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

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Not For Resale www.SmallEngineDiscount.com 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator Hose Clamp [A] (Loosen) Radiator Hose [B] Oil Cooler Water Hose Clamp [C] (Loosen) Oil Cooler Water Hose [D] Radiator Bolt [E] (Loosen) Radiator Bracket Bolt [F] • Disconnect Crankshaft Sensor Lead Connector (see Electrical System chapter) Stick Coil Harness Connector [A] • Remove: Air Cleaner Housing Bolt [A] • Loosen: Throttle Body Assy Clamps Bolts #3, 4 [B] (see Fuel System (DFI) chapter) Special Tool - Carburetor Drain Plug Wrench, Hex3: 57001–1269 • Remove: Left Radiator Cover [A] (see Cooling System chapter) Left Frame Cover [B] (see Frame chapter) Shift Lever [C] (see Crankshaft/Transmission chapter) Engine Sprocket Cover [D] (see Final Drive chapter) Radiator Hose Clamp [E] (Loosen) Radiator Hose [F] • Pull off the connectors from the engine and free the wiring from the clamps. ○For California Model, remove the separate. Starter Motor Lead [A] (see Electrical System chapter) Alternator Lead Connector [B] Neutral Switch Lead Connector [C] Side Stand Switch Lead Connector [D] • Remove: Engine Sprocket (see Final Drive chapter) [E]
Not For Resale www.SmallEngineDiscount.com Engine Removal/Installation ENGINE REMOVAL/INSTALLATION 8-7 • Remove: Camshaft Position Sensor Connector [A] Injector Harness Connector [B] Coolant Reserve Tank [A] (see Cooling System chapter) Air Cleaner Housing Bolt [B] Vacuum Switch Valve Hose [C] • Remove: Vacuum Switch Valve Tube [A] Inlet Air Pressure Sensor Tube [B] Throttle Body Assy [C] ○Loosen the #1,2 body assy clamps [D] and pull the throttle body out of the holders, and then remove it to the left side. Special Tool - Carburetor Drain Plug Wrench, Hex3: 57001–1269 • Remove: Breather Hose End [A] • Remove: Nuts [A] Clamp Bolts [B] Exhaust Pipe Assy [C]
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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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Camshaft, Camshaft Chain ENGINE TOP
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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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