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2008 Kawasaki Ninja Zx10r Zx-10r Zx1000 Service Repair Manual

2008 Kawasaki Ninja Zx10r Zx-10r Zx1000 Service Repair Manual pdf download

Kawasaki Ninja ZX10 ZX10R ZX1000 ZX-10R

Kawasaki Ninja ZX10 ZX10R ZX1000 ZX-10R(The picture only for reference)

Manual covers 

tables

LIST OF ABBREVIATIONS

COUNTRY AND AREA CODES

Periodic Inspection

Periodic Replacement Parts

Basic Torque for General Fasteners

Throttle Grip Free Play

Idle Speed

Throttle Body Vacuum

Main Throttle Sensor Output Voltage

Idle Speed

Valve Clearance

Example (Exhaust):

Adjustment Shims

Clutch Lever Free Play

Air Pressure (when Cold)

Tread Depth

Chain Slack

Drive Chain 20-link Length

Standard Chain

Recommended Disc Brake Fluid

Pad Lining Thickness

Sidestand Switch Operation

Water and Coolant Mixture Ratio (Recommended)

Recommended Engine Oil

Standard Spark Plug

Sample Diagnosis Sheet

Engine Won’t Turn Over

Poor Running at Low Speed

Poor Running or No Power at High Speed:

Main Throttle Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Main Throttle Sensor Output Voltage

Idle Speed

Output Voltage

Wiring Continuity Inspection

Main Throttle Sensor Resistance

Inlet Air Pressure Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Inlet Air Pressure Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Inlet Air Pressure Sensor Output Voltage

Inlet Air Temperature Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Inlet Air Temperature Sensor Resistance

Water Temperature Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Atmospheric Pressure Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Atmospheric Pressure Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Wiring Continuity Inspection

Wiring Continuity Inspection

Speed Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Speed Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Gear Position Switch Output Voltage

Output Voltage at 1 ∼ 6 Gear Positions

Vehicle-down Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Vehicle-down Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Subthrottle Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Subthrottle Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Subthrottle Sensor Resistance

Oxygen Sensor ##1 Output Voltage

Output Voltage (with Plugs)

Output Voltage (without Plugs)

Wiring Continuity Inspection

Exhaust Butterfly Valve Actuator Sensor Input Voltage

Input Voltage

Wiring Continuity Inspection

Exhaust Butterfly Valve Actuator Sensor Output Voltage

Output Voltage

Wiring Continuity Inspection

Exhaust Butterfly Valve Actuator Sensor Resistance

Antenna Resistance

Amplifier Input Voltage

Wiring Continuity Inspection

Stick Coil Input Voltage

Input Voltage

Subthrottle Valve Actuator Resistance

Subthrottle Valve Actuator Input Voltage

Input Voltage

Wiring Continuity Inspection

Exhaust Butterfly Valve Actuator Resistance

Wiring Continuity Inspection

Oxygen Sensor Heater ##1 and ##2 Resistance

Oxygen Sensor Heater ##1 and ##2 Power Source Voltage

Power Source Voltage

Wiring Continuity Inspection

Oxygen Sensor ##2 Output Voltage

Output Voltage (with Plugs)

Output Voltage (without Plugs)

Wiring Continuity Inspection

ECU Identification

ECU Grounding Inspection

ECU Power Supply Inspection

Fuel Pressure (with Engine Idling)

Amount of Fuel Flow

Fuel Pump Operating Voltage

Operating Voltage

Primary Fuel Injector Resistance

Secondary Fuel Injector Resistance

Primary Fuel Injector Power Source Voltage

Power Source Voltage

Secondary Fuel Injector Power Source Voltage

Power Source Voltage

Primary Fuel Injector Output Voltage [C]

Secondary Fuel Injector Output Voltage [D]

Output Voltage

Wiring Continuity Inspection (Primary Fuel Injectors)

Wiring Continuity Inspection (Secondary Fuel Injectors)

Injector Fuel Line Maximum Pressure

Radiator Cap Relief Pressure

Thermostat Valve Opening Temperature

Camshaft Journal/Camshaft Cap Clearance

Camshaft Journal Diameter

Camshaft Runout

Cam Height

Cylinder Compression

Cylinder Head Warp

Valve/Valve Guide Clearance (Wobble Method)

Valve Seating Surface Outside Diameter

Valve Seating Surface Width

Spring Plate Free Play

Spring Plate Free Play

Clutch Plate Assembly Length (Reference)

Friction Plate Thickness

Friction and Steel Plate Warp

Clutch Spring Free Length

Oil Pressure

Connecting Rod Big End Bearing Insert Selection

Crankshaft Main Bearing Insert Selection

Connecting Rod Bolt Stretch

Connecting Rod Bend

Connecting Rod Twist

Connecting Rod Big End Side Clearance

Connecting Rod Big End Bearing Insert/Crankpin Clearance

Crankpin Diameter

Crankpin Diameter Marks

Connecting Rod Big End Inside Diameter Marks

Crankshaft Side Clearance

Crankshaft ##3 Main Journal Width

Crankshaft Runout

Crankshaft Main Bearing Insert/Journal Clearance

Crankshaft Main Journal Diameter

Crankshaft Main Journal Diameter Marks

Crankcase Main Bearing Inside Diameter Marks

Cylinder Inside Diameter

Piston Diameter

Piston Ring/Groove Clearance

Piston Ring Groove Width

Piston Ring Thickness

Piston Ring End Gap

Shift Fork Ear Thickness

Gear Groove Width

Shift Fork Guide Pin Diameter

Shift Drum Groove Width

Rim Runout (with tire installed)

Axle Runout/100 mm (3.94 in.)

Balance Weight

Link Pin Outside Diameter

Link Plates Outside Width

Rear Sprocket Warp

Pedal Position

Brake Discs Thickness

Disc Runout

Rebound Damping Force Adjustment

Compression Damping Force Adjustment

Adjuster Protrusion (from the top plug nut surface)

Spring Action

Fork Oil

Oil Level (fully compressed, without spring)

Spring Free Length

Rebound Damping Force Adjustment

High Speed Compression Damping Force Adjustment

Low Speed Damping Force Adjustment

Spring Preload Setting

Spring Adjustment

Damping Force Adjustment

Kawasaki-recommended chargers:

Battery Terminal Voltage

Terminal Voltage: 11.5 ∼ less than 12.8 V

Terminal Voltage: less than 11.5 V

Table 1 Alternator Output Voltage

Table 2 Stator Coil Resistance at 20°C (68°F)

Regulator/Rectifier Resistance (Unit: kΩ)

Charging Voltage

Crankshaft Sensor Resistance

Connections:

Crankshaft Sensor Peak Voltage

Camshaft Position Sensor Resistance

Connections:

Camshaft Position Sensor Peak Voltage

Stick Coil Winding Resistance

Connections:

Stick Coil Primary Peak Voltage

Standard Spark Plug:

Condition:

Condition:

Condition:

Starter Motor Brush Length

Commutator Diameter

Testing Relay

Testing Turn Signal Relay

Air Switching Valve Resistance

User Key Indicator Light and Symbol Flashes

Water Temperature Sensor

Connections:

Connections:

Gear Position Switch Resistance (Unit: kΩ)

Relay Circuit Inspection (with the battery disconnected)

Relay Circuit Inspection (with the battery connected)

Diode Circuit Inspection

toc

EMISSION CONTROL INFORMATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Foreword

General Information

Before starting to perform an inspection service or carry out a

Battery Ground

Edges of Parts

Solvent

Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

Instrument

ZX1000E8F (US and CA Models) Left Side View

ZX1000E8F (US and CA Models) Right Side View

ZX1000E8F (EUR Models) Left Side View

ZX1000E8F (EUR Models) Right Side View

Frame Number

Engine Number

Overview

Prefixes for Units:

Units of Temperature:

Periodic Maintenance

The scheduled maintenance must be done in accordance with this c

The following tables list the tightening torque for the major fa

Inside Circlip Pliers:

Fuel System (DFI)

Throttle Control System Inspection

Engine Vacuum Synchronization Inspection

Special Tool –

Special Tool –

Special Tool –

Special Tool –

Idle Speed Inspection

Idle Speed Adjustment

Fuel Hose Inspection (fuel leak, damage, installation condition)

Evaporative Emission Control System Inspection (CAL and SEA Mode

Cooling System

Coolant Level Inspection

Radiator Hose and Pipe Inspection (coolant leak, damage, install

Torque –

Engine Top End

Valve Clearance Inspection

Valve Clearance Adjustment

Air Suction System Damage Inspection

Special Tool –

Clutch

Clutch Operation Inspection

Wheels/Tires

Tire Air Pressure Inspection

Wheel/Tire Damage Inspection

Tire Tread Wear Inspection

Wheel Bearing Damage Inspection

Special Tool –

Final Drive

Drive Chain Lubrication Condition Inspection

Drive Chain Slack Inspection

Drive Chain Slack Adjustment

Torque –

Wheel Alignment Inspection

Drive Chain Wear Inspection

Chain Guide Wear Inspection

Brake

Brake Fluid Leak (Brake Hose and Pipe) Inspection

Brake Hose Damage and Installation Condition Inspection

Torque –

Brake Operation Inspection

Brake Fluid Level Inspection

Torque –

Brake Pad Wear Inspection

Brake Light Switch Operation Inspection

Suspensions

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

Special Tools –

Steering Play Adjustment

Special Tool –

Torque –

Torque –

Steering Stem Bearing Lubrication

Steering Damper Oil Leak Inspection

Electrical System

Lights and Switches Operation Inspection

Headlight Aiming Inspection

Sidestand Switch Operation Inspection

Engine Stop Switch Operation Inspection

Others

Chassis Parts Lubrication

Pivots: Lubricate with Grease.

Points: Lubricate with Grease.

Cables: Lubricate with Rust Inhibitor

Bolts, Nuts and Fasteners Tightness Inspection

Bolt, Nut and Fastener to be checked

Replacement Parts

Air Cleaner Element Replacement

Fuel Hose Replacement

Coolant Change

Torque –

Torque –

Radiator Hose and O-ring Replacement

Torque –

Engine Oil Change

Torque –

Torque –

Oil Filter Replacement

Special Tool –

Special Tool –

Torque –

Brake Hose and Pipe Replacement

Torque –

Brake Fluid Change

Torque –

Torque –

Master Cylinder Rubber Parts Replacement

Special Tool –

Special Tool –

Torque –

Torque –

Caliper Rubber Parts Replacement

Torque –

Torque –

Torque –

Spark Plug Replacement

Torque –

Fuel System (DFI)

DFI System

DFI System Wiring Diagram

Terminal Numbers of ECU Connectors

Main Throttle Sensor [A]

Oil Pressure Gauge, 5 kgf/cm :

DFI Servicing Precautions

Torque –

The warning indicator light (LED) [A] is used for the FI indicat

Outline

Special Tool –

Sealant –

Special Tool –

DFI Diagnosis Flow Chart

Inquiries to Rider

NOTE

The warning indicator light (LED) [A] is used for the FI indicat

Self-diagnosis Outline

Self-diagnosis Procedures

Self-Diagnosis Flow Chart

Service Code Reading

Service Code Erasing

Backups

The main throttle sensor is a rotating variable resistor that ch

Main Throttle Sensor Removal/Adjustment

Main Throttle Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Main Throttle Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Main Throttle Sensor Resistance Inspection

Main Throttle Sensor Circuit

Inlet Air Pressure Sensor Removal

Inlet Air Pressure Sensor Installation

Inlet Air Pressure Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Inlet Air Pressure Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Special Tools –

Inlet Air Pressure Sensor Circuit

Inlet Air Temperature Sensor Removal/Installation

Torque –

Inlet Air Temperature Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Inlet Air Temperature Sensor Resistance Inspection

Inlet Air Temperature Sensor Circuit

Water Temperature Sensor Removal/Installation

Torque –

Water Temperature Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Water Temperature Sensor Resistance Inspection

Water Temperature Sensor Circuit

Atmospheric Pressure Sensor Removal

Atmospheric Pressure Sensor Installation

Atmospheric Pressure Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Atmospheric Pressure Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Atmospheric Pressure/Altitude Relationship

Atmospheric Pressure Sensor Circuit

The crankshaft sensor has no power source, and when the engine s

Crankshaft Sensor Removal/Installation

Crankshaft Sensor Resistance Inspection

Crankshaft Sensor Peak Voltage Inspection

Special Tool –

Crankshaft Sensor Circuit

The camshaft position sensor detects the position of the camshaf

Camshaft Position Sensor Removal/Installation

Camshaft Position Sensor Resistance Inspection

Camshaft Position Sensor Peak Voltage Inspection

Special Tool –

Camshaft Position Sensor Circuit

Speed Sensor Removal/Installation

Speed Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Speed Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Speed Sensor Circuit

Gear Position Switch Removal/Installation

Gear Position Switch Resistance Inspection

Gear Position Switch Output Voltage Inspection

Special Tool –

Special Tool –

Gear Position Switch Circuit

This sensor has a weight [A] with two magnets inside, and sends

Vehicle-down Sensor Removal

Vehicle-down Sensor Installation

Torque –

Vehicle-down Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Vehicle-down Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Vehicle-down Sensor Circuit

The subthrottle sensor is a rotating variable resistor that chan

Subthrottle Sensor Removal/Adjustment

Subthrottle Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Subthrottle Sensor Output Voltage Inspection

Special Tool –

Special Tool –

Subthrottle Sensor Resistance Inspection

Subthrottle Sensor Circuit

Oxygen Sensor ##1 Removal/Installation

Oxygen Sensor ##1 Inspection

Special Tool –

Special Tool –

Special Tool –

Oxygen Sensor Circuit

Exhaust Butterfly Valve Actuator Sensor Removal/Installation

Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection

Special Tool –

Special Tool –

Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio

Special Tool –

Special Tool –

Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

Exhaust Butterfly Valve Actuator Sensor Circuit

Antenna Resistance Inspection

Amplifier Input Voltage Inspection

Special Tool –

Special Tool –

Special Tool –

User Key Inspection

Immobilizer System Circuit

ECU Communication Line Inspection

Special Tool –

ECU Communication Line Circuit

Fuel Pump Relay Removal/Installation

Fuel Pump Relay Inspection

Special Tool –

Fuel Pump Relay Circuit

Stick Coil ##1: Service Code 51

Stick Coil Removal/Installation

Stick Coil Primary Winding Resistance Inspection

Stick Coil Input Voltage Inspection

Special Tool –

Special Tool –

Stick Coil Circuit

Radiator Fan Relay Removal/Installation

Radiator Fan Relay Inspection

Special Tool –

Radiator Fan Relay Circuit

Subthrottle Valve Actuator Removal

Subthrottle Valve Actuator Inspection

Subthrottle Valve Actuator Resistance Inspection

Subthrottle Valve Actuator Input Voltage Inspection

Special Tool –

Special Tool –

Special Tool –

Subthrottle Valve Actuator Circuit

Exhaust Butterfly Valve Actuator Removal

Exhaust Butterfly Valve Actuator Installation

Torque –

Torque –

Exhaust Butterfly Valve Actuator Inspection

Exhaust Butterfly Valve Actuator Resistance Inspection

Special Tool –

Special Tool –

Exhaust Butterfly Valve Actuator Circuit

Air Switching Valve Removal/Installation

Air Switching Valve Inspection

Special Tool –

Air Switching Valve Circuit

Oxygen Sensor Heater Removal/Installation

Oxygen Sensor Heater Resistance Inspection

Oxygen Sensor Heater Power Source Voltage Inspection

Special Tool –

Special Tool –

Oxygen Sensor Circuit

Oxygen Sensor ##2 Removal/Installation

Oxygen Sensor ##2 Inspection

Special Tool –

Special Tool –

Special Tool –

Oxygen Sensor Circuit

Light (LED) Inspection

Warning Indicator Light (LED) (FI/Immobilizer) Circuit

ECU Identification

ECU Removal

ECU Installation

ECU Power Supply Inspection

Special Tool –

Special Tool –

ECU Power Source Circuit

ECU Fuse Removal

ECU Fuse Installation

ECU Fuse Inspection

ECU Main Relay Removal/Installation

ECU Main Relay Inspection

Fuel Pressure Inspection

Special Tools –

Fuel Flow Rate Inspection

Special Tool –

Fuel Pump Removal

Fuel Pump Installation

Torque –

Fuel Pump Operation Inspection

Fuel Pump Operating Voltage Inspection

Special Tool –

Special Tool –

Pressure Regulator Removal

Fuel Filter Cleaning

Fuel Pump Circuit

Primary Fuel Injector Removal/Installation

Secondary Fuel Injector Removal/Installation

Fuel Injector Audible Inspection

Special Tool –

Fuel Injector Resistance Inspection

Fuel Injector Power Source Voltage Inspection

Special Tool –

Special Tool –

Special Tool –

Special Tool –

Fuel Injector Output Voltage Inspection

Special Tool –

Special Tool –

Fuel Injector Fuel Line Inspection

Fuel Injector Circuit

Free Play Inspection

Free Play Adjustment

Cable Installation

Cable Lubrication

Idle Speed Inspection/Adjustment

Synchronization Inspection/Adjustment

Throttle Body Assy Removal

Throttle Body Assy Installation

Torque –

Throttle Body Assy Disassembly

Throttle Body Assy Assembly

Torque –

and more

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