Appendix

Table of Contents

Additional Considerations for Racing................................................................................................... 16-2

Carburetor:....................................................................................................................................... 16-2

Spark Plug:...................................................................................................................................... 16-2

Spark Plug Inspection................................................................................................................ 16-3

Troubleshooting Guide......................................................................................................................... 16-4

Engine Doesn't Start Starting Difficulty:.......................................................................................... 16-4

Poor Running at Low Speed:........................................................................................................... 16-4

Poor Running or No Power at High Speed:..................................................................................... 16-5

Overheating:.................................................................................................................................... 16-5

Over Cooling:.................................................................................................................................. 16-5

Clutch Operation Faulty:................................................................................................................. 16-5

Gear Shifting Faulty:....................................................................................................................... 16-6

Abnormal Engine Noise:.................................................................................................................. 16-6

Abnormal Drive Train Noise:.......................................................................................................... 16-6

Abnormal Frame Noise:.................................................................................................................. 16-6

Oil Pressure Warning Light Goes On:............................................................................................ 16-6

Exhaust Smokes Excessively:....................................................................................................... 16-6

Handling and/or Stability Unsatisfactory:....................................................................................... 16-7

Brake Doesn't Hold:......................................................................................................................... 16-7

Battery Trouble:............................................................................................................................... 16-7

General Lubrication.............................................................................................................................. 16-8

Lubrication.................................................................................................................................. 16-8

Nut Bolt, and Fastener Tightness......................................................................................................... 16-9

Tightness Inspection.................................................................................................................. 16-9

Unit Conversion Table........................................................................................................................ 16-10

Prefixes for Units:.......................................................................................................................... 16-10

Units of Mass:................................................................................................................................ 16-10

Units of Volume:............................................................................................................................ 16-10

Units of Force:............................................................................................................................... 16-10

Units of Length:.............................................................................................................................. 16-10

Units of Torque:............................................................................................................................. 16-10

Units of Pressure:.......................................................................................................................... 16-10

Units of Speed:.............................................................................................................................. 16-10

Units of Power:.............................................................................................................................. 16-10

Units of Temperature:.................................................................................................................... 16-10

Additional Considerations for Racing

This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be experienced under racing conditions. KAWASAKI STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION.

Racing should be done under supervised conditions, and recognized sanctioning bodies should be contacted for further details. For those who desire to participate in competitive racing or related use, the following technical information may prove useful. However, please note the following important notes.

•You are entirely responsible for the use of your motorcycle under abnormal conditions such as racing, and Kawasaki shall not be liable for any damages which might arise from such use.

• Kawasaki's Limited Motorcycle Warranty and Limited Emission Control Systems Warranty specifically exclude motorcycles which are used in competition or related uses. Please read the warranty carefully.

• Motorcycle racing is a very sophisticated sport subject to many variables. The following information is theoretical only, and Kawasaki shall not be liable for any damages which might arise from alterations utilizing this information.

•When the motorcycle is operated on public roads, it must be in its original state in order to ensure safety and compliance with applicable regulations.

Carburetor:

Sometimes an alteration may be desirable for improved performance under special conditions when proper mixture is not obtained after the carburetor has been properly adjusted, and all parts cleaned and found to be functioning properly.

If the engine still exhibits symptoms of overly rich or lean carburetion after all maintenance and adjustments are correctly performed, the main jet can be replaced with a smaller or larger one. A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture.

Spark Plug:

The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be used, and the spark plug must be kept clean and the gap adjusted.

Tests have shown the plug listed in the " General Information" chapter to be the best plug for general use.

Since spark plug requirements change with the ignition and carburetion adjustments and with riding conditions, whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug.

A. Terminal B; Insulator

C. Cement

D. Gasket

E. Center Electrode

F. Gap (0.7 ~ 0.8 mm)

G. Reach

H. Side Electrode

When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 - 800*C (750 ~ 1, 450*F) and can be judged by noting the condition and color of the ceramic insulator around the center electrode. If the ceramic is clean and of a light brown color, the plug is operating at the right temperature.

A spark plug for higher operating temperatures is used for racing. Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a " colder" plug. If a spark plug with too cool a heat range is used - that is, a " cold" plug that cools itself too well - the plug will stay too cool to bum off the carbon, and the carbon will collect on the electrodes and the ceramic insulator.

The carbon on the electrodes conducts electricity, and can short the center electrode to ground by either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause preignition and knocking, which may eventually bum a hole in the top of the piston.

Spark Plug Inspection

Normal operation

• Remove the spark plug and inspect the ceramic insulator. ^Whether or not the right temperature plug is being used can be ascer­tained by noting the condition of the ceramic insulator around the electrode. A light brown color indicates the correct plug is being used. If the ceramic is black, it indicates that the plug is firing at too low a temperature, so the next hotter type should be used instead. If the ceramic is white, the plug is operating at too high a temperature and it should be replaced with the next colder type.

_________________________ CAUTION__________________________

И the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitch and reach (length o< threaded portion) and the same type electrode (regular type or projected type) as the standard plug. If the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the correct spark plug later.

Overheating

If the reach Is too long, carbon will build up on the exposed spark plug threads causing overheating, preigniton, and possibly burning a hole in the piston top. In addition, it may be impossible lo remove the plug without damaging the cylinder head.

Standard Spark Plug Threads Diameter: 10 mm Pitch: 1.0 mm

Reach: 19 mm

NOTE

О The heat range of the spark plug functions like a thermostat for the engine. Using the wrong type of spark plug can make the engine run too hot (resulting in engine damage) or too cold (with poor performance, misfiring, and stalling).

Troubleshooting Guide

NOTE

О 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 button not contacting

Wiring open or shorted

Ignition switch trouble

Engine stop switch trouble

Fuse blown

Starter motor rotating but engine doesn't turn over: Starter clutch trouble Engine won't turn over:

Valve seizure Rocker arm seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Alternator shaft bearing seizure No fuel flow: No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded:

Fuel level in carburetor float bowl too high Float valve worn or stuck open Starting technique faulty

(When flooded, crank the engine with the throttle fully opened to allow more air to reach the engine.) No spark; spark weak: Battery voltage low

Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect 1С igniter trouble

Neutral, starter lockout or side stand switch trouble Pickup coil trouble Ignition coil trouble Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Fuel/air mixture incorrect:

Pilot screw and/or idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged, poorly sealed, or missing Starter jet clogged

Compression Low:

Spark plug loose

Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Poor Running at Low Speed:

Spark weak:

Battery voltage low

Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect 1С igniter trouble Pickup coil trouble Ignition coil trouble Fuel/air mixture incorrect: Pilot screw maladjusted Pilot jet, or air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged

Air cleaner clogged, poorly sealed, or missing Starter plunger stuck open

Fuel level in carburetor float bowl too high or too low

Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Air cleaner O-ring damaged Compression low: Spark plug loose

Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other:

1С igniter trouble

Carburetors not synchronizing

Carburetor vacuum piston doesn't slide smoothly

Carburetor vacuum piston diaphragm damage

Engine oil viscosity too high

Drive train trouble

Brake dragging

Air suction valve trouble

Vacuum switch valve trouble

Poor Running or No Power at High Speed:

Firing incorrect:

Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect 1С igniter trouble Pickup coil trouble Ignition coil trouble Fuel/air mixture incorrect: Starter plunger stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged

Fuel level in carburetor float bowl too high or too low

Bleed holes of needle jet holder or needle jet clogged

Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Air cleaner O-ring damaged Water or foreign matter in fuel Carburetor holder loose Fuel tank air vent obstructed Fuel tap clogged. _r

Fuel line clogged Fuel pump trouble Compression low: Spark plug loose

Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak

Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.) Knocking:

Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect 1С igniter trouble Miscellaneous:

Throttle valve won't fully open

Carburetor vacuum piston doesn't slide smoothly

Carburetor vacuum piston diaphragm damaged

Brake dragging

Clutch slipping

Overheating

Engine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble Vacuum switch valve trouble 1С igniter trouble Fuei/air mixture incorrect: Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner duct loose Air cleaner poorly sealed, or missing Air cleaner O-ring damaged Air cleaner clogged Compression high:

Carbon built up in combustion chamber Engine load faulty: Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect:

Oil cooler clogged Gauge incorrect:.

Water temperature gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Cooling system component incorrect: Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling: Gauge incorrect:

Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect: Radiator fan switch trouble Thermostat trouble

Clutch Operation Faulty: Clutch slipping:

Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high

Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch fluid leakage Clutch fluid deteriorated

Clutch master cylinder primary or secondary cup damaged

Clutch master cylinder scratched inside

Primary gear worn or chipped

Camshaft chain tensioner trouble

Camshaft chain, sprocket, guide worn

Air suction valve damaged

Vacuum switch valve damaged

Alternator shaft coupling rubber damper damaged

Alternator shaft chain tensioner trouble

Alternator shaft chain, sprocket, guide worn

Gear Shifting Faulty:

Doesn't go into gear; shift pedal doesn't return:

Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Neutral positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear: Shift fork worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or broken Shift fork pin worn

Drive shaft, output shaft, and/or gear splines worn Overshifts:

Gear positioning lever spring weak or broken Shift mechanism arm spring broken

Abnormal Engine Noise: Knocking:

1С igniter trouble

Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap:

Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise:

Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Other noise:

Connecting rod small end clearance excessive

Connecting rod big end clearance excessive

Piston ring worn, broken, or stuck

Piston seizure, damage

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head connection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Abnormal Drive Train Noise:

Clutch noise:

Clutch rubber damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Transmission noise: Bearings worn

Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive chain noise:

Drive chain adjusted improperly Drive chain worn

Rear and/or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise: Front fork noise:

Oil insufficient or too thin Spring weak or broken Rear shock absorber noise:

Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise:

Bracket nut bolt, etc. not properly mounted or tightened

Oil Pressure Warning Light Goes On:

Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearings worn Crankshaft bearings worn Oil pressure switch damaged Wiring faulty Relief valve stuck open

O-ring at the oil passage in the crankcase damaged

Exhaust Smokes Excessively: White smoke:

Piston oil ring worn

Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke:

Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke: Main jet too small

Fuel level in carburetor float bowl too low

Air cleaner duct loose

Air cleaner O-ring damaged

Air cleaner poorly sealed or missing

Handling and/or Stability Unsatisfactory: Handlebar hard to turn:

Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem locknut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates: Tire worn

Swing arm pivot bearings worn Rim warped, or not balanced Wheel bearing worn Handlebar clamp loose Steering stem head nut loose Handlebar pulls to one side: Frame bent Wheel misalignment Swing arm bent or twisted Steering maladjusted Front fork bent

Right and left front fork oil level uneven Shock absorption unsatisfactory:

(Too hard)

Front fork oil excessive

Front fork oil viscosity too high

Rear shock absorber adjustment too hard

Tire air pressure too high

Front fork bent

(Too soft)

Tire air pressure too low

Front fork oil insufficient and/or leaking

Front fork oil viscosity too low

Rear shock adjustment too soft

Front fork, rear shock absorber spring weak

Rear shock absorber oil leaking

Brake fluid deteriorated

Primary or secondary cup damaged in master cylinder

Master cylinder scratched inside

Battery Trouble:

Battery discharged:

Battery faulty (e.g., plates sulphated, shorted

through sedimentation, electrolyte insufficient) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring faulty Battery overcharged: Alternator trouble Battery faulty

Brake Doesn't Hold:

Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad

General Lubrication

Lubrication

• Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.

• Lubricate the points listed below with indicated lubricant.

NOTE

О Whenever the vehicle has been operated under wet or rainy condi­tions, or especially after using a high-pressure water spray, perform the general lubrication.

Pivots: Lubricate with Motor Oil.

Clutch Lever Brake Lever Brake Pedal Side Stand Rear Brake Rod Joint

Points: Lubricate with Grease.

Throttle Inner Cable Lower Ends Choke Inner Cable Lower End Speedometer Inner Cable* {*): Grease the lower part of the inner cable sparingly.

Cables: Lubricate with Rust Inhibitor.

Choke Cable Throttle Cables

Special Tool - Pressure Cable Luber K56019-021 [A]

__ APPENDIX 16-9

Nut, Bolt, and Fastener Tightness

Tightness Inspection

•Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition.

NOTE

О For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

*lf there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by 1 /2 turn, then tighten it.

*lf cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Wheels:

Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Brakes:

Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension:

Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Bolts Swingarm Pivot Shaft Nut Uni-Trak Link Nuts Steering:

Stem Head Nut Handlebar Mounting Bolts Engine:

Engine Mounting Bolts Cylinder Head Bolts Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolt Clutch Master Cylinder Clamp Bolts Clutch Lever Pivot Nut Others:

Side Stand Bolt Footpeg Mounting Bolts Down Tube Mounting Bolts Footpeg Bracket Mounting Bolts

Unit Conversion Table

Prefixes for Units:

Units of Force:

Units of Temperature:

9(^eC+40)

— 40 = T

Periodic Maintenance Chart (ZX900-B3 other than US, CN)

This " Supplement - 1997 Model" chapter is designed to be used in conjuction with the front part of this manual (up to page 16-11). The maintenance and repair procedures described in this chapter are only those that are unique to the 1997 ZX900-B4 model. Most service operations for these models remain identical to those described in front of this chapter.

Complete and proper sen/icing of the 1997 ZX900-B4 model, therefore requires mechanics to read both this chapter and the text in front of this chapter.