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1、ZZR1400 ABSNinja ZX-14RNinja ZX-14R ABSKawasakiMotorcycleAssembly&PreparationManualForewordInordertoshipKawasakivehiclesasefficientlyaspossible,theyarepartiallydisassembledbeforecrating.Sincesomeofthemostcommonlyremovedpartshaveadirectbearingonavehiclesreliabilityandsafety,conscientiouspre-saleassem
2、blyandpreparationbecomesextremelyimportant.GoodsetupprocedurescanpreventneedlesswarrantyclaimsandgivecustomersagreatersenseofconfidenceinKawasakiandtheirKawasakiDealers.ThisAssemblyandPreparationManualexplainsstepbystepproceduresofthefollowingitemsforallKawasakiZZR1400ABS5NinjaZX-14RandNinjaZX-14RAB
3、S.1 .Uncrating2 .Assembly3 .PreparationThesellingdealerassumessoleresponsibilityforanyunauthorizedmodificationspriortosale.RefertoyourServiceBinderforanyServiceBulletinsspecifyingFactoryDirectedModifications(SpecialClaims)whichmustbeperformedbeforethevehicleisreadyforsale.Wheneveryouseethefollowings
4、ymbolsheedtheirinstructions!Alwaysfollowsafeoperatingandmaintenancepractices.!DANGERDANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjuryWARNINGWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.NOTICENOTICEisusedtoaddresspractices
5、notrelatedtopersonalinjury.NOTEoThisnotesymbolindicatespointsOfparticularinterestformoreefficientandconvenientoperation.KawasakiHeavyIndustries,Ltd.acceptsnoliabilityforanyinaccuraciesoromissionsinthispublication,althougheverypossiblemeasurehasbeentakentomakeitascompleteandaccurateaspossible.AIIproc
6、eduresandspecificationssubjecttochangewithoutnotice.Sep., 20112011KawasakiHeavyIndustries,Ltd.TableofContentsUncrating3OpeningCrate3PartsCheck4Assembly5SteeringStemHeadNut5HandlebarWeights5WindshieldbRearFairing6Seat6FrenchLabel(ForCanadianModels)7BrakeDiscCleaning7Preparation8BatteryService8Coolant
7、12FrontBrake13RearBrake15CIiHch16DriveChain18FrontFork19RearShockAbsorber21TireAirPressuresFuelEngineOil(4-stroke)ThrottleGripandCableRearBrakeLightSwitchdieSpeedAdjustmentHeadlightAimMultifunctionMeterFastenerCheckStandardTorqueTableTestRidetheMotorcycleA&PCheckListFirst,remove the lower bolt (D =2
8、2,L =10) at the steering stem and discard it.Remove the upper bolts (D=8,L=14)to take off the crate bracket and discard them.A.Lower Bolt (D=22,L=10)Take out all the bolts and screws and remove the top and sides of the crate.Lift the vehicle upward about 10 cm (4 in.)and remove the two lower support
9、 brackets.Roll the vehicle off the crate base.A.Lower Support Bracket (Both Sides)UncratingOpeningCrateAWARNINGCrateshavesharpedgesandmayhavenailsorscrewsthatcancausecutsandinjury.Alwayswearprotectivegloves,bootsandeyeprotectionwhenuncratingtopreventinjury.103003B!WARNINGThesteelcratepanelplatesandf
10、astenershavesharpedges.Alwayswearprotectivegloves,btsandeyeprotectionwhenuncratingtopreventinjury.B.UpperBolts(D=8,L=14)C.CrateBracketD.FoamPad Clearaspaceabout6m(20ft)squaretogiveyourselfplentyofspacetowork.,Placethecrateuprightonitsbase. Removethecardboardcover. Removethepartsbox.NOTICEWhenremovin
11、gthecratebracketfromthemotorcycle,becarefulnottodropanypartsorthebracketontothefueltankandothercomponents,andnottoscratchthefueltankorothercomponentswiththecratebracket.PartsCheckOpenthepartsbox,andcheckthepartsagainsttheillustrations.Theremaybeminordifferencesbetweentheseillustrationsandtheactualve
12、hicleparts.lnthefollowingchartsunderRemarks5D=diameterinmilimeters,andL=Iengthinmillimeters.W00524lBN2CNo.PartNameQtyRemarks1SteeringStemHeadNut1D=252WindshieldSocketBoltPlasticWasherWellnut1666D=5,L=161)=5.311.5D=53BatteryCompartmentCoverBoltWasher111D=6,L=14D=6.5164OtherthanPhilippineandSoutheastA
13、siaB2ModelsRearFairingSocketBoltPlasticWasherWelnut1444D=6,L=23D=6.5165HandlebarweightWeightScrewwithaNon-permanentLockingAgent22D=8,L=306FrenchLabelforCanadianModelonlyEmissionControlInformation1P/No.59465-08467BatteryElectrolyte,FTZ14-BS112V12Ah8Owner*sManual1AssemblySteeringStemHeadNutRemove the
14、steering stem head dummy nut and discard it. Do not remove the flat washer (D=25.5)under the dummy nutj A.Dummy NutIB.FlatWasherjInstallthesteeringstemheadnut(D=25)onItheflatwasherwiththechamferedsidefacingIupwardsandtightenthenuttothespecifiedItorque.iTorque:78N-m(8.0kgf-m,58ft-lb)A.Steering Stem H
15、ead Nut (D =25) B.Flat WasherHandlebarWeightsA.Handlebar WeightB.Screw (D=8,L=30)WindshieldFit the six wellnuts (D =5)into the holes in the edge of the windshield from the outside with their flanges out.A.WindshieldB.Wellnuts (D =5)Fit the windshield into the upper fairing so that the tab of the upp
16、er fairing fits into the front groove of the windshield,and align the bolt holes.A.Front GrooveB.TabClipper FairingInstallbothhandlebarweightsontheleftandrightendofthehandlebarwiththescrews(D=8,L=30)withanon-permanentlockingagentandtightenthem.Install the six plastic washers (D =5.3)and the socket b
17、olts (D=5,L =16)on the upper fairing.A.Rear FairingB.Socket Bolts (D =6,L=23)and PlasticWashers (D=6.5)A.PIasticWashersandBolts(D=5,L=16)B.WindshieldSeatRearFairingFitthefourwellnuts(D=6)intothemountingholesintheleftandrightsideoftherearfairingbracket.A.Wellnuts(D=6)B.FairingBracketInstalltherearfai
18、ringwiththefoursocketbolts(D=6,L=23)andtheplasticwashers(D=6.5),andtightenthebolts.SeafRemovalInserttheignitionkeyintotheseatlock,andturnthekeyclockwise.Removetheseatbypullingupandrearward.A.SeatB.SeatLockC.lgnitionKeyD.PullUpandRearwardSeafStaIIatiOnInserteachfrontslotoftheseatontotheholderbracketo
19、neachleftandrightsideofthefueltank.A.SeatB.SIotsC.BracketInserttheslotsintothereceivers,andinsertthehookattherearoftheseatintotheslot,thenpushdowntherearpartoftheseatuntilthelockclicks.A-ProjectionsB.HookC.SIots(Middleontheframe)D.SIot(Rearendontheframe)EJnsertPulluptherearendoftheseattomakesureitis
20、securelylocked.FrenchLabel(ForCanadianMOdeIS)NOTEORemovethefrontleftsidecover.SeetheuCooIantFilling,iteminCoolant,sectiononpage12inthePreParationchapter.OSticktheFrenchlabelontotheEnglishlabelontheleftsideoftheframeonlywhenrequired.WipeoffanyoilorgreasefromtheEnglishIabeLRefertothefollowingphotograp
21、hinthelabellocation.PeeltheFrenchlabeloffthebackingsheetandapplyitovertheEnglishlabel.A.Frame(LeftSide)B.EmissionControlInformation(P/No.59465-0846)BrakeDiscCleaningCleanthefrontandrearbrakediscsusingoillesssolvent.AWARNINGAnanticorrosivetreatmentappliedtothebrakediscswillincreasebrakingdistanceandc
22、ancauseanaccidentresultinginseriousinjuryordeath.Removetheanticorrosivetreatmentusinganoillesssolvent.PreparationBatteryServiceThebatteryusedinthismotorcycleisasealedtypeandneverneedstoberefilled.Followtheprocedureforactivatinganewbatterytoensurethebestpossiblebatteryperformance.BatteryRemovalRemove
23、thebolts.Pullingouttherightfairingcoveroutslowlytocleartheprojections.,Cleartherightinnerrubbercoverfromtherightfairingcover,andremovetherightfairingcoverbackwardA.RightFairingCoverB.Bolt(D=6,L=30)C.Bolt(D=6,L=14)D.Bolt(D=5,L=20)E.RightInnerRubberCoverF-ProjectionsG.TabsRemovethebatterycompartmentco
24、verbyremovingthebolt(D=,L=14).A.Bolt(D=6,L=14)B.BatteryCompartmentCoverC-ProjectionsRemovethebattery(一)cable,(一)terminalleadandframegroundcablebyremovingthebolt(D=6,L=16).Removethebatteryholderbracketbyremovingthebolts(D=6,L=16).A.Bolt(D=6,L=16)B.Battery(一)CableC.(一)TerminalLeadD.FrameGroundCableEBo
25、Its(D=6,L=16)F.BatteryHolderBracketSlightlypulloutthebatterytray.Removethebatterycover.A-BatteryTrayNOTICEBecarefulnottodropthebatteryfromthemotorcyclewhenpullingoutit.Donotgivethebatterytrayastrongpull,orthecablesmaybedamaged.BatteryActivationElectrolyteFillingMakesurethatthemodelnameoftheelectroly
26、tecontainermatchesthemodelnameofthebattery.Thesenamesmustbethesame.BatteryModelNameZX1400E/F:FTX14-BSA.Model Name of the ElectrolyteB.Model Name of the BatteryA.Sealing Sheet B.Filler PortsNOTICEEachbatterycomeswithitsownspecificelectrolytecontainer;usingthewrongcontainermayoverfillthebatterywithinc
27、orrectelectrolyte,whichcanshortenbatterylifeanddeterioratebatteryper-formance.Besuretousetheelectrolytecontainerwiththesamemodelnameasthebatterysincetheelectrolytevolumeandspecificgravityvarywiththebatterytype.NOTICEDonotremovethealuminumsealingsheetfromthefillerportsuntiljustpriortouse.Besuretouset
28、hededicatedelectrolytecontainerforcorrectelectrolytevolume.!DANGERSulfuricacidinbatteryelectrolytecancausesevereburns.Topreventburns,wearprotectiveclothingandsafetyglasseswhenhandlingelectrolyte.Iftheelectrolytecomesincontactwithyourskinoreyes,washtheareawithliberalamountsofwaterandseekmedicalattent
29、ionformoresevereburns.Placethebatteryonalevelsurface.Checktoseethatthesealingsheethasnopeeling,tears,orholesinit.Removethesealingsheet.NOTEOThebatteryisvacuumsealed.Ifthesealingsheethasleakedairintothebattery,itmayrequireaIongerinitialcharge.Removetheelectrolytecontainerfromthevinylbag.Detachthestri
30、pofcapsfromthecontainerandsetaside,thesewillbeusedlatertosealthebatteryNOTEODonotpierceorotherwiseopenthesealedcellsoftheelectrolytecontainer.Donotattempttoseparateindividualcells.A,StripofCapsB.SealedCellsPlacetheelectrolytecontainerupsidedownwiththesixsealedcellsintothefillerportsofthebattery.Hold
31、thecontainerlevel,pushdowntobreakthesealsofallsixcells.Youwillseeairbubblesrisingintoeachcellastheportsfill.NOTEODonottilttheelectrolytecontainer.Check the electrolyte tow.Ifnoairbubblesarecomingupfromthefillerports,orifthecontainercellshavenotemptiedcompletely,tapthecontainerafewtimes.NOTEOBecarefu
32、lnottohavethebatteryfalldown.E021148S1 CA.AirBubblesB.TaptheContainerKeepthecontainerinplace.Dontremovethecontainerfromthebattery,thebatteryrequiresalltheelectrolytefromthecontainerforproperoperation.NOTICERemovalofthecontainerbeforeitiscompletelyemptycanshortentheservicelifeofthebattery.Donotremove
33、thecontaineruntilitiscompletelyempty.,Afterfillingjetthebatterysitfor2060minuteswiththeelectrolytecontainerkeptinplace,whichisrequiredfortheelectrolytetofullypermeateintotheplates.Makesurethatthecontainercellshaveemptiedcompletely,andremovethecontainerfromthebatteryPlacethestripofcapslooselyoverthef
34、illerports,pressdownfirmlywithbothhandstoseatthestripofcapsintothebattery(dontpoundorhammer).Whenproperlyinstalled,thestripofcapswillbelevelwiththetopofthebattery.6P08012BS1COncethestripofcapsisinstalledontothebattery,neverremovethecaps,noraddwaterorelectrolytetothebatteryNOTEOChargingthebatteryimme
35、diatelyafterfillingcanshortenservicelife.InitialChargeNewlyactivatedsealedbatteriesrequireaninitialchargeStandardCharge:1.4A510hoursIfusingarecommendedbatterycharger,followthechargersinstructionsfornewlyactivatedsealedbattery.Kawasaki-recommendedchargers:BatteryMate150-9OptiMatePRO4-S/PROS/PRO2Yuasa
36、MB-2040/2060ChristieC10122SIftheabovechargersarenotavailable,useequivalentone.Letbatterysit30minutesafterinitialcharge,thencheckvoltageusingavoltmeter.(Volt-ageimmediatelyafterchargingbecomestemporarilyhigh.Foraccuratemeasuring,letthebatterysitforgiventime.)NOTEOChargingrateswillvarydependingonhowlo
37、ngthebatteryhasbeenstored,temperature,andthetypeofchargerused.Ifvoltageisnotatleast12.6volts,repeatchargingcycle.OToensuremaximumbatterylifeandcustomersatisfaction,itisrecommendedthebatterybeloadtestedatthreetimesitsamp-hourratingfor15seconds.Re-checkvoltageandiflessthan12.6voltsrepeatthechargingcyc
38、leandloadtest.Ifstillbelow12.6voltsthebatteryisdefective.BatteryInstallationMakesurethattheleadorcabledoesnotpinchwithanyparts.NOTICEInstallingthe(一)cabletothe(+)terminalofthebatteryorthe()cabletothe(一)terminalofthebatterycanseriouslydamagetheelectricalsystem.Installthebattery(一)cabletothebattery.A.
39、Battery(一)CableInstallthebattery(+)cabletothebatterysandtheninstallthebatterycoveronthebattery,andhooktheband.A.BatteryTrayB.Projectionsc.HolesInstallthebatteryholderbracket.Installthebolts(D=6,L=16).Installthecablesandleadsothattheyarepositionedovertheframe,inorderoftheframegroundcable,battery(一)ca
40、bleand(一)termi-nalleadfromthebottom.Installthebolt(D=6,L=16).Runthebattery(+)cableand(一)terminalleadundertheband.A.Battery()CableB.Battery(一)CableC.Bolt(D=6,L=16)D.FrameGroundCableE.(一)TerminalLeadF.BandInserttheprojectionsonthebatterycompartmentcoverintotheholesoftheframe.Insert the projections on
41、the battery tray into the holes of the battery compartment.Installthebolt(D=6,L=14).A.BatteryCompartmentCoverBaProjectionsc.Holes,Inserttherightfairingcoverhalfway,andfittherightinnerrubbercovertotherightfairingcover.A-RightFairingCoverB.RightInnerRubberCover,Insertthefrontpartoftherightfairingcover
42、securely.,Insertthetabsontherightfairingcoverunderthefueltankcoverfirst,andthenfittheprojectionstotheholes.,Installtheboltsandwashers.CoolantCoolantLevelInspectionSituatethemotorcyclesothatitisperpendiculartotheground.Checkthecoolantlevelthroughthecoolantlevelgaugeonthereservetanklocatedintheinsideo
43、ftherightfairing.ThecoolantlevelshouldbebetweentheF(Full)andL(Low)levellines.NOTEOCheckthelevelwhentheengineiscold(roomoratmospherictemperature).A-F(FuII)LeveILineB.L(Low)LevelLineC-ReserveTankIftheamountofcoolantisinsufficient,andaddcoolantintothereservetank.CoolantfillingRemovethebolts(D=6,D=5)and
44、washersontheleftfairingcover.Pullingouttheleftfairingcoveroutslowlytocleartheprojections.A.TabsB.Right Fairing Cover C-ProjectionsCleartheleftinnerrubbercoverfromtheleftfairingcover,andremovetheleftfairingcoverbackward.A.LeftFairingCoverB.BoltsandWashersC.LeftInnerRubberCover0.ProjectionsE-TabsRemov
45、ethecapfromthereservetankandaddcoolantthroughthefilleropeningtotheF(FuII)IeveIline.A.ReserveTankCapInstallthecapNOTEOApermanenttypeOfantifreezeisinstalledinthecoolingsystemwhenshipped.ltiscoloredgreenandcontainsethyleneglycol.ltismixedat50%andhasthefreezingpointof-35(-31oF)FrontBrakeFrontBrakeFluidL
46、evelInspectionWiththefrontbrakefluidreservoirheldhorizontal,checkthatthefluidlevelisbetweentheupperandlowerlevellines.A,UpperLevelLineB.LowerLevelLineC.FrontBrakeFluidReservoirD.ReservoirCapStopperScrewIfthefluidlevelinthereservoirislowerthanthelowerlevelline,checkforfluidleaksinthefrontbrakelinesandfilltheresen/oir.LoosenthereservoircapstopperscrewtoremovethefrontbrakefluidreservoircapanddiaphragmFilltheresen/oirtotheupperlevellinewithDOT4brakefluid,reinstallthediaphragmandrese
