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

16-24 ELECTRICAL SYSTEM

Precautions

There are a number of important precautions that are

musts when servicing electrical systems. Learn and ob-
serve all the rules below.

○

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.

○

Take care not to short the cables 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).

ELECTRICAL SYSTEM 16-25

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 [A] if necessary.

16-26 ELECTRICAL SYSTEM

Battery

Battery Removal

•

Turn off the ignition switch.

•

Remove the front seat (see Front Seat Removal in the
Frame chapter).

•

Slide the red cap [A].

•

Disconnect the negative (–) cable [B] and then positive
(+) cable [C].

NOTICE

Be sure to disconnect the negative (–) cable first.

•

Remove the band [D].

•

Remove the battery [A] from the rear fender.

Battery Installation

•

Visually inspect the surface of the battery container.
If any signs of cracking or electrolyte leakage from the
sides of the battery.

•

Put the battery into the rear fender so that the positive (+)
terminal faces right side of the motorcycle.

•

Install the band [A].

•

Connect the positive (+) cable [B] (red cap) to the positive
(+) terminal first, and then the negative (–) cable [C] to the
negative (–) terminal.

•

Apply a light coat of grease on the terminals to prevent
corrosion.

•

Cover the positive (+) terminal with the red cap [D].

NOTICE

If each battery cable is not correctly disconnected
or connected, sparks can arise at electrical connec-
tions, causing damage to electrical and DFI parts.

ELECTRICAL SYSTEM 16-27

Battery

Battery Activation

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

ZX636E/F: YTX9-BS

NOTICE

Each battery comes with its own specific elec-
trolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery per-
formance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.

NOTICE

Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.

DANGER

Sulfuric acid in battery electrolyte can cause severe
burns. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no peeling, tears,
or holes in it.

•

Remove the sealing sheet.

NOTE

○

The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.

•

Remove the electrolyte container from the vinyl bag.

•

Detach the strip of caps [A] from the container and set
aside, these will be used later to seal the battery.

NOTE

○

Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.

16-28 ELECTRICAL SYSTEM

Battery

•

Place the electrolyte container upside down with the six
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.

NOTE

○

Do not tilt the electrolyte container.

•

Check the electrolyte flow.
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.

NOTE

○

Be careful not to have the battery fall down.

•

Keep the container in place. Don’t remove the container
from the battery, the battery requires all the electrolyte
from the container for proper operation.

NOTICE

Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.

•

After filling, let the battery sit for 20

∼

60 minutes with the

electrolyte container kept in place, which is required for
the electrolyte to fully permeate into the plates.

•

Make sure that the container cells have emptied com-
pletely, and remove the container from the battery.

•

Place the strip of caps [A] loosely over the filler ports,
press down firmly with both hands to seat the strip of caps
into the battery (don’t pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.

NOTICE

Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.

NOTE

○

Charging the battery immediately after filling can
shorten service life.

ELECTRICAL SYSTEM 16-29

Battery

Initial Charge

•

Newly activated sealed batteries require an initial charge.

Standard Charge:

0.9 A × 5

∼

10 hours

If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:

Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO2

Yuasa MB-2040/2060

Christie C10122S

If the above chargers are not available, use equivalent
one.

•

Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter.

(Voltage immediately after

charging becomes temporarily high. For accurate mea-
suring, let the battery sit for given time.)

NOTE

○

Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.8 V, repeat
charging cycle.

○

To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.

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 Refreshing Charge).

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

and time conditions indicated on the battery.

NOTICE

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).

16-30 ELECTRICAL SYSTEM

Battery

DANGER

Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-
ous injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. 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. 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 and seek medial at-
tention for more severe burns.

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electric

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

Be careful, if a 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 with a digital voltmeter [A].

•

Remove the battery (see Battery Removal).

•

Measure the battery terminal voltage.

NOTE

○

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

If the reading is 12.8 V or more, no refresh charge is re-
quired, however, if the read is below the specified, refresh
charge is required.

Battery Terminal Voltage

Standard:

12.8 V or more

Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]

Refreshing Charge

•

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

•

Do refresh charge by following method according to the
battery terminal voltage.

WARNING

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

ELECTRICAL SYSTEM 16-31

Battery

Terminal Voltage: 11.5

∼

less than 12.8 V

Standard Charge 0.9 A × 5

∼

10 h (see following chart)

Quick Charge

4 A × 1 h

NOTICE

If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method:

0.9 A × 20 h

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 the battery condition after refresh charge.

○

Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.

Criteria

Judgement

12.8 V or higher

Good

12.0

∼

lower than 12.8 V

Charge insufficient

→

Recharge

lower than 12.0 V

Unserviceable

→

Replace

16-32 ELECTRICAL SYSTEM

Charging System

Alternator Cover Removal

•

Remove:

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

•

Free the lead from the clamp [A] and hook [B].

•

Remove:

Alternator Cover Bolts [A]
Alternator Cover [B]

Alternator Cover Installation

•

Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.

•

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

Sealant - Liquid Gasket, TB1211F: 92104-0004

•

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

•

Replace the alternator cover gasket with a new one.

•

Tighten:

Torque - Alternator Cover 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).

Stator Coil Removal

•

Remove:

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

•

Remove the stator coil [E] from the alternator cover.

ELECTRICAL SYSTEM 16-33

Charging System

Stator Coil Installation

•

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

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

•

Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.

•

Apply liquid gasket to the circumference of the alternator
lead grommet [A], and fit the grommet into the notch of
the cover securely.

Sealant - Liquid Gasket, TB1211F: 92104-0004

•

Secure the alternator lead with a holding plate [B], and
apply a non-permanent locking agent to the threads of
the plate bolt [C] and tighten it.

Torque - Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0

kgf·m, 87 in·lb)

•

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

Alternator Rotor Removal

•

Remove the alternator cover (see Alternator Cover Re-
moval).

•

Clean off the oil from the outer circumference of the rotor.

•

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

Special Tools - Grip [C]: 57001-1591

Rotor Holder: 57001-1666
Stopper [D]: 57001-1679
Rotor Holder Attachment: 57001-1689

•

Using the flywheel puller [A], remove the alternator rotor
from the crankshaft.

Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×

1.5: 57001-1405

NOTICE

Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.

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]

•

Install the alternator rotor.

16-34 ELECTRICAL SYSTEM

Charging System

•

Using a cleaning fluid, clean off any oil or dirt on the
washer [A] and dry it with a clean cloth.

•

Install the washer.

NOTE

○

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

•

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

•

Remove the rotor bolt and washer.

•

Check the tightening torque with flywheel puller [A].

Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×

1.5: 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.

•

Install the washer and rotor bolt.

•

Tighten the alternator rotor bolt [A] while holding the alter-
nator rotor steadily with the holder [B].

Special Tools - Grip [C]: 57001-1591

Rotor Holder: 57001-1666
Stopper [D]: 57001-1679
Rotor Holder Attachment: 57001-1689

Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114

ft·lb)

•

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

ELECTRICAL SYSTEM 16-35

Charging System

Charging Voltage Inspection

•

Check the battery condition (see Charging Condition In-
spection).

•

Warm up the engine to obtain actual alternator operating
conditions.

•

Remove the front seat (see Front Seat Removal in the
Frame chapter).

•

Check that the ignition switch is turned off, and connect
the hand tester [A] to the battery terminals [B].

Special Tool - Hand Tester: 57001-1394

•

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, disconnect the head-
light connector.). The readings should show nearly bat-
tery 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.

Charging Voltage

Connections

Tester Range

Tester (+) to

Tester (–) to

Reading

DC 25 V

Battery (+)

Battery (–)

14.3

∼

14.7 V

•

Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging 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.

Alternator Inspection

There are three types of alternator failures: short, open

(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires 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.

16-36 ELECTRICAL SYSTEM

Charging System

•

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

○

Turn the ignition switch off.

○

Remove the left inner cover (see Inner Cover Removal in
the Frame chapter).

○

Disconnect the alternator lead connector [A].

○

Connect the hand tester 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

at 4 000 r/min (rpm)

Connections

Tester

Range

Tester (+) to

Tester (–) to

Reading

AC 250 V

One BK lead

Another BK lead

46.4 V or

If the output voltage shows the value in the table, the al-
ternator operates properly. The regulator/rectifier is dam-
aged.
If the output voltage shows a much lower reading than
that given in the table, stop the engine and inspect the
stator coil resistance.

•

Check the stator coil resistance as follows.

○

Stop the engine.

○

Connect the hand tester as shown in the table 2.

Special Tool - Hand Tester: 57001-1394

○

Note the readings (total 3 measurements).

Table 2 Stator Coil Resistance

at 20°C (68°F)

Connections

Tester

Range

Tester (+) to

Tester (–) to

Reading

× 1

Ω

One BK lead

Another BK lead

0.11

∼

0.17

Ω

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 white leads
and chassis ground.
Any hand tester reading less than infinity (

∞

) indicates a

short, necessitating stator replacement.
If the stator coil has 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 16-37

Charging System

Regulator/Rectifier Inspection

•

Remove:

Left Inner Cover (see Inner Cover Removal in the Frame
chapter)
Bolts [A]

•

Disconnect the connectors [A].

•

Remove:

Regulator/Rectifier [B]

•

Set the hand tester to the × 1 k

Ω

range and make the

measurements shown in the table.

Special Tool - Hand Tester: 57001-1394

•

Connect the hand tester to the regulator/rectifier.
If the tester readings are not as specified, replace the
regulator/rectifier.

NOTICE

Use only Kawasaki Hand Tester 57001-1394 for this
test. A tester other than the Kawasaki Hand Tester
may show different readings.
If a megger or a meter with a large capacity battery
is used, the regulator/rectifier will be damaged.

Regulator/Rectifier Resistance

(Unit: k

Ω

)

Tester (+) Lead Connection

Terminal

BK1

BK2

BK3

BK/W

BK/Y

BK1

–

2.5

∼

7.5

2.5

∼

7.5

3.0

∼

9.0

2.5

∼

7.5

1.5

∼

4.5

BK2

2.5

∼

7.5

–

2.5

∼

7.5

3.0

∼

9.0

2.5

∼

7.5

1.5

∼

4.5

BK3

2.5

∼

7.5

2.5

∼

7.5

–

3.0

∼

9.0

1.5

∼

4.5

∞

–

∞

BK/W

2.5

∼

7.5

2.5

∼

7.5

3.0

∼

9.0

–

1.5

∼

4.5

(–)*

BK/Y

1.5

∼

4.5

1.5

∼

4.5

1.5

∼

4.5

3.5

∼

10.5

1.5

∼

4.5

–

(

−

)*: Tester (

−

) Lead Connection

ELECTRICAL SYSTEM 16-39

Ignition System

WARNING

The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil or ig-
nition coil lead while the engine is running, or you
could receive a severe electrical shock.

NOTICE

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 damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.

Crankshaft Sensor Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)

•

Disconnect the crankshaft sensor lead connector [A].

•

Remove:

Idle Gear (Starter Clutch Side) (see Starter Idle Gear
Removal in the Crankshaft/Transmission chapter)
Bolts [A]
Crankshaft Sensor Lead Grommet [B]
Crankshaft Sensor [C]

Crankshaft Sensor Installation

•

Tighten:

Torque - Crankshaft Sensor Bolts [A]: 5.9 N·m (0.60 kgf·m,

52 in·lb)

•

Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.

•

Apply liquid gasket to the circumference of the crankshaft
sensor lead grommet [B], and fit the grommet into the
notch of the crankcase securely.

Sealant - Liquid Gasket, TB1211F: 92104-0004

•

Run the crankshaft sensor lead correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

16-40 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Inspection

•

Disconnect the crankshaft sensor lead connector (see
Crankshaft Sensor Removal).

•

Set the hand tester [A] to the × 10

Ω

range and connect it

to the crankshaft sensor lead connector [B].

Special Tool - Hand Tester: 57001-1394

Crankshaft Sensor Resistance

Connections:

Meter (+)

→

BK/Y lead

Meter (–)

→

BK lead

Standard:

368

∼

552

Ω

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

•

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.

Crankshaft Sensor Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

○

Using the peak voltage adapter [A] is more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.

•

Disconnect the crankshaft sensor lead connector (see
Crankshaft Sensor Removal).

•

Set the hand tester [B] to the DC 10 V range, and connect
it peak voltage adapter.

Special Tools - Hand Tester: 57001-1394

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

•

Connect the adapter to the terminals of the crankshaft
sensor lead connector [C].

Connections:

Crankshaft Sensor

Lead Connector

Peak Voltage

Adapter

Hand Tester

BK/Y lead

←

R lead

→

(+)

BK lead

←

BK lead

→

(–)

•

Turn the engine stop switch to run position.

•

Turn the ignition switch on.

•

Pushing the starter button, turn the engine 4

∼

5 seconds

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

•

Repeat the measurements 5 or more times.

Crankshaft Sensor Peak Voltage

Standard:

2.6 V or more

If the reading is less than the standard, inspect the crank-
shaft sensor (see Crankshaft Sensor Inspection).

ELECTRICAL SYSTEM 16-41

Ignition System

Stick Coil Removal

•

Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).

•

Disconnect the stick coil connectors [A].

•

Pull out the stick coils [B] upward.

○

First, turn the stick coil by 90 degrees, and then pull it out
by twisting the coil head to the left and right while holding
it securely by hand.

NOTICE

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

Stick Coil Installation

•

Apply a thin coat of grease [A] to the stick coils for easy
installation.

•

Insert the stick coils [B] so that the coil heads align with
the lines [C] on the cylinder head cover.

NOTICE

Do not tap the coil head while installing the coil.

•

After installation, be sure the stick coils are installed se-
curely by pulling up them lightly.

•

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

•

Install the removed parts (see appropriate chapters).

Stick Coil 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:

0.85

∼

1.15

Ω

Secondary Windings:

5.0

∼

6.8 k

Ω

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

16-42 ELECTRICAL SYSTEM

Ignition System

Stick Coil Primary Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the stick coils (see Stick Coil Removal).

○

Do not remove the spark plugs.

•

Measure the primary peak voltage as follows.

○

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

○

Connect the peak voltage adapter [C] into the hand tester
[D] which is set to the DC 250 V range.

○

Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coil
connector and stick coil.

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

Connections:

Adapter (R, +)

→

Lead Wire-Peak Voltage Adapter (W)

Adapter (BK, –)

→

Lead Wire-Peak Voltage Adapter (R)

WARNING

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

•

Turn the engine stop switch to run position.

•

Turn the ignition 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:

120 V or more

•

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

Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel Sys-
tem (DFI) chapter)

Spark Plug Removal

•

Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.

Spark Plug Installation

•

Refer to the Spark Plug Replacement in the Periodic
Maintenance chapter.

ELECTRICAL SYSTEM 16-43

Ignition System

Spark Plug Condition Inspection

•

Remove the spark plugs (see Spark Plug Replacement in
the Periodic Maintenance chapter).

•

Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.

•

Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.

Spark Plug Gap: 0.7

∼

0.8 mm (0.028

∼

0.031 in.)

•

Use the standard spark plug or its equivalent.

Standard Spark Plug

Type:

NGK CR9E

Interlock Operation Inspection

•

Raise the rear wheel off the ground with the stand [A].

1st Check

•

Start the engine to the following conditions.

Condition:

Transmission Gear

→

1st Position

Clutch Lever

→

Release

Sidestand

→

Down or Up

○

Turn the ignition switch on and push the starter button.

○

Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is started, inspect the starter lockout switch,
gear position switch and relay box.

2nd Check

•

Start the engine to the following conditions.

Condition:

Transmission Gear

→

1st Position

Clutch Lever

→

Pulled in

Sidestand

→

○

Turn the ignition switch on and push the starter button.

○

Then the starter motor should turn when the starter sys-
tem circuit is normality.
If the starter motor does not turn, inspect the starter lock-
out switch, sidestand switch, relay box and starter relay.

16-44 ELECTRICAL SYSTEM

Ignition System

3rd Check

•

Inspect the engine for its secure stop after the following
operations are completed.

•

Run the engine to the following conditions.

Condition:

Transmission Gear

→

1st Position

Clutch Lever

→

Release

Sidestand

→

•

Set the sidestand on the ground, then the engine will stop.
If the engine may not be stopped, inspect the gear posi-
tion switch, sidestand switch and relay box.
If their parts are normality, replace the ECU.

IC Igniter Inspection

○

The IC igniter is built in the ECU [A].

•

Refer to the following items.

Interlock Operation Inspection (see Interlock Operation
Inspection)
Ignition System Troubleshooting (see Ignition System
section)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)

ELECTRICAL SYSTEM 16-47

Electric Starter System

Starter Motor Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Starter Clutch Cover (see Starter Idle Gear Removal in
the Crankshaft/Transmission chapter)

•

For KIBS equipped models, remove the KIBS hydraulic
unit (see KIBS Hydraulic Unit Removal in the Brakes
chapter).

•

Slide out the rubber cap [A].

•

Remove the starter motor cable terminal bolt [B].

•

Remove the starter motor mounting bolts [C].

•

Remove the starter motor [D] from the right side of the
motorcycle.

Starter Motor Installation

NOTICE

Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

•

Clean the starter motor legs [A] and crankcase [B] where
the starter motor is ground.

•

Replace the O-ring [A] with a new one.

•

Apply grease to the new O-ring.

•

Tighten the starter motor mounting bolts temporarily.

•

Install the starter clutch cover (see Starter Idle Gear In-
stallation in the Crankshaft/Transmission chapter).

•

Tighten:

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

16-48 ELECTRICAL SYSTEM

Electric Starter System

•

Install the starter motor cable [A] as shown.

•

Tighten:

Torque - Starter Motor Cable Terminal Bolt [B]: 2.9 N·m

(0.30 kgf·m, 26 in·lb)

•

Slide back the rubber cap to the original position.

•

Install the removed parts (see appropriate chapters).

Starter Motor Disassembly

•

Remove:

Starter Motor (see Starter Motor Removal)
Starter Motor Through Bolts [A]

•

Remove:

Right-hand End Cover [A]
Left-hand End Cover [B]
Armature [C]
Yoke [D]

Starter Motor Assembly

•

Apply a thin coat of grease to the oil seal [A].

•

Fit the dent [B] of the toothed washer [C] on the projection
right-hand end cover.

•

Install the washer [D].

Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 17