Мануал для kawasaki zx10r

Quick Reference Guide

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any 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 element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.

•Removal of the muffler(s) or any internal portion of the muffler(s).

•Removal of the air box or air box cover.

•Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following.

Battery Ground

Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

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

After all the parts including subassembly parts have been 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 may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

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 a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact 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 facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication 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. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Leads

A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

ZX1000JB (US and CA Models) Left Side View

ZX1000JB (US and CA Models) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZX1000JB (EUR Models) Left Side View

ZX1000JB (EUR Models) Right Side View

GENERAL INFORMATION 1-9

Model Identification

ZX1000KB (US and CA Models) Left Side View

ZX1000KB (US and CA Models) Right Side View

1-10 GENERAL INFORMATION

Model Identification

ZX1000KB (EUR Models) Left Side View

ZX1000KB (EUR Models) Right Side View

1-12 GENERAL INFORMATION

General Specifications

Specifications are subject to change without notice, and may not apply to every country.

1-14 GENERAL INFORMATION

Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC)

Overview

S-KTRC is a highly sophisticated system based on MotoGP racing technology. Unlike the KTRC system used on the GTR1400 ABS (Concours 14 ABS in N. America), which is designed to offer rider reassurance when traversing slippery surfaces, S-KTRC, is designed to maximize forward motion, allowing riding at the edge of traction.

The quickest acceleration requires a certain amount of slip, so in order to optimize traction, S-KTRC actually allows slip. The ideal slip ratio varies according to conditions. The system looks at a number of parameters to get an accurate real-time picture of what is going on: front and rear wheel speed (slippage), engine rpm, throttle position, slippage, acceleration, etc.

Using complex analysis, the system is able to predict when traction conditions are about to become unfavorable. By acting before slippage exceeds the range for optimal traction, drops in power can be minimized resulting in ultra-smooth operation.

There are three available modes that riders can set according to preference (and skill level). Each mode is able to accommodate a range of riding conditions. Of course, engine manageability is such that riders can opt to turn the system OFF without fear of making the bike uncontrollable.

By combining the setting with the power mode, the rider can choose various riding modes to suit the road conditions and riding skill.

The system becomes functional at 5 km/h (3.1 mph) or more. If a failure occurs in the system, the warning indicator light (yellow LED) and mode indicator symbol blink to let the rider know that the system stops functioning.

GENERAL INFORMATION 1-15

Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC)

System Components

1. FI ECU

The FI ECU analyzes the motorcycle conditions based on the signals from the front/rear wheel rotation sensors and FI sensors (such as the crankshaft sensor and main throttle sensor), and controls engine power by reducing the number of ignition and retarding the ignition timing. The mode-switching signal is transmitted to the FI ECU by the CAN system via the meter ECU. If a failure occurs in the system, the FI ECU deactivates S-KTRC and displays the warning indication in the meter.

2. Wheel Rotation Sensor

The wheel rotation sensor converts front and rear wheel rotation speed to a pulse signal and transmits it to the FI ECU.

As for the KIBS (Kawasaki Intelligent anti-lock Brake System) equipped model, a pulse signal is transmitted via the KIBS ECU.

3. Crankshaft Sensor

The crankshaft sensor converts the engine speed to a pulse signal and transmits it to the FI ECU.

4. Main Throttle Sensor

The main throttle sensor converts the throttle position to a voltage signal and transmits it to the FI ECU.

5. S-KTRC Button

The mode-switching signal is transmitted to the meter ECU by depressing the S-KTRC button (0.3 0.4 sec.).

1-16 GENERAL INFORMATION

Technical Information-Sport-Kawasaki TRaction Control System (S-KTRC)

6. Multifunction Meter

The multifunction meter receives a mode-switching signal and displays the mode [A], and transmits it to the FI ECU by the CAN system.

When a failure occurs in the system, the multifunction meter displays the warning indication by blinking the warning indicator light (yellow LED) [B] and mode indicator symbol.

It also displays the S-KTRC operating conditions in the level indicator [C].

7. KIBS ECU

As for the KIBS equipped model, the front and rear wheel sensor signals are transmitted to the FI ECU via the KIBS ECU.

Mode-switching

Depress the S-KTRC button on the left handlebar switch to change the mode. The mode can be changed only when the throttle grip is closed completely.

The S-KTRC OFF can be selected only when the motorcycle is at a stop. Changing to mode 1 from S-KTRC OFF is possible while riding.

NOTE

○When changing the mode, stop the motorcycle.

○The mode is retained if the ignition switch is turned to OFF or if the battery is disconnected.

○When the ignition switch is turned to OFF, and then back to ON while S-KTRC is OFF, the system will automatically be set to mode 1.

○If the battery is disconnected and then reconnected while S-KTRC is OFF, the S-KTRC is set in mode 1.

Mode 1: S-KTRC least restrictive among the three modes. This makes lengthy drifts and wheelies possible when exiting tight corners.

Mode 2: There is more S-KTRC interaction compared to mode 1. This makes slight drifts possible when exiting tight corners.

Mode 3: S-KTRC intervenes to prevent the rear wheel from spinning whenever possible.

GENERAL INFORMATION 1-17

Technical Information-Power Mode

The rider can choose from three engine power modes to suit their preferences and road conditions. The FI ECU controls the engine power by adjusting fuel injection, air intake, and ignition timing. It enables three-mode selection: Full Power (Mode F), Middle Power (Mode M), and Low Power (Mode

L).

In addition, combining each mode with each S-KTRC setting allows the rider to have more choices to be able to interact with various conditions.

Power Mode Operation

To change the mode, close the throttle grip completely, and depress the power mode button [A] (0.3 0.4 sec.).

Power Mode Positions

NOTE

○The power mode setting is maintained when the ignition switch is turned OFF, or when the battery is disconnected.

1-18 GENERAL INFORMATION

Technical Information-Power Mode

Mode F: The highest engine power output is achieved. The rider can use the full power of the engine.

Mode M: The throttle response is less sharp compared to mode F. Depending on the throttle application, full power can be accessed temporarily.

Mode L: About 60% of the highest engine power output is achieved. The throttle response is mildest among the three modes.

The current mode selection is displayed on the power mode indicator [A] in the multifunction meter.

If a failure occurs with a FI related components such as a subthrottle or main throttle sensor, the warning indicator light (red LED) and FI warning symbol will go ON, and/or the S-KTRC indicator [B] and warning indicator light (yellow LED) [C] blink. The current mode cannot be changed at this time.

GENERAL INFORMATION 1-19

Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)

Overview

Kawasaki Intelligent anti-lock Brake System (KIBS) offers enhanced braking stability (ABS performance equivalent to the current model) to supersport models, which pitch more than most motorcycles and also offers high-precision front and rear brake pressure control (high-precision ABS) for sport riding.

Precise control of the ABS operation decreases kickback to the brake lever and brake pedal during braking compared to the conventional system.

In addition to the front and rear wheel sensors in a conventional ABS, KIBS monitors a number of parameters: front caliper hydraulic pressure and information from the FI ECU (engine speed, throttle position, gear position, and clutch actuation).

KIBS uses an all-new BOSCH hydraulic unit which was designed specifically for motorcycle use. The new design is small and light weight (45% less volume and 800g lighter than current units). The unit is located close to the motorcycle’s center of gravity, behind the engine cylinder and above the sprocket cover.

System Components

1. KIBS ECU

With input from the front and rear wheel sensors and front caliper hydraulic pressure, the KIBS ECU analyzes various conditions on the motorcycle, and with additional information from the FI ECU (engine speed, throttle position, gear position, and clutch actuation) precisely controls the brake caliper hydraulic pressure. As a result, brake force is generated to suit conditions. If there is no engine information from the FI ECU, the KIBS is deactivated and the warning is displayed in the meter; however, the conventional ABS function is maintained.

2. Wheel Rotation Sensor

The wheel rotation sensor converts the front and rear wheel rotation speed to a pulse signal and transmits it to the KIBS ECU and FI ECU.

1-20 GENERAL INFORMATION

Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)

3. KIBS Hydraulic Unit

The KIBS hydraulic unit consists of the hydraulic unit and KIBS ECU and has the front caliper hydraulic pressure sensor built-in.

When receiving a signal from the KIBS ECU, the hydraulic unit increases or decreases the front and rear brake hydraulic pressure.

The front caliper hydraulic pressure sensor always monitors the front caliper hydraulic pressure and transmits the hydraulic pressure change to the KIBS ECU.

4. FI ECU

The FI ECU transmits information from the crankshaft sensor (engine speed), the main throttle sensor (throttle position), the gear position switch (gear position), and the starter lockout switch (ON/OFF) to the KIBS ECU by the CAN system.

5. Multifunction Meter

When a failure occurs in the system, the multifunction meter displays the warning indication by turning ON the warning indicator light (yellow LED) [A] and KIBS symbol [B].

Related Parts Locations

GENERAL INFORMATION 1-21

Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)

KIBS Control

1. ABS performance equivalent to the current model (enhanced braking stability)

By monitoring front caliper hydraulic pressure, KIBS regulates pressure increases reducing the tendency of the rear to lift. Before the ABS system fully reacts, KIBS system prevents the pressure from increasing too quickly thus suppressing rear lift. And after the ABS has decreased pressure to prevent wheel lock, it prevents a sudden pressure increase that could induce rear lift.

2. High-precision ABS to enhance front and rear braking performance

By monitoring front caliper hydraulic pressure, the KIBS system is able to regulate pressure changes precisely, so that slips are minimized resulting in smooth operation compared to the conventional ABS system.

1-22 GENERAL INFORMATION

Technical Information-Kawasaki Intelligent anti-lock Brake System (KIBS/ZX1000K model only)

3. Rear brake control enhancement during engine braking

By recognizing rear wheel slip due to engine brake force during aggressive throttle operation, and at high rpm or downshifting, the KIBS system prevents unnecessary ABS intervention to the rear wheel compared to the conventional ABS system.

GENERAL INFORMATION 1-23

Technical Information — Electronic Steering Damper (ESD/ZX1000JD/KD models)

1) Overview

This model has an Electronic Steering Damper (ESD) [A]. Unlike conventional manual adjustment method of Kawasaki, damping characteristics are adjusted by the electronic control unit.

2) Purpose

Designed to offer increased stability at high speed without interfering with light and nimble steering at low speed.

3) Advantages

Damping characteristics are properly adjusted by the electronic control unit based on primarily vehicle speed, and additionally acceleration/deceleration.

During public road riding, lighter damping characteristics are selected to preserve the natural nimble handling of this model.

During circuit riding, stiffer damping settings are chosen to enhance stability for better cornering. Like the public road riding settings, ESD provides the rider with moderate feedback while maintaining natural handling feel. (moderate and natural work fine here)

Electronic control is based on speed and acceleration, so at high speeds stability is enhanced.

4) Difference

Change the steering damper damping adjustment method from manual ( ZX1000JC/KC) to automatic (Stepper Motor).

1-24 GENERAL INFORMATION

Technical Information — Electronic Steering Damper (ESD/ZX1000JD/KD models)

5) Related Parts

Meter [A]

Electronic Steering Damper (ESD) [B]

GENERAL INFORMATION 1-25

Technical Information — Electronic Steering Damper (ESD/ZX1000JD/KD models)

ESD ECU [A]

FI ECU [B]

Rear Wheel Rotation Sensor [A]

6) Meter

Added an indicator “ESD” warning symbol [A] in the instruments.

The yellow warning indicator light [B] and ESD warning symbol go on whenever there is a malfunction in the ESD system.

At this time, the ESD system maintains the last damping force setting.

7) Error Display

Only Meter Diagnosis

When both “ESD” warning symbol [A] and yellow warning indicator light [B] go on , the LCD displays service code [C] by push the upper button [D] at odometer indication (see Self-Diagnosis Procedures in the Self-Diagnosis System chapter).

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

Periodic Replacement Parts

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.

L: Apply a non-permanent locking agent. Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R:Replacement Parts

S:Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant.

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-11

Torque and Locking Agent