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

More documents

Recommendations

Info

Not For Resale www.SmallEngineDiscount.com 4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the screws [A] and take off the left radiator cover [B]. • Remove: Radiator Fan Switch Lead Connector [A] Radiator Fan Switch [B] Radiator Fan Switch Installation • Tighten: Torque - Radiator Fan Switch : 18 N·m (1.8 kgf·m, 13 ft·lb) • Fill the coolant and bleed the air from cooling system (see Coolant Change in the Periodic Maintenance chapter ). Radiator Fan Switch Inspection • Refer to the Electrical System chapter for its inspections. Water Temperature Sensor Removal • Refer to the Fuel System (DFI) chapter. Water Temperature Sensor [A] Front [B] Water Temperature Sensor Inspection • Refer to the Electrical System chapter for the water Temperature Sensor Inspection.
Not For Resale www.SmallEngineDiscount.com ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View................................... 5-2 Specifications .................................... 5-6 Special Tools and Sealant ................. 5-8 Clean Air System............................... 5-10 Air Suction Valve Removal........... 5-10 Air Suction Valve Installation........ 5-10 Air Suction Valve Inspection ........ 5-10 Vacuum Switch Valve Removal ... 5-10 Vacuum Switch Valve Installation 5-10 Vacuum Switch Valve Test ........... 5-11 Clean Air System Hose Inspection.................................. 5-11 Cylinder Head Cover ......................... 5-12 Cylinder Head Cover Removal .... 5-12 Cylinder Head Cover Installation . 5-12 Camshaft Chain Tensioner ................ 5-14 Camshaft Chain Tensioner Removal.................................... 5-14 Camshaft Chain Tensioner Installation................................. 5-14 Camshaft, Camshaft Chain ............... 5-15 Camshaft Removal ...................... 5-15 Camshaft Installation ................... 5-15 Camshaft, Camshaft Cap Wear ... 5-17 Camshaft Runout......................... 5-17 Cam Wear.................................... 5-17 Camshaft Chain Removal ............ 5-18 Cylinder Head.................................... 5-19 Cylinder Compression Measurement ............................ 5-19 Cylinder Head Removal............... 5-20 Cylinder Head Installation ............ 5-20 Cylinder Head Warp..................... 5-21 Valves ................................................ 5-22 Valve Clearance Inspection ......... 5-22 Valve Clearance Adjustment........ 5-22 Valve Removal ............................. 5-22 Valve Installation .......................... 5-22 Valve Guide Removal .................. 5-22 Valve Guide Installation ............... 5-23 Valve-to-Guide Clearance Measurement (Wobble Method)..................................... 5-23 Valve Seat Inspection .................. 5-24 Valve Seat Repair ........................ 5-24 Cylinder, Pistons................................ 5-29 Cylinder Removal......................... 5-29 Cylinder Installation...................... 5-29 Piston Removal............................ 5-29 Piston Installation......................... 5-30 Cylinder Wear .............................. 5-31 Piston Wear ................................. 5-31 Piston Ring, Piston Ring Groove Wear.......................................... 5-31 Piston Ring Groove Width............ 5-32 Piston Ring Thickness ................. 5-32 Piston Ring End Gap ................... 5-32 Throttle Body Holder.......................... 5-33 Throttle Body Holder Installation.. 5-33 Muffler................................................ 5-34 Muffler Body Removal.................. 5-34 Exhaust Pipe Removal................. 5-34 Muffler Body and Exhaust Pipe Installation ................................. 5-34 5
Page 1 and 2:
Not For Resale www.SmallEngineDisco
Page 3 and 4:
Page 5 and 6:
© 2002 Kawasaki Heavy Industries,
Page 7 and 8:
Page 9 and 10:
Page 11 and 12:
Page 13 and 14:
Page 15 and 16:
Page 17 and 18:
Page 19 and 20:
General Specifications GENERAL INFO
Page 21 and 22:
Page 23 and 24:
Page 25 and 26:
Page 27 and 28:
Page 29 and 30:
Page 31 and 32:
Page 33 and 34:
Torque and Locking Agent PERIODIC M
Page 35 and 36:
Torque and Locking Agent PERIODIC M
Page 37 and 38:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
Page 45 and 46:
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Periodic Maintenance Procedures •
Page 53 and 54:
Page 55 and 56:
Page 57 and 58:
Periodic Maintenance Procedures PER
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
FUEL SYSTEM (DFI) 3-1 Fuel System (
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
Page 85 and 86:
Page 87 and 88:
Page 89 and 90:
Page 91 and 92:
Page 93 and 94:
Page 95 and 96:
Page 97 and 98:
FUEL SYSTEM (DFI) 3-21 Troubleshoot
Page 99 and 100:
Page 101 and 102:
DFI System Troubleshooting Guide FU
Page 103 and 104:
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Page 119 and 120:
Inlet Air Pressure Sensor (Service
Page 121 and 122:
Page 123 and 124:
Page 125 and 126:
Page 127 and 128:
Page 129 and 130:
Page 131 and 132:
Page 133 and 134:
For Resale www.SmallEngineDiscount.
Page 135 and 136:
Page 137 and 138:
Page 139 and 140:
Page 141 and 142:
Page 143 and 144: Subthrottle Valve Actuator (Service
Page 145 and 146: Not For Resale www.SmallEngineDisco
Page 153 and 154: Fuel Line • Open the fuel tank ca
Page 185 and 186: Coolant COOLING SYSTEM 4-9 Pressure
Page 193: Not For Resale www.SmallEngineDisco
Page 211 and 212: Camshaft, Camshaft Chain ENGINE TOP
Page 225 and 226: Cylinder, Pistons ENGINE TOP END 5-
Page 237 and 238: Clutch Cover CLUTCH 6-7 Clutch Cove
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
Page 253 and 254:
Page 255 and 256:
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
Page 263 and 264:
Page 265 and 266:
Page 267 and 268:
• Install the engine ground cable
Page 269 and 270:
Page 271 and 272:
Page 273 and 274:
Page 275 and 276:
Page 277 and 278:
Page 279 and 280:
Page 281 and 282:
Crankcase Splitting • Apply liqui
Page 283 and 284:
Crankshaft and Connecting Rods •
Page 285 and 286:
Crankshaft and Connecting Rods CRAN
Page 287 and 288:
Page 289 and 290:
Page 291 and 292:
Page 293 and 294:
Page 295 and 296:
Transmission CRANKSHAFT/TRANSMISSIO
Page 297 and 298:
Page 299 and 300:
Page 301 and 302:
Page 303 and 304:
Page 305 and 306:
Page 307 and 308:
Page 309 and 310:
Page 311 and 312:
Page 313 and 314:
Page 315 and 316:
Page 317 and 318:
Page 319 and 320:
Page 321 and 322:
Page 323 and 324:
Page 325 and 326:
Page 327 and 328:
Page 329 and 330:
Page 331 and 332:
Page 333 and 334:
Page 335 and 336:
Page 337 and 338:
Page 339 and 340:
Page 341 and 342:
Page 343 and 344:
Page 345 and 346:
Page 347 and 348:
Page 349 and 350:
Page 351 and 352:
Page 353 and 354:
Page 355 and 356:
Page 357 and 358:
Page 359 and 360:
Page 361 and 362:
Page 363 and 364:
Page 365 and 366:
Page 367 and 368:
Page 369 and 370:
Page 371 and 372:
Page 373 and 374:
Page 375 and 376:
Page 377 and 378:
Page 379 and 380:
Page 381 and 382:
Page 383 and 384:
Page 385 and 386:
Page 387 and 388:
Page 389 and 390:
Page 391 and 392:
Page 393 and 394:
Page 395 and 396:
Page 397 and 398:
Page 399 and 400:
Page 401 and 402:
Page 403 and 404:
Page 405 and 406:
Page 407 and 408:
ELECTRICAL SYSTEM 16-1 Electrical S
Page 409 and 410:
Page 411 and 412:
Page 413 and 414:
Page 415 and 416:
Page 417 and 418:
Page 419 and 420:
Page 421 and 422:
Page 423 and 424:
Page 425 and 426:
Page 427 and 428:
Page 429 and 430:
Page 431 and 432:
Page 433 and 434:
Page 435 and 436:
Page 437 and 438:
Page 439 and 440:
Page 441 and 442:
Page 443 and 444:
Page 445 and 446:
Ignition System ELECTRICAL SYSTEM 1
Page 447 and 448:
Page 449 and 450:
Page 451 and 452:
Page 453 and 454:
Page 455 and 456:
Page 457 and 458:
Page 459 and 460:
Page 461 and 462:
Page 463 and 464:
Page 465 and 466:
Page 467 and 468:
For Resale www.SmallEngineDiscount.
Page 469 and 470:
Page 471 and 472:
Page 473 and 474:
Page 475 and 476:
Page 477 and 478:
Meter, Gauge, Indicator Unit ELECTR
Page 479 and 480:
Page 481 and 482:
Page 483 and 484:
Page 485 and 486:
Page 487 and 488:
Page 489 and 490:
Page 491 and 492:
Page 493 and 494:
Page 495 and 496:
Page 497 and 498:
Page 499 and 500:
Page 501 and 502:
Page 503 and 504:
Page 505 and 506:
Page 507 and 508:
Page 509 and 510:
Page 511 and 512:
Page 513 and 514:
Page 515:
MODEL APPLICATION Year Model Beginn
show all

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

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?