![Kawasaki NINJA ZX-12R (2002-2004) [31/613] General information 1 21](/img/pdf.png)
Kawasaki NINJA ZX-12R (2002-2004) [31/613] General information 1 21
![Kawasaki NINJA ZX-12R (2002-2004) [31/613] General information 1 21](/views2/1121158/page31/bg1f.png)
GENERAL INFORMATION 1-21
Torque and Locking Agent
Torque
Fastener
N·m kgf·m ft·lb
Remarks
Uni-Track:
Rocker Arm Nut 34 3.5 25
Ti e-rod Nuts 59 6.0 44
Steering
Steering Stem Head Nut (ZX1200-B1/B2) 54 5.5 40
Steering Stem Head Nut (ZX1200-B3) 78 8.0 57
Steering Stem Nut 20 2.0 15
Handlebar Bolts 34 3.5 25 L
Handlebar Weight Bolts – – – L
Handlebar Switch Housing Screws 3.5 0.36 31 in·lb
Frame
Wind Shield Mounting Screws 0.40 0.040 3.5 in·lb
Rear Frame Bolts and Nuts 44 4.5 32
Front Footpeg Holder Bolts 25 2.5 18
Rear Footpeg Holder Bolts 34 3.5 25
Side Stand Bracket Bolts 49 5.0 36
Side Stand Mounting Bolt and Nut 44 4.5 32
Side Stand Switch Bolt 8.8 0.90 78 in·lb L
Electrical System
Spark Plugs 13 1.3 115 in·lb
Alternator R otor Bolt 110 11 81
Stator Coil Bolts 22 2.2 16 L
Alternator Lead Holding Plate Bolts 8.5 0.87 75 in·lb L
Engine Ground Lead Terminal Bolt 10 1.0 89 in·lb
Alternator Cover Bolts 15 1.5 11
Crankshaft Sensor Cover Bolts 15 1.5 11 L
Crankshaft Sensor Bolts 6.0 0.60 53 in·lb
Camshaft Position Sensor Bolt 12 1.2 106 in·lb
Timing Rotor Bolt 39 4.0 29
Starter Motor Mounting Bolts
12 1.2 106 in·lb
Handlebar Switch Housing Screws
3.5 0.36 31 in·lb
Radiator Fan Switch
18 1.8 13
Water Tem perature Sensor 25 2.5 18 SS
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb
Gear Position Switch Screws 4.0 0.40 35 in·lb L
Speed Sensor Bolt 10 1.0 89 in·lb
Fuel Level Sensor Bolts 6.9 0.70 61 in·lb
Front Brake Switch Light Screw 12 1.2 106 in·lb
Tail/Brake Light Assy Mounting Nuts 6.0 0.60 53 in·lb
Содержание
- Tables 1
- Quick reference guide 3
- Motorcycle service manual 5
- Ninja zx 12r 5
- List of abbreviations 6
- Read owner s manual before operating 6
- Emission control information 7
- The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 7
- Tampering with noise control system prohibited 8
- Foreword 9
- How to use this manual 9
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Before servicing 12
- Especially note the following 12
- Before servicing 13
- General information 1 3 13
- 4 general information 14
- Before servicing 14
- General information 1 5 15
- Model identification 15
- 6 general information 16
- General specifications 16
- General information 1 7 17
- General specifications 17
- 8 general information 18
- General specifications 18
- General information 1 9 19
- Honeycomb type catalytic converter 19
- Technical information kawasaki low exhaust emission system 19
- 10 general information 20
- Exhaust system zx1200 b1 b2 20
- Technical information kawasaki low exhaust emission system 20
- Exhaust system zx1200 b3 21
- General information 1 11 21
- Technical information kawasaki low exhaust emission system 21
- 12 general information 22
- Technical information monocoque frame 22
- Caution 23
- General information 1 13 23
- Technical information spark plug 23
- 14 general information 24
- Overview 24
- Related parts and function 24
- Technical information immobilizer system zx1200 b3 24
- General information 1 15 25
- Technical information immobilizer system zx1200 b3 25
- 16 general information 26
- Sequence of operation 26
- Technical information immobilizer system zx1200 b3 26
- Basic torque for general fasteners 27
- General information 1 17 27
- Torque and locking agent 27
- 18 general information 28
- Torque and locking agent 28
- General information 1 19 29
- Torque and locking agent 29
- 20 general information 30
- Torque and locking agent 30
- General information 1 21 31
- Torque and locking agent 31
- 22 general information 32
- Special tools and sealant 32
- General information 1 23 33
- Special tools and sealant 33
- 24 general information 34
- Special tools and sealant 34
- General information 1 25 35
- Special tools and sealant 35
- 26 general information 36
- Special tools and sealant 36
- General information 1 27 37
- Special tools and sealant 37
- 28 general information 38
- Special tools and sealant 38
- Cable wire and hose routing zx1200 b3 57
- General information 1 47 57
- Cable wire and hose routing zx1200 b3 59
- General information 1 49 59
- Cable wire and hose routing zx1200 b3 61
- General information 1 51 61
- Cable wire and hose routing zx1200 b3 63
- General information 1 53 63
- Cable wire and hose routing zx1200 b3 65
- General information 1 55 65
- Cable wire and hose routing zx1200 b3 67
- General information 1 57 67
- Cable wire and hose routing zx1200 b3 69
- General information 1 59 69
- 60 general information 70
- Prefixes for units 70
- Unit conversion table 70
- Units of force 70
- Units of length 70
- Units of mass 70
- Units of power 70
- Units of pressure 70
- Units of speed 70
- Units of temperature 70
- Units of torque 70
- Units of volume 70
- Periodic maintenance 71
- Periodic maintenance 2 1 71
- Table of contents 71
- Periodic maintenance 2 3 73
- Periodic maintenance chart 73
- 4 periodic maintenance 74
- Specifications 74
- Periodic maintenance 2 5 75
- Specifications 75
- 6 periodic maintenance 76
- Fuel system dfi 76
- Periodic maintenance procedures 76
- Periodic maintenance 2 7 77
- Periodic maintenance procedures 77
- Throttle grip free play 77
- 8 periodic maintenance 78
- Idle speed 78
- Periodic maintenance procedures 78
- Warning 78
- Engine vacuum 79
- Periodic maintenance 2 9 79
- Periodic maintenance procedures 79
- 10 periodic maintenance 80
- Periodic maintenance procedures 80
- Engine vacuum 81
- Periodic maintenance 2 11 81
- Periodic maintenance procedures 81
- 12 periodic maintenance 82
- Main throttle sensor output voltage 82
- Periodic maintenance procedures 82
- Periodic maintenance 2 13 83
- Periodic maintenance procedures 83
- Warning 83
- 14 periodic maintenance 84
- Periodic maintenance procedures 84
- Cooling system 85
- Periodic maintenance 2 15 85
- Periodic maintenance procedures 85
- Warning 85
- 16 periodic maintenance 86
- Periodic maintenance procedures 86
- Engine top end 87
- Periodic maintenance 2 17 87
- Periodic maintenance procedures 87
- Water and coolant mixture ratio recommended 87
- 18 periodic maintenance 88
- Periodic maintenance procedures 88
- Valve clearance 88
- Periodic maintenance 2 19 89
- Periodic maintenance procedures 89
- 20 periodic maintenance 90
- Inlet valve clearance adjustment chart 90
- Periodic maintenance procedures 90
- Exhaust valve clearance adjustment chart 91
- Periodic maintenance 2 21 91
- Periodic maintenance procedures 91
- 22 periodic maintenance 92
- Clutch 92
- Clutch lever free play 92
- Periodic maintenance procedures 92
- Warning 92
- Engine lubrication system 93
- Engine oil 93
- Periodic maintenance 2 23 93
- Periodic maintenance procedures 93
- 24 periodic maintenance 94
- Periodic maintenance procedures 94
- Tread depth 94
- Warning 94
- Wheels tires 94
- Chain slack 95
- Final drive 95
- Periodic maintenance 2 25 95
- Periodic maintenance procedures 95
- Warning 95
- 26 periodic maintenance 96
- Periodic maintenance procedures 96
- Warning 96
- Drive chain 20 link length 97
- Periodic maintenance 2 27 97
- Periodic maintenance procedures 97
- Rollers distance 97
- Warning 97
- 28 periodic maintenance 98
- Brakes 98
- Periodic maintenance procedures 98
- Periodic maintenance 2 29 99
- Periodic maintenance procedures 99
- Recommended disc brake fluid 99
- Warning 99
- 30 periodic maintenance 100
- Pad lining thickness 100
- Periodic maintenance procedures 100
- Brake light timing 101
- Brake master cylinder cup and dust seal replace 101
- Caliper piston dust seal replace 101
- Caution 101
- Front brake light switch inspection 101
- Pad lining thickness 101
- Periodic maintenance 2 31 101
- Periodic maintenance procedures 101
- Rear brake light switch inspection adjustment 101
- Rear brake pad wear inspection 101
- 32 periodic maintenance 102
- Periodic maintenance procedures 102
- Suspension 102
- Periodic maintenance 2 33 103
- Periodic maintenance procedures 103
- 34 periodic maintenance 104
- Fork oil 104
- Periodic maintenance procedures 104
- Oil level fully compressed without spring 105
- Periodic maintenance 2 35 105
- Periodic maintenance procedures 105
- 36 periodic maintenance 106
- Periodic maintenance procedures 106
- Periodic maintenance 2 37 107
- Periodic maintenance procedures 107
- 38 periodic maintenance 108
- Periodic maintenance procedures 108
- Fork oil 109
- Periodic maintenance 2 39 109
- Periodic maintenance procedures 109
- 40 periodic maintenance 110
- Oil level fully compressed without spring 110
- Periodic maintenance procedures 110
- Periodic maintenance 2 41 111
- Periodic maintenance procedures 111
- 42 periodic maintenance 112
- Front fork oil leak inspection 112
- Periodic maintenance procedures 112
- Rear shock absorber oil leak inspection 112
- Swingarm pivot lubrication 112
- Periodic maintenance 2 43 113
- Periodic maintenance procedures 113
- Steering 113
- 44 periodic maintenance 114
- Periodic maintenance procedures 114
- Electrical system 115
- General lubrication 115
- Periodic maintenance 2 45 115
- Periodic maintenance procedures 115
- 46 periodic maintenance 116
- Periodic maintenance procedures 116
- Nut bolt and fastener tightness 117
- Periodic maintenance 2 47 117
- Periodic maintenance procedures 117
- Fuel system dfi 119
- Fuel system dfi 3 1 119
- Table of contents 119
- 2 fuel system dfi 120
- Exploded view 121
- Fuel system dfi 3 3 121
- 4 fuel system dfi 122
- Exploded view 122
- Exploded view 123
- Fuel system dfi 3 5 123
- Exploded view 125
- Fuel system dfi 3 7 125
- Exploded view 127
- Fuel system dfi 3 9 127
- Exploded view 129
- Fuel system dfi 3 11 129
- 12 fuel system dfi 130
- Specifications 130
- Fuel system dfi 3 13 131
- Specifications 131
- 14 fuel system dfi 132
- Specifications 132
- Cable installation 133
- Cable lubrication 133
- Free play adjustment 133
- Free play inspection 133
- Fuel system dfi 3 15 133
- Throttle grip and cables 133
- Warning 133
- 16 fuel system dfi 134
- Cable lubrication 134
- Choke cable 134
- Choke cable free play 134
- Choke cable installation 134
- Free play adjustment 134
- Free play inspection 134
- Warning 134
- Caution 135
- Fuel system dfi 3 17 135
- Idle speed inspection 135
- Synchronization adjustment 135
- Synchronization inspection 135
- Throttle body assy 135
- Throttle body assy removal 135
- Throttle bore cleaning 135
- Warning 135
- 18 fuel system dfi 136
- Throttle body assy 136
- Warning 136
- Fuel system dfi 3 19 137
- Throttle body assy 137
- Warning 137
- 20 fuel system dfi 138
- Throttle body assy 138
- Warning 138
- Fuel system dfi 3 21 139
- Throttle body assy 139
- Warning 139
- 22 fuel system dfi 140
- Caution 140
- Throttle body assy 140
- Throttle body assy disassembly zx1200 b1 b2 140
- Fuel system dfi 3 23 141
- Throttle body assy 141
- 24 fuel system dfi 142
- Throttle body assy 142
- Fuel system dfi 3 25 143
- Throttle body assy 143
- 26 fuel system dfi 144
- Air cleaner element cleaning and inspection 144
- Air line 144
- Caution 144
- Element installation 144
- Element removal 144
- Oil draining 144
- Warning 144
- Air inlet duct installation 145
- Air inlet duct removal 145
- Air line 145
- Front duct removal installation 145
- Fuel system dfi 3 27 145
- 28 fuel system dfi 146
- Caution 146
- Fuel tank 146
- Fuel tank removal 146
- Warning 146
- Fuel system dfi 3 29 147
- Fuel tank 147
- Warning 147
- 30 fuel system dfi 148
- Fuel tank 148
- Fuel system dfi 3 31 149
- Fuel tank 149
- Fuel tank cleaning 149
- Warning 149
- Dfi system 151
- Fuel system dfi 3 33 151
- 34 fuel system dfi 152
- Dfi system 152
- Terminal numbers of ecu connectors 152
- Dfi system 153
- Fuel system dfi 3 35 153
- Dfi system 155
- Fuel system dfi 3 37 155
- 38 fuel system dfi 156
- Dfi system 156
- Terminal numbers of ecu connectors 156
- Dfi system 157
- Fuel system dfi 3 39 157
- 40 fuel system dfi 158
- Dfi servicing precautions 158
- Dfi servicing precautions 159
- Fuel system dfi 3 41 159
- 42 fuel system dfi 160
- Outline 160
- Troubleshooting the dfi system 160
- Fuel system dfi 3 43 161
- Troubleshooting the dfi system 161
- 44 fuel system dfi 162
- Troubleshooting the dfi system 162
- Fuel system dfi 3 45 163
- Troubleshooting the dfi system 163
- 46 fuel system dfi 164
- Dfi diagnosis flow chart 164
- Inquiries to rider 164
- Troubleshooting the dfi system 164
- Fuel system dfi 3 47 165
- Sample diagnosis sheet 165
- Troubleshooting the dfi system 165
- 48 fuel system dfi 166
- Troubleshooting the dfi system 166
- Dfi system troubleshooting guide 167
- Engine doesn t start starting difficulty 167
- Fuel system dfi 3 49 167
- 50 fuel system dfi 168
- Dfi system troubleshooting guide 168
- Dfi system troubleshooting guide 169
- Fuel system dfi 3 51 169
- Poor running at low speed 169
- 52 fuel system dfi 170
- Dfi system troubleshooting guide 170
- Dfi system troubleshooting guide 171
- Fuel system dfi 3 53 171
- 54 fuel system dfi 172
- Dfi system troubleshooting guide 172
- Dfi system troubleshooting guide 173
- Fuel system dfi 3 55 173
- Poor running or no power at high speed 173
- 56 fuel system dfi 174
- Dfi system troubleshooting guide 174
- Dfi system troubleshooting guide 175
- Fuel system dfi 3 57 175
- 58 fuel system dfi 176
- Self diagnosis 176
- Self diagnosis function 176
- Self diagnosis outline 176
- Fuel system dfi 3 59 177
- Self diagnosis 177
- Self diagnosis procedures 177
- Fuel system dfi 3 61 179
- How to read service codes 179
- Self diagnosis 179
- 62 fuel system dfi 180
- How to erase service codes 180
- Self diagnosis 180
- Fuel system dfi 3 63 181
- Self diagnosis 181
- 64 fuel system dfi 182
- Backups 182
- Self diagnosis 182
- Fuel system dfi 3 65 183
- Self diagnosis 183
- 66 fuel system dfi 184
- Self diagnosis 184
- Fuel system dfi 3 67 185
- Throttle sensor input voltage 185
- Throttle sensor service code 11 zx1200 b1 b2 185
- 68 fuel system dfi 186
- Idle speed 186
- Output voltage inspection 186
- Throttle sensor input voltage 186
- Throttle sensor output voltage 186
- Throttle sensor service code 11 zx1200 b1 b2 186
- Fuel system dfi 3 69 187
- Throttle sensor output voltage 187
- Throttle sensor service code 11 zx1200 b1 b2 187
- 70 fuel system dfi 188
- Throttle sensor resistance 188
- Throttle sensor service code 11 zx1200 b1 b2 188
- Fuel system dfi 3 71 189
- Throttle sensor service code 11 zx1200 b1 b2 189
- 72 fuel system dfi 190
- Main throttle sensor input voltage 190
- Main throttle sensor service code 11 zx1200 b3 190
- Wiring connection 190
- Fuel system dfi 3 73 191
- Idle speed 191
- Main throttle sensor output voltage 191
- Main throttle sensor service code 11 zx1200 b3 191
- Output voltage inspection 191
- Wiring connection 191
- 74 fuel system dfi 192
- Main throttle sensor resistance 192
- Main throttle sensor service code 11 zx1200 b3 192
- Resistance inspection 192
- Caution 193
- Fuel system dfi 3 75 193
- Inlet air pressure sensor service code 12 193
- Removal 193
- 76 fuel system dfi 194
- Inlet air pressure sensor input voltage 194
- Inlet air pressure sensor service code 12 194
- Fuel system dfi 3 77 195
- Inlet air pressure sensor input voltage 195
- Inlet air pressure sensor output voltage 195
- Inlet air pressure sensor service code 12 195
- 78 fuel system dfi 196
- Inlet air pressure sensor output voltage 196
- Inlet air pressure sensor service code 12 196
- Zx1200 b1 b2 196
- Digital volt meter connections 197
- Fuel system dfi 3 79 197
- Inlet air pressure sensor service code 12 197
- 80 fuel system dfi 198
- Inlet air pressure sensor service code 12 198
- Fuel system dfi 3 81 199
- Inlet air temperature sensor output voltage 199
- Inlet air temperature sensor service code 13 199
- 82 fuel system dfi 200
- Inlet air temperature sensor resistance 200
- Inlet air temperature sensor service code 13 200
- Fuel system dfi 3 83 201
- Inlet air temperature sensor service code 13 201
- Zx1200 b1 b2 201
- Zx1200 b3 201
- 84 fuel system dfi 202
- Water temperature sensor service code 14 202
- Fuel system dfi 3 85 203
- Water temperature sensor output voltage 203
- Water temperature sensor service code 14 203
- 86 fuel system dfi 204
- Sensor resistance inspection 204
- Water temperature sensor service code 14 204
- Zx1200 b3 204
- Atmospheric pressure sensor input voltage 205
- Atmospheric pressure sensor service code 15 205
- Fuel system dfi 3 87 205
- 88 fuel system dfi 206
- Atmospheric pressure sensor input voltage 206
- Atmospheric pressure sensor service code 15 206
- Output voltage inspection 206
- Atmospheric pressure sensor output voltage 207
- Atmospheric pressure sensor service code 15 207
- Fuel system dfi 3 89 207
- 90 fuel system dfi 208
- Atmospheric pressure sensor service code 15 208
- Zx1200 b1 b2 208
- Zx1200 b3 208
- Atmospheric pressure altitude relationship 209
- Atmospheric pressure sensor service code 15 209
- Fuel system dfi 3 91 209
- 92 fuel system dfi 210
- Crankshaft sensor service code 21 210
- Crankshaft sensor service code 21 211
- Fuel system dfi 3 93 211
- Zx1200 b3 211
- 94 fuel system dfi 212
- Camshaft position sensor service code 23 212
- Camshaft position sensor service code 23 213
- Fuel system dfi 3 95 213
- Zx1200 b3 213
- 96 fuel system dfi 214
- Speed sensor service code 24 214
- Fuel system dfi 3 97 215
- Speed sensor service code 24 215
- Zx1200 b1 b2 215
- Zx1200 b3 215
- 98 fuel system dfi 216
- Gear position switch service code 25 216
- Fuel system dfi 3 99 217
- Gear position switch input voltage connections to ecu zx1200 b1 217
- Gear position switch service code 25 217
- Input voltage at ecu except gear position 217
- Input voltage at ecu respective gear position 217
- Zx1200 b3 217
- 100 fuel system dfi 218
- Gear position switch input voltage connection to ecu 218
- Gear position switch service code 25 218
- Input voltage at gear position switch connector except gear pos 218
- Input voltage at gear position switch connector respective gear 218
- Fuel system dfi 3 101 219
- Gear position switch service code 25 219
- Zx1200 b1 b2 219
- 102 fuel system dfi 220
- Gear position switch service code 25 220
- Zx1200 b3 220
- Caution 221
- Fuel system dfi 3 103 221
- Removal 221
- Vehicle down sensor service code 31 221
- 104 fuel system dfi 222
- Vehicle down sensor service code 31 222
- Warning 222
- Fuel system dfi 3 105 223
- Vehicle down sensor output voltage 223
- Vehicle down sensor power source voltage 223
- Vehicle down sensor service code 31 223
- 106 fuel system dfi 224
- Vehicle down sensor service code 31 224
- Zx1200 b1 b2 224
- Fuel system dfi 3 107 225
- Vehicle down sensor service code 31 225
- Zx1200 b3 225
- 108 fuel system dfi 226
- Subthrottle sensor input voltage 226
- Subthrottle sensor service code 32 zx1200 b3 226
- Wiring connection 226
- Fuel system dfi 3 109 227
- Main throttle sensor output voltage 227
- Output voltage inspection 227
- Subthrottle sensor service code 32 zx1200 b3 227
- Wiring connection 227
- 110 fuel system dfi 228
- Resistance inspection 228
- Subthrottle sensor service code 32 zx1200 b3 228
- Throttle sensor resistance 228
- Amplifier input voltage 229
- Antenna resistance 229
- Fuel system dfi 3 111 229
- Immobilizer amplifier service code 35 zx1200 b3 229
- Input voltage 229
- 112 fuel system dfi 230
- Blank key detection service code 36 zx1200 b3 230
- Fuel injectors 1 2 3 4 service code 41 42 43 44 231
- Fuel system dfi 3 113 231
- Injector power source voltage at ecu 231
- 114 fuel system dfi 232
- Fuel injectors 1 2 3 4 service code 41 42 43 44 232
- Injector power source voltage at injector 232
- Fuel injectors 1 2 3 4 service code 41 42 43 44 233
- Fuel system dfi 3 115 233
- Injector output voltage at ecu 233
- Output voltage inspection 233
- 116 fuel system dfi 234
- Fuel injectors 1 2 3 4 service code 41 42 43 44 234
- Injector output voltage at injector 234
- Fuel injectors 1 2 3 4 service code 41 42 43 44 235
- Fuel system dfi 3 117 235
- 118 fuel system dfi 236
- Caution 236
- Fuel injectors 1 2 3 4 service code 41 42 43 44 236
- Injector resistance 236
- Injector resistance inspection 236
- Injector unit test 236
- Fuel injectors 1 2 3 4 service code 41 42 43 44 237
- Fuel line maximum pressure 237
- Fuel system dfi 3 119 237
- 120 fuel system dfi 238
- Fuel injectors 1 2 3 4 service code 41 42 43 44 238
- Zx1200 b1 b2 238
- Fuel injectors 1 2 3 4 service code 41 42 43 44 239
- Fuel system dfi 3 121 239
- Zx1200 b3 239
- 122 fuel system dfi 240
- Fuel pump relay operating voltage at ecu 240
- Fuel pump relay service code 45 46 240
- Fuel pump relay operating voltage at relay connector 241
- Fuel pump relay service code 45 46 241
- Fuel system dfi 3 123 241
- 124 fuel system dfi 242
- Fuel pump relay power source voltage 242
- Fuel pump relay service code 45 46 242
- Relay power source voltage 242
- Fuel pump relay service code 45 46 243
- Fuel system dfi 3 125 243
- 126 fuel system dfi 244
- Fuel pump relay service code 45 46 244
- Zx1200 b3 244
- Fuel system dfi 3 127 245
- Stick coils 1 2 3 4 service code 51 52 53 54 245
- 128 fuel system dfi 246
- Stick coil input voltage at ecu 246
- Stick coils 1 2 3 4 service code 51 52 53 54 246
- Fuel system dfi 3 129 247
- Stick coils 1 2 3 4 service code 51 52 53 54 247
- Zx1200 b1 b2 247
- 130 fuel system dfi 248
- Stick coils 1 2 3 4 service code 51 52 53 54 248
- Zx1200 b3 248
- Fuel system dfi 3 131 249
- Subthrottle valve actuator resistance 249
- Subthrottle valve actuator service code 62 zx1200 b3 249
- 132 fuel system dfi 250
- Input voltage at actuator 250
- Subthrottle valve actuator input voltage 250
- Subthrottle valve actuator service code 62 zx1200 b3 250
- Caution 251
- Ecu installation 251
- Ecu power supply inspection 251
- Ecu removal 251
- Fuel system dfi 3 133 251
- 134 fuel system dfi 252
- Ecu grounding inspection 252
- Zx1200 b1 b2 252
- Zx1200 b3 252
- Ecu power source inspection 253
- Fuel system dfi 3 135 253
- 136 fuel system dfi 254
- Ecu power source circuit zx1200 b1 b2 254
- Zx1200 b3 254
- Caution 255
- Dfi power source 255
- Ecu fuse inspection 255
- Ecu fuse installation 255
- Ecu fuse removal 255
- Ecu main relay inspection 255
- Ecu main relay removal 255
- Fuel system dfi 3 137 255
- Testing relay 255
- Fi indicator led light 257
- Fi indicator led light check 257
- Fuel system dfi 3 139 257
- Led light inspection 257
- Zx1200 b1 b2 257
- 140 fuel system dfi 258
- Fi indicator led light 258
- Zx1200 b3 258
- Fuel line 259
- Fuel pressure 259
- Fuel system dfi 3 141 259
- Warning 259
- 142 fuel system dfi 260
- Fuel line 260
- Warning 260
- Amount of fuel flow 261
- Fuel line 261
- Fuel system dfi 3 143 261
- Warning 261
- 144 fuel system dfi 262
- In tank fuel pump 262
- Warning 262
- Fuel system dfi 3 145 263
- In tank fuel pump 263
- Warning 263
- 146 fuel system dfi 264
- In tank fuel pump 264
- Pump operating voltage at pump 264
- Fuel system dfi 3 147 265
- In tank fuel pump 265
- Zx1200 b1 b2 265
- 148 fuel system dfi 266
- In tank fuel pump 266
- Zx1200 b3 266
- Caution 267
- Evaporative emission control system 267
- Fuel system dfi 3 149 267
- Hose inspection 267
- Parts removal installation 267
- Separator inspection 267
- Warning 267
- 150 fuel system dfi 268
- Evaporative emission control system 268
- Warning 268
- Cooling system 269
- Cooling system 4 1 269
- Table of contents 269
- 2 cooling system 270
- Exploded view 270
- Cooling system 4 3 271
- Specifications 271
- 4 cooling system 272
- Coolant flow chart 272
- Coolant flow chart 273
- Cooling system 4 5 273
- 6 cooling system 274
- Coolant 274
- Coolant 275
- Cooling system 4 7 275
- 8 cooling system 276
- Water pump 276
- Cooling system 4 9 277
- Water pump 277
- Water pump impeller disassembly assembly 277
- Water pump inspection 277
- Water pump installation 277
- 10 cooling system 278
- Caution 278
- Water pump 278
- Water pump housing assembly 278
- Water pump housing disassembly 278
- Water pump impeller inspection 278
- Cooling system 4 11 279
- Mechanical seal inspection 279
- Water pump 279
- 12 cooling system 280
- Radiator and radiator fan removal 280
- Radiator radiator fan 280
- Warning 280
- Caution 281
- Cooling system 4 13 281
- Radiator and radiator fan installation 281
- Radiator inspection 281
- Radiator radiator fan 281
- 14 cooling system 282
- Radiator cap relief pressure 282
- Radiator radiator fan 282
- Cooling system 4 15 283
- Thermostat 283
- 16 cooling system 284
- Thermostat 284
- Thermostat valve opening temperature 284
- Cooling system 4 17 285
- Hose and pipes 285
- 18 cooling system 286
- Caution 286
- Radiator fan switch water temperature sensor 286
- Radiator fan switch water temperature sensor inspection 286
- Radiator fan switch water temperature sensor installation 286
- Radiator fan switch water temperature sensor removal 286
- Engine top end 287
- Engine top end 5 1 287
- Table of contents 287
- 2 engine top end 288
- Exploded view 288
- Zx1200 b1 b2 288
- Engine top end 5 3 289
- Exploded view 289
- Zx1200 b3 289
- 4 engine top end 290
- Exploded view 290
- Engine top end 5 5 291
- Specifications 291
- 6 engine top end 292
- Specifications 292
- Engine top end 5 7 293
- Specifications 293
- 8 engine top end 294
- Air suction valve check 294
- Air suction valve installation 294
- Air suction valve removal 294
- Clean air system 294
- Clean air system 295
- Engine top end 5 9 295
- Vacuum switch valve closing pressure open close 295
- 10 engine top end 296
- Air switching valve installation zx1200 b3 296
- Air switching valve operation test zx1200 b3 296
- Air switching valve removal zx1200 b3 296
- Air switching valve unit test zx1200 b3 296
- Clean air system 296
- Clean air system hose inspection 296
- Cylinder head cover 297
- Engine top end 5 11 297
- 12 engine top end 298
- Cylinder head cover 298
- Camshaft chain tensioner 299
- Engine top end 5 13 299
- 14 engine top end 300
- Camshaft camshaft chain 300
- Camshaft camshaft chain 301
- Engine top end 5 15 301
- 16 engine top end 302
- Camshaft camshaft chain 302
- Camshaft journal camshaft cap clearance 302
- Camshaft journal diameter 302
- Cam height 303
- Cam wear 303
- Camshaft camshaft chain 303
- Camshaft chain removal 303
- Camshaft runout 303
- Engine top end 5 17 303
- 18 engine top end 304
- Cylinder compression 304
- Cylinder head 304
- Cylinder head 305
- Engine top end 5 19 305
- 20 engine top end 306
- Cylinder head 306
- Cylinder head 307
- Cylinder head warp 307
- Engine top end 5 21 307
- 22 engine top end 308
- Valves 308
- Engine top end 5 23 309
- Valve valve guide clearance wobble method 309
- Valves 309
- 24 engine top end 310
- Valve seating surface outside diameter 310
- Valve seating surface width 310
- Valves 310
- Engine top end 5 25 311
- Valves 311
- 26 engine top end 312
- Valves 312
- Engine top end 5 27 313
- Valves 313
- Cylinder pistons 315
- Engine top end 5 29 315
- 30 engine top end 316
- Caution 316
- Cylinder pistons 316
- Piston removal 316
- Cylinder pistons 317
- Engine top end 5 31 317
- 32 engine top end 318
- Cylinder inside diameter 318
- Cylinder pistons 318
- Piston diameter 318
- Piston ring groove clearance 318
- Piston ring groove width 318
- Cylinder pistons 319
- Engine top end 5 33 319
- Piston ring end gap 319
- Piston ring thickness 319
- 34 engine top end 320
- Throttle body holder 320
- Engine top end 5 35 321
- Muffler 321
- Muffler body removal 321
- Muffler installation 321
- Muffler removal 321
- Warning 321
- 36 engine top end 322
- Muffler 322
- Muffler body installation 322
- Clutch 323
- Clutch 6 1 323
- Table of contents 323
- 2 clutch 324
- Exploded view 324
- Clutch 6 3 325
- Specifications 325
- 4 clutch 326
- Clutch lever and cable 326
- Caution 327
- Clutch 6 5 327
- Clutch cover 327
- Clutch cover installation 327
- Clutch cover removal 327
- Warning 327
- 6 clutch 328
- Caution 328
- Clutch cover 328
- Clutch cover disassembly 328
- Release shaft installation 328
- Release shaft removal 328
- Clutch 6 7 329
- Clutch cover 329
- 8 clutch 330
- Clutch 330
- Clutch 331
- Clutch 6 9 331
- 10 clutch 332
- Clutch 332
- Clutch 333
- Clutch 6 11 333
- Clutch plate assembly length 333
- 12 clutch 334
- Clutch 334
- Clutch plate warp inspection 334
- Clutch plate wear damage inspection 334
- Clutch spring free length 334
- Clutch spring free length measurement 334
- Friction and steel plate warp 334
- Friction plate thickness 334
- Engine lubrication system 335
- Engine lubrication system 7 1 335
- Table of contents 335
- 2 engine lubrication system 336
- Exploded view 336
- Engine lubrication system 7 3 337
- Engine oil flow chart 337
- 4 engine lubrication system 338
- Specifications 338
- Engine lubrication system 7 5 339
- Engine oil and oil filter 339
- Warning 339
- 6 engine lubrication system 340
- Oil cooler 340
- Oil cooler installation 340
- Oil cooler removal 340
- Engine lubrication system 7 7 341
- Oil pan 341
- Warning 341
- 8 engine lubrication system 342
- Oil pan 342
- Engine lubrication system 7 9 343
- Oil pump oil pump drive gear and oil pressure relief valve 343
- 10 engine lubrication system 344
- Oil pressure relief valve inspection 344
- Oil pump drive gear installation 344
- Oil pump drive gear removal 344
- Oil pump oil pump drive gear and oil pressure relief valve 344
- Engine lubrication system 7 11 345
- Oil pump oil pump drive gear and oil pressure relief valve 345
- Warning 345
- 12 engine lubrication system 346
- Oil pressure 346
- Oil pressure measurement 346
- Warning 346
- Engine lubrication system 7 13 347
- Oil pressure switch 347
- Oil pressure switch installation 347
- Oil pressure switch removal 347
- Engine removal installation 349
- Engine removal installation 8 1 349
- Table of contents 349
- 2 engine removal installation 350
- Exploded view 350
- Caution 351
- Engine removal 351
- Engine removal installation 351
- Engine removal installation 8 3 351
- Warning 351
- 4 engine removal installation 352
- Engine removal installation 352
- Engine removal installation 353
- Engine removal installation 8 5 353
- 6 engine removal installation 354
- Engine removal installation 354
- Crankshaft transmission 355
- Crankshaft transmission 9 1 355
- Table of contents 355
- 2 crankshaft transmission 356
- Exploded view 356
- Crankshaft transmission 9 3 357
- Exploded view 357
- 4 crankshaft transmission 358
- Specifications 358
- Crankshaft transmission 9 5 359
- Specifications 359
- 6 crankshaft transmission 360
- Specifications 360
- Crankcase splitting 361
- Crankshaft transmission 9 7 361
- 8 crankshaft transmission 362
- Crankcase splitting 362
- Crankcase splitting 363
- Crankshaft transmission 9 9 363
- 10 crankshaft transmission 364
- Crankcase splitting 364
- Crankshaft and connecting rods 365
- Crankshaft transmission 9 11 365
- Warning 365
- 12 crankshaft transmission 366
- Caution 366
- Crankshaft and connecting rods 366
- Connecting rod bend 367
- Crankshaft and connecting rods 367
- Crankshaft transmission 9 13 367
- 14 crankshaft transmission 368
- Connecting rod big end bearing insert crankpin clearance 368
- Connecting rod big end side clearance 368
- Connecting rod twist 368
- Crankpin diameter 368
- Crankshaft and connecting rods 368
- Connecting rod big end bore diameter marks 369
- Crankpin diameter marks 369
- Crankshaft and connecting rods 369
- Crankshaft transmission 9 15 369
- 16 crankshaft transmission 370
- Crankshaft main bearing insert journal clearance 370
- Crankshaft main journal diameter 370
- Crankshaft main journal diameter marks 370
- Crankcase main bearing bore diameter marks 371
- Crankshaft and connecting rods 371
- Crankshaft side clearance 371
- Crankshaft transmission 9 17 371
- 18 crankshaft transmission 372
- Crankshaft and connecting rods 372
- Crankshaft runout 372
- Balancer 373
- Crankshaft transmission 9 19 373
- 20 crankshaft transmission 374
- Balancer 374
- Crankshaft transmission 9 21 375
- Starter motor clutch and torque limiter 375
- 22 crankshaft transmission 376
- Starter clutch inspection 376
- Starter motor clutch and torque limiter 376
- Starter motor clutch assembly 376
- Crankshaft transmission 9 23 377
- Starter motor clutch and torque limiter 377
- 24 crankshaft transmission 378
- Transmission 378
- Caution 379
- Crankshaft transmission 9 25 379
- External shift mechanism removal 379
- Transmission 379
- Warning 379
- 26 crankshaft transmission 380
- External shift mechanism inspection 380
- External shift mechanism installation 380
- Transmission 380
- Transmission shaft removal 380
- Crankshaft transmission 9 27 381
- Transmission 381
- 28 crankshaft transmission 382
- Transmission 382
- Crankshaft transmission 9 29 383
- Transmission 383
- 30 crankshaft transmission 384
- Transmission 384
- Crankshaft transmission 9 31 385
- Transmission 385
- 32 crankshaft transmission 386
- Gear groove width 386
- Shift drum groove width 386
- Shift fork ear thickness 386
- Shift fork guide pin diameter 386
- Transmission 386
- Crankshaft transmission 9 33 387
- Gear dog and gear dog hole damage 387
- Transmission 387
- Table of contents 389
- Wheels tires 389
- Wheels tires 10 1 389
- 2 wheels tires 390
- Exploded view 390
- Specifications 391
- Wheels tires 10 3 391
- 4 wheels tires 392
- Wheels rims 392
- Warning 393
- Wheels rims 393
- Wheels tires 10 5 393
- 6 wheels tires 394
- Warning 394
- Wheels rims 394
- Wheels rims 395
- Wheels tires 10 7 395
- 8 wheels tires 396
- Rim runout 396
- Warning 396
- Wheel inspection 396
- Wheels rims 396
- Axle runout 100 mm 3 4 in 397
- Balance weight 397
- Wheels rims 397
- Wheels tires 10 9 397
- 10 wheels tires 398
- Warning 398
- Wheels rims 398
- B installation completed 399
- Wheels rims 399
- Wheels tires 10 11 399
- When required total weight exceeds 20 g 0 1 oz install balance weight at both sides of rim flange as shown 399
- 12 wheels tires 400
- Air pressure when cold 400
- Warning 401
- Wheels tires 10 13 401
- 14 wheels tires 402
- Warning 402
- Repair 403
- Wheels tires 10 15 403
- 16 wheels tires 404
- Hub bearings 404
- Final drive 405
- Final drive 11 1 405
- Table of contents 405
- 2 final drive 406
- Exploded view 406
- Final drive 11 3 407
- Specifications 407
- 4 final drive 408
- Drive chain 408
- Drive chain installation 408
- Drive chain removal 408
- Drive chain wear inspection 408
- Lubrication 408
- Slack adjustment 408
- Slack inspection 408
- Wheel alignment inspection adjustment 408
- Final drive 11 5 409
- Sprocket coupling 409
- 6 final drive 410
- Sprocket coupling 410
- Coupling bearing installation 411
- Coupling bearing removal 411
- Final drive 11 7 411
- Rear sprocket warp 411
- Rear sprocket warp inspection 411
- Sprocket coupling 411
- 8 final drive 412
- Sprocket coupling 412
- Brakes 413
- Brakes 12 1 413
- Table of contents 413
- 2 brakes 414
- Exploded view 414
- Zx1200 b1 b2 414
- Brakes 12 5 417
- Exploded view 417
- Brakes 12 7 419
- Exploded view 419
- 8 brakes 420
- Specifications 420
- Brake pedal 421
- Brakes 12 9 421
- Length a 421
- Pedal position c 421
- 10 brakes 422
- Brake lever brake pedal 422
- Brakes 12 11 423
- Calipers 423
- Warning 423
- 12 brakes 424
- Calipers 424
- Warning 424
- Brakes 12 13 425
- Calipers 425
- Warning 425
- 14 brakes 426
- Calipers 426
- Brakes 12 15 427
- Calipers 427
- Warning 427
- 16 brakes 428
- Calipers 428
- Brakes 12 17 429
- Caliper dust seal damage 429
- Caliper piston and cylinder damage 429
- Calipers 429
- 18 brakes 430
- Brake pads 430
- Front brake pad removal 430
- Brake pads 431
- Brakes 12 19 431
- Warning 431
- 20 brakes 432
- Brake pad lining wear 432
- Brake pads 432
- Rear brake pad installation 432
- Warning 432
- Brakes 12 21 433
- Front master cylinder installation 433
- Front master cylinder removal 433
- Master cylinder 433
- 22 brakes 434
- Master cylinder 434
- Brakes 12 23 435
- Master cylinder 435
- 24 brakes 436
- Master cylinder 436
- Master cylinder inspection visual inspection 436
- Brake disc installation 437
- Brake disc removal 437
- Brake disc warp 437
- Brake disc wear 437
- Brake discs 437
- Brakes 12 25 437
- Disc runout 437
- Front disc thickness 437
- Rear disc thickness 437
- 26 brakes 438
- Brake fluid 438
- Warning 438
- Brake fluid 439
- Brakes 12 27 439
- 28 brakes 440
- Brake fluid 440
- Warning 440
- Brake hose inspection 441
- Brake hose removal installation 441
- Brake hoses 441
- Brakes 12 29 441
- Caution 441
- Suspension 443
- Suspension 13 1 443
- Table of contents 443
- 2 suspension 444
- Exploded view 444
- Exploded view 445
- Suspension 13 3 445
- 4 suspension 446
- Specifications 446
- Front fork 447
- Rebound damping force adjustment zx1200 b1 b2 447
- Suspension 13 5 447
- Warning 447
- Zx1200 b3 447
- 6 suspension 448
- Adjuster protrusion from top 448
- Compression damping force adjustment zx1200 b1 b2 448
- Front fork 448
- Spring action 448
- Warning 448
- Zx1200 b3 448
- Front fork 449
- Suspension 13 7 449
- 8 suspension 450
- Front fork 450
- Caution 451
- Front fork 451
- Inner tube inspection 451
- Suspension 13 9 451
- Warning 451
- 10 suspension 452
- Dust seal inspection 452
- Front fork 452
- Spring free length 452
- Spring tension 452
- Compression damping force adjustment 453
- Rear shock absorber 453
- Rebound damping force adjustment 453
- Suspension 13 11 453
- 12 suspension 454
- Rear shock absorber 454
- Spring adjustment 454
- Spring free length 454
- Spring preload setting 454
- Rear shock absorber 455
- Suspension 13 13 455
- Warning 455
- 14 suspension 456
- Swingarm 456
- Swingarm removal 456
- Suspension 13 15 457
- Swingarm 457
- 16 suspension 458
- Swingarm 458
- Suspension 13 17 459
- Tie rod rocker arm 459
- 18 suspension 460
- Needle bearing inspection 460
- Tie rod rocker arm 460
- Tie rod rocker arm sleeve inspection 460
- Uni track linkage lubrication 460
- Steering 461
- Steering 14 1 461
- Table of contents 461
- 2 steering 462
- Exploded view 462
- Specifications 463
- Steering 14 3 463
- 4 steering 464
- Steering 464
- Steering adjustment 464
- Steering inspection 464
- Steering 14 5 465
- Steering stem 465
- Stem stem bearing removal 465
- 6 steering 466
- Steering stem 466
- Steering 14 7 467
- Steering stem 467
- 8 steering 468
- Steering stem 468
- Warning 468
- Steering 14 9 469
- Steering stem 469
- Warning 469
- 10 steering 470
- Handlebar 470
- Handlebar installation 470
- Handlebar removal 470
- Frame 15 1 471
- Table of contents 471
- 2 frame 472
- Exploded view 472
- Exploded view 473
- Frame 15 3 473
- 4 frame 474
- Exploded view 474
- Frame 15 5 475
- Rear seat cover removal 475
- Rear seat installation 475
- Rear seat removal 475
- 6 frame 476
- Front seat installation 476
- Front seat removal 476
- Rear seat cover installation 476
- Frame 15 7 477
- Seat cover 477
- 8 frame 478
- Fairings 478
- Fairings 479
- Frame 15 9 479
- 10 frame 480
- Fairings 480
- Fairings 481
- Frame 15 11 481
- Lower inner covers left and right installation 481
- Upper fairing removal 481
- 12 frame 482
- Fairings 482
- Upper fairing disassembly 482
- Fairings 483
- Frame 15 13 483
- Upper fairing assembly 483
- 14 frame 484
- Fairings 484
- Fenders 485
- Frame 15 15 485
- Front fender installation 485
- Front fender removal 485
- Rear fender rear installation 485
- Rear fender rear removal 485
- 16 frame 486
- Fenders 486
- Frame 15 17 487
- Frame inspection 487
- Rear frame 487
- Rear frame installation 487
- Rear frame removal 487
- Warning 487
- 18 frame 488
- Storage box 488
- Storage box installation 488
- Storage box removal 488
- Frame 15 19 489
- Side stand 489
- Electrical system 491
- Electrical system 16 1 491
- Table of contents 491
- 2 electrical system 492
- Electrical system 16 3 493
- Exploded view 493
- 4 electrical system 494
- Exploded view 494
- Electrical system 16 7 497
- Exploded view 497
- 8 electrical system 498
- Specifications 498
- Electrical system 16 9 499
- Specifications 499
- 10 electrical system 500
- Parts location 500
- Electrical system 16 11 501
- Precautions 501
- Electrical system 16 13 503
- Electrical wiring 503
- 14 electrical system 504
- Battery 504
- Battery removal 504
- Caution 504
- Battery 505
- Electrical system 16 15 505
- 16 electrical system 506
- Battery 506
- Battery 507
- Electrical system 16 17 507
- Warning 507
- 18 electrical system 508
- Battery 508
- Caution 508
- Initial charge 508
- Precautions 508
- Warning 508
- Battery 509
- Battery terminal voltage 509
- Electrical system 16 19 509
- Terminal voltage 11 less than 12 v 509
- Terminal voltage less than 11 v 509
- Warning 509
- 20 electrical system 510
- Battery 510
- Alternator cover installation 511
- Alternator cover removal 511
- Charging system 511
- Electrical system 16 21 511
- Stator coil removal 511
- 22 electrical system 512
- Charging system 512
- Stator coil installation 512
- Alternator rotor installation 513
- Alternator rotor removal 513
- Charging system 513
- Electrical system 16 23 513
- 24 electrical system 514
- Charging system 514
- Charging system 515
- Electrical system 16 25 515
- Table 1 alternator output voltage 515
- Table 2 stator coil resistance 515
- 26 electrical system 516
- Charging system 516
- Rectifier circuit inspection 516
- Caution 517
- Charging system 517
- Electrical system 16 27 517
- 28 electrical system 518
- Caution 518
- Charging system 518
- Regulator rectifier output voltage 518
- Regulator rectifier output voltage inspection 518
- Charging system 519
- Electrical system 16 29 519
- Regulator rectifier output voltage 519
- 30 electrical system 520
- Charging system 520
- Charging system circuit 520
- Electrical system 16 31 521
- Ignition system 521
- Warning 521
- 32 electrical system 522
- Connections 522
- Crankshaft sensor inspection 522
- Crankshaft sensor installation 522
- Crankshaft sensor peak voltage inspection 522
- Ignition system 522
- Camshaft position sensor installation 523
- Camshaft position sensor removal 523
- Crankshaft sensor peak voltage 523
- Electrical system 16 33 523
- Ignition system 523
- 34 electrical system 524
- Camshaft position sensor inspection 524
- Camshaft position sensor peak voltage 524
- Camshaft position sensor peak voltage inspection 524
- Connections 524
- Ignition system 524
- Electrical system 16 35 525
- Ignition system 525
- Stick coil winding resistance 525
- 36 electrical system 526
- Ignition system 526
- Primary lead connection 526
- Stick coil primary peak voltage 526
- Warning 526
- Condition 527
- Connection 527
- Electrical system 16 37 527
- Ignition system 527
- Interlock operation voltage 527
- 38 electrical system 528
- Condition 528
- Ignition system 528
- 40 electrical system 530
- Ignition system 530
- Ignition system circuit zx1200 b1 b2 530
- Electrical system 16 41 531
- Ignition system 531
- Zx1200 b3 531
- 42 electrical system 532
- Caution 532
- Electric starter system 532
- Starter motor installation 532
- Starter motor removal 532
- Electric starter system 533
- Electrical system 16 43 533
- 44 electrical system 534
- Brush inspection 534
- Commutator cleaning and inspection 534
- Commutator diameter 534
- Electric starter system 534
- Starter motor brush length 534
- Electric starter system 535
- Electrical system 16 45 535
- 46 electrical system 536
- Connect the hand tester a and 12 v battery b to the starter relay c as shown 536
- Electric starter system 536
- If the relay does not work as specified the relay is defec tive replace the relay 536
- Remove starter cable a battery cable b disconnect connector c starter relay d 536
- Testing relay 536
- Electric starter circuit zx1200 b1 b2 537
- Electric starter system 537
- Electrical system 16 47 537
- 48 electrical system 538
- Electric starter system 538
- Zx1200 b3 538
- Electrical system 16 49 539
- Lighting system 539
- 50 electrical system 540
- Caution 540
- City light bulb replacement 540
- Headlight bulbs left and right replacement 540
- Lighting system 540
- Electrical system 16 51 541
- Lighting system 541
- 52 electrical system 542
- Headlight relays high low inspection 542
- Lighting system 542
- Testing relay 542
- Electrical system 16 53 543
- Headlight tail light circuit zx1200 b1 b2 543
- Lighting system 543
- 54 electrical system 544
- Lighting system 544
- Turn signal relay inspection 544
- Zx1200 b3 544
- Electrical system 16 55 545
- Lighting system 545
- Testing turn signal relay 545
- 56 electrical system 546
- Lighting system 546
- Turn signal light circuit 546
- Air switching valve resistance 547
- Air switching valve zx1200 b3 547
- Electrical system 16 57 547
- 58 electrical system 548
- Caution 548
- Fan motors inspection 548
- Fan relay removal 548
- Fan system circuit inspection 548
- Radiator fan system 548
- Electrical system 16 59 549
- Fan relay inspection 549
- Radiator fan circuit 549
- Radiator fan system 549
- Testing relay 549
- 60 electrical system 550
- Bulbs replacement 550
- Caution 550
- Meter unit disassembly 550
- Meter unit removal 550
- Electrical system 16 61 551
- 62 electrical system 552
- Electrical system 16 63 553
- 64 electrical system 554
- B1 model 555
- B2 b3 model 555
- Check 8 coolant temperature gauge inspection 555
- Check that the position of segment b matches the resis tance value of the variable rheostat 555
- Connect a variable rheostat a to terminal 10 and 12 as shown 555
- Connect the leads in the same circuit as for the check 1 555
- Electrical system 16 65 555
- If this display function does not work replace the meter assembly 555
- Resistance values are standard and they have tolerance 555
- 66 electrical system 556
- Electrical system 16 67 557
- Fi indicator light led b 557
- Oil pressure warning indicator light led a 557
- 68 electrical system 558
- Meter circuit zx1200 b1 b2 558
- Electrical system 16 69 559
- Zx1200 b3 559
- 70 electrical system 560
- Immobilizer system equipped models zx1200 b3 560
- Electrical system 16 71 561
- Immobilizer system equipped models zx1200 b3 561
- 72 electrical system 562
- Immobilizer system equipped models zx1200 b3 562
- Electrical system 16 73 563
- Immobilizer system equipped models zx1200 b3 563
- 74 electrical system 564
- Immobilizer system equipped models zx1200 b3 564
- User key indicator flashes 564
- 76 electrical system 566
- Immobilizer system equipped models zx1200 b3 566
- Electrical system 16 77 567
- Immobilizer system equipped models zx1200 b3 567
- 78 electrical system 568
- Immobilizer system equipped models zx1200 b3 568
- Electrical system 16 79 569
- Immobilizer system equipped models zx1200 b3 569
- 80 electrical system 570
- Immobilizer system equipped models zx1200 b3 570
- Electrical system 16 81 571
- Immobilizer system equipped models zx1200 b3 571
- 82 electrical system 572
- Immobilizer system equipped models zx1200 b3 572
- Electrical system 16 83 573
- Immobilizer system equipped models zx1200 b3 573
- 84 electrical system 574
- Immobilizer system equipped models zx1200 b3 574
- 86 electrical system 576
- Immobilizer system equipped models zx1200 b3 576
- Caution 577
- Electrical system 16 87 577
- Immobilizer system equipped models zx1200 b3 577
- 88 electrical system 578
- Immobilizer system equipped models zx1200 b3 578
- Electrical system 16 89 579
- Switches and sensors 579
- 90 electrical system 580
- Fan switch resistance 580
- Switches and sensors 580
- Electrical system 16 91 581
- Switches and sensors 581
- Water temperature sensor 581
- 92 electrical system 582
- Switches and sensors 582
- Electrical system 16 93 583
- Fuel level sensor resistance 583
- Fuel reserve switch inspection 1 583
- Switches and sensors 583
- 94 electrical system 584
- Switches and sensors 584
- Electrical system 16 95 585
- Fuse circuit inspection 585
- Junction box 585
- Junction box fuse circuit inspection 585
- Starter circuit headlight relay inspection 585
- 96 electrical system 586
- Diode circuit inspection 586
- Junction box 586
- Relay circuit inspection with the battery connected 586
- Relay circuit inspection with the battery disconnected 586
- Electrical system 16 97 587
- Junction box 587
- Junction box internal circuit other than u s a canadian australian and malaysian models 587
- Junction box internal circuit u s a canadian australian and malaysian zx1200 b2 b3 models 587
- 98 electrical system 588
- A headlight fan fuse removal 588
- A main fuse removal 588
- Junction box fuse removal 588
- Electrical system 16 99 589
- 110 electrical system 600
- Electrical system 16 111 601
- Table of contents 607
- Troubleshooting 607
- Troubleshooting 17 1 607
- 2 troubleshooting 608
- Engine doesn t start starting difficulty 608
- Poor running at low speed 608
- Troubleshooting guide 608
- Overheating 609
- Poor running or no power at high speed 609
- Troubleshooting 17 3 609
- Troubleshooting guide 609
- 4 troubleshooting 610
- Abnormal engine noise 610
- Clutch operation faulty 610
- Gear shifting faulty 610
- Over cooling 610
- Troubleshooting guide 610
- Abnormal drive train noise 611
- Abnormal frame noise 611
- Exhaust smokes excessively 611
- Handling and or stability unsatisfactory 611
- Oil pressure warning light goes on 611
- Troubleshooting 17 5 611
- Troubleshooting guide 611
- 6 troubleshooting 612
- Battery trouble 612
- Brake doesn t hold 612
- Troubleshooting guide 612
- Model application 613
- Part no 9924 1278 03 613
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