User manual KAWASAKI ZZR 1400

[. . . ] ZZR 1400 ZZR1400 ABS Ninja ZX-14 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 Appendix 17 j ZZR 1400 ZZR1400 ABS Ninja ZX-14 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. [. . . ] (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) G: Apply grease. R: Replacement Parts 9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert/crankpin Clearance Crankpin Diameter: Marking None Standard Service Limit ­­­ ­­­ 0. 13 0. 38 mm (0. 0051 0. 0150 in. ) 0. 048 0. 086 mm (0. 0019 0. 0034 in. ) 37. 984 38. 000 mm (1. 4954 1. 4961 in. ) 37. 984 37. 992 mm (1. 4954 1. 4957 in. ) 37. 993 38. 000 mm (1. 4958 1. 4961 in. ) 41. 000 41. 016 mm (1. 6142 1. 6148 in. ) 41. 000 41. 008 mm (1. 6142 1. 6145 in. ) 41. 009 41. 016 mm (1. 6145 1. 6148 in. ) TIR 0. 2/100 mm (0. 008/3. 94 in. ) TIR 0. 2/100 mm (0. 008/3. 94 in. ) 0. 58 mm (0. 023 in. ) 0. 12 mm (0. 0047 in. ) 37. 97 mm (1. 4949 in. ) ­­­ ­­­ ­­­ ­­­ ­­­ Connecting Rod Big End Inside Diameter: Marking None Connecting Rod Big End Bearing Insert Thickness: Brown Black Blue Connecting Rod Bolt Stretch: New Connecting Rod Used Connecting Rod Crankshaft Side Clearance Crankshaft Runout 1. 475 1. 480 mm (0. 05807 0. 05827 in. ) 1. 480 1. 485 mm (0. 05827 0. 05846 in. ) 1. 485 1. 490 mm (0. 05846 0. 05866 in. ) (Usable Range) 0. 25 0. 34 mm (0. 0098 0. 0134 in. ) 0. 25 0. 34 mm (0. 0098 0. 0134 in. ) 0. 05 0. 24 mm (0. 0020 0. 0094 in. ) TIR 0. 03 mm (0. 0012 in. ) or less ­­­ ­­­ ­­­ ­­­ ­­­ 0. 30 mm (0. 0118 in. ) TIR 0. 08 mm (0. 0031 in. ) 0. 09 mm (0. 0035 in. ) 37. 96 mm (1. 4945 in. ) ­­­ ­­­ ­­­ Crankshaft Main Bearing Insert/journal 0. 031 0. 063 mm (0. 0012 0. 0025 in. ) Clearance 37. 984 38. 000 mm Crankshaft Main Journal Diameter: (1. 4954 1. 4961 in. ) Marking None 37. 984 37. 992 mm (1. 4954 1. 4957 in. ) 1 37. 993 38. 000 mm (1. 4958 1. 4961 in. ) 41. 000 41. 016 mm Crankcase Main Bearing Inside Diameter: (1. 6142 1. 6148 in. ) CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Marking Standard 41. 000 41. 008 mm (1. 6142 1. 6145 in. ) 41. 009 41. 016 mm (1. 6145 1. 6148 in. ) Service Limit ­­­ ­­­ None Crankshaft Main Bearing Insert Thickness: Brown Black Blue Pistons Cylinder (Upper Crankcase) Inside Diameter Piston Diameter Piston/Cylinder Clearance Piston Ring/Groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second Transmission Shift Fork Ear Thickness Gear Groove Width Shift Fork Guide Pin Diameter Shift Drum Groove Width 1. 490 1. 494 mm (0. 0587 0. 0588 in. ) 1. 494 1. 498 mm (0. 0588 0. 0590 in. ) 1. 498 1. 502 mm (0. 0590 0. 0591 in. ) 83. 994 84. 006 mm (3. 3068 3. 3073 in. ) 83. 959 83. 974 mm (3. 3055 3. 3061 in. ) 0. 020 0. 047 mm (0. 0008 0. 0019 in. ) 0. 03 0. 07 mm (0. 0012 0. 0028 in. ) 0. 02 0. 06 mm (0. 0008 0. 0024 in. ) 0. 92 0. 94 mm (0. 0362 0. 0370 in. ) 1. 01 1. 03 mm (0. 0398 0. 0406 in. ) 0. 87 0. 89 mm (0. 0343 0. 0350 in. ) 0. 97 0. 99 mm (0. 0382 0. 0390 in. ) 0. 20 0. 30 mm (0. 0079 0. 0118 in. ) 0. 40 0. 55 mm (0. 0157 0. 0217 in. ) 5. 74 6. 00 mm (0. 2260 0. 2362 in. ) 6. 05 6. 15 mm (0. 238 0. 242 in. ) 6. 9 7. 0 mm (0. 272 0. 276 in. ) 7. 05 7. 20 mm (0. 278 0. 283 in. ) ­­­ ­­­ ­­­ 84. 10 mm (3. 3110 in. ) 83. 81 mm (3. 2996 in. ) ­­­ 0. 17 mm (0. 0067 in. ) 0. 16 mm (0. 0063 in. ) 1. 02 mm (0. 040 in. ) 1. 11 mm (0. 044 in. ) 0. 80 mm (0. 032 in. ) 0. 90 mm (0. 035 in. ) 0. 6 mm (0. 024 in. ) 0. 8 mm (0. 031 in. ) 5. 6 mm (0. 220 in. ) 6. 25 mm (0. 246 in. ) 6. 8 mm (0. 268 in. ) 7. 3 mm (0. 287 in. ) 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bore Diameter Marking None None Crankpin Diameter Marking Bearing Insert Size Color Part Number Brown Black Blue Bearing Insert Size Color Brown Black Blue Part Number 92139-0134 92139-0137 92139-0133 92139-0136 92139-0132 92139-0135 Journal Nos. 1, 3, 5 2, 4 1, 3, 5 2, 4 1, 3, 5 2, 4 92139-0131 92139-0130 92139-0129 None None Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Inside Journal Diameter Diameter Marking Marking None 1 1 None None None CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Bearing Puller: 57001-135 Piston Ring Compressor Belt, 57001-1320 80 91: Bearing Puller Adapter: 57001-317 Kawasaki Bond (Silicone Sealant): 56019-120 Piston Pin Puller Assembly: 57001-910 Kawasaki Bond: 92104-1064 Piston Ring Compressor Grip: 57001-1095 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting engine (see Engine Removal/Installation in · Remove theRemoval/Installation chapter). the Engine engine on a · Set thewhile parts areclean surface and hold the engine steady being removed. · Remove:(see Clutch Removal in the Clutch chapter) Clutch Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) External Shift Mechanism (see External Shift Mechanism Removal) upper · Remove the the M6crankcase bolts. First loosen M6 M7 M7 M8 Bolts [A] Bolt [B] Bolt with Clamp [C] Bolts with Washers [D] lower · Remove the the M7crankcase bolts. First loosen CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting Next, loosen the M10 Bolts [110] (sequence numbers). · If the crankshaft is to be removed, remove the pistons (see Piston Removal). Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. the front balancer [A] on the · Remove Front Balancer Removal). lower crankcase half [B] (see Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. When NOTE replacing the crankcase halves, install the thrust washers (t = 2. 5 mm, 0. 0984 in. ) on the upper crankcase half. solvent, clean off the · With aofhigh-flash point halves and wipe dry. mating surfaces the crankcase · Using compressed air, blow out the oil passages in the crankcase halves. drive shaft bearing [A] · Install the newas shown using a press. so that its stepped side [B] faces [C] with the screws [D]. · Install athe bearing plate locking agent to the bearing plate Apply non-permanent screw and tighten them. Torque - Bearing Position Plate Screws: 4. 9 N·m (0. 50 kgf·m, 43 in·lb) 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting the shift shaft · Install the new needle bearing [A] for using a press. so that its marked side [B] faces as shown, [C] so that its · Install the new oil seal crankcase [E]. surface [D] is flush with the surface of the · Install: Crankshaft, Pistons and Connecting Rods Transmission Shaft and Gears Dowel Pins [A] · Install the front balancer [A] on the upper crankcase half [B] (see Balancer Installation). · Before fitting the lower case on the upper case, check the following. are in the neutral position. Check to see that the shift drum and transmission gears gasket · Apply liquidhalf. [A] to the mating surface of the lower crankcase Sealant - Kawasaki Bond: 92104-1064 Aster tightening the crankcase bolts, wipe up the liquid gasket seeping out the output shaft bearing hole [D]. Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. CAUTION Do not apply liquid gasket to the grooves [B] inside from the crankshaft main bearing inserts, and balancer bearing. NOTE CAUTION Do not plug the inside of breather hole [C] with liquid gasket. CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting crankcase the upper crankcase half. · Fit the lower the breatherhalf to[A] on the upper crankcase hole · Be sure that with liquid gasket. [B] is not plugged · The M10 bolts have washers, replace them with new ones. solution to sur· Apply molybdenum disulfide oilthe threadsthe seatingM10 faces [A] of the washers and [B] of the bolts. · Tighten the lower crankcase bolts using the following steps. Following the sequence numbers on the lower crankcase half, tighten the M10 bolts [1 10] with washers. Torque - Crankcase Bolts (M10): 47 N·m (4. 8 kgf·m, 35 ft·lb) Tighten the M7 bolts [A]. Torque - Crankcase Bolts (M7): 20 N·m (2. 0 kgf·m, 15 ft·lb) 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting the upper bolts in the listed. · Tighten bolts havecrankcasereplace themorder new ones. washers, with The M8 Tighten: M8 M7 M7 M6 Bolts with Washers [A] Bolt with the clamp [B] Bolt [C] Bolts [D] Torque - Crankcase Bolts (M8): 27 N·m (2. 8 kgf·m, 20 ft·lb) Crankcase Bolts (M7): 20 N·m (2. 0 kgf·m, 15 ft·lb) Crankcase Bolts (M6): 12 N·m (1. 2 kgf·m, 106 in·lb) · After tightening all crankcase bolts, check the following items. the 1st to neutral, and neutral to 1st. Crankshaft and transmission shafts turn freely. [. . . ] Bracket (Push the joint portions of the brake pipe, and clamp them. ) 2. Brake Pipe (One Blue Paint Mark, ABS Hydraulic Unit Side) 3. Align the brake pipes with groove of the frame. Brake Pipe (One White Paint Mark, ABS Hydraulic Unit Side) 5. [. . . ]