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

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Not For Resale www.SmallEngineDiscount.com 7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodic Maintenance chapter) • Remove: Oil Filter (see Periodic Maintenance chapter) Water Hose [A] Oil Cooler Mounting Bolt [B] and Washer Oil Cooler [C] and Water Hose Oil Cooler Installation • Install: Water Hose [A] • Tighten: Torque - Water Hose Clamp Screws: 2.0 N·m (0.2 kgf·m, 17 in·lb) • Apply grease to the O-ring [B] before installation. • Install the oil cooler so that the crankcase rib [A] fits the slot [B] of the cooler. • Apply engine oil to the oil cooler mounting bolt [A] before installation. • Install: Washer [B] • Tighten: Torque - Oil Cooler Mounting Bolt: 78.5 N·m (8.0 kgf·m, 58 ft·lb) • Install: Oil Filter (see Periodic Maintenance chapter) • Pour: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodic Maintenance chapter)
Not For Resale www.SmallEngineDiscount.com Oil Pressure Measurement ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 Start the engine and warm up the engine. • Run the engine at the specified speed, and read the oil pressure gauge. If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. If the reading is much higher than the standard, check the oil passages for clogging. Oil Pressure Standard: 255 ∼ 314 kPa (2.6 ∼ 3.2 kgf/cm², 37 ∼ 46 psi) @4 000 r/min (rpm), oil temp. 90°C (194 °F) Stop the engine. • Remove the oil pressure gauge and adapter. WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed. • Apply a non-permanent locking agent to the oil passage plug, and install it. Torque - Oil Passage Plug (Right): 20 N·m (2.0 kgf·m, 14.5 ft·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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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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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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