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

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Not For Resale www.SmallEngineDiscount.com 5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolts [A] Muffler Body Mounting Bolts [B] Muffler Body [C] Exhaust Pipe Removal • Remove: Muffler Body Clamp Bolts [A] Exhaust Pipe Manifold Holder Nuts [B] Exhaust Pipe [C] Gaskets [D] Muffler Body and Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body connection gasket [B] with new ones and install them. ○Install the muffler body connection gasket until it is bottomed so that the chamfer side feces muffler body [C]. • Install: Muffler Body Exhaust Pipe [D] ○Install the muffler body until it is bottomed [E]. • Install: Dampers [F] Washer [G] • Tighten: Torque - Exhaust Pipe Manifold Holder Nuts [H]: 17 N·m (1.7 kgf·m, 12 ft·lb) Muffler Body Mounting Bolts [I] and Nuts [J]: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Body Clamp Bolts [K]: 17 N·m (1.7 kgf·m, 12 ft·lb)
Not For Resale www.SmallEngineDiscount.com Muffler ENGINE TOP END 5-35 ○Install the muffler body clamp bolts as shown. [L] Upper Side [M] Inside [N] Connection Part Detail • Thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts.
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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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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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Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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