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

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Not For Resale www.SmallEngineDiscount.com 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○Second, insert the lower engine mounting bolt [A]. ○Third, install the rear engine bracket [B] temporarily. ○Fourth, insert the middle engine mounting bolts [C]. ○Fifth, install the left upper engine mounting bolt [A] and tighten it. Torque - Left Upper Engine Mounting Bolt : 44 N·m (4.5 kgf·m, 32 ft·lb) ○Sixth, tighten the adjusting collar [A] until the clearance between the crankcase [B] and frame bracket [C] come to zero mm [D]. ○Seventh, tighten the collar locknut [E]. Torque - Adjusting Collar Locknut : 49 N·m (5.0 kgf·m, 36 ft·lb) Special Tool - Engine Mount Nut Wrench : 57001–1450 ○Eighth, fit the projections [A] of the baffle plate [B] in the holes [C] of the frame and front bracket [D].
Not For Resale www.SmallEngineDiscount.com Engine Removal/Installation ENGINE REMOVAL/INSTALLATION 8-11 ○Ninth, temporarily install: Front Engine Bracket [A] Front Right Engine Mounting Bolt [B] ○Tenth, tighten the rear bracket bolts. Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○Eleventh, tighten securely: Middle Engine Mounting Nut Lower Engine Mounting Nut Torque - Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) ○Twelfth, tighten the right upper engine mounting bolt. ○Lastly, tighten the front bracket bolts. Torque - Right Upper Engine Mounting Bolt : 44 N·m (4.5 kgf·m, 32 ft·lb) Front Bracket Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb) • Run the leads, cables and hoses correctly (see Cable, Wire and Hose Routing section in Appendix chapter). Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Periodic Maintenance chapter) Choke Cable (see Fuel System (DFI) chapter) Clutch Cable (see Periodic Maintenance chapter) Drive Chain (see Periodic Maintenance chapter) • Fill the engine with engine oil (see Periodic Maintenance chapter). • Fill the engine with coolant and bleed the air from the cooling system (see Periodic Maintenance chapter).
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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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