Ninja® ZX™-10R Ninja® ZX™-10R ABS

Recharge the Battery First! This motorcycle comes with a pre-filled,

pre-charged sealed battery, eliminating the need for dealers to prepare the battery by filling it with electrolyte. However, the battery must be charged upon initial receipt of each unit since it may have been warehoused for a significant time period before being delivered to your dealership.

After the initial charge at your dealership the battery should be recharged every six months. Because the battery will discharge more rapidly at high ambient temperatures, more frequent charging intervals may be required for dealerships located in hot climate zones.

When the battery is not charged periodically during long term storage, its internal resistance increases and could prevent the battery from being recharged. Refer to the "Battery Service" chapter for details.

The battery is located within the crate at the lower indicated with a dotted line. The battery can be removed from the crate for charging by cutting off a portion of the cardboard cover along the dotted line.

A. Battery Location B. Cardboard Cover

ForewordIn order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly removed parts have a direct bear-ing on a vehicle’s reliability and safety, consci-entious pre-sale assembly and preparation be-comes extremely important. Good setup pro-cedures can prevent needless warranty claimsand give customers a greater sense of confi-dence in Kawasaki and their Kawasaki Dealers.This Assembly and Preparation Manual ex-

plains step by step procedures of the followingitems for all Kawasaki Ninja ZX-10R and NinjaZX-10R ABS.

1. Uncrating2. Assembly3. Preparation

The selling dealer assumes sole responsibil-ity for any unauthorized modifications prior tosale. Refer to your Service Binder for any Ser-vice Bulletins specifying Factory Directed Mod-ifications (Special Claims) which must be per-formed before the vehicle is ready for sale.Whenever you see the following symbols

heed their instructions! Always follow safeoperating and maintenance practices.

DANGERDANGER indicates a hazardous situa-tion which, if not avoided, will result indeath or serious injury.

WARNINGWARNING indicates a hazardous situa-tion which, if not avoided, could resultin death or serious injury.

NOTICENOTICE is used to address practices notrelated to personal injury.

NOTENOTE indicates information that may help orguide you in the operation or service of thevehicle.

Kawasaki Heavy Industries, Ltd. accepts noliability for any inaccuracies or omissions in thispublication, although every possible measurehas been taken to make it as complete and ac-curate as possible. All procedures and specifi-cations subject to change without notice.

© 2015 Kawasaki Heavy Industries, Ltd. Sep., 2015

Table of Contents

Uncrating ...................................................................................... 3Opening Crate ............................................................................. 3Parts Check................................................................................. 5

Assembly ...................................................................................... 7Handlebar Weights ...................................................................... 7Windshield................................................................................... 7French Label ............................................................................... 7Brake Disc Cleaning.................................................................... 8

Preparation ................................................................................... 8Battery Service ............................................................................ 8Coolant ........................................................................................ 12Front Brake.................................................................................. 15Rear Brake .................................................................................. 17Clutch Lever and Cable............................................................... 19Drive Chain.................................................................................. 19Front Fork.................................................................................... 21Rear Shock Absorber .................................................................. 22Tire Air Pressures........................................................................ 23Fuel ............................................................................................. 23Engine Oil (4-stroke) ................................................................... 23Throttle Grip and Cable ............................................................... 24Rear Brake Light Switch.............................................................. 25Headlight Aim .............................................................................. 26Digital Meter ................................................................................ 27Fastener Check ........................................................................... 30Standard Torque Table ................................................................ 32Test Ride the Motorcycle ............................................................. 32A & P Check List ......................................................................... 32

UNCRATING 3

UncratingOpening Crate

WARNINGCrates have sharp edges and may havenails or screws that can cause cuts andinjury. Always wear protective gloves,boots and eye protection when uncrat-ing to prevent injury.

WARNINGThe steel crate panel plates and fasten-ers have sharp edges. Always wear pro-tective gloves, boots and eye protectionwhen uncrating to prevent injury.

•Clear a space about 6 m (20 ft) square to giveyourself plenty of space to work.• Place the crate upright on its base.•Remove the cardboard cover.•Remove the parts boxes.

NOTICEWhen removing the crate bracket fromthe motorcycle, be careful not to dropany parts or the bracket onto the fueltank and other components, and not toscratch the fuel tank or other compo-nents with the crate bracket.

•Take out all the bolts and screws and removethe top and sides of the crate.• Loosen the front axle holding nut.• Remove the left front support bracket bolt anddiscard it.• Remove the front axle holding nut, left frontsupport bracket and rubber washers and dis-card them.

A. Front Axle Holding NutB. Left Front Support BracketC. Left Front Support Bracket BoltD. Rubber Washers

•Remove the right front support bracket boltand discard it.• Remove the front axle holding bolt, right frontsupport bracket and rubber washers and dis-card them.

A. Front Axle Holding BoltB. Right Front Support BracketC. Right Front Support Bracket BoltD. Rubber Washers

•Remove the lower support bracket bolt on theleft and right sides and discard them.• Lift the vehicle upward about 10 cm (4 in.).• Remove the lower support brackets and rub-ber washers on the left and right sides.•Roll the vehicle off the crate base.

4 UNCRATING

A. Lower Support BracketB. Lower Support Bracket BoltC. Rubber Washer

NOTICEWhen rolling the vehicle off the cratebase, sharp edges on the crate can cutor damage tires.Cover sharp edges with waste cloth fortire protection as necessary.

UNCRATING 5

Parts Check•Open the parts box, and check the parts against the illustrations. There may be minor differencesbetween these illustrations and the actual vehicle parts. In the following charts under Remarks, D= diameter in millimeters, and L = length in millimeters.

No. Part Name Qty Remarks1 Windshield 12 Socket Bolt, Windshield 4 D = 5.3 × 11.53 Plastic Washer 4 D = 5, L = 164 Wellnut 4 D = 55 Socket Bolt, Windshield 2 D = 5, L = 206 Handlebar Weight 27 Weight Bolt with a Non-permanent Locking Agent 2 D = 8, L = 308 Flange Bolt, Rider’s Seat 2 D = 6, L = 229 Collar 2 D = 10, L = 11.510 Damper 2 10 × 20 × 1211 Damper 2 10 × 30 × 1012 Battery, YTZ10S 1 12 V 8.6 Ah13 Battery Label 114 Band, Battery 115 Owner’s Manual 1

(French Label for Canada Model only)16 French Table 117 Important Drive Chain Information 118 Tire and Load Data 119 Vehicle Emission Control Information 1

6 UNCRATING

No. Part Name Qty Remarks(ZX100RGFA, ZX1000SGFA and ZX1000SGFB Modelsonly)

1 Mark 1 Do not apply thismark onto the labels.

ASSEMBLY 7

AssemblyHandlebar Weights• Install both handlebar weights on the left andright end of the handlebar with the bolts (D =8, L = 30) with a non-permanent locking agentand tighten them.

A. Handlebar WeightB. Bolt (D = 8, L = 30)

Windshield•Fit the two wellnuts (D = 5) into the holes inthe edge of the windshield.

A. WindshieldB. Wellnuts (D = 5)

• Install the two wellnuts (D = 5) to the centercover.

A. Center CoverB. Wellnuts (D = 5)

• Install the windshield.• Install the four plastic washers (D = 5.3) andthe socket bolts (D = 5, L = 16 and D = 5, L =20) on the upper fairing.

A. WindshieldB. Plastic Washers and Socket Bolts (D =5, L = 16)

C. Plastic Washers and Socket Bolts (D =5, L = 20)

D. Upper Fairing

•Tighten the four bolts to the specified torque.Torque: 0.4 N·m (0.04 kgf·m, 3.5 in·lb)

French LabelWhen required, apply French label in the parts

bag over English label on the vehicle.•Wipe off any oil or grease from English label.Refer to the following figure for the label loca-tion.• Peel the label in the parts bag off the backingsheet and apply it over English label.

8 PREPARATION

For Canada Model

A. Vehicle Emission Control Information

B. Important Drive Chain InformationC. Tire and Load Data

Brake Disc Cleaning•Clean the front and rear brake discs usingoilless solvent.

WARNINGAn anticorrosive treatment applied tothe brake discs will increase brakingdistance and can cause an accidentresulting in serious injury or death. Re-move the anticorrosive treatment usingan oilless solvent.

A. Brake Disc

PreparationBattery ServiceBattery ActivationCharged Battery ServiceThis motorcycle comes with a pre-filled, pre

-charged sealed battery, eliminating the needfor dealers to prepare the battery by filling itwith electrolyte. However, the battery must becharged upon initial receipt of each unit sinceit may have been warehoused for a significanttime period before being delivered to your deal-ership.After the initial charge at your dealership the

battery should be recharged every six months.Because the battery will discharge more rapidlyat high ambient temperatures, more frequentcharging intervals may be required for dealer-ships located in hot climate zones.

NOTICEThis battery is a pre-filled, pre-chargedsealed battery. It is not necessary to fillthe battery with electrolyte. Do not try toremove the strip of caps.

Battery Recharging

DANGERBatteries produce an explosive gas mix-ture of hydrogen and oxygen that cancause serious injury and burns if ignited.Keep the battery away from sparks andopen flames during charging. Whenusing a battery charger, connect thebattery to the charger before turning onthe charger. This procedure preventssparks at the battery terminals whichcould ignite any battery gases.

PREPARATION 9

NOTICEAlways remove the battery from thevehicle for charging. If the battery ischarged while still installed, batteryelectrolyte may spill and corrode theframe or other parts of the motorcycle.Charging the battery at a rate higher thanspecified may ruin the battery. Chargingat a high rate causes excess heat whichcan warp the plates and cause internalshorting.Higher-than-normal charging rates alsocause the plates to shed active material.Deposits will accumulate, and can causeinternal shorting.If the temperature of the electrolyterises above 45°C (113°F) during charg-ing, reduce the charging rate to lowerthe temperature, and increase chargingtime proportionately.

NOTENever attempt to charge a frozen battery.Allow it to warm up to room temperature be-fore charging.Never leave a battery on a trickle chargerlonger than 48 hours. Serious damage to thebattery will occur.Always install the red insulating cap to thebattery positive (+) terminal while the batteryis stored.

•Remove the charging label, tape, terminalbolts, terminal nuts and cap.

A. Charging LabelB. TapeC. Terminal Bolts and NutsD. Cap

•Charge the battery with the standard chargingrates indicated on the battery.

Battery types YTZ10S

Standard Charge 0.9 A × 5 10hours

•Use a recommended battery charger, follow-ing the manufacturer’s instructions.

Kawasaki-recommended chargers:Battery Mate 150-9OptiMate PRO 4-S/PRO S/PRO 2Yuasa MB-2040/2060Christie C10122S

• If the recommended chargers are not avail-able, use equivalent one.

NOTECharging rates will vary depending on howlong the battery has been stored, tempera-ture, and the type of charger used.

•Determine battery condition after charging.NOTE

Determine the condition of the battery 30 min-utes after completion of the charge by mea-suring the terminal voltage according to thetable below.

Criteria Judgement12.8 V or higher Good

12.0 12.8 V Charge insufficientRecharge

12.0 V or lower UnserviceableReplace

NOTEIf it is less than 12.8 volts, repeat chargingcycle.If the minimum voltage specification cannotbe reached after three consecutive chargingattempts, the battery should be replaced.

•After recharging, record the charging dateand the name of person in charge of this jobto the label attached on the battery.

10 PREPARATION

A. Recharging Record LabelB. Record the Charging Date and theName of Person Here.

The battery recharging record label is at-tached on the battery side as shown.

A. Battery Recharging Record Label

The battery manufacturing date is printed onbattery top.

Example) 01 09 10 XXDay Month Year Mfg. location

A. BatteryB. Manufacturing Date

Battery Installation• Inspect the battery voltage using a voltmeter,and recharge the battery if the voltage read-ing is below 12.8 volts just before delivering toyour customer to ensure the maximum perfor-mance and customer satisfaction. (Refer tothe "Battery Recharging" section.)•Wipe off any dirt of the battery.• Turn the ignition switch off.• Insert the ignition key into the seat lock.• Lift the front part of the passenger’s seat up-ward while turning the key clockwise.• Remove the passenger’s seat forward.

A. Ignition KeyB. Passenger’s Seat

•Remove the seat cover bolts and washers.

A. Seat Cover Bolts and Washers

•Remove the upper seat cover backward toclear the hook portions.

PREPARATION 11

A. Upper Seat CoverB. Hook and Slot (Both Sides)C. Hooks (Both Sides)

•Remove the rider’s seat backward.

A. Rider’s Seat

•Place the battery in the battery case.• Install the band.•Connect the positive (+) cable to the (+) ter-minal first.• Then connect the negative (–) cable to the (–)terminal.• Put a light coat of grease on the terminals toprevent corrosion.•Cover the (+) terminal with the red cap.

A. BatteryB. BandC. Red Cap and (+) TerminalD. (–) Terminal

• Install the mounting dampers (10 × 20 × 12)and collars (D = 10, L = 11.5) into the holes ofthe rider’s seat stay.• Install the dampers (10 × 30 × 10) on therider’s seat stay.

A. Dampers (10 × 20 × 12)B. Collars (D = 10, L = 11.5)C. Dampers (10 × 30 × 10)D. Rider’s Seat

• Insert the hooks on the rider’s seat under thefuel tank bracket.

12 PREPARATION

A. Rider’s SeatB. HooksC. Fuel Tank Bracket

•Tighten the rider’s seat bolts (D = 6, L = 22).

A. Rider’s Seat Bolts (D = 6, L = 22)

•Fit the hook portions of the upper seat coverto the slots and hooks of the lower seat cover.

A. Upper Seat CoverB. Lower Seat CoverC. HooksD. Slots

•Tighten the seat cover bolts together with thewashers.

A. Seat Cover Bolts and Washers

• Insert the hook on the rear of the passenger’sseat into the slot in the frame.• Insert the projections at the front of the pas-senger’s seat into the latch holes on theframe.• Push down the front part of the passenger’sseat until the lock clicks.

A. HookB. SlotC. ProjectionsD. Latch Holes

•Pull up the front and rear ends of the pas-senger’s seat to make sure they are securelylocked.

CoolantCoolant Level Inspection•Position the motorcycle so that it is perpen-dicular to the ground.• Check the coolant level through the coolantlevel gauge on the reserve tank located to thebehind of the right lower fairing. The coolantlevel should be between the F (Full) and L(Low) level lines.

NOTECheck the level when the engine is cold (roomor atmospheric temperature).

PREPARATION 13

A. F (Full) Level LineB. L (Low) Level LineC. Reserve Tank

• If the amount of coolant is insufficient, addcoolant into the reserve tank.Coolant filling•Remove the quick rivets.

A. Quick Rivets

•Remove the bolts and washers.•Remove the bolt and collar.• Remove the bolt.

A. Bolts and WashersB. Bolt and CollarC. Bolt

•Clear the tab of the lower fairing outward fromthe upper fairing.

A. Upper FairingB. Lower FairingC. Tab

•Clear the tabs of the lower fairing downwardfrom the upper fairing.

A. Upper FairingB. Lower FairingC. Tabs

•Clear the tabs of the lower fairing downwardfrom the upper fairing.

14 PREPARATION

A. Upper FairingB. Lower FairingC. Tabs

•Remove the coolant reserve tank bolt.• Remove the reserve tank cap from the re-serve tank and add coolant through the filleropening to the F (Full) level line.

A. Coolant Reserve Tank BoltB. Reserve Tank Cap

NOTEA permanent type of antifreeze is installed inthe cooling system when shipped. It is mixedat 50% and has the freezing point of –35°C(–31°F).

• Install the reserve tank cap.• Install the reserve tank and tighten the coolantreserve tank bolt.Torque: 8.0 N·m (0.82 kgf·m, 71 in·lb)

• Insert the tabs of the lower fairing into theslots of the upper fairing.• Insert the projections of the lower fairing intothe holes of the upper fairing.

A. TabsB. ProjectionsC. SlotsD. Holes

• Insert the tabs of the lower fairing into theslots of the upper fairing.

A. TabsB. Slots

• Install the washer and collar.• Tighten the bolts.

PREPARATION 15

A. Washers and BoltsB. Collar and BoltC. Bolt

• Install the quick rivets.

A. Quick Rivets

Front BrakeFront Brake Fluid Level Inspection•With the front brake fluid reservoir held hor-izontal, check that the fluid level is betweenthe upper and lower level lines.

A. Front Brake Fluid ReservoirB. Upper Level LineC. Lower Level Line

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thefront brake lines and fill the reservoir.• Loosen the reservoir cap screws to removethe front brake fluid reservoir cap and di-aphragm.• Fill the reservoir to the upper level line withDOT4 brake fluid, reinstall the diaphragm andreservoir cap.• Tighten the reservoir cap screws to the spec-ified torque.Torque: 0.70 N·m (0.07 kgf·m, 6.2 in·lb)

WARNINGWhen working with the disc brake, ob-serve the precautions listed below.•Never reuse old brake fluid.•Do not use fluid from a container thathas been left unsealed or that has beenopen for a long time.•Do not mix two types and brands offluid for use in the brake. This lowersthe brake fluid boiling point and couldcause the brake to be ineffective. Itmay also cause the rubber brake partsto deteriorate.•Don’t leave the reservoir cap off forany length of time to avoid moisturecontamination of the fluid.•Don’t change the fluid in the rain orwhen a strong wind is blowing.•Brake fluid quickly damages paintedsurfaces; any spilled fluid should becompletely wiped up immediately.• If any of the brake line fittings or thebleed valve is opened at any time,the AIR MUST BE BLED FROM THEBRAKE LINE.

16 PREPARATION

•Operate the brake lever several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the front brakeline.• Also check for fluid leakage around the fit-tings.Brake Line Air Bleeding• Loosen the reservoir cap screws to removethe front brake fluid reservoir cap and di-aphragm, and check that there is plenty offluid in the reservoir.

NOTICEBrake fluid quickly damages paintedsurfaces. Wipe up any spilled fluid im-mediately.

NOTEThe fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

•Attach a clear plastic hose to the bleed valveon the front master cylinder and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the brake master cylinderend of the line.• Pump the brake lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve. Then releasethe lever. Repeat this operation until no moreair can be seen coming out into the plastichose.

NOTICEAfter pumping the brake lever severaltimes, releasing it without opening andclosing of the bleed valve may causebrake fluid to be blown back from themaster cylinder reservoir. Brake fluidspilt on painted surfaces and plasticparts will quickly damage them. Be sureto open and close the bleed valve.

A. Hold the brake lever applied.B. Quickly open and close the bleed valve

on the front master cylinder.C. Release the brake lever.

•Tighten the front master cylinder bleed valveto the specified torque.Torque: 5.5 N·m (0.56 kgf·m, 49 in·lb)

•Attach a clear plastic hose to the bleed valveon each front brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the brake master cylinderend of the line.• Pump the brake lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve. Then releasethe lever. Repeat this operation until no moreair can be seen coming out into the plastichose.

NOTICEAfter pumping the brake lever severaltimes, releasing it without opening andclosing of the bleed valve may causebrake fluid to be blown back from themaster cylinder reservoir. Brake fluidspilt on painted surfaces and plasticparts will quickly damage them. Be sureto open and close the bleed valve.

PREPARATION 17

A. Hold the brake lever applied.B. Quickly open and close the bleed valveon the front brake caliper.

C. Release the brake lever.

•Repeat the previous step one more time forthe other front disc brake.•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Tighten the bleed valve(s) to the specifiedtorque.Torque: 16 N·m (1.6 kgf·m, 12 ft·lb)

•Reinstall the diaphragm and reservoir cap.• Tighten the reservoir cap screws to the spec-ified torque.Torque: 0.70 N·m (0.07 kgf·m, 6.2 in·lb)

•Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.

Rear BrakeRear Brake Fluid Level Inspection•With the rear brake fluid reservoir held hor-izontal, check that the fluid level is betweenthe upper and lower level lines.

A. Rear Brake Fluid ReservoirB. Upper Level LineC. Lower Level LineD. Reservoir Cap Stopper BoltE. Reservoir Cap Stopper

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thebrake line, and fill the reservoir.• Loosen the reservoir cap stopper bolt to re-move the reservoir cap stopper, reservoir capand diaphragm.• Fill the reservoir to the upper level line withDOT4 brake fluid, reinstall the diaphragm andreservoir cap.

NOTICEBrake fluid quickly damages paintedsurfaces. Wipe up any spilled fluid im-mediately.

NOTEFirst, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

18 PREPARATION

A. Rear Brake Fluid ReservoirB. Reservoir CapC. ClockwiseD. 1/6 turn

•Reinstall the reservoir cap stopper.• Tighten the reservoir cap stopper bolt.•Operate the brake pedal several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the rear brakeline.• Also check for fluid leakage around the fit-tings.Brake Line Air Bleeding• Loosen the reservoir cap stopper screw toremove the rear brake reservoir cap and di-aphragm, and check that there is plenty offluid in the reservoir.

NOTICEBrake fluid quickly damages paintedsurfaces. Wipe up any spilled fluid im-mediately.

NOTEThe fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

•Attach a clear plastic hose to the bleed valveon the rear brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake pedal several times until no air bub-bles can be seen rising up through the fluidfrom the holes at the bottom of the reservoir.This bleeds the air from the rear brake mastercylinder end of the line.• Pump the brake pedal a few times until itbecomes hard and then, holding the pedalpushed down, quickly open (turn counter-clockwise) and close the bleed valve. Thenrelease the pedal. Repeat this operation untilno more air can be seen coming out into theplastic hose.

NOTICEAfter pumping the brake pedal severaltimes, releasing it without opening andclosing of the bleed valve may causebrake fluid to be blown back from themaster cylinder reservoir. Brake fluidspilt on painted surfaces and plasticparts will quickly damage them. Be sureto open and close the bleed valve.

A.Hold the brake pedal applied.B.Quickly open and close the bleed valveon the rear brake caliper.

C.Release the brake pedal.

•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Tighten the bleed valve to the specifiedtorque.Torque: 8.0 N·m (0.82 kgf·m, 71 in·lb)

•Reinstall the diaphragm and reservoir cap.

PREPARATION 19

NOTEFirst, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap is seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

•Reinstall the reservoir cap stopper.• Tighten the reservoir cap stopper bolt.• Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.

Clutch Lever and CableClutch Lever Free Play Inspection•Check that the clutch lever has the specifiedamount of free play as shown.

Clutch Lever Free Play:2 3 mm (0.08 0.12 in.)

A. AdjusterB. Free Play: 2 3 mm (0.08 0.12 in.)

• If the free play is incorrect, adjust the freeplay.

Clutch Lever Free Play Adjustment•Turn the adjuster so that the clutch lever willhave 2 3 mm (0.08 0.12 in.) of free play.• If it cannot be done, use the adjusting nuts atthe lower end of the clutch cable.

A. Adjusting NutsB. Clutch Cable

NOTEAfter the adjustment is made, start the engineand check that the clutch does not slip andthat it releases properly.For minor corrections, use the adjuster at theclutch lever.

Drive ChainDrive Chain Slack Inspection•Set the motorcycle up on its side stand.•Make sure that the drive chain has the speci-fied amount of play, and that the left and rightnotches are on the same marks or points onthe left and right of the swingarm.

WARNINGMisalignment of the wheel will result inabnormal tire wear and can cause an un-safe riding condition. Be sure the wheelis properly aligned.

•Rotate the rear wheel to find the positionwhere the chain is tightest, and measurethe maximum chain slack by pulling up andpushing down the chain midway between theengine sprocket and rear wheel sprocket.

Drive Chain Slack:25 35 mm (1.0 1.4 in.)

20 PREPARATION

A. 25 35 mm (1.0 1.4 in.)

• If the drive chain is too tight or too loose, ad-just it so that the chain slack will be within thestandard value.

WARNINGA chain that breaks or jumps off thesprockets could snag on the enginesprocket or lock the rear wheel, severelydamaging the motorcycle and causingit to go out of control. Inspect the chainfor damage and proper adjustment.

Drive Chain Slack Adjustment• Loosen the left and right chain adjuster lock-nuts.•Remove the cotter pin, and loosen the rearaxle nut.

A. Rear Axle NutB. Cotter PinC. Chain AdjusterD. Chain Adjuster Locknut

• If the chain is too loose, turn out the left andright chain adjusters evenly.• If the chain is too tight, turn in the left and rightchain adjusters evenly.• Turn both chain adjusters evenly until thedrive chain has the correct amount of slack.To keep the chain and wheel properly aligned,the wheel alignment indicator notches shouldalign with the same marks on each side ofthe swingarm.

A. MarksB. NotchC. IndicatorD. Chain AdjusterE. Chain Adjuster Locknut

NOTEWheel alignment can also be checked usingthe straightedge or string method.

•Tighten both chain adjuster locknuts.• Tighten the rear axle nut to the specifiedtorque.Torque: 130 N·m (13.3 kgf·m, 95.9 ft·lb)

•Rotate the wheel, measure the chain slackagain at the tightest position, and readjust ifnecessary.• Install a new cotter pin.

NOTEWhen inserting the cotter pin, if the slots in thenut do not align with the cotter pin hole in theaxle, tighten the nut clockwise up to the nextalignment.It should be within 30 degrees.Loosen once and tighten again when the slotgoes past the nearest hole.

PREPARATION 21

A. Cotter PinB. Turning Clockwise

•Bend the cotter pin over the nut.

A. Cotter PinB. Nut

WARNINGA loose axle nut can lead to an acci-dent resulting in serious injury or death.Tighten the axle nut to the proper torqueand be sure the cotter pin is installedcorrectly.

•Check the rear brake effectiveness.Front Fork

WARNINGIf both spring preload adjusters andboth rebound and compression damp-ing force adjusters are not adjustedequally, handling may be impaired anda hazardous condition may result. Setall suspension adjusters equally to therecommended settings.

Spring Preload Adjustment•Check the position of the spring preload ad-justers on the each fork leg.

STD Spring Preload:6 turns in (Clockwise from the fullyseated position).

A. Spring Preload AdjusterB. Allen Wrench

•To adjust the spring preload, turn the adjusterwith the Allen wrench or suitable tool. Adjustthe spring preload to the standard setting po-sition.

NOTICEDo not turn the adjuster beyond the fullyseated position or the adjusting mecha-nism may be damaged.

Rebound Damping Force Adjustment•Check the position of the rebound dampingforce adjusters on the each fork leg.

STD Rebound Damping Force:2 1/2 turns out (Counterclockwise fromthe fully seated position).

A. Rebound Damping Force Adjuster

22 PREPARATION

•To adjust the rebound damping force, turn theadjuster with flat tip screwdriver. Adjust therebound damping force to the standard set-ting position.

NOTICEDo not turn the adjuster beyond the fullyseated position or the adjusting mecha-nism may be damaged.

Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjuster on the each fork leg.

STD Compression Damping Force:3 1/2 turns out (Counterclockwise fromthe fully seated position).

A. Compression Damping Force Adjuster

•To adjust the compression damping force,turn the adjuster with flat tip screwdriver.Adjust the compression damping force to thestandard setting position.

NOTICEDo not turn the adjuster beyond the fullyseated position or the adjusting mecha-nism may be damaged.

Rear Shock AbsorberRebound Damping Force Adjustment•Check the position of the rebound dampingforce adjuster at the lower end of the rearshock absorber.

STD Rebound Damping Force:2 1/4 turns out (Counterclockwise fromthe fully seated position).

A. Rebound Damping Force Adjuster

•To adjust the rear shock absorber rebounddamping force, turn the adjuster with a flattip screwdriver. Adjust the rebound dampingforce to the standard setting position.

NOTICEDo not turn the adjuster beyond the fullyseated position or the adjusting mecha-nism may be damaged.

Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjuster at the lower end of the rearshock absorber.

STD Compression Damping:1 turn out (Counterclockwise from thefully seated position)

•To adjust the rear shock absorber compres-sion damping force, turn the adjuster with aflat tip screwdriver. Adjust the compressiondamping force to the standard setting posi-tion.

A. Compression Damping Force Adjuster

NOTICEDo not turn the adjuster beyond the fullyseated position or the adjusting mecha-nism may be damaged.

PREPARATION 23

Tire Air Pressures•To prevent flat-spotting during shipment, thetires are over-inflated before crating. Adjustthe pressures to the specified values in thefront and rear, and make sure to tighten thecaps securely.

Tire Air Pressure [when cold]:Front: 250 kPa (2.50 kgf/cm², 36 psi)Rear: 290 kPa (2.90 kgf/cm², 42 psi)

A. Tire Air Pressure Gauge

Fuel

WARNINGGasoline is extremely flammable andcan be explosive under certain condi-tions, creating the potential for seriousburns. When filling the tank, turn theignition switch off. Do not smoke. Makesure the area is well ventilated and freefrom any source of flame or sparks; thisincludes any appliance with a pilot light.

•Open the fuel tank cap, and check for debrisin the fuel tank.• Fill the fuel tank with one gallon or four litersof unleaded gasoline. Use a gasoline with aminimum octane rating shown below.

For US, Canada and California Specifica-tionsFuel Type Unleaded Gasoline

(RON + MON)MinimumOctaneRating

AntiknockIndex90 2

For Other than US, Canada and Cali-fornia SpecificationsUse clean, fresh unleaded gasoline with an

octane rating equal to or higher than that shownin the table.

Fuel Type Unleaded GasolineMinimumOctaneRating

Research Octane Number (RON)95

•Close the fuel tank cap and check for anyleaks.

Engine Oil (4-stroke)Engine Oil Level Inspection

NOTEThis vehicle’s engine is filled with 10W-40 oilfrom the factory. DO NOT DRAIN and refillthe crankcase before use. Check oil level anddrain bolt tightness.

Torque: 29 N·m (3.0 kgf·m, 21 ft·lb)

A. Engine Oil Drain Bolt

•Park the vehicle on level ground.• Before starting the engine, check that the en-gine has oil.•With the motorcycle held level, check that theengine has oil through the oil level inspectionwindow in the lower right side of the engine.

NOTICEIf the engine is run without oil, it will beseverely damaged.

•Start the engine and run it for several minutesat idle speed. Stop the engine, then wait sev-eral minutes until the oil settles.•With the motorcycle held level, check the en-gine oil level through the oil level inspectionwindow. The oil level should come up be-tween the upper and lower level lines next tothe oil level inspection window.

24 PREPARATION

A. Oil Level Inspection WindowB. Oil Filler CapC. Upper Level LineD. Lower Level Line

• If the oil level is too high, remove the excessoil through the oil filler opening, using a sy-ringe or some other suitable device.• If the oil level is too low, add oil to reach thecorrect level. Use the same type of oil that isalready in the engine.•When replacing the cap, be sure the O-ring isin place, and tighten the cap in finger tight.

Recommended Engine OilType: API SG, SH, SJ, SL or SM with

JASO MA, MA1 or MA2Viscosity: SAE 10W-40Capacity: 2.9 L (3.1 US qt)

[when filter is not removed]3.3 L (3.5 US qt)[when filter is removed]

NOTEDo not add any chemical additive to the oil.Oils fulfilling the above requirements are fullyformulated and provide adequate lubricationfor both the engine and the clutch.

Although 10W-40 engine oil is the recom-mended oil for most conditions, the oil viscositymay need to be changed to accommodateatmospheric conditions in your riding area.

Throttle Grip and CableThrottle Grip Free Play Inspection• Inspect the throttle grip free play. If the freeplay is incorrect, adjust the throttle cables.

Throttle Grip Free Play:2 3 mm (0.08 0.12 in.)

•Check that the throttle grip moves smoothlyfrom full open to close, and the throttle closesquickly and completely in all steering posi-tions by the return spring. If the throttle gripdoes not return properly, check the throttle ca-ble routing, grip free play, and for possible ca-ble damage. Then lubricate the throttle ca-bles.

A. Throttle GripB. 2 3 mm (0.08 0.12 in.)

•Run the engine at idle speed, and turn thehandlebars all the way to the right and left toensure that the idle speed does not change.If the idle speed increases, check the throttlegrip free play.

PREPARATION 25

WARNINGOperation with incorrectly routed, im-properly adjusted or damaged cablescould result in an unsafe riding con-dition. Be sure the cables are routedcorrectly, properly adjusted and are notdamaged in any way.

Throttle Grip Free Play Adjustment• Loosen both locknuts of the throttle cablesand turn both adjusters in completely to givethe throttle grip plenty of play.• Turn out the decelerator cable adjuster untilthere is no play when the throttle grip is com-pletely closed. Tighten the locknut.

A. Decelerator CableB. Accelerator CableC. AdjustersD. Locknuts

•Turn out the accelerator cable adjuster un-til the specified amount of play is obtained.Tighten the locknut.• Run the engine at idle speed, and turn thehandlebars all the way to the right and left toensure that the idle speed does not change.If the idle speed increases, check the throttlegrip free play.

Rear Brake Light SwitchRear Brake Light Switch Adjustment•Turn the ignition switch on. The brake lightshould illuminate when the brake pedal is de-pressed about 10 mm (0.4 in.)

A. Brake PedalB. 10 mm (0.4 in.)

• If it does not, turn the adjusting nut at the rearbrake light switch as required.•Remove the right front footpeg bracket bolts.• Pull the front footpeg bracket a little bit out-ward.

A. BoltsB. Right Front Footpeg Bracket

•To adjust the rear brake light switch, move theswitch up or down by turning the adjusting nut.

A. Rear Brake Light SwitchB. Adjusting NutC. Lights soonerD. Lights later

26 PREPARATION

NOTICETo avoid damaging the electrical con-nections inside the switch, be sure thatthe switch body does not turn during ad-justment.

• Install the right front footpeg bracket.• Tighten the right front footpeg bracket bolts tothe specified torque.Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

Headlight AimThe headlight beam is adjustable both hori-

zontally and vertically. Headlight aim must becorrectly adjusted for safe riding as well as on-coming drivers. In most areas it is illegal to ridewith improperly adjusted headlights.The headlight adjusters operate as following

tables.Left Adjusters

Turning Direction Moving Direction ofBeam

Clockwise Lower LeftCounterclockwise Upper Right

A. when turning adjuster clockwiseB. when turning adjuster counterclock-wise

C. Left Adjusters

Right Adjusters

Turning Direction Moving Direction ofBeam

Clockwise Lower RightCounterclockwise Upper Left

A. when turning adjuster clockwiseB. when turning adjuster counterclock-wise

C. Right Adjusters

NOTEDo not turn the upper bolts because the re-flector in the headlight comes off.

A. Upper bolts are not adjusters.

Horizontal AdjustmentThe headlight beam is adjustable horizontally.

If not properly adjusted horizontally, the beamwill point to one side rather than straight ahead.• To move the headlight beam leftward, turnthe left adjuster clockwise and turn the rightadjuster counterclockwise same number asthe left adjuster was turned until the beampoints straight ahead.Left Adjuster ClockwiseRight Adjuster Counterclockwise

PREPARATION 27

•To move the headlight beam rightward, turnthe left adjuster counterclockwise and turn theright adjuster clockwise same number as theleft adjuster was turned until the beam pointsstraight ahead.Left Adjuster CounterclockwiseRight Adjuster Clockwise

Vertical AdjustmentThe headlight beam is adjustable vertically. If

adjusted too low, neither low nor high beam willilluminate the road far enough ahead. If ad-justed too high, the high beam will fail to illumi-nate the road close ahead, and the low beamwill blind oncoming drivers.• To move the headlight beam upward, turn theboth adjusters counterclockwise same num-ber.Both Adjusters Counterclockwise

• To move the headlight beam downward, turnthe both adjusters clockwise same number.Both Adjusters Clockwise

For US and Canada Models

NOTEOn high beam, the brightest point should beslightly below horizontal. The proper angle is0.4 degrees below horizontal. This is a 50mm(2.0 in.) drop at 7.6 m (25 ft) measured fromthe center of the headlight, with the motorcy-cle on its wheels and the rider seated.

A. 50 mm (2.0 in.)B. Center of Brightest SpotC. 7.6 m (25 ft)D. Height of Headlight Center

For other than US and Canada Models

NOTEOn high beam, the brightest point should beslightly below horizontal with the motorcycleon its wheels and the rider seated. Adjustthe headlight to the proper angle according tolocal regulation.

Digital MeterCheck the Unit Setting: km/h, mphkm/h·Mph Display can alternate between

English and metric modes (mph and km/h)on the digital meter. Make sure that mph or

28 PREPARATION

km/h is correctly displayed according to localregulations before sale.

NOTEDo not operate the vehicle with the digital me-ter displaying the wrong unit (mph or km/h) ofthe digital meter. Shift the mph km/h displayon the digital meter as follows.

•Turn the ignition switch on.• Push the “SEL” button to display the odome-ter.

A. Multifunction ButtonB. Upper ButtonC. “SEL” ButtonD. Lower ButtonE. Lap Switch

•Push the “SEL” button while turning the lapswitch rightward. The display units can beshifted in the following order.

PREPARATION 29

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30 PREPARATION

Fastener Check•The torque values listed are for assembly and preparation items only, see the appropriate ServiceManual for a more comprehensive list. Check tightness of all fasteners that are in the table beforeretail delivery. Also check to see that each cotter pin or circlip is in place.

PREPARATION 31

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

Steering1 Handlebar clamp bolt (Left and Right) 25 2.5 18Brakes2 Front master cylinder clamp bolts 9.0 0.92 80 in·lb3 Front master cylinder bleed valve 5.5 0.56 49 in·lb4 Front caliper bleed valve (Left and Right) 16 1.6 125 Front caliper mounting bolt (Left and Right) 35 3.6 266 Rear caliper bleed valve 8.0 0.82 71 in·lb7 Rear master cylinder mounting bolts 25 2.5 18Wheels/Tires8 Front axle clamp bolts (Left and Right) 20 2.0 159 Front axle nut 130 13.3 95.9Suspension10 Front fork clamp bolts (Upper) (Left and Right) 20 2.0 1511 Swingarm pivot shaft nut 110 11.2 81.112 Swingarm pivot adjusting collar locknut 100 10.2 73.8Others13 Clutch lever clamp bolts 9.0 0.92 80 in·lb14 Front footpeg bracket bolts (Left and Right) 25 2.5 1815 Rear footpeg bracket bolts (Left and Right) 25 2.5 18Engine Oil Drain16 Engine oil drain bolt 29 3.0 21Cotter Pin or Circlip17 Front footpeg pin circlip (Left and Right) – – –18 Rear axle nut cotter pin – – –19 Rear footpeg pin circlip (Left and Right) – – –20 Rear master cylinder push rod cotter pin – – –21 Side stand bolt cotter pin – – –

32 PREPARATION

Standard Torque TableThe tables below, relating tightening torque to

thread diameter, lists the basic torque for thebolts, nuts and screws. Use these tables for thebolts, nuts and screws which are not specifiedthe tightening torque particularly on the previ-ous pages. All of the values are for use with drysolvent-cleaned threads.

Basic Torque for General FastenersFor Bolts and Nuts

TorqueThreadsDiameter(mm) N·m kgf·m ft·lb

5 4.5 0.46 40 in·lb6 8.0 0.82 71 in·lb8 20 2.0 1510 35 3.6 2612 60 6.1 44

For Screws, Plastic Part Tightening Por-tions and Plastic Washer TighteningPortions

TorqueThreadsDiameter(mm) N·m kgf·m ft·lb

4 1.2 0.12 11 in·lb5 3.0 0.31 27 in·lb6 4.0 0.41 35 in·lb

For Self-Tapping ScrewsTorqueThreads

Diameter(mm) N·m kgf·m ft·lb

All 1.2 0.12 11 in·lb

For WellnutsTorqueThreads

Diameter(mm) N·m kgf·m ft·lb

4 0.2 0.02 1.8 in·lb5 0.5 0.05 4.4 in·lb6 1.0 0.10 8.9 in·lb

Test Ride the Motorcycle•Complete the test ride checklist.Control Cables:Throttle cables must work without bindingin any steering position.

Steering:Action is free from lock-to-lock.

Suspension:Check operation front and rear.

Engine:Electric starter works properly and enginestarts promptly. Good throttle response andreturn.

Transmission and Clutch:Smooth operation.

Brakes:Adequate, smooth stopping power, No drag.

Digital Meter:Check operation

Electrical System:Headlight - check high and low beams.Taillight - check operation.Brake Light - check operation.Turn Signal Lights - check operation.Horn - check operation.Instrument Lights and Indicator Lights -Check operation.

Engine Stop Switch Works:Starter Interlock Switch Works:No Unusual Noises:No Fuel, Oil, Brake Fluid, or CoolantLeaks:PREPARATION COMPLETE.

WARNINGNew tires are slippery and may causeloss of control and serious injury ordeath. A break-in period of 160 km (100miles) is necessary to establish nor-mal tire traction. During break-in, avoidsudden and maximum braking, acceler-ation, and hard cornering.

A & P Check List•Complete the A & P Check List.

Part No.99931-1564-01

MODEL APPLICATIONYear Model Name2016 ZX1000RG Ninja ZX-10R2016 ZX1000SG Ninja ZX-10R ABS