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Ninja ZX-10R
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Motorcycle
Service Manual
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www.zxforums.com www.zxforums.com www.zxforums.com Quick Reference Guide GeneralInformation 1 j PeriodicMaintenance 2 j Fuel System(DFI) 3 j Cooling System 4 j EngineTop End 5 j Clutch 6 j EngineLubrication System 7 j EngineRemoval/Installation 8 j Crankshaft/Transmission 9 j Wheels/Tires 10 j www.zxforums.com FinalDrive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j ElectricalSystem 16 j Appendix 17 j This quick reference guide will assist you in locating a desired topic or pro- cedu
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www.zxforums.com www.zxforums.com www.zxforums.com Ninja ZX-10R www.zxforums.com 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, withoutthepriorwrittenpermissionofQualityDivision/ConsumerProducts&MachineryCompany/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in
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www.zxforums.com www.zxforums.com www.zxforums.com LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total in
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www.zxforums.com www.zxforums.com www.zxforums.com EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air
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www.zxforums.com www.zxforums.com www.zxforums.com TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofany device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or
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www.zxforums.com www.zxforums.com www.zxforums.com Foreword This manual is designed primarily for use by Guide shows you all of the product’s system trainedmechanicsinaproperlyequippedshop. and assists in locating their chapters. Each However,itcontainsenoughdetailandbasicin- chapter in turn has its own comprehensive Ta- formationtomakeitusefultotheownerwhode- ble of Contents. sirestoperformhisownbasicmaintenanceand Forexample,ifyouwantignitioncoilinforma- repair work. A basic knowledge of mecha
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GENERAL INFORMATION 1-1 www.zxforums.com www.zxforums.com www.zxforums.com General Information Table of Contents 1 Before Servicing..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-7 General Specifications.......................................................................................
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1-2 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tiononamotorcycle, readtheprecautionsgivenbelow. Tofacilitateactualoperations, notes, illustra- tions,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassem
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GENERAL INFORMATION 1-3 www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Arrangement andCleaningof RemovedParts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts Afterallthepartsincludingsubassemblypartshavebeen cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that ma
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1-4 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to asnugfit. Thentightenthemaccordingtothespecifiedse- quenceto prevent case warpage ordeformationwhich can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar- ter turn and then remove them. If the specifi
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GENERAL INFORMATION 1-5 www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks
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1-6 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive d
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GENERAL INFORMATION 1-7 www.zxforums.com www.zxforums.com www.zxforums.com Model Identification ZX1000D6F (Europe) Left Side View ZX1000D6F (Europe) Right Side View www.zxforums.com www.zxforums.com www.zxforums.com www.zxforums.com
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1-8 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com Model Identification ZX1000D6F (United States and Canada) Left Side View ZX1000D6F (United States and Canada) Right Side View www.zxforums.com Frame Number Engine Number www.zxforums.com www.zxforums.com www.zxforums.com
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GENERAL INFORMATION 1-9 www.zxforums.com www.zxforums.com www.zxforums.com General Specifications Items ZX1000D6F (Ninja ZX-10R) Dimensions Overall Length 2 065 mm (81.3 in.) Overall Width (CA), (CAL), (US) 730 mm (28.7 in.) 705 mm (27.8 in.) Overall Height 1 130 mm (44.5 in.) Wheelbase 1 390 mm (54.7 in.) Road Clearance 120 mm (4.7 in.) Seat Height 825 mm (32.5 in.) Dry Mass 175 kg (386 lb) Curb Mass: Front 102 kg (225 lb) Rear 100 kg (221 lb) Fuel Tank Capacity 17 L (4.5 US gal) Performance Mi
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1-10 GENERAL INFORMATION www.zxforums.com www.zxforums.com www.zxforums.com General Specifications Items ZX1000D6F (Ninja ZX-10R) Duration 292° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.611 (87/54) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 1st 2.533
