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

COOLING SYSTEM 4-1

Cooling System

Table of Contents

Exploded View........................................................................................................................

4-2

Specifications .........................................................................................................................

4-3

Coolant Flow Chart.................................................................................................................

4-4

Coolant ...................................................................................................................................

4-6

Coolant Deterioration Inspection.......................................................................................

4-6

Coolant Level Inspection...................................................................................................

4-6

Coolant Draining ...............................................................................................................

4-6

Coolant Filling ...................................................................................................................

4-6

Pressure Testing ...............................................................................................................

4-7

Cooling System Flushing ..................................................................................................

4-7

Water Pump............................................................................................................................

4-8

Water Pump Removal.......................................................................................................

4-8

Water Pump Installation....................................................................................................

4-9

Water Pump Impeller Disassembly/Assembly ..................................................................

4-9

Water Pump Inspection.....................................................................................................

4-9

Water Pump Impeller Inspection.......................................................................................

4-10

Water Pump Housing Disassembly ..................................................................................

4-10

Water Pump Housing Assembly .......................................................................................

4-10

Mechanical Seal Inspection ..............................................................................................

4-11

Radiator, Radiator Fan ...........................................................................................................

4-12

Radiator and Radiator Fan Removal ................................................................................

4-12

Radiator and Radiator Fan Installation .............................................................................

4-13

Radiator Inspection ...........................................................................................................

4-13

Radiator Cap Inspection ...................................................................................................

4-14

Thermostat .............................................................................................................................

4-15

Thermostat Removal.........................................................................................................

4-15

Thermostat Installation......................................................................................................

4-15

Thermostat Inspection ......................................................................................................

4-15

Hose and Pipes ......................................................................................................................

4-17

Hose Installation ...............................................................................................................

4-17

Hose Inspection ................................................................................................................

4-17

Radiator Fan Switch, Water Temperature Sensor ..................................................................

4-18

Radiator Fan Switch, Water Temperature SensorRemoval ..............................................

4-18

Radiator Fan Switch, Water Temperature SensorInstallation ...........................................

4-18

Radiator Fan Switch, Water Temperature SensorInspection ............................................

4-18

COOLING SYSTEM 4-3

Specifications

Item

Standard

Coolant Provided when Shipping

Type

Permanent type of antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)

Color

Green

Mixed Ratio

Soft water 50%, Coolant 50%

Freezing Point

–35°C (–31°F)

Total Amount

3.6 L (3.8 US qt) (reserve tank full level including radiator
and engine)

Radiator Cap

Relief Pressure

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi)

Thermostat

Valve Opening Temperature

∼

62°C (136

∼

144°F)

Valve Full Opening Lift

8 mm (0.31 in.) or more @75°C (167°F)

Special Tools - Bearing Driver, 32: 57001-382

Bearing Driver Set: 57001-1129

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

4-4 COOLING SYSTEM

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The

thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is less than 55°C (131°F), the thermostat closes so that the coolant flow
is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant
temperature is more than 58

∼

62°C (136

∼

144°F), the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 95

∼

101°C (203

∼

214°F), the radiator fan switch

conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.
When the coolant temperature goes down from the operation temperature by 3

∼

8°C (37

∼

46°F), the

fan switch opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine op-

erates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles

which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system

when the engine is running. When the pressure exceeds 0.95

∼

1.25 kgf/m² (14

∼

18 psi), the pressure

valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve
closes, and keeps the pressure at 0.95

∼

1.25 kgf/m² (14

∼

18 psi). When the engine cools down,

another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to
from a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank
to enter the radiator.

4-6 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•

Visually inspect the coolant in the reserve tank.
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambi-
ent temperature).

•

Check the coolant level in the reserve tank with the mo-
torcycle held perpendicular. The coolant level should be
between the “F” (full) [A] level and the “L” (low) [B] level.
If the coolant level is lower than the low level line, add
coolant to the full level line.

CAUTION

For refilling, add the specified mixture of coolant
and soft water.

Adding water alone dilutes the

coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added, but the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often, or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

COOLING SYSTEM 4-7

Coolant

Pressure Testing

•

Remove:

Right Lower Inner Cover (see Frame chapter)
Right Air Inlet Duct (see Fuel System (DFI) chapter)

•

Remove the radiator cap, and install a cooling system
pressure tester [A] on the filler neck.

NOTE

○

Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

•

Build up pressure in the system carefully until the pres-
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).

CAUTION

During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

•

Watch the gauge for at least 6 seconds.
If the pressure holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.

•

Remove the pressure tester, replenish the coolant, and
install the radiator cap.

Cooling System Flushing

Over a period of time, the cooling system accumulates

rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.

•

Drain the cooling system (see Coolant Change in the Pe-
riodic Maintenance chapter).

•

Fill the cooling system with fresh water mixed with a flush-
ing compound.

CAUTION

Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.

•

Warm up the engine, and run it at normal operating tem-
perature for about ten minutes.

•

Stop the engine, and drain the cooling system.

•

Fill the system with fresh water.

•

Warm up the engine and drain the system.

•

Repeat the previous two steps once more.

•

Fill the system with a permanent type coolant and bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).

COOLING SYSTEM 4-9

Water Pump

Water Pump Installation

•

Check to see that the knock pins [A].

•

Water pump housing [B] are in place to apply engine oil
at O-ring.

•

Apply molybdenum disulfide oil solution to the water (oil)
pump shaft [C] to the journal portion (about 10 mm (0.4
in.) [D]) of the water pump housing.

•

Install the water pump housing.

•

Clean the sliding surfaces [A] of the mechanical seal and
impeller with a high flash-point solvent.

•

Apply little coolant to the sliding surfaces.

•

Check to see that the knock pins [B] is in place.

•

Shift the transmission into 1st gear position.

•

Install:

Impeller
Bolt

Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 89

in·lb)

•

Apply high temperature grease to the O-ring of the cooling
pipe.

•

Install:

Water Pump Cover
Bolts
Cooling Hoses

Torque - Water Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106

in·lb)

Cooling Pipe Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

Water Pump Impeller Disassembly/Assembly

•

The sealing seat and rubber seal may be removed easily
by hand.

•

Apply coolant around the surfaces of the rubber seal and
sealing seat.

•

Install the rubber seal [A] and sealing seat [B] into the
impeller by pressing them by hand until the seat stops at
the bottom of the hole.

•

Tighten the water pump impeller bolt by special torque.

Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 89

in·lb)

Water Pump Inspection

•

Check the drainage outlet passage [A] at the bottom of
the water pump body for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Re-
place the mechanical seal unit.

4-10 COOLING SYSTEM

Water Pump

Water Pump Impeller Inspection

•

Visually inspect the impeller [A].
If the surface is corroded, or if the blades [B] are dam-
aged, replace the impeller.

Water Pump Housing Disassembly

CAUTION

Do not damage the hole wall of the water pump
housing.

•

Insert a bar [A] into the pump housing [B], and hammer
evenly around the circumference of the mechanical seal
bottom [C].

•

Take the oil seal [A] out of the housing [B] with a hook [C].

Water Pump Housing Assembly

CAUTION

Do not reuse the mechanical seal and oil seal.

•

Apply high temperature grease to the oil seal lips [A].

•

Press the new oil seal into the housing with a bearing
driver [B] until it stops at the bottom surface [C] of the
housing.

Special Tool - Bearing Driver Set: 57001-1129

CAUTION

Be careful not to damage the sealing surface of the
mechanical seal.

•

Press the new mechanical seal into the housing with stem
bearing driver [A] until its flange [B] touches the surface
[C] of the housing.

Special Tool - Bearing Driver, 32: 57001-382

4-14 COOLING SYSTEM

Radiator, Radiator Fan

CAUTION

When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular to the core sur-
face.
Run the steam gun following the core fin direction.

Radiator Cap Inspection

•

Check the condition of the top [B] and bottom [A] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.

•

Install the cap [A] on a cooling system pressure tester [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.

•

Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge hand flicks downward. Stop pumping and measure
leak time at once. The relief valve must open within the
specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

Standard:

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi)

If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.

COOLING SYSTEM 4-15

Thermostat

Thermostat Removal

•

Drain:

Coolant (Cylinder) (see Coolant Change in the Periodic
Maintenance chapter)

•

Remove:

Lower Fairings (see Frame chapter)
Fuel Hose (see Fuel System (DFI) chapter)
Water Temperature Sensor Connector
Cooling Hoses
Starter Motor Cable
Fitting Bolts [A]
Cooling Hose Fitting [B]

•

Remove:

Thermostat Housing Cover Bolts [A]
Thermostat Housing Cover [B]
Thermostat

Thermostat Installation

•

Install the thermostat [A] in the housing to that the air
bleeder hole [B] is on top.

•

Be sure to install the coolant-applied O-rings on the hous-
ing cover and fitting.

•

Tighten the housing cover and fitting bolts.

○

Apply a non-permanent locking agent to the thermostat
housing cover bolts.

Torque - Fitting Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

Thermostat Housing Cover Bolts: 8.0 N·m (0.80

kgf·m, 71 in·lb)

•

Fill the radiator with coolant (see Coolant Change in the
Periodic Maintenance chapter).

Thermostat Inspection

•

Remove the thermostat, and inspect the thermostat valve
[A] at room temperature.
If the valve is open, replace the thermostat with a new
one.

4-18 COOLING SYSTEM

Radiator Fan Switch, Water Temperature Sensor

Radiator Fan Switch, Water Temperature Sensor

Removal

CAUTION

The fan switch or the water temperature sensor
should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.

•

Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).

•

Remove:

Left Lower Inner Cover (see Frame chapter)
Radiator Fan Switch Lead Connectors [A]
Radiator Fan Switch [B]

•

Refer to the Fuel System (DFI) chapter for the Water Tem-
perature Sensor Removal/Installation.

Radiator Fan Switch, Water Temperature Sensor

Installation

•

Apply silicone sealant to the threads of the water temper-
ature sensor.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

•

Tighten the fan switch and water temperature sensor.

Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb)

Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18

ft·lb)

•

Fill the coolant and bleed the air from cooling system (see
Coolant Change in the Periodic Maintenance chapter).

Radiator Fan Switch, Water Temperature Sensor

Inspection

•

Refer to the Electrical System chapter for the Radiator
Fan Switch Inspection.

•

Refer to the Fuel System (DFI) chapter for the Water Tem-
perature Sensor Inspection.

ENGINE TOP END 5-1

Engine Top End

Table of Contents

Exploded View...................................

5-2

Specifications ....................................

5-5

Clean Air System...............................

5-8

Air Suction Valve Removal

(ZX1200-B1/B2) ........................

5-8

Air Suction Valve Removal

(ZX1200-B3

∼

)...........................

5-8

Air Suction Valve Installation

(ZX1200-B1/B2) ........................

5-8

Air Suction Valve Installation

(ZX1200-B3

∼

)...........................

5-8

Air Suction Valve Check...............

5-8

Vacuum Switch Valve Removal

(ZX1200-B1/B2) ........................

5-9

Vacuum Switch Valve Installation

(ZX1200-B1/B2) ........................

5-9

Vacuum Switch Valve Test

(ZX1200-B1/B2) ........................

5-9

Air Switching Valve Removal

(ZX1200-B3

∼

)...........................

5-10

Air Switching Valve Installation

(ZX1200-B3

∼

)...........................

5-10

Air Switching Valve Operation

Test (ZX1200-B3

∼

) ...................

5-10

Air Switching Valve Unit Test

(ZX1200-B3

∼

)...........................

5-10

Clean Air System Hose

Inspection..................................

5-10

Cylinder Head Cover .........................

5-11

Cylinder Head Cover Removal ....

5-11

Cylinder Head Cover Installation .

5-11

Camshaft Chain Tensioner ................

5-13

Camshaft Chain Tensioner

Removal ....................................

5-13

Camshaft Chain Tensioner

Installation .................................

5-13

Camshaft, Camshaft Chain ...............

5-14

Camshaft Removal ......................

5-14

Camshaft Installation ...................

5-14

Camshaft, Camshaft Cap Wear ...

5-16

Camshaft Runout .........................

5-17

Cam Wear....................................

5-17

Camshaft Chain Removal ............

5-17

Cylinder Head....................................

5-18

Cylinder Compression

Measurement ............................

5-18

Cylinder Head Removal ...............

5-19

Cylinder Head Installation ............

5-20

Cylinder Head Warp.....................

5-21

Valves ................................................

5-22

Valve Clearance Check................

5-22

Valve Removal .............................

5-22

Valve Installation ..........................

5-22

Valve Guide Removal ..................

5-22

Valve Guide Installation ...............

5-23

Valve-to-Guide Clearance

Measurement (Wobble
Method) .....................................

5-23

Valve Seat Inspection ..................

5-24

Valve Seat Repair ........................

5-24

Cylinder, Pistons................................

5-29

Cylinder Removal.........................

5-29

Cylinder Installation......................

5-29

Piston Removal............................

5-30

Piston Installation.........................

5-31

Cylinder Wear ..............................

5-32

Piston Wear .................................

5-32

Piston Ring, Piston Ring Groove

Wear..........................................

5-32

Piston Ring Groove Width............

5-32

Piston Ring Thickness .................

5-33

Piston Ring End Gap ...................

5-33

Throttle Body Holder..........................

5-34

Throttle Body Holder Installation..

5-34

Muffler................................................

5-35

Muffler Removal...........................

5-35

Muffler Installation........................

5-35

Muffler Body Removal..................

5-35

Muffler Body Installation...............

5-36

ENGINE TOP END 5-5

Specifications

Item

Standard

Service Limit

Clean Air System (ZX1200-B1/B2)

Vacuum Switch Valve Closing Pressure

Open

→

∼

49 kPa (310

∼

370 mmHg)

– – –

Camshafts

Cam Height:

Exhaust

36.643

∼

36.757 mm

36.54 mm

(1.4426

∼

1.4471 in.)

(1.439 in.)

Inlet

37.043

∼

37.157 mm

36.94 mm

(1.4584

∼

1.4629 in.)

(1.454 in.)

Camshaft Journal, Camshaft Cap Clearance

0.028

∼

0.071 mm

0.16 mm

(0.0011

∼

0.0028 in.)

(0.006 in.)

Camshaft Journal Diameter

23.950

∼

23.972 mm

23.92 mm

(0.9429

∼

0.9438 in.)

(0.942 in.)

Camshaft Bearing Inside Diameter

24.000

∼

24.021 mm

24.08 mm

(0.9449

∼

0.9457 in.)

(0.948 in.)

Camshaft Runout

TIR 0.02 mm (0.0008 in.)

TIR 0.1 mm

or less

(0.004 in.)

Cylinder Head

Cylinder Compression

(usable range)
1 029

∼

1 568 kPa (10.5

∼

kgf/cm², 149

∼

228 psi) @300

r/min (rpm)

– – –

Cylinder Head Warp

– – –

0.05 mm

(0.002 in.)

Valves

Valve Clearance:

Exhaust

0.22

∼

0.31 mm

– – –

(0.0087

∼

0.012 in.)

Inlet

0.15

∼

0.24 mm

– – –

(0.0059

∼

0.0094 in.)

Valve Head Thickness:

Exhaust

0.8 mm (0.03 in.)

0.5 mm

(0.02 in.)

Inlet

0.5 mm (0.02 in.)

0.25 mm

(0.0098 in.)

Valve Stem Bend

TIR 0.01 mm (0.0004 in.)

TIR 0.05 mm

or less

(0.002 in.)

Valve Stem Diameter:

Exhaust

4.955

∼

4.970 mm

4.94 mm

(0.1951

∼

0.1957 in.)

(0.194 in.)

Inlet

4.975

∼

4.990 mm

4.96 mm

(0.1959

∼

0.1965 in.)

(0.195 in.)

5-6 ENGINE TOP END

Specifications

Item

Standard

Service Limit

Valve Guide Inside Diameter:

Exhaust

5.000

∼

5.012 mm

5.07 mm

(0.1969

∼

0.1973 in.)

(0.200 in.)

Inlet

5.000

∼

5.012 mm

5.07 mm

(0.1969

∼

0.1973 in.)

(0.200 in.)

Valve/valve Guide Clearance (wobble
method):

Exhaust

0.09

∼

0.17 mm

0.35 mm

(0.0035

∼

0.0067 in.)

(0.014 in.)

Inlet

0.03

∼

0.11 mm

0.29 mm

(0.0012

∼

0.0043 in.)

(0.011 in.)

Valve Seat Cutting Angle

45°, 32°, 60°, 55°

– – –

Valve Seat Surface:

Width:

Exhaust

0.8

∼

1.2 mm

– – –

(0.03

∼

0.047 in.)

Inlet

0.5

∼

1.0 mm

– – –

(0.02

∼

0.039 in.)

Outside Diameter:

Exhaust

27.6

∼

27.8 mm

– – –

(1.086

∼

1.094 in.)

Inlet

32.6

∼

32.8 mm

– – –

(1.283

∼

1.291 in.)

Valve Spring Free Length:

Exhaust (Inner)

38.08 mm (1.499 in.)

36.7 mm

(1.44 in.)

Exhaust (Outer)

45.97 mm (1.810 in.)

44.3 mm

(1.74 in.)

Inlet (Inner)

37.97 mm (1.495 in.)

36.5 mm

(1.44 in.)

Inlet (Outer)

45.78 mm (1.802 in.)

44.2 mm

(1.74 in.)

Cylinder, Piston

Cylinder Inside Diameter

82.994

∼

83.006 mm

83.06 mm

(3.2675

∼

3.2679 in.)

(3.270 in.)

Piston Diameter

82.969

∼

82.984 mm

82.82 mm

(3.2665

∼

3.2671 in.)

(3.261 in.)

Piston/cylinder Clearance

0.010

∼

0.037 mm

– – –

(0.0004

∼

0.0015 in.)

Piston ring/groove Clearance:

Top

0.03

∼

0.07 mm

0.17 mm

(0.0012

∼

0.0028 in.)

(0.0067 in.)

Second

0.02

∼

0.06 mm

0.16 mm

(0.0008

∼

0.002 in.)

(0.0063 in.)

ENGINE TOP END 5-7

Specifications

Item

Standard

Service Limit

Piston Ring Groove Width:

Top

0.92

∼

0.94 mm

1.02 mm

(0.0362

∼

0.0370 in.)

(0.0402 in.)

Second

1.01

∼

1.03 mm

1.11 mm

(0.0398

∼

0.0406 in.)

(0.0437 in.)

Piston Ring Thickness:

Top

0.87

∼

0.89 mm

0.80 mm

(0.0343

∼

0.0350 in.)

(0.0315 in.)

Second

0.97

∼

0.99 mm

0.90 mm

(0.0382

∼

0.0390 in.)

(0.0354 in.)

Piston Ring End Gap:

Top

0.25

∼

0.40 mm

0.7 mm

(0.0098

∼

0.0157 in.)

(0.0276 in.)

Second

0.40

∼

0.55 mm

0.8 mm

(0.0157

∼

0.0217 in.)

(0.0315 in.)

Special Tools - Compression Gauge: 57001-221

Valve Spring Compressor Assembly: 57001-241
Piston Pin Puller Assembly: 57001-910
Piston Ring Compressor Grip: 57001-1095
Valve Seat Cutter, 45° - 35: 57001-1116
Valve Seat Cutter, 32° - 30: 57001-1120
Valve Seat Cutter, 32° - 35: 57001-1121
Valve Seat Cutter, 60° - 30: 57001-1123
Valve Seat Cutter Holder Bar: 57001-1128
Valve Seat Cutter, 45° - 30: 57001-1187
Valve Spring Compressor Adapter, 22: 57001-1202
Valve Guide Arbor, 5.0: 57001-1203
Valve Guide Reamer, 5.0: 57001-1204
Valve Seat Cutter Holder, 5.0: 57001-1208
Valve Seat Cutter, 55° - 35: 57001-1247
Fork Oil Level Gauge: 57001-1290
Piston Ring Compressor Belt, 80

∼

91: 57001-1320

Compression Gauge Adapter, M10 × 1.0: 57001-1458
Piston Base, 1.0: 57001-1459

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

5-8 ENGINE TOP END

Clean Air System

Air Suction Valve Removal (ZX1200-B1/B2)

•

Remove:

Lower Inner Covers (see Frame chapter)
Vacuum Switch Valve Hoses
Throttle Cable and Choke Cable Lower Ends (for Right
Side Air Suction Valve Removal) (see Fuel System (DFI)
chapter)
Air Suction Valve Cover Bolts [A]
Clamp [B]
Air Suction Valve Covers [C]
Air Suction Valve Assembly [D]

Air Suction Valve Removal (ZX1200-B3

∼

)

•

Remove:

Lower Inner Covers (see Frame chapter)

•

Separate the hoses [A] from the air suction valve cover.

•

Remove:

Air Suction Valve Cover Bolts [B]
Air Suction Valve Cover [C]
Air Suction Valve

Air Suction Valve Installation (ZX1200-B1/B2)

•

Install the valve assembly [A] so that its reeds [B] side
faces inside and it’s opening [C] side faces backward.

•

Install the air suction valve covers.

Torque - Air Suction Valve Cover Bolts: 12 N·m (1.2 kgf·m,

106 in·lb)

Air Suction Valve Installation (ZX1200-B3

∼

)

•

Install the air suction valve [A] so that its wider side [B] of
the reed valve case faces the front.

•

Tighten:

Torque - Air Suction Valve Cover Bolts: 12 N·m (1.2 kgf·m,

106 in·lb)

Air Suction Valve Check

•

Refer to the Air Suction Valve Inspection in the Periodic
Maintenance chapter.

ENGINE TOP END 5-9

Clean Air System

Vacuum Switch Valve Removal (ZX1200-B1/B2)

•

Remove:

Lower Inner Covers (see Frame chapter)

•

Pull off the switch valve hoses [A] and vacuum hose [B],
and remove the vacuum switch valve [C].

Vacuum Switch Valve Installation (ZX1200-B1/B2)

•

Install the vacuum switch valve so that the air hole [A]
faces downwards.

•

Route the hoses correctly (see General Information chap-
ter).

Vacuum Switch Valve Test (ZX1200-B1/B2)

•

Remove:

Lower Inner Covers (see Frame chapter)
Vacuum Switch Valve (see Vacuum Switch Valve Re-
moval)

•

Connect a vacuum gauge [A] and syringe [B] or fork oil
level gauge to the vacuum hoses as shown.

Special Tool - Fork Oil Level Gauge: 57001-1290

Air Flow [C]

•

Gradually raise the vacuum (lower the pressure) applied
to the vacuum switch valve, and check the valve opera-
tion. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum raises to
valve closing pressure, it should stop air flow.

Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]

If the vacuum switch valve does not operate as described,
replace it with a new one.

NOTE

○

The vacuum switch valve is checked whether there is
air flow through the air cleaner hose or not.

Vacuum Switch Valve Closing Pressure (Open

→

Close)

Standard:

∼

49 kPa (310

∼

370 mmHg)

High Vacuum [A]
Secondary Air Cannot Flow [B].

5-10 ENGINE TOP END

Clean Air System

Air Switching Valve Removal (ZX1200-B3

∼

)

•

Remove:

Lower Inner Covers (see Frame chapter)
Connector [A]
Air Switching Valve [B]

Air Switching Valve Installation (ZX1200-B3

∼

)

•

Install the air switching valve so that the air duct [A] faces
right side.

•

Route the hose correctly (see General Information chap-
ter).

Air Switching Valve Operation Test (ZX1200-B3

∼

)

•

Refer to the Air Switching Valve Operation Test in the
Electrical System chapter.

Air Switching Valve Unit Test (ZX1200-B3

∼

)

•

Refer to the Air Switching Valve Unit Test in the Electrical
System chapter.

Clean Air System Hose Inspection

•

Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, vacuum switch valve (ZX1200-B1/B2),
air switching valve (ZX1200-B3

∼

) and air suction valve

covers.
If they are not, correct them. Replace them if they are
damaged.

ENGINE TOP END 5-13

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway.

Retightening the

mounting bolts from this position could damage
the tensioner and the camshaft chain Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner Installation."
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.

•

Remove:

Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]

•

Remove the mounting bolts [E] and take off the camshaft
chain tensioner.

Camshaft Chain Tensioner Installation

•

Release the stopper [A] and push the push rod [B] into
the tensioner body [C].

○

Insert the push rod so that the push rod teeth are leaved
three (3) notches.

•

Install the tensioner body so that the stopper faces down-
ward.

•

Apply a non-permanent locking agent to the tensioner
mounting bolts [A].

•

Tighten the tensioner mounting bolts.

Torque - Camshaft Chain Tensioner Mounting Bolts: 12

N·m (1.3 kgf·m, 106 in·lb)

•

Install the spring [B], rod [C] and washer.

•

Tighten the cap bolt [D].

Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 9