
- Gear position switch 2 junction box 22 123
- Gear position switch fault code 25 123
- Gear position tester tester 123
- If the switch has an open or short circuit repair or replace it 123
- Positions 123
- Signal ecu 1 123
- The switch is normal if there is continuity in the respective gear 123
- _______________________ digital fuel injection dfi system 2 77 123
- 78 digital fuel injection dfi system 124
- Caution 124
- Vehicle down sensor fault code 31 124
- Caution 125
- Digital fuel injection dfi system 2 79 125
- Vehicle down sensor fault code 31 125
- Àwarning 125
- 80 digital fuel injection dfi system 126
- Vehicle down sensor fault code 31 126
- Vehicle down sensor fault code 31 127
- _______________________ digital fuel injection dfi system 2 81 127
- 82 digital fuel injection dfi system 128
- Caution 128
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 128
- And check the output voltage at the injector connector a when the wire is open the output voltage is 0 v 129
- As power source voltage inspection note the following 129
- Digital fuel injection dfi system 2 83 129
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 129
- If the output voltage is normal check the ecu for its ground and 129
- If the output voltage is normal check the wiring for continuity see 129
- If the output voltage is out of the standard perform audible inspec 129
- If the output voltage is out of the standard remove the left inner cover 129
- Needle adapter set b 129
- Next diagram if the wiring is good perform audible inspection for confirmation 129
- Output voltage inspection measure the output voltage at the ecu connector in the same way 129
- Power supply see this chapter if the ground and power supply are good replace the ecu 129
- Tion for confirmation 129
- 84 digital fuel injection dfi system 130
- Caution 130
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 130
- Caution 131
- Digital fuel injection dfi system 2 85 131
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 131
- 86 digital fuel injection dfi system 132
- Caution 132
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 132
- Digital fuel injection dfi system 2 87 133
- Fuel injectors 1 2 3 4 fault code 41 42 43 44 133
- 88 digital fuel injection dfi system 134
- Caution 134
- Fuel pump relay fault code 45 46 134
- Fuel pump relay fault code 45 46 135
- _______________________ digital fuel injection dfi system 2 89 135
- 90 digital fuel injection dfi system 136
- Fuel pump relay fault code 45 46 136
- Fuel pump relay fault code 45 46 137
- _______________________ digital fuel injection dfi system 2 91 137
- 92 digital fuel injection dfi system 138
- Caution 138
- Stick coils 1 2 3 4 fault code 51 52 53 54 138
- Digital fuel injection dfi system 2 93 139
- Stick coils 1 2 3 4 fault code 51 52 53 54 139
- 94 digital fuel injection dfi system 140
- Caution 140
- Evaporative emission control system california model only 140
- Warning 140
- A warning 141
- Digital fuel injection dfi system 2 95 141
- Evaporative emission control system california model only 141
- Cooling system 142
- Cooling system 3 1 142
- Cooling system ch 3 142
- Table of contents 142
- 2 cooling system 143
- Exploded view 143
- Cooling system 3 3 144
- Specifications 144
- 4 cooling system 145
- Coolant flow chart 145
- Coolant flow chart 146
- Cooling system 3 5 146
- 6 cooling system 147
- Caution 147
- Coolant 147
- Warning 147
- Coolant 148
- Cooling system 3 7 148
- Caution 149
- Coolant 149
- ____________________________________________ cooling system 3 7 149
- 8 cooling system 150
- Caution 150
- Coolant 150
- Caution 151
- Coolant 151
- Cooling system 3 9 151
- 10 cooling system 152
- Water pump 152
- Cooling system 3 11 153
- Water pump 153
- 12 cooling system 154
- Caution 154
- Water pump 154
- Cooling system 3 13 155
- Water pump 155
- 14 cooling system 156
- Radiator radiator fan 156
- Warning 156
- Caution 157
- Cooling system 3 15 157
- Radiator radiator fan 157
- 16 cooling system 158
- Radiator radiator fan 158
- Cooling system 3 17 159
- Thermostat 159
- 18 cooling system 160
- Hose and pipes 160
- Caution 161
- Cooling system 3 19 161
- Radiator fan switch water temperature sensor _________________ 161
- Engine top end 162
- Engine top end 4 1 162
- Engine top end ch 4 162
- Table of contents r 162
- 2 engine top end 163
- Exploded view 163
- Engine top end 4 3 164
- Exploded view 164
- 4 engine top end specifications 165
- Engine top end 4 5 166
- Specifications 166
- 6 engine top end 167
- Caution 167
- Clean air system 167
- Clean air system 168
- Engine top end 4 7 168
- 8 engine top end 169
- Cylinder head cover 169
- Cylinder head cover 170
- Engine top end 4 9 170
- 10 engine top end 171
- Camshaft chain tensioner 171
- Caution 171
- Camshaft camshaft chain 172
- Caution 172
- Engine top end 4 11 172
- 12 engine top end 173
- Camshaft camshaft chain 173
- C do not turn the camshaft when the plastigage is between the 174
- Cam wear remove the camshaft see camshaft removal measure the height a of each cam with a micrometer 174
- Camshaft camshaft cap wear cut strips of plastigage press gauge to journal width place a 174
- Camshaft camshaft chain 174
- Camshaft cap using plastigage a 174
- 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 174
- Each camshaft journal with a micrometer 174
- Engine top end 4 13 174
- If any clearance exceeds the service limit measure the diameter of 174
- If the cams are worn down past the service limit replace the camshaft 174
- If the camshaft journal diameter is less than the service limit replace 174
- If the clearance still remains out of the limit replace the cylinder head 174
- If the runout exceeds the service limit replace the camshaft 174
- Journal and camshaft cap 174
- Measure each clearance between the camshaft journal and the 174
- Strip on each journal parallel to the camshaft installed in the correct position 174
- The camshaft with a new one and measure the clearance again 174
- Tighten 174
- 14 engine top end 175
- Camshaft camshaft chain 175
- Cylinder head 176
- Engine top end 4 15 176
- 16 engine top end 177
- Cylinder head 177
- Cylinder head 178
- Engine top end 4 17 178
- 18 engine top end 179
- Cylinder head 179
- Engine top end 4 19 180
- Valves 180
- 20 engine top end 181
- Caution 181
- Valves 181
- Engine top end 4 21 182
- Inlet valve clearance adjustment chart 182
- Valves 182
- 22 engine top end 183
- Exhaust valve clearance adjustment chart 183
- Valves 183
- Caution 184
- Engine top end 4 23 184
- Valve see valve removal 184
- Valves 184
- 24 engine top end 185
- Valves 185
- Caution 186
- Engine top end 4 25 186
- Valves 186
- 26 engine top end 187
- Caution 187
- Valves 187
- Engine top end 4 27 188
- Valves 188
- Cylinder pistons 190
- Engine top end 4 29 190
- 30 engine top end 191
- Caution 191
- Cylinder pistons 191
- Caution 192
- Cylinder pistons 192
- Engine top end 4 31 192
- 32 engine top end 193
- All the rings 193
- At any point replace the piston 193
- Cylinder pistons 193
- If any of the measurements is less than the service limit on either of 193
- If the end gap of either ring is greater than the service limit replace 193
- If the width of any of the two grooves is wider than the service limit 193
- Measure the gap between the ends of the ring with a thickness gauge 193
- O when using new rings in a used piston check for uneven groove 193
- Piston ring end gap place the piston ring a inside the cylinder using the piston to locate 193
- Piston ring groove width measure the piston ring groove width o use a vernier caliper at several points around the piston 193
- Piston ring piston ring groove wear check for uneven groove wear by inspecting the ring seating 193
- Piston ring thickness measure the piston ring thickness 0 use the micrometer to measure at several points around the ring 193
- Replace the piston and all the piston rings 193
- The ring squarely in place set it close to the bottom of the cylinder where cylinder wear is low 193
- The rings replace all the rings 193
- The rings should fit perfectly parallel to groove surfaces if not 193
- Wear the rings should fit perfectly parallel to the groove sides if not replace the piston 193
- With a thickness gauge a to determine piston ring groove clearance 193
- With the piston rings in their grooves make several measurements 193
- Engine top end 4 33 194
- Throttle valve holder 194
- 34 engine top end 195
- Muffler 195
- Warning 195
- Engine top end 4 35 196
- Muffler 196
- Clutch 197
- Clutch 5 1 197
- Clutch ch 5 197
- Table of contents 197
- 2 clutch exploded view 198
- Clutch 5 3 199
- Specifications 199
- 4 clutch clutch lever and cable 200
- Warning 200
- Clutch 5 5 201
- Clutch lever and cable 201
- 6 clutch 202
- Clutch cover 202
- Warning 202
- Clutch 5 7 203
- Clutch cover 203
- 8 clutch 204
- Clutch cover 204
- Clutch 205
- Clutch 5 9 205
- 10 clutch 206
- Clutch 206
- Caution 207
- Clutch 207
- Clutch 5 11 207
- 12 clutch 208
- Clutch 208
- Clutch 209
- Clutch 5 13 209
- 8 engine lubrication system 210
- Oil pan 210
- Engine lube system ch 6 211
- Engine lubrication system 211
- Engine lubrication system 6 1 211
- Table of contents 211
- 2 engine lubrication system 212
- Exploded view 212
- Engine lubrication system 6 3 213
- Engine oil flow chart 213
- 4 engine lubrication system 214
- Specifications 214
- Caution 215
- Engine lubrication system 6 5 215
- Engine oil and oil filter 215
- Warning 215
- 6 engine lubrication system 216
- Engine oil and oil filter 216
- Engine lubrication system 6 7 217
- Oil cooler 217
- 8 engine lubrication system 218
- Oil pan 218
- Engine lubrication system 6 9 219
- Oil pan 219
- 10 engine lubrication system 220
- Oil pump oil pump drive gear and relief valve 220
- Oil pump oil pump drive gear and relief valve 221
- __________engine lubrication system 6 11 221
- 12 engine lubrication system 222
- Oil pump oil pump drive gear and relief valve 222
- Warning 222
- Engine lubrication system 6 13 223
- Oil pressure measurement 223
- Warning 223
- 14 engine lubrication system 224
- Oil pressure switch 224
- Engine removal ch 7 225
- Engine removal installation 7 1 225
- Engine removal lnstallation 225
- Table of contents 225
- 2 engine removal installation 226
- Exploded view 226
- A warning 227
- Caution 227
- Engine removal installation 7 3 227
- Engine removal lnstallation 227
- 4 engine removal installation 228
- Engine removal installation 228
- Engine removal installation 7 5 229
- Engine removal lnstallation 229
- 6 engine removal installation 230
- Engine removal lnstallation 230
- Crankshaft tranny ch 8 231
- Crankshaft transmission 231
- Crankshaft transmission 8 1 231
- Table of contents 231
- 2 crankshaft transmission 232
- Exploded view 232
- Crankshaft transmission 8 3 233
- Exploded view 233
- 4 crankshaft transmission 234
- Specifications 234
- Specifications _______________________________________________________ 235
- ________________________________ crankshaft transmissiqn 8 5 235
- 6 crankshaft transmission 236
- Caution 236
- Crankcase splitting 236
- Crankcase splitting 237
- Crankshaft transmission 8 7 237
- 8 crankshaft transmission 238
- Caution 238
- Crankcase splitting 238
- Caution 239
- Crankshaft and connecting rods 239
- Crankshaft transmission 8 9 239
- 10 crankshaft transmission 240
- Caution 240
- Crankshaft and connecting rods 240
- Warning 240
- Caution 241
- Crankshaft and connecting rods 241
- Crankshaft transmission 8 11 241
- Warning 241
- 12 crankshaft transmission 242
- Crankshaft and connecting rods 242
- Crankshaft and connecting rods 243
- Crankshaft transmission 8 13 243
- 14 crankshaft transmission 244
- Crankshaft and connecting rods 244
- Caution 245
- Crankshaft and connecting rods 245
- Crankshaft transmission 8 15 245
- 16 crankshaft transmission 246
- Crankshaft and connecting rods 246
- Crankshaft runout measure the crankshaft runout 246
- If the measurement exceeds the service limit replace the crankshaft 246
- Balancer 247
- Crankshaft transmission 8 17 247
- 18 crankshaft transmission 248
- Balancer 248
- Crankshaft transmission 8 19 249
- Starter motor clutch and torque limiter 249
- 20 crankshaft transmission 250
- Starter motor clutch and torque limiter 250
- Crankshaft transmission 8 21 251
- Starter motor clutch and torque limiter 251
- 22 crankshaft transmission 252
- Transmission 252
- Caution 253
- Crankshaft transmission 8 23 253
- Transmission 253
- 2 crankshaf17 ah 254
- Transmission 254
- Crankshaft transmission 8 25 255
- Transmission 255
- 26 crankshaft transmission 256
- Transmission 256
- Crankshaft transmission 8 27 257
- Transmission 257
- 28 crankshaft transmission 258
- Caution 258
- Transmission 258
- Crankshaft transmission 8 29 259
- Transmission 259
- 30 crankshaft transmission 260
- Transmission 260
- Transmission 261
- _______________________________ crankshaft transmission 8 31 261
- Table of contents 262
- Wheels tires 262
- Wheels tires 9 1 262
- Wheels tires ch 9 262
- 2 wheels tires 263
- Exploded view 263
- Specifications 264
- Wheels tires 9 3 264
- 4 wheels tires 265
- Caution 265
- Warning 265
- Wheels rims 265
- A warning 266
- Addendum 266
- Kawasaki 266
- Zx1200 a1 service manual 266
- Caution 267
- Wheels rims 267
- Wheels tires 9 5 267
- 6 wheels tires 268
- Warning 268
- Wheels rims 268
- Warning 269
- Wheels rims 269
- Wheels tires 9 7 269
- 8 wheels tires 270
- B installation completed 270
- Both sides of rim flange as shown 270
- Caution 270
- Check that the blade and weight seat fully on the rim flange and that 270
- Do not lubricate the tire bead with engine oil or petroleum distillates because they will deteriorate the tire 270
- Install the balance weight on the rim 0 slip the weight on the rim flange by pushing or lightly hammering the 270
- Lubricate the balance weight blade tire bead and rim flange with a 270
- Soap and water solution or rubber lubricant this helps the balance weight slip onto the rim flange 270
- The clip is hooked over the rim ridge and reaches rim flat portion installing balance weight a press or lightly hammer the weight in 270
- Weight in the direction shown in the figure 270
- Wheels rims 270
- When required total weight exceeds 20 g install balance weight at 270
- A warning 271
- Wheels tires 9 9 271
- 10 wheels tires 272
- Caution 272
- A warning 273
- Wheels tires 9 11 273
- 12 wheels tires 274
- Caution 275
- Hub bearings 275
- Wheels tires 9 13 275
- Final drive 276
- Final drive 10 1 276
- Final drive ch 10 276
- Table of contents 276
- 2 final drive 277
- Exploded view 277
- Final drive 10 3 278
- Specifications 278
- 4 final drive 279
- Drive chain 279
- Warning 279
- Drive chain 280
- Final drive 10 5 280
- 6 final drive 281
- Caution 281
- Drive chain 281
- Drive chain 282
- Final drive 10 7 282
- 8 final drive 283
- Sprocket coupling 283
- Caution 284
- Final drive 10 9 284
- Sprocket coupling 284
- 10 final drive 285
- Sprocket coupling 285
- Final drive 10 11 286
- Sprocket coupling 286
- Brakes 11 1 287
- Brakes ch 11 287
- Table of contents 287
- 2 brakes 288
- Exploded view 288
- 4 brakes 290
- Specifications 290
- Brake pedal 291
- Brakes 11 5 291
- 6 brakes 292
- Calipers 292
- Caution 292
- Warning 292
- Brakes 11 7 293
- Calipers 293
- Caution 293
- 8 brakes 294
- Calipers 294
- Rear caliper disassembly 294
- Brakes 11 9 295
- Calipers 295
- 10 brakes 296
- Brake pads 296
- Warning 296
- Brake pads 297
- Brakes 11 11 297
- Warning 297
- 12 brakes 298
- Master cylinder 298
- Brakes 11 13 299
- Caution 299
- Master cylinder 299
- 14 brakes 300
- Caution 300
- Master cylinder 300
- Brakes 11 15 301
- Master cylinder 301
- 16 brakes 302
- Brake discs 302
- Brake fluid 303
- Brakes 11 17 303
- Warning 303
- 18 brakes 304
- Brake fluid 304
- Warning 304
- Brake fluid 305
- Brakes 11 19 305
- 20 brakes 306
- A warning 306
- Brake fluid 306
- Brake hoses 307
- Brakes 11 21 307
- Suspension 308
- Suspension 12 1 308
- Suspension ch12 308
- Table of contents 308
- 2 suspension 309
- Exploded view 309
- Exploded view 310
- Suspension 12 3 310
- 4 suspension 311
- Specifications 311
- Front fork 312
- Suspension 12 5 312
- Warning 312
- 6 suspension 313
- Front fork 313
- Warning 313
- Front fork 314
- Suspension 12 7 314
- 8 suspension 315
- Front fork 315
- Front fork 316
- Suspension 12 9 316
- 10 suspension 317
- Front fork 317
- Front fork 318
- Suspension 12 11 318
- 12 suspension 319
- Caution 319
- Front fork 319
- Warning 319
- Front fork 320
- Suspension 12 13 320
- 14 suspension 321
- Rear shock absorber 321
- Rear shock absorber 322
- Suspension 12 15 322
- 16 suspension 323
- Rear shock absorber 323
- Warning 323
- Suspension 12 17 324
- Swingarm 324
- 18 suspension 325
- S a p i 325
- Suspension 12 19 326
- Swingarm 326
- 20 suspension_____________________________________ ________ 327
- Tie rod rocker arm 327
- Suspension 12 21 328
- Tie rod rocker arm 328
- Steering 329
- Steering 13 1 329
- Steering ch13 329
- Table of contents 329
- 2 steering 330
- Exploded view 330
- Specifications 331
- Steering 13 3 331
- 4 steering 332
- Steering 332
- Steering 13 5 333
- Steering stem 333
- 6 steering 334
- Steering stem 334
- Steering 13 7 335
- Steering stem 335
- Warning 335
- 8 steering 336
- Handlebar 336
- Frame 14 1 337
- Table of contents 337
- 2 frame 338
- Exploded view 338
- 4 frame 340
- Exploded view 340
- Frame 14 5 341
- 6 frame 342
- Frame 14 7 343
- Seat cover 343
- 8 frame 344
- Fairings 344
- Fairings 345
- Frame 14 9 345
- 10 frame 346
- Fairings 346
- Fairings 347
- Frame 14 11 347
- 12 frame 348
- Fairings 348
- Fenders 349
- Frame 14 13 349
- 14 frame 350
- Fenders 350
- A warning 351
- Frame 14 15 351
- Rear frame 351
- 16 frame 352
- Storage box 352
- Electrical system 353
- Electrical system 15 1 353
- Electrical system ch15 353
- Table of contents 353
- Electrical system 15 3 354
- Exploded view 354
- 4 electrical system 355
- Exploded view 355
- Electrical system 15 5 356
- Exploded view 356
- 6 electrical system 357
- Specifications 357
- Electrical system 15 7 358
- Parts location 358
- 8 electrical system 359
- Precautions 359
- Electrical system 15 9 360
- Electrical wiring 360
- 10 electrical system 361
- Battery 361
- Caution 361
- Battery 362
- Caution 362
- Electrical system 15 11 362
- 12 electrical system battery 363
- Battery 364
- Electrical system 15 13 364
- Warning 364
- 2 electrical system 365
- 14 electrical system 366
- A warning 366
- Battery 366
- Caution 366
- Awarning 367
- Battery 367
- Electrical system 15 15 367
- 16 electrical system 368
- Battery 368
- Battery standard charge time chart 368
- Determine battery condition after refreshing charge p determine the condition of the battery 30 minutes after completion of 368
- The charge by measuring the terminal voltage according to the table below 368
- Charging system 369
- Electrical system 15 17 369
- Charging system 370
- Electrical system 370
- Charging system 371
- Electrical system 15 19 371
- 20 electrical system 372
- Charging system 372
- Charging system 373
- Electrical system 15 21 373
- _____________________ caution_________________ 373
- _____________________ caution_____________________ 373
- 22 electrical system 374
- Charging system 374
- Charging system 375
- Charging system circuit 375
- Electrical system 15 23 375
- 24 electrical system 376
- Caution 376
- Ignition system 376
- Warning 376
- Electrical system 15 25 377
- Ignition system 377
- 26 electrical system 378
- Ignition system 378
- Caution 379
- Electrical system 15 27 379
- Ignition system 379
- 28 electrical system 380
- Ignition system 380
- Electrical system 15 29 381
- Ignition system 381
- Warning 381
- 30 electrical system 382
- Ignition system 382
- Electrical system 15 31 383
- Ignition system 383
- 32 electrical system 384
- I i i i i i i i i i i i i i ii i i iii i i 384
- Ignition system 384
- Ignition system circuit 384
- Electric starter system 385
- Electrical system 15 33 385
- Starter motor installation 385
- Starter motor removal 385
- 34 electrical system 386
- Electric starter system 386
- Starter motor assembly 386
- Starter motor disassembly 386
- Brush inspection 387
- Commutator cleaning and inspection 387
- Electric starter system 387
- Electrical system 15 35 387
- 36 electrical system 388
- Armature inspection 388
- Brush lead inspection 388
- Brush plate and terminal bolt inspection 388
- Electric starter system 388
- Starter relay inspection 388
- Electric starter system 389
- Electrical system 15 37 389
- 38 electrical system 390
- Electric starter circuit 390
- Electric starter system 390
- Caution 391
- Electrical system 15 39 391
- Headlight beam horizontal vertical adjustment 391
- Headlight bulb replacement 391
- Lighting system 391
- 40 electrical system 392
- Caution 392
- City light bulb replacement 392
- Lighting system 392
- Taii brake light bulb replacement 392
- Electrical system 15 41 393
- Headlight relay high low inspection 393
- Lighting system 393
- 42 electrical system 394
- Headlight tail light circuit 394
- Lighting system 394
- Electrical system 15 43 395
- Lighting system 395
- Turn signal relay inspection 395
- 44 electrical system 396
- Lighting system 396
- Turn signal light circuit 396
- Electrical system 15 45 397
- Radiator fan circuit 397
- Radiator fan system 397
- 46 electrical system 398
- Bulb replacement 398
- Meter unit disassembly 398
- Meter unit removal 398
- Caution 399
- Electrical system 15 47 399
- Meter unit inspection 399
- 48 electrical system 400
- Caution 401
- Electrical system 15 49 401
- 50 electrical system 402
- C indicates approximately 3 000 rpm if the input frequency is approxi 402
- Check 7 tachometer check connect the wires in the same circuit as for the check 1 the engine speed rpm equivalent to the input frequency is indicated 402
- Check 8 coolant temperature gauge inspection connect the wires 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 resistance value 402
- If this display function does not work replace the meter assembly 402
- If this meter function does not work replace the meter assembly 402
- In the oscillator a if the square wave is input into terminal 1 402
- Mately 100 hz 402
- Of the variable rheostat 402
- Resistance values are standard and they have tolerance 402
- Check 9 fuel gauge inspection connect the wires 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 resistance value 403
- Connect an other variable rheostat c to terminal 11 and 12 set the hand tester d to the dc 10 v range and connect it to 403
- Electrical system 15 51 403
- If this display function does not flush replace the meter assembly 403
- If this display function does not work replace the meter assembly 403
- O then the segment should flush 403
- Of the variable rheostat 403
- Resistance values are standard and they have tolerance 403
- Terminals of the variable rheostat as shown 403
- That the terminal voltage is less than 5 v 403
- When the 1 segment e appears adjust the variable rheostat c so 403
- 52 electrical system 404
- Electrical system 15 53 405
- Meter circuit 405
- 54 electrical system 406
- Brake light timing adjustment 406
- Brake light timing inspection 406
- Caution 406
- Switches and sensors 406
- Electrical system 15 55 407
- Switches and sensors 407
- 56 electrical system 408
- Radiator fan switch inspection 408
- Switches and sensors 408
- Water temperature sensor inspection 408
- Electrical system 15 57 409
- Speed sensor inspection 409
- Speed sensor installation 409
- Speed sensor removal 409
- Switches and sensors 409
- 58 electrical system 410
- Fuel level sensor inspection 410
- Switches and sensors 410
- And diodes can not be removed 411
- Apply tester positive wire apply tester negative wire 411
- Clean the dirty terminals and straighten slightly bent terminals check conductivity of the numbered terminals with the hand tester 411
- Fuel tank cover plate see digital fuel injection system chapter rubber cover connectors junction box 411
- If the tester does not read as specified replace the junction box 411
- Junction box 411
- Junction box fuse circuit inspection 411
- Make sure all connector terminals are clean and tight and none of 411
- Remove 411
- Remove the junction box check conductivity of the following numbered terminals by connecting 411
- Starter circuit headlight relay inspection 411
- The hand tester and one 12 v battery to the junction box as shown 411
- The junction box a has fuses b relays and diodes the relays 411
- Them have been bent 411
- U s a canada australia and malaysia models only the actual reading varies with the hand tester used 411
- ______________________ ________________electrical system 15 59 411
- 60 electrical system 412
- Diode circuit inspection 412
- Individual diodes but generally speaking the lower reading should be from zero to one half the scale 412
- Junction box 412
- Remove the junction box check conductivity of the following pairs of terminals 412
- The actual meter reading varies with the meter used and the 412
- The resistance should be low in one direction and more than ten 412
- Times as much in the other direction if any diode shows low or high in both directions the diode is defective and the junction box must be replaced 412
- U s a canada australia and malaysia models only 412
- U s a canada australia and malaysia models only the actual reading varies with the hand tester used apply tester positive wire apply tester negative wire 412
- Electrical system 15 61 413
- Junction box 413
- Junction box internal circuit other than u s a canada australia and malaysia 413
- Junction box internal circuit u s a canada australia and malaysia 413
- 62 electrical system 414
- A headlight fuse removal 414
- A main fuse removal 414
- Junction box fuse removal 414
- A ecu fuse removal 415
- Caution 415
- Electrical system 15 63 415
- Fuse inspection 415
- Fuse installation 415
- Electrical system 15 65 417
- 66 electrical system 418
- Wiring diagram australia 418
- Appendix 424
- Appendix 16 1 424
- Appendix ch16 424
- Table of contents 424
- 2 appendix 425
- Additional considerations for racing_______________________________ 425
- Spnrk plug 425
- Additional considerations lot racing 426
- Appendix 16 3 426
- Xign3ddv fr 9i 427
- A a tuuyh yuidv lu amia uw buul tsikmlhtg 428
- Appendix 16 5 428
- Engine doesn t start starting difficulty 428
- Fv each dro em listad is meant s m 428
- Ir rot nn nauuiailm ura qh ng wcry pnanl 428
- Mace common ditñculbes 428
- Poor running at low spoed 428
- Startar motor not rotating 428
- Troubleshooting guide 428
- 6 appendix 429
- Knneklng 429
- Over coolmq 429
- Poor running or nn power at high speed 429
- Ring inca reci 429
- Troubleshooting guide 429
- Abnormal engine noise 430
- Abnormnl drive train noise 430
- Appendix 16 7 430
- Baauuw shu wupuim ubbe jaiupe dai agec 430
- Clutch operation faulty 430
- Troubleshooting guide 430
- Vat shitting faulty 430
- 8 appendix 431
- Battery trouble 431
- Brake doesn t hold 431
- Brown smoke 431
- Exhaust smokes excessively 431
- Handling end or stability unsatisfactory 431
- Honuicbor nora to turn 431
- Oil pressure warning light goes on 431
- Troubleshooting guide 431
- Шаек чтоке 431
- Appendix 16 9 432
- Aray pvtnrm me genent 432
- General lubrication 432
- Lubrication penodic maintenance 432
- Oetatm under ef or rainy 432
- R e pe viy itte wn 432
- 10 appendix 433
- Nt t na mtn üw 433
- Nut bolt and fastener tightness 433
- Tempanara 433
- Titjfvncaa inppoaion 433
- Appendix 16 11 434
- Prefixes fur unite 434
- Unit conversion table 434
- Units o température 434
- Units of force 434
- Units ot uength 434
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Kawasaki Ninja ZX 12R Motorcycle Service Manual 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 Department Consumer Products Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication 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 Kawasaki Heavy Industries Ltd 2000 First Edition 1 Mar 29 2000 M
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