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

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Not For Resale www.SmallEngineDiscount.com 4-12 COOLING SYSTEM Radiator Radiator Removal WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Radiator Cover [A] and Screws [B] Lower Bolt [C] Bolt and Bracket [D] (from cylinder) Right Radiator Upper Bolt [E] Left Radiator Cover Front [F] • Remove: Right Radiator Hose [A] and Oil Cooler Hose [B] • Remove: Fuel Tank (see Fuel System (DFI) chapter) Radiator Fan Motor Connector [A] (BL/W, BK/Y leads) Front [B] • Remove: Fan Switch Lead Connector [A] Left Radiator Hose [B] Horn and Connectors [C] Left Radiator Upper Bolt [D] • Remove the radiator. CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Not For Resale www.SmallEngineDiscount.com Radiator • If necessary, remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] COOLING SYSTEM 4-13 Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20 % by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one. CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface. Run the steam gun, following the core fin direction. Radiator Cap Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) Radiator Cap • Check the condition of the bottom valve seal [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.
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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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• 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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