KawasakiZZR1400 ABSNinja ZX-14RNinja ZX-14R ABSMotorcycleAssembly &PreparationManual




as possible,they are partially disassem-bled before crating.Since some of the mostcommonly removed parts have a directbear- ing on a vehicle's reliability andsafety,consci- entious pre-sale assembly andpreparation be- comes extremelyimportant.Good setup pro- cedures canprevent needless warranty claims and givecustomers a greater sense of confi- dence inKawasaki and their Kawasaki Dealers.This Assembly and Preparation Manualex- plains step by step procedures of thefollow- ing items for all Kawasaki ZZR1400ABS,Ninja ZX-14R and Ninja ZX-14R ABS.1.Uncrating2.Assembly3.PreparationThe selling dealer assumes soleresponsibil- ity for any unauthorizedmodifications prior to sale.Refer to yourService Binder for any Ser- vice Bulletinsspecifying Factory Directed Mod- ifications(Special Claims)which must be per- formedbefore the vehicle is ready for sale.Whenever you see the followingsymbols heed their instructions! Alwaysfollow safe operating and maintenancepractices.!DANGERDANGER indicates a hazardous situa-tion which,if not avoided,will resultindeath or serious injuryWARNINGWARNING indicates a hazardous situa- tion which,if not avoided,could result in deathor serious injury.NOTICENOTICE is used to address practices not related to personal injury.NOTEoThis note symbol indicates points of particular interest for more eflicient and convenient op- eration.Kawasaki Heavy Industries,Ltd.accepts noliability for any inaccuracies or omissions in thispublication,although every possiblemeasure has been taken to make it ascomplete and ac- curate
as possible.Allprocedures and specifi- cations subject tochange without notice.
ForewordIn order to ship Kawasaki vehicles as effi-ciently


@2011 Kawasaki Heavy Industries,Ltd.Sep.,2011


(For Canadian Models) ............................................. 7Brake Disc Cleaning .........................................................................7Preparation ........................................................................................8Battery Service ................................................................................. 8Coolant ............................................................................................12Front Brake .................................................................................... 13Rear Brake ....................................................................................15Clutch ............................................................................................ 16Drive Chain ....................................................................................18Front Fork .......................................................................................19Rear Shock Absorber .....................................................................21Tire Air Pressures .......................................................................... 21Fuel ...............................................................................................22Engine Oil (4-stroke) ...................................................................... 22Throttle Grip and Cable ..................................................................23Rear Brake Light Switch .................................................................24Headlight Aim .................................................................................24Multifunction Meter
...................................................................... 25Fastener Check ............................................................................. 28Standard Torque Table ..................................................................30Test Ride the Motorcycle ............................................................... 30dle Speed Adjustment ................................................................... 24A & P Check List .............................................................................30
Table of ContentsUncrating ...........................................................................................3Opening Crate................................................................. 3Parts Check................................................................... 4Assembly ....................................................................... 5Steering Stem Head Nut ................................................. 5Handlebar Weights ..........................................................................5 Windshield....................................................................... bRear Fairing................................................................... 6Seat .............................................................................. 6French Label


·Place
● the crate upright on its base.NOTICEWhen removing the crate bracket from the motorcycle,be careful not to drop any parts or the bracket onto the fueltank and other components,andnot to scratch the fuel tank or other compo- nents with the crate bracket.● Remove the cardboard cover.Remove the parts box.
Opening CrateUNCRATING 3UncratingA WARNINGCrates have sharp edges and mayhave nails or screws that can causecuts and injury.Always wearprotective gloves, boots and eyeprotection when uncrat- ing toprevent injury.WC03003BS!WARNINGThe steel crate panel plates and fasten- ers have sharp edges.Always wear pro-tective gloves,boots and eye protection when uncrating to prevent injury.WC03004BS·Clear a space about 6 m (20 ft)square to giveyourself plenty of space to work.


·First,remove the lower bolt (D =22,L =10) at the steering stem and discard it.·Remove the upper bolts (D=8,L=14)to takeoff the crate bracket and discard them.A.Lower Bolt (D=22,L=10)B.Upper Bolts (D=8,L=14)C.Crate BracketD.Foam Pad·Take out all the bolts and screws and removeA.Lower Support Bracket (Both Sides)the top and sides of the crate.·Lift the vehicle upward about 10 cm (4 in.)andremove the two lower support brackets.Roll the vehicle off the crate base.


the actual vehicle parts.In the following charts under Remarks,D =diameter in milimeters,and L =length in millimeters.WC05241BN2 CNo.Part NameQtyRemarks1Steering Stem Head Nut1D=252WindshieldSocket BoltPlastic WasherWellnut1666D=5,L=16D=5.3×11.5D=53Battery Compartment CoverBoltWasher111D=6,L=14D=6.5×164Other than Philippine and Southeast Asia B2 ModelsRear FairingSocket BoltPlastic WasherWelnut1444D=6,L=23D=6.5×165Handlebar weightWeight Screw with a Non-permanent Locking Agent22D=8,L=306French Label for Canadian Model onlyEmission Control Information1P/No.59465-08467Battery Electrolyte,FTZ14-BS112 V 12 Ah8Owner's Manual1
4 UNCRATINGParts Check·Open the parts box,and check the parts against the illustrations.There may be minor differences between these illustrations and


ASSEMBLY 5AssemblySteering Stem Head Nut●Remove the steering stem head dummy nut and discard it.Do not remove the flat washer (D=25.5)under the dummy nutA.Dummy NutB.Flat WasherInstall the steering stem head nut (D=25)on the flat washer with the chamferedside facing upwards and tighten the nut tothe specified torque.Torque:78 N-m(8.0 kgf-m,58 ft-Ib)A.Steering Stem Head Nut (D =25)B.Flat WasherHandlebar Weights·Install both handlebar weights on the left and right end of the handlebar with the screws (D =8,L =30)with a non-permanent locking agent and tighten them.A.Handlebar WeightB.Screw (D=8,L=30)Windshield·Fit the six wellnuts (D =5)into the holes in the edge of the windshield from the outside with their flanges out.A.WindshieldB.Wellnuts (D =5)·Fit the windshield into the upper fairing so thatthe tab of the upper fairing fits into thefront groove of the windshield,and alignthe bolt holes.A.Front GrooveB.TabC.Upper Fairing


al
SeRemova
Inset the ignition key into the seat lock,andturn the key clockwise.·Remove the seat by pulling up and rearward.A.SeatB.Seat LockC.Ignition KeyD.Pull Up and Rearward
ansaon
Se
InsetIealfnt slot of the seat onto thethe fuel tank.holder bracket on each left and right side of
6 ASSEMBLY·Install the six plastic washers (D =5.3)andthe socket bolts (D=5,L =16)on the upperfairing.A.Plastic Washers and Bolts (D=5,L =16)B.WindshieldRear Fairing·Fit the four wellnuts (D =6)into the mounting holes in the left and right side of the rear fair- ing bracket.A.Wellnuts (D =6)B.Fairing Bracket·Install the rear fairing with the four socketbolts (D =6,L =23)and the plastic washers(D =6.5),and tighten the bolts.A.Rear FairingB.Socket Bolts (D =6,L=23)and Plastic Washers (D=6.5)Seat


ASSEMBLY 7A.SeatB.SlotsC.Bracket·Insert the slots into the receivers,and insertthe hook at the rear of the seat into the slot,then push down the rear part of the seatuntil the lock clicks.A.ProjectionsB.HookC.Slots (Middle on the frame)D.Slot (Rear end on the frame)E.Insert● Pull up the rear end of the seat to make sureit is securely locked.French Label (For CanadianModels) NOTEORemove the front left side cover. See the “Coolant Filling”item in “Coolant”section onpage 12 in the Preparation chapter.OStick the French label onto the English labelon the left side of the frame only when re-·Wipe off any oil or grease from the Englishlabel.Refer to the following photograph in thelabel location.·Peel the French label off the backing sheetand apply it over the English label.A.Frame (Left Side)B.Emission Control Information (P/No. 59465-0846)Brake Disc Cleaning·Clean the front and rear brake discs usingoilless solvent.AWARNINGAn anticorrosive treatment applied tothe brake discs will increase brakingdistance and can cause an accidentresulting in serious injury or death.Re- move the anticorrosive treatment using an oilless solvent.quired.


heprojections
he right inner . rubber cover from theright fairing cover,and remove the right fairingcover backwardA.Right Fairing CoverB.BoltC.BoltD.Bolt(D=6,L=30)(D=6,L=14)(D=5,L=20)E.Right Inner Rubber Cov