1986 Kawasaki Ninja 1000 Service Manual

The 1986 Kawasaki Ninja 1000 (GPz1000RX) is a high-performance sport motorcycle featuring a 997cc liquid-cooled inline-four engine, DOHC 16-valve configuration, 6-speed transmission, Uni-Trak rear suspension, and advanced aerodynamic fairing. This service manual covers maintenance procedures, specifications, troubleshooting, and repair guidelines for proper upkeep and optimal performance of this classic sport bike.

General Information

Key components: 997cc inline-four engine, aerodynamic fairing, digital instrumentation, anti-dive front forks, Uni-Trak rear suspension.

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

1. Every 600 miles/1000 km: Check chain tension and lubrication
2. Every 3000 miles/5000 km: Oil and filter change
3. Every 6000 miles/10000 km: Valve clearance inspection
4. Every 12000 miles/20000 km: Spark plug replacement
5. Annually: Brake fluid flush, coolant replacement

WARNING! Always use genuine Kawasaki parts for replacement. Follow torque specifications precisely.

Engine Specifications

• Engine Type: Liquid-cooled 4-stroke DOHC inline-four
• Displacement: 997cc
• Bore x Stroke: 74.0 x 58.0 mm
• Compression Ratio: 10.5:1
• Maximum Power: 125 hp @ 9,500 rpm
• Maximum Torque: 75 lb-ft @ 8,500 rpm
• Valve System: DOHC, 4 valves per cylinder
• Oil Capacity: 3.7 liters with filter change
• Cooling System: Liquid-cooled with radiator

Fuel System

Keihin CVK32 constant velocity carburetors with accelerator pump.

1. Carburetor Settings: Main jet #115, Pilot jet #35
2. Float Height: 15.5 mm ± 1.0 mm
3. Idle Speed: 1,100 ± 100 rpm
4. Sync Procedure: Use vacuum gauges for balanced operation

CAUTION! Use only unleaded gasoline with minimum 91 octane rating.

Electrical System

12V DC system with transistorized ignition and digital instrumentation.

Chassis & Suspension

Double cradle steel frame with advanced suspension systems.

1. Front Suspension: 38mm telescopic forks with anti-dive, 140mm travel
2. Rear Suspension: Uni-Trak system with 5-way preload adjustment
3. Front Wheel: 16-inch cast aluminum
4. Rear Wheel: 18-inch cast aluminum
5. Steering Head Bearings: Tapered roller bearings

Tip: Check suspension settings for riding conditions and load.

Brake System

Dual hydraulic disc brakes front, single disc rear.

• Front Brakes: Dual 280mm discs with 2-piston calipers
• Rear Brake: Single 270mm disc with single-piston caliper
• Brake Fluid: DOT 4
• Pad Thickness: Replace when less than 1.0 mm
• Rotor Thickness: Minimum 4.5 mm

Transmission & Clutch

6-speed constant mesh transmission with wet multi-plate clutch.

1. Gear Ratios: 1st: 2.571, 2nd: 1.777, 3rd: 1.380, 4th: 1.125, 5th: 0.961, 6th: 0.851
2. Primary Reduction: 1.750 (70/40)
3. Final Reduction: 2.466 (37/15)
4. Clutch Type: Wet multi-plate, cable operated
5. Clutch Play: 10-15 mm at lever end

WARNING! Use only recommended transmission oil for proper shifting.

Cooling System

Pressurized liquid cooling system with thermostat and radiator.

• Coolant Capacity: 2.4 liters
• Radiator Cap Pressure: 1.1-1.4 kg/cm²
• Thermostat Opening: 80-84°C
• Coolant Type: Ethylene glycol based, 50/50 mix with distilled water
• Water Pump: Mechanical impeller type

Troubleshooting

Service Note: Always diagnose systematically from simplest to most complex causes.

Wiring Diagrams

Complete electrical schematics available in manual supplement. Key circuits include:

1. Starting and charging system
2. Ignition and CDI unit
3. Lighting and signaling circuits
4. Instrument cluster wiring
5. Safety interlock switches

CAUTION! Disconnect battery before performing electrical work. Use proper test equipment.