Instruction/ maintenance manual of the product ZX-10R Kawasaki
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Ninja ZX-10R 2005 Ninja ZX-10R Racing Kit Manual This manual contains only the information of the racing kit parts. Refer to the base manual listed below for informat ion of the original model. Base Manual Part Number Ninja ZX-10R Motorcycle Service Manual 99924-1322-02 © 2005 Kawasaki Heavy Industries, Ltd.
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1 Congratulation on your purchase of raci ng kit parts for the 2005 Ninja ZX-10R. IMPORT ANT This manual provides how to install raci ng kit parts for the 2005 Ninja ZX-10R and how to tune up basically . As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-10R (P/No.
2 T able of Contents General Spec ificat ions ......................................................................................................... 3 Racing Kit Serv ice Data ........................................................................
3 General Specifications Item 2005 Ninja ZX-10R Racing Engine: Ignition timing 10°BTDC @1 100 r/min (rpm) Fuel (Recommended) Racing gasoline Engine oil (Recommended): Racing oil Level Between upper and lower levels of oil level gauge. Drive T rain: Primary drive reducti on ratio 1.
4 Input 3 rd /4 th Gear Selection T able 4th Gear A (=C) B A 13262-0134 (19/21) 13262-0286 (19/20) B 13262-0284 (19/21) 13262-0264 (19/20) 3rd Gear C 13262-0272 (16/21) 13262-0285 (16/20) Gear Identif.
5 Racing Kit Service Data Item Standard Cylinder Head, V alves: V alve timing: Duration: Intake 300° Exhaust 292° Camshaft timing (cam lift center): Intake 104° (A TDC) Exhaust 102° (BTDC) V alve clearance: Intake 0.22 mm Exhaust 0.20 mm Squish 0.
6 FREQENCY OPERA TION Each Race Every 3 races Every 5 races Every 10 races As Required Coolant - - change ● Radiator hoses, connections - - check* ● Frame Brake operation - - check* ● Brake pad .
7 Engine Parts Installation Air Intake Parts Remove the air cleaner element or cut the cleaner element off remaining the wire net to reduce the air flow resistance. ○ When removing the air cleaner element, remove the element and relational parts as shown below .
8 Camshaft Chain T ensioner Replace the cam chain tensioner with the ki t to decrease the flutter of tensioner . Apply the engine oil to the tensioner rod, O-ring and tensioner body , insert them into the tensioner body .
9 Camshafts, Sprockets Camshafts, Sprockets: Camshaft Duration Lift 491 18-0008 (STD) (Intake) 300° 9.1 mm 491 18-0023 (STD) (Exhaust) 292° 8.5 mm 491 18-0034 (Kit) (Intake) 310° 9.7 mm Adjust the valve clearance within the specif ied value. Intake: 0.
10 Method of measuring clearance of valve and piston –2. ○ Adjust the valve clearance and valve timing. ○ Remove the cylinder head, and put a small piece of modeling clay on the hollow of piston to prevent valve from coming in contact. ○ Install the cylinder head and adjust the camshaft chain timing.
11 Cylinder Head Before reassemble the cylinder head grind off the stepped portions of the port and smooth the inside of ports to make intake/exhaust gas flow smooth. ○ Grind of f the stepped portions on ly at the mating surface bet ween the carburetor holder and the intake port.
12 The combustion chambers are modified by cutting work but the edges shown must be hand finished for smooth corners. NOTE ○ When grinding the cylinder head su rface or using thinner gaske t, adjust the valve tim ing to keep that the valve to piston clearance is not less than the minimum value (IN: 0.
13 Piston 1.Kit Piston (13001-0061): SB Method Kit piston are exclusive the two piston ring for reduce the compress ion height (dimension between the center of piston pin hole to s houlder of the piston) and the mechanical friction loss. Kit piston has more reduced the weight compared the original piston.
14 Connecting Rod Bolts 1. Original Connecting Rod Use the original connecting bolts and nuts. Make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch.
15 2. Kit Connecting Rod Connecting Rod Bolt Use the kit connecting rod bolts (with t he original connecting rod bolts) and nuts. The kit connecting rod can use the original connecting rod bolt (92153-0491).
16 Connecting Rod Big End Bushings The connecting rod bushing in the kit has im proved its anti-seizure feature than standard one. Connecting Rod Big End Bushing/Crankpin Clearance ※ When adjust the clearance by measurement in case aiming the clearance 0.
17 Clutch Adjustment (Back-T orque Limiter Setting) The Ninja ZX-10R engine is equipped with t he Kawasaki back-torque limiter mechanism in the clutch. The back-torque limiter works to reduce the chance of rear wheel hop caused by engine braking during hard braking and down shifting.
18 When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers (provided as optional production parts) to keep t he preload of clutch springs according to the table below . Length [A] Part Number Height [B] 53.1 ~ 53.
19 [A] Spacers [G] Friction Plates [B] Needle Bearing [H] Spring Plate Assembly [C] Bushing [I] Steel Plates [D] Clutch Housing [J] Spring Plate [E] Clutch Hub [K] Spring Retainer [F] Sub Clutch Hub.
20 • Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub). • T o measure the effective stroke of clutch spring plate, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and fort h [C].
21 Spring Plate Assembly The ZX-10R engine is used with the leaf sprig bu ilt in type steel plate assembly (spring plate assembly) in the clutch. The spring pl ate assembly are available for increase the spring constant. When outbreak th e starting judder , use the spring plate assembly of the kit parts.
22 T ransmission Shimming By using washers with various thickness, keep the axial clearance between 0.3 mm and 0.4 mm, to prevent the inclination of gears and to keep smooth gear-shifting. Thickness (mm) Part No. Remarks 1.2 92200-0229 Kit 1.4 92200-0230 Kit 1.
23 Use the type B ~ D input shafts with the shim adjustment since their sizes are, different from the standard shaft, designed taking the shim adjustment into account in order to make the dog lengths of the 3 rd – 5 th & 2 nd – 6 th gear dogs equal.
24 1. Kit Alternator Installation When using the kit alternator , remove the related parts of the original alternator , and changing the around parts of the starter from original parts to kit parts. Install the kit alternator as shown in the illustration.
25 Stator Installation The stator is fixed to the cover 12 (14091-0444) by the bolts. Run the alternator lead from the inside of the cover as shown in the illustration, and fix the grommet by the plate (13271-0149: original part) and bolt (130Y0508: original part).
26 1. In case of without Starter Motor ※ Refer to the illustration of 1. Kit Alternator Installation. Remove the [2] ~ [6], [8] parts and insert t he plugs to the hole of the starter motor inserted as shown in the illustration.
27 W ater T emperature Sensor The original water temperature sensor inst alled in the cylinder head must be remain and connected to the main harness because the el ectronic control unit (E.C.U.) needs the output signal from the original water temperature sensor .
28 W ater Pipe Installation Use the kit main radiator only . Divide the original water hose (39062-0022) between the cylinder head and the radiator and insert the water pipe (39192-001 1). Install the kit water temperature sensor (for water temperature gauge of kit meter , 21 176-1099) to the kit water pipe.
29 Use the kit sub radiator with the kit main radiator . W ater Inlet of Radiator Body Divide the original water hose (39062-0022) between the cylinder head and the radiator and insert the water pipe (39192-0039). Install the kit water temperature sensor (for water temperature gauge of kit meter , 21 176-1099) to the kit water pipe.
30 Oil Catch T ank (Kit) Use the oil catch tank for the engine blowby gas. Oil Catch tank: 52001-0002 T ank Capacity: Approximately 570 cc Oil Catch T ank Installation Install the mounting bracket wi th regulator under the cross pi pe of the frame by the bolts (use the original regulator mounting bolts).
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32 Cover Gaskets The kit cover gasket are available of the 2005 model ZX-10R. They are made from “metal-f oam” and made easy to separate. Starter Clutch Cover: 1 1061-0168 Idle Gear Cover: 1 1061-071 1 Clutch Cover: 1 1061-0134 Oil Pan: 1 1061-0169 ECU (Kit) The 2005 model ZX-10R kit ECU has fo llowing functions.
33 Frame Parts Installation Throttle Parts (Kit Parts) The following throttle cases, grip and reels ar e available as kit parts. These kit parts quicken throttle response to the twist grip.
34 Final Drive Parts (Kit Parts) 1) Drive Chain #520 Joint endless drive chain is available as an kit parts. 2) Chain Guard 1. Guard: 55020-0028 2. Bolt: 130J1020 3. Swingarm (Left Side) Brake Pads (Kit Parts) The front and rear brake pads for racing use ar e available.
35 Steering Damper (Kit Parts) The steering damper is useful at high speeds to prevent handlebar vibration. The steering damper should be installed to do not the steering handle movement stop by the steering damper itself at the fully locked position both left and right side.
36 NOTE ○ The holder ’ s one side mating surface are shi fted from center about 1.5 mm to ensure tightening force. ○ Install the holder properly shown below to avoid steering damper operation stick. 1. No Gap 2. Gap (3 mm or less) ○ Install the holder to 31 mm range below to avoid the journal position.
37 ○ When install the steering damper which st roke less than 150 mm, apply the suitable stopper as shown below . 1. Steering Damper 2. Holder 3. Holder 4.
38 Seat Height Adjustment Loosen the nut (1) and insert the spacer (2) as required. T ighten the nut (1) to 59 N·m (6.0 kgf·m, 43 ft·lb) of torque.
39 Seat Height Adjustment.
40 Front Fork Springs (Kit Parts) The kit front fork springs are available for racing. 1) Front Fork Specifications Items Original Rebounded damping setting (Upper) 9th (0 ~ -13) Compression damping setting (Lower) 7th (0 ~ -16) Fork oil KA Y ABA KHL 15-10 Fork oil level 91 mm Oil lock Oil lock piece Oil seal – – – Spring length 240.
41 Fork Spring Installation.
42 Electrical System Battery Use the original battery with 12 V 10 Ah or more capacity . Main Harness and Sub Harness (Kit Part) Main harness and sub harness are available for ra cing use as kit parts. Select one of them in accordance with your race regulation.
43 Main Harness Combination Parts T able Use the kit main harness or sub harness with the following parts as a set. Parts Main Harness (26031-0328) + Sub Harness (26031-0308) Main Harness (26031-0328).
44 When using the kit main harness and sub harness (Original meter: 26031-0308), the following original parts are not required. Original Main Harness Ignition Switch Rear Brake Light Switch Side Stand.
45 Throttle Bodies 1. Injector #1 2. White T ape 3. Injector #2 4. Injector #3 5. Injector #4 6. Inlet Air T emperature Sensor (Black) 7. Main Harness (Brown) 8. Main Throttle Sensor (White) 9. Inlet Air Pressure Sensor (Black) 10. Subthrottle Sensor (Black) 1 1.
46 Kit Main Harness Installation.
47 1. T o throttle bodies connector (Gray). 2. Crankshaft Sensor Connector (Brown) 3. Battery Ground Cable (Use Original Part) 4 Frame Ground 5. Regulator 6. Starter Relay 7. T o front sub harness connector (26031-0307 or 26031-0308). 8. Camshaft Position Sensor (Gray) 9.
48 1. Relay Box (Original) 2. T urn Signal Relay (Original) 3. Exhaust Butterfly V alve Actuator (Original) 4. T o connect the E.C.U (Black). 5. Fuse Box 6. T o connect the relay box (Gray). 7. Relay Box (27002-3703) 8. T o Connect atmospheric pressure sensor (Black).
49 Sub Harness (Original Meter) Installation 1. T o connect the original meter (Black). 2. T o connect the right switch housing (Black). 3. T o connect the left switch housing (Black). 4. T o connect the main harness (26031-0328) (Gray). Install the front sub harness (26031-0328) fo r the original meter as shown in the illustration.
50 Sub Harness (Kit Meter) Installation 1. Shift up Indicator Lamp (23016-0006) 2. T o connect the shift up indicator lamp (Green). 3. T achometer with Wate r T emperature Gauge (25031-1 142) 4. T o connect the tachometer with water temperature gauge (Black).
51 Kit Sub Harness (26031-0244) Installation Install the kit sub harness (26031-0244) as shown in the illustration. 1. E.C.U. 2. Sub Harness (26031-0244) 3. T o connect the inter face box (Black). 4. Bullet T erminal Pull off the # 22 pin (Red / Green Lead) from the main harness side connector .
52 NOTE ○ When pull of f the # 22 pin lead from the c onnector , pulling up the white claw for unlock the lead. ○ Be sure to lock the leads after pull of f the # 22 pin lead. Left Switch Housing Wiring Change When using the sub harness (26031-0244), change the wiring of the original main harness for the function of speed control switch.
53 Auto Shifter Installation 1. Side Stand Switch Connector 2. Speed Sensor Connector When using the auto shifter , connect the shifter connecto r to the side stand switch connector of the Original main harness. Change the shape of the shifter connector for mismatch connectors.
54 Wiring Diagram (with Original Meter).
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56 Wiring Diagram (with Kit Meter).
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Racing Kit P ar ts List.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-3 Camshaft(s)/T ensioner Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 12048 12048-0011 TENSIONER-.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-4 Crankshaft/Piston(s) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13001 13001-0061 PIST ON-ENGINE 4 (OPTION) 13002 13002-0008 PIN-PIST ON 4 (OPTION) 13008 13008-0019 RING-SET-PIST ON 4 (OPTION) 13251 13251-0015 ROD-ASSY-CONNECTING,L=110.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-5 Clutch Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13089 13089-0011 PLA TE-CLUTCH,STD +40% 1 (OPTION) 13089A 13089-0012 PLA TE-CLUTCH,STD +60% 1 (OPTION) 39108 39108-0004 RET AINER-SPRING,T=5.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-6 T ransmission(1/2)(TYPE-B) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13127 13127-0030 SHAFT-.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-7 T ransmission(2/2)(TYPE-B) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 92200E 92200-0230 W ASHER,28.3X34.0X1.4 AR (OPTION) 92200F 92200-0231 W ASHER,28.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-8 T ransmission(1/2)(TYPE-C) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13127 13127-0031 SHAFT-.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-9 T ransmission(2/2)(TYPE-C) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 92200E 92200-0230 W ASHER,28.3X34.0X1.4 AR (OPTION) 92200F 92200-0231 W ASHER,28.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-10 T ransmission(1/2)(TYPE-D) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13127 13127-0032 SHAFT.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-11 T ransmission(2/2)(TYPE-D) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 92200E 92200-0230 W ASHER,28.3X34.0X1.4 AR (OPTION) 92200F 92200-0231 W ASHER,28.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-12 Gear Change Drum/Shift Fork(s) Quantity-ZX1000 ’05 Ref. No . P ar t No .
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-13 Engine Cover(s) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 11004 11004-0022 GASKET-HEAD ,T=0.55 1 (OPTION) 11004A 11004-0023 GASKET-HEAD ,T=0.45 1 (OPTION) 11004B 11004-0026 GASKET-HEAD ,T=0.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine B-14 Fuel Injection Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 21175 21175-0073 CONTROL UNIT-ELEC.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine C-3 Generator Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 11053 11053-1557 BRA CKET ,OIL T ANK 1 (.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine C-4 Starter Motor Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13107 13107-0096 SHAFT 1 (OPTION) 13.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Engine C-5 Radiator Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 35063 35063-0216 ST A Y ,MAIN 1 (OPTION) .
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Chassis C-6 Swingarm Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 13271 13271-0581 PLA TE 1 (OPTION) 16 DEC.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Chassis C-7 Rear Hub Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 43082 43082-0005 P AD-ASSY-BRAKE,FR,F963.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Chassis C-8 Handlebar Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 11053 11053-1241 BRA CKET ,STEERING D A.
This catalog covers: GRID NO . This g rid cov ers: ’05 ZX1000-CR2 Chassis C-9 Meter(s) Quantity-ZX1000 ’05 Ref. No . P ar t No . Descr iption Spec Code CR2 11053 11053-1673 BRA CKET ,KIT METER 1 (.
Doc No. 99929-1870-01.
An important point after buying a device Kawasaki ZX-10R (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki ZX-10R yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki ZX-10R - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki ZX-10R you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki ZX-10R will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki ZX-10R, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki ZX-10R.
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki ZX-10R. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki ZX-10R along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
