Haynes Kawasaki Zx900, 1000 & 1100 Liquid-Cooled Fours 1983-97 (Haynes Motorcycle Repair Manuals)

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Kawasaki ZX900, 1000 & 1100 Liquid-cooled Fours Service and Repair Manual by Mark Coombs and Penny Cox (1681-248-10Y4)

Models covered ZX900 A (GPZ900R). 908cc. UK April 1984 to 1996 ZX900 A (Ninja). 90Bec. US November 1983 to 1986 ZXl 000 A (GPZl OOORX). 997cc. UK November 1985 to September 1989 ZX1000 A (Ninja 1000R). 997cc. US September 1985 to 1987 ZX1000 B (ZX-10). 997cc. UK December 1987 to April 1991 ZX1000 B (Ninja ZX-1 0). 997cc. US April 1988 to 1990 ZXl100 C (ZZ-Rl100). 1052cc. UK March 1990 to December 1992 ZX1100 C (Ninja ZX-11C). 1052cc. US 1990 to 1993 ZX1100 0 (ZZ-R1100). 1052cc. UK December 1992 to 1997 ZX1100 0 (Ninja ZX-11 D). 1052cc. US 1993 to 1997

o Hayne. Publishing 1999

A booII in the Hayne. ServIce and Repair Manual Series All right' rnerved. No part of this book may be r8i)I'Odueed Of'transmitted In any form or by any means: electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission In writing from the copyright holder.

Prinled In IheUSA

Hayne. Publishing

SpaOlmOVI'ld. Measuremenr is raken with fo/1I.lege/rherluilycompressedOl'

~e:;:~s=rad from

TYlllpressureslyres-cold: UKZX900A1 10A6mode1s· Upl097 .5 kg (2 15 Ib) load. bt:tIow 1JO mph (210 kmh) .... 97.5- 18 1 kg(2 15399 Ib) Ioad,below 130 mph (210 kmh) Abovf!lJOmph(210kmh) UKZX900A7-onmodels . us ZX900 Al 10A3mode1s: Up 10 97.5 kg (215 1b) load 97.5-1BOkg(215-397Ib)1oad UKZX1000AmodeIs: Below lJOmph(210 kmh) Above 130 mph (210 kmh) UK ZX l 000B models Upt097.5kg(215Ib)Ioad,belowl30mph(210kmh) .... 97.5 - 181 kg(215-399 Ib) load. bt:tIow 130 mph (210 kmh} AbovelJOmph(2 10kmh) . . . US ZXl000 A and ZXl000 B models ZXl100 CIU models

2.25 kglcm>(32 psol 2.50 kglcm> (36 pso") 2.50kglcm> (36 psi) 2.50kglcm>(36 pso)

2.50 kglcm>{36 2.50 kglcm> (36 2.90kglcm>(41 290 kglcm> (41

2.25 kglcm>(36 pso) 2.50 kglcm> (36 psol

2.501 (36 pso)

2.SOkglcm>(36psol 2.SOkglcm>(36psol

2 .SO kglcm2(36pso) 2.90kglcm>(41psol

P5'1

2.SOkglcm>(36psol 2.90kglcm>(4 1 psol 2.90kglcm>(41 PS/) 2.90kglcm>{41psi) 2.90kglcm>(41psj)

2.SO kglCm> (36 2.50 kglCm> (36 2.50 kglcm> (36 2.SOkglcm>(36 2.90 kglcm2 (41

psol psi) pso) psi}

pso) pso) psI) pSI)

Recommend ed fluids and lubricants SAE 10W/40. l OW/SO. 20W/40 or 2fJW/SO SE or SF class (min imum) Uoleacled or 1eacIed. Minimum octane rating 91 (Researd1methodlRON)

SAE JO engine oil. SEciass Frontlol"ks· ZX900Al to A6and ZXl000 A models . .. ZX900A7_on.ZX1000Band ZX1100ClUmodeis Brakeandclutchllukl Rnal dnvecllaln ... . .................. . Wheel bearings and speedometer dnve gearbox. Steeringheadbearlngs ................. . Swinging armandsllSP8"sion li nkagepivots ......... . Allcontrolpivots.stand,standpivotsandthrottletwislgnp Conlrojca~es

SAE lfJWloI"koil SAE1OWl2Oforkoil OOT4speci1ication SAE90gearoil Highmel!ing-poinlgmase Geoeral pyrpose grease Molybdenum-disu lphidegrease Goodqua!itygeneralpyrposegrease Eng ine oi l

Note: The pre-ride inspection outlined in the owner's manual covers checks and maintenance that should be carried out on a daily basis. It's condensed and included at the beginning of this Manual to remind you of its importance. Always perlorm the pre-ride inspection at every maintenance interval (in addition to the procedures listed). The intervals listed below are the shortest intervals recommended by the manufacturer for each particular operation during the model years covered in this manual. Your owner's manual may have different intervals for your model.

Daily or before riding

o See 'Daily (pre-ride) checks' at the beginning of this Manual.

Every 6000 miles (10 000 km) Ail of the 3000 miles maintenance tasks plus the following

o Change the engine/transmission oil and filter o

o

o o o o o o o

After the initial 500 miles (800 km) Note: This check is usually perlormed by a Kawasaki dealer after the first 500 miles from new. Thereafter, maintenance is carried out acccording to the following intervals of the schedule.

Monthly or every 500 miles (800 km)

o Adjust the drive chain (Section 1)

rD

o

(Section 13) Clean the air filter element (Section 14) Renew the spark plugs (Section 15) Check and adjust the valve clearances (Section 16) Clean/renew the fuel filter (Section 17) Change the fork oil (Section 18) Check the cooli ng system (Section 19) Clean the coolant filter (Section 20) Lubricate the swinging arm and suspension linkage bearings (Section 21) Check fastener security (Section 22) Check the wheels (Section 23)

Every 12 000 miles (20 000 km) All of the 6000 miles maintenance tasks plus the following

o Renew the air filter element (Section 24) o Renew the brake and clutch fluid renewal (Section 25) o Lubricate the steering head bearings (Section 26)

Check the suspension settings (Section 2)

o Check the battery (Section 3)

Every 24 000 miles (40 000 km) All of the 12 000 miles maintenance tasks plus the following

Every 3000 miles (5000 km)

o Check the spark plugs (Section 4) o Check the fuel and oil lines (Section 5) o Check the air suction valves (US and ZX11 00 0 models) (Section 6) o Check and synchronise the carburettors (Section 7) o Check the brake pads (Section 8) o Check the drive chain (Section 9) o Check the steering (Section 10) o Lubricate the cables, stands and controls (Section 11) o Check the headlamp alignment (Section 12)

o

Renew the coolant (Section 27)

Every 2 years

o Overhaul the brake and clutch components o

(Section 28) Renew the anti-dive unit seal s (ZX900 A 1 to A6 and ZX1000 A models) (Section 29)

Every 4 years

o Renew the hydraulic hoses and fuel lines (Section 30)

1· 4

Component locations

ZX900 A component locations on lett-hand akk 7 -"Jr fiIr&r 8 Engine oil /eYeI sJghtgiass 9 Engine oil NI8r pj.JfJ

4 Idle speed aqUstw 5 &litftHy 6 DrIve chain

ZX900 A component Iocatlons on right-hand IJide 7 Front brake fluid re5fIfVOir 8 Fori< oil drain pkJ{J Steering Ile8d bearings

Coo/a'tl filtlP' (UK} AJr suction vaIve5 (1.JS)

9 Eng/rIe 0/1 drIJjn pJugs 10 Engine 01/ filter

Component locations

ZXl000 A componenllocatlons on lett-hand side 7 Engine oil level s/ghlga53 8 Engine oil filler pIuQ 9 Coolant teWtVOir

, CMch ftvid ruetVOir 2 VIWes WId sparlf plugs :I FIJfII,., Mer

4 Idle spHd lIdjusrer 5 &tter)' 6 Dttve chBIn

! Blake pllds

ZX1000 A c:omponenllQeatlons on right-hand side 4 Coo/aead bearings

2 Rear brIM fluid ",sarvoir :I Akrilter

9 Engine of! dnJin piugs 10 Engine 011 rilUJr

"5

1. 6

Component locations

%)[1000 B c:ompc>nenlloc:ations on left-hand ,Idt I Clutch fluid res8I'VOir 2 Valves wrd 5PfIrl< plugs

3 Idle spftd ~r..

-4 FlAIl tank and pump fiIfer3 .5 Banet)' 6 DrivIJ chain

7 Engine oil '-111 sightglau

8 Engine oil fiRer c.,

,--

10 Forltoil chin plug

%)[100(1 B o;omponenllocations on right-"-"d-'de

I

RearbtMe

fluid ~

2 AJr~tter 3 CooIiJnt filter (UK)

.., Air suction vafves (US) 5 SIMring head .btI;Irlngs

8 Front bnlke fluid reservoir

7 Coolant reservoir Bra~8 pad$

8

9 Engine oil dr8in plugs 10 Et'If}ine oil 1iitf1r

Component locations

ZX1100 C/O componenllonS on right-hand tide Valves and sperl{ plIfp 6 Front bmIre fluid ~ Sfetlti1g htMId ~ 7 Brake pttds

"7

1. 8

Maintenance & Servicing

Introduction Perlodi\;

routine

maintenance

Is

a

continuous process w!1id hoI1~ont81 Mljusters are aituated on the back of the lludlamp unit

Every 6000 miles (10 000 km) 13 Engineltransmission oil and M er change 1 Ills Important tnal the engineIIransmission oil i$ changed at this int.rval \0 enlure adequate lubrication at the engine and transmission components. II regular all changes are overiooked Ike proIor>ged UM 01

4.0 litr8$ (7.1 Imp plnt/4.2 US qt) capacity . beneath the engine unit and remove both drain plugs from the sump (see illustr;JtIon). A!lthe engine will be hot, take greal care to avoid scaIcIing your hands on the escaping oil or on the eKh3l15t system . RemoYe the oil filler plug to assist dralnlrlg. Once the 011 has drained trom the engIne unit slac ken the si ngle central bolt which retains the olllllt.r cover, noting thaI approximately anol her O.S

degraded and contaminated all will lead 10 premature engine we .... The oil should be charqed with the engine ., II. normal operatO'lg lemperat..e. after a $hOrt run . lhIs tnSUI'es lila! the oil is relatively thin and will ~ d ...... quicker and more eompIeIaty, Eo any ImPJritles will be tleId In suspension.

Chedl the old oil carefully. H • ~oiI ...n~lnloll ; ; cfNn PM. StI'IIIII pieces at '""tlli 01" other rfIIItenll/ CIIII N . .sIIy cMtl'Chd. H Ihe oil Is VItfY melllllle colored, then 'he engine Is ~ng.....,. from breillI·1n (n_ engine} 01" from Insuftlc/en' lubricll lion. H ",.,.. .,.. l1li11 .. 01" ch/pl of metal In ~ oil, ttI«I somelhlng Is drasticlllly wrong Intemlllly and ~ ~ .../II ~ to be disnHmbIed '01" Inspection

HI

PI..::e the maehirIe

011 its cenlrfl Sland and I1fI!OYe the lower fairing section (see Chapt.. 2

6). Place a suitably-sized container. of at least

litre of oil will be released as soon as the bah Is loosened , !hen lower the coYfjr away from the engine. Remove the element baffle, element. nat washer and spring from the fill ... eover and sapamle the t:ov1Ir and centre bolt. Clean all the filter componeDtIIS . I!W Il IIO\NIIS

(U! SIC'O - LIC"oJ WW O"g - 6"L

. '_"~lIlL1id ;}p,n6)j.101 .IOI:IIIIIIS

g_"

(UI 59L -01 lUlU (II! LSL'O -1;61"01 ww C·S· 6', (II! sre-oJ ww C"" (UI roz"O - 661 "0) WW o;\'S - Sva'O - OZO'O

..... ."

"'" ...,"""""

(1,11 ,6S(I'O - 0690-01 ww ron - 86'"\ lUI 0600-0 - 99SO 'Q) ww 96)"1 - I>6n iLll99SS~tion). Be carefut as the rings are brittle and will break easily if overstressed.

tU Method of removing piston rings

2-14 Engine, clutch and gearbox

" .2Febl'k:ated clutch holdi ng tool 01 the aaokshatt (see

10 Alternator/starter clutch drive components - removal I The

alternator/starter clutch drive components can be removed with the engine un~ in or out of the frame. If the work is to be carried out with the engine in the frame ~ will fir$! be necessary to drain the 041 as described In Chapter t , and remove the lower and righth 7 8 9

-

10 Nuf-30ff Radiator BoIt-2off FfOfIt coolant pipe Spacer - 2 off 12 Water pump to cylinder Mounting rubber - 3 off 13 Water pump to cylinder Radiator guard SCrew-40ff meta/pipe 14 {)mjn plug Fanswilch Fan 15 Sealing washer 8oI/-30ff

"

15 17 18 19 20 21

Water pump cover Water pump 8leedbolt Sealing washer Lower mela/ pipe Carburettor wwmer pipe check valve

'-'

22 Lower hose

23 Expansion tank 24 Thennostet housing 25 Temperature sensor switch 26 Bleed valve 27 Thermostat 28 Thennostal cover/filler

-

29 Radiator cap 30 Radiator to thermostat

U_ _

"

32 Upper metal pipe 33 Carburettor warmer pipe filter assembly ,

~,

' UK models only

Note: carburet/or warmer pipe assembly difflfflXl slightly on UK ZXIOOO 81 model. The filter a5SlJffibly (item 33) was taken off the housing (item 24). and the check valve shown In iram 21 was omittoo.

thermostat

Cooling system 3- 5

1.1d Cooling system components· ZXl 100 0 models I Radiator 2 Belt - 2 off 3 ~-2off 4 Mounring II.IbbtJ, - 2 off

5

~ rorgtNUd

5 Screw-40ff 7Nul-70ff B Mounting IIJbber 9 FtIIl switch

10 Fan

"

BoIt - 3 off

12 FtOntcool8fl1 pipe 13 Lowerhose 14 Lo_ mer31 pipe 15 Dmin p/al and top up if

7 When the machine haa been t1dd8f1 for the ,"lllme after relilling. allow the engine to ccoI down and check the level at the radiator . . cap 10 ensure !hat no lurther pockets of • Nve been expelled , topping up if ~. All &ubseqUllllI cOackI 01 the level 11th' recommended maintenance inlervals 3IIou4d be checked at the expanaOn tank. as 6nct1bed in 'Daily (pre-ride) checks' at the bIgrV'ing 01 this Manual.

Radiator - removal, cleaning, examination and refi!1ing

~

... ~

I f>.ernoo (7 psi) O.S kglcm> (7 psi)

ZXHlOO 8 models . .. .. .. ... .. ..... .. ZXI 100 C models • . ...................... . . ZX110001Tl()(lel, ...... ............ .. ........ ..

-"'"""~

0.1 kg/cm> (0 - 14 pel) Nonadjuslable

'"m

Ibltt

,., •.,

13.S 14.S

Torque settings Handlebar 10 top yoke moonllr.g bolts: ZX900 A7-on models All Olher models Top yoke fflIaining nul

L9

Yoke~~;

ZX900 and ZXlOOO A models - top and bottom ZXlOOO B models - lop and bottom ................ • . ZXl100 C/O models; Top .•..••••...••.. ................ ...... • .

"""~ Fronlfork lop bolla . Front fork ~ rod rtll8lnlng bolt ZX900 AI to A6 models ZXlOOO model, ZX900 A7· on and ZX I 100 C/O models Swir.g ir.g arm pivot shaft nUI(s) SuspensIon unit and linkage pivot bolts: All $UspenIion unit and linkage bolts e~cepI ZX900 upper suspension un~ mounting boll . ZX900 upper wspensIon unit mounting bolt ZX900 A2-on models ZX900Al model •

1 GenentI dHcrIption

All model, are lilted with loo (142 psi) Not applicable

,., "

u.- ..... O.S - I.S kglcm> (7 - 21 pal) o - I .S kg/cm> (0 - 21 psi)

'"

15.0 21.0

21.0 IS.0 16.5

..,.,,.,,

"., ".,

•,.,.,

"., "'".0

,.,

frsme. conslructed 01 tubular steel and using the engine unit as a s tressed member. The frsme on ZXl000 A models Is 01 a lull credit' deslgn and Is coolirucilld of square-sec1oo $1"1. Both the ZX l 000 Band ZX' , 00 C/O model$ use a lull c rad le Iype Irame constructed totslly In an aluminium a lloy and braCed to Increese rigidity. All models employ Kawasakl's Uni-1Jak raar suspension Iyllem where a square· section aluminium Iwlnglng arm acts on a single suspension ..... It via s linkage. The rear suspension unit has a 4 position damping adjuster and all unilS a~C4lP1 thai lilted to ZXI 100 C/O models are air assisted.

45.0 65.0

2 ffont forks - A!n'\Oval

1 PI_ ItKt machine on ~s centre stand an.. remoye Ihe futl.itan k a nd complete fslrlng . Place lOme blocks un.demuth the c rankc"," a nd remove the Iront wheel as described In Section 2 of Chapter 7 . 2 Slacken the tOp yooke COY'" relSlnlng &crews (where fitted) and remove ttKt coyer. Ramo .... the Allen bolts which secure the handlebar castings 10 the top yoke end lift

Frame and fork s 6- 3

them clear. On ZXttOO D models there is no requirement to rem0v9 lhe handlebar castings from the top yoke unless you intend dismantling tile fOeld. Note. however. that such a repair wi ll destroy the finish of the component. and renewal may therefore be the most satisfactory course of action. II a steel component is merely benl it can be straightened after the affected area has beeo

heated to a dull cherry red colour. using a blow lamp or welding torch. Again the finish will be destroyE!d, bu t the surface can be refin ished at relatively low cost.

20 Speedometer and ~ tachometer heads - removal, examination and refitting ~

:r:

1 The instrument assembly is secu red to the fairing mounting braCket by two bolts. On ZX900 and ZXl000 A mod&fs these bolts are read ily accessible. although on ZXl100 C/O m~s ~ wil l first be necessary to remove Ihe upper fairing. and on ZX 1000 B models the upper fairing inner sections and screen. 2 Remove the instrument panel mounting bolts and partial ly withdraw the assembly. Unscrew the speedometer drive cab le retaining ring from the underside of the panel and separate the Instrumeot panel wiring trom the main loom. The assembly can then be lilted clear 01 the machine. 3 Slacken all the screws which reta in the bottom cover and remove it from Ihe assembly. Release the two nuts which secure the instruments to the mount ing bracket and separate the two components (see illustration). The top cover can be removed once its retaining screws have been withdrawn 4 Each instrument head is mounted onto the hOUSing by two small crosshead screws

Before removing the speedometer on ZX900 and ZX 1000 models it Is first necessary to remove the uppe r speedometer drive gearbox. This is also retained by two small crosshead screws. On all models disconnect the tachometer wiring belore attempting to remove the Instrument head (see illustration) . 5 Note that these instruments are delicate and shoutd be handled carefully at all times Do not drop them or hold them upside down as th is will damage the heads. Also do not allow them to come into contact with any dirt grease. oil or water 6 The speedomete r and taChometer heads are sealed units and cannot be dismant led any further. Apart from defects in the drive or drive cable (speedometer) or relevant wiring (tachometer) an instrument is difficult to repair and must be renewed. Alternatively, it may be possible to have the instrument repaired by a suitable sp&C~list or to obtain a second- hand item from a breaker. 7 The electronic tachometer can be tested as described in Chapter 6 8 Remember that a speedometer in correcl working order is a statutory requ irement in the UK. Apart from this legal necessity, reference to the odometer readings is the most satisfactory means of keeping trag as follows, 3 Pass a 1 ".." drill up through the ceotre 01 the pin and dri~ througtl the ~x housing. UsIng

the 1 mmtJOlt as, pilot hole, drill 8 3.0- 3.5 mm hole in the underside of the gearbox housing. The roll .,., C8I'I thtn be tapped ouI 01 pIecfI with a drift. The bush, pinion and tIYust washers can then be removed from In. housing. On reassembly always fit a new roll pOol and stake it In ~ to pr1I'I8O"tt it dropping out

Tachome ter 4 The tachometer Is eiectrically operated and is controlled by the ignition s)I$tem. Should the tachometer mallunctlon the inSln.lment head and relevant wiring should be examined lIS described in Chapter 8.

~ examination and maintenance ~

22 Speedometer drive cable -

'"

1 The cable is secured at each end by mgs wNch shooJd be slackened n tightened with e pair of pliers ( _ Illustration). II the cable is thought to be 11 fault, remove It from the machine, and spin the inner cable at one end. If the other end 01 the cable falls to tum, ttle cable Is broken and should be renewed. 2 II the operation of the speedometer has become jer1(y and excaes/Ye Iotce is needed 10 tum the cable manually as described abo¥a, the cable IIhouId be r_wed. Lubrication II dilllaJtt with this typa of eabIe, but an _ _ chain lubricant or a slilcooe-based lubricant can often be Introduced using the al:lfow', tllin extension nozzle. Do not apply excess lubricant to the upper end of the cable ottwwise there Is II risk of ~ working up into tht Instrument head. On refitting ensure the cabII Is correctly routed, secured by any ties or guides and is not Ir8Wed or kinked anywher.. knurled

1 Windscreen 2 Upper falrirlQ inner ~

---

3 Rear view minors 4 Upper~ 5 Upper faIr*Ig moutl(jng

6 HNdlIlmp i-'lspecfion 7

Mlddlef~

,,---

B """"""''''''''"'' 9 Lower fairing 10 Lower fairing Inner ~

12 Lo_faIMg

23 Fairing removal and refitting ZX900 models 1 Slacken and remove the ~hl screws which secure the lower fairing to the middle fairing and the screws which retain the lower I~ Inner CO\Iers ISH Mlu.tratlonsJ. Release boIh

23.1' Fairing - ZX900 model.

23.1 b ZX900 - note the nuts fitted to the two lower lalring mounting bolb

Frame and forks 6-19

the Iowllf fairing mounting bolts and nuts and

lower the fairirag away!n)m the machine. 2 Remove lne six middle lalring mounl ing botts. all 01 which life lIiIuated below the radiator. and carefutly lower the middle lairing ~ from the machine noting the tangs INt Ioeate wiltl the UpPfi la.iring ($ee ilustratlonsj.1f neicesswy. the cowlings fitted to aach side of tha radiator can than be removed OrlCe their ratalnlng sc rews have been roteased. 3 Slacken and remove the lop yoke cover retaining screws and 11ft the cover claar. Release tha knurled ring which ralains the upper end 01 the speedometer cable and free the cable from the Instrument panel. Remove the two bolts which mount the Instrument assembly to the fairing bl"acket and pull the

23.3 COVe. the fuel tank wjth a clean rag and rest the Instr\.lmef1t p.aneI on the tank

23Ac .. and disconnect the tum signal wiring connectors

assembly upwards. COvIlf the fuel tank with a clear1 thicl< cloth and rest the instrumef1ts on

lalring can then be manoeuvred clear 01 lIS mounting bracket.

tha fuel tank (..a illustration). Ensura the In$ttumeI\ts are left in an upright position to prevent them beng damaged in any way. .. RMase the I5Cf8WS whidl retain each 01 the upper fairing Inner COVe