Kawasaki NINJA ZX-12R (2002-2004) [12/613] 2 general information
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Kawasaki NINJA ZX-12R (2002-2004) [12/613] 2 general information

Kawasaki NINJA ZX-12R (2002-2004) [12/613] 2 general information
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.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering t he engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For t he same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Cables
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the leads from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery.
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. But if this Service
Manual has installation or assembly procedures, follow them. Note parts locations and cable,
lead, and hose routing during removal or disassembly so they can be installed or assembled i n
the same way. It is preferable to mark and record the locations and routing as m uch as possible.
(4) 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 evenly in a cross pattern. This is to avoid
distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. Where
there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must
be tightened in the order and method indicated.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. U se a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in order
to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is Stoddard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.
(10)Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts m ay block engine oil passages and cause seri-
ous damage. An example of non-permanent locking agent commonly available in North America
is Loctite Lock’n Seal (Blue).
(11) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.

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