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

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Not For Resale www.SmallEngineDiscount.com 3-98 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air. CAUTION Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap. Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank. Remove the fuel tank (see Fuel Tank Removal). • Fuel Pump section in this chapter). • shake the tank to remove dirt and fuel deposits. Draw the solvent out of the fuel tank. Dry the tank with compressed air. Install the fuel pump (see Fuel Pump Installation). • Install the fuel tank (see Fuel Tank Installation). Remove the fuel pump inlet hose and the fuel pump (see Pour some high flash-point solvent into the fuel tank and
Not For Resale www.SmallEngineDiscount.com Evaporative Emission Control System FUEL SYSTEM (DFI) 3-99 Parts Removal/Installation WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. 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. CAUTION If gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one. • To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. • Be sure to plug the return hose to prevent fuel spilling before fuel tank removal. If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air. • Connect the hoses according to the diagram of the system (see Cable, Wire, and Hose Routing section in the Appendix chapter). Make sure they do not get pinched or kinked. • Route hoses with a minimum of bending so that the air or vapor will not be obstructed. Canister Installation • Refer to the Evaporative Emission Control System Inspection in the Periodic Maintenance chapter. Hose Inspection • Refer to the Evaporative Emission Control System Inspection in the Periodic Maintenance chapter. Separator Inspection • Refer to the Evaporative Emission Control System Inspection in the Periodic Maintenance chapter.
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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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Inlet Air Pressure Sensor (Service
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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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