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

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Not For Resale www.SmallEngineDiscount.com 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE ○The mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks 36.000 ∼ 36.008 mm (1.4173 ∼ 1.4176 in.) None 36.009 ∼ 36.016 mm (1.4177 ∼ 1.4179 in.) • Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding. Size Color [B] Crankcase Main Crankshaft Main Bearing Insert* Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos. 1 Brown 92028–1868 3, 5 92028–1829 1, 2, 4 None 1 Black 92028–1867 3, 5 None 92028–1828 1, 2, 4 None None Blue 92028–1866 3, 5 92028–1827 1, 2, 4 *The bearing inserts for Nos. 1, 2 and 4 journals have an oil groove, respectively. • Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage.
Not For Resale www.SmallEngineDiscount.com Starter Motor Clutch CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its flange [B] fits in the holder recess [C]. • Apply a non-permanent locking agent to the threads of the starter motor clutch bolts, and tighten them. Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter) Starter Idle Gear • Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C]. If the clutch does not operate as it should or if it makes noise, go to the next step. • Remove and disassemble the starter motor clutch, and visually inspect the clutch parts. If there is any worn or damaged part, replace it. NOTE ○Examine the starter motor clutch gear as well. Replace it if it is worn or damaged.
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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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Cylinder, Pistons ENGINE TOP END 5-
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Clutch Cover CLUTCH 6-7 Clutch Cove
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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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