Kawasaki ZZ-R1100
Motorcycle
Service Manual Quick Reference Guide
General Information 1
Fuel System 2
Cooling System 3
Engine Top End [4
Clutch 5
Engine Lubrication System 6
Engine Removal/installation 7
Crankshaft/Transmission 8
Wheels/Tires 9
Final Drive 10
Brakes 11
Suspension 12
Steering 13
Frame [14
Electrical System 15
Thia quick reference guido wil ssiet you in Appendix 16
tere he pages back oath he Back tab Supplement — 1999 - 2001 Models | 17
of the desired chapter number with the
black tab on the edge at each table of
contents page.
‘eRefer to the sectional table of contents for
Ine exact pages to locate the specific topic.
required. LIST OF ABBREVIATIONS.
A ‘ampere(s) Ib pound(s)
ABDC _ | after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC | after top dead center N newton(s)
BBDC — | bofore bottom dead center Pa pascal(s)
BDC bottom dead cenier PS. horsepower
BTDC | before top dead center psi pound(s) per square inch
6. degroo(s) Colsius ' revolution
pc direct current rpm revolution(s) por minute
F farad(s) TDC top dead center
Fs degree(a) Fahrenheit TR total indicator reading
ft oot, feet v volt(s)
‘orar(s) w watt(s)
h hour(s) o ohms)
liter(s)
This warning may apply to any of the following
components or any aseombly containing one oF
more of these components:
Brake Shoes or Pads
CCluten Friction Material
Gaskets
Insulators
WARNING.
‘CONTAINS SAFETY INSTRUCTIONS
ASBESTOS
ecg Raa eOperate if possible out of doors or in a well
‘Sensor ventilated place
ve heath ePreferably use hand tools or low speed tools
‘equipped, if necessary. with an appropriate dust
extraction facility. If high speed tools are used,
they should slays be so equipped
if possible, dampen before cutting or driling.
@Dampen dust and place it in properly closed
receptacte and dispose of it sately.
Fotow stew
Read OWNER’S MANUAL before operating. 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 reaulations of the
United Statos Environmental Protection Agency and California Air Rosourcos 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
vopors are routed through an oil separator to the intake side of the engine. While the engine
Js operating, the vapors are drawn into combustion chamber, where they are burned along
with the fuel and air supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharaed into the atmosphere by the exhaust
of this motorcycle, The fual and ignition systems of this motorcycle have beon carsfully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere
Instead, fuel vapors ate routed into the running engine to be burned, or stored in a canister
when the engine is stopped. Liquid fuel is cought by a vapor separator and returned to tho
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 tile 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 purchasor.
(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 reulations under this,
title following its sale and delivery to the ultimate purchaser..."
(Continued on next page.) NOTE
© The phrase "remove or render inoperative any device or element of design” has been
generally interpreted as follows:
7. Tampering does net inclide the temporary removal or rendering inoperative of
devices or elements of design in order to perform maintenance.
2. Tampering could include:
a. Meladjustment 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
5 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 8Y CIVIL PENALTIES NOT
EXCEEDING $10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law probibits the following acts or tho causing thereof; (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repeit, or replacement, of any
device or oloment of design incorporated into any new vehicle for the purpose of noise control prior
{0 its sale or delivery to the ultimate purchaser of whila itis in use, or (2) the use of the vehicle after
such device or element of design hes been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
‘e Replacement of the original exhaust system of muffler with a component not in compliance with
Federal regulations.
‘Removal of the muffler(s) or any internal portion of the mufiler(s).
‘@ Removal of the air Dox 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 8 properly equipped shop.
However, it contains enough detail and basic
information to make it useful to the owner who
desires 10 perform his own basic maintenance and
repair work. A basic knowledge of mechanics, the
proper use of tools, and workshop procedures must
bbe understood in order to cary out maintenance and
repair satisfactorily. Whenever the owner has
insufficient experience or doubts his ability to do the
work, ell adjustments, maintenence, 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 tho 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 substi-
tute tools may adversely afiect safe operation,
For the duration of the warranty period,
we recommend that all repaits and scheduled
maintenance be performed in accordance with this
service manual. Any owner maintenance or repait
Procedure not performed in accordance with this
manual may void the warranty.
To get the longest lite out of your motorcycle.
Follow the Periodic Maintenance Chart in the
Service Manual
‘@8e alert for problems and non-scheduled mainte-
nance.
@Uso propor tools and genuine Kawasaki Motorcy:
cle parts, Special too’s, gauges, and testers that
‘are necessary when servicing Kawasaki motorcy-
cles are introduced by the Special Too! 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 keop complete records of mainte
ance and repair with dates and any new pars
installed.
How to Use This Manual
In prepering this manual, we divided the product
imto its major systems. These systems became the
manual's chapters. All information for a particular
system from edjustment through disassembly and
inspection is located in a single chapter.
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 compre-
hensive Table of Contents.
The Periodic Maintenance Chart is located in the
General Information chapter. The chart gives a time
schedule for roquired maintonance operations.
If you want spark plug information, for example,
90 to the Periodic Maintenance Chart first. The chart
tolls you how frequently to cloan and gap the plug.
Next, 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
‘Spark Plug section,
Whenever you seo these WARNING and
CAUTION symbols, heed their instructions! Always
follow safe operating and maintenance practices.
AAWARNING
This warning symbol identifies special
instructions or procedures which. if not
correctly followed, could result in personal
injury, or loss of life.
‘CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to
or destruction of equipment. This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
© This note symbol indicates points of partic
ular interest for more efficient and convenient
operation.
‘@lndicates a procacural step or work to be cone.
COlndicates a procedural sub-step or how ta do the
work of the procedural step it follows. It also
precedes the text of a NOTE.
4tIndicates 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
uring assembly. GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing.
Modol Identification
General Specifications
Periodic Maintenance Chart
Torque and Locking Agent
Special Tools and Sealart ....
Cable, Wire, and Hose Routing 1-2_GENERAL INFORMATION
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate
unnecessary work, Photographs, diagrams, notes, cautions. warnings. and detailed descriotions have been
included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic
knowledge is also required for successful work.
Especially note the following:
(1) Din
Bofore removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will
work 25 an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new
part, ciean off any dust or metal flings.
(2) Battory Ground
Remove the ground (-) lead from the bettery before performing any disassembly operations on the
motorcycle. This prevents:
(a) the possibilty of accidentally turning the engine aver while partially disassembled.
(b) sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tightening Sequence
Generally, when installing @ part with several bolts, nuts, or screws, start thom all in their holes and
tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avold distortion of the
pert and/or causing gas or oil leakage. Conversely when loosening the bolts. nuts, or sorews, fist loosen
all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication
in this Service Manual, the bolts, nuts, or screws must be tightened in the order and methad indicated.
(4) Torque
‘When torque values are given in this Service Manual, use them. Either ta0 litle or too much torque may
lead to serious damage. Use a good quailty, reliable torque wrench,
(5) Force
Common sense should dictate how much force is necessary in assembly and disessembly. If « part seems
especially difficult to remove or install, siop and examine what may be causing the probiem. Whenever
topping is necessary, tap lightly using a woaden or plestic-faced mallet. Use an impact driver for screws
(particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads.
(6) Edges
Wotch for sharp edges, especially during major engine disassembly and assembly. Protect your hands
with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash Point Solvent
'A hiigh-flash point solvent ie recommended to reduce fire danger. A commercial solvent commonly
available in North America is Stoddard solvent (generic name). Always follow manufscturer and container
directions regarding the use of any solvent.
(8) Gasket, O-Ring
‘Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket
should be free of foreign matter and perfectly smocth to avoid oil or compression leaks.
(8) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be
used. Apply sparingly. Excessive amounts may block engine oil pessages and cause serious damage. An
example of a non-permanent locking agont commonly available in North America is Loctite Lock'n Seal
(Blue)
(10) Press:
‘A patt installed using @ press or driver, such as a wheel bearing, should first be coated with oil on its outer
‘inner circumference so that it will go into place smoothly.
(11) Ball Bearing and Neadle Beating
Do not remove any ball ot needle bearings that ore pressed in unless it is necessary. Ifthey are removed.
replace them with new ones.
‘When installing a bearing. press it in with the marked side facing out using a suitable driver until it is
botiomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by
friction. GENERAL INFORMATION 1-3
(12) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals
should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the
face of the seal is even with the end of the hole
(13) Seal Guide
A seal guide is required for certain oll or grease seals during installation to evoid damage to the see! lips.
Before a shaft passes through @ seal, apply a litte high temperature grease on the lips to reduce rubber 10
metal friction.
(14) Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, es removal weakens and
deforms them. When installing circlips and retaining rings, take care to compress or expand them only
enough to install them and no more.
(18) Cotter Pin
Roplace any cotter pins that were removed with new ones, as removal deforms and breaks them.
(10) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing
surfaces have an adequate lubricate film. During assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing surface which has lost its ubricatve fim. Old grease and dicy oii should
be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.
Don't use just any oil or grease. Some oils and greases in particular should be used only in carain
applications and may be harmful if used in an epplication for which they are not intended. This manual
makes reference to molybdenum disulfide grease (MoS: ) in the assembly of certain engine and chassis
parts, Always check manufacturer recommendations before using such special lubricants
(17) Electrical Wires
Al the elecvical wires are either single-color or two-color and, with only 2 few exceptions, must be
connected to wires of the samo color. On any of the two-color wires thare is a greator amount of one color
and a lesser amount of a second color, so a two-color wire is identified by first the primary color an then
the secondary color. For example, a yellow wire with thin red stripes is referred to as.a "yellow/red” wit
it would be a “red/yellow" wiea if the colors wore reversed to make red the main color.
‘Wire (cross-section) Name of Wire Color
Red
Wire Strands
Yellow/ Red
Yellow
Red
(18) Replacement Fans
When there is a replacement instruction, replace these parts with new ones every time they are removed,
These replacement parts will be damaged or lose thoir original function once removed.
(18) Inspection
When paris have been disassembled, visually inspect these parts for the following conditions or other
damage. If there is any doubt es to the condition of thom, replace them with new ones.
Abrasion rack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizuro
(20) Specifications
Specification terms are defined as follows:
"Standards": Show dimensions or porformancos which brand-naw parts or systems have.
“Service Limits”: Indicate the usable limits. If the measurement shows excessive wear or deteriorated
performance, repiace the damaged parts 1-4 GENERAL INFORMATION
Model Identification
2X1100-D1 (US and Canadian Models) Left Side View:
2X1100-D1 (US and Canadian Models) Riaht Side View: GENERAL INFORMATION 1-5
2X1100-D1 (European Model) Right Side View:
2X1100-D1 (European Model) Right Side View: 1-6 GENERAL INFORMATION
Item 2x1100-D1-
Dimensions:
Overall length 2165 mm, (Gi (N) (S) (SW) (GR) 2180 mm
Overall wth 730 mm
Overallheignt 4205 mm
Wheelbase 1495 mm, D3 ~: (G)[EU)'SP)INLY 1 )(FUK)IN)(GR) 1500 mm
Road elearance 110mm
‘Seat heignt 780 mm
Dry mass: 233 kg. (Cal) 233.5 ko
Curbmass: Front 190 kg
Rear 139 kg, (Cal) 139.5ko
Fuol tank capacity 240
Performance:
Minimurn turning radius 20m
Engine:
Type
‘Coating system
Bore and stioke
Displacoment
‘Compression ratio
‘Maximum horsepower
Maximum torque
Carburetion system
Starting sysiom
Ignition system
Timing advance
Ignition timing
4-stroke, DOHC, +-cylinger
Liquid-cooled
76.0 x58.0 mm
4052 mL.
VOE1 (F)IO.N
4108 kW (147 PS) @ 10500 ¢/min (rpm),
JAR) (K) 74 KW (190 PS) @9000 ¢/min (1pm),
(F) 75.1 kW (-) @8509 din (rom) (UTAC'S norm),
03~:75.1 KW (-) @8400 rimin (rpm) {UTAGS norm),
(S) $5 kW (75 PS) @6000 r/min (rom),
(SW) 68 KW (@2 PS) @8500 r/min (rpm),
(u)-.
(UK) 92 KW (-~) @9500 r/min (rom) (ISO4106),
DB: 108 KW (147 PS) @ 10500 renin (rpm)
(G) 74 KW (100 PS) @9000 rmin (rpm) (DIN)
Ds: (G) 74 kW (100 PS) @9500 rimin (rpm) (DIN)
Dé ~: (G) 72 kW (98 PS) @9300 r/min (1pm) (DIN)
440. Nem (11.2 kgm, 81 ft1B) @ 8500 e/min (pm).
(AR) (&) 90 Nem (9.2 kgm, 67 feb) @ 7000 rimin (Pm),
(FU) (UK) ~,
(5) 90 Nem (9.2 kg-m, 67 fulb) @5500 rimin (rpm),
(SW) 86 Nom (8.8 kgm, 64 f-lb) @4500 rimin (rpm),
(G) 30NN-m (9.2 kgm, 67 t-bo)
©7000 s/min (pr) (DIN)
Ds ~: (G) 93 N-m (9.5 ko-m, 69 ft-lb)
{©5000 r/min (pm) (DIN)
Carburetors, Keihin CVK:D 40 x 4
Electric starter
Battery and coll (vansistorized)
Electronically advanced
From 10° BTDC @1000 r/min (rpm) to
40” BTDC @6000 r/min (rpm)
(Cal) From 75° BTDG @ 1200 rimin (rpm) to
40° BTDC @6000 vin (rom)
(S),D8 ~ () From 7.5" BTOC 6 1300 ¢/min (1pm) to
40° BTDC @6000 ymin (rpm)
(U) (C) From 75" BTDG @ 1000 r/min (rpm) to
40" BTDC 6900 r/min (rpm) GENERAL INFORMATION 1-7
tem zx1100-01 ~
‘Spark plug NGK CAGE 07 ND U27ESR-N
Cylinder numbering method Lett to right, 1-2-3-4
Firing ordor 1.243
Vaive timing:
Inlet Open 40° BTDC. (F) 20°
Close 70) ABDG, (F) 50°
Duration 290" (F) 260"
Exhaust Open 63° BBDC. (F) 45°
Close 43° ATDC, (F) 25°
Duration 286° (F) 250°
Lubrication system
Forced lubrication (wet sump with elor)
Engine
Grade SE,SF, oF SG class
Viscosity SAE1OW.40, 10W-50, 20W.-£0, or 20W-50
Capacity 35L
Drive Train:
Primary reduction system
Type Gear
Reduction ratio 1.637 (98/58)
Clutch type Wet muti disc
Transmission:
Type 6-speed, constant mesh, retum shit
Geerratos: 1st 2,800 (42/15)
2nd 2.055 (37/10)
ard 1.890 (35/22)
ath 1.238 (32/24)
‘th 1.183 (8028)
ath 1.035 (29/28)
Final drive system:
Type Chain drive
Reduction ratio 2.647 (45/17), DS ~: (GFUK)(GF)(N\EU)SPHINL) 1) 2588 (44/17)
Qveral crive ratio
Frame:
Type
Caster (rake angie)
Trail
Fronttire: Type
Size
Rear tio: Type
size
Front suspension: Type
Wheel travel
ear suspension: Type
Wheel travel
Brake type Front
Fear
4.490 @ Top gear D3~: ()(FYUK)(GA)N)IEUYEPHNLY |) 4.990
@Top gear
Tupuiar, double cradle
255°
107 mm
Tupeiess
320/70 ZR17
Tuboless
180155 ZR17
‘Telesconic fork
420 mm
‘Swing arm (uni-trak)
112mm
Dual dice
Single disc 1-8 GENERAL INFORMATION
tem 2x4100-01 -
Electrical Equipme
Battery r2V12 An
Headlight: Type ‘Semisealed beam
Bulb 2V60/55W (quartz-halogen)
Tailorake light 42.V/5/21 W x2 (C) (Cal) (U) 12V8/27W x2
Aternator: Type Three-phase AC
Rated output 28.6 A 6000 r/min (rem), 14
Spectications subiect to change without notics, and may not apply to every country.
(AS) + Australia Modal (8) = Switzerlana
(AR) = Austria Mode! (GA): South Africa Modo!
(©) = Canada Model (SW): Sweden Model
(Cal) + California Model (WU) » USA. Modo!
©): France Model (UK): UK Mode!
(@) + Germany Model (EU): Europe Model
(GR) : Greece Mode! (SP): Span Model
(1) = Maly Model (NL): Netherlands Model
(N)_ = Norway Model (6): Korea Mode! Periodic Maintenance Chart
GENERAL INFORMATION 1-9
Tho scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition. The initial maintenanes is vitally important and must not be neglected.
iahever IN
PELUEY wri ay TODOMETER READING
Efs [s/s /§
4 Ss [S/S] 8 (S/S) 5
OPERATION S /E/E/S /E/E/S
trey [/s /e/e/e (efe/e
Spark plug -clean and gap" elelefelele
Valve cloaranes - check” e e ° e
‘Ar suction valve - check" elelelelele
Ar leaney element and air vent filer- clear ° ° °
Air cleaner element and air vent fiter- replace |S cleaning °
Throtle op play - check * . e . .
Tele spoad- chock * elelelelelele
Engine vacuum Synchronization - check e@lelejelelele
Fuel system - check * e . °
Fuel hoses, connections ~ check = elelelelele
Coolant change 2years °
Evaporative omiasion contol syaien
(Cal) -check” SASS ETS sR.
Engine ol change years | © ° . =
‘Oi tier = repiace [le ° e °
Radiator hoses. connections - chack * _years | © e e °
Fuel fiter-replace . . .
Fuel hose replace ayears
‘Clutch fuid level - check ™ month |e [elelelelel|e
‘Guutch tid charge 2years °
(Cluteh hose and pipe - replace a years
‘Clutch master cylinder cup and dust seal replace | 2 years
‘Ciutch slave cylinder piston seal - replace. 2years
Dive chain woar -cheok ™ elelelelele
Dive chain ~ lubricate OOK
| Drive chain slack - check * 800 km
Brake ped wear - check = elelelelele
Brake fuidlevel- check” month |e [ele|elelele
Brake fuid- change: years ° |
Brake nose - replace years
Brake hoses, connections ~ check" elelelelele
Brake master cylinder cup and dust seal replace | 2 years
Caliper piston seal and dust seal - replace 2 years
Brake light awitch - check * Lelelelelelele
Steering check * elelelelelele
Steering stem bearing - lubricate 2years °
Front fork cil~ change . :
Tite wear - check" —— =| elelelelele
‘Swing arm pivot, unitrak inkage lubricate ° ° °
Battery electrolyte level - check ™ month | @ [elelelelele
General lubrication - perform T elelelelele
Nuts, boli, and fasteners tighin@ss Gheok = ° ° ° e
Coolant fiter- clean “Tyee |
F: For higher odometer readings, repeat at the frequency interval established here.
(Cal) : California Mode! only
Replace, add, adjust, clean, or torque i necessary. 1-40 GENERAL INFORMATION
(Other than U.S.A. and Canada Models)
Whichever ODOMETER READING
FREQUENCY ey a
<
ever Lf is
Brey > Ag
‘Spark plug -clean and G20" e
Vawe learance check” ° e
“Airsucton valve = check = °
‘cleaner element and ai vent fitar clean
Throtle gp play - check * ° °
ide speed - check * e e
‘Carburetor synonronization - check °
Fual hoses. connections - chek” °
Coolant = change 2yeare e
Engine oll- change Sronhs| © felelelelele
Oilfiter -replace ° e e e
adhator hoses, connections - check °
Cich fu evel - check * Tom |e [elelelelele
‘Giuteh uid chenge Byears e
Cluich hose and pipe - replace a years
‘utch mastor cylinder cup and dust seal
years
= replace
Glutch stave cylinder piston seal- replace ‘Tyears
Drve chan wear = check elelelelele
Drive chan -lubicate BOOK
Drive chain slack - chook = 7000 «re
Brake pad wear check." e[elelelele
Brake fluid level - check * month | @ |e@|e|el/elele
Brake uid - change 2 years °
‘Brake hoses, connections - check elelelelele
[aia otro eed seat a
Caliper pston seal and dust seal replace a years
Brake fight switch - check” @l[el[elelelele
Steering - check” elfelelelelele
‘Soaring stem baaving -Wbicate 2 years e
Front fork ol - change 2 years Oo
Front fork oll leak Check” ° ° °
ear shock absorber oll eak check ° e °
Tire wear - check" elelelelele
Swing arm pivot, uni tak kage — lubricate ° ° °
Battery electroyte level -check™ Srontns elelelelele
‘General lubrication - perform e| Te °
Nuts, Gots, and fasteners ighinass - cveck™ ° ° ° °
Coolant fiter= clean year
T : For higher odometer readings, repeat at the frequency interval established here.
* + Replace, add, adjust. clean, or torque if necessary. GENERAL INFORMATION 1-17
Torque and Locking Agent
The following table list the tightening torque for the msjar fasteners, and the pats requiring use of @ non-permanent
focking agent or liquid gasket
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads,
0: Appian cil to the threads, seated surface, or washer
'S = Tighten tho fasteners following the specified sequence.
SS: Apply sifcone sealant to the threads.
Fastener Torque Remarks
Nm kgm ft-lb
Cooling System:
Fen switch 18 18 139
Water temperature sensor 15 15 110 ss
Bleed valve 78 | 080 69 in-tb
Water pump cover bolts 98 10
Water pump drain plug 98 10
Engine Top End:
Camshaft cap bolts 12 12 s
Rocker shaft end bolts 5 25
Oil hose fitting 22 2.2
Oil hose banjo bolt 25 25
Carburetor holder bolts qua! =A L
Cylinder head bolts: 11 mm dia. 51 52 os
10 mm dia. 38 40 | as
6mmdia 98 10 87 in-tb
Cylinder bolts 15 4B Sao
Upper chain guide mounting bolt - - =< il) oa
Rear chain guide mounting bolts 0 20 145 L
Chain tensioner mounting bolts 98 10 87 in-lb
Camshaft sprocket bolts 15 15 110 L
Clutet
Clutch hose banjo bolts 26 25 18.0
Clutch pipe nipple 18 18 130
Clutch lever pivot nut 59 0.60 52 in-lb
Clutch master cylinder clamp bolts 4 14 95 in-b 8
Clutch slave cylinder bolts - - - LQ)
Bleed valve 78 080 89 inl
Right cover bolts = - La)
Right cover damper boks - - - L
Clutch spring bolts " 14 95 in-ib
Clutch hub nut 130 135 98
Engine Lubrication Syster
Oil hose banjo bolts (14 mm dia.):
Coolor side 26 26 180
Oil pan side 34 35 25
Gil hose banjo bolti& mm ia.) 15 15 110
Gil pan bolts = - 2 Lay
Drain plugs 29 30 22
il pressure switch 6 15 11.0 ss
Gil pen plug 20 20 145 L
Crankcase mein oil pessage plug 18 18 130
Crankcase plug 18 18 130 1-12 GENERAL INFORMATION
Fastener Torque Remarks
Nem ko-m ft-lb
Oil pipe banjo bolts(12 mm cia.) B 25 180
Oil pimp gear holder screws - - - L
Oil pump mounting boks 12 12 108 in-Ib ig
Oil fiter bolt 20 20 145
Engine Removal/Installati
Engine mounting nuts. = 8mm 20 20 148
10mm 44 45 33
Down tube mounting bolts 4a 45 33
Crankshaft/Transmission:
Crankshaft cap bolts 2 33 24
Balancer shaft guide pin plate bolt - - - L
Balancer shaft clamp lever mounting bolt - - - L
Alternator shaft chain tensioner bolts - - = L
Crankcase botts: 9mm dia 2 33 24 s
3 mm dia ) Sey 28 20
Timea, ||| 9B 48 130
6 mm dia. 18 18 11.0
Connecting 1od big end cap nuts See p8-11
‘Altemator shaft chain sprocket bolt 25 26 180
Altenator shaft nut 89 60 43
Alternator shaft boit 2 25 180
One-way clutch bolts 12 12 104 in-Ib L
Shift drum bearing holder bolts - = - L
External shift mechanism return spring pin 23 30 22 L
External shift mechanism cover bolts 98 10 87 in-lb Lay
Neutral switch 15 15 11.0
Wheels/Tires:
Front axle nut 145; 150 110
Front axle clamp bolts 20 2.0 145
Rear axle nut 110 10 80
Final Drive:
Engine sprocket nut 125 130 94
Engine sprocket cover damper bolts - - - L
Rear sprocket nuts 74 78 54
Rear sprocket studs - - = L
Chain adjuster clamp boks 39 40 29
Brakes:
Brake lever pivot nut 88 0.90 78 in-Ib
Front moster cylinder clamp boits " 1. 95 in-tb s
Brake hose banjo bolts 25 25 180
Bleed valves 78 0.80 69 in-Ib
Caliper mounting bolts: Front 34 35 25
Rear 25 25 18
Front caliper assembly bolts a 24 150
Brake disc mounting bolts 23 23 165
Brake pedal pivot bolt 88 0.90 78 in-ib
Rear master cylinder mounting bolts 23 23 165
Push rod nut 18 18 130
Torque link bolts/nut 25 25 18.0 GENERAL INFORMATION 1-13
Fastonor Torque Remarks
Nm kgm ftlb
‘Suspension:
Front fork top plugs 23 23 165
Front fork clamp bolts(Upper) 2B 29 2
Front fork clamp nuts(Lower) a 24 150
Front fork bottom Allen bolts a 62 45 L
Front axle clamp bolts 20 20 145
Rear shock absorber mounting nuts 59 60 43
‘Swing arm pwvot nut 8 9.0 65
Rocker arm pivot nut 59 60 43
Tie-rod bolts 59 60 43
Steering:
Handlebar weight bolts - - - i
Handlebar holder bolts 20 20 145
Steering stem head nut 39 40 29
Stooring stom nut 49 050 43 in-tb
Frame:
Downtube bolts a4 45 33
Side stand switch sorews - - - L
Center stand spring hook bolts - = - L
Side stand bracket mounting bolts 49 50 26 L
Side Stand Bolt a“ 35 25
Electrical System:
Spark plugs 14 14 400
up coil cover bolts, - - - L2)
iming rotor bolt 6 25 180
Pickup coil holder bolts L
Alternator mounting bolts 25 25 180
Alternator coupling bolts 98 10 87 in-lo
Alternator cover nuts, 44 0.45 39 in-to
Aterator cover studs 8g 090 18 in-Io
The table below, relating tightening torque to Basic Torque for General Fasteners
thread diameter, lists the basic torque for the bolts Frege dia, To
and nuts, Use this table for only the bolts and nuts pa
which do not require a specific torque value. All of fore Naw fem Fe
the values are for use with dry solvent-cleaned 6 | 94-49 [035~050 | 30~ 43 in-tb
threads. 6 | &9~78 |0.80 ~ 0.80) 62 ~ 69 in-ib
8 ta~19 | 14-19 | 100~135
10 | 25~34 | 26~35 | 190~250
12 «| 44-61 | 45~62 | 33 ~45
14 | 73~98 | 74~100| 54 ~72
16 [115 ~155/11.5~160| 63~115
1g |165~ 225] 17.0~ 230) 125 ~ 165
20__|225~325| 23~33 | 165 ~240 4-14 GENERAL INFORMATION
Special Tools and Sealant
Bearing Puller Adapter: 5701-138
@
‘Compression Gauge: §7001-221
@
‘Steering Stem Bearing Driver. §7001-137
Valve Spring Compressor Assembly: 5701-241
=.
NO
Inside Circlip Pliers: §7001-143
Bearing Puller Adapter: 57001-317
Bozring Puller: 57001-1658
Piston Pin Puller Assembly: 7001-910
Hand Tester: 87001-1394 GENERAL INFORMATION 1-15
il Seal & Bearing Remover: 67001-1058
Piston Ring Compressor Grip: 67001-1095,
oS
TS
Le
Steering Stem Bearing Driver Adapter: 57001-1074
Piston Ring Compressor Belt, 067 ~ 979: 57001-1097
hoa
Head Pipe Outer Race Press Shatt: 57001-1075
‘Steering Stem Nut Wrench: 57001-1100
Head Pipe Outer Race Driver. 57001-1076
Head Pipe Outer Race Remover, 57001-1107
|
les
Head Pipe Outer Race Driver 57001-1077
Valve Seat Cutter. 45" ~ 0275: 57001-1114
© 1-16 GENERAL INFORMATION
Valve Seat Cutter, 45° ~ 082; 67001-1116
Valve Seat Cutter, 32° - 933: 57001-1199
2
©
Valve Seat Cutter, 32° - 30: 57001-1120
Valve Spring Compressor Adapter, 22: 57001-1202
2
&
Valve Seat Cutter, 60° - 30: 57001-1123
Valve Guide Arbor, @5: 57001-1203
©
a
Valve Seat Cutter Holder Bar. 87001-1128
Valve Guide Reamer, 05: 57001-1204
a
oe
Bearing river Set §7001-1129
Valve Seat Cutter Holder, @5: 67001-1208
se GENERAL INFORMATION 1-17
Fork Outer Tube Weight: 57001-1218
Piston Base, 96: 57001-1263
Front Fork Oil Seal Driver: 67001-1219
Bearing Removor Shatt: 57001-1285
Coil Tester: 57001-1242
Bearing Remover Head, 15x O17: 57001-1267
&
‘Spark Plug Wrench, Hex 16: 57001-1262
Fork Oil Level Gauge: 97001-1290
s-
Jack: 57001-1238
Bearing Remover Head, ©20 x ©22: 57001-1293
& 1-18 GENERAL INFORMATION
‘Compression Gauge Adapter, M10 X 1.0: 57001-1317
Kewasaki Bond (Liquid Gasket ~ Black): 92104-1003
=
foe
Valve Seat Cutter, 60° — 33: 57001-1334.
Kawasaki Bond (Liquid Gasket - Stver): 92104-002
8
gy
\
Hexagon Wrench, Hex 29: 57001-1335
&
=
Vacuum Gauge: 57001-1369
Kawacaki Bond (Silicone Sealant): 58019-120
“Ba
ioe
ee GENERAL INFORMATION 1-19
Cable, Wire, and Hose Routing
3, Main Hames
4. Water Temp. Sensor Leads
5. Ground Load
8. Fan Motor Lead
7. #2,3 Ignition Coil Leads
8, Right Hom Lead
9. Alternator Lead
10. Pickup Coil Leod
411. Battery (-) Lead
12. Oil Pressure Switch Lead
13. Rear Brake Switch Lead.
14, Junction Box Load,
15. Fuel Level Gauge Lead
16. Tail/Brake Light Lead
17. Right Turn Signal Lead
18. Licence Light Lead
19. Left Turn Signal Lead
20. Tum Signal Relay Lead
21. Rectifier Lead
22.1C Igniter Lead
23. Starner Relay Lead
24. Fuel pump Relay lead
25, Side Stand Switch Lead
28. Noutral Switch Load
1
2. Cable passing in Right Hole
27.
28,
29.
30.
31
32
33
34.
36.
Cables passing in Left Hole
Throwtle Cable
Choke Cable
Ignition Switch Leacs
Left Switch Case Leeds
Main Hames
Right Switch Case Leads
Cooling Fan Switch Lead
Loft Horn Lead
Loft Hendleber Switch Lead
Right Handlebar Switch Lead
Ignition Switch Leads
Clamp
White Color Tape Wound
‘on Main Harness
#1, 4 Ignition Coil Leads
Fuel Pump Lead 1-20 GENERAL INFORMATION
eG
ae
3) a)
Sea
CRAANY
RS&s
TEETER
8. Clamp Following Leads
1. Fuel Pump Lead
2. Ground Lead
Pickup Coil Lead
Alternator Lead
3. Oil Pressure Switch Lead
4. Battery (—) Lead
Neutral Switch Lead
9. Fuel Pump Relay
10. Starter Motor Lead
11. Starter Relay
5. Rear Brake Switch Lead
6. Junction Box
7. Igniter
12. To Starter Motor
13. Main Harness
14. Battery (+) Lead
15. Rectifier
16. Turn Signal Relay GENERAL INFORMATION 1-21
Fairing Inside Harness Leads
(@) 3. Guards
1. Clamp
2. Upper Fairing
3, Right Tum Signal Lead
4. Clamp
5. Headlight
6. Lett Tum Signal Lead
1. Clamp
2. Speedometer
3. Bracket
1. Cables passing in Left Hole
Throtle Cable
Choke Cable
Ignition Switch Leads
Left Handlebar Leads
2. Cable passing in Right Hole
Main Harnoss
Right Handlebar Leads
4. Ignition Switch Lead
5. Throttle and Choke Cables
6. Left Handlebar Switch Lead
7. Clamp
8. Ground Lead
9. Radiator
10. Fan Switch Lead
11. Band
12. Down Tube 4-22 GENERAL INFORMATION
1. Front Brake Hose
2. Throttle Cables
3. Right Handlebar Switch Lead
4, Bands
5. Main Hames
6. Ignition Switch Lead
7. Choke Cable
8, Left Handlebar Switch Lead
9, Clutch Hose
10. Speedometer Cable
11. Clamp
12, Side Stand Switch
13, Band
14, Oil Pressure Switch Lead GENERAL INFORMATION 1-23
Ignition Coil Read
Right Rear Tum Signal Lead
Clamp
Tighten to the tail Light
Left Rear Tum Signal Lead
1.#1,4 Ignition Coil
2. #2, 3 Ignition Coil
3. Heat Sealed
(Whito paint mark should
bbe on top).
4. White paint
5. Bolt
6. Nut 4-24 GENERAL INFORMATION
Air Filter
Vacuum Switch Valve (Other than California Model)
3,
6.
7.
8.
10.
n
12
13
14,
16,
16.
17.
Screen
‘White paint
ID mark for R.H.screen
Air Vont Filtor
Clamp
Air Duct
. Clump
Clamp
Reservoir Tank Hose
Pipe
To #1, 4 Carburetors
Pipe
Tube
Nut
Screw
Screw
18, Duct 1D Mark
20.
Lor R mark should be up.
it Cleanor Housing
Plugs
Front Drain Tube
Rear Drain Tube
Catch Tank
Plug
Vecuum Switch Valve
‘Vacuum Switch Valve Hose
To Bottom of Air Cleaner
Housing
Vacuum Tube
To #1 Carburetor Holder
To #4 Carburetor Holder GENERAL INFORMATION 1-25
Fuel Pump Pipe
1. Fuel Pump Pipe:
Route under cross pipe
2, Connect pipe so that while paint on|
Pipe is top,
Cooling System
1. Reservoir Tank 8. Thermostat Body
Cap 8. Water Temp. Switch
3. Drain Hose 10. Radiator
4. Clamps. 11. Groove
5. Insert drain hose tip in breather case, 12. White Color Painted
6. Reservoir Tank Hose
13. Insert hose so that white paint meets with groove.
7. Radiator Cap 4-26 GENERAL INFORMATION
Brake Hose
(1) Front Brake
see
2. Front Caliper
3. Banjo Bolts
4. Bleed Valve
5. Brake Hose
| 6. Three Way Joint
7. Front Master Cylinder
8. Boot
9. Clamp
10. Rear Reservoir Tank
11. Rear Master Cylinder
12, Banjo Bolt
13. Clamp
14. Brake Hose
19. Rear Caliper
16. Brake Disc GENERAL INFORMATION 1-27
Evaporative Emission Control System (California Model Only)
1. Vacuum Valve 11. #3 Carburetor Holder
2. Tube (Yellow) 12. To Vacuum Switch Valve Hose Connecter
43. Catch Tank
4. Plug
5. Canister
6. Tube (Blue)
7. Separator
8 Tube (Rog)
8. Tube (Green)
10 Tube (White) 4-28 GENERAL INFORMATION
4. Vacuum Switch Valve
2. Vacuum Switch Valve Hose:
2, To Bottom of Air Cleaner Housing
4. Vacuum Tube
5. To#1 Carburetor Holder
6. (4 Carburetor Holder
7, Tupe (Greer)
ToCanister
1. Air Gleaner Housing Front Left and Right Drain Tubes
Front of air Cleaner housing ~» Under igntion col + Clamps (Lelt and Right,
Air Cleaner Housing Rear Drain Tube
‘Three Way Joint
Tube (Yelow)
‘This area should be lowest position inthe yellow tube line.
Clamp
Clamp
Nomeen GENERAL INFORMATION 1-29
Sereen
3. White Paint
1D mark for RH-screen
‘Air Vent Finer
Vacuum Valve
‘Tube(Yetlow)
Clamp
‘Ar Dust
Clamp
Pere mae
ube
‘To # 2Carburetor Holder
10. Clamp
11, Reservoir Tank Hose
12. Pipe
Tot, 4 Carburetors
13, Pipe
14, Tube
18. Nut
16. Sorew
17. Screw
18, Duct ID Mark
Lor R mark should be up.
19. To##2 Carburetor Helder
20, Ait Cleaner Housing GENERAL INFORMATION 1-31
1. Tube (Yellow)
Three Way Joint at (G) —+ Front of erankcase breather hose + Under ignition coll + Under frame —+ Inside of r
fark hose + Front of thermostat > Vacuum Valve.
2. Vacuum Hose
# 2 Carburetor Holder —+ Under ignition coil + Under frame + inside of radiator tank hose -+ Frent of thermostat —*
Yacuum Valve.
3. Thermostat
4. Tubes (White, Green, Yellow) and Reservoir Tank Hose
Route these tubes and hose between frame and carburetor.
5. Tube (White)
#3 Carburetor + Clamp at (B) -> Separator
6. Clamp Following ones at (B)
Tube (White)
Racervoir Tank Hose
Main Wiring Harness
7. Separator
8. Tube (Red)
‘Soparator ~ Back of battery caso -+ Fuel tank.
8. Tube (Blue)
‘Separator ~> Back of battery case -> Fuel tank.
10. Reservoir Tank Hose
‘Thermostat Cap —+ Clamp at (A) -+ Clamp at (8) —> Reservoir Tank.
11. Reservoir Tank
12. Reservoir Tank Overtiow Tube
Reservoir Tank -> Clamp at (D) and (E) -» Breather at side of battery case.
1. Three Way Joint
44, To Vacuum Valve
18. To Catch Tank
16. To Canister
17. Tubes (Yellow, Green)
Route these tubos at ront of erarkcace breather tube.
18 Engine Breather Tube
18, Clamp
Route tube (Yellow) at outside and tube (Green)
20. Clamp
21, Tube (Bluo)
Separator ~ Clamp at F) — canister.
22. Tube (Green)
Joint (H) + at ront of crarkease broather tube —> Clamp at (C) > Clamp at (F) —+ Canister.
23. Tube (Yellow)
‘Three Way Joint at (G) —+ Clamp at(C) -> Clamp (F) -> Canister.
24. Canister
ide. FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View 2-2
Specifications. 25
Throttle Grio and Cables... 2-6
Fioe Play Inepostion 2.6
Free Play Adjustment 26
‘Cable Installation Notes. 2-6
Cable Lubrication ....0msnunenennse 2-6
Choke Cable es 2-7
7
27
27
2-7
28
28
28
28
Free Play Inspection.
Free Play Adjustment ..
Installation Notes. 3
Lubrication . mn
Corburstors.
Idle Speed Inspection...
lle Speed Adjustment...
‘Synchronization Inspection.
Synchronization Adjustment onus.
Service Fuel Level Inspection.
Sonic Fuol Level Adjustmont
Fuel System Cleanliness Inspection
Removal
Installation Notes...
Disassombly/Assembly Notes.
‘Soparation/Assembly Notes.
Cleaning. ri
Inspection
High Atitude Performance Adjustment
(US mode).
Coolant Filter Cieanng
(Ar. G. F.1,NL. UK, K Models).
Air Cleaner.
Housing Removal
Housing installation Notes...
Element Removal
Element Installation.
Element Cleaning and Inspection,
Oil Draining.
Air Cleaner Housing Installation.
Fuel Tank,
Removal
Installation Notes.
Inspection.. oa
Cleaning a
Fuel Tap Removal
Fuel Tap Installation Notes.
Fuel Tap inspection...
Air Vert Filter Cleaning...
Evaporative Emission Control System
(Caifornia Model Only)
Parts Remevalinctalation Notes.
Hose Inspection...
Separator Inspection.
Separator Operation Test
Canister Inspection. 2.2 FUEL SYSTEM
Exploded View
4. Jet Noodle
2. Pilot Screw
3. Pilot Jet
4. Main Jet
5. Needle Je¥Bleod Pipe
6. Fuel Filter
7. Fuel Level Sensor
8. Vacuum Valve,
(©): Canada Modet
: Model
jermany,France,|taly,
.de, Switzerland, UK
‘and Korea Models
(8): Switzeriand Model
(W): USA. Model
(UK): UK Model
G: Apply grease.
0: Apply ai FUEL SYSTEM 2-3 2-4 FUEL SYSTEM FUEL SYSTEM 2-5
Specifications
Item Standard
Throttle Grip and Cables:
Throttle grip ree play 2~3mm
Choke Cable:
Choke cable free play 2~3mm
Carburetors:
‘Make, type Keihin, CVKD40
Main jot #1, 44: 160(188)
#243: 158 (155)
Main airjet 70
Jet needle INQBX, (FR) #1, #4 N6OU
Piot jet 38 [35]
Pilot at jot 420, (UK) 130,
Starner jet 98
Pilot screw 20 tums out, (Cal)(S) (U) ~
Service fuel level 45 4 11mm below the mark
Float height 134.2mm
fee speed 950 ~1050 r/min (rpm)
(Cal)(S) 1150 ~ 1250 r/min (rpm)
Synchronization vacuum Less than 2:7 kPa (26m Ha)
(Cal: California Mode!
(S): Switzerland Model
(U): U.S. Model
[1s High Attitude(US only)
‘Special Too! ~ Fuel Level Gauge: 57001-1017
Pilot Screw Adjuster, A: 57001-1299"
‘Vacuum Gauge: 57001-1359
Pilot Screw Adjuster, C: 57001-1202"
(): You may use whichever too! you like.
ZX1100-D3- (Refer to the above, noting the following):
Hem ‘Standard
Carburetors:
Jet needle NOX, (E) #1.4:NIV, #23: NIVL
Pilot ai et 120
Pilot sorow 2.0 turns out, (E) 13/4 tums cut, (G)(UK) 1 6/8 tums out,
(Can (5) (U) -
Idle speed 950 ~ 1050 r/min (rpm), (8) 1250 ~ 1950 r/min (rpm)
(E): Europe Models except for Austiia, Sweden, and Switzerland Models,
(G): Gormany Modo!
(UK): UK Model 2-6 FUEL SYSTEM
Throttle Grip and Cables
Free Play Inspection
© Check the throtle grip free piay [A]
+ If the free play is ncorrect, adjust the throtle cable
Throttle Grip Free Play
Standard: = 2 ~ 3mm
‘© Chock that the throttle grip moves smoothly from full open to close,
and. the throte closes quickly and completely in all steering
Positions by the return spring.
4 If the throtle gp does not return properly, check the throttle cable
routing, grip tree play, and cable damage. Then lubricate the throtte
cable.
‘© lun the engine at the idle speed, and turn the handlebar all the way
to the right and left io ensure thai the idle spaed does nat change.
+ If the idle epeed inereaso, check the throttle cabio froe play and the
cable routing.
Free Play Adjustment
Loosen the locknut (A
‘© Tum the adjuster [8] until the proper amount of tree play can be
obtained.
© Tighten the locknut securely.
4 If the proper amount of free play cannot be obtained by using the
adjuster only, use the adjuster in the middle part of the accelerator
cable.
Loosen the locknut and screw the adjuster at the upper end of the
‘accelerator cable all the way in.
Tighten the locknut securely.
@Remove the fuel tank and air cleaner housing (see Fuel Tank
Removal)
@ Loosen the locknut [A] at the middle part of the accelerator cable.
@Tumn the adjuster (8) until the proper amount of throttle grip free play
's obtained.
Tighten the locknut securely.
4f the proper amount of fiee play can not be obtained in the adjustable
range of the adjuster, use the adjuster at the upper end of the acceler
ator cable agein.
Cable Installation Notes
@ install the throtte cables in accordance with the Cable Routina section
in the General Information chapter
@install the lower ends of the throttle cable in tho cable bracket on the
carburetor after instaling the upper ends of the throttle cable in the
arip.
‘© After installation, adjust each cable properly.
ES
Operation with incorrectly routed or improperly adjusted cables
‘could reeultin an uneate riding condition.
Cable Lubrication
Whenever the cable ie removed, and in accordance with the Poriodio
Naintenance Cher (see General Information chapter), do the folowing.
‘@Apply a thin coating of grease to the cable lower ends.
‘eLubricate the cabla with 2 penetrating rust inhibio’ Choke Cable
FUEL SYSTEM 2-7
Fiee Play Inspection
{@Check that the choke inner cable slides smoothly by moving the choke
lever [A] to the front and rear
“It there is any irregularity, check the choke cable play [8]
‘@Push the choke lever all the way to the front.
‘eCheck choke cable free play.
Determine the amount of choke cable play at the choke lever. Pull the
‘choke lover until the starter plunger lever [A] at the carburetor touches
the starter plunger (B]; the amount of choke lover lower end travel is
‘the amount of choke cable play.
ef the fee piay is incorrect, adjust the choke cable.
Choke Cable Free Play [C]
Standard: 2 ~ 3mm
Free Play Adjustment
‘@Remove the fuel tank (see Fuel Tank Removal).
‘@Lcosen the locknut [A], and turn the adjuster [8] until the cable has
the proper emount of free play.
‘@TTighten the locknut securely
Installation Notes
‘@install the choko eable in sccordance with the Cable Routing section
in the General Information chapter.
‘@Atter installation, adjust the cable properly.
Win
Incorrectly routed or improperty adjusted cable
could result in an unsafe riding condition.
Lubrication
Whenever the choke cable is removed, lubricate the choke cable as
follows:
‘eApply a thin coating of grease to the cable upper end,
‘eLubrcate the cabo with a ponoirating rust inhibitor. 2-8 FUEL SYSTEM
Carburetors
Idle Speed Inspection
‘eStart the engine and warm it up thoroughly.
‘eWith the engine idling, turn the handlebar to both sides.
+Ithandlebar movement changes the idle speed, the throttle cables may
be improperly adjusted or ncorrectly routed, or damaged. Be sure 10
correct any of these conditions before riding (see Cable Routing
section in tie General Infomation chapter)
‘Operation with an improperly adjusted, incorrectly routed, or damaged
cable could result in an unsafe
‘eCheck idle spead
xf the idle speed is out of the specified range, edjust it
Idle Speed
Standard: 1,000 = 60 r/min (rpm)
(Catitomia, Swiss Models) 1,200 + £0 rimin pm)
ZX1100-3- : (Swiss Model) 1.300 = 50 r/min (rpm)
Jdlle Speed Adjustment
(@Start the engine and warm it up thoroughy.
@Tum the adjusting screw [A until the idle speed is correct.
(©Open and ciose the throttle few times to make sure that the idle
speed is within the specified range. Readjust if necessary.
‘Synchronization Inspection
‘@Set the motorcycle on its center stand,
‘@Statt the engine and warm it up theroughy.
‘© Check idle speed,
‘@ Remove the fuel tank. (see Fuel Tank Removal)
‘@Supply fuel to the carburetors with an auxiliary fuel tank.
‘@ Remove the inner rear faring,
‘@ Remove the air cleaner housing.
‘@Pull the vacuum noses off, and attach the vacuum gauge [A] to the
fittings [B] on the carburetors.
‘Special Tool ~ Vacuum Gauge: 57001-1369
‘@Start the engine and let it idle to moacure the carburetor intake vacuum,
>If the vacuum is incorect, adjust the synchronization
Carburetor Synchronization Vacuum
‘Standard: Less than 27 kPa (2 emHg) diference
between any two carburetors. FUEL SYSTEM 2-9
Synchronization Adjustment
{@Turn the adjusting serew to syncheonize tho carburetor.
(OFFist synctronize the left two and then the right two carbureiors by ci
‘reans othe let nd rat adusting screws (A, CI. Then sehen fn Vea ais.
the let two carburetors and the right two carburetors using the center 6
adjusting screw [8]
XI the carburetor synchronization cannot be obiained by using the
agjusting screws, check for dirt or blockage, and then check the pilot ) a
screw settings. a
‘Special Tool ~ Pilot Screw Acjuster, A: 57001-1299 or
Pilot Screw Acjuster, C: 57001-1292
@ Check the carburetor synchrenization again.
NOTE
(©Do not turn the pilot screves carelessly during carburetor synehroni-
zation. You may cause poor running at law engine speed.
‘eCneck idle speed.
Service Fuel Level Inspection
Gasoline is extremely flammable and can be explosive under certain
‘conditions. Turn the ignition switch OFF. Do notsmoke. Make sure
the area ie well-ventilated and free from any source ol flame or
sparks; this includes any appliance with a pilot ight.
@Romove the carburetors, and hold them upright on a stand (see
‘Carburetor Removal)
‘ePrepare an auxiliary fuel tank and connect the fuel ose to the
‘carburetors.
‘@ Prepare a fuel hose (6 mm in diameter and about 300 mm long).
‘@Conneet the fus! lavel gauge [A] to the earburetor float bow! with the
fuel hose.
‘Special Tool ~ Fuel Level Gauge: 57001-1017
‘@Hold the gauge [/] vertically against the side of the carburetor body
's0 that the “zero” ine (B] is several milimeters higher than the bottom
‘edge of the carburetor body.
‘@ Feed fuel to the carburetor, then turn the carburetor drain plug [C] out
a few tums.
@Wait until the fuel level in the gauge settes.
NOTE
Do not lower the "20:0" line below the bottom edge of the
carburetor body. If the gauge is lowered and then raised again, the
fuel level measured shows somewhat higher than the actual fuel
level. If the gauge is lowered 100 far, dump the fuel ino a surtaole
‘eantaines and start the procedure over again. 2-10 FUEL SYSTEM
‘@Read the fue! level (D] in the gauge and compare to the specification
‘Serew in the carburetor drain plug,
‘@Siop feeding and remove the fuel level gauge.
>If the fuel level is incorect, adjust it (see Service Fuel Level Adjust
mort)
Service Fuel Level
Standard: 4.5 41 mm below the mark
Service Fuel Level Adjustment
“AWARNING
Gasoline is extremely flammable and canbe explosive under certain
conditions. Turn the ignition switch OFF. Do not smoke. Make sure
the area is well-ventilated and free from any source of flame or
sparks; this includes any appliance with a pilot light.
@Remove the carburetor, and drain the fuel into a suitable container
@Remove the float bowl
@Remove the screw {A} and take out the float (81,
@Bend the tang [A] on the flost arm very slightly to change the float
height. Increasing the float hoight lowers the fuel level and decreasing
the float height rises the fue! level.
Float Height
Standard: 13+ 2mm
NOTE
(Do nor push the needle rod (A) in during the float height measure
‘ment (6)
(@ Assemble the carburetor, and recheck the fuel level
Ifthe fuel level cannot be adjusted by this method, the float or the float
valve is damaged. FUEL SYSTEM 2-11
Fuel System Cleanliness Inspection
ENNIS
Gasoline is extremely flammable and can be explosive under certain
‘conditions. Turn the ignition switch OFF. Do not smoke. Make sure
the area ie well-ventilated and tree from any source of flame or
Sparks; this includes any appliance with a pilot ight
(© Remove the following.
Seat
Fuel Tank
‘@ Connect a suitable hose to the fitting et the bottom of ach carburetor
‘oat bowl
‘@ Run the lower ends of the hoses into a suitable container
Tun the fuel tap to the PRI postion
‘@Turn out each drain plug a few tums and drain the flost bowls
Special Tool ~ Pilot Screw Adjuster, A: 57001-1239 or
Pilot Screw Adjuster, C: 57001-1292 [A]
© Check to see it water oF dirt comes out
‘@Tighten the drain plugs and turn the fuel tap to the ON position.
‘If any water 0 dirt appears during the above inspection, clean the fuel
ayatem (¢oe Carburetor Cleaning and Fuel Tank Cieaning),
Removal
Ea
Gasoline is extremely flammable and can be explosive under certain
‘conditions. Turn the ignition ewitch OFF. De notsmoke. Make cure
the area ‘s wellventilated and free from any source of flame or
sparks; ths includes any appliance with a plot ight.
@Remove:
Seat
Rea
Inner Tank
Fuel Tank
Air Cleaner Rear Housing
‘@Loosen the clamps, and pull the carburetors off the hovers.
‘@Take out the carburetor essembiy.
‘@Remave the throttie cable and choke cable lower ends.
‘@Stut piace of lint-free, cloan cloth into the carburetor holders and the
intake ducts to keep din out of the engine and air cleaner 2-12 FUEL SYSTEM
Installation Notes
‘@ Route the cables, hemness, and hoses correcty (see General Infooma-
tion chapter).
Tighten the clamps[A] for the carburetor holders.
{© Chock fual leakage from the carburetor.
En
Fuel spilled trom the carburetors is hazardous.
(@ Agiust the following items if necessary.
Idle Speed
Carburetor Synctronization
Throttle Cable
Choke Cable
Disassembly/Assembly Notes
GN
‘Gasoline Is extremely flammable and can be explosive under certain
conditions, Tum the ignition switch OFF. Donot smoke. Make sure
the area ts well-ventilated and free trom any source of flame ot
‘sparks; this includes any appliance with a plot light.
@ For the US and Swiss madels. remove the pilot screw plug as follows:
(© Punch a hole in the plug and pry there with an aw! or other suitable
tool
‘@ Tum in the pilot screw and count the number of turns unt it sats fully
‘but not tightly, and then remove the screw. This is to set the sorew to
its original position when assembling.
‘© After installing the upper chamber cover, check thet the vacuum piston,
slides up and down smoothly without binding in the carburetor bore.
‘CAUTION
During carburetor disassembly, be careful not to damage the
diaphragm. Never use 2 sharp edge to remove the diaphragm.
@ Turn in the pilot screw [A] fully but not tightly, and then back it out
the same number of tuins counted during cisessembly.
@For the US and Swiss made install the pilot serew plug as follows:
‘Olnstall a new plug [B] in the pilot screw tole, and apply a small
‘amount of a bonding agent [C] to the citcumierence of the plug to fix
the plug,
CAUTION
‘Do not apply too much bonding agent tothe plug or the pilot screw
itself may be fixed. FUEL SYSTEM 2-13
(@Turn the carburetor body upside-down, and drop the noodle jot [A]
into place s0 that the smaller diameter end [8] of the jet goes in frst.
‘© Carefully screw in the needle jet holder. It will seat against the needle
Je, pushing the end of the et into the carburetor bore.
CAUTION
Donot lorce the needle jetholder [A] and main jet [8] or overtighten
them, They could be damaged requiring replacement.
{@Sip the needle through the hole in the center of the vacuum piston,
‘and put the spring seat [A] on the top of theneedle. Turn the seat 50
thatit does not block the hole (8 at the bottom of the vacuum piston.
Separation/Assembly Notes
‘@Read the WARNING in the Carburetor Disassembly/ Assembly Notes.
{@The centor lines of the oarburetor bores must be parallel both horizon
tally and vertically. If they ae not, loosen the mounting screws and
align the carburetors on a flat surface. Retighten the mounting screws.
‘@Aiter assembling the choke mechanism, check to see that the starter
plunger laver slides right to left smoothly without abnormal fiction,
‘CAUTION
Fuel mixture trouble could result the starter does net seat properly
in te rest position after the choke lover ia returned.
‘@ Visually synchronize the throne (buttery) valves.
(OCheck to see that all throttle valves open and close smoothly without
‘binding when turing the pulley.
(Visually check the clearance [A] between the throttle valve and the
ccerburetor bore in each carburetor.
It there is a difference between any two carburetors, turn the balance
adjusting screw(s) [B] to obtain the same clearance. 2-14 FUEL SYSTEM
Cleaning
“AWARNING
Clean the carburetors in a well-ventilated area, and take care that
there is no spark or flame anywhere near the working area; this
inckides any appliance with a pilot light Because of the danger of
highly flammable liquids, do not use gasoline or low flach-peint
solvents to clean the carburetors.
- ‘CAUTION
‘Do not use compressed alr on an assembled carburetor, or the floats
‘may be crushed by the pressure, and the vacuum piston diaphragms
may be damaged.
Remove se many rubber or plastic parts rom the carburetor as
possible betore cleaning the carburetor with a cleaning solution.
This will prevent damage to or deterioration ofthe parts.
‘The carburetor body has plastic parts that cannot be removed. Do
rot use a strang carburetor cleaning solution which could attack
these parte; instead, use a mild high flash-point cleaning solution
sale for plastic parts.
Do net use wire or any other hard instrument to clean carburetor
parts, especially jets, as they may be damaged.
© Disassemble the carburetor.
@lmmerse all the metal pans in a carburetor cleaning solution.
@Rinse the parts in water.
@When the parts are clean. dry them with compressed air.
@Blow through the ait and fuel passages with compressed ar
‘@ Assemble the carburstor.
Inspection
Pan
‘Gasoline is extremely flammable andcen be explosive under certain
conditions. Turn the ignition switch OFF. Donot smoke. Make sure
the area Is well-ventilated and free from any source of flame or
sparks: this includes any appliance with a plot light.
‘@Remrove the carburetors.
{@8etore d'sassembiing the carburetors, check the fuel level (see Fuel
Level Inspection).
IF the fuel level is incorrect, inspect the rest of the carburetor before
correcting it
‘@Move the choke shaft left and release it 10 check that the starter
plungers move smoothly and return by spring tension,
“IF the starter plungers do not work properly, replace the carburetors.
‘eTumn the throttle cable pulley to check that the throttle butterily valves
[A] move smootniy and retum by spring tension
kIF the throttle valves do not move smoothly, replace the carburetors. FUEL SYSTEM 2-15
‘eDissssomble the carburetors.
(@Clean the carburetors.
‘eCheck that the O-rings on the float bow! and drain plug and tne
diaphragm on the vacuum piston are in good condition
If any of the O-rings or diaphragms aro not in goed condition, replace
them.
‘eCheck the plastic tip (A) of the tlost valve needle |B]. It should be
smooth, without any grooves, scratches, or teas, |
“If th plastic tip is damaged [C}, replace the noodle.
‘@Push in the rod [0] in the other end of the float valve nesdie and then
epmcait Pus nd release
deIf it does not spring out, replace the needle.
@Check the tapered portion [A] of the pilot screw (B] for wear or
damage,
“IF the pilot screw is worn or damaged on the tapered portion, it will
prevent the engine from iding smoothly. Replace it
®
|@Check that the vacuum piston [A] moves smoothly in the carburetor
body. The surface of the piston must not be excessively worn,
>If the vacuum piston does not move smoothly, or if it is very loose in
‘carburetor body, replace the carburetor
High Atitude Performance Adjustment
(US model)
To improve the EMISSION CONTROL PERFORMANCE of vehicle
‘operated above 4000 feet, Kewasaki recommends the following
Enviromental Protection Agency (EPA) approved modification
{© Change the main jot and plot ot for high akitudo usa
High Altitude Carburetor Specifications,
Pilot Jot: #38 (02064-1101)
Main Jet #156 (#18 cyl. 92009-1944)
#155 (42,8 cyl. 92063-1332)
Coolant Filter Cleaning (AR, G, F, |, NL, S, UK K Models). —©_{~-—————
Before winter seascn starts, clean the fiter of carburetor system,
‘eRemove the fuel tank (see Fuel Tank Removal)
rain the coolant (se2 Cooling System chapter)
‘eRemove the fer [A] from the cooling hosas [B] of sarburetor system.
‘eBlow off crt and sediment en the fiter with compressed zir.
(AR. G.I. NL.S, UK, K Models)
Austria, Germary, France, laly, Netherlands,
Swiizetland, UK and Korea Models 2-16 FUEL SYSTEM
Air Cleaner
Housing Removal
‘@ Remove:
Seat
Fuel Tank
Inner Rear Faring
‘@ Remove the mounting bolt [A], and take off the upper housing (E]
‘@ Remove:
Air cleaner Screan [A]
Air Cleaner Elomont [B]
Ait Cleaner Drain Hoses
Engine Breather Hose
Air Duct
‘@ Remove the lower housing mounting bolts[Al, and take off the front
housing [B] from the carburetor.
Housing installation Notes
‘@Connect the front and rear drain tubes 10 the lower housing (see
General Information chapter)
‘@Fit the O-ring [A] of the rear housing in place.
@ install the rubber plugs[B] in place.
Element Removal
@Remove:
Air Cleaner Upper Housing Mounting Bolts
‘@Remove the upper housing.
{eT ske out the element. FUEL SYSTEM 2-17
Element Installation
‘@Element installation s the reverse of removal
@ install the soreon [A] so that the protrusion side faces the carburetor.
Element Cleaning and Inspection
NOTE
On dusty areas. the element should be cleaned more frequentiy than
‘the recommanded interval.
Aer riding through cain or on muddy roads, the element should be
cleaned immediately.
(Since repeated cleaning opens the pores of the foam in the element,
replace it with a new one in accordance with the Periodic Mainto-
‘nance Chart. Also if there is 9 break in the element material or any.
‘other demage to the elerment, replace the element with a new one.
EES
CCleanthe element in a well-ventilated area, and make sure that there
are no sparks or flame anywhere near the working area.
Because of the danger of highly flammable liquide, do not use
_gasoline or @ low flest-point solvent to clean the element.
@Take out the air cleaner element [A] trom the lower air cleaner
housing,
@Clean the element in a bath of high flash-point solvent, and then dry
it with compressod air or by shaking it.
@Atter cleaning, saturate a clean, lint-free towel with SE class SAE 30
cil and apply the oil to the element by tapping the element outside with
the towel.
© Visually check the element for tears or breaks,
%1f the element has any tears or brezks, replace the element.
‘@ Replace the element according to the Periagie Maintenance Chart (seo
General Information chapter)
Oil Draining
A drain hose [A] is connected to the bottom of the air cleaner
housing, o drain ol accumulated at the bottom of the housing.
(@ Visually check the drain hose ifthe oll accumulates in the hose.
211 any wator 0” cil accumulates in the tank, dain it by taking off the
ain plug [B] at the lower end of the drain hose
Pon
1¢ plug in the drain hose after draining. Olt on
tures will make them slippery and can cause an accident and inju 2.18 FUEL SYSTEM
Air Cleaner Housing Installation
'@ Be eure to fit the engine brosthor hose and draining hoses into the air
cleaner housing (see Cable Routing in the General Infomation
Chapter) Fuel Tank
Removal
Win)
Gasoline is extremely flammable and can be explosive under certain
conditions. Turn the ignition switch OFF. Do notsmeke. Make sure
the area is well-ventilated and free from ary source of flame or
sparks; this includes ary appliance with pilot ight.
‘CAUTION
For California model, i gasoline, solvent, water or any other liquid
teers the carisler, the canister’s vapor absorbing capacity is greatly
reduced. I! the canister does become contaminated, replace it with
‘@Remove
Seat
(@Turn the fuel tap to the ON oF RES position.
‘@Pull tho ful hose[A} off the tap.
NOTE
(©Do not pull ether wo fuel hoses{B), [C] off the tank, other wise fuel
will flow out
‘@ Remove the fuel tank mounting bolts [4].
‘@Disconnect the fuel level sensor lead connector
(@ Remove the fuel tank
(Drain the fuel tank
© Place a suitable container under the fuel tank
‘0Tumm the fuel tap to the PRI position to dain the fuol into the container
©The fuel level sersor [A] is installed at the bottom of the fuel tank, if
itis replaced with new one, remove it.
Installation Notes
‘@ Read the above WARNING.
‘Route the hoses and leads correctly (see General information chapter).
(@Be sure the hoses ae clamped securely to prevent leaks.
FUEL SYSTEM 2-19 2-20 FUEL SYSTEM
Inspection
‘@-Visually inspect the gaskets on the tank and cap for any damage.
‘Replace the gaskets if they are damaged.
) from the fuel tank, and open the tank cop.
{@ Check to see if the breather and water drain pipes (aso the fuel rerum
pipe for the Califomia model) in the tank are not clogged. Check the
tank cap breather also,
rif they are clogged, remove the tank and drain it, and then blow the
breather free with compressed air.
‘CAUTION
‘Donot apply compressed air othe air ventholes [A] on thetank cap.
‘This could cause damage and clogging of the labyrinth in the cap.
PGI
(Clean the tank in a well-ventilated area, and tate care that there are
‘no sparks or flame anywhere near the working area. Because of the
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