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

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Not For Resale www.SmallEngineDiscount.com 5-32 ENGINE TOP END Cylinder, Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard Service Limit Top [A] 0.83 ∼ 0.85 mm 0.93 mm (0.0327 ∼ 0.0335 in.) (0.037 in.) Second [B] 0.82 ∼ 0.84 mm 0.92 mm (0.0323 ∼ 0.0331 in.) (0.036 in.) If the width of any of the two grooves is wider than the service limit at any point, replace the piston. Piston Ring Thickness • Measure the piston ring thickness. ○Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard Service Limit Top [A] 0.77 ∼ 0.79 mm 0.70 mm (0.0303 ∼ 0.0311 in.) (0.028 in.) Second [B] 0.77 ∼ 0.79 mm 0.70 mm (0.0303 ∼ 0.0311 in.) (0.028 in.) If any of the measurements is less than the service limit on either of the rings, replace all the rings. NOTE ○When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard Service Limit Top 0.20 ∼ 0.30 mm 0.6 mm (0.0079 ∼ 0.0118 in.) (0.024 in.) Second 0.35 ∼ 0.50 mm 0.8 mm (0.0138 ∼ 0.0197 in.) (0.031 in.) If the end gap of either ring is greater than the service limit, replace all the rings.
Not For Resale www.SmallEngineDiscount.com Throttle Body Holder ENGINE TOP END 5-33 Throttle Body Holder Installation Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that its hole fit on the projection [C] of the holder. • Tighten: Torque-Throttle Body Holder Bolts [D]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle Body Holder Clamp Screws [E]: 2.0 N·m (0.2 kgf·m, 17 in·lb)
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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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Subthrottle Valve Actuator (Service
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Fuel Line • Open the fuel tank ca
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Page 185 and 186: Coolant COOLING SYSTEM 4-9 Pressure
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Page 225: Cylinder, Pistons ENGINE TOP END 5-
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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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