Sale!

2000-2001 Kawasaki ZX1200A Ninja ZX-12R Motorcycle Service Manual

$68.32

Out of stock

Want a Restock Notification?

SKU: 99924-1253-03 Category:

Description

This 2000-2001 Kawasaki ZX1200A Ninja ZX-12R Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the 2000-2001 Kawasaki ZX1200A Ninja ZX-12R motorcycles.

Table of Contents
General Information
Before Servicing
Model Identification
General Specifications
Periodic Maintenance Chart
Technical Information – KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM)
Technical Information — Monocoque Frame
Technical Information — Spark Plug
Torque and Locking Agent
Special Tools and Sealant
Cable, Wire, and Hose Routing

Digital Fuel Injection (DFI) System
Exploded View
Specifications
Throttle Grip and Cables
Free Play Inspection
Free Play Adjustment
Cable Installation
Cable Lubrication
Fast Idle Cable
Free Play Inspection
Free Play Adjustment
Fast Idle Cable Installation
Cable Lubrication
Throttle Body Assembly
Idle Speed Inspection
Idle Speed Adjustment
Throttle Bore Cleaning
Synchronization Inspection
Synchronization Adjustment
Throttle Body Assembly Removal
Throttle Body Assembly Installation
Throttle Body Assembly Disassembly
Throttle Body Assembly Assembly
Air Line
Element Removal
Element Installation
Air Cleaner Element Cleaning and
Oil Draining
Air Intake Rubber Duct Removal
Air Intake Rubber Duct Installation
Front Air Intake Duct Removal/Install
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Inspection
Fuel Tank Cleaning
Return Fuel Check Valve Inspection
DFI System
DFI Servicing Precautions
Troubleshooting the DFI System
Outline
Inquiries to Rider
Problem Chart
ECU
ECU Removal
ECU Installation
ECU Power Supply Inspection
DFI Power Source
ECU Fuse Removal
ECU Fuse Installation
ECU Fuse Inspection
ECU Main Relay Removal
ECU Main Relay Inspection
FI Indicator LED Light
LED Light Inspection
Fuel Line
Fuel Pressure Inspection
Fuel Flow Rate Inspection
In-tank Fuel Pump
Fuel Pump Removal
Pump Filter Cleaning
Fuel Pump Installation
Operation Inspection
Operating Voltage Inspection
Self-Diagnosis
Self-diagnosis Outline
Self-diagnosis Function
Self-diagnosis Procedures
How to Read Fault Codes
How to Erase Fault Codes
Fault Code Table
Backups
Throttle Sensor (Fault Code 11)
Throttle Sensor Removal/Adjustment
Input Voltage Inspection
Output Voltage Inspection
Resistance Inspection
Inlet Air Pressure Sensor (Fault Code 12)
Removal
Installation
Input Voltage Inspection
Output Voltage Inspection
Inlet Air Temperature Sensor (Fault Code 13)
Removal/Installation
Output Voltage Inspection
Sensor Resistance Inspection
Water Temperature Sensor (Fault Code 14)
Removal and  Installation
Output Voltage Inspection
Sensor Resistance Inspection
Atmospheric Pressure Sensor (Fault Code 15)
Removal
Installation
Input Voltage Inspection
Output Voltage Inspection2
Crankshaft Sensor (Fault Code 21)2
Crankshaft Sensor Removal/lnstallation 2
Crankshaft Sensor Inspection2
Cam Sensor (Fault Code 23)2
Cam Sensor Removal/Installation2
Cam Sensor Inspection*
Speed Sensor (Fault Code 24)2
Speed Sensor Removal/Installation2
Speed Sensor Inspection2
Gear Position Switch (Fault Code 25)2
Gear Position Switch Removal2
Gear Position Switch Installation2
Gear Position Switch Input Voltage Inspection:
Gear Position Switch Inspection:
Vehicle-down Sensor (Fault Code 31):
Removal:
Installation:
Inspection:
Fuel Injectors (#1 #2, #3, #4: Fault Code 41, 42, 43, 44)
Power Source Voltage Inspection
Output Voltage Inspection
Audible Inspection
Injector Signal Test
Injector Resistance Inspection
Injector Unit Test
Injector Fuel Line Inspection
Fuel Pump Relay (Fault Code 45, 46)
Fuel Pump Relay Removal
Operating Voltage Inspection
Power Source Voltage Inspection
Relay Inspection
Stick Coils (#1, #2, 43, #4: Fault Code 51, 52, 53, 54)
Removal/Installation
Input Voltage Inspection
Evaporative Emission Control System (California Models Only)
Parts Removal/Installation
Hose Inspection (Periodic Inspection)
Separator Inspection
Separator Operation Test
Canister Inspection (Periodic Inspection)

Cooling System
Exploded View
Specifications
Coolant Flow Chart
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Cooling System Flushing
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Water Pump Impeller Inspection
Water Pump Housing Disassembly
Water Pump Housing Assembly
Mechanical Seal Inspection
Water Pump Impeller Assembly
Radiator, Radiator Fan
Radiator and Radiator Fan Removal
Radiator and Radiator Fan Installation
Radiator Inspection
Radiator Cap Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hose and Pipes
Hose Installation
Hose Inspection
Radiator Fan Switch, Water Temperature Sensor
Radiator Fan Switch, Water Temperature Sensor Removal
Radiator Fan Switch, Water Temperature Sensor Installation
Radiator Fan Switch, Water Temperature Sensor Inspection

Engine Top End
Exploded View
Specifications
Clean Air System
Air Suction Valve Removal
Air Suction Valve Installation
Air Suction Valve Inspection
Vacuum Switch Valve Removal
Vacuum Switch Valve Installation
Vacuum Switch Valve Test
Clean Air System Hose Inspection
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft, Camshaft Chain
Camshaft Removal
Camshaft Installation
Camshaft, Camshaft Cap Wear
Camshaft Runout
Cam Wear
Camshaft Chain Removal
Camshaft Chain Wear
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Cylinder, Pistons
Cylinder Removal
Cylinder Installation
Piston Removal
Piston Installation
Cylinder Wear
Piston Wear
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Throttle Valve Holder
Throttle Body Holder Installation
Muffler
Muffler Removal
Muffler Installation
Muffler Body Removal
Muffler Body Installation

Clutch
Exploded View
Specifications
Clutch Lever and Cable
Lever Free Play Inspection
Lever Free Play Adjustment
Cable Removal
Cable Installation
Cable Lubrication
Clutch Lever Installation
Clutch Cover
Clutch Cover Removal
Clutch Cover Installation
Release Shaft Removal
Release Shaft Installation
Clutch Cover Disassembly
Clutch Cover Assembly
Clutch
Clutch Removal
Clutch Installation
Clutch Plate Assembly Inspection
Clutch Plate Assembly Adjustment
Clutch Plate, Wear, Damage Inspection
Clutch Plate Warp Inspection
Clutch Spring Free Length Measurement

Engine Lubrication System
Exploded View
Engine Oil Flow Chart
Specifications
Engine Oil and Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Oil Cooler
Oil Cooler Removal
Oil Cooler Installation
Oil Pan Removal
Oil Pan Installation
Oil Pump Oil Pump Drive Gear and Oil Pressure Relief Valve
Oil Pump Removal
Oil Pump Installation
Oil Pump Inspection
Oil Pump Drive Gear Removal
Oil Pump Drive Gear Installation
Oil Pressure Relief Valve Inspection
Oil Pressure Measurement
Oil Pressure Measurement
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation

Engine Removal / Installation
Exploded View
Engine Removal/Installation
Engine Removal
Engine Installation

Crankshaft / Transmission
Exploded View
Specifications
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Crankshaft and Connecting Rods
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
Crankshaft Main Bearing Insert/Journal Wear
Crankshaft Side Clearance
Crankshaft Runout
Balancer
Balancer Removal
Balancer Installation
Balancer Damper Inspection
Starter Motor Clutch and Torque Limiter
Starter Motor Removal / Installation
Starter Motor Clutch Removal
Starter Motor Clutch Installation
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly
Starter Clutch Inspection
Torque Limiter Removal
Torque Limiter Installation
Transmission
Shift Pedal Removal
Shift Pedal Installation
External Shift Mechanism Removal
External Shift Mechanism Installation
External Shift Mechanism Inspection
Transmission Shaft Removal
Transmission Shaft Installation
Transmission Disassembly
Transmission Assembly
Shift Drum and Fork Removal
Shift Drum and Fork Installation
Shift Drum Disassembly
Shift Drum Assembly
Shift Fork Bending
Shift Fork/Gear Groove Wear
Shift Fork Guide Pin/Drum Groove Wear
Gear Dog and Gear Dog Hole Damage

Wheels/Tires
Exploded View
Specifications
Wheels (Rims)
Front Wheel Removal
Front Wheel Installation
Rear Wheel Removal
Rear Wheel Installation
Wheel Inspection
Axle Inspection
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Tires
Air Pressure Inspection/Adjustment
Tire Inspection
Tire Removal
Tire Installation
Repair
Hub Bearings
Hub Bearing Removal
Hub Bearing Installation
Hub Bearing Inspection

Final Drive
Exploded View
Specifications
Drive Chain
Slack Inspection
Slack Adjustment
Wheel Alignment Inspection Adjustment
Drive Chain Wear Inspection
Lubrication
Drive Chain Removal
Drive Chain Installation
Sprocket, Coupling
Engine Sprocket Removal
Engine Sprocket Installation
Rear Sprocket Removal
Rear Sprocket Installation
Sprocket Wear Inspection
Rear Sprocket Warp Inspection
Coupling Bearing Removal
Coupling Bearing Installation
Coupling Installation
Coupling Bearing Inspection and Lubrication
Damper Inspection

Brakes
Exploded View
Specifications
Brake Pedal]
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Calipers
Front Caliper Removal
Rear Caliper Removal
Caliper Installation
Front Caliper Disassembly
Front Caliper Assembly
Rear Caliper Disassembly
Rear Caliper Assembly
Brake Pads
Front Brake Pad Removal
Front Brake Pad Installation
Rear Brake Pad Removal
Rear Brake Pad Installation
Brake Pad Lining Wear
Master Cylinder
Front Master Cylinder Removal
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Brake Discs’
Brake Disc Removal
Brake Disc Installation
Brake Disc Wear
Brake Disc Warp
Brake Fluid
Brake Fluid Level Inspection
Brake Fluid Change
Bleeding the Brake Line
Brake Hoses
Brake Hose Removal/Installation
Brake Hose Inspection

Suspension
Exploded View
Specifications
Front Fork
Rebound Damping Force Adjustment
Compression Damping Force Adjustment
Spring Preload Adjustment
Front Fork Removal (each fork leg)
Front Fork Installation
Fork Oil Change
Front Fork Disassembly
Front Fork Assembly
Inner Tube Inspection
Dust Seal Inspection
Spring Tension
Rear Shock Absorber
Rebound Damping Force Adjustment
Compression Damping Force Adjustment
Spring Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Scrapping
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Bearing Removal
Swingarm Bearing Installation
Swingarm Bearing, Sleeve Inspection and Lubrication
Chain Slider Inspection
Tie-Rod, Rocker Arm
Tie-Rod Removal
Tie-Rod Installation
Rocker Arm Removal
Rocker Arm Installation
Needle Bearing Inspection
Tie-Rod, Rocker Arm Sleeve Inspection
Tie-Rod, Rocker Arm Needle Bearing Lubrication (Periodic Maintenance)

Steering
Exploded View
Specifications
Steering
Steering Inspection ” ”
Steering Adjustment
Steering Stem
Stem, Stem Bearing Removal
Stem, Stem Bearing Installation
Steering Bearing Lubrication and Inspection
Steering Stem Warp
Handlebar
Handlebar Removal
Handlebar Installation

Frame
Exploded View
Seats
Rear Seat Removal
Rear Seat Installation
Rear Seat Cover Removal
Rear Seat Cover Installation
Front Seat Removal
Front Seat Installation
Seat Cover
Seat Cover Removal
Seat Cover Installation
Fairings
Lower Fairing Removal
Lower Fairing Installation
Inner Fairing Removal
Inner Fairing Installation
Wind Shield Removal
Wind Shield Installation
Inner Cover Removal
Inner Cover Installation
Upper Fairing Removal
Air Intake Duct Removal
Air Intake Duct Installation
Hot Wind Cover Installation
Fenders
Front Fender Removal
Front Fender Installation
Rear Fender Rear Removal
Rear Fender Rear Installation
Rear Fender Front Removal
Rear Fender Front Installation
Rear Frame
Rear Frame Removal
Rear Frame Installation
Frame Inspection
Storage Box
Storage Box Removal
Storage Box Installation

Electrical System
Exploded View
Specifications
Parts Location
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Cover Removal
Alternator Cover Installation
Stator Coil Removal
Stator Coil Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Inspection
Regulator/Rectifier Inspection
Regulator/Rectifier Output Voltage Inspection
Ignition System
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Cam Sensor Removal
Cam Sensor Installation
Cam Sensor Inspection
Cam Sensor Peak Voltage Inspection
Stick Coil (Ignition Coil together with Spark
Cap) Removal
Stick Coil (Ignition Coil together with Spark
Cap) Installation
Stick Coil (Ignition Coll together with Spark
Cap) Inspection
Stick Coil Primary Peak Voltage Inspection
Spark Plug Removal•
Spark Plug Installation
Spark Plug Cleaning and Inspection
Spark Plug Gap Inspection
Interlock Operation Inspection•
1C Igniter Inspection
Ignition System Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Lead Inspection
Brush Plate and Terminal Bolt Inspection
Starter Relay Inspection
Lighting System
Headlight Beam Horizontal/Vertical Alignment
Headlight Bulb Replacement
City Light Bulb Replacement
Tail/Brake Light Bulb Replacement
Headlight Relay (High/Low) Inspection
Turn Signal Relay Inspection
Radiator Fan System
Fan System Circuit Inspection
Fan Motor Inspection
Meter
Meter Unit Removal
Meter Unit Disassembly
Bulb Replacement
Meter Unit Inspection
Switches and Sensors
Brake Light Timing Inspection
Brake Light Timing Adjustment
Switch Inspection
Radiator Fan Switch Inspection
Water Temperature Sensor Inspection
Speed Sensor Removal
Speed Sensor Installation
Speed Sensor Inspection
Fuel Level Sensor Inspection
Fuel Reserve Switch Inspection
Junction Box
Junction Box Fuse Circuit Inspection
Starter Circuit/Headlight Relay Inspection
Diode Circuit Inspection
Fuse

Appendix
Additional Considerations for Racing
Spark Plug:
Spark Plug Inspection
Troubleshooting Guide
General Lubrication
Lubrication (Periodic Maintenance)
Nut, Bolt, and Fastener Tightness
Tightness Inspection
Unit Conversion Table

Additional information

Weight 3 lbs
Dimensions 9.5 × 11 × 1 in

No further products found.