General Information

Three Way Joint at (G) Front of crankcase breather hose > Under ignition coil -> Under frame -> Inside of radiator tank hose -* Front of thermostat Vacuum Valve. 2 Carburetor Holder Under ignition coil -> Under frame - inside of radiator tank hose Front of thermostat - 4. Tubes (White, Green, Yellow) and Reservoir Tank Hose Route these tubes and hose between frame and carburetor. 3 Carburetor -* Clamp at (B) -* Separator 6. Clamp Following ones at (B) Tube (White) Raservoir Tank Hose...

Info

(compressed from spring free length) Special Tool - Fork Cylinder Holder Handle 57001-183 Oil Seal & Bearing Remover 57001-1058 Steering Stem Nut Wrench 57001-1100 Bearing Driver Set 57001-1129 Fork Outer Tube Weight 57001-1218 Front Fork Oil Seal Driver 57001-1219 Fork Oil Level Gauge 57001-1290 Hexagon Wrench, Hex 29 57001-1335 Special Tool - Fork Cylinder Holder Handle 57001-183 Oil Seal & Bearing Remover 57001-1058 Steering Stem Nut Wrench 57001-1100 Bearing Driver Set 57001-1129 Fork...

Table of Contents

Exploded Special Clean Air Air Suction Valve Vacuum Switch Valve Installation Note 4-6 Vacuum Switch Valve Clean Air System Hose Cylinder Head Camshaft Chain Camshaft, Camshaft Chain, Rocker Shaft 4-10 Camshaft, Rocker Shaft Removal 4-10 Camshaft, Rocker Shaft Installation 4-10 Chain Timing Camshaft and Sprocket Assembly 4-11 Camshaft, Camshaft Cap Wear 4-12 Camshaft Chain Cylinder Cylinder Compression Measurement 4-13 Valve Clearance Valve Valve Valve Guide Valve Guide Seat Seat Seat Cutter...

Engine Lubrication System

SAE 10W-40, 10W-50, 20W-40, or 20W-50 3.2L (when filter is not removed) 3.5L (when filter is removed) Oil pressure 4,000 r min(rpm), oil temp. 90 C(194 F) 196 294 kPa(2.0 3.0 kg cm2, 28 43 psi) Special Tool - Kawasaki Bond (Silicone Sealant) 56019-120 Special Tool - Kawasaki Bond (Silicone Sealant) 56019-120

Oil Pressure Measurement

Warm up the engine, and then stop the engine. Remove the oil passage plug, and attach the gauge and adapter to the plug hole. Special Tool - Oil Pressure Gauge, 10 kg cm2 57001-164 A Oil Pressure Gauge Adapter, M18 x 1.5 57001-1278 Take care against burns from hot engine oil that will drain through the oil passage when the plug id removed. Run the engine at the specified speed, and read the oil pressure gauge. *lf the oil pressure is significantly below the specification, inspect the oil pump...

Motorcycle Mechanic Institute History

Clutch spring free length Friction plate thickness Friction and steel plate warp Special Tool - Kawasaki Bond (Silicone Sealant) 56019-120 Special Tool - Kawasaki Bond (Silicone Sealant) 56019-120 Check the clutch fluid level in the reservoir. Lower Level LinefA Upper Level Line B

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ZX1100-D3 Wiring Diagram (Other than US. Canada and Australia) junction sox i. Horn Fuse ioa 2.ignition Fuse ioa Neutral indicator Light gv 12vj.4w x Speedometer fuel Gauge Light 12Vl.7V Right Turn signa Light 12V3. 4W Left Turn Signal indicator Light 12V3. 4H oil Pressure warning light 12VJ. 4W Speedometer fuel Gauge Light 12Vl.7V

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and...

Awarning

Zzr1100 Coil Connection

To avoid extremely high voltage shocks, do not touch the coil or lead. lf the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. To determine which part is defective, measure the arcing distance again with the spark plug caps removed from the spark plug leads by turning the caps counterclockwise . lf the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with...

1100 Kawasaki Valve Guide Tool

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. Special Tool - Valve Spring Compressor Assembly 57001-241 A Valve Spring Compressor Adapter, 22 57001-1202 Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. Install the springs so that the closed coil end faces downwards. Valve Stem Spring Seats Oil...

Harley Wl Alternator Shaft Dimensions

The upper crankcase half, lower crankcase half, and main bearing cap are machined t the factory in the assembled state, so they must be replaced as a set. Standard 0.05 0.20 mm Service Limit 0.40 mm Crankshaft Runout Measure the crankshaft runout. lf the measurement exceeds the service limit, replace the crankshaft. Unscrew the balancer shaft clamp bolts, and pull off the clamp lever. Unscrew the balancer shaft guide pin plate, and take off the plate and guide pin. Pull the balancer shaft with...

Bearing Driver Set Part No 570001-1129

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Special Tools - Bearing Remover Shaft 57001-1265 Bearing Remover Head, 15 x 17 57001-1267 Bearing Remover Head, 20 x 22 57001-1293 Before installing the wheel bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. Replace the bearings with new ones. Press in the...

Do not overapply a nonpermanent locking agent to the threads This may block the oil passage

Check that the knock pin A , nozzle, and O-ring C are in place. The small hole of the nozzle B must face the bracket. Check that the oil pump shaft catches A of both components are vertical. Before installing the oil pump, be sure the shaft and rotors turn freely. Remove the following Upper and Lower Fairings Engine Oil drain Oil Hose Banjo Bolts cooler side Oil Cooler Mounting Bolts A Oil Screen Mounting Bolt B To remove the oil cooler hoses, remove the mufflers. Installation is the reverse of...

Throttle Grip and Cables

Free Play Inspection Check the throttle grip free play A . Free Play Inspection Check the throttle grip free play A . Turn the adjuster B until the proper amount of free play can be obtained. lf the proper amount of free play cannot be obtained by using the adjuster only, use the adjuster in the middle part of the accelerator cable. Loosen the locknut and screw the adjuster at the upper end of the accelerator cable all the way in. Remove the fuel tank and air cleaner housing see Fuel Tank...

Wheels I Tires

Exploded Wheels Front Wheel Front Wheel Rear Wheel Rear Wheel Installation Axle Wheel Balance Balance Balance Weight Balance Weight Air Pressure Hub Installation Speedometer Gear Disassembly and T1 145 N-m 15.0 kg-m, 110 fl-lb T2 110 N-m 11.0 kg-m, 80 ft-lb BRIDGESTONE BATTRAX BT-50F E DUNLOP SPORT D203F METZELER ME33 Laser BRIDGESTONE BATTRAX BT-50R E DUNLOP SPORT D203 METZELER ME55 A Metronic Germany Refer to the above, adding the following METZELER ME Z1 Front Tubeless PIRELLI MTR 03...

Is The Zx11 Pickup Coil In

The bearing inserts for Nos. 2 and 4 journals have an oil groove. The bearing inserts for Nos. 2 and 4 journals have an oil groove. Crankshaft side clearance Crankshaft runout Alternator shaft chain 20 link length Shift fork ear thickness Gear shift fork groove width Shift fork guide pin diameter Shift drum groove width 4.9 5.0 mm 5.05 5.15 mm 7.9 8.0 mm 8.05 8.20 mm Special Tool - Steering Stem Bearing Driver 57001-137 Bearing Puller 57001-158 Inside Circlip Pliers 57001-143 Bearing Puller...

Torque and Locking Agent

The following table list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the Remarks column mean L Apply a non-permanent locking agent to the threads. 0 Apply an oil to the threads, seated surface, or washer. S Tighten the fasteners following the specified sequence. SS Apply silicone sealant to the threads. Letters used in the Remarks column mean L Apply a non-permanent locking agent to the threads. 0...

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart...

Emission Control Information

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control...

Special Tools and Sealant

Kawasaki 550 Head Gasket Leak

Steering Stem Bearing Driver 57001 -137 Valve Spring Compressor Assembly 57001 -241 Steering Stem Bearing Driver 57001 -137 Valve Spring Compressor Assembly 57001 -241 Piston Pin Puller Assembly 57001-910 Fork Cylinder Holder Handle 57001 -183 Piston Pin Puller Assembly 57001-910 Fork Cylinder Holder Handle 57001 -183 Oil Seal amp Bearing Remover 57001 -1058 Piston Ring Compressor Grip 57001 -1095 Oil Seal amp Bearing Remover 57001 -1058 Piston Ring Compressor Grip 57001 -1095 Steering Stem...

Zzr1100 Air Vent Filter

O This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn't Start, Starting Difficulty Starter motor not rotating Starter lockout or neutral switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter motor rotating but engine doesn't turn over Starter clutch trouble Engine won't turn over Valve...