User manual KAWASAKI NINJA ZX-12R

[. . . ] Ninja ZX-12R Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Troubleshooting 17 j Ninja ZX-12R Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] TDC Mark [A] for #1, #4 Pistons Timing Mark [B] (crankcase halves mating surface) · · Remove: Chain Tensioner (see Camshaft Chain TenCamshaft sioner Removal) Camshaft Cap Bolts [A] Upper Camshaft Chain Guide [B] Camshaft Cap [C] Camshafts [D] Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase. · CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. Camshaft Installation · Be sure to install the following parts. Pins [A] · Apply molybdenum disulfide oil solution to all cam parts and journals. If a new camshaft is to be used, apply molybdenum disulfide grease to the cam surfaces. The exhaust camshaft has a 320 EX mark [A] and the NOTE inlet camshaft has a 320 IN mark [B]. Be careful not to mix up these shafts. ENGINE TOP END 5-15 Camshaft, Camshaft Chain If the camshaft position sensor rotor is removed, install it as follows. Insert the pin [A] into the holes [B] in the camshaft and boss [C]. Fit the projection [A] of the rotor on the camshaft recess Apply a non-permanent locking agent to the camshaft position sensor rotor bolt [C], and tighten it. Torque - Camshaft Position Sensor Rotor Bolt: 12 N·m (1. 2 kgf·m, 106 in·lb) [B]. the crankshaft at #1, · Position tension side (exhaust#4 piston TDC. chain taut side) [A] of the · Pull the the chain to install the camshaft chain with the camshaft sprockets · Engagethe timing marks on the sprockets are positioned so that The timing mark [B] of #1, #4 T must be aligned with the mating surface [C] of crankcase of rear side. The timing marks must be aligned with the cylinder head upper surface [D]. EX mark [E] IN mark [F] #1 Pin [G] #31 Pin [H] #32 Pin [I] as shown. 5-16 ENGINE TOP END Camshaft, Camshaft Chain the camshaft cap camshaft chain · Install [B]. While pushing [A] and upperchain, tighten all guide the camshaft Install the longer bolts to the #10 and #14 position shown by triangle marks. First tighten the all camshaft cap and chain guide bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence. camshaft bolts and chain guide bolts. · Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). · Install the cylinder head cover (see Cylinder Head Cover Installation). Camshaft, Camshaft Cap Wear plastigage (press gauge) · Cut strips of on each journal parallel to to journal width. Place a strip the camshaft installed in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using plastigage [A]. Tighten: Torque - Camshaft Cap Bolts: 12 N·m (1. 2 kgf·m, 106 in·lb) Upper Camshaft Chain Guide Bolts: 12 N·m (1. 2 kgf·m, 106 in·lb) Torque - Camshaft Cap Bolts: 12 N·m (1. 2 kgf·m, 106 in·lb) Upper Camshaft Chain Guide Bolts: 12 N·m (1. 2 kgf·m, 106 in·lb) · · Do not turn the camshaft when the plastigage is between the journal and camshaft cap. Camshaft Journal, Camshaft Cap Clearance Standard: 0. 028 0. 071 mm (0. 0011 0. 0028 in. ) Service Limit: 0. 16 mm (0. 006 in. ) NOTE If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23. 950 23. 972 mm (0. 9429 0. 9438 in. ) Service Limit: 23. 92 mm (0. 942 in. ) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again If the clearance still remains out of the limit, replace the cylinder head with camshaft cap. ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Runout the camshaft · Remove camshaft in a(see Camshaft Removal). or on V Set the camshaft alignment jig · blocks. · Measure runout with a dial gauge at the specified place as shown. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: TIR 0. 02 mm (0. 0008 in. ) or less Service Limit: TIR 0. 1 mm (0. 004 in. ) Cam Wear · Remove the camshaft (see Camshaft Removal). height with a · Measure theare worn[A] of each cam servicemicrometer. If the cams down past the limit, replace the camshaft. Cam Height Standard: Exhaust Inlet Service Limit: Exhaust Inlet 36. 54 mm (1. 439 in. ) 36. 94 mm (1. 454 in. ) 36. 643 36. 757 mm (1. 4426 1. 4471 in. ) 37. 043 37. 157 mm (1. 4584 1. 4629 in. ) Camshaft Chain Removal · Split the crankcase (see Crankshaft/Transmission chapter). · Remove the camshaft chain [A] from the crankshaft sprocket. 5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE up the engine · Warmthe engine. Stop · Remove: · Lower Inner Covers (see Frame chapter) Baffle Plate (see Cylinder Head Cover Removal) Stick Coils (see Electrical System chapter) Spark Plugs (see Electrical System chapter) Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. [. . . ] Check conductivity of the numbered terminals with the hand tester. If the tester does not read as specified, replace the junction box. Fuse Circuit Inspection Tester Connection 1 - 1A 1-2 3A - 4 6-5 6 - 10 6-7 6 - 17 Tester Reading () 0 0 0 0 0 0 0 Tester Connection 1A - 8 2-8 3A - 8 6-2 6 - 3A 17 - 3A Tester Reading () Starter Circuit/Headlight Relay Inspection · Remove the junctionofbox. following numbered terminals · Check conductivity the and one 12 V battery to the by connecting the hand tester junction box as shown. If the tester does not read as specified, replace the junction box. 16-96 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading () Headlight Relay *7 - 8 *7 - 13 (+) (­) *13 - 9 Not ** Starter Circuit Relay Tester Connection 9 - 11 12 - 13 (+) (­) 13 - 11 (+) (­) 12 - 11 Tester Reading () Not ** *: U. S. A, Canadian, Australian, and Malaysian Models only **: The actual reading varies with the hand tester used. Relay Circuit Inspection (with the battery connected) Battery Connection (+) (­) Headlight Relay Starter Circuit Relay *9 ­ 13 11 ­ 12 Tester Connection *7 ­ 8 (+) (­) 13 ­ 11 Tester Reading () 0 Not ** (+): Apply tester positive lead. [. . . ]