User manual KAWASAKI NINJA ZX-10R

[. . . ] Ninja ZX-10R 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 17 j Appendix Ninja ZX-10R 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 Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter). · · · ENGINE TOP END 5-37 Valves 5-38 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal · Remove: (see Fuel Tank Removal in the Fuel System Fuel Tank (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Loosen the throttle body assy holder bolts as shown sequence [1 3] in the figure, and remove them. Remove the throttle body assy holders [B]. · · Throttle Body Assy Holder Installation the new O-rings · Be sure to installthe new O-ring. Apply grease to · Install the clamps [B] as shown. · Tighten the holder bolts following the tightening sequence · [1 3]. Torque - Throttle Body Assy Holder Bolts [C]: 10 N·m (1. 0 kgf·m, 89 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2. 0 N·m (0. 20 kgf·m, 18 in·lb) Upside View [E] ENGINE TOP END 5-39 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. What until the muffler cool down. Muffler Body Removal · Remove: (see Seat Cover Removal in the Frame Seat Cover chapter) Bolts [A] Right Rear Footpeg Bracket [B] with Cover [C] · Remove: Body Assembly Nuts [A] Right Muffler Right Muffler Body Mounting Bolt [B] Remove the right muffler body [C] to backward. Remove the bolt [D] and muffler body cover [E] as necessary. · · Remove: Bolts [A] Left Rear Footpeg Bracket [B] · Remove: Body Assembly Nuts [A] Left Muffler Left Muffler Body Mounting Bolt [B] Remove the left muffler body [C] to backward. Remove the bolt [D] and muffler body cover [E] as necessary. · 5-40 ENGINE TOP END Muffler Muffler Body Installation If the muffler body cover [A] was removed, install it. in the muffler cover. Fit the dampers [B] of the muffler body into the slots [C] · Replace the muffler body gasket [E] with a new ones. · Installthe muffler stay [F] through the hole [G] of the rear Pass · fender front [H]. Tighten: Torque - Muffler Body Assembly Nuts [I]: 22 N·m (2. 2 kgf·m, 16 ft·lb) Muffler Body Mounting Bolts [J]: 25 N·m (2. 5 kgf·m, 18 ft·lb) Torque - Muffler Body Cover Bolts [D]: 7. 0 N·m (0. 70 kgf·m, 62 in·lb) up the engine, wait until · Throughly warm all the bolts and nuts. the engine cools down, retighten · Install the removed parts (see appropriate chapters). ENGINE TOP END 5-41 Muffler Middle and Rear Exhaust Pipe Removal the left · Removethe rearmuffler body (see Muffler Body Removal). Loosen · Remove the rearexhaust pipe clamp bolt [A]. of motorexhaust pipe [B] from left side · cycle. · Remove: Body (see Muffler Body Removal) Right Muffler Exhaust Butterfly Valve Cable Lower Ends (see Exhaust Butterfly Valve Cable Removal) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Exhaust Pipe Stay Bolt [A] Loosen the middle exhaust pipe clamp bolt [B]. Remove the middle exhaust pipe [C] from right side of motorcycle. · · 5-42 ENGINE TOP END Muffler Middle and Rear Exhaust Pipe Installation · Replace the middle exhaust pipe gasket [A] with a new one. Install the middle exhaust pipe gasket until it is bottomed · · so that the chamfer side (inner) faces front exhaust pipe [B]. Tighten: Torque - Middle Exhaust Pipe Stay Bolt [D]: 25 N·m (2. 5 kgf·m, 18 ft·lb) middle · Install the[F] exhaust pipe clamp bolt [E] as shown. Upside Outside [G] 35° 55° [H] Front View [I] Tighten: · a new one. · Replace the rear exhaust pipe gasket [J]itwithbottomed so Install the rear exhaust pipe gasket until is Torque - Middle Exhaust Pipe Clamp Bolt: 17 N·m (1. 7 kgf·m, 13 ft·lb) that the chamfer side (outer) faces rear exhaust pipe [K]. Install the rear exhaust pipe clamp bolt [L] as shown. Fit the projection [M] of the rear exhaust pipe into the slot [N] in the clamp. Fit the damper [O] of the rear exhaust pipe into the stopper [P] of the middle exhaust pipe. Install the left and right muffler body (see Muffler Body Installation). Tighten: · · · · Torque - Rear Exhaust Pipe Clamp Bolt: 17 N·m (1. 7 kgf·m, 13 ft·lb) ENGINE TOP END 5-43 Muffler butterfly valve cable, and · Install the exhaustValve Cable Installation). adjust (see Exhaust Butterfly up the engine, · Throughly warm all the bolts. [. . . ] Install the engine ground cable as shown. APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Install the idle adjuster screw direction as shown. Align the clamp with the speed sensor. 17-22 APPENDIX Cable, Wire, and Hose Routing 1. Run the drain hose inside the radiator hose. [. . . ]