Content .. 4 5 6 7 ..

Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 6

FUEL SYSTEM (DFI) 3-61

Throttle Grip and Cables

Free Play Inspection

•

Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.

Free Play Adjustment

•

Refer to the Throttle Control System Inspection in the Pe-
riodic Maintenance chapter.

Cable Installation

•

Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section in the Appendix chapter.

•

Install the lower ends of the throttle cables in the throttle
pulley on the throttle body assy after installing the upper
ends of the throttle cables in the grip.

•

After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).

WARNING

Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.

Cable Lubrication

•

Refer to the Chassis Parts Lubrication in the Periodic
Maintenance chapter.

3-62 FUEL SYSTEM (DFI)

Throttle Body Assy

Idle Speed Inspection

•

Refer to the Idle Speed Inspection in the Periodic Main-
tenance chapter.

Synchronization Inspection/Adjustment

•

Refer to the Engine Vacuum Synchronization Inspection
in the Periodic Maintenance chapter.

Throttle Body Assy Removal

WARNING

Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

NOTICE

Never drop the throttle body assy especially on a
hard surface. Such a shock to the body assy can
damage it.

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)

•

Remove the pad [A]

•

Disconnect:

Fuel Injector Connectors [B]
Intake Air Pressure Sensor #1 Connector [C]
Subthrottle Valve Actuator Connector [D]
Intake Air Pressure Sensor #2 Connector [E]
Main Throttle Sensor Connector [F]
Subthlottle Sensor Connector [G]

•

For the CAL model, remove the vacuum hose.

•

Loosen the throttle body assy holder clamp bolts [A].

FUEL SYSTEM (DFI) 3-63

Throttle Body Assy

•

Disconnect the adjusting screw [A] from the clamp.

•

Remove the throttle body assy from the throttle body assy
holders.

•

Remove:

Bolt [A]
Holder Plate [B]
Throttle Cable Lower Ends

•

After removing the throttle body assy, stuff pieces of lint
-free, clean cloth into the throttle body assy holders.

NOTICE

If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

Throttle Body Assy Installation

•

Apply a thin coat of grease to the throttle cable lower ends.

•

Fit the accelerator cable end and the decelerator cable
end into the throttle pulley.

•

Install the holder plate [A] securely.

•

Apply a non-permanent locking agent to the threads of
the holder plate bolt [B], and tighten it.

Torque - Throttle Cable Holder Plate Bolt: 3.9 N·m (0.40

kgf·m, 35 in·lb)

•

Install the throttle body assy holder clamp, and tighten the
clamp bolts (see Throttle Body Assy Holder Installation in
the Engine Top End chapter).

•

Turn the throttle grip and make sure that the throttle pulley
moves smoothly and return by spring force.

•

Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

•

Adjust:

Throttle Grip Free Play (see Throttle Control System In-
spection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)

3-64 FUEL SYSTEM (DFI)

Throttle Body Assy

Throttle Body Assy Disassembly

1. Throttle Body Assy
2. Subthrottle Valve Actuator
3. Main Throttle Sensor
4. Subthrottle Sensor
5. Fuel Injectors
6. Delivery Pipe Assy
7. Intake Air Pressure Sensor #1
8. Intake Air Pressure Sensor #2

NOTICE

Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.

•

Remove the throttle body assy (see Throttle Body Assy
Removal).

•

Remove the screws [A] to pull out the fuel injectors [B]
from the throttle body assy together with the delivery pipe
assy [C].

NOTE

○

Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.

FUEL SYSTEM (DFI) 3-65

Throttle Body Assy

•

Remove the fuel injectors [A] from the delivery pipe assy
[B].

NOTE

○

Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.

NOTICE

Never drop the fuel injector especially on a hard
surface. Such a shock to the injector can damage
it.

Throttle Body Assy Assembly

•

Before assembling, blow away dirt or dust from the throttle
body and delivery pipe assy by applying compressed air.

•

Replace the O-rings [A] of the joint pipe [B] with new ones.

•

Apply engine oil to the new O-rings, and insert it to the
delivery pipes [C].

○

Insert the joint pipe so that the short side [D] faces right
side.

○

Left and right delivery pipes are identical.

•

Replace the O-rings [A] of each primary fuel injector [B]
with new ones.

•

Apply engine oil to the new O-rings, insert them to the
delivery pipe assy [C] and confirm whether the injectors
turn smoothly or not.

•

Replace the dust seals [A] with new ones.

•

Apply engine oil to the new dust seals.

•

Install the fuel injectors along with the delivery pipe assy
to the throttle body.

•

Tighten:

Torque - Delivery Pipe Assy Mounting Screws: 3.43 N·m

(0.35 kgf·m, 30 in·lb)

•

Install the throttle body assy (see Throttle Body Assy In-
stallation).

3-66 FUEL SYSTEM (DFI)

Air Cleaner

Air Cleaner Element Removal/Installation

•

Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.

Air Cleaner Element Inspection

•

Remove the air cleaner element (see Air Cleaner Element
Replacement in the Periodic Maintenance chapter).

•

Visually check the element [A] for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment.

Air Cleaner Oil Draining

A drain hose is connected to the bottom of the air cleaner

to drain water or oil accumulated in the cleaner part.

•

Remove the upper fairing assembly (see Upper Fairing
Assembly Removal in the Frame chapter).

•

Visually check the catch tank [A] of the drain hose, if the
water or oil accumulates in the tank.
If any water or oil accumulates in the catch tank, remove
the catch tank from the drain hose and drain it.

WARNING

Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the catch
tank after draining.

Air Cleaner Housing Removal

•

Remove the fuel tank (see Fuel Tank Removal).

•

Free the lead from the clamp [A].

•

Disconnect the intake air temperature sensor lead con-
nector [B].

•

Remove the bolt [C].

•

Disconnect:

Air Cleaner Drain Hose [A]
Breather Hose [B]

FUEL SYSTEM (DFI) 3-67

Air Cleaner

•

Loosen the air cleaner housing clamp bolt [A] on both
sides.

•

Disconnect the air switching valve hose [A] from the air
cleaner housing [B].

Air Cleaner Housing Installation

•

Install the clamp bolt heads [A] outside as shown.

•

Install the air switching valve hose to the air cleaner hous-
ing, so that white paint of the hose [B] is turned to the front
side rib.

•

Install the air cleaner housing on the throttle body assy.

○

Push in the ducts [C] touch the stopper [D] of the throttle
body.

•

Tighten:

Torque - Air Cleaner Housing Clamp Bolts: 2.0 N·m (0.20

kgf·m, 18 in·lb)

•

Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

•

Tighten the bolt [E] securely.

3-68 FUEL SYSTEM (DFI)

Air Cleaner

Air Cleaner Housing Disassembly

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)
Intake Air Temperature Sensor (see Intake Air Temper-
ature Sensor Removal/Installation in the Self-Diagnosis
System chapter)
Clamps [A]
Ducts [B]
Air Cleaner Element [C] (see Air Cleaner Element Re-
placement in the Periodic Maintenance chapter)

Air Cleaner Housing Assembly

•

Install the ducts [A] to the air cleaner housing.

○

Fit the projections [B] of the duct into the slits on the air
cleaner housing.

○

Do not twist the ducts.

FUEL SYSTEM (DFI) 3-69

Air Cleaner

•

Install:

Air Cleaner Frame Gasket [A]
Pads [B]
Air Cleaner Element Gasket [C]
Air Cleaner Element [D]
Air Cleaner Case Gasket [E]
Upper Air Cleaner Housing [F]
Air Cleaner Housing Assembly Screws [G]

•

Tighten:

Torque - Air Cleaner Housing Assembly Screws: 1.2 N·m

(0.12 kgf·m, 11 in·lb)

•

Install the air cleaner housing (see Air Cleaner Housing
Installation).

3-70 FUEL SYSTEM (DFI)

Air Line

Air Intake Duct Removal

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Meter Bracket (see Meter Unit Removal/Installation in
the Electrical System chapter)

•

Free the leads [A].

•

Remove:

Air Intake Duct Mounting Bolts [B] (Both Sides)
Air Intake Duct [C]

Air Intake Duct Installation

•

Check that the pad [A] is in place on the air intake duct.

•

Apply a non-permanent locking agent to the threads of
the air intake duct mounting bolts, and tighten them.

Torque - Air Intake Duct Mounting Bolts:

9.8 N·m (1.0

kgf·m, 87 in·lb)

•

Run the lead correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

Air Intake Duct Disassembly

•

Remove:

Air Intake Duct (see Air Intake Duct Removal)
Pad [A]
Seal [B] and Screen [C]
Air Intake Duct Assembly Screws [D]
Holder [E]
Pipe [F]

FUEL SYSTEM (DFI) 3-71

Air Line

Air Intake Duct Assembly

•

Assembly is the reverse of disassembly.

•

Fit the projections [A] of the holder [B] to the hole of the
air intake ducts.

•

Tighten:

Torque - Air Intake Duct Assembly Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

•

Install the pad so that the open side [A] faces downward.

3-72 FUEL SYSTEM (DFI)

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the potential
for serious burns. Make sure the area is well venti-
lated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (-) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

•

Turn the ignition switch off.

•

Wait until the engine cools down.

•

Remove:

Front Seat (see Front Seat Removal in the Frame chap-
ter)

•

Open the fuel tank cap [A] to lower the pressure in the
tank.

○

During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.

•

Draw the fuel out from the fuel tank with a commercially
available pump [A].

○

Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.

○

Put the hose through the fill opening [C] into the tank and
draw the fuel out.

Front [D]

WARNING

Spilled fuel is flammable and can be explosive un-
der certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for re-
mained fuel spillage.

FUEL SYSTEM (DFI) 3-73

Fuel Tank

•

Remove:

Fuel Tank Bolts [A]

•

Slide the dust cover [A].

•

Open the clamp [B].

•

Disconnect:

Battery (–) Terminal [C]
Fuel Pump Lead Connector [D]
Fuel Tank Drain Hose [E]
Fuel Tank Breather Hose [F]

•

Remove:

Fuel Tank Bolt [G]

•

Be sure to place a piece of cloth around the fuel hose joint.

•

Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.

When removing with standard tip screwdriver

•

Insert the standard tip screwdriver [A] into slit on the joint
lock [B].

•

Turn the driver to disconnect the joint lock.

When removing with fingers

•

Open and push up [C] the joint lock with your fingers.

NOTICE

Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

3-74 FUEL SYSTEM (DFI)

Fuel Tank

•

Pull the fuel hose joint [A] out of the outlet pipe.

WARNING

Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.

•

Close the fuel tank cap.

•

Remove the fuel tank, and place a it on a flat surface.

○

Do not apply the load to the fuel outlet pipe of the fuel
pump.

•

Clean the pipe [A].

•

Cover the pipe and the hose joint [B] with the vinyl bags
[C] to keep it clean.

Fuel Tank Installation

•

Note the above WARNING (see Fuel Tank Removal).

•

Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).

•

Check that the dampers [A] and pad [B] are in place on
the frame and the fuel tank.
If the dampers and pad are damaged or deteriorated, re-
place them.

FUEL SYSTEM (DFI) 3-75

Fuel Tank

•

When installing the pad [A] and hooks [B], install them as
shown.

16 mm (0.63 in.) [C]
View A [D]
View B [E]

•

Remove the vinyl bag on the pipe and fuel hose joint.

•

Check the joint lock for deformation and wear.
If the joint lock is deformed, replace the fuel hose with a
new one.

•

Check that there are no flaws, burrs, and adhesion of
foreign materials on the delivery pipe [A].

•

Apply engine oil to the pipe.

•

Insert [A] the fuel hose joint [B] straight onto the fuel outlet
pipe until the hose joint clicks.

•

Push [C] the joint lock [D] until the hose joint clicks.

3-76 FUEL SYSTEM (DFI)

Fuel Tank

•

Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked and does
not come off.

WARNING

Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.

If it comes off, reinstall the hose joint.

•

Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).

•

Installed removed parts (see appropriate chapters).

Fuel Tank and Cap Inspection

•

Visually inspect the gasket [A] on the tank cap for any
damage.
Replace the gasket if it is damaged.

•

Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.

NOTICE

Do not apply compressed air to the air vent holes
[D] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNING

Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.

•

Remove:

Fuel Tank (see Fuel Tank Removal)
Fuel Pump (see Fuel Pump Removal)

•

Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.

•

Draw the solvent out of the fuel tank.

•

Dry the tank with compressed air.

•

Install:

Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)

FUEL SYSTEM (DFI) 3-77

Evaporative Emission Control System (CAL Model)

The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Al-
though no adjustments are required, a thorough visual in-
spection must be made at the intervals specified by the Pe-
riodic Maintenance Chart.

Parts Removal/Installation

WARNING

Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch off. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.

NOTICE

If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.

•

Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.

Hose Inspection

•

Refer to the Evaporative Emission Control System In-
spection (CAL Model) in the Periodic Maintenance chap-
ter.

Purge Valve Inspection

•

Refer to the Purge Valve Inspection in the Self-Diagnosis
System chapter.

Canister Inspection

•

Refer to the Evaporative Emission Control System In-
spection (CAL Model) in the Periodic Maintenance chap-
ter.

COOLING SYSTEM 4-1

Cooling System

Table of Contents

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

4-2

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

4-4

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

4-6

Special Tools and Sealant ......................................................................................................

4-7

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

4-8

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

4-8

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

4-8

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

4-8

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

4-8

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

4-8

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

4-9

Coolant Reserve Tank Removal .......................................................................................

4-9

Coolant Reserve Tank Installation ....................................................................................

4-9

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

4-10

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

4-10

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

4-10

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

4-10

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

4-10

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

4-10

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

4-10

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

4-11

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

4-11

Radiator ..................................................................................................................................

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

Radiator Filler Neck Inspection .........................................................................................

4-14

Heat Insulation Plate Removal..........................................................................................

4-15

Heat Insulation Plate Installation.......................................................................................

4-15

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

4-16

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

4-16

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

4-16

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

4-16

Hoses and Pipes ....................................................................................................................

4-18

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

4-18

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

4-18

Water Temperature Sensor ....................................................................................................

4-19

Water Temperature Sensor Removal/Installation .............................................................

4-19

Water Temperature Sensor Inspection .............................................................................

4-19

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Heat Insulation Plate Bolt

3.9

0.40

35 in·lb

Radiator Upper Bolts

9.8

1.0

87 in·lb

Coolant By-pass Fitting Bolt

8.8

0.90

78 in·lb

Water Hose Clamp Screws

3.0

0.31

27 in·lb

Oil Cooler Mounting Bolts

2.0

Water Temperature Sensor

1.2

106 in·lb

Thermostat Housing Cover Bolts

5.9

0.60

52 in·lb

Coolant Drain Bolt (Cylinder)

9.8

1.0

87 in·lb

Water Hose Fitting Bolts

9.8

1.0

87 in·lb

Water Pump Cover Bolts

1.2

106 in·lb

Coolant Drain Bolt (Water Pump)

8.8

0.90

78 in·lb

Impeller Bolt

9.8

1.0

87 in·lb

13. ZX636E Model

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket.

R: Replacement Parts

W: Apply water.

4-4 COOLING SYSTEM

Coolant Flow Chart

1. Radiator
2. Radiator Fan
3. Radiator Cap
4. Radiator Overflow Hose
5. Reserve Tank Overflow Hose
6. Reserve Tank
7. Air Bleeder Hose
8. Oil Cooler Intake Hose
9. Oil Cooler

10. Water Pump

11. Cylinder Jacket

12. Oil Cooler Outlet Hose
13. Cylinder Head Jacket
14. Hot Coolant
15. Cold Coolant

COOLING SYSTEM 4-5

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 100°C (212°F), the radiator fan relay conducts to

operate the radiator fan. The radiator fan draws air through the radiator core when there is not suffi-
cient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
coolant temperature is below 97.5°C (208°F), the fan relay 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 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

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 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form 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

Specifications

Item

Standard

Coolant Provided when Shipping

Type (Recommended)

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

2.5 L (2.6 US qt) (Reserve tank full level, including
radiator and engine)

Radiator Cap

Relief Pressure

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi)

Thermostat

Valve Opening Temperature

∼

62°C (136

∼

144°F)

Valve Full Opening Lift

8 mm (0.31 in.) or more at 75°C (167°F)

COOLING SYSTEM 4-7

Special Tools and Sealant

Bearing Driver Set:
57001-1129

Oil Seal Driver

37.5:

57001-1660

Liquid Gasket, TB1211F:
92104-0004

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•

Remove the upper fairing assembly (see Upper Fairing
Assembly Removal in the Frame chapter).

•

Visually inspect the coolant in the reserve tank [A].
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded.

If the coolant is

brown, iron or steel parts are rusting. 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

•

Refer to the Coolant Level Inspection in the Periodic Main-
tenance chapter.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance
chapter.

Pressure Testing

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Radiator Cap [A]

○

Remove the radiator cap in two steps. First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.

•

Install the 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).

NOTICE

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.

•

Install the upper fairing assembly (see Upper Fairing As-
sembly Installation in the Frame chapter).

COOLING SYSTEM 4-9

Coolant

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.

NOTICE

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).

Coolant Reserve Tank Removal

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Bolt [A]

•

Remove the cap [B] and poor the coolant into a container.

•

Remove:

Radiator Overflow Hose [C]
Reserve Tank Overflow Hose [D]
Coolant Reserve Tank [E]

Coolant Reserve Tank Installation

•

Install the following to the coolant reserve tank [A].

Gasket [B]
Cap [C]
Collar [D]

•

Install the coolant reserve tank and tighten the bolt [E].

•

Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).

•

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

4-10 COOLING SYSTEM

Water Pump

Water Pump Removal

•

Refer to the Oil Pump Removal in the Engine Lubrication
System chapter.

Water Pump Installation

•

Refer to the Oil Pump Installation in the Engine Lubrica-
tion System chapter.

Water Pump Inspection

•

Remove the left lower fairing (see Lower Fairing Removal
in the Frame chapter).

•

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 (see Water Pump Housing
Disassembly/Assembly).

Water Pump Impeller Disassembly/Assembly

•

Remove the water pump impeller (see Oil Pump Removal
in the Engine Lubrication System chapter).

•

The sealing seat [A] and rubber seal [B] may be removed
easily by hand.

•

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

•

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

•

Install the water pump impeller (see Oil Pump Installation
in the Engine Lubrication System chapter).

Water Pump Impeller Inspection

•

Remove the water pump cover (see Oil Pump Removal
in the Engine Lubrication System chapter).

•

Visually inspect the impeller [A].
If the surface is corroded or if the blades are damaged,
replace the impeller.

Water Pump Housing Disassembly

NOTICE

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].

COOLING SYSTEM 4-11

Water Pump

•

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

Water Pump Housing Assembly

NOTICE

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

NOTICE

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

•

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

Special Tool - Oil Seal Driver

37.5: 57001-1660

Mechanical Seal Inspection

•

Remove the impeller (see Oil Pump Removal in the En-
gine Lubrication System chapter).

•

Visually inspect the mechanical seal.
If any one of the parts is damaged, replace the mechani-
cal seal as a unit.

Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal [C]

4-12 COOLING SYSTEM

Radiator

Radiator and Radiator Fan Removal

•

Drain:

Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Re-
moval)

•

Slide the dust cover [A].

•

Open the clamp [B].

•

Disconnect the radiator fan motor lead connector [C].

•

Loosen the water hose clamp screw [A].

•

Disconnect the water hose [B].

•

Remove:

Cap
Radiator Upper Bolt (Left) [C] and Horn

•

Loosen the water hose clamp screw [A].

•

Disconnect:

Water Hose [B]
Air Bleeder Hose [C]

•

Remove:

Radiator Lower Bolt [D]
Cap (ZX636E Model)
Radiator Upper Bolt (Right) [E]
Radiator [F]

NOTICE

Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.

•

Remove:

Radiator Fan Mounting Bolts [A]
Radiator Fan [B]

COOLING SYSTEM 4-13

Radiator

Radiator and Radiator Fan Installation

If the radiator bracket [A] was removed, install it.

•

Install the radiator fan to the radiator.

•

Tighten the radiator fan mounting bolts.

•

When installing the pads [B], install it so that the corners
[C] align.

•

Run the radiator fan motor lead correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).

•

Install the rubber dampers [D] and collars [E] as shown.

○

Face the small diameter side of the damper to the collar.

•

Install the horn [F].

•

Tighten:

Torque - Radiator Upper Bolts [G]: 9.8 N·m (1.0 kgf·m, 87

in·lb)

•

Tighten the radiator lower bolt [H].

•

Install the caps [I].

ZX636E Model [J]

•

Install the hoses and clamps (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

•

Tighten:

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

•

Install the removed parts (see appropriate chapters).

Radiator Inspection

•

Remove the radiator (see Radiator and Radiator Fan Re-
moval).

•

Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed,

carefully

straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.

4-14 COOLING SYSTEM

Radiator

NOTICE

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 [C] (not oblique
[D]) to the core surface.
Run the steam gun, following the core fin direction.

Radiator Cap Inspection

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Radiator Cap

•

Check the condition of the bottom [A] and top [B] 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 needle flicks downward. Stop pumping and mea-
sure 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, 13

∼

psi)

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

Radiator Filler Neck Inspection

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Radiator Cap

•

Check the radiator filler neck for signs of damage.

•

Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.

Content .. 4 5 6 7 ..