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

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Not For Resale www.SmallEngineDiscount.com
Not For Resale www.SmallEngineDiscount.com CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View................................... 9-2 Specifications .................................... 9-6 Special Tools and Sealant ................. 9-8 Crankcase Splitting............................ 9-9 Crankcase Splitting ...................... 9-9 Crankcase Assembly ................... 9-9 Crankshaft and Connecting Rods...... 9-12 Crankshaft Removal .................... 9-12 Crankshaft Installation ................. 9-12 Connecting Rod Removal ............ 9-12 Connecting Rod Installation......... 9-12 Crankshaft/Connecting Rod Cleaning.................................... 9-15 Connecting Rod Bend.................. 9-16 Connecting Rod Twist.................. 9-16 Connecting Rod Big End Side Clearance.................................. 9-16 Connecting Rod Big End Bearing Insert/Crankpin Wear ................ 9-17 Crankshaft Side Clearance .......... 9-18 Crankshaft Runout....................... 9-18 Crankshaft Main Bearing Insert/Journal Wear................... 9-19 Starter Motor Clutch .......................... 9-21 Starter Motor Clutch Removal/Installation.................. 9-21 Starter Motor Clutch Assembly .... 9-21 Starter Motor Clutch Inspection ... 9-21 Transmission ..................................... 9-22 Shift Pedal Removal .................... 9-22 Shift Pedal Installation ................. 9-22 External Shift Mechanism Removal .................................... 9-23 External Shift Mechanism Installation ................................. 9-24 External Shift Mechanism Inspection.................................. 9-24 Transmission Shaft Removal ....... 9-25 Transmission Shaft Installation .... 9-25 Transmission Shaft Disassembly. 9-25 Transmission Shaft Assembly...... 9-26 Shift Drum and Fork Removal...... 9-28 Shift Drum and Fork Installation... 9-29 Shift Drum Disassembly............... 9-29 Shift Drum Assembly ................... 9-29 Shift Fork Bending ....................... 9-29 Shift Fork/Gear Groove Wear ...... 9-30 Shift Fork Guide Pin/Drum Groove Wear............................. 9-30 Gear Dog and Gear Dog Hole Damage..................................... 9-30 9
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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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Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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