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

More documents

Recommendations

Info

Not For Resale www.SmallEngineDiscount.com 9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: 57001–135 Kawasaki Bond (Silicone Sealant): 56019–120 Bearing Puller Adapter: 57001–317 Kawasaki Bond (Silicone Sealant): 92104–1063
Not For Resale www.SmallEngineDiscount.com Crankcase Splitting CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter) External Shift Mechanism (see External Shift Mechanism Removal) Starter Motor (see Electrical System chapter) Oil Pump (see Engine Lubrication System chapter) Alternator Rotor (see Electrical System chapter) Oil Filter (see Periodic Maintenance chapter) Oil Cooler (see Engine Lubrication System chapter) If the crankshaft is to be removed, remove the pistons (see Engine Top End chapter). • Remove the upper crankcase bolts. ○First loosen the M6 bolts. M6 Bolts [A] M7 Bolts [B] M8 Bolts [C] • Remove the oil pan, oil pressure relief valve, oil screen and oil pipes (see Engine Lubrication System chapter). • Remove the lower crankcase bolts and clamp. ○First loosen the M7 bolts. M7 Bolts [A] M9 Bolts [B] • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high-flash point solvent, clean off the mating surfaces of the crankcases halves and wipe dry. • Using compressed air, blow out the oil passages in the crankcase halves.
Page 1 and 2:
Not For Resale www.SmallEngineDisco
Page 3 and 4:
Page 5 and 6:
© 2002 Kawasaki Heavy Industries,
Page 7 and 8:
Page 9 and 10:
Page 11 and 12:
Page 13 and 14:
Page 15 and 16:
Page 17 and 18:
Page 19 and 20:
General Specifications GENERAL INFO
Page 21 and 22:
Page 23 and 24:
Page 25 and 26:
Page 27 and 28:
Page 29 and 30:
Page 31 and 32:
Page 33 and 34:
Torque and Locking Agent PERIODIC M
Page 35 and 36:
Torque and Locking Agent PERIODIC M
Page 37 and 38:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
Page 45 and 46:
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Periodic Maintenance Procedures •
Page 53 and 54:
Page 55 and 56:
Page 57 and 58:
Periodic Maintenance Procedures PER
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
FUEL SYSTEM (DFI) 3-1 Fuel System (
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
Page 85 and 86:
Page 87 and 88:
Page 89 and 90:
Page 91 and 92:
Page 93 and 94:
Page 95 and 96:
Page 97 and 98:
FUEL SYSTEM (DFI) 3-21 Troubleshoot
Page 99 and 100:
Page 101 and 102:
DFI System Troubleshooting Guide FU
Page 103 and 104:
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Page 119 and 120:
Inlet Air Pressure Sensor (Service
Page 121 and 122:
Page 123 and 124:
Page 125 and 126:
Page 127 and 128:
Page 129 and 130:
Page 131 and 132:
Page 133 and 134:
For Resale www.SmallEngineDiscount.
Page 135 and 136:
Page 137 and 138:
Page 139 and 140:
Page 141 and 142:
Page 143 and 144:
Subthrottle Valve Actuator (Service
Page 145 and 146:
Page 147 and 148:
Page 149 and 150:
Page 151 and 152:
Page 153 and 154:
Fuel Line • Open the fuel tank ca
Page 155 and 156:
Page 157 and 158:
Page 159 and 160:
Page 161 and 162:
Page 163 and 164:
Page 165 and 166:
Page 167 and 168:
Page 169 and 170:
Page 171 and 172:
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
Page 179 and 180:
Page 181 and 182:
Page 183 and 184:
Page 185 and 186:
Coolant COOLING SYSTEM 4-9 Pressure
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
Page 193 and 194:
Page 195 and 196:
Page 197 and 198:
Page 199 and 200:
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Camshaft, Camshaft Chain ENGINE TOP
Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
Page 221 and 222:
Page 223 and 224:
Page 225 and 226:
Cylinder, Pistons ENGINE TOP END 5-
Page 227 and 228: Not For Resale www.SmallEngineDisco
Page 237 and 238: Clutch Cover CLUTCH 6-7 Clutch Cove
Page 267 and 268: • Install the engine ground cable
Page 277: Not For Resale www.SmallEngineDisco
Page 281 and 282: Crankcase Splitting • Apply liqui
Page 283 and 284: Crankshaft and Connecting Rods •
Page 285 and 286: Crankshaft and Connecting Rods CRAN
Page 295 and 296: Transmission CRANKSHAFT/TRANSMISSIO
Page 329 and 330:
Page 331 and 332:
Page 333 and 334:
Page 335 and 336:
Page 337 and 338:
Page 339 and 340:
Page 341 and 342:
Page 343 and 344:
Page 345 and 346:
Page 347 and 348:
Page 349 and 350:
Page 351 and 352:
Page 353 and 354:
Page 355 and 356:
Page 357 and 358:
Page 359 and 360:
Page 361 and 362:
Page 363 and 364:
Page 365 and 366:
Page 367 and 368:
Page 369 and 370:
Page 371 and 372:
Page 373 and 374:
Page 375 and 376:
Page 377 and 378:
Page 379 and 380:
Page 381 and 382:
Page 383 and 384:
Page 385 and 386:
Page 387 and 388:
Page 389 and 390:
Page 391 and 392:
Page 393 and 394:
Page 395 and 396:
Page 397 and 398:
Page 399 and 400:
Page 401 and 402:
Page 403 and 404:
Page 405 and 406:
Page 407 and 408:
ELECTRICAL SYSTEM 16-1 Electrical S
Page 409 and 410:
Page 411 and 412:
Page 413 and 414:
Page 415 and 416:
Page 417 and 418:
Page 419 and 420:
Page 421 and 422:
Page 423 and 424:
Page 425 and 426:
Page 427 and 428:
Page 429 and 430:
Page 431 and 432:
Page 433 and 434:
Page 435 and 436:
Page 437 and 438:
Page 439 and 440:
Page 441 and 442:
Page 443 and 444:
Page 445 and 446:
Ignition System ELECTRICAL SYSTEM 1
Page 447 and 448:
Page 449 and 450:
Page 451 and 452:
Page 453 and 454:
Page 455 and 456:
Page 457 and 458:
Page 459 and 460:
Page 461 and 462:
Page 463 and 464:
Page 465 and 466:
Page 467 and 468:
For Resale www.SmallEngineDiscount.
Page 469 and 470:
Page 471 and 472:
Page 473 and 474:
Page 475 and 476:
Page 477 and 478:
Meter, Gauge, Indicator Unit ELECTR
Page 479 and 480:
Page 481 and 482:
Page 483 and 484:
Page 485 and 486:
Page 487 and 488:
Page 489 and 490:
Page 491 and 492:
Page 493 and 494:
Page 495 and 496:
Page 497 and 498:
Page 499 and 500:
Page 501 and 502:
Page 503 and 504:
Page 505 and 506:
Page 507 and 508:
Page 509 and 510:
Page 511 and 512:
Page 513 and 514:
Page 515:
MODEL APPLICATION Year Model Beginn
show all

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

Create successful ePaper yourself

Delete template?

Save as template?