User manual KAWASAKI NINJA ZX-12R

[. . . ] Ninja ZX-12R 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 Troubleshooting 17 j Ninja ZX-12R 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 Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] When the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. Check the seat after each turn. · CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. After making the 32° grind, return to the seat O. D. To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat O. D. measurement step above. ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° or 55° angle until the seat width is within the specified range. To make the 60° or 55° grind, fit 60° or 55° cutter into the holder, and slide it into the valve guide. After making the 60° or 55° grind, return to the seat width measurement step above. Correct Width [B] · the valve to the the seat · Lap within the rangesseat, onceabove. are specified Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. Lapper [A] Valve Seat [B] Valve [C] The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment section of Periodic Maintenance chapter). · · · 5-28 ENGINE TOP END Valves ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal · Remove: Head (see Cylinder Head Removal) Cylinder · Cooling Hoses [A] Oil Pipe [B] Remove the cylinder [C]. Cylinder Installation If a new cylinder is used, use new piston rings. If new pistons and/or a new cylinder are installed, apply NOTE thin coat of molybdenum disulfide grease to the new pistons and cylinder bores. the cylinder gasket · Replace [A] and new cylinderwith a new one, and install the pins gasket. Apply molybdenum disulfide oil solution to the cylinder · bore, external of pistons and piston rings. The openings of thebe positionedrailsshownbe the oil ring steel must about 30 40° of angle from the opening of the top ring. [. . . ] Leave the fuel reserve switch with leads for inspection connected for one (1) minute. ELECTRICAL SYSTEM 16-95 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection · Remove: Cover (see Fuel System (DFI) chapter) Fuel Tank · · Rubber Cover Connectors Junction Box Make sure all connector terminals are clean and tight, and none of them have been bent. Clean the dirty terminals, and straighten slightly­bent terminals. If the tester does not read as specified, replace the junction box. Fuse Circuit Inspection Tester Connection 1 - 1A 1-2 3A - 4 6-5 6 - 10 6-7 6 - 17 Tester Reading () 0 0 0 0 0 0 0 Tester Connection 1A - 8 2-8 3A - 8 6-2 6 - 3A 17 - 3A Tester Reading () Starter Circuit/Headlight Relay Inspection · Remove the junctionofbox. [. . . ]