Quiz: how well do you know your Kawasaki Ninja ZX-10R?

21 questions. After each answer you get a short explanation and a link to the manual page that covers it in detail.

During a radiator cap test on the ZX-10R, how long must the gauge hand stay within the specified range after the relief valve opens?
At least 6 seconds. The relief valve must open within 112–142 kPa (16–21 psi) and the pressure must hold for at least 6 seconds. Wet the cap sealing surfaces first to avoid false leaks. Radiator Cap Inspection

What can damage the windshield and other plastic parts of your Ninja if they touch it?
Brake fluid or window cleaner. Gasoline, brake fluid, window cleaners and thread-lockers can make plastic deteriorate and break. If contact happens, wash immediately with water and mild detergent, then inspect. Windshield and Other Plastic Parts

When installing the ZX-10R engine, what is the tightening torque of the left front engine mounting bolt?
44 N·m. The left front bolt and right front bolt are both 44 N·m (32 ft·lb). The adjusting collar locknut is 49 N·m and needs the special engine mount nut wrench 57001-1450. Engine Installation

When preparing the motorcycle for long storage, how should tire pressure be changed?
Reduced by about 20%. Tire pressure should be reduced by about 20%, and ideally both wheels raised on a stand. Also drain fuel, fit fresh oil and slow-charge the battery (1 A or less) monthly. Storage

What is the tightening torque of the swingarm pivot shaft nut on the ZX-10R?
108 N·m. The pivot shaft nut is 108 N·m, the adjusting collar locknut 98 N·m and the shaft itself 20 N·m. The locknut needs swingarm pivot nut wrench 57001-1597. Swingarm Installation

What is the maximum ethanol content in gasohol approved for your Kawasaki?
10%. Gasoline with up to 10% ethanol is approved; methanol blends should be avoided and never exceed 5%. For 30–60 days of non-use, add a fuel stabilizer. Fuels Containing Oxygenates

After tightening the steering damper mounting bolts on the ZX-10R, what should you confirm?
There is play in the steering damper. Confirm there is play in the damper after tightening (bolts 11 N·m with non-permanent locking agent). On electronic damper models, route the main harness under the bracket. Steering Damper Installation

What do you apply to the threads of the oil pressure switch before tightening it to 15 N·m?
Silicone sealant. Silicone sealant (Liquid Gasket TB1211) goes on the threads after cleaning with high flash-point solvent. The terminal bolt is only 1.5 N·m, with grease on the terminal. Oil Pressure Switch Installation

How is the oil filler plug tightened when reassembling the clutch cover?
Hand-tighten. The filler plug is only hand-tightened, after replacing its O-ring and greasing the new one. Clutch cover plate bolts get locking agent and 9.8 N·m. Clutch Cover Assembly

On a KIBS-equipped ZX-10R, how does the rear wheel rotation sensor signal reach the ECU?
Through the KIBS hydraulic unit. On KIBS models the signal passes through the hydraulic unit; other models go direct. The ECU uses it for speed and S-KTRC control, and sets service code 24 on faults. Rear Wheel Rotation Sensor Signal (Service Code 24)

How soon must you finish applying TB1207B liquid gasket to the lower crankcase half and join the halves?
Within 7 minutes. TB1207B must be applied within 7 minutes; TB1216B allows 20 minutes. Never put sealant near main bearing inserts or oil passages. Crankcase Halves Assembly

What should you do if a wheel balance weight has play on the rim rib?
Replace it; never reuse it. Play means the blade or clip stretched, so replace the weight. Weights come in 10, 20 and 30 g, and more than 90 g (four or more) means find the cause. Balance Weight Installation

What does the side stand switch on this Kawasaki do?
Prevents starting in gear with stand down. The engine will not start if the transmission is in gear and the side stand is down. Before moving off, check the stand is up, pull the clutch and select 1st. Moving Off

What is the service limit for rear sprocket runout (warp) on the ZX-10R?
TIR 0.5 mm. Standard is 0.4 mm or less; above 0.5 mm TIR replace the sprocket. Measure with a dial gauge near the teeth while turning the raised rear wheel. Rear Sprocket Warp Inspection

What is the tightening torque for the air cleaner housing clamp bolts on the ZX-10R?
2.0 N·m. Clamp bolts get 2.0 N·m (18 in·lb), while the housing assembly screws take only 1.1 N·m. Install the clamp bolt heads inside and seat the ducts against the throttle body stoppers. Air Cleaner Housing Installation

If the engine stalls just when shifting into 1st gear, what does the troubleshooting guide suggest checking?
Side stand left down. A side stand left down or a clutch that doesn't fully disengage can stall the engine in 1st. Also note: after a fall, turn the ignition OFF first or the engine may not restart. Troubleshooting guide

What is the cylinder head warp service limit on the ZX-10R?
0.05 mm. If warp exceeds 0.05 mm, replace the head. Below that, you can lap it on emery paper on a surface plate, first No. 200 then No. 400. Cylinder Head Warp Inspection

In the lights check, if a light does not go off with the ignition OFF, which part should be replaced?
Ignition switch. All lights should go off when the ignition is turned OFF; if not, replace the ignition switch. On immobilizer models the red warning light will blink. Lights and Switches Operation Inspection

What is the rating of the KIBS motor relay fuse on the ZX-10R?
30 A. The KIBS motor relay fuse is 30 A, while the solenoid valve relay fuse is 20 A. The circuit also lists a 12 V 8.6 Ah battery. KIBS System Circuit

What should a passenger do while the motorcycle is moving?
Sit still, feet on footpegs, hold on. Improper passenger positioning or sudden movements affect control. The passenger should hold the rider or seat strap, and animals must not be carried. Loading and accessories information

What should you do if a warning label on your Kawasaki is missing or worn?
Get a replacement from a dealer and fit it in the right place. Labels carry safety-critical information and must be in the shown locations. The sample labels list part numbers so your dealer can supply the correct replacement. Location of labels

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