Kawasaki Zx 12r (Zx1200 B1 3) 02 A 04 Service Manual

Motorcycle

Thisquickreferenceguidewillassist youinlocatingadesiredtopicorprocedure.

•Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeat eachtableofcontentspage.

•Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

NinjaZX-12R

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityAssuranceDepartment/ConsumerProducts&Machinery Company/KawasakiHeavyIndustries,Ltd.,Japan.

Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossible carehasbeentakentomakeitascompleteandaccurateaspossible.

Therightisreservedtomakechangesatanytimewithoutpriornoticeandwithoutincurringanobligation tomakesuchchangestoproductsmanufacturedpreviously.SeeyourMotorcycledealerforthelatest informationonproductimprovementsincorporatedafterthispublication.

Allinformationcontainedinthispublicationisbasedon thelatestproductinformationavailableatthetime ofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

A ampere(s) lb pound(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter N newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch °C degree(s)Celsius r revolution

DC directcurrent rpm revolution(s)perminute F farad(s) TDC topdeadcenter °F degree(s)Fahrenheit TIR totalindicatorreading ft foot,feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s)

Toprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission(1)andexhaustemission(2)controlsystemsincompliancewithapplicableregulationsof theUnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.Additionally,Kawasakihasincorporatedanevaporativeemissioncontrolsystem(3)incompliance withapplicableregulationsoftheCaliforniaAirResourcesBoardonvehiclessoldinCalifornia only.

1.CrankcaseEmissionControlSystem

Thissystemeliminatesthereleaseofcranckcasevaporsintotheatmosphere.Instead,the vaporsareroutedthroughanoilseparatortotheinletsideoftheengine.Whiletheengineis operating,thevaporsaredrawnintocombustionchamber,wheretheyareburnedalongwiththe fuelandairsuppliedbythefuelinjectionsystem.

2.ExhaustEmissionControlSystem

Thissystemreducestheamountofpollutantsdischargedintotheatmospherebytheexhaust ofthismotorcycle.Thefuel,ignition,andexhaustsystemsofthismotorcyclehavebeencarefully designedandconstructedtoensureanefficientenginewithlowexhaustpollutantlevels.

TheexhaustsystemofthismodelmotorcyclemanufacturedprimarilyforsaleinCaliforniaincludesacatalyticconvertersystem.

3.EvaporativeEmissionControlSystem

Vaporscausedbyfuelevaporationinthefuelsystemarenotventedintotheatmosphere.Instead,fuelvaporsareroutedintotherunningenginetobeburned,orstoredinacanisterwhen theengineisstopped.Liquidfueliscaughtbyavaporseparatorandreturnedtothefueltank.

TheCleanAirAct,whichistheFederallawcoveringmotorvehiclepollution,containswhatis commonlyreferredtoastheAct’s"tamperingprovisions."

"Sec.203(a)Thefollowingactsandthecausingthereofareprohibited...

(3)(A)foranypersontoremoveorrenderinoperativeanydeviceorelementofdesigninstalled onorinamotorvehicleormotorvehicleengineincompliancewithregulationsunderthis titlepriortoitssaleanddeliverytotheultimatepurchaser,orforanymanufacturerordealer knowinglytoremoveorrenderinoperativeanysuchdeviceorelementofdesignaftersuch saleanddeliverytotheultimatepurchaser.

(3)(B)foranypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortrading motorvehiclesormotorvehicleengines,orwhooperatesafleetofmotorvehiclesknowinglytoremoveorrenderinoperativeanydeviceorelementofdesigninstalledonorina motorvehicleormotorvehicleengineincompliancewithregulationsunderthistitlefollowingitssaleanddeliverytotheultimatepurchaser..."

NOTE

$10,000PERVIOLATION.

TAMPERINGWITHNOISECONTROLSYSTEMPROHIBITED

Federallawprohibitsthefollowingactsorthecausingthereof:(1)Theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofany deviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrol priortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse,or(2)theuseofthe vehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativeby anyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow:

• Replacementoftheoriginalexhaustsystemormufflerwithacomponentnotincompliance withFederalregulations.

• Removalofthemuffler(s)oranyinternalportionofthemuffler(s).

• Removaloftheairboxorairboxcover.

• Modificationstothemuffler(s)orairinletsystembycutting,drilling,orothermeansifsuch modificationsresultinincreasednoiselevels.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhodesirestoperformhisownbasicmaintenanceand repairwork.Abasicknowledgeofmechanics, theproperuseoftools,andworkshopproceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Whenevertheownerhasinsufficientexperienceor doubtshisabilitytodothework,alladjustments,maintenance,andrepairshouldbecarriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyand toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsor equipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Forthedurationofthewarrantyperiod, werecommendthatallrepairsandscheduled maintenancebeperformedinaccordancewith thisservicemanual.Anyownermaintenanceor repairprocedurenotperformedinaccordance withthismanualmayvoidthewarranty.

Togetthelongestlifeoutofyourvehicle:

• FollowthePeriodicMaintenanceChartinthe ServiceManual.

• Bealertforproblemsandnon-scheduled maintenance.

• UsepropertoolsandgenuineKawasakiMotorcycleparts.Specialtools,gauges,and testersthatarenecessarywhenservicing Kawasakimotorcyclesareintroducedbythe SpecialToolCatalogorManual.Genuine partsprovidedassparepartsarelistedinthe PartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’ttakeshortcuts.

• Remembertokeepcompleterecordsofmaintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUseThisManual

Inthismanual,theproductisdivitedintoits majorsystemsandthesesystemsmakeup themanual’schapters.TheQuickReference

Guideshowsyoualloftheproduct’ssystem andassistsinlocatingtheirchapters.Each chapterinturnhasitsowncomprehensive TableofContents.

Forexample,ifyouwantignitioncoilinformation,usetheQuickReferenceGuidetolocate theElectricalSystemchapter.Then,usethe TableofContentsonthefirstpageofthechaptertofindtheIgnitionCoilsection.

WheneveryouseetheseWARNINGand CAUTIONsymbols,heedtheirinstructions! Alwaysfollowsafeoperatingandmaintenance practices.

WARNING

Thiswarningsymbolidentifiesspecial instructionsorprocedureswhich,ifnot correctlyfollowed,couldresultinpersonalinjury,orlossoflife.

CAUTION

Thiscautionsymbolidentifiesspecial instructionsorprocedureswhich,ifnot strictlyobserved,couldresultindamagetoordestructionofequipment.

Thismanualcontainsfourmoresymbols(in additiontoWARNINGandCAUTION)whichwill helpyoudistinguishdifferenttypesofinformation.

NOTE

○

Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• Indicatesaproceduralsteporworktobe done.

○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaNOTE.

Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspectionintheproceduralsteporsub-stepitfollows.

Inmostchaptersanexplodedviewillustration ofthesystemcomponentsfollowstheTableof Contents.Intheseillustrationsyouwillfindthe instructionsindicatingwhichpartsrequirespecifiedtighteningtorque,oil,greaseoralocking agentduringassembly.

BeforeServicing

Beforestartingtoserviceamotorcycle,carefulreadingoftheapplicablesectionisrecommendedto eliminateunnecessarywork.Photographs,diagrams,notes,cautions,warnings,anddetaileddescriptionshavebeenincludedwherevernecessary.Nevertheless,evenadetailedaccounthaslimitations, acertainamountofbasicknowledgeisalsorequiredforsuccessfulwork.

Especiallynotethefollowing:

(1)Dirt

Beforeremovalanddisassembly,cleanthemotorcycle.Anydirtenteringtheengineorother partswillworkasanabrasiveandshortenthelifeofthemotorcycle.Forthesamereason,before installinganewpart,cleanoffanydustormetalfilings.

(2)BatteryCables

Disconnecttheground(–)cablefromthebatterybeforeperforminganydisassemblyoperations onthemotorcycle.Thispreventstheenginefromaccidentallyturningoverwhileworkisbeing carriedout,sparksfrombeinggeneratedwhiledisconnectingtheleadsfromelectricalparts,as wellasdamagetotheelectricalpartsthemselves.Forreinstallation,firstconnectthepositive cabletothepositive(+)terminalofthebattery.

(3)Installation,Assembly

Generally,installationorassemblyisthereverseofremovalordisassembly.ButifthisService Manualhasinstallationorassemblyprocedures,followthem.Notepartslocationsandcable, lead,andhoseroutingduringremovalordisassemblysotheycanbeinstalledorassembledin thesameway.Itispreferabletomarkandrecordthelocationsandroutingasmuchaspossible.

(4)TighteningSequence

Generally,wheninstallingapartwithseveralbolts,nuts,orscrews,startthemallintheirholes andtightenthemtoasnugfit.Thentightenthemevenlyinacrosspattern.Thisistoavoid distortionofthepartand/orcausinggasoroilleakage.Converselywhenlooseningthebolts, nuts,orscrews,firstloosenallofthembyaboutaquarterturnandthenremovethem.Where thereisatighteningsequenceindicationinthisServiceManual,thebolts,nuts,orscrewsmust betightenedintheorderandmethodindicated.

(5)Torque

WhentorquevaluesaregiveninthisServiceManual,usethem.Eithertoolittleortoomuch torquemayleadtoseriousdamage.Useagoodquality,reliabletorquewrench.

(6)Force

Commonsenseshoulddictatehowmuchforceisnecessaryinassemblyanddisassembly.If apartseemsespeciallydifficulttoremoveorinstall,stopandexaminewhatmaybecausingthe problem.Whenevertappingisnecessary,taplightlyusingawoodenorplastic-facedmallet.Use animpactdriverforscrews(particularlyfortheremovalofscrewsheldbyalockingagent)inorder toavoiddamagingthescrewheads.

(7)Edges

Watchforsharpedges,especiallyduringmajorenginedisassemblyandassembly.Protectyour handswithglovesorapieceofthickclothwhenliftingtheengineorturningitover.

(8)High-FlashPointSolvent

Ahigh-flashpointsolventisrecommendedtoreducefiredanger.AcommercialsolventcommonlyavailableinNorthAmericaisStoddardsolvent(genericname).Alwaysfollowmanufacturer andcontainerdirectionsregardingtheuseofanysolvent.

(9)Gasket,O-ring

DonotreuseagasketorO-ringonceithasbeeninservice.Thematingsurfacesaroundthe gasketshouldbefreeofforeignmatterandperfectlysmoothtoavoidoilorcompressionleakage.

(10)LiquidGasket,Non-PermanentLockingAgent

Followmanufacturer’sdirectionsforcleaningandpreparingsurfaceswherethesecompounds willbeused.Applysparingly.Excessiveamountsmayblockengineoilpassagesandcauseseriousdamage.Anexampleofnon-permanentlockingagentcommonlyavailableinNorthAmerica isLoctiteLock’nSeal(Blue).

(11)Press

Apartinstalledusingapressordriver,suchasawheelbearing,shouldfirstbecoatedwithoil onitsouterorinnercircumferencesothatitwillgointoplacesmoothly.

BeforeServicing

(12)BallBearingandNeedleBearing

Donotremoveaballbearingoraneedlebearingunlessitisabsolutelynecessary.Replace anyballorneedlebearingsthatwereremovedwithnewones,asremovalgenerallydamages bearings.Installbearingswiththemarkedsidefacingoutapplyingpressureevenlywithasuitable driver.Onlypressontheracethatformsthepressfitwiththebasecomponenttoavoiddamaging thebearings.Thispreventsseverestressontheballsorneedlesandraces,andpreventraces andballsorneedlesfrombeingdented.Pressaballbearinguntilitstopsatthestopperinthe holeorontheshaft.

(13)OilSealandGreaseSeal

Replaceanyoilorgreasesealsthatwereremovedwithnewones,asremovalgenerallydamagesseals.Whenpressinginasealwhichhasmanufacturer’smarks,pressitinwiththemarks facingout.Sealsshouldbepressedintoplaceusingasuitabledriver,whichcontactsevenlywith thesideofseal,untilthefaceofthesealisevenwiththeendofthehole.Beforeashaftpasses throughaseal,applylittlehightemperaturegreaseonthelipstoreducerubbertometalfriction.

(14)Circlip,RetainingRing,andCotterPin

Replaceanycirclipsandretainingrings,andcotterpinsthatwereremovedwithnewones,as removalweakensanddeformsthem.Wheninstallingcirclipsandretainingrings,takecareto compressorexpandthemonlyenoughtoinstallthemandnomore.

(15)Lubrication

Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforeallthe rubbingsurfaceshaveanadequatelubricativefilm.Duringassembly,oilorgrease(whichever ismoresuitable)shouldbeappliedtoanyrubbingsurfacewhichhaslostitslubricativefilm.Old greaseanddirtyoilshouldbecleanedoff.Deterioratedgreasehaslostitslubricativequalityand maycontainabrasiveforeignparticles.

Don’tusejustanyoilorgrease.Someoilsandgreasesinparticularshouldbeusedonlyin certainapplicationsandmaybeharmfulifusedinanapplicationforwhichtheyarenotintended. Thismanualmakesreferencetomolybdenumdisulfidegrease(MoS2)andmolybdenumdisulfide oilintheassemblyofcertainengineandchassisparts.Themolybdenumdisulfideoilisamixture ofengineoilandmolybdenumdisulfidegreasewithaweightratio(10:1),whichcanbemadein yourworkshop.Alwayscheckmanufacturerrecommendationsbeforeusingsuchspeciallubricants.

(16)ElectricalLeads

Alltheelectricalleadsareeithersingle-colorortwo-colorand,withonlyafewexceptions,must beconnectedtoleadsofthesamecolor.Onanyofthetwo-colorleadsthereisagreateramount ofonecolorandalesseramountofasecondcolor,soatwo-colorleadisidentifiedbyfirstthe primarycolorandthenthesecondarycolor.Forexample,ayellowleadwiththinredstripesis referredtoasa"yellow/red"lead;itwouldbea"red/yellow"leadifthecolorswerereversedto makeredthemaincolor.

(17)ReplacementParts

Whenthereisareplacementinstruction,replacethesepartswithnewoneseverytimetheyare removed.Thesereplacementpartswillbedamagedorlosetheiroriginalfunctiononceremoved.

1-4GENERALINFORMATION

BeforeServicing

(18)Inspection

Whenpartshavebeendisassembled,visuallyinspectthesepartsforthefollowingconditions orotherdamage.Ifthereisanydoubtastotheconditionofthem,replacethemwithnewones. AbrasionCrackHardeningWarp BentDentScratchWear ColorchangeDeteriorationSeizure

(19)Specifications

Specificationtermsaredefinedasfollows: "Standards"showdimensionsorperformanceswhichbrand-newpartsorsystemshave. "ServiceLimits"indicatetheusablelimits.Ifthemeasurementshowsexcessivewearordeterioratedperformance,replacethedamagedparts.

(20)Instrument

Useameterthathasenoughaccuracyforanaccuratemeasurement. Readthemanufacturer’sinstructionsthoroughlybeforeusingthemeter. Incorrectvaluesmayleadtoimproperadjustments.

GeneralSpecifications

Items

ZX1200-B1 ∼ B3

Dimensions

OverallLength 2085mm(82.09in.)

OverallWidth 740mm(29.13in.)

OverallHeight 1200mm(47.24in.)

Wheelbase 1450mm(57.09in.)

RoadClearance 120mm(4.72in.)

SeatHeight 820mm(32.28in.)

DryMass 210kg(463lb)

CurbMass: Front 125kg(276lb)

Rear 121kg(267lb)

FuelTankCapacity 19.0L(5.0USgal)

Performance

MinimumTurningRadius 3.0m(9.8ft)

Engine

Type

4-stroke,DOHC,4-cylinder

CoolingSystem Liquid-cooled

BoreandStroke 83.0×55.4mm(3.27×2.18in.)

Displacement 1199mL(73.16cuin.)

CompressionRatio 12.2

MaximumHorsepower

(H)131kW(178PS)@9500r/min(rpm), (AU)ZX1200-B1/B2:130kW(177PS)@10500r/min(rpm), (AU)ZX1200-B3:131kW(178PS)@10500r/min(rpm), (HR)78.2kW(106.4PS)@8500r/min(rpm), (MY)ZX1200-B1/B2:131kW(178PS)@9500r/min(rpm), (MY)ZX1200-B3:128kW(174PS)@9500r/min(rpm) (US),(CA)–––

MaximumTorque

(H,AU)134N·m(13.7kgf·m,99ft·lb)@7500r/min(rpm), (MY)ZX1200-B1/B2:134N·m(13.7kgf·m,99ft·lb)@7500 r/min(rpm), (MY)ZX1200-B3:130N·m(13.3kgf·m,96ft·lb)@7500r/min (rpm), (HR)111N·m(11.3kgf·m,82ft·lb)@5000r/min(rpm), (US),(CA)–––

GeneralSpecifications

Items ZX1200-B1 ∼ B3

ValveTiming:

Inlet: Open 46°BTDC Close 74°ABDC Duration 300° Exhaust: Open 69°BBDC Close 45°ATDC Duration 294°

LubricationSystem Forcedlubrication(wetsumpwithcooler) EngineOil: Grade APISE,SForSG APISHorSJwithJASOMA Viscosity SAE10W-40 Capacity 3.6L(3.8USqt)

DriveTrain

PrimaryReductionSystem: Type Gear ReductionRatio 1.596(83/52) ClutchType Wet,multidisc Transmission: Type 6-speed,constantmesh,returnshift GearRatios: 1st 2.429(34/14) 2nd 1.824(31/17) 3rd 1.440(36/25) 4th 1.250(30/24) 5th 1.130(26/23) 6th 1.033(31/30)

FinalDriveSystem: Type Chaindrive ReductionRatio 2.556(46/18) OverallDriveRatio 4.215@Topgear

Frame

Type Pressbackbone Caster(RakeAngle) 23.5° Trail 98mm(3.86in.)

FrontTire: Type Tubeless Size 120/70ZR17M/C(58W)

RearTire: Type Tubeless Size 200/50ZR17M/C(75W)

GeneralSpecifications

Items ZX1200-B1 ∼ B3

FrontSuspension: Type Telescopicfork(upside-down) WheelTravel 120mm(4.72in.)

RearSuspension: Type Swingarm(uni-trak) WheelTravel 140mm(5.51in.)

BrakeType: Front Dualdiscs Rear Singledisc

ElectricalEquipment Battery 12V12Ah

Headlight: Type Semi-sealedbeam Bulb 12V60/55W(quartz-halogen)×2

Tail/BrakeLight 12V5/21W×2

Alternator: Type Three-phaseAC

RatedOutput 31A/14V@5000r/min(rpm)

Specificationsaresubjecttochangewithoutnotice,andmaynotapplytoeverycountry.

AU:AustralianModel

US:U.S.A.Model

CA:CanadianModel

MY:MalaysianModel

HR:WVTAApprovalModel,HoneycombCatalyticConverter(RestrictedPower)

H:WVTAApprovalModel,HoneycombCatalyticConverter

TechnicalInformation–KAWASAKILOWEXHAUSTEMISSIONSYSTEM

Sincetheemissionregulationsbecomemoresevere,Kawasakihasadoptedatypeofsimplified KAWASAKILOWEXHAUSTEMISSIONSYSTEM(KLEEN),whichhavenocatalystprotectionsystem,accordingtoeachregulationofdifferentcountries.

Themufflerwithbuilt-incatalysthasthesamedurabilityastheconventionalmuffler,however,do notuseleadedgasolineanddonotcoastwiththeignitionsystemOFF.Runningtheenginewithout ignitiondamagescatalyst.

RefertotheZX900EServiceManual(PartNo.99924-1255)formoreinformationabouttheKLEEN (theory,maintenance,andhandlingprecautions),includingthesecondaryairinjectionsystem.

HoneycombTypeCatalyticConverter

○

Theconverterisathree-waycatalyticconverter,anditssurfaceiscoveredwithaluminauponwhich platinumandrhodiumareapplied,andhasacylindricalmetalichoneycombstructuremadebybendingacorrugatedsheetandaflatsheetofstainlesssteelintoaspiralofincreasingdiameter.The honeycombstructureisconvenientforthecatalyticconverterbecauseithasalargesurfacearea butsmallsizetoreacteffectivelyandhaslowexhaustresistance.Inaddition,itsinherentstrength helpsresistvibration,andhassimplestructureweldeddirectlyonthesilencer.

○Generally,thetemperatureoftheexhaustgasmustbehigherthanactivationtemperature,sothe convertersareinstalledintheexhaustmanifoldrearendwherethetemperatureofexhaustgasis stillhigh.And,theconverterswillbeactivatedevenunderlowloadconditions.

○

Aftertheexhaustgasisdilutedwiththesecondaryairinjection,thecatalyticconverterworkswell becauseofrichoxygentoreduceCO,HC,andNOx.Accordingly,wecankeeptheexhaustgas emissionwithinregulation.

○Thistypeofconverterworksmoreefficientlyasathree-waycatalyticconvertertoreduceCO,HC, andNOx thanthepipetypecatalyticconverterbecauseofitsmoreanddensercatalysts.