Introduction
Kawasaki Motors Corp., U.S.A., (KMC) unveiled the future of its
sportbike DNA in the form of the all-new 2004 NINJA® ZX-10R
motorcycle, serving notice to Superbike racers and sportbike
enthusiasts that Kawasaki is committed to its heritage of building
uncompromising, high-performance motorcycles.
The NINJA ZX-10R puts Kawasaki at the front of sportbike design
and performance. From the overall shape to the smallest detail,
the ZX-10R combines high technology with the latest innovations,
including a new, high-output engine, ultra-narrow aluminum frame,
ergonomic design and compact bodywork with a frontal area smaller
than those of most 600cc sportbikes.
Tom Orbe, vice president of marketing at KMC, said the ZX-10R
is a sportbike worthy of Kawasaki's image and it sends
a clear message to the motorcycling world that the green brand
is pulling out all the stops to be number one on the race track.
"The NINJA ZX-10R is designed to have the best power-to-weight
ratio and best handling on the track," said Orbe. "It
will provide riders with more than enough power and handling
to take on the competition."
Kawasaki engineers utilized a "stack" design for the
extraordinarily compact, liquid-cooled, 998cc inline four-cylinder
engine. The crank axis, input shaft and output shaft of the NINJA
ZX-10R engine are positioned in a triangular layout to reduce
engine length, while the high-speed generator is placed behind
the cylinder bank to reduce engine width. With a bore and stroke
of 76 x 55mm, the ZX-10R engine's one-piece cylinder and crankcase
assembly reduces weight and increases rigidity. The double overhead
cams are machined from chromoly steel billet for strength, four
valves per cylinder improve high-rpm breathing, and the forged,
lightweight pistons offer high heat resistance to further enhance
the bike's power-to-weight ratio.
To obtain maximum benefit from the ZX-10R's electronic fuel injection,
engineers turned to advanced flow analysis to "streamline"
the engine's intake tract. A Ram Air duct located at the front
of the fairing provides the coolest air possible, while the fuel
injection assembly features electronically controlled sub throttles
to smooth power delivery. An ultra-lightweight titanium four-into-one
exhaust system incorporates a butterfly valve at the collector
to improve overall power characteristics. The titanium oval-shaped
muffler is wrapped with a sheet of ultra-thin walled aluminum
and has a non-restrictive honeycomb catalyzer to reduce exhaust
emissions.
In addition to liquid cooling, the ZX-10R engine features a liquid-cooled
oil cooler adjacent to the oil filter to reduce oil temperatures.
"Slosh" analysis was also used to design the internal
structure of the oil pan, thereby reducing windage losses and
helping to maintain low oil temperatures.
A multi-plate wet clutch with a back torque limiter transfers
power to a six-speed, close-ratio transmission idealized for
closed-course competition. The back torque limiter automatically
disengages the clutch under hard braking and deceleration to
prevent rear wheel hop during corner entry.
The engine is bolted into all-aluminum twin-tube backbone frame
that arches over the engine rather than around it, as with conventional
sportbike designs. Constructed of thin-walled castings and pressed
aluminum sheets welded together for optimum lightness, the ZX-10R
frame provides exceptional high-speed stability and responsive
handling, yet is no wider than most 600cc-class sportbikes.
Front suspension duties are handled by fully adjustable 43mm
forks and many of the fork's internal parts are crafted from
aluminum to minimize weight. A gull-type aluminum swingarm connected
to Kawasaki's UNI-TRAK® linkage and a fully adjustable shock
handles rear suspension duties. The entire rear suspension system
is both lightweight and torsionally rigid, and also features
adjustable ride height.
The ZX-10R features all-new six-spoke, cast-aluminum wheels.
By utilizing six spokes in place of the traditional three-spoke
design, engineers were able to reduce rim thickness, yet the
wheels are both stronger and lighter. To provide as much traction
as possible, the ZX-10R rides on a 120/70ZR17 front tire and
ultra-wide 190/50ZR17 rear tire.
Stopping power for the ZX-10R is provided by dual 300mm front
disc brakes featuring petal disc design, radially mounted four-piston
calipers, and a single 220mm rear disc brake. First introduced
on Kawasaki's own NINJA ZX-6R and ZX-6RR sportbikes, the radial
front brake design utilizes mounting points at both the top and
bottom of the caliper, with the mounting bolts inserted through
the rear of the caliper instead of the side or front as on conventional
designs. This racing-inspired setup makes the caliper more rigid
to improve brake feel over a wider range of operation.
With the help of a front area smaller than that of a NINJA ZX-6R,
the angular body work and racing-style ergo
nomics of the ZX-10R
minimizes aerodynamic drag on the race track. A central ram air
duct incorporated into the nose of the fairing provides cool,
dense air to the airbox, which is situated between the frame
tubes. The top portion of the fuel tank is also concave, so the
competition rider can tuck in tightly behind the small windscreen.
Pop nuts are used to fasten the bodywork to the frame, making
disassembly and service easier, and the light, five-piece tail
section opens at the top for easy maintenance.
Other features include multi-reflector headlights, forged aluminum
handlebars that are gun-drilled to reduce weight, LCD display
with radial tachometer and digital speedometer, plus a stop watch
function and LED tail light.
Kawasaki anticipates that numerous privateers will be eager to
race the ZX-10R in closed-course competition, so Team Green™,
Kawasaki's amateur racing support program, is creating a contingency
plan which will be unveiled before the 2004 Superbike season
gets underway.
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Features
Engine
- Liquid-cooled, 998cc four-stroke, inline four-cylinder engine
utilizes stacked layout used for compact dimensions, contributing
to the ZX-10R's narrow profile
- One-piece cylinder/crankcase saves weight and is more rigid
- Forged pistons have flat top for compact combustion chamber
- Cams machined from chromoly steel billet and surface treated
with soft nitride for light weight and durability
- Tappet surfaces treated with soft nitriding to help prevent
wear
- Intake and exhaust valves use single springs with oval cross
sections to lower overall engine height
- Flow analysis used to design cylinder head, maximizing engine
breathing at high rpm
- All-titanium four-into-one exhaust system includes butterfly
valve to enhance low-rpm power
- Oval-shaped aluminum muffler with internal titanium parts reduces
noise and includes honeycomb catalyzer to reduce emissions
- Electronic fuel injection with sub-throttle assembly and 43mm
throttle bodies provide best power characteristics and ridability
- High-speed generator is clutch driven and is positioned behind
the cylinder bank to reduce engine width
- Liquid-cooled oil cooler helps to maintain consistent oil temperatures
- Sloshing analysis used to design internal structure of oil
pan, reducing windage and helping to maintain low oil temperatures
- Magnesium engine covers reduce overall dry weight
Transmission
- Close-ratio six-speed transmission optimizes on-track performance
- Multi-plate wet clutch with back torque limiter prevents rear
wheel hop under hard braking and deceleration
Chassis
- All-aluminum, twin-spar backbone frame utilizes thin-walled
castings and pressed sheets welded together for light weight
provides high-speed stability and responsive handling,
yet is no wider than most 600cc sportbikes
- Frame arches over the engine rather than around it, giving
the ZX-10R the narrowest possible profile for excellent riding
position and ride "feel"
- Fully-adjustable 43mm forks and internal aluminum parts feature
circuit setting for competition
- Top triple clamp features "lightening holes" to reduce
weight
- Gull-type aluminum swingarm with oval pipe brace, UNI-TRAK®
linkage and fully adjustable shock is lightweight and torsionally
rigid
- Rear suspension includes ride height adjustment
Brakes & Wheels
- Dual 300mm front disc brakes feature radial-mounted four-piston
calipers and single 220mm rear disc brake the first petal
discs in the liter bike class enhance cooling and prevent
warpage
- Cast-aluminum wheels utilize six spokes in place of the traditional
three-spoke design, so rim thickness is reduced, yet the wheels
are stronger and lighter
Bodywork & Ergonomics
- Front fairing is narrower than most 600cc sportbikes
- Central ram air duct provides the induction system with the
coolest, densest air possible
- Pop nuts make disassembly quick and easy
- Three-dimensional computer-assisted design used to develop
ergonomic and aerodynamic layout
- Three-piece front fender increases aerodynamic efficiency
- Top of the fuel tank is concave so the rider can tuck in more
tightly behind the windscreen
- Fuel tank bottom is flat to provide engine with stable fuel
level
- Compact rear fender is slim and light
- Inner fender's flowing design matches the shape of the swingarm
to achieve unity of function and style
- Five-piece W-shaped seat cowl flows from the tank the rear
tail section for an aggressive, high-quality image and is easily
removed for maintenance
Additional Features
- Forged aluminum handlebars are strong and gun drilled to further
reduce weight
- Powerful dual multi-reflector 55W headlights provide best possible
nighttime visibility
- Digital LCD instrument panel includes tachometer, speedometer,
water temperature gauge, shift indicator, clock and stop watch
function
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Technical Specifications
Engine
Four-stroke, DOHC, inline four, 16 valves
Horsepower: (PS) 184*
Displacement: 998cc
Starting: Electric
Bore x stroke: 76.0 x 55mm
Compression ratio: 12.7:1
Cooling: Liquid
Induction: Electronic fuel injection with four 43mm throttle
bodies
Ignition: TCBI with digital advance
Transmission: Six-speed, close ratio with multi-plate wet clutch
and back torque limiter
Chassis
Frame: All-aluminum twin-tube backbone
Rake / trail: 24 degrees / 4.0 inches
Suspension, front: 43mm inverted cartridge fork with DLC coating,
adjustable preload,compression and rebound damping
Suspension, r
ear: Gull-type aluminum swingarm, UNI-TRAK®
linkage system, fully adjustable gas-charged shock with stepless
compression/rebound damping, adjustable spring preload, adjustable
ride height
Wheels, Tires & Brakes
Tire, front: 120/70ZR17
Tire, rear: 190/50ZR17
Brakes, front / rear: Dual 300mm hydraulic petal disc with radial-mounted,
opposed four-piston caliper / Single 220mm hydraulic petal disc
with radial-mounted caliper
Measures & Weights
Seat height: 32.5 inches
Dry weight: 375 pounds
Fuel capacity: 4.5 gallons
Wheelbase: 54.5 inches
Colors
Candy Thunder Blue 
Lime Green 
Pearl Blazing Orange 
Black 
* Maximum horsepower in top gear with Ram air - actual performance
may vary.
** Price and specifications subject to change
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