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

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Clean Air System
ENGINE TOP END 5-11
Vacuum Switch Valve Test
• Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Vacuum Switch Valve
• Connect a vacuum gauge [A] and syringe [B] or fork oil
level gauge to the vacuum hoses as shown.
Special Tool - Fork Oil Level Gauge: 57001–1290
Air Flow [C]
• Gradually raise the vacuum (lower the pressure) applied
to the vacuum switch valve, and check the valve operation.
When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum raises to
valve closing pressure, it should stop air flow.
Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]
If the vacuum switch valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just
blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open → Close)
Standard: 45 ∼ 53 kPa (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi)
High Vacuum [A]
Secondary air cannot flow [B]
Clean Air System Hose Inspection
• Be certain that all the hoses are routed without being flattened
or kinked, and are connected correctly to the air
cleaner housing, vacuum switch valve, #1 and #4 carburetor
holders and air suction valve covers.
If they are not, correct them. Replace them if they are
damaged.