04-05 Zx10 Race Kit Manual 5u54n

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 information of the original model.

Base Manual Ninja ZX-10R Motorcycle Service Manual

© 2005 Kawasaki Heavy Industries, Ltd.

Part Number 99924-1322-02

First Edition (1): Feb. 7, 2005

Congratulation on your purchase of racing kit parts for the 2005 Ninja ZX-10R.

IMPORTANT This manual provides how to install racing 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. 99924-1322-02). When you participate in a race, it is necessary to modify the machine for the regulation. So we want you to ask for the tuning up shop.

WARNING AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE. CAUTION When operating the engine, be careful not to trouble persons with noise. Do not turn the engine with loud engine and exhaust noise.

DISCLAIMER OF WARRANTY ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR IMPLIED.

BASIC WORKS IN INSTALLING KIT PARTS We are going to make up the original Ninja ZX-10R for the racing machine. We recommend that the rider himself should do the basic works, removing parts or installing parts etc., given advices by the tuning shop. In a race, although trouble will be apt to happen, if you participate in basic works, you can discriminate cause of trouble, so you can return the race soon. But concerning difficult technical works, you should ask to tuning shop.

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Table of Contents General Specifications .........................................................................................................3 Racing Kit Service Data .......................................................................................................5 Periodic Maintenance Chart.................................................................................................5 Engine Parts Installation ......................................................................................................7 Air Intake Parts .................................................................................................................7 Camshaft Chain Tensioner ...............................................................................................8 Camshafts, Sprockets.......................................................................................................9 Cylinder Head ................................................................................................................. 11 Cylinder Compression ....................................................................................................12 Piston..............................................................................................................................13 Crankshaft Main Journal Bushings .................................................................................13 Connecting Rod Bolts .....................................................................................................14 Connecting Rod Big End Bushings.................................................................................16 Clutch Adjustment (Back-Torque Limiter Setting) ...........................................................17 Transmission ..................................................................................................................21 Alternator ........................................................................................................................23 Water Temperature Sensor.............................................................................................27 Radiator ..........................................................................................................................27 Oil Catch Tank (Kit).........................................................................................................30 Cover Gaskets ................................................................................................................32 ECU (Kit) ........................................................................................................................32 Frame Parts Installation .....................................................................................................33 Throttle Parts (Kit Parts) .................................................................................................33 Final Drive Parts (Kit Parts) ............................................................................................34 Brake Pads (Kit Parts) ....................................................................................................34 Steering Damper (Kit Parts)............................................................................................35 Seat Height Adjustment ..................................................................................................38 Front Fork Springs (Kit Parts) .........................................................................................40 Electrical System ...............................................................................................................42 Battery ............................................................................................................................42 Main Harness and Sub Harness (Kit Part)......................................................................42 Left Switch Housing Wiring Change ...............................................................................52 Auto Shifter Installation...................................................................................................53 Wiring Diagram (with Original Meter)..............................................................................54 Wiring Diagram (with Kit Meter) ......................................................................................56

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General Specifications Item

2005 Ninja ZX-10R Racing

Engine: Ignition timing Fuel (Recommended) Engine oil (Recommended): Level Drive Train: Primary drive reduction ratio

10°BTDC @1 100 r/min (rpm) Racing gasoline Racing oil Between upper and lower levels of oil level gauge. 1.611 (87/54)

Transmission Gear Table

In Out 1st Teeth (Out/In) Gear Ratio In Out 2nd Teeth (Out/In) Gear Ratio

3rd

In Out Teeth (Out/In) Gear Ratio

4th

In Out Teeth (Out/In) Gear Ratio

5th

6th

In Out Teeth (Out/In) Gear Ratio In Out Teeth (Out/In) Gear Ratio

STD（Type A）

Type B

Type C

Type D

13127-0020 13262-0170 38/15 2.533 13262-0185 13262-0152 39/19 2.053 See Gear Selection 13262-0182 33/19 1.737 See Gear Selection 13262-0166 32/21 1.525 13262-0135 13262-0183 29/21 1.381 13262-0136 13262-0171 30/23 1.304

13127-0030 13262-0267 31/13 2.385 See Gear Selection 13262-0268 34/13 1.789 See Gear Selection 13262-0269 31/20 1.550 13262-0265 13262-0270 29/20 1.450 13262-0266 13262-0271 29/21 1.381

13127-0031 13262-0275 34/14 2.429 See Gear Selection 13262-0276 28/16 1.750

13127-0032 13262-0281 37/16 2.313 13262-0279 13262-0282 36/18 2.000

13262-0273 13262-0277 28/20 1.400 13262-0274 13262-0278 28/21 1.333

13262-0280 13262-0283 28/22 1.273

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Input 3rd/4th Gear Selection Table

3rd Gear

4th Gear A (=C) B 13262-0134 (19/21) 13262-0286 (19/20) 13262-0284 (19/21) 13262-0264 (19/20) 13262-0272 (16/21) 13262-0285 (16/20)

A B C

Gear Identification Slit Number Table

1st 2nd 3rd 4th 5th 6th

Input Output Input Output Input Output Input Output Input Output Input Output

Standard (Type A) 0 1 1 1 1 0 0 2 2 1 1 0

Type B 2 2 2 2 1 1 0 0 2 2

Engine Sprocket

13144-0021 13144-0022

#520-16T #520-17T

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Type C 3 3 0 3 3 3 3 3

Type D 4 4 2 2 4 4

Racing Kit Service Data Item

Standard

Cylinder Head, Valves:

Valve timing: Duration: Intake Exhaust Camshaft timing (cam lift center): Intake Exhaust Valve clearance: Intake Exhaust Squish Valve to piston clearance: Intake Exhaust Ignition System:

300° 292° 104° (ATDC) 102° (BTDC) 0.22 mm 0.20 mm 0.85 mm 1.45 mm @10°ATDC 1.80 mm @10°BTDC NGK CR9EIA-9 (STD), R0045Q-10 or R0373A-10 13 N·m (1.3 kgf·m, 113 in·lb)

Spark plugs Spark plug tightening torque

These values show the specifications when standard cylinder head and gasket are used.

Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQENCY OPERATION Engine Clutch plate - - check*

Each Race

Every Every Every As 3 races 5 races 10 races Required

●

Throttle grip play - - check*

●

Spark plug - - clean/gap*

●

Engine oil - - change

●

Oil filter - - replace

●

Valve lapping

●

Cylinder head/valve - - decarbonization

●

Cylinder - - check*

●

Piston/cylinder clearance - - check*

●

Piston ring, piston, and piston pin - - replace

●

Crankshaft main bearing - - check*

●

Connecting rod big end bearing - - check*

●

Transmission gear, bearing - - check*

●

Engine sprocket - - check*

●

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FREQENCY OPERATION Coolant - - change Radiator hoses, connections - - check*

Each Race

Every Every Every As 3 races 5 races 10 races Required ●

●

Frame Brake operation - - check*

●

Brake pad wear - - check*

●

Brake fluid level - - check*

●

Brake fluid - - change*

year

Brake master cylinder cup and dust seal - - replace

year

Brake caliper piston seal and dust seal - - replace

year

Brake hose - - replace

2 years

Drive chain - - adjust

●

Drive chain - - lubricate

●

Drive chain wear - - check*

●

Drive chain guide - - replace

If damaged

Front fork - - clean/check*

●

Front fork oil - - change

First change after 2 races, then every 5 races

Nut, bolt, and fastener tightness - - check*

●

Fuel system - - clean

●

Fuel hose, fuel filter - - replace

●

Steering play - - check*

●

Steering stem bearing - - grease

●

Rear sprocket - - replace

●

General lubrication of chassis - - perform

●

Wheel bearing (rear) - - grease

●

Swingarm pivot, uni-track linkage - - grease

●

Swingarm pivot, uni-track linkage - - check*

●

*: Replace, add, adjust, clean, or torque if necessary.

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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.

1. Relational Parts of Secondary Air: Remove the Parts. 2. Remove the parts or cut the cleaner element off remaining the wire net. 3. Secondary Air ages on Cylinder Head: Plug the holes, or press-fit the plugs (92066-1005) instead of the original pins. Output of Secondary Air on Air Cleaner: Plug the hole 4. Air Cleaner Drain Tube: Use it cutting it in suitable length.

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Camshaft Chain Tensioner Replace the cam chain tensioner with the kit 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. ○ Check to see that the tensioner rod turns freely in the body, if not, polish the tensioner rod or fine the female threads in the body with a tap (Diameter × Pitch = 6 mm × 1.0 mm). Install the tensioner on the cylinder block with the tensioner rod is fully pushed back. Turn the tensioner rod in with a screwdriver until it becomes hard to turn. Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to take up any gap and tighten the locknut. After adjusting the tensioner rod、if the tensioner rod does not stick out from the tensioner body, use the kit long tensioner rod (13116-1166). NOTE ○ Never forward the tensioner rod forcibly, this will increase mechanical loss of the tensioner and may damage to the chain guide. ○ The cam chain tensioner must be adjusted at every race.

1. Tensioner Body 2. Tensioner Rod: 13116-1166 (Kit) 3. O-ring

4. O-ring 5. Locknut

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Camshafts, Sprockets Camshafts, Sprockets:

Camshaft Duration Lift 49118-0008 (STD) (Intake) 300° 9.1 mm 49118-0023 (STD) (Exhaust) 292° 8.5 mm 49118-0034 (Kit) (Intake) 310° 9.7 mm Adjust the valve clearance within the specified value. Intake: 0.15 ~ 0.24 mm, Exhaust: 0.17 ~ 0.22 mm More performance is expected when adjusted from middle value to upper limit between adjustable range. If you can not adjust the valve timing for racing, install the camshaft sprocket to the camshaft using the round bolt holes and adjust the cam chain timing according to the Ninja ZX-10R Service Manual. If you adjust the valve timing, install the sprocket to the camshaft between the adjustable range of the long bolt holes. Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11 ft·lb) of torque. Valve Timing

Timing (cam lift center) Original (when the round bolt holes are used) Race use (when the long bolt holes are used)

Intake 104° 108° (Recommended)

Exhaust 100° ~ 102° 102° (Recommended)

○ When grinding the cylinder head bottom surface, grinding the cylinder top surface or

using thinner gaskets, be sure the valve to piston clearance especially. ○ When using the sprocket long bolt holes and adjusting the valve timing to be different from the standard timing, check the valve to piston clearance of all cylinders after adjusting the valve clearance correctly. Valve to Piston Clearance (Min.)

Intake Exhaust

0.7 mm 1.2 mm

If the valve to piston clearance is less than the minimum value, do not start the engine because the valves will touch the piston and the engine may be damaged. Adjust the valve timing again to keep the valve to piston clearance more than the minimum value. Method of measuring clearance of valve and piston –1. ○ Holding the crankshaft at 10° ATDC (intake) and 10° BTDC (exhaust) of crankshaft timing, measure the amount of the tappet movement until the valve comes in with the piston pushing the tappet.

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○ ○ ○ ○ ○

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 . Install the cylinder head and adjust the camshaft chain timing. Turn the crankshaft by two rotations or more. Remove the cylinder head and measure the thickness of the clay. The thickness of the collapsed clay is a clearance of the valve and the piston.

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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 off the stepped portions only at the mating surface between the carburetor holder and the intake port. When using the kit camshaft (12044-0043), grind off the inside of the intake port to extent 1mm from the original port diameter for improve the performance. Mark the carburetor holders so that they can be installed in their original positions. Grind off and smooth the stepped portions at the mating surface between the valve seat and the port. Smooth the inside of the intake port and exhaust port. Chamfer the machining edge of the cylinder head where the valve seat installed, also smooth the dome of the combustion chamber with the valves installed. Excessive smoothing may reduce the cylinder compression. Use the hand grinder. Use #200 oil stone for eliminating any stepped portion and #300 oil stone for finishing. NOTE

○ These procedures make air resistance less and intake/exhaust gas flow more smooth.

However, much more effect can not be expected by excessive grinding and smoothing. It may be done to the extent of getting rid of uneven surfaces.

A: Stepped Portions : Grind Area ( All around port )

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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 surface or using thinner gasket, adjust the valve timing

to keep that the valve to piston clearance is not less than the minimum value (IN: 0.7 mm, EX: 1.2 mm).

Cylinder Compression

○

○

○ ○ ○

To adjust the cylinder compression, adjust the thickness of the cylinder head gasket or smooth the cylinder head under surface or cylinder top surface to make the piston squish 0.65 mm. Keep the piston squish more than 0.65 mm. Grind off the cylinder head under surface to 0.4 mm. Do not grind the cylinder upper surface. This can raise the compression ratio while keeping the clearance of the piston and valve, and one of the squish. Although, as the engine machining is uneven, determine the cutting dimension after keeping the recess and the squish before machining. Position the piston at Top Dead Center, and put a small piece of modeling clay on the shoulder of the piston. Install the cylinder head gasket and cylinder head, and tighten the head bolts to the specified torque. Remove the cylinder head and measure the thickness of the clay. The thickness of the collapsed clay is the size of the squish. The most preferable squish measurement is 0.65 mm. Select proper cylinder head gasket.

Cylinder Head Gasket

Part No. 11004-0026 11004-0022 11004-0023 11004-0034

Tightening thickness 0.65 mm（Original） 0.55 mm 0.45 mm 0.40 mm

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Remarks KIT KIT KIT KIT

Piston 1.Kit Piston (13001-0061): SB Method Kit piston are exclusive the two piston ring for reduce the compression height (dimension between the center of piston pin hole to shoulder of the piston) and the mechanical friction loss. Kit piston has more reduced the weight compared the original piston. Establish the cylinder compression in 14.3 to use the this piston and grind off the cylinder head under surface to 0.4 mm ○ Always use the higher octane rating gasoline for prevent the knocking. Use the kit piston rings and the kit pistons. Change the kit pistons from the original pistons inspect the squish (refer to the Cylinder Compression section). Use the kit pistons (13001-0061) following below. ○ Use the kit connecting rod assemblies (13251-0015) ○ Use the kit piston rings (13008-0019). ○ Use the kit piston pins and snap rings. ○ There are the machining edge for the valve relief portions of the piston heads. Must be hand finished for smooth corners. (Round the corner to R1)

Crankshaft Main Journal Bushings Crankshaft Main Journal Bushings: Use original bushings.

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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. Connecting Rod : 13251 – 0005 Bolt : 92153 – 0491 92153 – 0809 (Kit Part : Attached Recess) Nut : 92015 - 1311

Install the original bolts into the connecting rod. Before every tightening, use a point micrometer to measure the length of the bolts and record the values to find the bolt stretch. Apply a small amount of molybdenum disulfide grease to the threads and seating surfaces of nuts and bolts. Tighten the big end nuts at the torque (reference torque) of 20 N·m (2.0 kgf·m, 14.5 ft·lb). Check the length of the bolts and find the bolt stretch. Bolt Length after tightening – Bolt Length before tightening = Stretch Bolt Stretch Usable Range: 0. 32 mm (0.0126 in.) target

Turn the big end nuts more until the bolt stretch reaches the usable range. NOTE ○ Replace the original bolts with new ones if they have already been tightened up to

usable range 2 times. ○ Replace the bolts with new ones if they are used for the engine with a not clear feature.

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2. Kit Connecting Rod Connecting Rod Bolt Use the kit connecting rod bolts (with the original connecting rod bolts) and nuts. The kit connecting rod can use the original connecting rod bolt (92153-0491). When using the original connecting rod bolts, make recesses at both ends of the original connecting rod bolt to measure its length and determine the bolt stretch. Connecting rod : 13251 – 0035 Bolt : 92153 – 0809 (Attached Recess) Nut: 92015 - 1311

※Installation of the kit connecting rod bolt is same as installation of the original connecting rod bolt in the 1. original connecting rod section. Refer to the 1. original connecting rod section.

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Connecting Rod Big End Bushings The connecting rod bushing in the kit has improved 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 0.050 mm. Crankpin Diameter Marks ○: 34.493~34.500 mm None: 34.484~34.492 mm

Connecting Rod Big End Bore Diameter Marks ○: 37.509~37.516 mm None: 37.50037.508 mm [A]. Diameter Mark (○ or no mark) [B]. Weight Mark (Alphabet, E, F et)

Connecting Rod Big End Bushings Kit Bushing Part Color Thickness Number Blue 92139-0109 1.488 ~ 1.493 mm Black 92139-0110 1.483 ~ 1.488 mm Brown 92139-0111 1.478 ~ 1.483 mm [A]. Color Mark

Big End Bearing Bushing Selection ○ Crankshaft Connecting Rod None Bushing Brown 34 ~ 60 μm Clearance (recommend)

○ ○

None None Black 32 ~ 58μm

None ○ Blue 30 ~ 56μm

NOTE ○ Make the clearances between the crankshaft main Journals and the connecting rod big

ends within the prescribed allowances. Excessive clearances will cause the oil pressure at the connecting rod big end to drop and lead to the damage of the bearing.

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Clutch Adjustment (Back-Torque Limiter Setting) The Ninja ZX-10R engine is equipped with the 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. The back-torque limiter operating condition can be changed by changing the total thickness of clutch plates and changing the number of leaf springs. Try different settings and select the best.

The standard setting of length [A], total thickness of clutch plates shown below, becomes about 53.6 mm (Supposed combination of steel plates is the plate with spring × 1 pcs. + t 2.6 × 8 pcs.). For this setting the effective stroke of clutch spring plate during the back-torque limiter operation is adjusted between 0.45 and 0.75 mm. By increasing the effective stroke the back-torque limiter causes more slip. The effective stroke increases by decreasing the length [A]. The length [A] between 52.8 and 53.6 mm is available by changing the combination of the steel plates. Replace one steel plate with a thinner one and try the setting. If the operation of the back-torque limiter is not enough replace other steel plates one by one. Thickness (mm) 2.3 1.6 2.9

Part Number 13089-1084 13089-1115 13089-1093

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When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers (provided as optional production parts) to keep the preload of clutch springs according to the table below. Length [A] Part Number Height [B] 53.1 ~ 53.6 mm 13092-1041 6 mm (standard) 52.6 ~ 53.0 mm 39108-0004 5 mm 52.0 ~ 52.5 mm 39108-0006 4.5 mm ※If you have clutch slip during acceleration use shorter spring retainers by one size to increase preload of clutch springs. The original springs and retainers can be used if the length [A] is between 52.8 ~ 53.6 mm. For precise setting the measurement of the effective stroke of clutch spring plate is recommended. • Remove oil from clutch plates. • Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.

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[A] [B] [C] [D] [E] [F]

Spacers Needle Bearing Bushing Clutch Housing Clutch Hub Sub Clutch Hub

[G] [H] [I] [J] [K]

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Friction Plates Spring Plate Assembly Steel Plates Spring Plate Spring Retainer

• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub). • To 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 forth [C]. The difference between the highest and lowest gauge readings is the amount of the effective stroke of clutch spring plate. [D] Drive Shaft

After installing the clutch to the engine, measure and record the depth [B] shown below, the length from the clutch spring plate to the top surface of the sub clutch hub, using a caliper or a depth gauge. Manage the depth [B] to adjust the effective stroke after that, because the friction disks would be worn and the length [A] would change. The decrease of the depth [B] from the initial setting shows the increase of the effective stroke of clutch spring plate from the value initially measured.

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Spring Plate Assembly

The ZX-10R engine is used with the leaf sprig built in type steel plate assembly (spring plate assembly) in the clutch. The spring plate assembly are available for increase the spring constant. When outbreak the starting judder, use the spring plate assembly of the kit parts. Whenever the plate thickness is difference for adjusting the clutch plate, take care the length [A]. Part Number 13089-0003 13089-0011 13089-0012

Spring Constant Standard 40 % up comparison standard 60 % up comparison standard

ID Color None White Blue

※Identification Color: The ID marks are on the springs between the steel plates.

Transmission Type B ~ D of the kit gears are available of the 2005 model ZX-10R. To change the gear ratios with combination the gears. Remove the three steel balls (600A0500) from the output shaft assembly. This is done to start easily the engine with the second gear. Replace the circlips with new ones if they were removed.

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Transmission 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.

① Spline washer

② Plane washer A

③ Plane washer B

Thickness (mm) 1.2 1.4 1.6 1.8 2.0 0.8 1.0 1.2 1.4 1.6 1.4

Part No. 92200-0229 92200-0230 92200-0050 92200-0231 92200-0232 92200-0225 92200-0226 92200-0051 92200-0227 92200-0228 92200-0138

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Remarks Kit Kit Original Kit Kit Kit Kit Original Kit Kit Kit

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 in order to make the dog lengths of the 3rd – 5th & 2nd – 6th gear dogs equal. Adjust the dog length of each gears to smooth gear-shifting.

Standard Adjusting ①-2 Use the standard spline washer t1.6 mm (92200-0050) ②-2 Use the standard spline washer t1.2 mm (92200-0051) When thin the washer of ①-1 (②-1) from the standard washer and thickly the washer of ① -2 (②-2) from the standard washer to increase the dog length of gears also reverse the combination to reduced the dog length of gear.

Alternator Racing kit of the 2005 model ZX-10R are available the alternator to install the left end of the crankshaft. To quicken response by reducing the flywheel mass and to reduce the weight, use the kit alternator. Also use the kit alternator improve the engine ability Kit Alternator Rated Output 10 A @ 8 000 rpm (original: 30 A @ 5 000 rpm) ※ Effective current 7~8 A for running the race method vehicle. Select and use the kit alternator or original alternator for racing conditions.

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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. Used Parts Table Part Name 1 Starter motor 2 Shaft 1 3 Shaft 2 4 Circlip 5 Needle bearing 6 Shaft 3 7 Idle gear cover 8 Idle gear 9 Stator 10 Rotor 11 Busing 12 Starter clutch cover 13 Bolt 1 14 Needle bearing 15 Starter clutch 16 Bolt 2 17 Starter clutch gear 18 Snap ring

Part No. 21116-0013 13107-0097 13107-0096 480J1300 92046-1217 13107-0098 14091-0443 59051-0053

Remark Original

21001-0033 92139-0121 14091-0444 92153-0451 92046-0004 13194-3704 92150-1880 16805-0012 92033-3731

Original Original Original Original Original

Remove the original starter clutch related parts. When removing the original starter clutch from the case, carefully remove the snap ring. For disassembly, replace the new one when the reuse is hard for damaging, etc.

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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). Be careful not to give too much torsion to the lead wire. Kit Alternator Installation

Regulator Use the kit alternator and the kit regulator (21066-0010) as a set. Install the kit regulator same position of the original regulator. Connect the kit sub harness (26031-0323) between the kit regulator and the kit alternator.

25

1. In case of without Starter Motor ※ Refer to the illustration of 1. Kit Alternator Installation. Remove the [2] ~ [6], [8] parts and insert the plugs to the hole of the starter motor inserted as shown in the illustration. Part Name Part No. Remark 1 Plug 92066-1332 Kit 2 Plug 92066-1333 Kit 3 O-ring 92055-1262 Kit 4 Bolt 130G0625 Kit 5 Nut 312B0600 Kit Caulking the bolt for unplug the plug. Insert the plug into the hole of the starter motor and tighten the nut. Apply liquid gasket.

2. Original Alternator removal Remove the original alternator related parts for use the kit alternator. Close the holes of the alternator cover and crankcase as shown in the illustration. ※Used parts as following table. Sealed Parts for Alternator Part Name Part No. Remark 1 Grommet 92071-0022 Kit 2 Plate 13271-0149 Original 3 Bolt 130Y0508 Original Sealed Parts for Crankcase Part Name 4 Plug 5 O-ring 6 Alternator shaft lever 7 Bolt 8 Bolt

Part No. 92066-0052 670B2020 13168-0035 92151-1930 92153-0758

Remark Kit Kitl Original Original Original

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Water Temperature Sensor The original water temperature sensor installed in the cylinder head must be remain and connected to the main harness because the electronic control unit (E.C.U.) needs the output signal from the original water temperature sensor.

Radiator 2005 model ZX-10R racing kit provides the capacity increased type main radiator and added the sub radiator to improved the cooling function. Replace of the kit main radiator (39060-0022) is enough effectives of the cooling performance but at high ambient temperature, using the kit sub radiator (39060-0021) with kit main radiator increase cooling performance more. Radiator Installation

Main Radiator Install the kit radiator mounting stay (35063-0216) to the same position of the original radiator mounting stay on the crankcase and tighten it. ※As some stays may not be able to install according to the applied muffler, remodel the stay or make suitable one by your owe. Sub Radiator Install the sub radiator stays as shown in the illustration. ○ Fix the right side kit stay (35063-0217) on the crankshaft sensor cover [A] by the bolts. ○ Fix the left kit side stay (35063-0217) on the starter cover [B] by the bilts. Fix a wire netting in front of sub radiator for prevent the fin damages due to the stepping stone. Machine the original cowl to meet the outline of radiator. Fill the space between the cowl and the sides of radiator by fixing a sponge or the like.

NOTE ○ After radiator’s installation, be sure to check that there is no interference between the

radiator and the manifold, tire and the front fork full bottomed. ○ The original radiator cannot combine with the kit sub radiator.

27

Water 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 (39192-0011). Install the kit water temperature sensor (for water temperature gauge of kit meter, 21176-1099) to the kit water pipe. Pinch the terminal of the kit water temperature sensor ground lead (26011-0071) between the water hose and the kit water pipe and clamp it on the hose as shown in the illustration. Install the other side terminal of the ground lead with the crankshaft sensor cover by the bolt.

Water Outlet of Radiator Body Same situation of the original radiator.

28

Use the kit sub radiator with the kit main radiator. Water 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, 21176-1099) to the kit water pipe. Pinch the terminal of the kit water temperature sensor ground lead (26011-0071) between the water hose and the kit water pipe and clamp it on the hose as shown in the illusturation. Install the other side terminal of the ground lead with the crankshaft sensor cover.

Water Outlet of Kit Main Radiator Remove the original water pipe (39192-0029) and install the kit water pipe (39192-0038). Install the kit water hose (39062-1072) between the water pipe and the kit sub radiator. Reserve tank Installation When using the radiator (Kit), the original reserve tank cannot be used. Prepare a suitable substitute reserve tank. Reserve Tank should be equipped with a band so as not to affect the running and the handling.

NOTE ○ Capacity of a reserve tank should be more than 200 cc. ○ Position of the hose to a reserve tank.

* End of the hose to the radiator should be always in the coolant. * End of the hose to atmosphere should be always beyond the coolant surface.

29

Oil Catch Tank (Kit) Use the oil catch tank for the engine blowby gas. Oil Catch tank: 52001-0002 Tank Capacity: Approximately 570 cc Oil Catch Tank Installation

Install the mounting bracket with regulator under the cross pipe of the frame by the bolts (use the original regulator mounting bolts). Install the oil catch tank to the bracket as shown in the illustration. Used Bolts: 13061-0113 (X3) After installing the oil catch tank, make sure not to interface with the drive chain, swingarm (suspension at fully bottomed). Close the boss of oil drain of the oil catch tank with M6 bolt and gasket, add the wiring not to be missing. Oil Catch Tank Hose Installation 1 92192-0226 Crankcase to oil catch tank 2 92192-0227 Oil catch tank to air cleaner Remove the original breather hose (92192-0035). Install the hose clamps so that the kit clamps (92171-0338) are catch tank side and the original clamps (92171-0391) are other side on the hoses. Run the hoses as shown in the illustration. NOTE ○ Protect the hose and check the no blockade at the its curved part when the hose is afraid

of interfering with edge part on the way of the hose routing. Specially, about the hose toward the crankcase, check the no blockage by the fuel pump.

30

31

Cover Gaskets The kit cover gasket are available of the 2005 model ZX-10R. They are made from “metal-foam” and made easy to separate. Starter Clutch Cover: 11061-0168 Idle Gear Cover: 11061-0711 Clutch Cover: 11061-0134 Oil Pan: 11061-0169

ECU (Kit) The 2005 model ZX-10R kit ECU has following functions. Refer to the Kawasaki FI Calibration Tool Instruction manual for the ECU function set up method. 1. Auto Shift Functions Be sure use the point type sensor. Recommended: Dynojet mode or Battle Factory mode Part installation is refer to the Electrical Part Installation section in this Manual. 2. Pit Road Engine Revolution Limit Functions ON/Off Changing Switch Part Number: 27010-0040 (use the kit meter) Part installation is refer to the Electrical Part Installation section in this Manual.

3. Shift Indicator Functions Part installation is refer to the Electrical Part Installation section in this Manual. NOTE ○ When using the original meter, lit the shift up indicator light so that the shift up indicator

lamp of the kit does not used. ○ Use the shift up indicator lamp of the kit together with the kit meter but do not function as the FI indicator light.

32

Frame Parts Installation Throttle Parts (Kit Parts) The following throttle cases, grip and reels are available as kit parts. These kit parts quicken throttle response to the twist grip. 1) Throttle Case

Parts Throttle Case, Upper Throttle Case, Lower Bolts (2) Grip, Right

P/No. 32099-0004 32099-0005 120S0625 46075-1143

2) Throttle Reels

Tow types are available. Twist Grip Turn Angle to Full Throttle 59101-0001 R21.5 60° 59101-0002 R20.0 65° Throttle Reel Travel Angle················Effective angle excluding throttle cable free play. P/No.

I.D. Mark

1. Identification Mark

1. 2. 3. 4. 5. 6. 7. 8.

Upper Case: 32099-0004 Lower Case: 32099-0005 Reel, 60°: 59101-0001 Reel, 65°: 59101-0002 Throttle Cable, Acceleration: 54012-0150 Throttle Cable, Deceleration: 54012-0151 Bolt: 120S0625 Install the upper case and lower case which mating clearance backward.

33

Final Drive Parts (Kit Parts) 1) Drive Chain

#520 t 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 are available. The front pads are for higher braking force, and the rear pads are for higher braking force. Front Brake Pads

P/No. 43082-0005 Original 43082-1293 (ZX-6RR Original)

Mark F9633 C93YT C93ZM

Braking Force High ↨ Low

NOTE ○ Removing the plate (13271-0365) from original front brake pads of ZX-10R is

permissible. Rear Brake Pads

P/No. Original 43082-1220 43082-1192

Mark FO GG C93G C93

34

Braking Force High ↨ Low

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. 1) Recommended Steering Damper

OHLINS SD2005 2) Stroke

SD2005: 150 mm 3) Installation

Install the steering damper carefully to avoid the steering damper as a stopper.

1. 2. 3. 4. 5.

Steering Damper: OHLINS SD2005 Holder: 13280-0090 Holder: 13280-0091 Bolt, Allen: 120P0635 Steering Damper Bracket: 11053-1241

35

NOTE ○ The holder’s one side mating surface are shifted 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.

1. Journal

36

○ When install the steering damper which stroke less than 150 mm, apply the suitable

stopper as shown below.

1. 2. 3. 4. 5.

Steering Damper Holder Holder Bolt, Allen Stopper (Apply and tighten with ram duct installation bolt)

4) Damper Adjuster

Standard Position: 8th click [1st click (harder) is fully clockwise click] Usable Range: 1st to 12 ~ 17th click

37

Seat Height Adjustment Loosen the nut (1) and insert the spacer (2) as required. Tighten the nut (1) to 59 N·m (6.0 kgf·m, 43 ft·lb) of torque. When changing the seat height, adjust the spring preload of the rear shock absorber. ○ As the rear suspension tends to be softer when raising the seat height with the adjusting spacer of the seat height applied, adjust the spring preload of the rear shock absorber as required. ○ One turn of the spring adjusting nut changes the spring length by 1.5 mm.

38

Seat Height Adjustment

39

Front Fork Springs (Kit Parts) The kit front fork springs are available for racing. 1) Front Fork Specifications

Items Rebounded damping setting (Upper) Compression damping setting (Lower) Fork oil Fork oil level Oil lock Oil seal Spring length Spring constant Spacer length Sub spring stroke

Original 9th (0 ~ -13) 7th (0 ~ -16) KAYABA KHL 15-10 91 mm Oil lock piece ––– 240.3 mm (muount), 245.3 mm (free) 9.25 N/mm 101 mm 20.5 mm

2) Front Fork Spring

P/No. A × B × C (mm) Original 4.8 × 28.7 × 245.3 44026-0046 4.8 × 28.7 × 245.3 44026-0047 4.8 × 28.7 × 245.3 44026-0048 4.9 × 28.5 × 245.3 A: Coil Diameter B: Spring Inside Diameter C: Spring Free Length

Number of Wiring 15 15.4 14.6 15.6

Spring Constant K = 9.25 N/mm K = 9.0 N/mm K = 9.5 N/mm K = 9.75 N/mm

3) Front Fork Spring Replacement

Replace the main spring referring to the Fork Oil Change section of the base Service Manual. NOTE ○ Install the kit springs facing the smaller spring end diameter side upward.

Identification Mark

The following ID marks are on the springs. Spring 44026-0046 (K = 9.0) 44026-0047 (K = 9.5) 44026-0048 (K = 9.75)

40

ID Mark (Smaller diameter end side) One slit Two slit Three slit

Fork Spring Installation

41

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 racing use as kit parts. Select one of them in accordance with your race regulation. Main Harness (with Original Meter and Kit Meter): 26031-0328 Sub Harness (with Throttle Bodies): 26031-0329 Sub Harness (with Kit Meter): 26031-0307 Sub Harness (with Original Meter): 26031-0308 Sub Harness (with Original Meter and Original Main Harness): 26031-0244 Meter (Kit Parts) Installation

1. Shift Up Indicator Lamp (Kit): 23016-0006 2. Tachometer with Water Temperature Gauge (Kit): 25031-1142 3. Damper (Kit): 39156-0098 4. Meter Bracket (Kit): 11053-1673 5. Collar (Kit): 92152-0058 6. Rivet (Kit): 92039-1106 7. Bracket (Kit): 11053-1747 8. Bracket (Kit): 11053-1748 9. Bolt (Kit): 130J0618 10. Nut (Kit): 92015-1233 11. Ram Air Duct (Original): 39045-0014 Insert the three collars [5] into the damper [3]. Insert the rivet [6] from the backside of the meter bracket [4] and fix them. Install the bracket [4] to the original air duct [11].

42

Main Harness Combination Parts Table Use the kit main harness or sub harness with the following parts as a set. Main Harness (26031-0328) + Sub Harness (26031-0308) ○

Parts

Meter Assembly (Original)

Main Harness (26031-0328) + Sub Harness (26031-0307)

○

Tachometer with Water temperature Gauge (Kit)

○

Water Temperature Gauge Lead (Kit)

○

Water temperature sensor (Kit)

○ ○

Relay Box (Kit)

Sub Harness (26031-0244)

○

NOTE ○ When using the main harness (26031-0328) with the sub harness (26031-0329) of the

throttle bodies and relay box (27002-3703) required. ○ When using the sub harness (26031-0244) no kit parts required. Removal Parts When using the kit main harness and sub harness (kit meter: 26031-0307), the following original parts are not required. Original Main Harness Meter Assembly Bracket (Rear View Mirror & Meter Assembly) Ignition Switch Left Switch Housing Rear Brake Light Switch Side Stand Switch Relay Box Turn Signal Relay Head Light, Tail/ Brake Light License Plate Light Front Right Turn Signal Light Front Left Turn Signal Light Rear Right Turn Signal Light Rear Left Turn Signal Light Horn

43

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 Switch Relay Box Turn Signal Relay Head Light, Tail/ Brake Light License Plate Light Front Right Turn Signal Light Front Left Turn Signal Light Rear Right Turn Signal Light Rear Left Turn Signal Light Horn Kit Meter When using the kit tachometer with water temperature gauge, the following kit parts, kit main harness (26031-0328) and kit sub harness (26031-0307) are required. Tachometer with Water Temperature Gauge (Kit): 25031-1142 Water Temperature Gauge Lead (Kit): 26011-1779 Water Temperature Gauge Ground Lead (Kit): 26011-0071 Water Temperature Sensor (Kit): 21176-1099

44

Throttle Bodies

1. Injector #1 2. White Tape 3. Injector #2 4. Injector #3 5. Injector #4 6. Inlet Air Temperature Sensor (Black) 7. Main Harness (Brown) 8. Main Throttle Sensor (White) 9. Inlet Air Pressure Sensor (Black) 10. Subthrottle Sensor (Black) 11. Subthrottle Valve Actuator (Black) Remove the original sub harness (26031-0195) from the throttle bodies. Install the kit sub harness (26031-0329) as shown in the upside illustration. NOTE ○ Injector lead connector #1 marked the white tape. ○ Install the bands same position after install the kit sub harness, however clamp the band

so that the harness tube are not crush. ○ Be careful that the sub harness does not to interference the throttle cables.

45

Kit Main Harness Installation

46

1. 2. 3. 4 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

To throttle bodies connector (Gray). Crankshaft Sensor Connector (Brown) Battery Ground Cable (Use Original Part) Frame Ground Regulator Starter Relay To front sub harness connector (26031-0307 or 26031-0308). Camshaft Position Sensor (Gray) Ignition Coils (Gray) Water Temperature Sensor (Black) Vehicle-down Sensor (Gray) Fuel Pump (Black) To battery Ground terminal (Semitransparent) Auto Shifter (Yellow) Auto Shifter (Blue) To speed sensor connector (Black). Speed Sensor (Original) To gear position switch connector (Green) Gear Position Switch Lead (Original)

Remove the original main harness from the frame. Install the kit main harness (26031-0328) as shown in the illustration. Connect the [2] crankshaft sensor connector to the original crankshaft sensor connector. Use the original part for the [3] battery ground cable. Connect the [8] camshaft position sensor connector to the camshaft position sensor at the cylinder head front side. Use the original part for [9] ignition coil connector at the cylinder head upper side. Connect the [10] water temperature sensor connector to the water temperature sensor at under the #1. #2 intake ducts of cylinder. When using the recommended auto shifter to connect the [15] auto shifter connector. Do not use the [14] auto shifter. NOTE ○ When using the kit tachometer, always connect the water temperature sensor at the

cylinder head rear side. ○ For recommended auto shifter, refer to the Kawasaki FI Calibration Tool Instruction Manual of another sheet.

47

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Relay Box (Original) Turn Signal Relay (Original) Exhaust Butterfly Valve Actuator (Original) To connect the E.C.U (Black). Fuse Box To connect the relay box (Gray). Relay Box (27002-3703) To Connect atmospheric pressure sensor (Black). Atmospheric Pressure Sensor (Original) To connect the inter face box (Black).

Remove the original relay box and original turn signal relay. Remove the [3] exhaust butterfly valve actuator except the exhaust pipes are used. Drill the rear fender for the relay box (27002-3703) installation, however be careful that the relay box does not to interference the around parts.

48

Sub Harness (Original Meter) Installation

1. 2. 3. 4.

To connect the original meter (Black). To connect the right switch housing (Black). To connect the left switch housing (Black). To connect the main harness (26031-0328) (Gray).

Install the front sub harness (26031-0328) for the original meter as shown in the illustration. When using the original meter, use the left and right original switch housings. NOTE ○ When using the original meter, function the head light dimmer switch or/and ing

button for the speed control switch function. ○ Hold the stop watch function of the stop watch switch.

49

Sub Harness (Kit Meter) Installation

1. 2. 3. 4. 5. 6. 7.

Shift up Indicator Lamp (23016-0006) To connect the shift up indicator lamp (Green). Tachometer with Water Temperature Gauge (25031-1142) To connect the tachometer with water temperature gauge (Black). To connect the right switch housing (Black). To connect the speed control switch (27010-0040) (Black). To connect the main harness (26031-0328) (Gray).

Install the front sub harness for the original meter as shown in the illustration. NOTE ○ When using the kit front sub harness (26031-0307), possible use the Original

(46094-0040), and kit (46091-1809) of the right switch housing.

50

Kit Sub Harness (26031-0244) Installation

Install the kit sub harness (26031-0244) as shown in the illustration.

1. 2. 3. 4.

E.C.U. Sub Harness (26031-0244) To connect the inter face box (Black). Bullet Terminal

Pull off the # 22 pin (Red / Green Lead) from the main harness side connector. ○ Mark - # 22 Pin Position Mark - Unused Install the bullet terminal in the packing of the sub harness to the # 22 pin. Connect the # 22 bullet terminal to the bullet terminal of the sub harness.

51

NOTE ○ When pull off the # 22 pin lead from the connector, pulling up the white claw for unlock

the lead. ○ Be sure to lock the leads after pull off 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. Change the pin lead position (refer to right figure). From ① Red / Green Lead to ② Position. From ③ Black / Yellow Lead to ④ Position.

52

Auto Shifter Installation

1. Side Stand Switch Connector 2. Speed Sensor Connector When using the auto shifter, connect the shifter connector to the side stand switch connector of the Original main harness. Change the shape of the shifter connector for mismatch connectors.

53

Wiring Diagram (with Original Meter)

54

55

Wiring Diagram (with Kit Meter)

56

57

Racing Kit Parts List

This catalog covers:

’05 ZX1000-CR2 Engine

GRID NO.

B-3

This grid covers:

Camshaft(s)/Tensioner Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

12048

12048-0011 (OPTION) 13116 13116-1160 (OPTION) 13116A 13116-1166 (OPTION) 49118 49118-0034 (OPTION) 92015 92015-1078 (OPTION)

TENSIONER-ASSY

1

ROD-PUSH

1

ROD-PUSH

AR

92055

92055-0053 (OPTION) 92055A 92055-011 (OPTION)

1

CAMSHAFT-COMP,INTAKE

1

NUT,FLANGED,6MM

1

RING-O,20.8X1.9

1

RING-O,5MM

1

DEC.16,2004



GRID NO.

B-4

This grid covers:

Crankshaft/Piston(s) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13001

13001-0061 (OPTION) 13002-0008 (OPTION) 13008-0019 (OPTION) 13251-0015 (OPTION) 92015-1311 (OPTION)

13002 13008 13251 92015 92033

92033-1161 (OPTION) 92139 92139-0109 (OPTION) 92139A 92139-0110 (OPTION) 92139B 92139-0111 (OPTION) 92153 92153-0809 (OPTION)

2

PISTON-ENGINE

4

PIN-PISTON

4

RING-SET-PISTON

4

ROD-ASSY-CONNECTING,L=110.45

4

NUT,FLANGED,8MM

8

RING-SNAP,PISTON PIN

8

BUSHING,CRANK PIN,BLUE BUSHING,CRANK PIN,BLACK BUSHING,CRANK PIN,BROWN BOLT,CON-ROD,8X45.5

DEC.16,2004

AR 8 AR 8



GRID NO.

B-5

This grid covers:

Clutch Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13089

13089-0011 (OPTION) 13089A 13089-0012 (OPTION) 39108 39108-0004 (OPTION) 39108A 39108-0006 (OPTION)

3

PLATE-CLUTCH,STD +40%

1

PLATE-CLUTCH,STD +60%

1

RETAINER-SPRING,T=5.0(STD-1.0)

6

RETAINER-SPRING,T=4.5(STD-1.5)

6

DEC.16,2004



GRID NO.

B-6

This grid covers:

Transmission(1/2)(TYPE-B) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13127

13127-0030 (OPTION) 13144 13144-0021 (OPTION) 13144A 13144-0022 (OPTION) 13262 13262-0152 (OPTION) 13262A 13262-0185 (OPTION)

SHAFT-TRANSMISSION INPUT,13T

1

SPROCKET-OUTPUT,16T,#520

1


1

GEAR,OUTPUT 2ND,39T

1

GEAR,INPUT 2ND,19T

1

13262B 13262-0264 (OPTION) 13262C 13262-0265 (OPTION) 13262D 13262-0266 (OPTION) 13262E 13262-0267 (OPTION) 13262F 13262-0268 (OPTION)

GEAR,INPUT 3RD&4TH,19T&20T

1

GEAR,INPUT 5TH,20T

1

GEAR,INPUT 6TH,21T

1

GEAR,OUTPUT LOW,31T

1

GEAR,OUTPUT 3RD,34T

1

13262G 13262-0269 (OPTION) 13262H 13262-0270 (OPTION) 13262I 13262-0271 (OPTION) 13262J 13262-0284 (OPTION) 13262K 13262-0285 (OPTION)

GEAR,OUTPUT 4TH,31T

1

GEAR,OUTPUT 5TH,29T

1

GEAR,OUTPUT 6TH,29T

1


1


1

13262L 13262-0286 (OPTION) 92200 92200-0225 (OPTION) 92200A 92200-0226 (OPTION) 92200B 92200-0227 (OPTION) 92200C 92200-0228 (OPTION)


1

92200D 92200-0229 (OPTION)

4

WASHER,28.1X34.0X0.8

AR


AR


AR


AR


AR

DEC.16,2004



GRID NO.

B-7

This grid covers:

Transmission(2/2)(TYPE-B) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

92200E 92200-0230 (OPTION) 92200F 92200-0231 (OPTION) 92200G 92200-0232 (OPTION)

5


AR


AR


AR

DEC.16,2004



GRID NO.

B-8

This grid covers:

Transmission(1/2)(TYPE-C) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13127



1


1


1

GEAR,OUTPUT 2ND,39T

1

GEAR,OUTPUT 4TH,32T

1


GEAR,INPUT 2ND,19T

1


1

GEAR,INPUT 5TH,20T

1

GEAR,INPUT 6TH,21T

1

GEAR,OUTPUT LOW,34T

1


GEAR,OUTPUT 3RD,28T

1

GEAR,OUTPUT 5TH,28T

1

GEAR,OUTPUT 6TH,28T

1


1


1



1

92200D 92200-0229 (OPTION)

6


AR


AR


AR


AR


AR

DEC.16,2004



GRID NO.

B-9

This grid covers:

Transmission(2/2)(TYPE-C) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2


7


AR


AR


AR

DEC.16,2004



GRID NO.

B-10

This grid covers:

Transmission(1/2)(TYPE-D) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13127



1


1


1


1

GEAR,INPUT 5TH,21T

1


GEAR,OUTPUT 4TH,32T

1

GEAR,OUTPUT 5TH,29T

1

GEAR,OUTPUT 3RD,33T

1

GEAR,INPUT 2ND,18T

1

GEAR,INPUT 6TH,22T

1


GEAR,OUTPUT LOW,37T

1

GEAR,OUTPUT 2ND,36T

1

GEAR,OUTPUT 6TH,28T

1


1


1



1

92200D 92200-0229 (OPTION)

8


AR


AR


AR


AR


AR

DEC.16,2004



GRID NO.

B-11

This grid covers:

Transmission(2/2)(TYPE-D) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2


9


AR


AR


AR

DEC.16,2004



GRID NO.

B-12

This grid covers:

Gear Change Drum/Shift Fork(s) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13145

13145-0021 (OPTION)

10

CAM-CHANGE DRUM

DEC.16,2004

1



GRID NO.

B-13

This grid covers:

Engine Cover(s) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

11004

11004-0022 (OPTION) 11004A 11004-0023 (OPTION) 11004B 11004-0026 (OPTION) 11004C 11004-0034 (OPTION) 11061 11061-0117 (OPTION)

GASKET-HEAD,T=0.55

1

GASKET-HEAD,T=0.45

1

GASKET-HEAD,T=0.65

1

GASKET-HEAD,T=0.50

1

GASKET,STARTER COVER,B

1

11061A 11061-0134 (OPTION) 11061B 11061-0168 (OPTION) 11061C 11061-0169 (OPTION) 13271 13271-0149 (OPTION) 14091 14091-0443 (OPTION)

GASKET,CLUTCH COVER

1

GASKET,STARTER COVER,SMALL

1

GASKET,PAN-OIL

1

PLATE

1

COVER,STARTER,SMALL

1

14091A 14091-0444 (OPTION) 92055 92055-1262 (OPTION) 92066 92066-1005 (OPTION) 92066A 92066-1332 (OPTION) 92066B 92066-1333 (OPTION)

COVER,STARTER,LARGE

1

RING-O,24.4X3.1

1

PLUG

4

PLUG,STARTER HOLE

1

PLUG,STARTER HOLE

1

BOLT-FLANGED,6X25

1

BOLT-FLANGED,M5X8

1

NUT-HEX,6MM

1

130

130G0625 (OPTION) 130A 130Y0508 (OPTION) 312 312B0600 (OPTION)

11

DEC.16,2004



GRID NO.

B-14

This grid covers:

Fuel Injection Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

21175

21175-0073 (OPTION) 21176 21176-1099 (OPTION) 26011 26011-0071 (OPTION) 26011A 26011-1779 (OPTION) 26031 26031-0240 (OPTION)

CONTROL UNIT-ELECTRONIC

1

SENSOR,TEMP

1

WIRE-LEAD,TEMP SENSOR EARTH

1

WIRE-LEAD

1

HARNESS,INTERFACE BOX

1

26031A 26031-0244 (OPTION) 26031B 26031-0307 (OPTION) 26031C 26031-0308 (OPTION) 26031D 26031-0328 (OPTION) 26031E 26031-0329 (OPTION)

HARNESS,FOR STD HARNESS

1

HARNESS,KIT METER

1

HARNESS,STD METER

1

HARNESS,MAIN

1

HARNESS,ENGINE SUB

1

27002

RELAY-ASSY

1

27002-3703 (OPTION)

12

DEC.16,2004



GRID NO.

This grid covers:

C-3

Generator Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

11053 13271 21001 21066 26031 52001 92022 92066 92071 92150


BRACKET,OIL TANK

1

PLATE

1

GENERATOR

1

REGULATOR-VOLTAGE

1

HARNESS

1


TANK-OIL

1

WASHER,6.2X11X1

1

PLUG

1

GROMMET

1

BOLT,SOCKET,6X20

3

CLAMP

2

TUBE,CASE-TANK

1

TUBE,TANK-AIR CLEANER

1

BOLT-FLANGED,M5X8

1

BOLT-FLANGED,M6X10

1

BOLT-FLANGED-SMALL,M6X8

2

O RING,20MM

1

92171

92171-0338 (OPTION) 92192 92192-0226 (OPTION) 92192A 92192-0227 (OPTION) 130 130Y0508 (OPTION) 130A 130Y0610 (OPTION) 132

132L0608 (OPTION) 670B2020 (OPTION)

670

13

DEC.16,2004



GRID NO.

C-4

This grid covers:

Starter Motor Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13107

13107-0096 (OPTION) 13107A 13107-0097 (OPTION) 13107B 13107-0098 (OPTION) 59051 59051-0053 (OPTION) 92046 92046-1217 (OPTION)

SHAFT

1

SHAFT

1

SHAFT,IDLE GEAR

1

GEAR-SPUR,IDLE

1

BEARING-NEEDLE,6BTM109

1

92139

BUSHING

1

CIRCLIP-TYPE-C,13MM

1

92139-0121 (OPTION) 480J1300 (OPTION)

480

14

DEC.16,2004



GRID NO.

C-5

This grid covers:

Radiator Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

35063

35063-0216 (OPTION) 35063A 35063-0217 (OPTION) 35063B 35063-0218 (OPTION) 39060 39060-0021 (OPTION) 39060A 39060-0022 (OPTION)

STAY,MAIN

1

STAY,RH,SUB RAD

1

STAY,LH,SUB RAD

1

RADIATOR,SUB

1

RADIATOR,MAIN

1

39062

39062-1072 (OPTION) 39192 39192-0011 (OPTION) 39192A 39192-0038 (OPTION) 39192B 39192-0039 (OPTION) 49085 49085-1066 (OPTION)

HOSE-COOLING

2

PIPE-WATER

1

PIPE-WATER,LH,SUB RAD

1

PIPE-WATER,RH,SUB RAD

1

CAP-ASSY-PRESSURE

1

92015

92015-1487 (OPTION) 92043-1436 (OPTION) 92075-1123 (OPTION) 92171-0179 (OPTION) 130L0612 (OPTION)

NUT

2

PIN

3

DAMPER,RUBBER

3

BOLT-FLANGED,M6X12

2

554A1000 (OPTION)

PIN-SNAP,10MM

3

92043 92075 92171 130 554

15

CLAMP

11

DEC.16,2004


’05 ZX1000-CR2 Chassis

GRID NO.

This grid covers:

C-6

Swingarm Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

13271

13271-0581 (OPTION)

16

PLATE

1

DEC.16,2004



GRID NO.

C-7

This grid covers:

Rear Hub Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

43082

43082-0005 (OPTION) 43082A 43082-1192 (OPTION) 43082B 43082-1220 (OPTION) 44026 44026-0046 (OPTION) 44026A 44026-0047 (OPTION)

PAD-ASSY-BRAKE,FR,F9633

2

PAD-ASSY-BRAKE,RR,C93

1

PAD-ASSY-BRAKE,RR,C93G

1

SPRING-FRONT FORK,K=9.00N/MM

2


2

44026B 44026-0048 (OPTION) 55020 55020-0028 (OPTION) 92057 92057-1529 (OPTION) 92058 92058-1090 (OPTION) 130 130J1020 (OPTION)


2

GUARD,CHAIN

1

CHAIN,DRIVE,120L(#520)

1

T-CHAIN,DRIVE(#520)

1

BOLT-FLANGED,10X20

1

17

DEC.16,2004



GRID NO.

This grid covers:

C-8

Handlebar Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

11053

11053-1241 (OPTION) 13280 13280-0090 (OPTION) 13280A 13280-0091 (OPTION) 27010 27010-0040 (OPTION) 31064 31064-1151 (OPTION)

BRACKET,STEERING DAMPER

1

HOLDER,STEERING DAMPER

1

HOLDER,STEERING DAMPER

1

SWITCH,SPEED CONTROL

1

PIPE-COMP,GRIP

1

32099

32099-0004 (OPTION) 32099A 32099-0005 (OPTION) 46075 46075-1143 (OPTION) 46091 46091-1809 (OPTION) 54012 54012-0150 (OPTION)

CASE,UPP

1

CASE,LWR

1

GRIP,THROTTLE

1

HOUSING-ASSY-CONTROL,RH

1

CABLE-THROTTLE,OPENING

1

54012A 54012-0151 (OPTION) 59101 59101-0001 (OPTION) 59101A 59101-0002 (OPTION) 92160 92160-1625 (OPTION) 120 120P0635 (OPTION)

CABLE-THROTTLE,CLOSING

1

REEL,R21.5,60DEG

1

REEL,R20.0,65DEG

1

DAMPER,KILL SWITCH

1

BOLT-SOCKET,6X35

2

BOLT-SOCKET,6X25,BLACK

2

SCREW-PAN-CROS

2

120A 120S0625 (OPTION) 220 220C0522 (OPTION)

18

DEC.16,2004



GRID NO.

C-9

This grid covers:

Meter(s) Quantity-ZX1000

Ref. No.

Part No.

Description

Spec Code

’05 CR2

11053

11053-1673 (OPTION) 11053A 11053-1747 (OPTION) 11053B 11053-1748 (OPTION) 13061 13061-0124 (OPTION) 23016 23016-0006 (OPTION)

BRACKET,KIT METER

1

BRACKET,COWLING STAY,LH

1

BRACKET,COWLING STAY,RH

1

BOSS

2

LAMP-ASSY,INDICATOR

1

25031


METER-ASSY

1

PAD,KIT METER

1

NUT,FLANGED,6MM,BLACK

2

RIVET

3

COLLAR

3

92153-1275 (OPTION) 130J0618 (OPTION) 554B1200 (OPTION) 670E2014 (OPTION)

BOLT,6X12

2

BOLT-FLANGED,6X18

2

PIN-SNAP

2

O RING,14MM

2

39156 92015 92039 92152 92153 130 554 670

19

DEC.16,2004

Doc No. 99929-1870-01

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