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GPZ900R (1984-1990)
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Kawasaki GPZ900R (1984-1990) [2/293] Read owner s manual before operating

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Quick reference guide 1
Read owner s manual before operating 2
Emission control inform ation 3
Да й 3
Да кй ж 3
Й кй 3
Cautio 6
Foreword 6
General information 8
Table of contents 8
Fuel system 18
Table of contents 18
Cautio 26
Warnin 26
Cautio 27
Cautio 29
Warnin 33
Cooling system 34
Table of contents 34
Caution 37
Cautio 38
Cautio 40
Caution 45
Engine top end 46
Table of contents 46
Cautio 52
Cautio 54
Cautio 55
Cautio 56
Cautio 66
Clutch 74
Table of contents 74
Early model 76
Laic model 76
Along with common hand tools the following more 77
Specialized tool is required for complete clutch servicing 77
Cautio 80
Caution 81
Caution i 83
Bypass valve assembl 86
Bypass valve cleaning and inspectio 86
Bypass valve disassembl 86
Engine lubrication system 86
Engine oh and or filter chang 86
Engine oh level inspectio 86
Oh pressure measurement 86
Oh pump and relief vlave remova 86
Oh pump drive gear installatio 86
Oh pump drive gear remova 86
Oh pump gear installation note 86
Oh screen remova 86
Oil filter and bypass valve installation note 86
Oil filter and bypass valve remova 86
Oil pan installation note 86
Oil pan remova 86
Oil pump and relief valve installation note 86
Oil pump assembly notes 86
Oil pump disassembl 86
Oil pump gear remova 86
Oil pump inspectio 86
Oil screen cleaning and inspectio 86
Oil screen installation not 86
Relief valve inspectio 86
Table of contents 86
Along with common hand tools the following more 90
Oil pressure gauge 57001 164 90
Oil pressure gauge adapter 57001 1188 90
Specialized tools are required for complete engine lubrication system servicing 90
Cautio 91
Warnin 92
Caution 94
Broken wires 97
Check the screen carefully lor any damage holes and 97
Lf the screen is damaged replace it 97
Oh screen cleaning and inspection clean the oil screen with high flash point solvent and 97
Remove any particles stuck to it 97
While cleaning the screen check for any metal particles that might indicate internal engine damage 97
Engine installatio 98
Engine remova 98
Engine removal lnstallation 98
Table of contents 98
Alternator shaft and 100
Alternator shaft and starter clutch installation note 100
Alternator shaft chain wea 100
Balancer installation note 100
Balancer remova 100
Ball and needle bearing wea 100
Ball and needle bearing wear 100
Chain and sprocket 100
Chain and sprocket removal 100
Chain guide wea 100
Chain tensioner installation not 100
Chain tensioner remova 100
Connecting rod bend twis 100
Connecting rod big end bearing nsert crankpin wear 100
Connecting rod big end side clearanc 100
Connecting rod installation notes 100
Connecting rod remova 100
Crankcase assembl 100
Crankcase splittin 100
Crankshaft connecting rod cleaning 100
Crankshaft installation note 100
Crankshaft main bearing insert joumal wea 100
Crankshaft remova 100
Crankshaft runou 100
Crankshaft side clearanc 100
Crankshaft transmission 100
Damper inspectio 100
External shift mechanism inspectio 100
External shift mechanism installation note 100
External shift mechanism removal 100
Gear backlas 100
Gear dog gear dog hole damage 100
Installation not 100
Needle bearing wea 100
Shift drum and fork installation 100
Shift drum and fork remova 100
Shift fork bending 100
Shift fork gear groove wea 100
Shift fork guide pin shift drum groove wea 100
Starter clutch removal 100
Starter motor clutch inspection 100
Table of contents 100
Transmission shaft assembl 100
Transmission shaft disassemb l 100
Transmission shaft installatio 100
Transmission shaft remova 100
Along with common hand tools and precision instru ment specialized tools arc required for complete crank shaft lransmission servicing 105
Cautio 107
Caution 108
Axle inspectio 122
Front hub bearing installatio 122
Front hub bearing remova 122
Front wheel installatio 122
Front wheel remova 122
Grease seal inspection and lubricatio 122
Hub bearing inspection and lubricatio 122
Rear hub bearing ins tai la tio 122
Rear hub bearing remova 122
Rear wheel installatio 122
Rear wheel removal 122
Speedometer gear housing assembl 122
Speedometer gear housing disassembl 122
Speedometer gear housing lubricatio 122
Table of contents 122
Tire inspection 122
Tire installatio 122
Tire removal 122
Tire repai 122
Wheel balanc 122
Wheels tires 122
Cautio 125
Cautio 126
Cautio 127
Caution 133
Coupling bearing inspection and lubricatio 136
Coupling bearing installatio 136
Coupling bearing remova 136
Damper inspectio 136
Drive chain installatio 136
Drive chain lubricatio 136
Drive chain remova 136
Drive chain slack adjustmen 136
Drive chain slack inspectio 136
Drive chain wear inspectio 136
Engine sprocket installatio 136
Engine sprocket remova 136
Final drive 136
Grease seal inspection and lubricatio 136
Rear sprocket coupling installatio 136
Rear sprocket coupling remova 136
Sprocket war 136
Sprocket wea 136
Table of contents 136
Wheel a lignmen t inspectio 136
Wheel alignment adjustmen 136
Use following tools in the set 138
Warnin 139
Warnin 140
Cautjon j 141
Cautldn 143
Bleeding the brake lin 146
Brake fluid chang 146
Brake hose inspection 146
Brake hose replacement 146
Brake pedal position adjustmen 146
Brake pedal position inspectio 146
Brakes 146
Caliper assembly notes 146
Caliper disassembly note 146
Caliper holder shaft wea 146
Caliper installation note 146
Disc cleaning 146
Disc war 146
Disc wea 146
Dust seal and cover damag 146
Fluid level inspection 146
Fluid seal damag 146
Front caliper remova 146
Front master cylinder assembly note 146
Front master cylinder disassembly note 146
Front master cylinder installation note 146
Front master cylinder remova 146
Inspection and adjustment after installatio 146
Lining wea 146
Master cylinder inspectio 146
Pad installation not 146
Pad remova 146
Piston cylinder damage 146
Rear caliper remova 146
Rear master cylinder assembly note 146
Rear master cylinder disassembly note 146
Rear master cylinder installation note 146
Rear master cylinder remova 146
Reservoir assembly note 146
Reservoir disassembly note 146
Table of contents 146
Castrol girling universal castrol gt lima castrol disc brake fluid check shock premium heavy duty 148
Cautio 153
Ca utio n 154
A lower level line b upper level line 156
Brake disc 2 measuring area 156
Chom the reservoir horizontal when checking brake fluid level 156
Disc cleaning 156
Disc warp 156
Fluid level inspection 156
In accordance with the periodic maintenance charl inspect the brake fluid level in the iron and teat brake fluid reservoirs check the brake fluid level in the reservoir 156
Jack up the motorcycle so that the front wheel is olf the ground and lum the handlebar fully to one side set up a dial gauge against the front disc as illustrated and measure disc runout remove the jack set the motorcycle up on its center stand and then measure the rear disc runout ii runout exceeds the service limit replace the disc 156
Poor braking can he caused by oil on the disc oil on the disc must be cleaned off with an oil less cleaning fluid such as trichloroethylene or acetone 156
The fluid level must be kept above the lower level lines if the fluid level is lower than the lower level line fill the reservoir to the upper level line of the reservoir 156
A ir pressure a djust men t 160
A n ti dive valve inst alia tion 160
Air pressure inspectio 160
Ant dive valve removal 160
Anti dive adjustment 160
Anti dive system part replacemen 160
Anti dive valve assembly test 160
Brake fluid and fork oh leak inspectio 160
Brake plunger assembly test 160
Damping force adjustment 160
Fork oh change 160
Front fork assembl 160
Front fork disassembl 160
Front fork installation each fork leg 160
Front fork removal teach fork teg 160
Guide bush inspection 160
Inner tube inspectio 160
Metal pipe damage 160
Oil seal and dust seal inspection 160
Rear shock absorber adjustmen 160
Rear shock absorber installatio 160
Rear shock absorber removal 160
Spring tension 160
Suspension 160
Swing arm needle bearing inspectio 160
Swing arm needle bearing lubricatio 160
Swing arm remova 160
Swing arm sleeve inspectio 160
Table of contents 160
Tcv installation notes 160
Tcv travel control valve remova 160
Tcv troubleshootin 160
Tie rod rocker a rm installation noto 160
Tie rod rocker arm needle bearing inspectio 160
Tie rod rocker arm needle bearing lubricatio 160
Tie rod rocker arm sleeve inspectio 160
A air valve 164
A anti dive adjuster c triangular mark b position number 164
A drain screw 164
Air pressure adjustment pul the motorcycle on its center stand and raise the front wheel off die ground using a jack or other suitable stand under the engine 164
Anti dive adjustment 164
Cautio 164
Check and adjust the air pressure when the front fork is cold room temperature 164
Check to see that both adjusters are turned to the same relative position 164
Fork oh change release the air in both fork legs through the air valve at the top of the fork leg unscrew the drain screw and lop plug from one fork leg and pull out the fork spring and spring seat 164
Odo not use tire gauges for checking the air suspension s air pressure they may not indicate the correct pressure because of air leaks that occur when the gauge is applied to the valve c lower air pressure is for comfortable riding but it should be increased for high speed riding or riding on bad roads 164
The anti divc adjuster on each front fork leg has 3 positions so that the anti dive system can be adjusted for different road and loading conditions the numbers on the adjuster show the setting position of the anti dive system turn the anti divc adjuster until you feel a click so that the desired position number aligns with the triangular mark 164
Use the air pressure gauge special tool p n 52005 1003 specially made for air suspensions 164
Cautio 167
Bearing wear damag 175
Grease seal deterioration damag 175
Steering 175
Steering a di us tmen 175
Steering inspectio 175
Steering stem bearing lubricatio 175
Steering stem installation 175
Steering stem remova 175
Steering stem war 175
Table of contents 175
Controls 181
Handlebars installation note 181
Left handlebar remova 181
Right handlebar remova 181
Table of contents 181
Fairing stay installation not 184
Fairing stay remova 184
Front fender installation not 184
Front fender remova 184
Left footpeg bracket installation not 184
Left footpeg bracket remova 184
Lower fairing installatio 184
Lower fairing remova 184
Middle fairing installatio 184
Middle fairing remova 184
Rear fender front section installation not 184
Rear fender front section remova 184
Rear fender rear section installation not 184
Rear fender rear section remova 184
Rear frame installatio 184
Rear frame remova 184
Right footpeg bracket installation not 184
Right footpeg bracket remova 184
Seat cover installatio 184
Seat cover remova 184
Table of contents 184
Upper fairing installatio 184
Upper fairing remova 184
Cautio 192
Alternator assembly note 196
Alternator disassembl 196
Alternator installation note 196
Alternator remova 196
Alternator t roubleshooting 16 15 196
Armature inspectio 196
Ball bearing inspectio 196
Battery conditio 196
Battery initial chargin 196
Battery ordinary chargin 196
Battery test chargin 196
Brush and lead assembly inspection 196
Brush inspectio 196
Brush plate inspectio 196
Brush spring inspectio 196
Bulb replacement note 196
Carbon brush lengt 196
Commutator cleaning and inspection 196
Electrical system 196
Electrolyte level inspectio 196
Fail brake light lens removal installation note 196
Fan switch relay inspectio 196
Fan system circuit inspection fan inspection fan relay inspection 196
Fuel gauge operation inspection 196
Headlight beam horizontal adjustmen 196
Headlight beam vertical adjustmen 196
Headlight bulb replacement note 196
Headlight reserve lighting system inspection 196
Headlight unit removal installation not 196
Ic igniter inspectio 196
Ignition cod removal installation note 196
Ignition coil inspectio 196
License plate light bulb replacement notes 196
Meter and gauge removal installation not 196
Pickup coil inspectio 196
Pickup coil removal installation note 196
Rectifier inspectio 196
Regulator inspectio 196
Rotor coil inspectio 196
Slip ring cleanin 196
Slip ring diamete 196
Spark plug cleaning and inspectio 196
Spark plug ga 196
Spark plug removal installation note 196
Starter motor disassembly assembly note 196
Starter motor removal installation note 196
Starter relay inspectio 196
Stator coil inspectio 196
Table of contents 196
Tach voltmeter inspection 196
Tait brake light bulb replacement note 196
Test no battery discharge 196
Test no battery overcharge 196
Test no nois 196
Turn signa light bulb replacement not 196
Water temperature gauge operation inspectio 196
Cautio 205
Warning 205
Caurion 206
Cautio 206
Warning 206
Cautio 212
Cautio 213
Warning 213
Any meter reading less than infinity indicates a 217
Check the pickup coil air gaps clearance between the 217
For any ignition system problems always check the 217
Ic igniter inspection remove the ic igniter set the ohmmeter to the x i k 2 range and make the measurements shown in the table 217
If there is more resistance than the specified value the coil has an open lead and must be replaced much less than this resistance means the coil is shorted and must he replaced 217
Igniter 217
Ignition coil inspection measuring arcing distance 217
Ignition system wiring llr t sec wiring inspection 217
Lf both air gaps arc not equal reposition the pickup coils 217
Lf the meter readings are not as specified replace the ic 217
Measure the resistance between the pickup coil leads and chassis ground 217
Measured with hand tester 57001 983 a tester other than the kawasaki hand tester may show different readings 217
Of the ignition coil is made by measuring arcing distance with a suitable tester for the 3 needle method 217
Pickup coil inspection disconnect rhe pickup coil connector zero the ohmmeter and connect it to pickup coil 217
Short necessitating replacement of the pickup coil assembly 217
The most accurate test for determining the condition 217
Timing rotor projection and the pickup coil core 217
Using the highest resistance range of the ohmmeter 217
Cautio 219
Cautio 220
Cautio 223
Battery 224
Dimmer switch 224
Failure indicator 224
Headlight 224
Headlight relay 224
High beam indicator light 224
Ignition switch 224
Junction box 224
Main relay 224
Reserve lighting device 224
Sec starter system 224
See starter system 224
Starter circuit relay 224
Starter relay 224
_j a x cc m 224
Cautio 227
Caution j 229
Cautio 232
Appendix 236
Lubricatio 236
Spark plug inspectio 236
Table of contents 236
Tightness inspectio 236
Cautio 238
Supplement 1986 model 246
General information 247
Fuel system 253
A i inkagc lever b idle adjusting screw 256
Correct throttle grip free play is obtained 256
Idle adjusting screw with the throttle grip closed 256
The evaporative emission control system is almost 256
The same as lor the zx900 a2 refer to the following hose routing diagram 256
Tighten the locknut check that the throttle linkage lever stops against the 256
Turn the accelerator cable adjusting nut until the 256
Wheels tires 256
Electrical system 257
Steering 257
Supplement 1987 model 260
Supplement 1988 1989 models 262
General information 263
Fuel system 268
Engine top end 269
I he clean air system for the swiss model is the same as 269
Or the us model refer io the clean air system us model page 4 7 269
Wheels tires 269
Supplement 1990 model 270
Table of contents 270
A caution 271
General information 272
Zx900 a7 272
Zx900 a7 273
Engine top end 276
Fuel system 276
A caution 277
Engine lubrication system 277
Crankshaft t ransmission 278
Owhon using the modified crankcases and crankcase bolts refer to the following 278
The crankcases and crankcase bolts will be modified for larger diameter 278
Owhen using the modified crankcases and crankcase bolts refer to the following 279
The crankcases and crankcase bolts will be modified lot larger diameter 279
Wheels tires 280
Caution 281
Final drive 281
____________ a caution 281
Brakes 282
Caution 284
________ 284
Suspension 286
Qfork oil level may also be measured using the oil syringe specie tool 288
The gauge tube is graduated in 1 cm division othe syringe body is graduated in 10 ml divisions excluding the gouge tube which is about 5 ml capacity 288
The tape measure rod or oil syringe pipe should be in the middle of the inner tube or the correct oil level can not be measured 288
A caution 290
Controls 291
Electrical system 292

Kawasaki GPZ900R (1984-1990) [2/293] Read owner s manual before operating

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