Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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Not For Resale www.SmallEngineDiscount.com 3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment • Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Choke Lever Operation ○Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10 °C, 50 °F or below) or at high altitude. The DFI system has an automatic choke system, using a water temperature sensor, and an atmospheric pressure sensor, which provide startability. NOTE ○Pull [A] the choke lever fully when using. The choke doesn’t work with the lever knob halfway. Front [B] ○When flooded, do not crank the engine with the throttle fully opened like a carburetor. This promotes engine flooding because more fuel is supplied automatically by the DFI system. Choke Lever Play Inspection • Push the choke lever [A] fully and ensure by your finger that the choke cam [B] has the specified play. Choke Lever Free Play Standard: 0 ∼ 0.5 mm (0 ∼ 0.02 in.) • Pull [C] the choke lever fully and ensure that the choke cam turns the choke link [D]. Front [E] If the free play is incorrect, adjust the choke cable. Choke Lever Play Adjustment Remove the fuel tank (see this chapter). • Loosen the locknut [A], and turn the adjuster [B] until the cable has the proper amount of free play. • Tighten the locknut against the adjuster securely. Front [C] Cable Removal/Installation • Refer to the Throttle Assy section in this chapter for removal/installation of the throttle cables and choke cable. Cable Lubrication and Inspection • Refer to the General Lubrication in the Periodic Maintenance Chapter.
Not For Resale www.SmallEngineDiscount.com Throttle Body Assy FUEL SYSTEM (DFI) 3-89 Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection in the Periodic Maintenance chapter . Throttle Bore Cleaning • Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Engine Vacuum Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. High Altitude Performance Adjustment • Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pressure change due to high altitude and the ECU compensates the change. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) cable terminal. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Be prepared for fuel spillage: any spilled fuel must be completely wiped up immediately. • Remove: Fuel Tank (see Fuel Tank Removal) Vacuum Switch Valve Vacuum Hose [A] (from air cleaner housing [B]) Front [C] • Remove the vacuum hoses from the positions [A] shown. Front [B]
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© 2002 Kawasaki Heavy Industries,
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General Specifications GENERAL INFO
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Torque and Locking Agent PERIODIC M
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Torque and Locking Agent PERIODIC M
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Periodic Maintenance Procedures •
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Periodic Maintenance Procedures PER
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FUEL SYSTEM (DFI) 3-1 Fuel System (
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FUEL SYSTEM (DFI) 3-21 Troubleshoot
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DFI System Troubleshooting Guide FU
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Cylinder, Pistons ENGINE TOP END 5-
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Clutch Cover CLUTCH 6-7 Clutch Cove
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• Install the engine ground cable
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Crankcase Splitting • Apply liqui
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Crankshaft and Connecting Rods •
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Crankshaft and Connecting Rods CRAN
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Transmission CRANKSHAFT/TRANSMISSIO
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ELECTRICAL SYSTEM 16-1 Electrical S
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Ignition System ELECTRICAL SYSTEM 1
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Meter, Gauge, Indicator Unit ELECTR
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MODEL APPLICATION Year Model Beginn
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