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

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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
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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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Page 143 and 144: Subthrottle Valve Actuator (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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