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

Crankcase Splitting
• Apply liquid gasket [A] to the mating surface of the lower
crankcase half.
Sealant -Kawasaki Bond (Silicone Sealant): 92104–1063
CAUTION
Do not apply liquid gasket around the crankshaft
main bearing inserts, and oil passage holes.
• Fit the lower crankcase to the upper crankcase.
• Apply molybdenum disulfide grease to the seating surface
[A] on the lower crankcase for the M9 bolts [B].
[C] Washer
CRANKSHAFT/TRANSMISSION 9-11
• Tighten the lower crankcase bolts using the following
steps.
○Following the sequence numbers on the lower crankcase
half, tighten the M9 bolts [1 ∼ 6] L= 81 mm (3.19 in.).
Torque - Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 30 ft·lb)
○Tighten the M9 bolts [7 ∼ 10] L= 95 mm (3.74 in.) with
washers.
Torque - Crankcase Bolts (M9): 49 N·m (5.0 kgf·m, 36 ft·lb)
○Tighten the M7 bolts [A].
Torque - Crankcase Bolts (M6): 20 N·m (2.0 kgf·m, 14.5
ft·lb)
[B] Clamp
• Tighten the upper crankcase bolts in the order listed.
Torque - Crankcase Bolts (M8) [A]: 27 N·m (2.8 kgf·m, 20
ft·lb)
Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 14.5
ft·lb)
[G] Clamp
[B] L= 85 mm (3.35 in.)
[C] L= 50 mm (1.97 in.)
Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 104 in·lb)
[D] L= 60 mm (2.36 in.)
[E] L= 40 mm (1.57 in.)
[F] L= 90 mm (3.54 in.)
• After tightening all crankcase bolts, check the following
items.
○Crankshaft and transmission shafts turn freely.
○While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
○When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions. Not For Resale
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