Electrical System

Table of Contents

Parts Location.................................................................. 15-2

Exploded View................................................................. 15-3

Specifications.................................................................. 15-6

ZX900-B1, B2 Wiring Diagram (US and Canada) 15-7

ZX900-B1, B2 Wiring Diagram (Australia)...................... 15-8

ZX900-B1, B2 Wiring Diagram

(United Kingdom)............................................................. 15-9

ZX900-B1, B2 Wiring Diagram

(European Models except United Kingdom)................. 15-10

Precautions.................................................................... 15-11

Electrical Wiring............................................................ 15-12

Wiring Inspection..................................................... 15-12

Battery............................................................................ 15-13

Charging Condition Inspection................................ 15-13

Refreshing Charge................................................... 15-13

Alternator........................................................................ 15-15

Removal................................................................... 15-15

Installation................................................................ 15-15

Disassembly............................................................ 15-15

Assembly................................................................. 15-17

Operational Inspection............................................ 15-19

Test No. 1 -Battery Discharged.......................... 15-19

Test No. 2-Battery Overcharged......................... 15-20

Test No. 3-Noise................................................. 15-20

Stator Coil Inspection.............................................. 15-20

Rotor Coil Inspection............................................... 15-21

Slip Ring Cleaning................................................... 15-21

Slip Ring Diameter................................................... 15-22

Carbon Brush Length............................................... 15-22

Rectifier Inspection.................................................. 15-22

Regulator Inspection................................................ 15-22

Alternator Ball Bearing Inspection........................... 15-23

Ignition System............................................................. 15-24

Pickup Coil Removal............................................... 15-25

Pickup Coil Installation............................................ 15-25

Pickup Coil Inspection............................................. 15-26

Ignition Coil Removal/Installation........................... 15-26

Ignition Coil Inspection............................................ 15-26

Spark Plug Removal................................................ 15-27

Spark Plug Installation............................................. 15-28

Spark Plug Gap Inspection...................................... 15-28

1С Igniter Inspection................................................ 15-28

Starter Motor.................................................................. 15-31

Removal................................................................... 15-31

Installation................................................................ 15-31

Disassembly............................................................ 15-31

Assembly................................................................ 15-32

Brush Inspection..................................................... 15-33

Commutator Cleaning and Inspection.................... 15-33

Armature Inspection................................................ 15-33

Brush Lead Inspection............................................ 15-34

Brush Plate and Terminal Bolt Inspection.............. 15-34

Starter Relay Inspection......................................... 15-34

Lighting System..........................,............................... 15-36

Headlight Beam Horizontal Adjustment................. 15-36

Headlight Beam Vertical Adjustment...................... 15-36

Headlight Bulb Replacement.................................. 15-37

Headlight Diode Inspection

(Europe models except U.K.)................................. 15-37

Tail/Brake Light Bulb Replacement........................ 15-40

License Plate Light Bulb Replacement.................. 15-40

Turn Signal Relay Inspection................................. 15-40

Fuel Pump..................... 1............................................ 15-43

Removal/Installation............................................... 15-43

Fuel Pump Relay Inspection.................................. 15-43

Fuel Pump Operational Inspection......................... 15-43

Radiator Fan System................................................... 15-45

Fan System Circuit Inspection............................... 15-45

Fan Motor Inspection.............................................. 15-45

Meters, Gauges........................................................... 15-46

Removal.................................................................. 15-46

Meter, Gauge Disassembly.................................... 15-46

Bulb Replacement................................................... 15-46

Meter, Gauge Assembly......................................... 15-46

Tachometer Inspection........................................... 15-47

Water Temperature Gauge Inspection................... 15-48

Fuel Gauge Operation Inspection.......................... 15-49

Switches and Sensors................................................. 15-50

Front Brake Light Switch Inspection...................... 15-50

Rear Brake Light Switch Adjustment...................... 15-50

Radiator Fan Switch Inspection............................. 15-50

Water Temperature Sensor Inspection.................. 15-51

Fuel Level Sensor Inspection................................. 15-51

Junction Box................................................................ 15-52

Junction Box Fuse Circuit Inspection.................... 15-52

Starter Circuit/Headlight Relay Inspection............ 15-52

Diode Circuit Inspection......................................... 15-53

Fuse............................................................................. 15-55

30A Main Fuse Removal........................................ 15-55

Junction Box Fuse Removal.................................. 15-55

Fuse Installation..................................................... 15-55

Fuse Inspection...................................................... 15-55

Parts Location

1. Ignition Coils

2. Alternator

3. Starter Motor

4. Fuel Pump

5. Fuel Pump Relay

6. Junction Box

7. Starter Lockout Switch

8. Radiator Fan Switch

9. Neutral Switch

10. Side Stand Switch

11. Turn Signal Relay

12. Starter Relay and Main Fuse

13. 1С Igniter

14. Rear Brake Light Switch

15. Front Brake Light Switch

16. Water Temperature Sensor

17. Pickup Coil

18. Oil Pressure Switch

1. City Light (Except AS, CN, US)

2. Headlight (AS, CN, UK, US)

3. Headlights (Europe except UK)

4. Turn Signal Lights

5. Pickup Coil

6. 1С Igniter

7. Tail/Brake Lights

8. License Light

AS: Australia IT: Italy

L: Apply a non permanent locking agent.

T1: 13 N-m (1.3 kg-m, 113 in-lb)

T2: 9.8 N-m (1.0 kg-m, 87 in-lb)

T3: 7.8 N-m (0.80 kg-m, 69 in-lb)

T4: 25 N-m (2.5 kg-m, 18.0 ft-lb)

T5: 1.0 N-m (0.10 kg-m, 9 in-lb)

1. Fuel Pump Relay 2. Fuel Pump 3. Starter Motor Clutch 4. Starter Relay EO: Apply engine oil. L Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease.

T1: 25 N-m (2.5 kg-m, 18.0 ft-lb) T2: 54 N-m (5.5 kg-m, 40 ft-lb) T3: 4.4 N-m, (0.45 kg-m, 39 in-lb) T4: 2.5 N-m (0.25 kg-m, 22 in-lb) T5: 3.4 N-m (0.35 kg-m, 30 in-lb)

T6: 11 N-m (1.1 kg-m, 95 in-lb) T7: 4.9 N-m (0.50 kg-m, 43 in-lb) T8: 5.9 N-m (0.60 kg-m, 52 in-lb) T9: 9.8 N-m (1.0 kg-m, 87 in-lb) T10: 12 N-m (1.2 kg-m, 104 in-lb)

L Apply a non-permanent locking agent.

SS: Apply silicone sealant.

Tl: 3.4 N-m (0.35 kg-m, 30 in-lb)

T2: 18 N-m (1.8 kg-m, 13.0 ft-lb)

T3: 7.8 N-m (0.80 kg-m, 69 in-lb)

T4: 15 N-m (1.5 kg-m. 11.0 ft-lb)

T5: 1.0 N-m (0.10 kg-m, 9 in-lb)

Specifications

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

ZX900-B1, В2, ВЗ Wiring Diagram (US and Canada)

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starter Lockout switch

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ZX900-B1, B2, B3 Wiring Diagram (Australia)

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ZX900-B1, В2, ВЗ Wiring Diagram (United Kingdom)

ZX900-B1, B2, B3 Wiring Diagram (European Models except United Kingdom)

ignition Switch

Neutral indicator Light 12VJ.4W

Tachometer Light 12V1.7Wx2

Right Handlebar swI tehee

1. Head Iight switch

2. Front Brake Light switch

3. Engine Stop Switch 4.Starter Button

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Radiator Fan

speedometer Light 12V1.7WX2

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water Temperature Gauge

Fuel Gauge

water Temp/Fuel Gauge Light 12V1.7W

High Beam indicator Light 12V3.4W Turn signal indicator Light 12V3.4W

oil Pressure warning Light 12V3.4W

City Light 12*51

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Front Right Turn signal Light 12V21W

Left Handlebar switches

1. Horn Button

2. Turn Signal switch

3. Dimmer switch

4. starter Lockout Switch

5. Passing Button

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Precautions

There are a number of important precautions that are musts when

servicing electrical systems. Learn and observe all the rules below.

О Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts.

OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests.

OThe electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.

О To prevent damage to electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.

О Because of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may burn out the starter motor windings.

О Do not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram, as the meter or gauge panel could be warped by excessive heat radiated from the bulb.

OTake care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground.

О Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again.

О Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation.

О Measure coil and winding resistance when the part is cold (at room temperature).

О Color Codes:

В К Black G Green P Pink

BL Blue GY Gray PU Purple

BR Brown LB Light blue R Red

CH Chocolate LG Light green W White DG Dark green 0 Orange Y Yellow

О Electrical Connectors Female Connectors [A]

Male Connectors [B]

Electrical Wiring

Battery

CCS*

Charging Condition Inspection

Battery charging condition can be checked by measuring battery terminal voltage.

• Remove:

Seat(s)

• Disconnect the battery terminal leads.

CAUTION

Refreshing Charge

• Disconnect the battery terminal leads (see Charging Condition Inspection).

• Remove the battery [А].

• Refresh-charge by following method according to the battery terminal voltage.