Kawasaki Voyager XII

Motorcycle Service Manual SupplementQuick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference g u i d e will assist you in locating a desired t o p i c o r procedure. •Bend the pages back t o m a t c h t h e black t a b of the desired c h a p t e r n u m ber with the black tab o n t h e e d g e at each table of contents p a g e . •Refer to the sectional table of c o n t e n t s for the exact pages to l o c a t e t h e specific topic required. E 2 | 3 | 4 | 5 | 6 | 7 | 1 9 | 10| 11 1 | 13| 14 15| 1 Supplement - 1999 ~ 2003 Models 17 | Kawasaki Motorcycle Service Manual Supplement All rights reserved. No parts of this publication m a y b e r e p r o d u c e d , stored in a retrieval system, or transmitted in any form or by any m e a n s , electronic m e c h a n i c a l p h o t o c o p y i n g , recording or otherwise, without the prior written permission of Quality A s s u r a n c e D i v i s i o n / C o n s u m e r Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability c a n b e accepted for any i n a c c u r a c i e s or o m i s s i o n s in this publication, although every possible care has been taken to make it as c o m p l e t e a n d accurate a s possible. The right is reserved to make c h a n g e s at a n y time without prior n o t i c e a n d without incurring an obligation to make such c h a n g e s to products m a n u f a c t u r e d previously. S e e y o u r Motorcycle dealer for the latest information on product improvements i n c o r p o r a t e d after this publication. All information contained in this publication is based on the latest p r o d u c t information available at the time of publication. Illustrations and p h o t o g r a p h s in this publication a r e i n t e n d e d for reference use only and may not depict actual model component parts. © 1997 Kawasaki Heavy Industries, Ltd. 11th Edition ( 1 ) : M a y 25, 2007 (K) •Dampen dust and place it in properly closed receptacle and dispose of it safely. . they should always be so equipped. • I f possible. feet gram(s) hour(s) Liter(s) lb m min N Pa PS psi r rpm TDC TIR V W n pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower p o u n d ( s ) per square i n c h revolution r e v o l u t i o n ( s ) per m i n u t e t o p d e a d center t o t a l i n d i c a t o r reading volt(s) watt(s) ohm(s) & This warning may apply to any of the following components or any assembly containing one or more of these components:Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS •Operate if possible out of doors or in a well ventilated place. WARNING CONTAINS ASBESTOS Read OWNER'S MANUAL before operating. with an appropriate dust extraction facility.LIST OF A B B R E V I A T I O N S A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft 9 h L ampere(s) a f t e r b o t t o m dead center alternating current a f t e r t o p dead center b e f o r e b o t t o m dead center b o t t o m dead center b e f o r e t o p dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit f o o t . dampen before cutting or drilling. If high speed tools are used. •Preferably use hand tools or low speed tools equipped. if necessary. Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California A i r Resources Board. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. fuel vapors are routed into the running engine t o be burned.M EMISSION C O N T R O L INFORMATION To protect the environment in which we all live. or who operates a fleet o f m o t o r vehicles knowingly t o remove or render inoperative any device or element o f design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser. the vapors are routed through an oil separator to the intake side of the engine. contains what is commonly referred t o as the Act's "tampering provisions. or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. servicing. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Liquid fuel is caught by a vapor separator and returned to the fuel tank. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. (3) (A) for any person t o remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance w i t h regulations under this title prior to its sale and delivery t o the ultimate purchaser.. A d d i t i o n a l l y ." "Sec. or trading motor vehicles or motor vehicle engines. (3)(B) for any person engaged in the business of repairing. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere.. 203(a) The f o l l o w i n g acts and the causing thereof are prohibited. 2. or stored in a canister when the engine is stopped. the vapors are drawn into combustion chamber. Instead. which is the Federal law covering motor vehicle pollution.. Instead. While the engine is operating. leasing. selling. where they are burned along w i t h the fuel and air supplied by the carburetion system. 1. The Clean A i r A c t ." (Continued on next page) . Kawasaki has incorporated an evaporative emission control system (3) in compliance w i t h applicable regulations of the California Air Resources Board on vehicles sold in California only. 3.. THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. Among those acts presumed to constitute tampering are the acts listed below: • Replacement of the original exhaust system or muffler w i t h a component not in compliance with Federal regulations. Permanently removing. Maladjustment of vehicle components such that the emission standards are exceeded. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW. . or replacement. • Removal of the muffler(s) or any internal portion of the muffler(s). disconnecting. •Modifications to the muffler(s) or air intake system by cutting. Tampering could include: a. repair. TAMPERING WITH NOISE C O N T R O L S Y S T E M PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes o f maintenance. b. d.000 PER VIOLATION. or rendering inoperative any component or element of design of the emission control systems. of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery t o the ultimate purchaser or while it is in use. or other means if such modifications result in increased noise levels. c. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Addition of components or accessories that result in the vehicle exceeding the standards. drilling. 2. • Removal of the air box or air box cover.NOTE o The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. For the duration of your warranty period. if n o t strictly observed. and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special T o o l Manual. The Periodic Maintenance Chart is located in the General I n f o r m a t i o n chapter. A n y owner maintenance or repair procedure not performed in accordance w i t h this manual may v o i d t h e warranty. oThis warning symbol identifies special instructions or procedures w h i c h . and w o r k s h o p procedures must be understood in order t o carry o u t maintenance and repair satisfactorily. Whenever you see these W A R N I N G and C A U T I O N symbols. read the t e x t . heed their instructions! Always f o l l o w safe operating and maintenance practices. if n o t correctly f o l l o w e d . A basic knowledge of mechanics. Most service operations are identical t o those for the Z G 1 2 0 0 A . f o r example. especially. Special tools. gauges. Whenever the owner has insufficient experience or doubts his ability t o do the work. I f y o u want spark plug information. . T h e chart tells y o u h o w frequently t o clean and gap the plug. the proper use of tools. could result in personal injury. use the Quick Reference Guide t o locate t h e Electrical System chapter. How t o Use this Manual In preparing this manual. and the use of substitute tools may adversely affect safe operation. This manual is designed primarily f o r use b y trained mechanics in a properly equipped shop. In order t o perform t h e work efficiently and to avoid costly mistakes. we recommend that all repairs and scheduled maintenance be performed in accordance w i t h this service manual. • Be alert for problems and non-scheduled maintenance. j CAUTION j oThis caution symbol identifies special instructions or procedures w h i c h . These systems became the manual's chapters. The Quick Reference G u i d e shows you all of the product's systems and assists in locating their chapters. However. Genuine parts provided as spare parts are listed in the Parts Catalog. T o get the longest life out of your M o t o r cycle: • Follow the Periodic Maintenance Chart in t h e Service Manual. N e x t . • F o l l o w the procedures in this manual carefully. Precision measurements can o n l y be made if the proper instruments are used. Then. it contains enough detail and basic information t o make i t useful to the owner w h o desires t o perform his o w n basic maintenance and repair work. we divided the p r o d u c t i n t o its major systems. The maintenance and repair procedures described in this Supplement are only those t h a t are unique to the ZG1200B. • Use proper tools and genuine Kawasaki M o t o r cycle parts. Complete and proper servicing of the Z G 1 2 0 0 B therefore requires both this Supplement and the base Service Manual. Each chapter in t u r n has its o w n comprehensive Table o f Contents. use t h e Table of Contents on the first page of t h e chapter t o f i n d the Spark Plug section. and t h e n d o the w o r k carefully in a clean area. d o n o t use makeshift tools or equipment. go t o the Periodic Maintenance Chart first. D o n ' t take shortcuts. • Remember t o keep c o m p l e t e records of maintenance and repair w i t h dates and any new parts installed.Foreword This ZG1200B Service Manual Supplement is designed t o be used in conjunction w i t h the ZG1200A Service Manual (P/N 99924-1064-01). A l l information f o r a particular system f r o m adjustment through disassembly and inspection is located in a single chapter. thoroughly familiarize yourself w i t h t h e procedures before starting work. or loss o f life. maintenance. could result in damage t o or destruct i o n of equipment. Whenever special tools or equipment are specified. The chart gives a t i m e schedule f o r required maintenance operations. all adjustments. and repair should be carried o u t only by qualified mechanics. oIndicates a procedural sub-step or how to do the work of the procedural step it follows.This manual contains five more symbols (in addition t o W A R N I N G and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation. or NOTE. oil. It also precedes the t e x t of a WARNING. . ^Indicates a conditional sub-step or what action t o take based upon the results of the conditional step it follows. grease or a locking agent during assembly. • Indicates a procedural step or work to be done. In most chapters an exploded view illustration of the system components follows the Table of Contents. * Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In these illustrations you will find the instructions indicating which parts require specified tightening torque. C A U T I O N . and Hose R o u t i n g * 1-2 1-3 1-5 1-6 1-7 "Refer t o Base Manual .General Information Table of Contents Before Servicing Model Identification General Specifications Periodic Maintenance Chart T o r q u e and Locking A g e n t Cable. Wire. Model Identification ZG1200-B1 L e f t S i d e Viem: . 10W50. 4-cylinder Liquid-cooled 78.5 kg 158.5 m f r o m 5 0 k m / h 2. or 2 0 W 5 0 4. 1-2-3-4 1-2-4-3 Front Rear 2520 m m 965 m m 1505 m m 1620 m m 140 m m 755 m m 330 kg © ) 330.5 kg 202.0 L 20° B T D C 48° A B D C 248° 54° B B D C 14° A T D C 248° Forced lubrication (wet sump) 4-stroke. DOHC. SF or SG class S A E 1 0 W 4 0 .0 x 6 2 . 20W40.U 9 L e f t t o right. Keihin C V K 3 0 x 4 Electric starter Battery and coil (transistorized) Electronically advanced 10° B T D C @800 r / m i n (rpm) N G K D P R 8 E A .9 or ND X 2 4 E P R .General Specifications ( g j ) : California Model Items Dimensions: Overall length Overall w i d t h Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Fuel tank capacity Performance: Braking distance M i n i m u m turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Carburetion system Starting system Ignition system T i m i n g advance Ignition timing Spark plug Cylinder numbering method Firing order Valve timing: Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil: Grade Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Gear 1.5 kg 23. 6 m m 1196 m L 10.0 Carburetors.706 ( 9 9 / 5 8 ) Wet m u l t i disc SE.2 L 12.9 m 203 kg ZG1200-B1~ . Items Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio Final gear case oil: Type Capacity Frame: Type Caster (rake angle) Trail Front tire: Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake type: Front Rear Electrical Equipment: Battery Headlight: Type Bulb Tail/brake light Alternator: Type Rated output Voltage regulator: Type ZG1200-B15-speed.5"C). double cradle 30" 121 mm Tubeless M130/90-16 Tubeless M150/90-15 M/C Telescopic fork (pneumatic) 140 mm Swing arm 100 mm Dual disc Single disc 12 V 20 Ah Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12 V 8/27 W x 4.800(36/20) 1.035 (29/28) 0. .470 @Top gear API GL-5 Hypoid gear oil SAE 80 ( . B2 . and may not apply to every country. SAE 90 (5"C~) 210 mL Tubular.733(41/15) 1. constant mesh.333 (32/24) 1.5 V Short-circuit Specifications subject to change without notice.424 (15/22 x 32/9) 3.838 (26/31) Shaft 2. 13. return shift 2.: 12 V 8/27 W x2 Three-phase AC 35 A @7500 r/min (rpm). replace Brake light switch . connections -. repeat at t h e frequency interval established here. and fastener tightness .check* Air suction valve .check* Cylinder head b o l t tightness .check* Steering stem bearing .check (US)* Air cleaner element . S .change Clutch f l u i d hose and pipe -.change Propeller shaft j o i n t -.check* Brake f l u i d -.check* Carburetor synchronization ~ check * Fuel system . bolt.lubricate Fuel hose -.replace Air cleaner oil drain reservoir .change Brake hose . add. • : Replace. clean. or torque if necessary. The initial maintenance is vitally important and must not be neglected. adjust.check* Brake f l u i d level -. connections .check* Final gear case oil -.check* Radiator hoses.Periodic Maintenance Chart The scheduled maintenance must be done in accordance w i t h this chart to keep the motorcycle in good running condition.change Tire wear -.lubricate Front f o r k oil .check* Swing arm p i v o t -.change Final gear case oil level . (Cal): California vehicle o n l y (US) : U .check* Evaporative emission control system -check (Cal)* Engine oil -. only (page) : See base manual .replace Clutch master cylinder cup and dust seal -.perform Nut.replace Brake lining or pad wear .clean Throttle grip play .replace Clutch slave cylinder piston seal .check* Brake master cylinder cup and dust seal .change Oil filter -.check* I Every /v* wWZWZf/^ Page • • • • • • • (15-20) (15-20) (4-7) (2-15) 2-3 (2-8) (2-9) (2-10) (2-20) • • • • • • year • • • • • • • • • • • • • • • • • • year 2 years (6-5) (6-5) 2-5 (3-12) (3-4) (10-5) (10-5) (10-9) (5-5) (5-5) (5-7) (5-8) (11-13) (11-5) (11-6) (11-14) (11-8) (11-11) (15-39) (13-4) (13-8) (12-5) (9-10) (12-13) (16-8) (16-8) • 4 years month 2 years 4 years 2 years 2 years month 2 years 4 years 2 years 2 years • • 2 years • • • • • • • • t : For higher odometer readings.check* Coolant -.lubricate General lubrication .replace Clutch f l u i d level .check* Clutch f l u i d . Whichever ^ F R E Q U E N C Y ^ ^ fODOMETER READING OPERATION Spark plug ~ clean Spark plug -.check* Idle speed -. A .check* Steering -.replace Caliper piston seal and dust seal .replace Brake hoses. 9 0. adding the f o l l o w i n g . Torque Fastener Clutch: Clutch spring bolt holders {ZG1200-B5 ~ ) Electrical System: Cancel switch (throttle) adjusting screw l o c k n u t Cancel switch (throttle) mounting screws Cancel switch (rear brake) mounting screws Rear speaker mounting nuts L : A p p l y a non-permanent locking agent t o t h e threads.Torque and Locking Agent Refer t o the base manual. 4.50 4 3 in-lb L L L — L N-m kg-m ft-lb Remarks . o f antenna mount. o f throttle cables and their routing.Cable. 1-12) Viewed from Top junction Box Throttle Accelerator Cable (for throttle grip) Throttle Decelerator Cable Actuator Throttle Accelerator Cable (for actuator) Throttle Accelerator Cable (for carburetors) Choke Cable Connecting Pipe Ignition Coil (#1 & 4) . o f choke cable routing. W i r e . noting the following. a n d Hose R o u t i n g Refer •Change •Change •Change to the base manual. Control Cables (p. 4. 10. * Antenna Lead Choke Cable To Vacuum Switch Valve Cylinder Head Cover Carburetors Surge Tank To Vacuum Valve To Liquid/Vapor Separator To Canister Rear Speaker Leads : California Model Only Viewed from Left Viewed from Top . *7. *8. 1. 6. 5.Vacuum Hoses and Breather Hoses {p. 1-18) Change o f choke cable routing. 3. 2. *9. Throttle Grip and Cables Throttle Cable Inspection Throttle Cable Adjustment Throttle Cable Installation Note Throttle Cable Lubrication Throttle Cable Inspection Choke Cable Choke Cable Free Play Inspection Choke Cable Adjustment Choke Cable Lubrication Choke Cable Inspection Carburetors Idle Speed Inspection Idle Speed Adjustment Carburetor Synchronization Inspection Carburetor synchronization Fuel Level Inspection Fuel Level Adjustment Fuel System Cleanliness Inspection Carburetor Removal/ Installation Notes Carburetor Disassembly/ Assembly Notes Carburetor Separation/ Assembly Notes Carburetor Cleaning Carburetor Inspection 2-2 2-2 Air Cleaner Air Cleaner Element Removal Air Cleaner Element Installation Notes .. Air Cleaner Element Cleaning Air Cleaner Element Inspection * * 2-3 2-3 2-4 2-4 * Air Cleaner Housing Removal Air Cleaner Oil Drain Reservoir Oil Draining Fuel Pump Fuel Pump Removal Fuel Pump Installation Notes Fuel Filter Fuel Filter Removal * * * * * * * * * * 2-5 2-5 * * * * 2-5 * Fuel Filter Installation Notes Fuel Filter Inspection Fuel Tank and Fuel Level Sensor Fuel Tank Removal Fuel Tank Installation Notes Fuel Level Sensor Removal/ Installation Notes Fuel Tank Cleaning Fuel Tank Inspection * * * Check Valve Inspection Evaporative Emission Control System (US California Vehicle Only) Parts Removal/Installation Notes Hose Inspection Separator Inspection Separator Operation Test Canister Inspection Vacuum Valve Inspection * * * * * * 2-5 * * Refer to Base Manual . ..Fue! System Table of Contents Exploded View Specifications Special Tools High Altitude Performance Adjustment (US Model) High Altitude Carburetor Adjustment. 1. •Addition of cancel switch for cruise control. Cancel Switch (throttle) : Non-permanent locking agent Specifications Refer t o t h e base manual. Item T h r o t t l e G r i p a n d Cables: T h r o t t l e g r i p free play A c t u a t o r p u l l e y free play 2 — 4 mm 3. •Change of throttle accelerator cable.0 .Exploded View Refer to the base manual.5 m m Standard . n o t i n g t h e f o l l o w i n g . noting the following. Junction Box of Throttle Accelerator Cable Assembly 2.5. the distance between the pulley and the stopper is the amount of actuator pulley free play. Actuator Pulley Free Play Actuator Pulley Free Play 1. Cancel Switch (throttle) Connector . adjust the throttle cables. adjust the throttle cables. B. Stopper A. A t this time. Actuator Pulley Free Play 3.T h r o t t l e G r i p a n d Cables Cancel Switch (Throttle) Connections BL OWhen throttle grip is completely closed * l f the cancel switch does not operate properly. check the cancel switch (throttle) at the carburetors operates properly using an ohmmeter. •Holding the actuator in its original position if it is removed. Throttle Grip Free Play A.4 mm Actuator Pulley Free Play Inspection •Remove the fairing. check actuator pulley free play at the pulley. Turn the actuator pulley until the carburetor pulley starts to move. Actuator Pulley 2. BK Throttle Cable Inspection Throttle Grip Free Play Inspection •Check throttle grip free play by lightly turning the throttle grip back and forth. • H H H H i A. * l f free play is not correct. Actuator Cancel Switch Operation Inspection •Check the decelerator cable mounting bracket at the carburetors moves down by pushing the throttle grip closed. Decelerator Cable Mounting Bracket B. Throttle Grip Free Play 2 . •Start the engine. and check the cancel switch at the carburetors operates properly using an ohmmeter. Do not forget to securely tighten the locknuts after adjustment. Throttle Cable Adjustment •Loosen the locknut and turn out the decelerator cable adjuster at the throttle grip until the inner cable just becomes tight. oOperation with an improperly adjusted. Tighten the locknuts. * l f idle speed varies. turn out the adjuster continuously one more turn. Tighten the locknut.Actuator Pulley Free Play 3 0 — 5 5 mm •Loosen the locknuts and slide the accelerator cable adjuster at the actuator until the correct actuator pulley free play is obtained. Then. mount the cable lower ends on their brackets as shown. oOperation with an improperly adjusted. •Turn the handlebar from side to side while idling the engine. the throttle cables may be poorly routed or they may be damaged. * l f the actuator pulley free play is incorrect. Adjusters D. use the cable adjusters at the carburetors. incorrectly routed. NOTE oIf the throttle cables can not be adjusted by using the cable adjusters at the throttle grip or the actuator. Accelerator Cable B. Locknuts Throttle Cable Installation Note •When replacing throttle cables with new ones. •Correct any problem before operating the motorcycle. • T u r n the handlebar from side to side while idling the engine. Tighten the locknut. the throttle cables may be poorly routed or they may be damaged. * l f all checks are correct. or damaged cable could result in an unsafe riding condition. •Loosen the locknut and turn the accelerator cable adjuster at the throttle grip until the correct throttle grip free play is obtained. * l f idle speed varies. •Correct any problem before operating the motorcycle. adjust the throttle cables. Decelerator Cable C. turn out the decelerator cable adjuster until the cancel switch turns to o f f with the throttle grip closed and stop it. incorrectly routed. * l f the cancel switch does not operate properly. •Push the throttle grip completely closed. . A. make the following test: •Start the engine. or damaged cable could result in an unsafe riding condition. • I f the cancel switch (throttle) was removed. . drain it by taking o f f the drain plug at the lower end o f the drain hose. Oil Drain Reservoir {CAUTION*} oDo not disassemble the junction box of the accelerator cable assembly. install and adjust the cancel switch (see Switches in the Electrical System chapter). or the air is drawn in through it. Throttle Decelerator Cable 2.Oil Draining •Visually check the reservoir if the water or oil accumulates in it. Throttle Accelerator Cable A. noting the following. Disassembling the box may upset the cable joints and cause the cable malfunction. and catches water or oil from the bottom o f the surge tank. •Be sure to install the plug firmly. * l f any water or oil accumulates in the reservoir. B. Check and drain the reservoir in accordance with the Periodic Maintenance Chart. Drain Plug Carburetors Carburetor Disassembly/Assembly Notes Refer to the base manual. 1. A i r Cleaner O i l D r a i n Reservoir An air cleaner oil drain reservoir is provided beneath the surge tank. and Fan Switch Radiator Removal Notes Radiator Installation Notes Radiator Inspection Radiator Cleaning Water Pump Water P u m p Removal Water Pump Installation Notes Pump Impeller Inspection Thermostat and Temperature Sensor Thermostat Removal Note Thermostat Installation Notes Thermostat Inspection Hoses and Pipes Hose and Pipe Removal Note Hose and Pipe Installation Notes Hose Inspection . Fan.Cooling System Table of Contents Exploded V i e w Specifications Coolant F l o w Chart Coolant Coolant Level Inspection Coolant Inspection Coolant Change Cooling System A i r Bleeding Mechanical Seal Inspection (Visual Leak Inspection) Cooling System Pressure Test Cooling System Flushing Radiator Cap Radiator Cap Inspection Radiator. Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Notes Camshaft Chain Tensioner Installation Notes Replacement Chain Tensioner Installation Notes Camshafts and Sprockets Camshaft Removal Notes Camshaft Installation Notes (Including Chain Timing Procedure) . . . . . . Camshaft Sprocket Installation Notes . . Cylinder Head Warp Cylinder Head Cleaning Carburetor Holders Carburetor Holder Installation Notes. . . Cam Height Measurement Camshaft Runout Camshaft Bearing Oil Clearance Inspection Camshaft Chain and Guides Camshaft Chain Removal Note Camshaft Chain Guide Removal Notes Camshaft Chain Wear Camshaft Chain Guide Wear Hydraulic Lash Adjuster (HLA) H LA Removal Notes HLA Installation Notes HLA Air Bleeding HLA Leak-down Measurement HLA Troubleshooting Guide Cylinder Head Cylinder Head Removal Note Cylinder Head Installation Notes . .Engine Top End Table of Contents Exploded View Specifications Special Tools Clean Air System (US model) Air Suction Valve Installation Note Air Suction Valve Inspection Vacuum Switch Valve Test Cylinder Head Covers Cylinder Head Cover Removal Notes Cylinder Head Cover Installation Notes . . Valve Head Thickness Valve Stem Bend Valve/Valve Guide Clearance Measurement (Wobble Method) . Valves Valve Mechanism Removal Notes . Valve Mechanism Installation Notes . . . . . Cylinder Compression Measurement . Piston Ring End Gap Exhaust Pipes and Mufflers Muffler Removal Notes Exhaust Pipe and Muffler Installation Notes * Refer to Base Manual . . . . Valve Seat Inspection Valve Seat Repair Cylinders and Pistons Piston Removal Notes Piston Installation Notes Cylinder Installation Notes Cylinder Inside Diameter Piston Diameter Piston/Cylinder Clearance Cylinder Boring and Honing Piston/Cylinder Seizure Piston Cleaning Piston Ring and Ring Groove Wear. . . Clutch Table of Contents Exploded View o x.• Specifications Special Tool Clutch Fluid Clutch Fluid Recommendation Clutch Fluid Level Inspection Clutch Fluid Changing Clutch Line A i r Bleeding Clutch Master Cylinder Clutch Master Cylinder Removal Clutch Master Cylinder Installation Notes Clutch Master Cylinder Disassembly Clutch Master Cylinder Assembly Notes Clutch Master Cylinder Inspection Clutch Slave Cylinder Clutch Slave Cylinder Removal Notes Clutch Slave Cylinder Installation Note Clutch Slave Cylinder Disassembly Clutch Slave Cylinder Assembly Notes Clutch Slave Cylinder Inspection Clutch Clutch Removal Clutch Installation Notes Clutch Hub Disassembly Spring Plate Free Play Measurement (ZG1200-B5 ~ ) Friction and Steel Plate Replacement (ZG1200-B5 ~ ) Friction Plate Wear. Damage Inspection Friction or Steel Plate Warp Inspection Clutch Spring Free Length Measurement Clutch Housing Finger Inspection Clutch Hub Spline Inspection Cam Damper Inspection * * * * * * * * * * * * * * * 5-4 5-4 * * * * * * * 5-3 . Exploded View Refer t o the base manual. noting the following. . 2 m m 33. 5 5 .60 m m (with new f r i c t i o n plates) 0 .0.•Addition of diaphragm plate. Specifications ZG1200-B5 ~ : Item Clutch Fluid: Grade Brand (recommended) Standard D.T.1 m m 1.3 m m 32.55 .0.30 .15 m m Service L i m i t .4 Heavy D u t y Brake Fluid Castrol Girling-Universal Castrol GT ( L M A ) Castrol Disc Brake Fluid Check Shock Premium Heavy D u t y Clutch: Spring plate free play 0.0 .0.85 m m (with used f r i c t i o n plates) F r i c t i o n and steel plate warp Clutch spring free length Less than 0.2 m m 0. 8 5 mm (with new f r i c t i o n plates but reassembled) 0. 55 . * l f the free play is not within the standard range. • Measure the free play (see Spring Plate Free Play Measurement). • Install the plates temporarily for measurement purposes. change one o f the steel plates to a thicker or thinner one to get the correct clearance. do the following. noting the following. Spring Hate Free Play (with used friction plates) Standard: 0. • Install the following parts on an extra drive shaft. * l f the free play exceeds the service limit.6 mm plate. Move back and forth. • If the steel plates are also replaced with new ones. Spring Plate Free Play (with new friction plates but reassembled) Standard: 0. • Move the clutch housing gear back and forth while holding the drive shaft steady.60 mm When using all the new friction plates but reassembling them. set a dial gauge against the raised center of the clutch spring plate.3 mm thick steel plates. change one o f the steel plates to a thicker or thinner one to get the correct clearance.15 mm Steel Plates Thickness (mm) Part Number 13089-1068 13089-1004 13089-1067 1. • Install the plates temporarily for measurement purposes. 2. •Assemble the clutch hub. install seven 2.85 mm When reusing all the used plates. do the following.0.85 mm Service Limit: 1.0. if the free play is excessive. * l f the free play is not within the standard range.0. On the other hand. change all of the friction plates. • Measure the free play (see Spring Plate Free Play Measurement).Refer to the base manual. Spring Plate Free Play (with new friction plates) Standard: 0. resulting in rear wheel hop. • Measure the free play (see Spring Plate Free Play Measurement). Spacers Oil Pump Driven Gear Clutch Housing Bearing and Collar Clutch Housing Thrust Washer Sleeve Clutch Hub (Assembled) Friction Plates Steel Plates Spring Plate • T o measure the free play. and all nine friction plates in the housing temporarily. for measurement purposes. The difference between the highest and lowest gauge readings is the amount o f free play. Friction and Steel Plate Replacement (ZG 1200-B5 ~ ) When using all the new friction plates. do the following. Dial Gauge 3. Drive Shaft 4. the clutch lever may feel "spongy" or pulsate when pulled. one 2. Spring Plate Free Play Measurement (ZG1200-B5 ~ ) Insufficient clutch free paly will cause the engine braking effect to be more sudden.30 .55 . Raised Center . Bypass Valve Disassembly Bypass Valve Assembly Bypass Valve Cleaning and Inspection Oil Pan and Oil Pressure Switch Oil Pan Removal Oil Pan Installation Notes Oil Pan and Relief Valve Oil Pump and Relief Valve Removal Oil Pump and Relief Valve Installation Notes .ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View Engine Oil Flow Chart Specifications Special Tools Engine Oil and Filter Engine Oil Level Inspection Engine Oil and/or Filter Change Oil Filter and Bypass Valve Removal Oil Filter and Bypass Valve Installation Notes. Oil Pump Disassembly Oil Pump Assembly Notes Oil Pump Drive Gear Removal Oil Pump Drive Gear Installation Oil Pump Gear Removal Oil Pump Gear Installation Notes Oil Pressure Measurement Oil Pump Inspection Relief Valve Inspection Oil Screens Oil Screen Removal Oil Screen Installation Note Oil Screen Cleaning and Inspection . ENGINE R E M O V A L / I N S T A L L A T I O N 7-1 Engine Removal/Installation Table of Contents Exploded View Engine R e m o v a l / I n s t a l l a t i o n . Engine Removal Engine Installation Notes * Refer t o Base Manual . . . .. Connecting Rods Inspection/Maintenance Crankshaft/Connecting Rod Cleaning . . .. Dog Hole. . Connecting Rods Removal/Installation Flywheel Removal/Installation Notes .. .. . . Shift Drum. Crankshaft Removal Crankshaft Installation Notes Connecting Rod Removal Connecting Rod Installation Notes Crankshaft. Connecting Rod Bend/Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert/Crankpin Wear Crankshaft Runout Crankshaft Main Bearing Insert/Journal Wear Crankshaft Side Clearance Balancers Balancer Removal Balancer Installation Notes Balancer Gear Inspection Damper Inspection Needle Bearing Wear Alternator Shaft/Starter Motor Clutch Alternator Shaft and Starter Clutch Removal * * * * * 8-2 8-2 * * * * * * * * * * * * * 8-2 * * 8-2 8-2 * Alternator Shaft and Starter Clutch Installation Notes Starter Clutch Disassembly Starter Clutch Assembly Notes Alternator Shaft Chain Wear Chain Guide Wear Damper Inspection Starter Motor Clutch Inspection Ball and Needle Bearing Wear Transmission Transmission External Shift Mechanism.Crankshaft/Transmission Table of Contents Exploded View Specifications Special Tools Crankcase Splitting Crankcase Splitting Crankcase Assembly Notes Crankshaft/Connecting Rods Crankshaft. Transmission Shaft Disassembly Transmission Shaft Assembly Notes . Forks. . Transmission Shaft Removal Transmission Shaft Installation Notes . . and Recess Damage Ball and Needle Bearing Wear .. . Shift Drum and Fork Removal Shift Drum and Fork Installation Notes Gear Backlash Shift Fork Bending Shift Fork/Gear Groove Wear Shift Fork Guide Pin/Shift Drum Groove Wear Gear Dog.. . External Shift Mechanism Removal External Shift Mechanism Installation Notes External Shift Mechanism Inspection Transmission Shafts. . Balancer Installation Notes Refer to the base manual. noting the following. Mark 2. Oil Passage Hole 3. L : Non-permanent locking agent Crankcase Splitting Viewed from Bottom Crankcase Assembly Notes Refer to the base manual. Balancer Weights . 1. noting the following. •Change of external shift mechanism arm spring type. •Distinction of balancer mechanism side washers. noting the following. hold the balancers so that the mark on each balancer weight aligns with the center of the oil passage hole (see the figure in Balancers section). •When fitting the lower crankcase half on the upper crankcase half.8-2 CRANKSHAFT/TRANSMISSION Exploded View Refer to the base manual. Wheels/Tires Table of Contents Exploded View Specifications . Special Tools Wheels Front Wheel Removal Front Wheel Installation Notes Rear Wheel Removal Rear Wheel Installation Notes Wheel (Rim) Inspection A x l e Inspection Wheel Balance Tires Tire Removal Tire Installation Tire Inspection Tire Repair Recommendation Wheel Bearings and Grease Seals Wheel Bearing Removal Notes Wheel Bearing Installation Notes Wheel Bearing Inspection Grease Seal Inspection Speedometer Gear Housing Speedometer Gear Housing Disassembly Notes Speedometer Gear Housing Assembly Notes * Refer t o Base Manual 9-2 9-2 * * * * 9"3 * 9-3 * * * * . 26 k g / c m 1 .Exploded V i e w Refer to the base manual. 4 0 psi) . •Change of rear wheel air valve type. Item Tires: Standard t i r e : Front Rear M130/90-16 Standard D U N LOP F21 Tubeless M150/90-15 M/C D U N LOP K 4 2 5 A Tubeless Tire air pressure: Front Rear 225 kPa (2. noting the following.8 k g / c m ' .445 lb) load 225 kPa (2. Specifications Refer t o the base manual. 32 psil U p t o 120 kg (265 lb) load 120 .25 k g / c m ! .2 0 2 kg (265 . noting the following. 3 2 psi) 280 kPa (2. lubricate the stem with a soap and water solution. and pull the stem through the rim from the inside out until it snaps into place. Valve Seat 6. Valve Core 3. oDo not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. Air valve installation procedures are only those that are unique to the ZG1200-B4 ~ • Install a new valve in the rim. noting the following. oReplace the air valve whenever the tire is replaced. 1. 2. oRemove the valve cap. Apply soap and water solution. Pull the stem out. Tire Installation Refer to the base manual.New air valve and rim are used on the f r o n t wheel. • Remove the air valve and discard it. Valve Opened . 1. Stem Seal 4. Plastic Cap 2. Valve Stem 5. oDo not reuse the air valve. Table of Contents Final Drive Exploded View Specifications Special Tools Final Gear Case Oil Final Gear Case Oil Level Inspection Final Gear Case Oil Change Final Gear Case Final Gear Case Removal Final Gear Case Installation Notes Final Gear Case Disassembly Final Gear Case Assembly Notes Bevel Gear Inspection Pinion J o i n t Inspection Ball Bearing Inspection Needle Bearing Inspection Oil Seal Inspection Propeller Shaft Propeller Shaft Removal Propeller Shaft Installation Notes Propeller Shaft J o i n t Lubrication Propel ler Shaft I nspection Propeller Shaft Sliding Joint Inspection Front Bevel Gears Front Gear Case Removal Front Gear Case Installation Notes Front Gear Case Disassembly Front Gear Case Assembly Notes Driven Gear Disassembly Driven Gear Assembly Notes Damper Cam Removal Damper Cam Installation Notes Front Bevel Gear Adjustment Bevel Gear Inspection Cam Damper Inspection Ball Bearing Inspection Tapered Roller Bearing Inspection Needle Bearing Inspection Oil Seal Inspection Rear Wheel Coupling Rear Wheel Coupling Installation Note Damper Inspection * * * * * * * * * * * * * * * * * * * * * * * I 10 ' * * * . Brakes Table of Contents Exploded V i e w Specifications Special T o o l Brake F l u i d Brake F l u i d Requirement Brake Fluid Level Inspection Brake F l u i d Changing Brake Line A i r Bleeding Master Cylinders F r o n t Master Cylinder Removal F r o n t Master Cylinder Installation Notes Rear Master Cylinder Removal Rear Master Cylinder Installation Notes F r o n t Master Cylinder Disassembly F r o n t Master Cylinder Assembly Notes Rear Master Cylinder Disassembly Rear Master Cylinder Assembly Notes Master Cylinder Inspection Calipers Caliper Removal Caliper Installation Notes Caliper Disassembly Notes Caliper Assembly Notes Fluid Seal Damage Dust Seal and Cover Damage Piston and Cylinder Damage Caliper Holder Shaft Wear Pads Pad Removal Pad Installation Notes Lining Wear Discs Disc Removal Disc Installation Notes Disc Wear Disc Warp Brake Hoses Brake Hose Inspection Brake Hose Replacement 11-2 * * * * * * * 11-2 * 11-2 * 11-2 * * * * * * * * * * * * * * * * * * . oApply a non-permanent locking agent to the threads of the switch mounting screws. There are two types of terminal on the unit: the large terminals for the front brake light switch and the small ones for the cancel switch. noting the following. Front Brake Light Switch and Master Cylinders Front Master Cylinder Installation Note Refer to the base manual. •Addition of cancel switches for cruise control. Wire Connections Switch Front brake light switch Cancel switch (front brake) Wire Color Terminal BK Large BL Small Rear Master Cylinder Installation Notes Refer to the base manual. noting the following. 1. . noting the following. perform the following.Exploded View Refer to the base manual. oCheck and adjust the cancel switch (see Switches in the Electrical System chapter). and tighten them to install the switch. •If the cancel switch (rear brake) was removed from the master cylinder bracket. •The front brake light switch and the cancel switch (front brake) are combined in a unit. Suspension Table of Contents Exploded View Specifications Special Tools Front Fork A i r Pressure Adjustment Fork Oil Change Front Fork Removal Front Fork Installation Notes Fork Leg Disassembly Fork Leg Assembly Notes Inner Tube Inspection Guide Bush Inspection Oil Seal and Dust Seal Inspection Rear Shock Absorbers A i r Pressure Adjustment Damping Force Adjustment Rear Shock Absorber Removal Rear Shock Absorber Installation Notes Rear Shock Absorber Oil Filling Rear Shock Absorber Inspection Rear Shock Absorber Scrapping Swing A r m Swing A r m Removal Swing A r m Installation Notes Swing A r m Bearing Removal Swing A r m Bearing Installation Swing A r m Bearing Inspection Swing A r m Bearing Lubrication * * * * * * * * * * * * * * * * * * * 12-2 . Specifications Refer t o t h e base manual. noting t h e f o l l o w i n g . Item Front Fork: Fork oil: Viscosity Amount/side Oil level S A E 10W20 Standard 336 (352 : Z G 1 2 0 0 .B 4 .5 m L 177 (158 : ZG1200-B4 ±2 m m (fully compressed) .) ±2. Steering Table of Contents Exploded View Special Tools Steering A d j u s t m e n t Steering Inspection Steering A d j u s t m e n t Handlebar Handlebar Removal Handlebar Installation Notes Steering Stem and Bearings Steering Stem a n d Bearing Removal Steering Stem and Bearing Installation Notes Steering Stem Bearing Inspection and Lubrication Grease Seal and O-ring Inspection Steering Stem Warp * Refer t o Base Manual . Frame Table of Contents Exploded V i e w Fairing Fairing Removal Fairing Installation Notes W i n d Deflectors Wind Deflector Removal Travel T r u n k and Saddlebags Travel T r u n k Removal Notes Travel T r u n k Installation Note Saddlebag Removal Note Saddlebag Installation Notes (Including Tail End A l i g n m e n t ) Bracket Removal Notes Bracket Installation Note F r o n t Fender Front Fender Installation Note Rear Fender Rear Fender Removal Note Seats Seat Removal Note Rear Frame Rear Frame Removal Notes Rear Frame Installation Notes * Refer t o Base Manual 14-2 14-3 14-3 14-3 14-4 14-4 * . •Addition of bottom cover of fairing. •Addition of wind deflectors on fairing edges. noting the following. •Change of travel trunk braces. •Change of pocket on left inner cover of fairing. •Change of antenna mount.Exploded V i e w Refer to the base manual. . •Addition of rear speaker bracket on travel trunk. Fairing Fairing Removal Refer to the base manual. •Check and adjust the throttle cables if the actuator was free from the throttle cable. Bottom Cover B. Actuator (for cruise control) Fairing Installation Notes Refer to the base manual. •Be sure to cover the cruise control unit with the watertight seat. Fader Control Unit B. Bolts •The fader control unit of the audio system is mounted on the fairinp left inner cover. . noting the following. A. Mounting Nuts •Remove the electrical components from the fairing bracket. noting the following. Screws C. •Remove the fairing bottom cover. Cruise Control Unit B. Watertight Seat A. A. A. Clamps . Wind Deflectors A.Wind Deflectors Wind Deflector Removal •Pull the wind deflectors off the edges of the fairing. Wind Deflector B. A. The clamps come off with the deflectors. . . . . . . * Headlight Reserve Lighting System Inspection Turn Signal Circuit Turn Signal Control Unit Inspection . . Armature Inspection Field Coil Inspection Brush Plate Inspection Starter Motor Relay Inspection Lighting System Headlight Circuit Headlight Beam Horizontal Adjustment * Headlight Beam Vertical Adjustment . .Electrical System Table of Contents Precautions ZG1200B Main Wiring Diagram ZG1200B Audio Wiring Diagram Exploded View Specifications Special Tools Battery Precautions Electrolyte Electrolyte Level Inspection Battery Charging Battery Condition Battery Initial Charging Battery Ordinary Charging Battery Test Charging Alternator Alternator Removal Note Alternator Installation Notes Alternator Disassembly Notes Alternator Assembly Notes Alternator Operational Inspection Carbon Brush Length Brush Spring Tension Rotor Coil Inspection Slip Ring Cleaning Slip Ring Diameter Stator Coil Inspection Rectifier Inspection Ball Bearing Inspection Ignition System IC Igniter Installation Note Ignition Coil Installation Notes Spark Plug Removal Note Spark Plug Installation Note IC Igniter Inspection Pickup Coil Inspection Ignition Coil Inspection Spark Plug Cleaning and Inspection Spark Plug Gap Electric Starter System Starter Motor Removal Note Starter Motor Installation Note Starter Motor Disassembly Note Starter Motor Assembly Notes Carbon Brush Length 15-3 15-4 15-5 15-6 Brush Spring Inspection Commutator Cleaning and Inspection . . Turn Signal Relay Inspection * Bulb Replacement Bulb Replacement Notes * Fuel Pump 15-20 Fuel Pump Internal Resistance Cooling Fan Circuit Cooling Fan Circuit Inspection Fan Motor Inspection Fan Switch Inspection Meters and Gauges Meter Assembly Removal/ Installation Notes Meter Assembly Separation/ Assembly Notes * Meter and Gauge Replacement Notes . . . . . . Tachometer Inspection * Fuel Gauge Operation Inspection Water Temperature Gauge Operation Inspection * Indicator Light Self-check Unit Inspection * AV/AC Signal Unit Inspection Distance Sensor Inspection AV Control Circuit Inspection AC Control Circuit Inspection Electrolyte Level Sensor Inspection . . Fuel Level Sensor Inspection Water Temperature Sensor Inspection . Switches 15-6 Rear Brake Light Switch Adjustment .6 Switch Inspection 15-7 Relays 15-8 Relay Inspection 15-8 Diodes 15-8 Diode Inspection 15-8 Fuses Fuse Inspection. . 1 5 . . . . 15-6 Cancel Switch (rear brake) Adjustment . Electrical Wiring Wiring Inspection Cruise Control System 15-8 Outline 15-8 Troubleshooting 15-13 Wiring Inspection 15-14 Indicator SET Light Inspection 15-14 Actuator Inspection 15-18 Control Unit Inspection 15-19 Throttle Cable Inspection 15-19 * Refer to Base Manual . Cancel Switch (throttle) Adjustment. . . . . i i . f Ld I .L " .Z G 1 2 0 0 B A u d i o System Wiring Diagram Left Handlebar Swii Switch Auto Snt Switch/ Program Change Switch Muting Switch > . . noting the following.4 g N_m T1 (0 5 Q kg_m 43 j n -lb) . •Addition of cruise control system. . •Addition of fader control and rear speakers.Exploded View Refer to the base manual. 4. check the operation of the cancel switch (throttle) at the carburetors by depressing the decelerator cable bracket. 2. CAUTION oToo much turning out of the adjusting screw from the switching position may cause damaging the cancel switch because the cable bracket pushes the switch contact excessively. adjust the cancel switch. adding the following. The cancel switch should turn off after about 15 mm of pedal travel. Cancel Switch (throttle) Adjusting Screw Locknut Decelerator Cable Bracket Cancel Switch (rear brake) Adjustment •Using an ohmmeter. turn the adjusting screw out until the cancel switch turns off and stop it. turn the screw out more 3/4 to 1 turn. 5 A o r less Standard O F F w i t h t h r o t t l e grip c o m p l e t e l y closed O F F a f t e r a b o u t 15 m m pedal t r a v e l Cancel Switch (throttle) Connections bl|bk Refer to the base manual. 20 n 0 . 1. check the operation of the cancel switch (rear brake) at the brake pedal bracket by depressing the brake pedal. The cancel switch should turn o f f with the cable bracket depressed completely.Specifications Refer t o t h e base m a n u a l . Tighten the locknut applying a non-permanent locking agent to the threads. •Then. •Depressing the decelerator cable bracket. Cancel Switch (throttle) Adjustment •Using an ohmmeter. When decelerator cable bracket is depressed Cancel Switch (throttle) Adjustment • I f it does not. n o t i n g t h e f o l l o w i n g . •Loosen the locknut and turn the adjusting screw in until the screw attaches to the stopper on the cable bracket. 3. Item Switches: Cancel s w i t c h ( t h r o t t l e ) Cancel s w i t c h (rear brake) Cruise C o n t r o l S y s t e m : A c t u a t o r c l u t c h c o i l resistance A c t u a t o r m o t o r o p e r a t i n g amperage Approx. . Cancel Switch (front brake) B. Cancel Switch (throttle) B.Cancel Switch (rear brake) Adjustment Cancel Switch (rear brake) Connections BL When brake pedal is depressed BK C— • O Cruise Control Switch Connections BL/W I B K / Y SET/DECEL RESUME/ACCEL • o V Cruise Control Main Switch Connections BK/W When ON button is pushed on When OFF button is pushed on R BR O H O c* •O 1. Cancel Switch (throttle) Connections When throttle grip is closed Cancel Switch (front brake) Connections BL When brake lever is pulled in BL A. •Loosen the locknut and turn the adjusting screw until the correct switch operation can be obtained. adjust the cancel switch. 3. Cruise Control Switch C. •Tighten the locknut. A. 4. Cancel Switch (rear brake) Brake Pedal Adjusting Screw Locknut Cancel Switch (rear brake) Connections When brake pedal is depressed 15 mm or more • I f it does not. 2. Cruise Control Main Switch O" •D . noting the following. Cancel Switch (rear brake) Switch Inspection Refer to the base manual. When the cruise control is cancelled. It is engaged with the motor by the electromagnetic clutch when the cruise control is set. The cable pulley is ordinarily free from the pulley drive motor. At the same time.Relays Relay Inspection Refer to the base manual for inspection of the cruise circuit relay. Once a speed has been set.80 mph) in the overdrive (5th gear). The actuator contains an electromagnetic clutch. actuator. the motor moves the pulley and operates the throttle accelerator cable. etc. The control unit memorizes a set speed and controls the actuator to operate the throttle accelerator cable and keep a vehicle speed with the set speed. The cruising speed can be set and then adjusted to a faster or slower speed by the control switch. A. The throttle acceleration cable assembly has the junction box in the middle so that the carburetor pulley can be controlled by the actuator besides the throttle grip. This system contains the control unit. the resume function can be used to return the set speed. changing gears. This cruise control is cancelled when braking. and a cable pulley. Diode Assembly (Headlight and Cruise) . the pulley is disengaged from the motor and returned back the original position with its spring. Cruise Control System A. The distance sensor sends a vehicle speed signal to the control unit. and distance sensor (speed sensor). a pulley drive motor.128 km/h (30 . Relay (cruise circuit) Outline: This vehicle is equipped with Kawasaki's Cruise Control system which is designed to maintain any speed between 48 . Cruise Control System . o Resumes the set speed after braking. and cancel-related switches. changing gears. or closing the throttle grip completely. Distance Sensor oSends a vehicle speed signal t o the control unit. control switch. changing gears. engine stop switch. Cancel-related Switches* oBrake Light Switches oStarter L o c k o u t S w i t c h oOverdrive S w i t c h oCancel Switches (throttle. f r o n t and rear brakes) oCancel the cruise control when braking. Indicator Lights oON oSET oShow when the system is " o n " and when a cruising speed has been " s e t " .Components and Functions Component Control U n i t Function oReceives the signals f r o m the distance sensor. . and cruise control main switch work also as t h e cancelrelated switches. Control Switch oSET/DECEL oRESUME/ACCEL oAllows a cruising speed t o be set and then adjusted t o a faster or slower speed. etc. Actuator oControls the throttle accelerator cable t o maintain a vehicle speed. oMemorizes a set speed. Main Switch oON oOFF oSwitches on or o f f the system. " T h e ignition switch. oControls the actuator and the indicator SET light. Control Unit Terminals Terminal No. I Pulley Drive Motor Limit Swithes Electromagnetic Clutch Indicator SET Light Battery (+) Brake Light Switches Main Switch Starter Lockout Switch Brake Light Fuse — — Distance Sensor Control Switch (SET/DECEL) Cancel Switches (throttle and brakes) Control Switch (RESUME/ACCEL) Ground (—) Overdrive Switch — 19 20 17 15 X > 4 — 7 8 E 11 9 X 4 —^ 16 14 12 10 2 1 XT n—HZZP U „ = . oPulling the front brake lever. oPulling the clutch lever. The set speed is maintained at the time when the control switch is released. (8) Blowing down the brake light fuse.80 mph) in OD (5th gear). (3) or (8) of the cancellation condition. Resume Function If the cruise control was cancelled with any cancellation condition except for (1). If the cruise control was cancelled with the (1). (2). (3)Turning OFF the main switch. and stays the vehicle speed at 128 k m / h (80 mph). oDepressing the rear brake pedal.128 km/h (30 — 80 mph) without any cancellation condition. Pushing the control switch to the DECEL direction and holding it decelerates the vehicle speed continuously and cancels the cruise control when the vehicle speed reaches 44 km/h. the vehicle speed can be accelerated or decelerated automatically by pushing the control switch. (2)Turning OFF the engine stop switch. the vehicle speed can be returned to the set speed by pushing the control switch to the RESUME direction.Cruise Control Setting When the vehicle is running at a speed between 48 — 128 km/h (30 . Pushing the control switch to the ACCEL direction and holding it accelerates the vehicle speed continuously until the vehicle speed reaches 128 km/h (80 mph). ON Vehicle speed is accelerating with automatic acceleration. Cruise Control Function Indicator Light SET OFF Goes on Flashes 60 c / m * Flashes 120 c / m * Goes on Goes o f f Goes on ON OFF *c/m : cycle(s) per minute . or rear brake). Automatic Acceleration and Deceleration When the cruise control is set. (10) Running below 44 km/h (27 mph). oDepressing the rear brake pedal. (6)Turning OFF the overdrive (5th gear) switch. oChanging gears from 5th. (3). The cruise control is cancelled automatically under the following conditions. front brake. Vehicle speed is decelerating with automatic deceleration. (12) Stopping the signal from the distance sensor (speed sensor). and (8) as shown in the Cruise Control Cancellation. Indicator Light Operation Condition Main Switch OFF Cruise control is set. the memory of the set speed was erased and the resume function does not operate. oClosing the throttle grip completely. (1)TurningOFF the ignition switch. and the main switch is ON. (9) Losing more than 8 km/h (5 mph) from the set speed. (2). (5)Turning ON the starter lockout switch. the vehicle speed can be set by pushing the control switch to the SET direction. Cruise control is cancelled. (4)Turning ON the front or rear brake light switch. (7)Turning OFF any o f cancel switches (throttle. Cruise Control Cancellation The cruise control can be cancelled with the following operations. (11) Running above 144 km/h (89 mph). and the vehicle is running at a speed between 48 . oPulling the f r o n t brake lever. Vehicle speed is returning to the set speed with resume function. oCancel-related switch wiring o T h r o t t l e cables oActuator oControl unit A u t o m a t i c acceleration/deceleration or resume f u n c t i o n does n o t operate c o r r e c t l y . check the system by the following "Troubleshooting Guide" table. oDistance sensor w i r i n g oActuator oControl u n i t oThrottle cables Indicator SET light does n o t operate correctly. olndicator SET light w i r i n g oControl unit . Troubleshooting Guide Symptoms Vehicle speed can n o t be set. oControl switch w i r i n g oActuator oControl unit Vehicle speed fluctuates largely w h e n running w i t h cruise c o n t r o l . Test Items oControl unit power supply wiring oControl switch wiring oDistance sensor w i r i n g oCancel-related switch wiring oBrake light fuse w i r i n g o T h r o t t l e cables oActuator oControl unit Set speed can n o t be cancelled. The "Troubleshooting Guide" shows the relation ship between various kinds of symptoms of cruise control system trouble and the test item by which the system should be inspected. Each test procedure is explained individually on the pages before the table.Troubleshooting: If trouble is suspected in the cruise control system. first inspect the related wire(s) and connector(s). inspect the bulb and the wire(s) supplying battery power. Terminal Numbers and Wire Colors in Control Unit 13P Connector (viewed from unit side) 7 8 9 10 11 12 X 14 15 16 X 17 19 20 Indicator SET Light Inspection •Disconnect the control unit 13P connector. If the wire(s) and connector(s) prove good. or fuse referring to the appropriate sections. relay. * l f the above check proves good. engine stop switch. inspect the related switch.Wiring Inspection •Disconnect the control unit 13P connector. •Ground the #7 terminal (R/Y) in the harness side connector with an auxiliary wire. then repair or replace the damaged part(s). . •Connect the multimeter to the terminal (wire) in the disconnected female connector (main harness side) as indicated in the table and read the meter. the control unit must be replaced. and main switch. * l f the multimeter does not read as shown in the table. diode assembly. * l f the indicator SET light does not turn on. •Turn on the ignition switch. Refer to the Meters and Gauges section for the distance sensor. The indicator SET light should turn on. oBrake lever is pulled. Main Switch oMeter ( + ) .) #19 (BK/Y) . Cancel Switches (throttle.# 1 0 ( Y / R ) oMeter ( .# 1 9 ( B K / Y ) ignition O N and engine stop switch RUN.) #19 (BK/Y) 12V ON when with main switch switch oMeter ( .Wiring Test Wiring Battery (+) Battery Power Supply Meter Range 25 V DC Connections oMeter ( + ) # 8 (R) Meter Reading (Criteria) 12V when i g n i t i o n switch O N and engine stop switch RUN. f r o n t and rear brakes) x 1 £2 oOne meter lead -*• # 1 6 (BK) oAnother -* G r o u n d «n when a n y cancel switch O F F . Overdrive Switch X 1 S2 oOne meter lead -»• # 2 0 (O/W) oAnother -»• G r o u n d O n when transmission is in overdrive ( 5 t h ) . o T h r o t t l e grip is closed. oBrake lever is pulled.) . oBrake pedal is depressed. tween On a n d oAnotherGround Brake Light Switches 25VDC oMeter ( + ) -*• # 9 ( B L / R ) oMeter ( . Distance Sensor x1 n oOne meter lead # 1 4 (BK/W) Pointer oscillates 4 times per wheel r e v o l u t i o n be. RESUME/ ACCEL oOne meter lead -»• # 1 7 ( Y ) oAnother #19 (BK/Y) On when RESUME/ ACCEL switch O N .) -»• # 1 9 ( B K / Y ) 12V when a n y brake light switch O N w i t h ignition switch O N . 12V when brake light fuse is O K . oBrake pedal is depressed. Brake Light Fuse 25VDC oMeter ( + ) -»• # 1 2 ( B L ) oMeter ( . Cancel-related Switches Starter Lockout Switch x1 n oOne meter lead -»• # 1 1 ( Y / G ) oAnother-* Ground O n when c l u t c h lever is pulled w i t h transmission in gear. SET/DECEL Cruise Control Switch x1 n oOne meter lead -»• # 1 5 (B L/W) oAnother -» # 1 9 ( B K / Y ) Ofi when SET/DECEL switch O N . 14. 2. 12. 7. Diode Assembly Headlight Circuit Cruise Circuit Relay Brake Light Relay To Brake Lights 11. 5. 15. 4. 10. 9. Main Relay Ignition Switch Fuse Case 10 A Fuse 10 A Fuse #1 #2 #4 © #5 #6 #7 #8 #9 #10 #11 #12 #14 #15 #16 #17 #19 #20 .Cruise Control Circuit 1. 13. Control Unit Actuator Main Switch Indicator SET Light Indicator ON Light 6. 3. 8. 25. 18. Overdrive Switch Cancel Switch (Throttle) Engine Stop Switch Front Brake Light Switch Control Switch 26. 27. J I J. i i A 5 > i >. 19. 24. Cancel Switch (Front Brake) Cancel Switch (Rear Brake) Rear Brake Light Switch 12 V Battery ® n>/< n R / i TTtt cc > ? ml i t ft > S -BK/W— BR— -BL/R —BL— — BL— -BL/W—BK— -BK/Y-BK/Yo>s © s i 4 £ j 5 * I co m C D i | i A J. 17. 30 A Fuse Distance Sensor Meter and Gauge Circuit Starter Lockout Switch Neutral Switch 21.16. 20. i T T | l A i f f HiliilX o SET/ © DECEL il co co TT i r d s n A: RESUME/ ACCEL . 22. 28. 29. 23. * l f the resistance is not as specified. Actuator Operation Check: Pulley Drive Motor Operation (Opening) Test [CAUTION] oDo not apply battery voltage to the #4 (BL/W) terminal. and check the pulley drive motor operation. Turn the pulley counterclockwise until the dutch plate engages with the dog pins (until the pulley is locked). The pulley should be locked by the clutch operation. or the diode in the actuator may burn out. the clutch plate and the dog pins may not engage completely. replace the actuator. NOTE owhen the pulley is still turned with a heavy resistance. 20 J2 B. Pulley Electromagnetic Clutch Coil Resistance Approx. . Electromagnetic Clutch Coil Resistance: •Measure the clutch coil resistance between the # 5 (BL/O) and the #6 (BL/R) terminals in the actuator connector. •Connect the 12 V battery as shown and try to turn the pulley again. A. or the control unit may be damaged. Clutch Plate Clutch Operation Test Connector (BL/W) * l f the clutch does not operate above. •Turn the actuator cable pulley by hand.Actuator Inspection | CAUTION | oDisconnect the actuator connector from the control unit whenever the actuator is inspected. * l f it does not turn and/or return back with the spring smoothly. replace the actuator. •Connect another 12 V battery and the ammeter as shown. replace the actuator. oPulley does not turn and ammeter shows 1A or more. Full Closing Position Pulley Drive Motor Operation (Closing) Test Control Unit Inspection * l f all wirings and components other than the control unit check out good. oPulley does not turn and ammeter shows 1A or more. Pulley Drive Motor Operation (Closing) Correct oPulley turns clockwise automatically and ammeter shows 0.Pulley Drive Motor Operation (Opening) Correct oPulley turns counterclockwise automatically and ammeter shows 0. * l f the pulley drive motor does not operate correctly. * l f the pulley drive motor does not operate correctly. replace the actuator. Throttle Cable Inspection •Refer to Fuel System chapter for the throttle cables. and check the clutch operation. oPulley does not turn and ammeter shows OA. * l f the clutch does not operate correctly. Incorrect oPulley does not return back to original position. A. oPulley does not turn and ammeter shows OA. Clutch Operation Correct oPulley returns back to original position.5A or less. connecting the #1 (BL/BK) and #2 (BL/Y) terminals reversely. •While the pulley turns automatically. •Connect the battery leads. then pulley stops at full opening position and ammeter shows OA at the same time. and check the pulley drive motor operation. (BL/W) . Incorrect oPulley turns counterclockwise automatically but ammeter shows 1A or more. Full Opening Position B. replace the actuator.5A or less. disconnect the wire from the #6 terminal (BL/R) to stop supplying battery power to the clutch. Incorrect oPulley turns clockwise automatically but ammeter shows 1A or more. replace the actuator. then pulley stops at full closing position and ammeter shows OA at the same time. the control unit is trouble. Fuel Pump Circuit (ZG1200-B2 ~ ) © < o Tl t ? ? © n ® © 7 £ a ] ^ m m O o L " -Y/R— — W — © 1. 8. 7. Engine Stop Switch Starter Button Starter Circuit Relay Fuel Pump Ignition Coil (#1 & 4) Ignition Circuit Ignition Switch Fuse Case 30A Fuse Battery .Fuel Pump Refer to the base manual. 4. 6. 3. noting the following. 5. 9. 2. 10. Appendix Table of Contents A d d i t i o n a l Considerations f o r Racing Carburetor Spark Plug Spark Plug Inspection Troubleshooting Guide General Lubrication Lubrication N u t . B o l t . and Fastener Tightness Tightness Inspection U n i t Conversion Table * * * 16-2 * * * * * Refer t o Base Manual IjjlB . Cruise Control Faulty: Vehicle speed can't be set: Engine stop switch trouble Ignition switch trouble Diode trouble Relay trouble Main-switch trouble Control switch trouble Distance sensor trouble Brake light switch maladjustment or trouble Starter lockout switch trouble Overdrive switch trouble Cancel switch maladjustment or trouble Throttle cable maladjustment or trouble Actuator trouble Control unit trouble Wiring open or shorted Fuse blown Set speed can't be cancelled: Brake light switch trouble Starter lockout switch trouble Overdrive switch trouble Cancel switch trouble Throttle cable maladjustment or trouble Actuator trouble Control unit trouble Wiring open or shorted Automatic acceleration/deceleration or resume function doesn't operate correctly: Control switch trouble Actuator trouble Control unit trouble Wiring open or shorted Vehicle speed fluctuates largely when running with cruise control: Distance sensor trouble Throttle cable maladjustment or trouble Actuator trouble Control unit trouble Indicator SET light doesn't operate correctly: Wiring open or shorted Control unit trouble .Troubleshooting Guide Refer to the base manual. adding the following. B 1 3 .1999 ~ 2003 Models Table of Contents Foreword H o w to U s e this M a n u a l G e n e r a l Information M o d e l Identification G e n e r a l Specifications E n g i n e Lubrication System Specifications E n g i n e Oil a n d Oil Filter E n g i n e Oil C h a n g e Wheels/Tires Specifications Electrical S y s t e m Z G 1 2 0 0 .B17 Wiring Diagram 17-2 17-2 17-3 17-3 17-4 17-5 17-5 17-5 17-5 17-6 17-6 17-8 17-8 m .Supplement . B 1 3 ~ B17 models therefore requires mechanics to read both this chapter a n d t h e front of this m a n u a l .Foreword How to Use this Manual This " S u p p l e m e n t . .B 1 3 ~ B 1 7 models.Part No.1999 ~ 2 0 0 3 Models" d e s i g n e d to be used in conjunction with the front part of this m a n u a l (up to 16-2) a n d / o r Base M a n u a l Z G 1 2 0 0 A Service Manual . 99924-1064 -01. The specifications a n d m a i n t e n a n c e p r o c e d u r e s described in this chapter a r e only those hat are unique to t h e Z G 1 2 0 0 . Complete a n d proper s e r v i c i n g of the Z G 1 2 0 0 . General Information Model Identification ZG1200-B14 Left Side View . 1 5 M/C 7 4 H Tubeless M130/90-16 67H 1 1 3 0 / 9 0 . a n d may not apply to every country. B14 ZG1200-B15. 20W-40 or 2 0 W .0 L SAE10W-40 Forced lubrication (wet sump) ZG1200-B13. 13. .General Information General Specifications Items Engine: Lubrication system E n g i n e oil: Type API SE.5 0 4. S F or S G API SH or SJ with J A S O MA Viscosity Capacity Electrical Equipment: Battery Headlight: Type Bulb Tail/brake light: Bulb Alternator: Type R a t e d output Voltage regular: Type Frame: Front tire: Type Size R e a r tire: Type Size Tubeless M 1 5 0 / 9 0 .5 V 12 V 27/8 W x 2 12 V 21/5 W x 2 Semi-sealed b e a m 12 V 60/55 W (quartz-halogen) 12 V 2 0 A h SAE10W-40.1 6 M/C 6 7 H Short-circuit Three-phase A C 35 A 0 7 500 r/min (rpm). B16 ZG1200-B17 Specifications subject to change without notice. 10W-50. S U P P L E M E N T - 1999 ~ 2003 M O D E L S Engine Lubrication Specifications Item Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity Standard System 17-5 SAE 10W-40, 10W-50, 20W-40 o r 2 0 W - 5 0 (ZG1200-B14, B15) SAE 10W-40 (ZG1200-B16 on and after) 3.2 L (when filter is not removed) 3.5 L (when filter is removed) 4.0 L (when engine is completely dry) Between upper and lower levels About 370 k P a (3.8 kgf/cm 2 , 54 psi) Capacity Oil level Oil Pump and Relief Valve: Oil Pressure @4 000 r/min (rpm), Oil Temp. 80°C (176°F) Engine Oil a n d Oil Filter Engine Oil Change Recommended Engine Oil Type: API SE, SF or SG API SH or SH with JASO MA Viscosity: SAE10W-40 Capacity: 3.2 L (when filter is no removed) 3.5 L (when filter is removed) 4.0 L (when engine is completely dry) NOTE OAlthough 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. SAE 20W-50 I I I SAE 20W-40 ) ' I > SAE 10W-50 1 1 1 SAE I0W-40 ) > Wheels/Tires Specifications Item Tires: S t a n d a r d tire: Front 130/90-16 67H 130/90-16 M/C 6 7 H ( Z G 1 2 0 0 - B 1 7 ) DUNLOP F21 T u b e l e s s ( Z Q 1 2 0 0 - B 1 4 - B 1 5 ) DUNLOP D 4 0 4 F W T u b e l e s s ( Z G 1 2 0 0 - B 1 6 - B 1 7 ) Rear M150/90-15M/C 7 4 H 150/90B15 MC 7 4 H ( Z G 1 2 0 0 - B 1 7 ) DUNLOP K425A T u b e l e s s ( Z G 1 2 0 0 - B 1 4 - B 1 5 ) [DUNLOP D404G Tubeless (ZQ1200-B16-B17) Tire air pressure: Front Rear 225 kPa (2.25 kgf/cm s , 32 psi) Up to 120 kg (265 lb) load 120-202 kg (265-445 lb) load 2 2 5 kPa (2.25 k g f / c m ! , 3 2 psi) 2 8 0 kPa (2.8 kgf/cm 2 , 4 0 psi) Standard B 1 7 Wiring Diagram .Electrical S y s t e m ZG1200-B13 . Electrical System . KAWASAKI HEAVY INDUSTRIES. or JKAZG9B1DLB502501 JKAZG9B1OMB503301 JKAZG9B1DNB504201 JKAZG9B1 •PB504901 JKAZG9B1URB505751 JKAZG9B1DSB506651 JKAZG9B1DTB507601 JKAZG9B1DVB508501 JKAZG9B1 • W B 5 0 9 1 0 1 JKAZG9B1 DXB509901 JKAZG9B1DWB509101 JKAZG9B1 D1B511901 JKAZG9B1 D2B513201 JKAZG9B1D3B514201 • : T h i s digit in t h e f r a m e n u m b e r c h a n g e s f r o m o n e m a c h i n e t o a n o t h e r .1 0 8 9 . LTD.MODEL APPLICATION Year 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Model ZG1200-B1 ZG1200-B2 ZG1200-B3 ZG1200-B1 ZG1200-B5 ZG1200-B6 ZG1200-B7 ZG1200-B8 ZG1200-B9 ZG1200-B10 ZG1200-B11 ZG1200-B12 ZG1200-B13 ZG1200-B14 ZG1200-B15 ZG1200-B16 ZG1200-B17 Beginning Frame No. J K A Z G 9 B 1 nHAOOOOOl.6 l * i n P r i n t e d in J a p a n . JKAZG9B1DKB501701 or or J K A Z G 9 B 1 D L A 0 0 1 4 0 1 . Consumer Products & Machinery Company Part No.99924-1089-61 Kawasaki I I I I I I I I I M I HI M I I I I I URN * 9 9 9 2 4 . or JKAZG9B1DHB500001 JKAZG9B1DJA000901. JKAZG9B1DJB500501 JKAZG9B1DKA001201.