Index Manuals Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year)

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Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 1

1-6 GENERAL INFORMATION

General Specifications

Items

ZX1200-B1

∼

B6F

Dimensions

Overall Length

2 085 mm (82.09 in.)

Overall Width

740 mm (29.13 in.)

Overall Height

1 200 mm (47.24 in.)

Wheelbase

1 450 mm (57.09 in.)

Road Clearance

120 mm (4.72 in.)

Seat Height

820 mm (32.28 in.)

Dry Mass

210 kg (463 lb)

Curb Mass:

Front

125 kg (276 lb)

Rear

121 kg (267 lb)

Fuel Tank Capacity

19.0 L (5.0 US gal)

Performance

Minimum Turning Radius

3.0 m (9.8 ft)

Engine

Type

4-stroke, DOHC, 4-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

83.0 × 55.4 mm (3.27 × 2.18 in.)

Displacement

1 199 cm

(73.16 cu in.)

Compression Ratio

12.2

Maximum Horsepower

(HF) 131 kW (178 PS) @9 500 r/min (rpm),
(AU) ZX1200-B1/B2: 130 kW (177 PS) @10 500 r/min (rpm),
(AU) ZX1200-B3

∼

: 131 kW (178 PS) @10 500 r/min (rpm),

(HR) 78.2 kW (106.4 PS) @8 500 r/min (rpm),
(MY) ZX1200-B1/B2: 131 kW (178 PS) @ 9 500 r/min (rpm),
(MY) ZX1200-B3

∼

: 128 kW (174 PS) @9 500 r/min (rpm)

(US), (CA) – – –

Maximum Torque

(HF, AU) 134 N·m (13.7 kgf·m, 99 ft·lb) @7 500 r/min (rpm),
(MY) ZX1200-B1/B2: 134 N·m (13.7 kgf·m, 99 ft·lb) @7 500
r/min (rpm),
(MY) ZX1200-B3

∼

: 130 N·m (13.3 kgf·m, 96 ft·lb) @7 500

r/min (rpm),
(HR) 111 N·m (11.3 kgf·m, 82 ft·lb) @5 000 r/min (rpm),
(US), (CA) – – –

Carburetion System

FI (Fuel Injection), ZX1200-B1/B2: MIKUNI 46 EIS × 4
ZX1200-B3

∼

: KEIHIN ( 46 × 4)

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced (digital igniter in ECU)

Ignition Timing

10° BTDC @1 000 r/min (rpm)

Spark Plugs

NGK CR9EKPA

Cylinder Numbering Method

Left to right, 1-2-3-4

Firing Order

1-2-4-3

GENERAL INFORMATION 1-7

General Specifications

Items

ZX1200-B1

∼

B6F

Valve Timing:

Inlet:

Open

46° BTDC

74° ABDC

Duration

300°

Exhaust:

Open

69° BBDC

45° ATDC

Duration

294°

Lubrication System

Forced lubrication (wet sump with cooler)

Engine Oil:

Grade

API SE, SF or SG
API SH or SJ with JASO MA

Viscosity

SAE 10W-40

Capacity

3.6 L (3.8 US qt)

Drive Train

Primary Reduction System:

Type

Gear

Reduction Ratio

1.596 (83/52)

Clutch Type

Wet, multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st

2.429 (34/14)

2nd

1.824 (31/17)

3rd

1.440 (36/25)

4th

1.250 (30/24)

5th

1.130 (26/23)

6th

1.033 (31/30)

Final Drive System:

Type

Chain drive

Reduction Ratio

2.556 (46/18)

Overall Drive Ratio

4.215 @Top gear

Frame

Type

Press backbone

Caster (Rake Angle)

23.5°

Trail

98 mm (3.86 in.)

Front Tire:

Type

Tubeless

Size

120/70 ZR17 M/C (58W)

Rear Tire:

Type

Tubeless

Size

200/50 ZR17 M/C (75W)

1-8 GENERAL INFORMATION

General Specifications

Items

ZX1200-B1

∼

B6F

Rim Size:

Front

17 × 3.50

Rear

17 × 6.00

Front Suspension:

Type

Telescopic fork (upside-down)

Wheel Travel

120 mm (4.72 in.)

Rear Suspension:

Type

Swingarm (uni-trak)

Wheel Travel

140 mm (5.51 in.)

Brake Type:

Front

Dual discs

Rear

Single disc

Electrical Equipment

Battery

12 V 12 Ah

Headlight:

Type

Semi-sealed beam

Bulb

12 V 60/55 W (quartz-halogen) × 2

Tail/Brake Light

12 V 5/21 W × 2

Alternator:

Type

Three-phase AC

Rated Output

31 A/14 V @5 000 r/min (rpm)

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

AU: Australian Model
US: U.S.A. Model
CA: Canadian Model

MY: Malaysian Model

HF: WVTA Approval Model with Honeycomb Catalytic Converter (Full Power Model)

HR: WVTA Approval Model with Honeycomb Catalytic Converter (Restricted Power Model)

GENERAL INFORMATION 1-9

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Since the emission regulations become more severe, Kawasaki has adopted a type of simplified

KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys-
tem, according to each regulation of different countries.

The muffler with built-in catalyst has the same durability as the conventional muffler, however, do

not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without
ignition damages catalyst.

Refer to the ZX900E Service Manual (Part No. 99924-1255) for more information about the KLEEN

(theory, maintenance, and handling precautions), including the secondary air injection system.

Honeycomb Type Catalytic Converter

○

The converter is a three-way catalytic converter, and its surface is covered with alumina upon which
platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-
ing a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter. The
honeycomb structure is convenient for the catalytic converter because it has a large surface area
but small size to react effectively and has low exhaust resistance. In addition, its inherent strength
helps resist vibration, and has simple structure welded directly on the muffler body.

○

Generally, the temperature of the exhaust gas must be higher than activation temperature, so the
converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is
still high. And, the converters will be activated even under low load conditions.

○

After the exhaust gas is diluted with the secondary air injection, the catalytic converter works well
because of rich oxygen to reduce CO, HC, and NO

. Accordingly, we can keep the exhaust gas

emission within regulation.

○

This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,
and NO

than the pipe type catalytic converter because of its more and denser catalysts.

1. Manifold
2. Muffler Body
3. Honeycomb Type Catalyst
4. Non-Catalyst
5. Mark for Manifold
6. Mark for Muffler Body

1-10 GENERAL INFORMATION

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Exhaust System (ZX1200-B1/B2)

HF: WVTA Approval Model with Honeycomb Catalytic Converter (Full Power Model)

HU: WVTA Approval Model with Honeycomb Catalytic Converter (Left Side Traffic Full Power Model)
HR: WVTA Approval Model with Honeycomb Catalytic Converter (Restricted Power Model)

GENERAL INFORMATION 1-11

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Exhaust System (ZX1200-B3)

HF: WVTA Approval Model with Honeycomb Catalytic Converter (Full Power Model)

HU: WVTA Approval Model with Honeycomb Catalytic Converter (Left Side Traffic Full Power Model)
HR: WVTA Approval Model with Honeycomb Catalytic Converter (Restricted Power Model)

1-12 GENERAL INFORMATION

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Exhaust System (ZX1200-B4)

HF: WVTA Approval Model with Honeycomb Catalytic Converter (Full Power Model)

HU: WVTA Approval Model with Honeycomb Catalytic Converter (Left Side Traffic Full Power Model)
HR: WVTA Approval Model with Honeycomb Catalytic Converter (Restricted Power Model)

GENERAL INFORMATION 1-13

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM

Exhaust System (ZX1200B6F)

HF: WVTA Approval Model with Honeycomb Catalytic Converter (Full Power Model)

HU: WVTA Approval Model with Honeycomb Catalytic Converter (Left Side Traffic Full Power Model)
HR: WVTA Approval Model with Honeycomb Catalytic Converter (Restricted Power Model)

1-14 GENERAL INFORMATION

Technical Information - Monocoque Frame

Why a monocoque? Like all breakthrough innovations, the choice appears quite obvious after the

fact. When large-section aluminium spars are wrapped around an already wide, large-displacement
in-line Four engine, the resulting package must of necessity be wide. The ZX-12R’s all-aluminium box
-section monocoque chassis eliminates these perimeter spars in favor of a large box section running
over the top of the engine.

This frame design surpasses the levels of chassis stiffness and strength associated with conven-

tional aluminium twin-beam frames, but with considerably less breadth. Without the twin beams or
other frame elements running around the side of the engine, the fairing can be much narrower, re-
sulting in a much slimmer overall package and significantly better aerodynamics. Further, in a radical
departure, the hollow structure also doubles as an airbox for the Ram Air system, eliminating the need
for a space-consuming, conventional airbox.

And ultimately, it is the synergy of combining a compact, massively powerful engine with this super

stiff and slim chassis structure that explains much of the ZX-12R’s superlative high-speed perfor-
mance.

•

All-new frame-integrated Ram Air system adds consider-
able horsepower in the higher speed ranges.

•

Monocoque frame allows for the use of perfectly straight,
highly efficient inlet ports.

•

Using the frame backbone as an airbox saves space and
creates a very efficient airbox.

•

Battery mounts inside the frame and the battery cover is
a structural element.

•

Revolutionary new all-aluminum monocoque frame for
high rigidity and lightweight.

•

Huge box section and heat-freated cast steering
head/swingarm pivot areas realize an extremely
stiff structure and contribute to the ZX-12R’s superb
high-speed stability and nimble, super sport handling
performance.

•

By eliminating the dual large-section beams of conven-
tional aluminum frames, this frame design makes possi-
ble a much narrower and more compact overall package
and greatly improves aerodynamics.

GENERAL INFORMATION 1-15

Technical Information - Spark Plug

ZX1200-B is equipped with the Kawasaki recommended

spark plug (NGK CR9EKPA). By using the Kawasaki rec-
ommended spark plug, the idling stability, the fuel consump-
tion improvement, and the maintenance free spark plug is
planed.

This spark plug is calculated 3 or 4 times as durable as

the usual one (NGK CR9EK).

Feature

1. This spark plug is more superior to the usual one with

the ignition for the ignition point protruding.

2. Further, this spark plug is superior to the usual one with

the endurance for the Pt alloy [A] covering around the
center electrode and for the opposed area improvement
of the side electrodes.

Specification

1. Standard Spark Plug CR9EKPA, two side electrodes,

M10 threads

2. Hotter Spark Plug CR8EKPA, two side electrodes, M10

threads

CAUTION

Use only the recommender spark plug. Do not use
other spark plug, even though it may fit, because it
could cause the engine failure of the idling stability,
etc.

1-16 GENERAL INFORMATION

Technical Information - Immobilizer System (ZX1200-B3

∼

: Equipped Model)

Overview

This system provides a theft proof device by means of matching a code between the inbuilt key

transponder and the ECU (Electronic Control Unit). If this code does not match, the fuel pump, injec-
tors, ignition system and sub-throttle valve actuator will not operate and the engine will not start.

Related Parts and Function

1. Transponder (Inside Keys)
2. Master Key
3. User Keys
4. FI Indicator Light
5. Immobilizer Antenna
6. Ignition Switch
7. Immobilizer Amplifier

8. Starter Relay
9. Battery

10. Electronic Control Unit (ECU)

11. Junction Box

12. Fuse Box
13. Immobilizer/Kawasaki Diagnostic System

Connector

Master Key (1 piece)

The master key (colored red) has an inbuilt transponder, containing a master key code. These

codes are unique to each key. This code and an additional two user key codes must be registered
in the ECU for the system to operate. The master key is necessary when registering user keys and
should not be used as the main key to start the motorcycle except in emergencies (loss or damage of
user keys). It should be kept in a safe place.

GENERAL INFORMATION 1-17

Technical Information - Immobilizer System (ZX1200-B3

∼

: Equipped Model)

Transponder (in Keys)

The transponder (made by Texas Instruments, Inc.) has an integrated circuit with a unique code

that also calculates data sent by the ECU. When the ignition switch is turned ON, the transponder
is excited by the radio wave transmitted from the antenna and then transmits a unique code to the
antenna.

User Key (2 pieces)

The user keys (colored black) should be used when riding the motorcycle. These keys have unique

codes which differ from the master key. Up to a maximum of five user key codes can be stored by
the ECU at any one time. These codes can not be registered to the ECU without firstly registering the
master key code.

Antenna

The antenna transmits a radio wave to excite the transponder, receives the code from the transpon-

der and then transmits the code to the ECU through the amplifier.

Ignition Switch

The ignition switch turns the main circuit ON and OFF.

Amplifier

The amplifier (which is approximately the same size as a match box), amplifies signals from the

antenna and the ECU.

ECU

The ECU has the capacity to store a maximum of six key code memories (one master and five user

keys). The owner can have a total of five user keys at any one time. The master key memory can not
be rewritten after initial registration, whereas the user key memories can be rewritten as necessary.
When the ECU communicates with the transponder, a cipher generator changes the code every time
it is used to avoid cloning.

FI Indicator Light

The condition or the failure of the immobilizer system is indicated by various patterns of the FI indi-

cator light blinking.

1. Immobilizer Amplifier
2. Immobilizer Antenna
3. Ignition Switch
4. Meter Unit
5. FI Indicator Light
6. Ignition Fuse 10 A
7. ECU Fuse 15 A
8. Junction Box

9. ECU Main Relay

10. Starter Relay

11. Main Fuse 30 A

12. Battery 12 V 12 Ah
13. Immobilizer/Kawasaki Diagnostic System

Connector

14. Electronic Control Unit (ECU)

1-18 GENERAL INFORMATION

Technical Information - Immobilizer System (ZX1200-B3

∼

: Equipped Model)

Sequence of Operation

1. Turn ON the ignition switch, the ECU, amplifier and antenna start working, and the meter assembly

FI indicator lights up.

2. The transponder excited by radio waves transmitted from the antenna receives the ciphered code

from the ECU.

3. The transponder transmits the calculated result from the key’s unique code to the ECU.
4. The ECU compares this with its memorized code, and if they match the engine can start. At this

time, the FI indicator in the meter assembly is switched off.

GENERAL INFORMATION 1-19

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

L: Apply a non-permanent locking agent to the threads.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

O: Apply oil to the threads and seating surface.

S: Tighten the fasteners following the specified sequence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

R: Replacement Parts

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and

nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads

Torque

dia.(mm)

N·m

kgf·m

ft·lb

3.4

∼

4.9

0.35

∼

0.50

∼

43 in·lb

5.9

∼

7.8

0.60

∼

0.80

∼

69 in·lb

∼

1.4

∼

1.9

10.0

∼

13.5

∼

2.6

∼

3.5

19.0

∼

4.5

∼

6.2

∼

7.4

∼

10.0

∼

115

∼

155

11.5

∼

16.0

∼

115

165

∼

225

17.0

∼

23.0

125

∼

165

225

∼

325

∼

165

∼

240

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Fuel System (DFI)

Inlet Air Pressure Sensor Bolt

1.2

106 in·lb

Inlet Air Pressure Sensor Bracket Nut

1.2

106 in·lb

Atmospheric Pressure Sensor Bolts

1.2

106 in·lb

Gear Position Switch Screws

4.0

0.40

35 in·lb

Crankshaft Sensor Bolts

6.0

0.60

53 in·lb

Camshaft Position Sensor Bolt

1.2

106 in·lb

Crankshaft Position Sensor Rotor Bolt

1.2

106 in·lb

Delivery Pipe Screws (ZX1200-B1/B2)

5.0

0.50

44 in·lb

Delivery Pipe Screws (ZX1200-B3

∼

)

3.4

0.35

30 in·lb

Nipple Assy Screws

3.4

0.35

31 in·lb

Inlet Air Temperature Sensor

7.8

0.80

69 in·lb

Fuel Level Sensor Bolts

6.9

0.70

61 in·lb

Fuel Pump Bolts

6.9

0.70

61 in·lb

L, S

Fuel Hose Clamp Bolts

1.5

0.15

13 in·lb

Cooling System

Cooling Hose Clamp Screws

2.0

0.20

18 in·lb

1-20 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Coolant Fitting Nozzle (ZX1200-B1/B2)

1.2

106 in·lb

Coolant Drain Plug (Water Pump)

1.2

106 in·lb

Coolant Drain Plug (Cylinder)

1.0

89 in·lb

Radiator Fan Switch

1.8

Water Temperature Sensor

2.5

Water Pump Impeller Bolt

1.0

89 in·lb

Water Pump Cover Bolts

1.2

106 in·lb

Cooling Pipe Bolt

1.2

106 in·lb

Thermostat Housing Cover Bolts

8.0

0.80

71 in·lb

Fitting Bolts

1.2

106 in·lb

Engine Top End

Spark Plugs

1.3

115 in·lb

Air Suction Valve Cover Bolts

1.2

106 in·lb

Baffle Plate Bolts

1.0

89 in·lb

Cylinder Head Cover Bolts

1.0

89 in·lb

Camshaft Chain Tensioner Mounting Bolts

1.2

106 in·lb

Camshaft Cap Bolts

1.2

106 in·lb

Upper Camshaft Chain Guide Bolts

1.2

106 in·lb

Front Camshaft Chain Guide Bolt (Upper)

2.5

Front Camshaft Chain Guide Bolt (Lower)

1.2

106 in·lb

Rear Camshaft Chain Guide Bolt

2.5

Camshaft Position Sensor Bolt

1.2

106 in·lb

Camshaft Position Sensor Rotor Bolt

1.2

106 in·lb

Cylinder Head Bolts: M11 First Tighten

2.3

MO, S

(Washer)

Cylinder Head Bolts: M11 Final Tighten

6.0

MO, S

(Washer)

Cylinder Head Bolts: M7

2.0

Cylinder Head Jacket Plugs

2.2

Throttle Body Holder Bolts

1.2

106 in·lb

Muffler Body Connection Nuts

3.5

Guard Mounting Bolts

1.2

106 in·lb

Exhaust Pipe Holder Studs

–

(Stopped)

Crankshaft Sensor Cover Bolts

1.5

Clutch

Clutch Lever Clamp Bolts

7.8

0.80

69 in·lb

Clutch Cover Bolts

1.5

L (2)

Clutch Cover Damper Plate Bolts

7.0

0.70

62 in·lb

Clutch Spring Bolts

8.8

0.90

78 in·lb

Clutch Hub Nut

135

100

Engine Lubrication System

Oil Level Gauge Bolts

1.2

106 in·lb

GENERAL INFORMATION 1-21

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Oil Filler Plug

1.5 or

Hand

-Tight

0.15 or

Hand

-Tight

13 in·lb

or Hand

-Tight

Engine Oil Drain Plug

2.0

Oil Filter (Cartridge Type)

3.2

EO, R

Oil Cooler Passage Bolt

7.8

Oil Cooler Mounting Bolts

2.5

Oil Pan Bolts

1.5

L (1)

Oil Pipe Holder Bolts

1.2

106 in·lb

Oil Pressure Relief Valve

1.5

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Screw

1.5

0.15

13 in·lb

Water Pump Impeller Bolt

1.0

89 in·lb

Engine Removal/Installation

Engine Mounting Bolts and Nuts: M12

6.0

Engine Mounting Bolts and Nuts: M8

2.5

Engine Mounting Bracket Bolt: M10

4.5

Adjusting Collars

2.5

Crankshaft/Transmission

Breather Plate Bolts

1.0

89 in·lb

Breather Tube Bracket Bolts

1.2

106 in·lb

Crankcase Bolts: M10

5.0

MO, S

Upper Crankcase Bolts: M8, L85

2.8

Upper Crankcase Bolts: M7

2.5

Lower Crankcase Bolts: M8, L99

2.3

Lower Crankcase Bolts: M7

2.0

Oil Passage Plugs (Each Side)

2.0

Connecting Rod Big End Nuts

in the text

←

Timing Rotor Bolt

4.0

Starter Torque Limiter Cover Bolts

1.2

106 in·lb

Oil Pressure Switch

1.5

Gear Positioning Lever Bolt

1.0

89 in·lb

Shift Shaft Return Spring Pin (Bolt)

3.0

Speed Sensor Bolt

1.2

106 in·lb

Shift Drum Bearing Holder Bolt

1.2

106 in·lb

Shift Drum Bearing Holder Screw

5.4

0.55

48 in·lb

Shift Drum Cam Bolt

1.2

106 in·lb

Balancer Shaft Clamp Lever Bolt

2.5

Balancer Shaft Clamp Bolt

1.2

106 in·lb

Oil Pipe Holder Bolts (Crankshaft Pipe)

1.2

106 in·lb

Oil Pipe Holder Bolt (Transmission Pipe)

1.2

106 in·lb

Oil Nozzle

2.5

0.25

22 in·lb

Starter Clutch Shaft Bolt

2.5

1-22 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Starter Clutch Shaft Plate Bolt

1.2

106 in·lb

Wheels/Tires

Front Axle Clamp Bolts

2.0

Front Axle Nut

127

Rear Axle Nut

127

Rear Sprocket Nuts

6.0

Air Valve Cap

0.15

0.015

1.3 in·lb

Final Drive

Engine Sprocket Nut

127

Engine Sprocket Cover Bolts

1.2

106 in·lb

Chain Guide Bolt

1.2

106 in·lb

Rear Sprocket Nuts

6.0

Rear Axle Nut

127

Brakes

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

3.5

Brake Lever Pivot Bolt

1.2

0.12

11 in·lb

Brake Lever Pivot Bolt Locknut

6.0

0.60

52 in·lb

Front Reservoir Cap Screws

1.5

0.15

13 in·lb

Front Brake Light Switch Screws

1.2

0.12

11 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

Front Caliper Mounting Bolts

3.5

Front Caliper Assembly Bolts

2.1

Brake Disc Mounting Bolts

2.8

Front Brake Pad Spring Bolts (ZX1200-B1/B2)

3.0

0.30

27 in·lb

Front Brake Pad Pins (ZX1200-B3

∼

)

1.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.8

Rear Caliper Mounting Bolts

2.5

Rear Caliper Assembly Bolts

3.0

Brake Pedal Mounting Bolt

8.8

0.90

78 in·lb

Suspension

Front Fork Clamp Bolts (Upper)

2.0

Front Fork Clamp Bolts (Lower)

2.0

Front Fork Top Plugs

2.3

Piston Rod Nut

2.8

Front Fork Bottom Allen Bolts

4.0

Front Axle Clamp Bolts

2.0

Rear Shock Absorber Bracket Nut

6.0

Rear Shock Absorber Nuts (Upper and Lower)

3.5

Swingarm Pivot Shaft Nut

127

Swingarm Pivot Shaft Lock Nut

GENERAL INFORMATION 1-23

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Uni-Track:

Rocker Arm Nut

3.5

Tie-rod Nuts

6.0

Steering

Steering Stem Head Nut (ZX1200-B1/B2)

5.5

Steering Stem Head Nut (ZX1200-B3

∼

)

8.0

Steering Stem Nut

2.0

Handlebar Bolts

3.5

Handlebar Weight Bolts

–

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

4.5

Front Footpeg Holder Bolts

2.5

Rear Footpeg Holder Bolts

3.5

Side Stand Bracket Bolts

5.0

Side Stand Mounting Bolt and Nut

4.5

Side Stand Switch Bolt

8.8

0.90

78 in·lb

Electrical System

Spark Plugs

1.3

115 in·lb

Tail/Brake Light Assy Mounting Nuts

6.0

0.60

53 in·lb

Crankshaft Sensor Cover Bolts

1.5

Crankshaft Sensor Bolts

6.0

0.60

53 in·lb

Camshaft Position Sensor Bolt

1.2

106 in·lb

Timing Rotor Bolt

4.0

Alternator Rotor Bolt

110

Stator Coil Bolts

2.2

Alternator Lead Holding Plate Bolts

8.5

0.87

75 in·lb

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Alternator Cover Bolts

1.5

Starter Motor Mounting Bolts

1.2

106 in·lb

Handlebar Switch Housing Screws

3.5

0.36

31 in·lb

Radiator Fan Switch

1.8

Water Temperature Sensor

2.5

Gear Position Switch Screws

4.0

0.40

35 in·lb

Speed Sensor Bolt

1.2

106 in·lb

Fuel Level Sensor Bolts

6.9

0.70

61 in·lb

Front Brake Switch Light Screw

1.2

106 in·lb

Engine Ground Lead Terminal Bolt

1.0

89 in·lb

1-24 GENERAL INFORMATION

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Bearing Puller:
57001-135

Inside Circlip Pliers:
57001-143

Outside Circlip Pliers:
57001-144

Oil Pressure Gauge, 10 kgf/cm²:
57001-164

Compression Gauge, 20 kgf/cm²:
57001-221

Valve Spring Compressor Assembly:
57001-241

Bearing Puller Adapter:
57001-317

Bearing Driver, 32:
57001-382

Piston Pin Puller Assembly:
57001-910

GENERAL INFORMATION 1-25

Special Tools and Sealant

Oil Pressure Gauge Adapter, PT 1/8:
57001-1033

Oil Seal & Bearing Remover:
57001-1058

Head Pipe Outer Race Press Shaft:
57001-1075

Piston Ring Compressor Grip:
57001-1095

Steering Stem Nut Wrench:
57001-1100

Head Pipe Outer Race Remover ID > 37 mm:
57001-1107

Valve Seat Cutter, 45° - 35:
57001-1116

Valve Seat Cutter, 30° - 30:
57001-1120

Valve Seat Cutter, 32° - 35:
57001-1121

Valve Seat Cutter, 60° - 30:
57001-1123

1-26 GENERAL INFORMATION

Special Tools and Sealant

Valve Seat Cutter Holder Bar:
57001-1128

Bearing Driver Set:
57001-1129

Valve Seat Cutter, 45° - 30:
57001-1187

Valve Spring Compressor Adapter, 22:
57001-1202

Valve Guide Arbor, 5:
57001-1203

Valve Guide Reamer, 5:
57001-1204

Valve Seat Cutter Holder, 5:
57001-1208

Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216

Jack:
57001-1238

Clutch Holder:
57001-1243

GENERAL INFORMATION 1-27

Special Tools and Sealant

Valve Seat Cutter, 55° - 35:
57001-1247

Oil Filter Wrench:
57001-1249

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Fork Piston Rod Puller, M12 × 1.25:
57001-1289

Fork Oil Level Gauge:
57001-1290

Pilot Screw Adjuster, C:
57001-1292

Flywheel Holder:
57001-1313

Piston Ring Compressor Belt, 80

∼

91:

57001-1320

Flywheel & Pulley Holder:
57001-1605

Steering Stem Bearing Driver, 42.5:
57001-1344

1-28 GENERAL INFORMATION

Special Tools and Sealant

Steering Stem Bearing Driver Adapter, 41.5:
57001-1345

Bearing Remover Head, 25 × 28:
57001-1346

Socket Wrench:
57001-1370

Bearing Remover Shaft, 13:
57001-1377

Hand Tester:
57001-1394

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1405

Fork Cylinder Holder:
57001-1443

Head Pipe Outer Race Driver, 55:
57001-1446

Head Pipe Outer Race Driver, 47:
57001-1447

Lead Wire - Voltage Regulator Adapter:
57001-1448

GENERAL INFORMATION 1-29

Special Tools and Sealant

Lead Wire - Peak Voltage Adapter:
57001-1449

Fork Spring Compressor Set:
57001-1452

Clutch Gear Setting Screw:
57001-1455

Needle Adapter Set:
57001-1457

Compression Gauge Adapter, M10 × 1.0:
57001-1458

Piston Base, 10:
57001-1459

Throttle Sensor Setting Adapter:
57001-1521

Hook Wrench T = 3.2 R37:
57001-1522

Fork Oil Seal Driver, 43:
57001-1530

Throttle Sensor Setting Adapter:
57001-1538

1-30 GENERAL INFORMATION

Special Tools and Sealant

Key Registration Unit:
57001-1582

Fork Spring Compressor:
57001-1587

Grip:
57001-1591

Rotor holder:
57001-1592

Fuel Pressure Gauge Adapter:
57001-1593

Fuel Hose:
57001-1607

Clamp:
57001-1613

Kawasaki Bond (Silicone Sealant):
56019-120

Kawasaki Bond (Liquid Gasket - Black) TB1215:
92104-1062

GENERAL INFORMATION 1-31

Cable, Wire, and Hose Routing

1-32 GENERAL INFORMATION

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-33

Cable, Wire, and Hose Routing

Dummy Page

1-34 GENERAL INFORMATION

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-35

Cable, Wire, and Hose Routing

1. ECU Guard
2. Connect the connectors of the Regulater/Rectifier leads.
3. Clamp
4. Connect the connectors of the fuel pump and fuel gauge leads.
5. Connect the connector of the Regulater/Rectufier and Altenator Leads (ZX1200-B3

∼

)

6. To Alternator
7. Install the clamp with air cleaner cap.
8. Insert the harness into the clamps
9. To Left Switch Housing

10. To Immobilizer Antenna (ZX1200-B3

∼

)

11. To Ignition Switch

12. Immobilizer Amplifier Connector (ZX1200-B3

∼

)

13. To Right Switch Housing
14. Junction Box
15. Put the harness into the holes of the clamp.
16. To Battery Tray
17. To Rear Brake Light Switch
18. Put the harness into the holes of the fenders.
19. Crankshaft Sensor Lead
20. Right Lower Fairing
21. Engine
22. Fuel Tank
23. Bracket (Install the bracket with the fuel tank)
24. Fan Relay
25. Fuel Pump Relay
26. ECU 15 A Fuse
27. Fuel Pump and Fan Relay
28. ECU Relay.

1-36 GENERAL INFORMATION

Cable, Wire, and Hose Routing (ZX1200-B1/B2)

GENERAL INFORMATION 1-37

Cable, Wire, and Hose Routing (ZX1200-B1/B2)

1. Clamp the leads so that the speed sensor lead is out side.
2. To Side Stand Switch
3. Clamp the side stand switch lead.
4. Install the rubber cap of the oil pressure warning light switch as shown.
5. Clamp the harness just before the diverging point.
6. To Horn
7. Run the harness between the water pipe and hose.
8. Fan Switch
9. Clamp the fan switch lead.

10. Run the harness over the cover.

11. Run the fan switch lead through the clamps of baffle plate.

12. Do not connect the throttle sensor lead connector to the intake air pressure sensor, because

the pressure sensor is broken by the opposite electrical connection.

13. Intake Air Pressure Sensor
14. Run the tube left side of the boss on the throttle body.
15. Throttle sensor
16. Intake Air Temperature Sensor
17. After connecting the connector insert it into the damper.
18. Water Temperature Sensor
19. Clamp the horn lead and reserve tank hose.
20. Regulator/Rectifier
21. ECU
22. Atmospheric Pressure Sensor
23. Insert the dumpers of the ECU into the holes of the fender.
24. Position the tube end downward.
25. Connect the vacuum tube of the throttle body.
26. Tighten the sensor bracket bolt with the ground lead.
27. Touch the stopper of the bracket onto the frame.

Content .. 1 2 ..

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