2012款川崎ZX-14R 装配说明书.docx

ZZR1400 ABSNinja ZX-14RNinja ZX-14R ABSKawasakiMotorcycleAssembly&PreparationManualForewordInordertoshipKawasakivehiclesasefficientlyaspossible,theyarepartiallydisassembledbeforecrating.Sincesomeofthemostcommonlyremovedpartshaveadirectbearingonavehicle'sreliabilityandsafety,conscientiouspre-saleassemblyandpreparationbecomesextremelyimportant.GoodsetupprocedurescanpreventneedlesswarrantyclaimsandgivecustomersagreatersenseofconfidenceinKawasakiandtheirKawasakiDealers.ThisAssemblyandPreparationManualexplainsstepbystepproceduresofthefollowingitemsforallKawasakiZZR1400ABS5NinjaZX-14RandNinjaZX-14RABS.1 .Uncrating2 .Assembly3 .PreparationThesellingdealerassumessoleresponsibilityforanyunauthorizedmodificationspriortosale.RefertoyourServiceBinderforanyServiceBulletinsspecifyingFactoryDirectedModifications(SpecialClaims)whichmustbeperformedbeforethevehicleisreadyforsale.Wheneveryouseethefollowingsymbolsheedtheirinstructions!Alwaysfollowsafeoperatingandmaintenancepractices.!DANGERDANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjuryWARNINGWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.NOTICENOTICEisusedtoaddresspracticesnotrelatedtopersonalinjury.NOTEoThisnotesymbolindicatespointsOfparticularinterestformoreefficientandconvenientoperation.KawasakiHeavyIndustries,Ltd.acceptsnoliabilityforanyinaccuraciesoromissionsinthispublication,althougheverypossiblemeasurehasbeentakentomakeitascompleteandaccurateaspossible.AIIproceduresandspecificationssubjecttochangewithoutnotice.Sep., 20112011KawasakiHeavyIndustries,Ltd.TableofContentsUncrating3OpeningCrate3PartsCheck4Assembly5SteeringStemHeadNut5HandlebarWeights5WindshieldbRearFairing6Seat6FrenchLabel(ForCanadianModels)7BrakeDiscCleaning7Preparation8BatteryService8Coolant12FrontBrake13RearBrake15CIiHch16DriveChain18FrontFork19RearShockAbsorber21TireAirPressuresFuelEngineOil(4-stroke)ThrottleGripandCableRearBrakeLightSwitchdieSpeedAdjustmentHeadlightAimMultifunctionMeterFastenerCheckStandardTorqueTableTestRidetheMotorcycleA&PCheckListFirst,remove the lower bolt (D =22,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 brackets.Roll the vehicle off the crate base.A.Lower Support Bracket (Both Sides)UncratingOpeningCrateAWARNINGCrateshavesharpedgesandmayhavenailsorscrewsthatcancausecutsandinjury.Alwayswearprotectivegloves,bootsandeyeprotectionwhenuncratingtopreventinjury.103003B!WARNINGThesteelcratepanelplatesandfastenershavesharpedges.Alwayswearprotectivegloves,btsandeyeprotectionwhenuncratingtopreventinjury.B.UpperBolts(D=8,L=14)C.CrateBracketD.FoamPad Clearaspaceabout6m(20ft)squaretogiveyourselfplentyofspacetowork.,Placethecrateuprightonitsbase. Removethecardboardcover. Removethepartsbox.NOTICEWhenremovingthecratebracketfromthemotorcycle,becarefulnottodropanypartsorthebracketontothefueltankandothercomponents,andnottoscratchthefueltankorothercomponentswiththecratebracket.PartsCheckOpenthepartsbox,andcheckthepartsagainsttheillustrations.Theremaybeminordifferencesbetweentheseillustrationsandtheactualvehicleparts.lnthefollowingchartsunderRemarks5D=diameterinmilimeters,andL=Iengthinmillimeters.W00524lBN2CNo.PartNameQtyRemarks1SteeringStemHeadNut1D=252WindshieldSocketBoltPlasticWasherWellnut1666D=5,L=161)=5.3×11.5D=53BatteryCompartmentCoverBoltWasher111D=6,L=14D=6.5×164OtherthanPhilippineandSoutheastAsiaB2ModelsRearFairingSocketBoltPlasticWasherWelnut1444D=6,L=23D=6.5×165HandlebarweightWeightScrewwithaNon-permanentLockingAgent22D=8,L=306FrenchLabelforCanadianModelonlyEmissionControlInformation1P/No.59465-08467BatteryElectrolyte,FTZ14-BS112V12Ah8Owner*sManual1AssemblySteeringStemHeadNutRemove the 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 Head 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 upper 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 bolts (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.FairingBracketInstalltherearfairingwiththefoursocketbolts(D=6,L=23)andtheplasticwashers(D=6.5),andtightenthebolts.SeafRemovalInserttheignitionkeyintotheseatlock,andturnthekeyclockwise.Removetheseatbypullingupandrearward.A.SeatB.SeatLockC.lgnitionKeyD.PullUpandRearwardSeafStaIIatiOnInserteachfrontslotoftheseatontotheholderbracketoneachleftandrightsideofthefueltank.A.SeatB.SIotsC.BracketInserttheslotsintothereceivers,andinsertthehookattherearoftheseatintotheslot,thenpushdowntherearpartoftheseatuntilthelockclicks.A-ProjectionsB.HookC.SIots(Middleontheframe)D.SIot(Rearendontheframe)EJnsertPulluptherearendoftheseattomakesureitissecurelylocked.FrenchLabel(ForCanadianMOdeIS)NOTEORemovethefrontleftsidecover.SeetheuCooIantFilling,itemin"Coolant,sectiononpage12inthePreParationchapter.OSticktheFrenchlabelontotheEnglishlabelontheleftsideoftheframeonlywhenrequired.WipeoffanyoilorgreasefromtheEnglishIabeLRefertothefollowingphotographinthelabellocation.PeeltheFrenchlabeloffthebackingsheetandapplyitovertheEnglishlabel.A.Frame(LeftSide)B.EmissionControlInformation(P/No.59465-0846)BrakeDiscCleaningCleanthefrontandrearbrakediscsusingoillesssolvent.AWARNINGAnanticorrosivetreatmentappliedtothebrakediscswillincreasebrakingdistanceandcancauseanaccidentresultinginseriousinjuryordeath.Removetheanticorrosivetreatmentusinganoillesssolvent.PreparationBatteryServiceThebatteryusedinthismotorcycleisasealedtypeandneverneedstoberefilled.Followtheprocedureforactivatinganewbatterytoensurethebestpossiblebatteryperformance.BatteryRemovalRemovethebolts.Pullingouttherightfairingcoveroutslowlytocleartheprojections.,Cleartherightinnerrubbercoverfromtherightfairingcover,andremovetherightfairingcoverbackwardA.RightFairingCoverB.Bolt(D=6,L=30)C.Bolt(D=6,L=14)D.Bolt(D=5,L=20)E.RightInnerRubberCoverF-ProjectionsG.TabsRemovethebatterycompartmentcoverbyremovingthebolt(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.FrameGroundCableEBoIts(D=6,L=16)F.BatteryHolderBracketSlightlypulloutthebatterytray.Removethebatterycover.A-BatteryTrayNOTICEBecarefulnottodropthebatteryfromthemotorcyclewhenpullingoutit.Donotgivethebatterytrayastrongpull,orthecablesmaybedamaged.BatteryActivationElectrolyteFillingMakesurethatthemodelnameoftheelectrolytecontainermatchesthemodelnameofthebattery.Thesenamesmustbethesame.BatteryModelNameZX1400E/F:FTX14-BSA.Model Name of the ElectrolyteB.Model Name of the BatteryA.Sealing Sheet B.Filler PortsNOTICEEachbatterycomeswithitsownspecificelectrolytecontainer;usingthewrongcontainermayoverfillthebatterywithincorrectelectrolyte,whichcanshortenbatterylifeanddeterioratebatteryper-formance.Besuretousetheelectrolytecontainerwiththesamemodelnameasthebatterysincetheelectrolytevolumeandspecificgravityvarywiththebatterytype.NOTICEDonotremovethealuminumsealingsheetfromthefillerportsuntiljustpriortouse.Besuretousethededicatedelectrolytecontainerforcorrectelectrolytevolume.!DANGERSulfuricacidinbatteryelectrolytecancausesevereburns.Topreventburns,wearprotectiveclothingandsafetyglasseswhenhandlingelectrolyte.Iftheelectrolytecomesincontactwithyourskinoreyes,washtheareawithliberalamountsofwaterandseekmedicalattentionformoresevereburns.Placethebatteryonalevelsurface.Checktoseethatthesealingsheethasnopeeling,tears,orholesinit.Removethesealingsheet.NOTEOThebatteryisvacuumsealed.Ifthesealingsheethasleakedairintothebattery,itmayrequireaIongerinitialcharge.Removetheelectrolytecontainerfromthevinylbag.Detachthestripofcapsfromthecontainerandsetaside,thesewillbeusedlatertosealthebatteryNOTEODonotpierceorotherwiseopenthesealedcellsoftheelectrolytecontainer.Donotattempttoseparateindividualcells.A,StripofCapsB.SealedCellsPlacetheelectrolytecontainerupsidedownwiththesixsealedcellsintothefillerportsofthebattery.Holdthecontainerlevel,pushdowntobreakthesealsofallsixcells.Youwillseeairbubblesrisingintoeachcellastheportsfill.NOTEODonottilttheelectrolytecontainer.Check the electrolyte tow.Ifnoairbubblesarecomingupfromthefillerports,orifthecontainercellshavenotemptiedcompletely,tapthecontainerafewtimes.NOTEOBecarefulnottohavethebatteryfalldown.E021148S1 CA.AirBubblesB.TaptheContainerKeepthecontainerinplace.Don'tremovethecontainerfromthebattery,thebatteryrequiresalltheelectrolytefromthecontainerforproperoperation.NOTICERemovalofthecontainerbeforeitiscompletelyemptycanshortentheservicelifeofthebattery.Donotremovethecontaineruntilitiscompletelyempty.,Afterfillingjetthebatterysitfor2060minuteswiththeelectrolytecontainerkeptinplace,whichisrequiredfortheelectrolytetofullypermeateintotheplates.Makesurethatthecontainercellshaveemptiedcompletely,andremovethecontainerfromthebatteryPlacethestripofcapslooselyoverthefillerports,pressdownfirmlywithbothhandstoseatthestripofcapsintothebattery(don'tpoundorhammer).Whenproperlyinstalled,thestripofcapswillbelevelwiththetopofthebattery.6P08012BS1COncethestripofcapsisinstalledontothebattery,neverremovethecaps,noraddwaterorelectrolytetothebatteryNOTEOChargingthebatteryimmediatelyafterfillingcanshortenservicelife.InitialChargeNewlyactivatedsealedbatteriesrequireaninitialchargeStandardCharge:1.4A510hoursIfusingarecommendedbatterycharger,followthecharger'sinstructionsfornewlyactivatedsealedbattery.Kawasaki-recommendedchargers:BatteryMate150-9OptiMatePRO4-S/PROS/PRO2YuasaMB-2040/2060ChristieC10122SIftheabovechargersarenotavailable,useequivalentone.Letbatterysit30minutesafterinitialcharge,thencheckvoltageusingavoltmeter.(Volt-ageimmediatelyafterchargingbecomestemporarilyhigh.Foraccuratemeasuring,letthebatterysitforgiventime.)NOTEOChargingrateswillvarydependingonhowlongthebatteryhasbeenstored,temperature,andthetypeofchargerused.Ifvoltageisnotatleast12.6volts,repeatchargingcycle.OToensuremaximumbatterylifeandcustomersatisfaction,itisrecommendedthebatterybeloadtestedatthreetimesitsamp-hourratingfor15seconds.Re-checkvoltageandiflessthan12.6voltsrepeatthechargingcycleandloadtest.Ifstillbelow12.6voltsthebatteryisdefective.BatteryInstallationMakesurethattheleadorcabledoesnotpinchwithanyparts.NOTICEInstallingthe(一)cabletothe(+)terminalofthebatteryorthe(÷)cabletothe(一)terminalofthebatterycanseriouslydamagetheelectricalsystem.Installthebattery(一)cabletothebattery.A.Battery(一)CableInstallthebattery(+)cabletothebatterysandtheninstallthebatterycoveronthebattery,andhooktheband.A.BatteryTrayB.Projectionsc.HolesInstallthebatteryholderbracket.Installthebolts(D=6,L=16).'Installthecablesandleadsothattheyarepositionedovertheframe,inorderoftheframegroundcable,battery(一)cableand(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 the battery tray into the holes of the battery compartment.Installthebolt(D=6,L=14).A.BatteryCompartmentCoverBaProjectionsc.Holes,Inserttherightfairingcoverhalfway,andfittherightinnerrubbercovertotherightfairingcover.A-RightFairingCoverB.RightInnerRubberCover,Insertthefrontpartoftherightfairingcoversecurely.,Insertthetabsontherightfairingcoverunderthefueltankcoverfirst,andthenfittheprojectionstotheholes.,Installtheboltsandwashers.CoolantCoolantLevelInspectionSituatethemotorcyclesothatitisperpendiculartotheground.Checkthecoolantlevelthroughthecoolantlevelgaugeonthereservetanklocatedintheinsideoftherightfairing.ThecoolantlevelshouldbebetweentheF(Full)andL(Low)levellines.NOTEOCheckthelevelwhentheengineiscold(roomoratmospherictemperature).A-F(FuII)LeveILineB.L(Low)LevelLineC-ReserveTankIftheamountofcoolantisinsufficient,andaddcoolantintothereservetank.CoolantfillingRemovethebolts(D=6,D=5)andwashersontheleftfairingcover.Pullingouttheleftfairingcoveroutslowlytocleartheprojections.A.TabsB.Right Fairing Cover C-ProjectionsCleartheleftinnerrubbercoverfromtheleftfairingcover,andremovetheleftfairingcoverbackward.A.LeftFairingCoverB.BoltsandWashersC.LeftInnerRubberCover0.ProjectionsE-TabsRemovethecapfromthereservetankandaddcoolantthroughthefilleropeningtotheF(FuII)IeveIline.A.ReserveTankCapInstallthecapNOTEOApermanenttypeOfantifreezeisinstalledinthecoolingsystemwhenshipped.ltiscoloredgreenandcontainsethyleneglycol.ltismixedat50%andhasthefreezingpointof-35(-31oF)FrontBrakeFrontBrakeFluidLevelInspectionWiththefrontbrakefluidreservoirheldhorizontal,checkthatthefluidlevelisbetweentheupperandlowerlevellines.A,UpperLevelLineB.LowerLevelLineC.FrontBrakeFluidReservoirD.ReservoirCapStopperScrewIfthefluidlevelinthereservoirislowerthanthelowerlevelline,checkforfluidleaksinthefrontbrakelinesandfilltheresen/oir.LoosenthereservoircapstopperscrewtoremovethefrontbrakefluidreservoircapanddiaphragmFilltheresen/oirtotheupperlevellinewithDOT4brakefluid,reinstallthediaphragmandrese