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

16-8 ELECTRICAL SYSTEM

Specifications

Item

Standard

Battery

Type

Sealed battery

Capacity

12 V 12 Ah

Voltage

12.6 V or more

Charging System

Type

Three-phase AC

Alternator Output Voltage

∼

120 V @4 000 r/min (rpm)

Stator Coil Resistance

0.3

∼

0.5

Ω

@20°C (68°F)

Charging Voltage

14.2

∼

15.2 V

(Regulator/rectifier Output Voltage)

Ignition System

Crankshaft Sensor Resistance

423

∼

517

Ω

Crankshaft Sensor Peak Voltage

3.6 V or more

Camshaft Position Sensor Resistance

400

∼

460

Ω

Camshaft Position Sensor Peak Voltage 0.2 V or more
Interlock Operation Voltage

4 V or more

Stick Coil:

Primary Winding Resistance

ZX1200-B1/B2

0.85

∼

1.15

Ω

ZX1200-B3

∼

1.04

∼

1.56

Ω

Secondary Winding Resistance

ZX1200-B1/B2

9.2

∼

13.8 k

Ω

ZX1200-B3

∼

10.8

∼

16.2 k

Ω

Primary Peak Voltage

ZX1200-B1/B2

80 V or more

ZX1200-B3

∼

88 V or more

Spark Plug:

Spark Plug Gap

0.7

∼

0.9 mm (0.028

∼

0.035 in.)

Electric Starter System

Starter Motor:

Brush Length

12 mm (0.47 in.), Service limit 8.5 mm (0.33 in.)

Commutator Diameter

28 mm (1.10 in.), Service limit 27 mm (1.06 in.)

Switch and Sensor

Rear Brake Light Switch Timing

ON after about 10 mm (0.39 in.) pedal travel

Engine Oil Pressure Switch Connections When engine is stopped: ON

When engine is running: OFF

Fan Switch Resistance:

Rising Temperature

From OFF to ON @95

∼

101°C (203

∼

214°F)

Falling Temperature

Fan stops with the temperature 3

∼

8°C (37

∼

46°F)

lower than the operation temperature range.
ON: Less than 0.5

Ω

OFF: More than 10 M

Ω

Water Temperature Sensor Resistance

in the text

ELECTRICAL SYSTEM 16-9

Specifications

Item

Standard

Fuel Level Sensor Resistance:

Full Position

∼

Ω

Empty Position

122

∼

126

Ω

Special Tools - Rotor Puller: 57001-1216

Flywheel Holder: 57001-1313
Flywheel and Pulley Holder: 57001-1605
Hand Tester: 57001-1394
Flywheel Puller Assembly: 57001-1405
Peak Voltage Adapter: 57001-1415
Lead Wire - Voltage Regulator Adapter: 57001-1448
Lead Wire - Peak Voltage Adapter: 57001-1449
Needle Adapter Set: 57001-1457
Key Registration Unit: 57001-1582
Pully Holder, Grip: 57001-1591
Rotor Holder: 57001-1592

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

ELECTRICAL SYSTEM 16-11

Precautions

There are a number of important precautions that should

be followed servicing electrical systems.

○

Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.

○

Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.

○

The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.

○

To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is on, or while the engine is
running.

○

Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor wind-
ings.

○

Do not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.

○

Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.

○

Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again

○

Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.

○

Measure coil and winding resistance when the part is cold
(at room temperature).

○

Color Codes:

BK: Black

G: Green

P: Pink

BL: Blue

GY: Gray

PU: Purple

BR: Brown

LB: Light blue

R: Red

CH: Chocolate

LG: Light green

W: White

DG: Dark green

O: Orange

Y: Yellow

○

Electrical Connectors

Female Connectors [A]

ELECTRICAL SYSTEM 16-13

Electrical Wiring

Wiring Inspection

•

Visually inspect the wiring for signs of burning, fraying,
etc.
If any wiring is poor, replace the damaged wiring.

•

Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.

•

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○

Set the tester to the × 1

Ω

range, and read the tester.

If the tester does not read 0

Ω

, the lead is defective. Re-

place the lead or the wiring harness [B] if necessary.

16-14 ELECTRICAL SYSTEM

Battery

Battery Removal

CAUTION

Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
ON, as this could damage the ECU (Electronic Con-
trol Unit).
Never reverse the connections of the battery, this
could damage the ECU.

•

Turn off the ignition switch.

•

Remove:

Seats (see Frame chapter)
Fuel Tank Cover (see Fuel System (DFI) chapter)
Battery Compartment Cover Bolts [A]
Battery Compartment Cover [B]

•

Slightly pull out the battery tray [A].

•

Slide out terminal cover [B] to disconnect the negative (–)
cable [C] and release the leads and cable from the clamp
[D] on the battery tray.

•

Slide out covers [A] and [C] to disconnect the starter motor
cable [B] and main harness connector [D].

•

Disconnect the main negative harness connector [E].

•

Remove the battery tray along with the battery from the
battery compartment.

•

Unhook the rubber band [B] and remove the battery cover
[A].

ELECTRICAL SYSTEM 16-15

Battery

•

Remove:

Positive (+) Cable [A]
Battery [B]

Battery Installation

•

Place the battery in the tray.

NOTE

○

Put the (+) terminal side of the battery on the (+) symbol
[A] and the (–) terminal side on the (–) symbol [B].

•

Connect the capped cable [A] to the (+) terminal.

•

Put light coat of grease on the (+) terminal to prevent cor-
rosion.

•

Cover the (+) terminal with its protective cap [B].

•

Install:

Battery Cover
Rubber Band

•

Insert the battery tray along with the battery into the bat-
tery compartment.

•

Connect the capped starter motor cable [A] to the termi-
nal, tighten the nut and cover the cap.

○

Cross the starter motor cable over the main harness.

•

Connect the black cable [B] to the (–) terminal.

•

Put light coat of grease on the (–) terminal to prevent cor-
rosion and cover the cap.

•

Connect the connectors [C] and [D], cover the cap to the
connector [C].

•

Confirm that the projection [A] of the battery tray fits into
the hole in the left side of the frame.

•

Install:

Removed Parts

16-16 ELECTRICAL SYSTEM

Battery

Electrolyte Filling

•

Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.

Battery Model Name for ZX1200-B: YTX14-BS

CAUTION

Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.

•

Check to see that there is no peeling, tears or holes in the
seal sheet on the top of the battery.

•

Place the battery on a level surface.

•

Remove the seal sheet [A].

CAUTION

Do not remove the seal sheet sealing the filler ports
[B] until just before use.

NOTE

○

A battery whose seal sheet has any peeling, tears, or
holes, requires a refreshing charge (initial charge).

•

Take the electrolyte container out of the plastic bag.

•

Detach the seal cap [A] from the container.

NOTE

○

Do not discard the seal cap because it is used as the
battery plugs later.

○

Do not peel back or pierce the seals [B] on the container.

•

Place the electrolyte container upside down aligning the
six seals with the six battery filler ports.

•

Push the container down strongly enough to break the
seals. Now the electrolyte should start to flow into the
battery.

NOTE

○

Do not tilt the container as the electrolyte flow may be
interrupted.

ELECTRICAL SYSTEM 16-17

Battery

•

Make sure air bubbles [A] are coming up from all six filler
ports.

○

Leave the container this way for 5 minutes or longer.

NOTE

○

If no air bubbles are coming up from a filler port, tap [B]
the bottom of the container two or three times. Never
remove the container from the battery.

CAUTION

Fill the electrolyte into the battery until the con-
tainer is completely emptied.

•

Be certain that all the electrolyte has flowed out.

•

Tap the bottom the same way as above if there is any
electrolyte left in the container.

•

Now pull the container gently out of the battery.

•

Let the battery sit for

minutes. During this time, the

electrolyte permeates the special separators and the gas
generated by chemical reaction is released.

•

Fit the seal cap [A] tightly into the filler ports until the seal
cap is at the same level as the top of the battery.

NOTE

○

Do not hammer. Press down evenly with both hands.

WARNING

Once you installed the seal cap after filling the bat-
tery, never remove it, nor add any water or elec-
trolyte.

16-18 ELECTRICAL SYSTEM

Battery

Initial Charge

While a Sealed battery can be used after only filling with electrolyte, a battery may not be able to

sufficiently move a starter motor to start an engine in the cases shown in the table below, where an
initial charge is required before use. However, if a battery shows a terminal voltage of 12.6 V or more,
using a digital volt meter, after 10 minutes of filling, no initial charge is necessary.

NOTE

○

To measure battery terminal voltage, use a digital voltmeter which can be read one decimal place
voltage.

Condition requiring initial charge

Charging method

At low temperature (lower than 0°C)

1.4 A × 2

∼

3 hours

Battery has been stored under high temperature and humidity.
Seal sheet has been removed, or broken - peeling, tear or hole.
Battery two or more years old from date of manufacture.

Battery manufacturing date is printed on battery top.

Example)

Day

Month

Year

Mfg. location

1.4 A × 15

∼

20 hours

Precautions

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.

2) Refreshing charge

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been

discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see this chapter).

When a fast charge is inevitably required, do it following precisely the maximum charge current

and time conditions indicated on the battery.

CAUTION

This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months:

Give a refresh charge before you store the motorcycle and store it with the negative cable re-

moved. Give a refresh charge

once a month

during storage.

4) Battery life:

If the battery will not start the engine even after several refresh charges, the battery has ex-

ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-
lem).

WARNING

Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery
gases.
No fire should be drawn near the battery, or no terminals should have the tightening loos-
ened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.

ELECTRICAL SYSTEM 16-19

Battery

Interchange

The sealed battery can fully display its performance only when combined with a proper vehicle elec-

tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped
with the sealed battery.

Be careful, if the sealed battery is installed on a motorcycle which had an ordinary battery as original

equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

Battery charging condition can be checked by measuring

battery terminal voltage.

•

Remove the battery (see Battery Removal).

•

Measure the battery terminal voltage.

NOTE

○

Measure with a digital voltmeter [A] which can be read
one decimal place voltage.

If the reading is below the specified, refreshing charge is
required.

Battery Terminal Voltage

Standard:

12.6 V or more

Refreshing Charge

•

Remove the battery [A] (see Battery Removal).

•

Refresh-charge by following method according to the bat-
tery terminal voltage.

WARNING

This battery is sealed type. Never remove seal cap
[B] even at charging. Never add water. Charge with
current and time as stated below.

Terminal Voltage: 11.5

∼

less than 12.6 V

Standard Charge: 1.4 A × 5

∼

10 h (see following

chart)

Quick Charge:

6.0 A × 1 h

CAUTION

If possible, do not quick charge. If the quick charge
is done due to unavoidable circumstances, do stan-
dard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method: 1.4 A × 20 h

16-20 ELECTRICAL SYSTEM

Battery

NOTE

○

Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.

Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D].

•

Determine battery condition after refreshing charge.

○

Determine the condition of the battery 30 minutes after
completion of the charge by measuring the terminal volt-
age according to the table below.

Criteria

Judgement

12.6 V or more

Good

12.0

∼

less than 12.6 V

Charge insufficient

→

Recharge

less than 12.0 V

Unserviceable

→

Replace

Battery Terminal Voltage (V) [A]
Charge Time (h) [B]

ELECTRICAL SYSTEM 16-21

Charging System

Alternator Cover Removal

•

Remove:

Left Lower Fairing (see Frame chapter)

•

Place a suitable container under the alternator cover [A].

•

Remove:

Alternator Cover Bolts [B]
Clamps [C]
Alternator Cover

If necessary, remove the stator coil from the alternator
cover (see Stater Coil Removal).

Alternator Cover Installation

•

Apply silicone sealant to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.

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

•

Check that knock pins [B] are in place on the crankcase.

•

Install a new gasket, the alternator cover and clamps.

•

Tighten the cover bolts.

Torque - Alternator Cover Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)

Stator Coil Removal

ZX1200-B1

∼

•

Remove:

Lower Fairing (see Frame chapter)
Lift up Fuel Tank (see Fuel System (DFI) chapter)
Reserve Tank with Bracket (see Cooling System chap-
ter)
Alternator Lead Connectors [A] and [C]
Breather Hose Lower End [B]

ZX1200-B3

∼

•

Remove:

Lower Fairing (see Frame chapter)
Lift up Fuel Tank (see Fuel System (DFI) chapter)
Reserve Tank with Bracket (see Cooling System chap-
ter)
Alternator Lead Connectors [A]

•

Remove the front end of the shift lever rod to loosen the
rear lower engine mounting bolt.

•

Loosen the upper and lower engine mounting bolts to
move the collar [A] on the rear upper engine mounting
bolt downward.

Alternator Lead [B]

16-22 ELECTRICAL SYSTEM

Charging System

•

Remove the alternator leads [A] from the clamps [B].

•

Remove:

Alternator Cover (see Alternator Cover Removal)
Holding Plate Bolts [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
Stator Coil [D]

Stator Coil Installation

•

Install the stator coil.

•

Apply a non-permanent locking agent to the threads of
the stator coil bolts and tighten them.

Torque - Stator Coil Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)

•

Apply silicone sealant to the circumference of the alter-
nator lead grommet, and fit the grommet into the notch of
the cover securely.

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

•

Secure the alternator lead with a holding plate, and apply
a non-permanent locking agent to the threads of the plate
bolts and tighten them.

Torque - Alternator Lead Holding Plate Bolts: 8.5 N·m (0.87

kgf·m, 75 in·lb)

•

Install:

Alternator Cover (see Alternator Cover Installation)
Removed Parts

Alternator Rotor Removal

ZX1200-B1/B2

•

Remove:

Alternator Cover (see Alternator Cover Removal)

•

Wipe oil off the outer circumference of the rotor.

•

Hold the alternator rotor steady with the flywheel holder
[A], and remove the rotor bolt [B].

Special Tool - Flywheel Holder: 57001-1313

ELECTRICAL SYSTEM 16-23

Charging System

ZX1200-B3

∼

•

Remove:

Alternator Cover (see Alternator Cover Removal)

•

Wipe oil off the outer circumference of the rotor.

•

Hold the alternator rotor steady with the rotor holder [A],
and remove the rotor bolt [B].

Special Tools - Pully Holder,Grip [C]: 57001-1591

Rotor Holder: 57001-1592

•

Remove the alternator rotor [B] from the crankshaft with
the rotor puller [A].

Special Tool - Rotor Puller: 57001-1216

Alternator Rotor Installation

•

Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.

Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]

•

Fit the woodruff key [C] securely in the slot in the crank-
shaft before installing the alternator rotor.

•

Align the groove [D] of the rotor with the woodruff key.

NOTE

○

Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.

○

Install the rotor and tighten it with 70 N·m (7.0 kgf·m, 52
ft·lb) of torque.

○

Remove the rotor bolt.

○

Check the drawing torque with the part (bolt) of the fly-
wheel puller.

Special Tool - Flywheel Puller Assembly: 57001-1405

If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.

•

Tighten the alternator rotor bolt while holding the alterna-
tor rotor steady with the flywheel holder.

Special Tool - Flywheel Holder: 57001-1313

Torque - Alternator Rotor Bolt: 110 N·m (11 kgf·m, 81 ft·lb)

•

Install the alternator cover (see Alternator Cover Installa-
tion).

16-24 ELECTRICAL SYSTEM

Charging System

Alternator Inspection

There are three types of alternator failures: short, open

(lead burned out), or loss in rotor magnetism. A short or
open in one of the stator coil leads will result in either a
low output, or no output at all. A loss in rotor magnetism,
which may be caused by dropping or hitting the alternator,
by leaving it near an electromagnetic field, or just by aging,
will result in low output.

•

To check the alternator output voltage, do the following
procedures.

○

Turn off the ignition switch.

○

Remove the seat cover (see Frame chapter).

○

Disconnect the alternator lead connectors [A].

○

Connect the hand tester [B] as shown in the table 1.

Special Tool - Hand Tester: 57001-1394

○

Start the engine.

○

Run it at the rpm given in the table 1.

○

Note the voltage readings (total 3 measurements).

Table 1 Alternator Output Voltage

Connections

Tester Range

Tester (+) to

Tester (–) to

Reading @4

000 rpm

250 V AC

One Yellow

Lead

Another

Yellow Lead

∼

120 V

If the output voltage shows the value in the table, the alter-
nator operates properly and the regulator/rectifier is dam-
aged. A much lower reading than that given in the table
indicates that the alternator is defective.

•

Check the stator coil resistance as follows.

○

Stop the engine.

○

Connect the hand tester as shown in the table 2.

○

Note the readings (total 3 measurement).

Table 2 Stator Coil Resistance

Connections

Tester Range

Tester (+) to

Tester (–) to

Reading

× 1

Ω

One Yellow

Lead

Another

Yellow Lead

0.3

∼

0.5

Ω

@20°C (68°F)

If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.

•

Using the highest resistance range of the hand tester,
measure the resistance between each of the Yellow leads
and chassis ground.
Any hand tester reading less than infinity (

∞

) indicates a

short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.

ELECTRICAL SYSTEM 16-25

Charging System

Regulator/Rectifier Inspection

ZX1200-B1/B2

•

Remove:

Seat Cover (see Frame chapter)
Connectors [A] (disconnect)
Bolts [B]
Regulator/Rectifier [C]

ZX1200-B3

∼

•

Remove:

Seat Cover (see Frame chapter)
Connector [A] (disconnect)

•

Remove:

Lift up Fuel Tank (see Fuel System (DFI) chapter)
Connectors [A] (disconnect)

•

Remove:

Bolts [A]
Regulator/rectifier [B]

Rectifier Circuit Check

•

Check conductivity of the following pair of terminals.

Rectifier Circuit Inspection

W/R1-Y1,

W/R1-Y2,

W/R1-Y3

W/R2-Y1,

W/R2-Y2,

W/R2-Y3

Tester connection

BK1-Y1,

BK1-Y2,

BK1-Y3

BK2-Y1,

BK2-Y2,

BK2-Y3

16-26 ELECTRICAL SYSTEM

Charging System

•

For ZX1200-B3 model

∼

; as shown in the figurer.

The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is
defective and must be replaced.

NOTE

○

The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.

Regulator Circuit Check

To test the regulator out of circuit, use three 12 V batteries

and a test light (12 V 3

∼

6 W bulb in a socket with leads).

CAUTION

The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.

•

Check to be sure the rectifier circuit is normal before con-
tinuing.

Regulator Circuit Test: 1st Step

•

Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown.

•

Check Y1, Y2, and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

•

For ZX1200-B3 model

∼

; as shown in the figure.

ELECTRICAL SYSTEM 16-27

Charging System

Regulator Circuit Test: 2nd Step

•

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1st
Step".

•

Apply 12 V to the BR (voltage monitoring) terminal.

•

Check Y1, Y2, and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

•

For ZX1200-B3 model

∼

; as shown in the figure.

Regulator Circuit Test: 3rd Step

•

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1st
Step".

•

Momentarily apply 24 V to the BR terminal by adding a 12
V battery.

•

Check Y1, Y2, and Y3 terminals respectively.

CAUTION

Do not apply more than 24 V to the regulator/recti-
fier and do not leave the 24 V applied for more than
a few seconds, or the unit will be damaged.

•

For ZX1200-B3 model

∼

; as shown in the figure.

If the test light did not light when the 24 V was applied
momentarily to the BR terminal, the regulator/rectifier is
defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.

16-28 ELECTRICAL SYSTEM

Charging System

Regulator/Rectifier Output Voltage Inspection

•

Check the battery condition (see Battery section).

•

Remove the seat cover (see Frame chapter).

•

Warm up the engine to obtain actual alternator operating
conditions.

•

Turn off the ignition switch, and connect the lead wire
-voltage regulator adapter [A] between the regulator/rec-
tifier lead 5 pins connectors [B] as shown in the figure.

•

Connect the hand tester to the connector [C] of the
adapter as shown in the table.

•

For ZX1200-B3 model

∼

; Check that the ignition switch is

turned off, and connect the hand tester as shown in the
table.

•

Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. (To turn off the headlight of U.S.A., Canadian,
Australian and Malaysian models, disconnect the head-
light connector in the upper fairing.) The readings should
show nearly battery voltage when the engine speed is low,
and as the engine speed rises, the readings should also
rise. But they must be kept under the specified voltage.

Regulator/Rectifier Output Voltage (ZX1200-B1/B2)

Connections

Tester Range

Tester (+) to

Tester (–) to

Reading

25 V DC

White/Red

Black

14.2

∼

15.2 V

Special Tools - Hand Tester: 57001-1394

Lead Wire - Voltage Regulator Adapter:

57001-1448

Regulator/Rectifier Output Voltage (ZX1200-B3

∼

)

Connections

Tester Range

Tester (+) to

Tester (–) to

Reading

25 V DC

Battery (+)

Battery (–)

14.2

∼

15.2 V

Special Tool - Hand Tester: 57001-1394

•

Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
If the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
If the battery voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.

16-30 ELECTRICAL SYSTEM

Ignition System

WARNING

The ignition system produces extremely high volt-
age. Do not touch the spark plugs or stick coils
while the engine is running, or you could receive
a severe electrical shock.

CAUTION

Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU (Electronic Control Unit) damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and ECU.

Crankshaft Sensor Removal

•

Remove:

Left Lower Fairing (see Frame chapter)
Crankshaft Sensor Lead Connector [A]
Hot Wind Cover (see Frame chapter)

○

Pull the connector forward.

•

Remove:

Crankshaft Sensor Cover Bolts [A] with Clamp [B]
Crankshaft Sensor Cover [C]

•

Remove:

Crankshaft Sensor Bolts [A]
Crankshaft Sensor [B]

ELECTRICAL SYSTEM 16-31

Ignition System

Crankshaft Sensor Installation

•

Route the crankshaft sensor lead correctly (see Cable,
Wire, and Hose Routing in General Information chapter).

•

Install the crankshaft sensor and tighten the crankshaft
sensor bolts.

Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53

in·lb)

•

Apply silicone sealant [A] to the crankshaft sensor lead
grommet and crankcase halves mating surface on the
front and rear sides of the crankshaft sensor cover mount.

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

•

Apply a non-permanent locking agent to the threads of
the crankshaft sensor cover bolts and tighten them.

Torque - Crankshaft Sensor Cover Bolts: 15 N·m (1.5

kgf·m, 11 ft·lb)

•

Install the other removed parts.

Crankshaft Sensor Inspection

•

Remove:

Lower Fairing (see Frame chapter)
Crankshaft Sensor Lead Connector [A]

•

Set the hand tester [B] to the × 10

Ω

range and connect it

to the yellow and black leads in the connector.

Special Tool - Hand Tester: 57001-1394

If there is more resistance than the specified value, the
sensor coil has an open lead and must be replaced. Much
less than this resistance means the sensor coil is shorted,
and must be replaced.

Crankshaft Sensor Resistance: 423

∼

517

Ω

•

Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (

∞

) indicates a short,

necessitating replacement of the crankshaft sensor as-
sembly.

Crankshaft Sensor Peak Voltage Inspection

•

Remove:

Lower Fairing (see Frame chapter)
Crankshaft Sensor Lead Connector [A]

•

Set the hand tester [B] to the 10 V DC range.

•

Connect the peak voltage adapter [C] to the hand tester
and crankshaft sensor leads in the connector.

Special Tool - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Connections

Crankshaft Sensor Lead

Adapter

Hand Tester

Yellow

←

Red

→

(+)

Black

←

Black

→

(–)

16-32 ELECTRICAL SYSTEM

Ignition System

•

Turn the ignition switch and engine stop switch on.

•

Pushing the starter button, turn the engine 4

∼

5 sec-

onds with the transmission gear in neutral to measure the
crankshaft sensor peak voltage.

•

Repeat the measurement 5 or more times.

Crankshaft Sensor Peak Voltage

Standard:

3.6 V or more

If the peak voltage is lower than the standard, inspect the
crankshaft sensor.

Camshaft Position Sensor Removal

•

Remove:

Left Lower Inner Cover (see Frame chapter)
Air Inlet Duct [B] (see Fuel System (DFI) chapter)
Camshaft Position Sensor Lead Connector [A] (discon-
nect)
Left Side Rivet Screw [D] of Baffle Plate [C]
Baffle Plate [E]
Clamp [F] (flatten)

•

Lift the left side of the baffle plate and take out the
camshaft position sensor lead connector.

•

Remove:

Camshaft Position Sensor Bolt [A]
Camshaft Position Sensor [B]

Camshaft Position Sensor Installation

•

Apply grease or engine oil to the O-ring on the camshaft
position sensor.

•

Tighten:

Torque - Camshaft Position Sensor Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

ELECTRICAL SYSTEM 16-33

Ignition System

Camshaft Position Sensor Inspection

•

Remove:

Left Lower Inner Cover (see Frame chapter)
Camshaft Position Sensor Lead Connector [A] (discon-
nect)

•

Set the hand tester to the × 10

Ω

range and connect it to

the yellow and black leads in the connector.

Special Tool - Hand Tester: 57001-1394

If there is more resistance than the specified value, the
sensor coil has an open lead and must be replaced. Much
less than this resistance means the sensor coil is shorted,
and must be replaced.

Camshaft Position Sensor Resistance: 400

∼

460

Ω

•

Using the highest resistance range of the tester, mea-
sure the resistance between the camshaft position sensor
leads and chassis ground.
Any tester reading less than infinity (

∞

) indicates a short,

necessitating replacement of the camshaft position sen-
sor.

Camshaft Position Sensor Peak Voltage Inspection

•

Remove:

Left Lower Inner Cover (see Frame chapter)
Camshaft Position Sensor Lead Connector [A]

•

Set the hand tester [B] to the 10 V DC range.

•

Connect the peak voltage adapter [C] to the hand tester
and camshaft position sensor leads in the connector.

Special Tool - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Connections

Camshaft Position

Sensor Lead

Adapter

Hand Tester

Black

←

Red

→

(+)

Yellow

←

Black

→

(–)

•

Turn the ignition switch and engine stop switch on.

•

Pushing the starter button, turn the engine 4

∼

5 sec-

onds with the transmission gear in neutral to measure the
camshaft position sensor peak voltage.

•

Repeat the measurement 5 or more times.

Camshaft Position Sensor Peak Voltage

Standard:

0.2 V or more

If the peak voltage is lower than the standard, inspect the
camshaft position sensor.

16-34 ELECTRICAL SYSTEM

Ignition System

Stick Coil (Ignition Coil together with Spark Plug Cap)

Removal

•

Remove:

Inner Lower Covers (see Frame chapter)
Baffle Plate

•

Disconnect the stick coil connectors [B].

•

Pull the stick coils [A] off the spark plugs.

CAUTION

Do not pry the connector part of the coil while re-
moving the coil.

Stick Coil (Ignition Coil together with Spark Plug Cap)

Installation

•

Install the coil with following steps.

○

Connect the connector.

○

Insert the coil as shown being careful of the coil head
direction.

○

Be sure the stick coils are installed securely by pulling up
it lightly.

CAUTION

Do not tap the coil head while installing the coil.

Stick Coil (Ignition Coil together with Spark Plug Cap)

Inspection

•

Remove the stick coils (see Stick Coil Removal).

•

Measure the primary winding resistance [A] as follows.

○

Connect the hand tester between the coil terminals.

○

Set the tester to the × 1

Ω

range, and read the tester.

•

Measure the secondary winding resistance [B] as follows.

○

Connect the tester between the plug terminal and (–) coil
terminal.

○

Set the tester to the × 1 k

Ω

range and read the tester.

Stick Coil Winding Resistance

Primary Windings:

ZX1200-B1/B2

0.85

∼

1.15

Ω

ZX1200-B3

∼

1.04

∼

1.56

Ω

Secondary Windings:

ZX1200-B1/B2

9.2

∼

13.8 k

Ω

ZX1200-B3

∼

10.8

∼

16.2 k

Ω

If the tester does not read as specified, replace the coil.

ELECTRICAL SYSTEM 16-35

Ignition System

Stick Coil Primary Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the stick coils (see Stick Coil Removal), but do
not remove the spark plugs.

•

Measure the primary peak voltage as follows.

○

Disconnect the stick coil connector, and connect the lead
wire-peak voltage adapter [A] between the stick coil con-
nector and stick coil.

○

Connect a commercially peak voltage adapter [B] be-
tween the lead wire-peak voltage adapter and the hand
tester [C] which is set to the 250 V DC range.

○

Install the new spark plug [D] into each stick coil [E], and
ground them onto the engine.

ECU [F]
Battery [G]

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire-Peak Voltage Adapter: 57001

-1449

Primary Lead Connection

Adapter (R, +) to lead wire-peak voltage adapter (W)
Adapter (BK, –) to lead wire-peak voltage adapter (R)

WARNING

To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.

•

Turn the ignition switch and the engine stop switch ON.

•

Pushing the starter button, turn the engine 4

∼

5 seconds

with the transmission in neutral to measure the primary
peak voltage.

•

Repeat the measurements 5 times for one stick coil.

Stick Coil Primary Peak Voltage

Standard:

ZX1200-B1/B2:

80 V or more

ZX1200-B3

∼

88 V or more

•

Repeat the test for the other stick coil.
If the reading is less than the specified value, check the
following.

Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)

If the stick coils and crankshaft sensor are normal, check
the ECU (see Fuel System (DFI) chapter).

Spark Plug Removal

•

Remove:

Stick Coils (see Stick Coil Removal)

•

Remove the spark plugs with the 16 mm plug wrench.

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 16