1986 Kawasaki Ninja 900 Shop Manual

The 1986 Kawasaki Ninja 900 (GPz900R) is a revolutionary sport motorcycle featuring a 908cc liquid-cooled inline-four engine, DOHC 16-valve configuration, 6-speed transmission, Uni-Trak rear suspension, and advanced aerodynamic design. This comprehensive shop manual covers all maintenance, repair, and service procedures for the complete motorcycle system. Below are key sections for specifications, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

1. General Information 2. Specifications 3. Maintenance Schedule 4. Engine Service 5. Fuel System 6. Chassis & Suspension 7. Electrical System 8. Transmission & Clutch 9. Brake System 10. Troubleshooting 11. Wiring Diagrams

General Information

Key components: 908cc inline-four engine, Steel double-cradle frame, Anti-dive front forks, Uni-Trak rear suspension, Dual front disc brakes, 6-speed transmission.

Component	Description
Engine Type	908cc liquid-cooled 4-stroke inline-four
Bore x Stroke	72.5mm x 55.0mm
Compression Ratio	10.5:1
Fuel System	Four Keihin CVK34 carburetors
Ignition System	Transistorized electronic ignition
Transmission	6-speed constant mesh
Final Drive	#530 chain
Frame Type	Steel double-cradle
Front Suspension	39mm telescopic forks with anti-dive
Rear Suspension	Uni-Trak with adjustable preload

Specifications

Displacement: 908cc
Power Output: 113 hp @ 9,500 rpm
Torque: 65 lb-ft @ 8,500 rpm
Fuel Capacity: 5.8 gallons (22 liters)
Oil Capacity: 3.7 quarts (3.5 liters) with filter change
Front Tire: 110/90V16
Rear Tire: 130/80V18
Wheelbase: 59.1 inches (1,500 mm)
Seat Height: 30.7 inches (780 mm)
Dry Weight: 498 lbs (226 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and safety.

Every 600 miles/1,000 km: Check chain adjustment, tire pressure, brake pads
Every 3,000 miles/5,000 km: Change engine oil and filter
Every 6,000 miles/10,000 km: Clean and sync carburetors, check valve clearance
Every 12,000 miles/20,000 km: Replace spark plugs, air filter, brake fluid
Every 24,000 miles/40,000 km: Check cam chain tensioner, replace coolant

WARNING! Always use genuine Kawasaki parts for optimal performance and safety.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder Head Removal: Drain coolant, remove cam cover, timing chain, cylinder head bolts
Valve Adjustment: Set piston at TDC compression, adjust clearance to 0.10-0.15mm (intake), 0.15-0.20mm (exhaust)
Piston/Cylinder Service: Measure cylinder bore, check piston ring end gap
Crankshaft Service: Check runout, bearing clearance, connecting rod play
Camshaft Timing: Align timing marks, set chain tensioner

CAUTION! Use proper torque specifications and sequence for all engine fasteners.

Fuel System

Keihin CVK34 carburetor service and adjustment procedures.

Carburetor Removal: Drain fuel, disconnect throttle cables, remove airbox boots
Float Level: Set to 17.5mm ± 1.0mm
Pilot Screw: Initial setting 2-1/4 turns out from lightly seated
Synchronization: Use vacuum gauges to balance all four carburetors
Fuel Filter: Replace if contaminated or every 12,000 miles

Tip: Always use fresh fuel and stabilizer for extended storage periods.

Chassis & Suspension

Frame, suspension, and steering maintenance procedures.

Front Fork Service: Drain oil, inspect seals, refill with 10W fork oil
Rear Suspension: Check Uni-Trak linkage bearings, adjust preload
Steering Head Bearings: Check for play, adjust or replace as needed
Wheel Alignment: Check and adjust chain tension for proper alignment
Swingarm Pivot: Lubricate bearings every 12,000 miles

WARNING! Always check torque specifications for all chassis components.

Electrical System

Complete electrical system testing and repair procedures.

Component	Specification
Battery	12V 14Ah
Alternator Output	280W @ 5,000 rpm
Spark Plug	NGK DR8ES-L / Gap: 0.7-0.8mm
Fuse Box	Main 30A, Headlight 15A, Signal 10A
Starter Motor	0.7 kW

Testing Procedures: Use multimeter to check voltage, resistance, and continuity.

Transmission & Clutch

6-speed transmission and wet multi-plate clutch service.

Clutch Adjustment: Adjust cable free play to 2-3mm at lever
Transmission Oil: Use SAE 10W-40 motorcycle oil, capacity 2.6 quarts
Shift Mechanism: Check shift drum, forks, and gears for wear
Clutch Plates: Measure thickness, replace if below service limit
Neutral Switch: Test continuity, replace if faulty

CAUTION! Always drain oil when engine is warm for complete drainage.

Brake System

Dual front disc and single rear disc brake maintenance.

Brake Pad Replacement: Check thickness, replace if below 1mm
Brake Fluid: Use DOT 4, replace every 2 years or 12,000 miles
Brake Discs: Check for warpage and thickness (min 4.0mm)
Caliper Service: Clean pistons, replace seals if leaking
Master Cylinder: Check for leaks, rebuild if necessary

WARNING! Always bleed brakes properly to remove air from system.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Dirty carbs, weak battery	Clean carburetors, charge/test battery
Poor idle	Sync needed, vacuum leak	Synchronize carbs, check intake boots
Overheating	Low coolant, stuck thermostat	Check coolant level, test thermostat
Electrical issues	Bad connections, regulator	Check grounds, test charging system
Transmission noise	Worn gears, low oil	Check oil level, inspect transmission

Service Tips: Always follow proper diagnostic procedures before disassembly.

Wiring Diagrams

Complete electrical schematics for the entire motorcycle system.

Main Harness: Color-coded wiring diagram with connector locations
Ignition System: CDI unit, coils, spark plug wiring
Charging System: Alternator, regulator/rectifier, battery connections
Lighting System: Headlight, taillight, turn signals, instrument cluster
Starting System: Starter motor, solenoid, safety switches