Supplement -1997 Model

Table of Contents

General Information............................................................................................................................. 17-2

Model Identification...................................................................................................................... 17-2

General Specifications................................................................................................................ 17-3

WheelsAires......................................................................................................................................... 17-6

Specification................................................................................................................................. 17-6

Suspension.......................................................................................................................................... 17-7

Specifications............................................................................................................................... 17-7

Frame................................................................................................................................................... 17-8

Exploded View.............................................................................................................................. 17-8

Electirical System.............................................................................................................................. 17-10

Wiring Diagram.................................................................................................................................. 17-10

General Information

Model Identification ZX900-B4 (European Model)

ZX900-B4 (US and Canadian Models)

General Specifications

Wheels/Tires

Specification

Suspension

Specifications

L: Apply a non-permanent

locking agent. O: Apply oil.

ELECTRICAL SYSTEM

Turn signal switch С

ЭЗ

К Kawasaki

KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products Group

Part No. 99924-1171-04

___________ CAUTION

Fill until the container is completely emptied.

• Be certain that all the electrolyte has flowed out.

•Tap the bottom the same way as above if there is any electrolyte left in the container.

• Now pull the container gently out of the battery.

• Let the battery sit for 20 minutes. During this time, the electrolyte permeates the special separators and the gas generated by chemical reaction is released.

•Situate the motorcycle so that it is perpendicular to the ground. •Remove the fuel tank (see Fuel Tank Removal).

• Prepare an auxiliary fuel tank and connect the fuel hose to the carburetors.

• Prepare a fuel hose (6 mm in diameter and about 300 mm long). •Connect the fuel level gauge [A] to the carburetor float bowl with the

fuel hose.

Special Tool - Fuel Level Gauge: 57001-1017

• Hold the gauge vertically against the side of the carburetor body so that the " zero" line [B] is several millimeters higher than the mark [C] on the carburetor body.

• Feed fuel to the carburetor, then turn the carburetor drain plug [D] out a few turns.

•Wait until the fuel level in the gauge settles.

• Keeping the gauge vertical, align the " zero" line with the mark.

NOTE

О Do not lower the " zero" line below the mark of the carburetor body. If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level. If the gauge is lowered too far. dump the fuel into a suitable container and start the procedure over again.

• Read the fuel level [E] in the gauge and compare to the specification. •Screw in the carburetor drain plug.

• Remove the carburetor, and drain the fuel into a suitable container.

• Remove the float bowl.

• Remove the screw [A] and take out the float [В].

• Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

Float Height

Standard: 13 ± 2 mm

NOTE

О Do not push the needle rod [A] in during the float height measure­ment [5].

•Assemble the carburetor, and recheck the fuel level. *lf the fuel level cannot be adjusted by this method, the float or the float valve [C] is damaged.

Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure, and the vacuum piston diaphragms may be damaged.

Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage to or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash-point cleaning solution safe for plastic parts.

Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

• Remove the carburetors.

• Before disassembling the carburetors, check the fuel level (see Fuel Level Inspection).

*lf the fuel level is incorrect, inspect the rest of the carburetor before correcting it.

• Move the starter plunger lever to the left and release it to check that the starter plungers move smoothly and return by spring tension.

*lf the starter plungers do not work properly, replace the carburetors.

•Turn the throttle cable pulley to check that the throttle butterfly valves [A] move smoothly and return by spring tension.

*lf the throttle valves do not move smoothly, replace the carburetors.

• Disassemble the carburetors.

• Clean the carburetors.

• Check that the O-rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good condition.

*lf any of the O-rings or diaphragms are not in good condition, replace them.

•Check the plastic tip [A] of the float valve needle [В]. It should be smooth, without any grooves, scratches, or tears.

*lf the plastic tip is damaged [C], replace the needle.

• Push the rod [D] in the other end of the float valve needle, and then release it.

*lf the rod does not spring out, replace the needle.

• Check the tapered portion [A] of the pilot screw [B] for wear or damage.

*lf the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it.

• Check that the vacuum piston [A] moves smoothly in the carburetor

body. The surface of the piston must not be excessively worn. *lf the vacuum piston does not move smoothly, or if it is very loose in carburetor body, replace the carburetor.

• Before removing the fuel level sensor, check that the fuel level in the fuel tank is low enough to remove the sensor. The fuel level should^ be below the opening for the sensor mounting.

• Remove:

Fuel Tank (see Fuel Tank Removal) Mounting Bolts [A] Fuel Level Sensor [B]

• Check the gasket on the sensor for damage. *lf it is damaged, replace it with a new one.

• Be sure to install the gasket in its place.

• Connect the hoses to the separator, and install the separator on the motorcycle.

Canister Inspection

• Remove the canister, and disconnect the hoses from the canister.

•Visually inspect the canister for cracks and other damage.

• Remove:

Right Inner Fairing and Lower Fairings (see Frame chapter) Radiator Cap [A]

•Place a container under the drain plug [A] at the bottom of the water pump [В].

• Drain the coolant from the radiator and engine by removing the drain plug.