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

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Not For Resale www.SmallEngineDiscount.com 6-12 CLUTCH Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then replace the steel plate(s) which brings the length within the specified range. • Remove: Spring Bolts Spring Holders Springs Spring Plate • Replace the following steel plate(s). Part No. Thickness 13089–1073 2.0 mm (0.08 in.) 13089–1084 2.3 mm (0.09 in.) (STD) 13089–1115 2.6 mm (0.10 in.) NOTE ○Do not use the steel plate of 2.0 mm (0.08 in.) and 2.6 mm (0.10 in.) thickness at the same time. • Install the removed parts, and inspect the clutch plate assembly length. Torque - Clutch Spring Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb) Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness Standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Service Limit: 2.4 mm (0.094 in.) Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp Standard: 0.2 mm (0.008 in.) or less Service Limit: 0.3 mm (0.012 in.) Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 75.42 mm (2.97 in.) Service Limit: 71.8 mm (2.83 in.)
Not For Resale www.SmallEngineDiscount.com ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................................................................................................................ 7-2 Engine Oil Flow Chart............................................................................................................. 7-4 Specifications ......................................................................................................................... 7-6 Special Tools and Sealant ...................................................................................................... 7-7 Engine Oil and Oil Filter.......................................................................................................... 7-8 Oil Level Inspection........................................................................................................... 7-8 Engine Oil Change............................................................................................................ 7-8 Oil Filter Replacement ...................................................................................................... 7-8 Oil Pan.................................................................................................................................... 7-9 Oil Pan Removal ............................................................................................................... 7-9 Oil Pan Installation ............................................................................................................ 7-9 Oil Pressure Relief Valve........................................................................................................ 7-10 Oil Pressure Relief Valve Removal ................................................................................... 7-10 Oil Pressure Relief Valve Installation ................................................................................ 7-10 Oil Pressure Relief Valve Inspection................................................................................. 7-10 Oil Pump................................................................................................................................. 7-11 Oil Pump Removal............................................................................................................ 7-11 Oil Pump Installation ......................................................................................................... 7-11 Oil Pump Drive Gear Removal.......................................................................................... 7-13 Oil Pump Drive Gear Installation....................................................................................... 7-13 Oil Cooler................................................................................................................................ 7-14 Oil Cooler Removal........................................................................................................... 7-14 Oil Cooler Installation........................................................................................................ 7-14 Oil Pressure Measurement..................................................................................................... 7-15 Oil Pressure Measurement ............................................................................................... 7-15 Oil Pressure Switch ................................................................................................................ 7-16 Oil Pressure Switch Removal ........................................................................................... 7-16 Oil Pressure Switch Installation ........................................................................................ 7-16 7
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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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Coolant COOLING SYSTEM 4-9 Pressure
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Page 211 and 212: Camshaft, Camshaft Chain ENGINE TOP
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Page 237 and 238: Clutch Cover CLUTCH 6-7 Clutch Cove
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Page 267 and 268: • Install the engine ground cable
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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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