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2013 Kawasaki ZR1000DD Service Repair Manual .pdf



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Z1000
Z1000 ABS

Motorcycle
Service Manual

Quick Reference Guide

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.

General Information

1 j

Periodic Maintenance

2 j

Fuel System (DFI)

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

Z1000
Z1000 ABS

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 Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 2009 Kawasaki Heavy Industries, Ltd.

5th Edition (0) : May 11, 2012

LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L

ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)

lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W


pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)

COUNTRY AND AREA CODES
AT

Austria

AU

Australia

BR
CA
CAL

Brazil
Canada
California

CH

Switzerland

DE

Germany

GB

United Kingdom

MY

Malaysia

PH

Philippine
Southeast Asia B1 (with Evaporative
SEA-B1
Emission Control System)
SEA-B2
Southeast Asia B2
TH
Thailand
US
United States
WVTA
WVTA Model with Honeycomb
(FULL H) Catalytic Converter (Full Power)
GB WVTA WVTA Model with Honeycomb Catalytic
(FULL H) Converter (Left Side Traffic, Full Power)
WVTA
WVTA Model with Honeycomb
(78.2 H)
Catalytic Converter (78.2 Kw Power)

EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”

NOTE

○The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.






Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.








How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and
maintenance practices.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.

○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................

1
1-2
1-7
1-10
1-13

1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.

Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.

Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.

GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.

Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.

GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.

1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.

GENERAL INFORMATION 1-7
Model Identification
ZR1000DA (United States and Canada) Left Side View

ZR1000DA (United States and Canada) Right Side View

Frame Number

Engine Number

1-8 GENERAL INFORMATION
Model Identification
ZR1000DA (Europe) Left Side View

ZR1000DA (Europe) Right Side View

GENERAL INFORMATION 1-9
Model Identification
ZR1000EA Left Side View

ZR1000EA Right Side View

1-10 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Curb Mass:
ZR1000D
ZR1000E
Front:
ZR1000D
ZR1000E
Rear:
ZR1000D
ZR1000E
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower

Maximum Torque

Carburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plug
Cylinder Numbering Method
Firing Order
Valve Timing:
Intake:
Open
Close

ZR1000DA ∼ DD/EA ∼ ED
2 095 mm (82.48 in.)
805 mm (31.7 in.)
1 085 mm (42.72 in.)
1 440 mm (56.69 in.)
140 mm (5.51 in.)
815 mm (32.1 in.)
218 kg (481 lb)
221 kg (487 lb)
111 kg (245 lb)
112 kg (247 lb)
107 kg (236 lb)
109 kg (240.2 lb)
15 L (4.0 US gal.)
3.0 m (9.8 ft)
4-stroke, DOHC, 4-cylinder
Liquid-cooled
77.0 × 56.0 mm (3.03 × 2.20 in.)
1 043 cm³ (63.64 cu in.)
11.8 : 1
101.5 kW (138 PS) @9 600 r/min (rpm)
(MY, TH, SEA-B1/B2) 100 kW (136 PS) @9 000 r/min (rpm)
(WVTA (78.2 H)) 78.2 kW (106 PS) @9 100 r/min (rpm)
(CA, US) – – –
110 N·m (11.2 kgf·m, 81.1 ft·lb) @7 800 r/min (rpm)
(WVTA (78.2 H)) 95 N·m (9.7 kgf·m, 70 ft·lb) @7 500 r/min (rpm)
(CA, US) – – –
FI (Fuel Injection) KEIHIN TTK38 × 4
Electric starter
Battery and coil (transistorized)
Electronically advanced (digital igniter)
From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC
@5 200 r/min (rpm)
NGK CR9EIA-9
Left to right, 1-2-3-4
1-2-4-3

31° BTDC
65° ABDC

GENERAL INFORMATION 1-11
General Specifications
Items
Duration
Exhaust:
Open
Close
Duration
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
Front Suspension:
Type
Wheel Travel

ZR1000DA ∼ DD/EA ∼ ED
276°
58° BBDC
18° ATDC
256°
Forced lubrication (wet sump)
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
4.0 L (4.2 US qt)

Gear
1.627 (83/51)
Wet multi disc
6-speed, constant mesh, return shift
2.600
1.950
1.600
1.389
1.238
1.136

(39/15)
(39/20)
(24/15)
(25/18)
(26/21)
(25/22)

Chain drive
2.800 (42/15)
5.178 @Top gear
Tubular, diamond
24.5°
103 mm (4.06 in.)
Tubeless
120/70 ZR17 M/C (58W)
J17M/C × MT3.50
Tubeless
190/50 ZR17 M/C (73W)
J17M/C × MT6.00
Telescopic fork (upside-down)
120 mm (4.72 in.)

1-12 GENERAL INFORMATION
General Specifications
Items
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/Brake Light
Alternator:
Type

ZR1000DA ∼ DD/EA ∼ ED
Swingarm
138 mm (5.43 in.)
Dual discs
Single disc
12 V 8 Ah
Semi-sealed beam
12 V 55 W × 2/55 W (Hi/Lo)
LED
Three-phase AC

Specifications are subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-13
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro

Units of Length:

Symbol
M
k
c
m
µ

×
×
×
×
×

Power
1 000 000
1 000
0.01
0.001
0.000001

Units of Mass:
kg
g

×
×

2.205
0.03527

=
=

lb
oz

=
=
=
=
=
=
=
=
=

gal (US)
gal (IMP)
qt (US)
qt (IMP)
pint (US)
pint (IMP)
oz (US)
oz (IMP)
cu in

=
=
=
=

kg
lb
N
lb

Units of Volume:
L
L
L
L
L
L
mL
mL
mL

×
×
×
×
×
×
×
×
×

0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102

×
×
×
×

×
×
×

0.6214
3.281
0.03937

=
=
=

mile
ft
in

=
=
=
=
=
=

kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb

=
=
=
=
=
=

kgf/cm²
psi
cmHg
kPa
psi
kPa

=

mph

=
=
=
=

PS
HP
kW
HP

Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m

×
×
×
×
×
×

0.1020
0.7376
8.851
9.807
7.233
86.80

Units of Pressure:

Units of Force:
N
N
kg
kg

km
m
mm

0.1020
0.2248
9.807
2.205

Units of Temperature:

kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg

×
×
×
×
×
×

0.01020
0.1450
0.7501
98.07
14.22
1.333

Units of Speed:
km/h

×

0.6214

Units of Power:
kW
kW
PS
PS

×
×
×
×

1.360
1.341
0.7355
0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System (DFI)................................................................................................................
Throttle Control System Inspection...................................................................................
Engine Vacuum Synchronization Inspection.....................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Inspection..........
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ..........
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Air Suction System Damage Inspection............................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Tire Tread Wear Inspection...............................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Final Drive............................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Wheel Alignment Adjustment............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Wear Inspection ...........................................................................................
Brakes..................................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................
Rocker Arm Operation Inspection.....................................................................................
Tie-Rod Operation Inspection ...........................................................................................
Steering ...............................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................

2-3
2-7
2-12
2-14
2-15
2-15
2-15
2-15
2-19
2-20
2-20
2-21
2-22
2-22
2-22
2-23
2-23
2-24
2-28
2-29
2-29
2-30
2-30
2-30
2-30
2-31
2-32
2-32
2-32
2-33
2-33
2-33
2-34
2-34
2-35
2-35
2-36
2-36
2-36
2-37
2-38
2-39
2-39
2-39
2-39
2-39
2-40
2-40
2-40
2-40

2

2-2 PERIODIC MAINTENANCE
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Headlight Aiming Adjustment............................................................................................
Sidestand Switch Operation Inspection ............................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication .................................................................................................
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
Replacement Parts ..............................................................................................................
Air Cleaner Element Replacement....................................................................................
Fuel Hose Replacement ...................................................................................................
Coolant Change ................................................................................................................
Radiator Hose and O-ring Replacement...........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose Replacement .................................................................................................
Brake Fluid Change ..........................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Spark Plug Replacement ..................................................................................................

2-42
2-43
2-43
2-45
2-45
2-46
2-47
2-48
2-48
2-50
2-51
2-51
2-51
2-53
2-56
2-57
2-57
2-58
2-60
2-61
2-62
2-66

PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection
FREQUENCY Whichever
comes
first
1
ITEM
Fuel System
Throttle control system (play,
smooth return, no drag) - inspect
Engine vacuum synchronization inspect

year

year
year
year

Coolant leak (water hose and
pipe) - inspect

year

Water hose damage - inspect

year

Tire air pressure - inspect

year

12

18

24

30

36


















































2-15



2-21






2-22




year

Tire tread wear, abnormal wear inspect
year

2-15
2-19
2-20
2-20
2-20

2-22
2-22
2-22

2-23

Every 42 000 km (26 250 mile)

Wheel/tire damage - inspect

Wheel bearing damage - inspect





Coolant level - inspect

Water hose installation condition inspect
Engine Top End
US, CA, CAL
Models
Valve clearance Other than
inspect
US, CA, CAL
Models
Air suction system damage inspect
Clutch
Clutch operation (play,
disengagement, engagement) inspect
Wheels and Tires

6

See
Page

Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Idle speed - inspect
Fuel leak (fuel hose and pipe) inspect
Fuel hose and pipe damage inspect
Fuel hose and pipe installation
condition - inspect
Evaporative emission control
system function (CAL), (SEA-B1),
(TH) - inspect
Cooling System

* ODOMETER READING
× 1 000 km
(× 1 000 mile)

2-23







2-28







2-29
















2-30
2-30
2-30
2-31

2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1
ITEM
Final Drive
Drive chain lubrication condition inspect #
Drive chain slack - inspect #

* ODOMETER READING
× 1 000 km
(× 1 000 mile)
6

30

36

2-32

Every 1 000 km (600 mile)

2-32



year
year
year
year
6
months







Brake pad wear - inspect #
Brake light switch operation inspect
Suspension
Front forks/rear shock absorber
operation (damping and smooth
stroke) - inspect
Front forks/rear shock absorber
oil leak - inspect

24

Every 600 km (400 mile)

Drive chain guide wear - inspect

Brake fluid level - inspect

18

Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Drive chain wear - inspect #
Brakes
Brake fluid leak (brake hose and
pipe) - inspect
Brake hose and pipe damage inspect
Brake hose and pipe installation
condition - inspect
Brake operation (effectiveness,
play, no drag) - inspect

12

See
Page



year

Rocker arm operation - inspect
Tie-rods operation - inspect














































2-34









2-35

2-34

2-36
2-36
2-36
2-36
2-37
2-38







2-39













2-39








2-40
















2-43










2-48

2-39
2-40

Steering
Steering play - inspect

year



Steering stem bearings - lubricate 2 years
Electrical System
Lights and switches operation inspect
Headlight aiming - inspect
Sidestand switch operation inspect
Engine stop switch operation inspect
Others
Chassis parts - lubricate
Bolts and nuts tightness - inspect

year
year
year
year

year



2-42

2-45
2-46
2-47

2-50

PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
comes
first

* ODOMETER READING
× 1 000 km
(× 1 000 mile)
1

12

24

36

48

ITEM
Air cleaner element # - replace
Fuel hose - replace

Every (0.6) (7.5) (15) (22.5) (30)
Every 18 000 km (11 250 mile)
5 years

Coolant - change

3 years

Radiator hose and O-ring - replace

3 years

Engine oil # - change

year

Oil filter - replace

year

Brake hose - replace

4 years

Brake fluid - change

2 years

Rubber parts of master cylinder and caliper replace

4 years

Spark plug - replace






















See
Page

2-51
2-51
2-53
2-56








2-57
2-57
2-58
2-60
2-61,
2-62
2-66

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.

Fastener
Fuel System (DFI)
Air Cleaner Duct Clamp Bolts
Delivery PipeAssembly MountingScrews
Throttle Body Assy Holder Clamp Bolts
Upper Air Cleaner Housing Screws
Intake Air Temperature Sensor Screw
Oxygen Sensor (Equipped Models)
Water Temperature Sensor
Exhaust Butterfly Valve Actuator Mounting
Screws
Exhaust Butterfly Valve Actuator Pulley Bolt
Fuel Pump Bolts
Cooling System
Coolant By-pass Fitting Bolt
Coolant Drain Bolt
Radiator (Water) Hose Clamp Screws
Thermostat Housing Bolts
Water Pipe Bolts
Water Pump Cover Bolts
Water Pump Impeller Bolt
Engine Top End
Air Suction Valve Cover Bolts
Camshaft Cap Bolts
Camshaft Chain Tensioner Cap Bolt
Camshaft Chain Tensioner Mounting Bolts
Camshaft Sprocket Bolts
Cylinder Head Bolts (M10) (First)
Cylinder Head Bolts (M10) (Final)
Cylinder Head Bolts (M6)
Cylinder Head Cover Bolts
Front Camshaft Chain Guide Bolt (Lower)

N·m

Torque
kgf·m

ft·lb

2.0
3.43
2.9
1.1
1.2
44
30

0.20
0.35
0.3
0.11
0.12
4.5
3.1

18 in·lb
30 in·lb
26 in·lb
9.7 in·lb
11 in·lb
32
22

1.2

0.12

11 in·lb

5.0
9.8

0.51
1.0

44 in·lb
87 in·lb

8.8
11
2.9
5.9
12
11
9.8

0.90
1.1
0.30
0.60
1.2
1.1
1.0

78 in·lb
97 in·lb
26 in·lb
52 in·lb
106 in·lb
97 in·lb
87 in·lb

L

9.8
12
20
11
15
20
54
12
9.8
12

1.0
1.2
2.0
1.1
1.5
2.0
5.5
1.2
1.0
1.2

87 in·lb
106 in·lb
15
97 in·lb
11
15
40
106 in·lb
87 in·lb
106 in·lb

L
S

Remarks

L

L
L

L
S, MO
S, MO
S
S

2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Front Camshaft Chain Guide Bolt (Upper)
Plugs
Rear Camshaft Chain Guide Bolt
Spark Plugs
Throttle Body Assy Holder Bolts
Upper Camshaft Chain Guide Bolts
Exhaust Butterfly Valve Actuator Bolts
Exhaust Butterfly Valve Actuator Pulley Bolt
Muffler Body Mounting Bolts
Premuffler Chamber Mounting Bolt
Muffler Body Clamp Bolts
Clutch
Clutch Lever Assembly Clamp Bolts
Clutch Spring Bolts
Clutch Cover Bolts
Clutch Hub Nut
Engine Lubrication System
Engine Oil Drain Bolt
Lower Fairing Bracket Bolts
Oil Cooler Bolts
Oil Filler Plug
Oil Filter
Oil Filter Pipe
Oil Pan Bolts
Oil Passage Plug
Oil Pressure Relief Valve
Oil Pressure Switch
Radiator (Water) Hose Clamp Screws
Engine Removal/Installation
Lower Adjusting Collar Locknut
Lower Adjusting Collar
Lower Engine Bracket Bolts
Lower Engine Mounting Nut
Middle Engine Bracket Bolts
Middle Engine Mounting Nut
Upper Adjusting Collar
Upper Adjusting Collar Locknut
Upper Engine Bracket Bolts
Upper Engine Mounting Bolt (L = 40)
Upper Engine Mounting Bolt (L = 65)
Crankshaft/Transmission
Balancer Shaft Clamp Bolt
Balancer Shaft Clamp Lever Bolt

N·m
25
19.6
25
13
12
12
4.3
5.0
34
34
21

Torque
kgf·m
2.5
2.0
2.5
1.3
1.2
1.2
0.44
0.51
3.5
3.5
2.1

ft·lb
18
14
18
115 in·lb
106 in·lb
106 in·lb
38 in·lb
44 in·lb
25
25
15

7.8
8.8
9.8
135

0.80
0.90
1.0
13.8

69 in·lb
78 in·lb
87 in·lb
99.6

29
12
12
2.0
17
25
12
20
15
15
2.9

3.0
1.2
1.2
0.2
1.7
2.5
1.2
2.0
1.5
1.5
0.30

21
106 in·lb
106 in·lb
18 in·lb
13
18
106 in·lb
15
11
11
26 in·lb

49
9.8
59
44
25
44
5.0
49
44
44
44

5.0
1.0
6.0
4.5
2.5
4.5
0.51
5.0
4.5
4.5
4.5

36
87 in·lb
44
32
18
32
44 in·lb
36
32
32
32

S
S
S
S
L, S
S
S
S
S
S
S

9.8
25

1.0
2.5

87 in·lb
18

L

Remarks

L

L

S

R

G, R
L
S
L
L
SS

PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Breather Side Plate Bolt
Connecting Rod Big End Nuts
Breather Plate Bolts
Shift Drum Bearing Holder Bolts
Oil Passage Plugs
Oil Passage Plug
Starter Motor Clutch Bolts
Crankcase Bolts (M7)
Crankcase Bolts (M9)
Crankcase Bolts (M6)
Crankcase Bolts (M8)
Gear Positioning Lever Bolt
Neutral Switch
Shift Drum Cam Bolt
Shift Pedal Mounting Bolt
Shift Shaft Return Spring Pin
Wheels/Tires
Front Axle
Front Axle Clamp Bolt
Rear Axle Nut
Final Drive
Chain Adjuster Clamp Bolts
Drive Chain Guide Bolts
Engine Sprocket Nut
Rear Sprocket Nults
Speed Sensor Mounting Bolt
Brakes
Bleed Valves
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Pad Pins
Front Brake Reservoir Bolt
Front Brake Reservoir Screw
Front Caliper Assembly Bolts
Front Caliper Mounting Bolts
Front Master Cylinder Bleed Valve
Front Master Cylinder Clamp Bolts
Front Master Cylinder Reservoir Cap Screws
Brake Pedal Bolt
Brake Pipe Joint Nuts (ABS Equipped Models)

Torque
N·m
kgf·m
5.9
0.60
see the text

9.8
1.0
12
1.2
20
2.0
9.8
1.0
12
1.2
20
2.0
42
4.2
12
1.2
27
2.8
12
1.2
15
1.5
12
1.2
25
2.5
39
4.0

ft·lb
52 in·lb

87 in·lb
106 in·lb
15
87 in·lb
106 in·lb
15
31
106 in·lb
20
106 in·lb
11
106 in·lb
18
29

108
20
98

11.0
2.0
10

79.7
15
72

64
9.8
125
59
6.9

6.5
1.0
12.7
6.0
0.70

47
87 in·lb
92.2
44
61 in·lb

7.8
25
1.0
5.9
27
1.2
15
7.8
1.2
22
34
7.8
11
1.5
8.8
18

0.80
2.5
0.10
0.60
2.8
0.12
1.5
0.80
0.12
2.2
3.5
0.80
1.1
0.15
0.90
1.8

69 in·lb
18
8.8 in·lb
52 in·lb
20
11 in·lb
11
69 in·lb
11 in·lb
16
25
69 in·lb
97 in·lb
13 in·lb
78 in·lb
13

Remarks

MO
L
L
L
L
S
S, MO
S
S

L
L

MO
L

Si
L

L
L

S
L

2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut
Suspension
Front Fork Bottom Allen Bolts
Front Fork Top Plugs
Lower Front Fork Clamp Bolts
Piston Rod Nuts
Upper Front Fork Clamp Bolts
Rear Shock Absorber Nut (Lower)
Rear Shock Absorber Bolt (Upper)
Swingarm Pivot Shaft
Swingarm Pivot Adjusting Collar Locknut
Swingarm Pivot Shaft Nut
Tie-rod Nuts
Torque Link Nuts
Rocker Arm Nut
Steering
Handlebar Holder Bolts
Handlebar Holder Nuts
Left Switch Housing Screws
Right Switch Housing Screws
Steering Stem Head Bolt
Steering Stem Nut
Frame
Center Fairing Assembly Screws
Front Fender Assembly Screws
Front Fender Mounting Bolts
Rear View Mirror (Lower Hexagonal Area)
Rear View Mirror (Upper Hexagonal Area)
Front Footpeg Bracket Bolts
Rear Footpeg Bracket Bolts
Rear Frame Bolts
Rear Frame Joint Bracket Bolts
Sidestand Bolt
Sidestand Locknut
Sidestand Bracket Bolts
Sidestand Switch Bolt
Electrical System
Front Brake Light Switch Screw
Front Turn Signal Light Mounting Screws
Licence Plate Light Mounting Screws

N·m
27
25
25
17

Torque
kgf·m
2.8
2.5
2.5
1.7

ft·lb
20
18
18
12

35
34
25
20
20
34
34
20
98
108
34
34
34

3.6
3.5
2.5
2.0
2.0
3.5
3.5
2.0
10
11.0
3.5
3.5
3.5

26
25
18
15
15
25
25
15
72
79.7
25
25
25

25
34
3.5
3.5
108
25

2.5
3.5
0.36
0.36
11.0
2.5

18
25
31 in·lb
31 in·lb
79.7
18

1.2
1.2
3.9
30
18
25
25
25
44
44
29
49
8.8

0.12
0.12
0.40
3.1
1.8
2.5
2.5
2.5
4.5
4.5
3.0
5.0
0.90

11 in·lb
11 in·lb
35 in·lb
22
13
18
18
18
32
32
21
36
78 in·lb

1.2
1.2
1.2

0.12
0.12
0.12

11 in·lb
11 in·lb
11 in·lb

Remarks
L

AL

R

R
R

R

L
S
R, S
L
L

PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
Fastener
Meter Unit Mounting Screws
Oxygen Sensor (Equipped Models)
Switch Housing Screws
Alternator Cover Bolts (Engine No. ∼
ZRT00DE013356)
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
Alternator Rotor Bolt
Brush Holder Screw
Crankshaft Sensor Bolts
Crankshaft Sensor Cover Bolts (Engine No. ∼
ZRT00DE013356)
Crankshaft Sensor Cover Bolts
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Spark Plugs
Starter Motor Through Bolts
Starter Motor Cable Terminal Nut
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Stator Coil Bolts
Timing Rotor Bolt
Water Temperature Sensor
Engine Ground Cable Terminal Bolt
Neutral Switch
Sidestand Switch Bolt
Speed Sensor Mounting Bolt

N·m
1.2
44
3.5

Torque
kgf·m
0.12
4.5
0.36

ft·lb
11 in·lb
32
31 in·lb

9.8

1.0

87 in·lb

12
12
155
3.8
5.9

1.2
1.2
15.8
0.39
0.60

106 in·lb
106 in·lb
114
34 in·lb
52 in·lb

9.8

1.0

87 in·lb

12
15
2.0
13
4.9
5.9
9.8
11
12
39
30
9.8
15
8.8
6.9

1.2
1.5
0.20
1.3
0.50
0.60
1.0
1.1
1.2
4.0
3.1
1.0
1.5
0.90
0.70

106 in·lb
11
18 in·lb
115 in·lb
43 in·lb
52 in·lb
87 in·lb
97 in·lb
106 in·lb
29
22
87 in·lb
11
78 in·lb
61 in·lb

Remarks

L

SS
G

L

L
L

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners
Threads Diameter
(mm)
5
6
8
10
12
14
16
18
20

N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼ 19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325

Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼ 1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23.0 ∼ 33.0

ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240

2-12 PERIODIC MAINTENANCE
Specifications
Item
Fuel System (DFI)
Throttle Grip Free Play
Idle Speed
Bypass Screws (Turn Out)
Throttle Body Vacuum
Air Cleaner Element
Cooling System
Coolant:
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Engine Top End
Valve Clearance:
Exhaust
Intake
Clutch
Clutch Lever Free Play
Engine Lubrication System
Engine Oil:
Type
Viscosity
Capacity

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 100 ±50 r/min (rpm)
2 1/2 (for reference)
40.7 ±1.3 kPa (305 ±10 mmHg) at idle
speed
Viscous paper element

– – –
– – –
– – –

Permanent type of antifreeze
Green
Soft water 50%, Coolant 50%
–35°C (–31°F)
2.9 L (3.1 US qt)







0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

– – –
– – –

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

– – –

API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
SAE 10W-40
3.2 L (3.4 US qt) (when filter is not
removed)
3.8 L (4.0 US qt) (when filter is removed)
4.0 L (4.2 US qt) (when engine is
completely dry)

– – –

– – –
– – –













– – –
– – –
– – –
– – –

Wheels/Tires
Tread Depth:
Front:
ZR1000D
ZR1000E

4.0 mm (0.16 in.)
3.8 mm (0.15 in.)

1 mm (0.04 in.),
(AT, CH, DE)
1.6 mm (0.06 in.)

Rear:
ZR1000D
ZR1000E

5.5 mm (0.22 in.)
5.4 mm (0.21 in.)

Up to 130 km/h (80 mph):
2 mm (0.08 in.),
Over 130 km/h (80 mph):
3 mm (0.12 in.)

Air Pressure (when Cold):
Front
Rear

Up to 180 kg (397 lb) load:
250 kPa (2.5 kgf/cm², 36 psi)
Up to 180 kg (397 lb) load:
290 kPa (2.9 kgf/cm², 42 psi)

– – –
– – –

PERIODIC MAINTENANCE 2-13
Specifications
Item
Final Drive
Drive Chain Slack
Drive Chain Wear (20-link
Length)
Standard Chain:
Make
Type
Link
Brakes
Brake Fluid:
Grade
Brake Pad Lining
Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug:
Type

Standard
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit
– – –
319 mm (12.56 in.)

ENUMA
EK525ZX
112 Links

– – –
– – –
– – –

DOT4

– – –

4.0 mm (0.16 in.)
5.0 mm (0.20 in.)

1 mm (0.04 in.)
1 mm (0.04 in.)

Pulled ON
ON after about 10 mm (0.39 in.) of
pedal travel

– – –

NGK CR9EIA-9

– – –

– – –

2-14 PERIODIC MAINTENANCE
Special Tools
Inside Circlip Pliers:
57001-143

Spark Plug Wrench, Hex 16:
57001-1262

Steering Stem Nut Wrench:
57001-1100

Vacuum Gauge:
57001-1369

Jack:
57001-1238

Throttle Sensor Setting Adapter:
57001-1538

Oil Filter Wrench:
57001-1249

Fuel Hose:
57001-1607

Attachment Jack:
57001-1252

Jack Attachment:
57001-1608

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