ninja h2 sx · items for all kawasaki ninja h2 sx. 1. uncrating 2. assembly 3. preparation the...

Ninja H2 SX

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

pre-charged sealed battery, eliminating the needfor dealers to prepare the battery by filling it withelectrolyte. However, the battery must be chargedupon initial receipt of each unit since it may havebeen warehoused for a significant time periodbefore being delivered to your dealership.After the initial charge at your dealership the bat-

tery should be recharged every six months. Be-cause the battery will discharge more rapidly athigh ambient temperatures, more frequent charg-ing intervals may be required for dealerships lo-cated in hot climate zones.When the battery is not charged periodically dur-

ing long term storage, its internal resistance in-creases and could prevent the battery from beingrecharged. Refer to the "Battery Service" chapterfor details.The battery is located within the crate at the lower

indicated with a dotted line. The battery can beremoved from the crate for charging by cutting offa portion of the cardboard cover along the dottedline.

A. Battery Location (Right Rear Side)

B. Cardboard Cover

Foreword

In 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 H2 SX.

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.

NOTE○NOTE 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.

© 2017 Kawasaki Heavy Industries, Ltd. Nov., 2017

Table of Contents

Uncrating ...................................................................................... 3Opening Crate ............................................................................. 3Parts Check................................................................................. 6

Assembly ...................................................................................... 8Windshield................................................................................... 8Brake Disc Cleaning.................................................................... 8French Labels (For Canada Model) ............................................ 8

Preparation ................................................................................... 9Battery Service ............................................................................ 9Coolant ........................................................................................ 12Front Brake.................................................................................. 13Rear Brake .................................................................................. 15Clutch .......................................................................................... 17Drive Chain.................................................................................. 18Front Fork.................................................................................... 19Rear Shock Absorber .................................................................. 21Tire Air Pressures........................................................................ 22Fuel ............................................................................................. 22Engine Oil (4-stroke) ................................................................... 22Throttle Grip and Cable ............................................................... 23Rear Brake Light Switch.............................................................. 24Headlight Aim .............................................................................. 25Digital Meter ................................................................................ 26Fastener Check ........................................................................... 28Standard Torque Table ................................................................ 31Test Ride the Motorcycle ............................................................. 31A & 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 Nut

B. Left Front Support Bracket

C. Left Front Support Bracket Bolt

D. 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 Bolt

B. Right Front Support Bracket

C. Right Front Support Bracket Bolt

D. Rubber Washers

• Loosen the pivot holding nut.• 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 pivot holding nut, pivot holdingbolt, lower support brackets and rubber wash-ers.

•Roll the vehicle off the crate base.

4 UNCRATING

A. Pivot Holding Nut

B. Pivot Holding Bolt

C. Lower Support Bracket

D. Lower Support Bracket Bolt

E. 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

This page intentionally left blank.

6 UNCRATING

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.

UNCRATING 7

No. Part Name Qty Remarks

1 Windshield 1

2 Cover, Windshield 1

3 Wellnut 6

4 Washer 6

5 Socket Bolt 6 D = 5, L = 16

6 Band, Battery 1

7 Battery, YTZ10S 1 12 V 8.6 Ah

8 Battery Label 1

9 Pad, Battery 1

10 Owner’s Manual 1

11 Took Kit 1

(French Label for Canada Model only)

12 French Table 1

13 Important Drive Chain Information 1

14 Tire and Load Data 1

15 Vehicle Emission Control Information 1

8 ASSEMBLY

AssemblyWindshield

• Install the cover and wellnuts to the wind-shield.

A. Windshield

B. Cover

C. Wellnuts

• Install the windshield.• Install the washers and tighten the bolts onthe upper fairing.

A. Windshield

B. Washers and Bolts

C. Upper Fairing

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

French Labels (For Canada Model)When required, apply French labels in the

parts bag over English labels on the vehicle.

•Wipe off any oil or grease from English labels.Refer to the following figure for the label loca-tions.

• Peel each label in the parts bag off the back-ing sheet and apply it over English label.

A. Vehicle Emission Control Information

B. Tire and Load Data

C. Important Drive Chain Information

PREPARATION 9

PreparationBattery Service

Battery 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.

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.

NOTE○Never 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 Label

B. Tape

C. Terminal Bolts and Nuts

D. Cap

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

10 PREPARATION

Battery types YTZ10S

Standard Charge0.9 A × 5 10

hours

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

Kawasaki-recommended chargers:Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO 2

Yuasa MB-2040/2060

Christie C10122S

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

NOTE○Charging 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 Judgement

12.8 V or higher Good

12.0 12.8 V Charge insufficient→ Recharge

12.0 V or lowerUnserviceable→ Replace

NOTE○If 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.

A. Recharging Record Label

B. 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 XX

Day Month Year Mfg. location

A. Battery

B. Manufacturing Date

PREPARATION 11

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.• Apply pad to the battery as shown.

A. Battery

B. Pad

C. About 16.5 mm (0.65 in.)

D. About 2 mm (0.08 in.)

•Make sure the ignition switch is turned 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.• Remove the ignition key.

A. Ignition Key

B. Passenger’s Seat

• Lift the rear part of the rider’s seat upward,and remove the rider’s seat.

A. Rider’s Seat

•Place the battery on the battery case.•Connect the red capped positive cable to the(+) terminal first.

• Then connect the negative cable to the (–)terminal.

NOTE○When installing the terminals, make the gapsbetween the terminals and battery.

A. Gaps

B. Positive (+) Terminal

C. Negative (–) Terminal

•Put a light coat of grease on the terminals toprevent corrosion.

•Cover the positive (+) terminal with the redcap.

• Install the band to hold the battery and posi-tive (+) cable as shown.

12 PREPARATION

A. Negative (–) Terminal

B. Positive (+) Terminal

C. Gaps

D. Band

• Insert the hooks at the front of the rider’s seatinto the slots of the bracket.

• Fit the tab at the rear of the rider’s seat on theguide.

A. Hooks

B. Slots

C. Tab

D. Guide

• Insert the hook at the rear of the passenger’sseat into the slot.

• Insert the latch plate at the front of the pas-senger’s seat into the latch hole.

• Push down the front part of the passenger’sseat until the lock clicks.

A. Hooks

B. Slot

C. Latch Plate

D. Latch Hole

Coolant

Coolant 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 middle fairing. The coolantlevel should be between the F (Full) and L(Low) level lines.

NOTE○Check the level when the engine is cold (roomor atmospheric temperature).

A. F (Full) Level Line

B. L (Low) Level Line

C. Reserve Tank

• If the amount of coolant is insufficient, addcoolant into the reserve tank.

Coolant Filling•Remove the bolts and washer.

PREPARATION 13

A. Bolts and Washers

B. Bolt

•Detach the projection from the grommet.

A. Projection

NOTE○The cap will not turn unless the hose is dis-connected.

•Remove the cap from the reserve tank andadd coolant through the filler opening to the F(Full) level line.

A. Clamp

B. Hose

C. Reserve Tank Cap

• Install the reserve tank cap.• Install the removed parts.

NOTE○A 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).

Front Brake

Front 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 Reservoir

B. Upper Level Line

C. Lower Level Line

D. Reservoir Cap Stopper Screw

• 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 stopper screw to re-move the front brake fluid reservoir cap anddiaphragm.

• Fill the reservoir to the upper level line withDOT4 brake fluid, reinstall the diaphragm andreservoir cap.

14 PREPARATION

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.

•Do not leave the reservoir cap off forany length of time to avoid moisturecontamination of the fluid.

•Do not 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.

NOTE○First, tighten the front 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.

A. Reservoir

B. Cap

C. Clockwise

D. 1/6 turn

•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.

NOTE○The 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.

PREPARATION 15

A. Hold the brake lever applied.

B. Quickly open and close the bleed valveon the front master cylinder.

C. Release the brake lever.

•Tighten the front master cylinder bleed valveto the specified torque.Torque: 5.4 N·m (0.55 kgf·m, 48 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.

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 front caliper bleed valve(s) to thespecified torque.Torque: 8.0 N·m (0.82 kgf·m, 71 in·lb)

•Reinstall the diaphragm and reservoir cap.• Tighten the reservoir cap stopper screw to thespecified torque.

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

Rear Brake

Rear 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.

16 PREPARATION

A. Rear Brake Fluid Reservoir

B. Upper Level Line

C. Lower Level Line

D. Reservoir Cap Stopper Bolt

E. 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.

NOTE○First, 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.

A. Rear Brake Fluid Reservoir

B. Reservoir Cap

C. Clockwise

D. 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.


•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.

PREPARATION 17

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.


• Tighten the rear caliper bleed valve to thespecified torque.Torque: 5.4 N·m (0.55 kgf·m, 48 in·lb)

•Reinstall the diaphragm and reservoir cap.NOTE

○First, 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

Clutch Fluid Level Inspection•With the clutch fluid reservoir held horizontal,check that the fluid level is between the upperand lower level lines.

A. Upper Level Line

B. Lower Level Line

C. Clutch Fluid Reservoir

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in theclutch line and fill the reservoir.

• Remove the clutch fluid reservoir cap and di-aphragm.

• Fill the reservoir to the upper level linewith DOT4 clutch fluid, and reinstall the di-aphragm.

• Tighten the reservoir cap.•Operate the clutch lever several times.• If it feels spongy, there might be air in theclutch line.

• If necessary, bleed the air in the clutch lines.• Also check for fluid leakage around the fit-tings.

Clutch Line Air Bleeding•Remove the reservoir cap and diaphragm,and check that there is plenty of fluid in thereservoir.


•Attach a clear plastic hose to the bleed valveon the clutch master cylinder and run theother end of the hose into a container.

•With the reservoir cap off, slowly pump theclutch 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 clutch master cylinderend of the line.

18 PREPARATION

•Pump the clutch 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.

A. Hold the clutch lever applied.

B. Quickly open and close the bleed valveon the clutch master cylinder.

C. Release the clutch lever.

•Tighten the clutch master cylinder bleed valveto the specified torque.Torque: 5.4 N·m (0.55 kgf·m, 48 in·lb)

•Attach a clear plastic hose to the bleed valveon the clutch slave cylinder and run the otherend of the hose into a container.

•With the reservoir cap off, slowly pump theclutch 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 clutch slave cylinderend of the line.

• Pump the clutch lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve.Then release the lever. Repeat this operationuntil no more air can be seen coming out intothe plastic hose.

A. Hold the clutch lever applied.

B. Quickly open and close the bleed valveon the clutch slave cylinder.

C. Release the clutch lever.


• Tighten the clutch slave cylinder bleed valveto the specified torque.Torque: 8.4 N·m (0.86 kgf·m, 74 in·lb)

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

Drive Chain

Drive Chain Slack Inspection•Set the motorcycle up on its side stand.• 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.)

A. 25 35 mm (1.0 1.4 in.)

PREPARATION 19

• 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 bearing housing clamp bolts grad-ually and evenly.

A. Clamp Bolts

•Turn the chain adjuster until the drive chainhas correct amount of slack with the hookwrench (Special Tool:57001-1863).

• If the chain is too loose, turn the chain ad-juster counterclockwise.

• If the chain is too tight, turn the chain adjusterclockwise.

A. Chain Adjuster

B. HookWrench (Special Tool:57001-1863)

C. Clockwise (direction to loose)

•Pushing the rear wheel to the right side of thevehicle.

•Confirm that there is not a clearance betweenthe chain adjuster and the swingarm.

A. Right Side

B. No Clearance

C. Chain Adjuster

D. Swingarm

•Tighten the bearing housing clamp bolts tothe specified torque following the tighteningsequence (A→ B→ A→ B→ A→ B→ A).

Torque: 33 N·m (3.4 kgf·m, 24 ft·lb)

Front Fork

WARNINGImproper fork leg adjustment can causepoor handling and loss of stability,which could lead to an accident.Always adjust the fork legs on the leftand right side to the same setting.

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

STD Spring Preload:(ZX1002A)

8 mm (0.31 in.) from the top of adjuster

20 PREPARATION

A. Spring Preload Adjuster

B. Adjusting Range

STD Spring Preload:(ZX1002B)

9 mm (0.35 in.) from the top of adjuster


B. Adjusting Range

•Turn the adjuster clockwise with a wrench toincrease spring preload and stiffen the sus-pension.

• Turn the adjuster counterclockwise to de-crease spring preload and soften the suspen-sion.

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 at the top of each front forkleg.

STD Rebound Damping Force:6 clicks (Counterclockwise from the fullyseated position.)

A. Rebound Damping Force Adjuster

B. ZX1002A

C. ZX1002B

•Turn the adjuster clockwise with a flat tipscrewdriver to increase damping force.

• Turn the adjuster counterclockwise to de-crease damping force.


Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjusters at the lower end of eachfront fork leg.

STD Compression Damping Force:9 clicks (Counterclockwise from the fullyseated position.)

A. Compression Damping Force Adjuster



PREPARATION 21


Rear Shock Absorber

Spring Preload Adjustment•Check the position of the spring preload ad-juster on the right rear footpeg bracket.

STD Spring Preload:4 clicks (Clockwise from the fully seatedposition.)


•Turn the adjuster clockwise to increase springpreload.

• Turn the adjuster counterclockwise to de-crease spring preload.


Rebound Damping Force Adjustment•Check the position of the rebound dampingforce adjusters at the lower end of the rearshock absorber.

STD Rebound Damping Force:3/4 turns out (Counterclockwise fromthe fully seated position.)

A. Rebound Damping Force Adjuster




Compression Damping Force Adjust-ment•Check the position of the compression damp-ing force adjusters at the top of the rear shockabsorber.

• The adjuster has the high speed adjuster andthe low speed adjuster.STD Compression Damping Force:(High Speed Adjuster)1 2/4 turns out (Counterclockwise from the

fully seated position.)(Low Speed Adjuster)5 clicks (Counterclockwise from the fully

seated position.)

A. Compression Damping Force Adjuster(High Speed Adjuster)

B. Compression Damping Force Adjuster(Low Speed Adjuster)

22 PREPARATION

(High Speed Adjuster)•Turn the high speed adjuster clockwise with awrench to increase damping force.

• Turn the high speed adjuster counterclock-wise to decrease damping force.(Low Speed Adjuster)•Turn the adjuster clockwise with a flat tipscrewdriver to increase damping force.


NOTE○Turning the high speed adjuster has the lowspeed adjuster turning. Although the lowspeed adjuster turns with the high speed ad-juster when turning the high speed adjuster,the low speed adjuster setting position doesnot change.


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: 290 kPa (2.90 kgf/cm², 42 psi)

Rear: 290 kPa (2.90 kgf/cm², 42 psi)

A. Tire 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 andCalifornia 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 Gasoline

MinimumOctaneRating

Research Octane Number (RON)95

•Close the fuel tank cap and check for anyleaks.

Engine Oil (4-stroke)

Engine Oil Level Inspection

NOTE○This 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: 25 N·m (2.5 kgf·m, 18 ft·lb)

PREPARATION 23

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.

A. Oil Level Inspection Window

B. Oil Filler Cap

C. Upper Level Line

D. 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 to the specifiedtorque.Torque: 25 N·m (2.5 kgf·m, 18 in·lb)

Recommended Engine Oil

Type: API SG, SH, SJ, SL or SM withJASO MA, MA1 or MA2

Viscosity: SAE 10W-40

Capacity: 3.5 L (3.7 US qt)

[when filter is not removed]

4.3 L (4.5 US qt)

[when filter is removed]

NOTE○Do 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 Cable

Throttle 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.)

24 PREPARATION

•Check that the throttle grip moves smoothlyfrom full open to close, and the throttle closesquickly and completely by the return spring inall steering positions.

• If the throttle grip does not return properly,check the throttle cable routing, grip free play,and for possible cable damage. Then lubri-cate the throttle cables.

A. Throttle Grip

B. Throttle Grip Free Play

•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.

WARNINGOperation with incorrectly routed or im-properly adjusted cables could result inan unsafe riding condition. Be sure thecables are routed correctly and properlyadjusted.

Throttle Grip Free Play Adjustment•Slide the rubber covers.• Loosen the locknuts at the upper ends of thethrottle cables, and screw both throttle cableadjusters completely so as to give the throttlegrip plenty of play.

• Turn the decelerator cable adjuster until thereis no play when the throttle grip is completelyclosed. Tighten the locknut.

A. Rubber Covers

B. Accelerator Cable

C. Decelerator Cable

D. Adjusters

E. Locknuts

Rear Brake Light Switch

Rear Brake Light Switch Adjustment•Turn the ignition switch on.• The brake light should illuminate when thebrake pedal is depressed about 7 mm (0.28in.).

A. Brake Pedal

B. 7 mm (0.28 in.)

• If the light does not come on, adjust the rearbrake light switch.

• Remove the rear brake fluid reservoir bolt andstopper.

• Remove the right front footpeg bracket bolts.• Pull the footpeg bracket a little bit outward.

PREPARATION 25

A. Rear Brake Fluid Reservoir Bolt andStopper

B. Right Front Footpeg Bracket Bolts

C. Right Front Footpeg Bracket

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

A. Cover

B. Rear Brake Light Switch

C. Adjusting Nut

D. Lights sooner

E. Lights later

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

•Slide back the cover to the original position.• 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 in·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 an improperly adjusted headlights.

Horizontal Adjustment•Turn the horizontal adjuster in or out until thebeam points straight ahead.

Vertical Adjustment•Turn the vertical adjuster in or out to adjustthe headlight vertically.

A. Horizontal Adjusters

B. Vertical Adjusters

For US and Canada Models

NOTE○On 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 Spot

C. 7.6 m (25 ft)

D. Height of Headlight Center

26 PREPARATION

For other than US and Canada Models

NOTE○On 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 Meter

Check the Unit Setting: km/h, mphMph·km/h Display can alternate between

English and metric modes (mph and km/h)on the digital meter. Make sure that mph orkm/h is correctly displayed according to localregulations before sale.

NOTE○Do not operate the vehicle with wrong unit(mph or km/h) of the speedometer.○The unit setting can be selected from four unittypes.

•Turn the ignition switch on.• Push and hold the mode button to enter to thesetting mode.

• Push the upper button or lower button to dis-play the “UNIT.”

A. Upper Button

B. Middle Button

C. Lower Button

D. Reset Button

E. Mode Button

(ZX1002A)

•Push the mode button. The current settingstarts blinking.

• Push the upper button or lower button to se-lect the type.

• Push the mode button. The current settingstops blinking.

: Flow when pushing upper button

: Flow when pushing lower button

PREPARATION 27

(ZX1002B)•Push the mode button.• Push the upper button or lower button to se-lect the unit type.

• Push the mode button.

A. Unit

: Flow when pushing mode button

: Flow when pushing upper button

: Flow when pushing lower button

28 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 29

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

Frame/Steering

1 Steering stem head nut 80 8.2 59

2 Handlebar bolt 35 3.6 26

3 Handlebar holder clamp bolt 25 2.5 18

4 Handlebar holder positioning bolt 10 1.0 89 in·lb

Brakes

5 Front master cylinder clamp bolt 11 1.1 97 in·lb

6 Front master cylinder bleed valve 5.4 0.55 48 in·lb

7 Front caliper mounting bolt (left and right) 35 3.6 26

8 Front caliper bleed valve (left and right) 8.0 0.82 71 in·lb

9 Rear caliper mounting bolt 35 3.6 26

10 Rear caliper bleed valve 5.4 0.55 48 in·lb

11 Rear master cylinder mounting bolt 25 2.5 18

Wheel

12 Front axle clamp bolt (left and right) 20 2.0 15

13 Front axle nut 130 13.3 95.9

14 Rear wheel nut 110 11.2 81.1

Suspension

15 Upper front fork clamp bolt 20 2.0 15

16 Rear shock absorber bracket nut 35 3.6 26

17 Upper rear shock absorber nut 35 3.6 26

18 Lower rear shock absorber nut 35 3.6 26

19 Tie-rod nut 35 3.6 26

20 Rocker arm nut 35 3.6 26

21 Swingarm pivot shaft nut 110 11.2 81.1

Clutch

22 Clutch master cylinder clamp bolt 11 1.1 97 in·lb

23 Clutch master cylinder bleed valve 5.4 0.55 48 in·lb

24 Clutch slave cylinder mounting bolt 10 1.0 89 in·lb

25 Clutch slave cylinder bleed valve 8.4 0.86 74 in·lb

30 PREPARATION

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

Engine Oil Drain

26 Engine oil drain bolt 25 2.5 18

Others

27 Front footpeg bracket bolt (Left and Right) 25 2.5 18

28 Rear footpeg bracket bolt (Left and Right) 25 2.5 18

29 Heel guard bolt 8.0 0.82 71 in·lb

30 Bearing housing clamp bolt 33 3.4 24

Cotter Pin or Circlip

31 Front footpeg pin circlip (Left and Right) – – –

32 Rear footpeg pin circlip (Left and Right) – – –

33 Rear master cylinder push rod cotter pin – – –

PREPARATION 31

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·lb

6 8.0 0.82 71 in·lb

8 20 2.0 15

10 35 3.6 26

12 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·lb

5 3.0 0.31 27 in·lb

6 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·lb

5 0.5 0.05 4.4 in·lb

6 1.0 0.10 8.9 in·lb

Test Ride the Motorcycle

•Complete the test ride checklist.NOTE

○Some noise from the super charger tensionercould occur when starting vehicle after longstorage. However, if there is no problem onthe function of the tensioner, that noise willdisappear after riding for a while.

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

32 PREPARATION

Electrical System:

Headlight - check high and low beams.

Taillight - check operation.

Brake Light - check operation.

Turn Signal Lights - check operation.

Cornering 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.99931-1589-01

MODEL APPLICATIONYear Model Name

2018 ZX1002AJ Ninja H2 SX

2018 ZX1002BJ Ninja H2 SX

ninja h2 sx · items for all kawasaki ninja h2 sx. 1. uncrating 2. assembly 3. preparation the...

Documents