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

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Not For Resale www.SmallEngineDiscount.com 9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Muffler Mounting Bolt [B] Footpeg Bracket [C] • Remove the bolt [A], footpeg [B], and shift pedal [C]. Shift Pedal Installation Apply grease to the oil seal lip. • Press the oil seals [A] in the shift pedal housing [B] so that the oil seal surfaces are flush with the housing end [C] as shown. • Apply grease to the sliding surfaces [A] on the footpeg holder [B]. • Apply a non-permanent locking agent to the shift pedal mounting bolt [C]. • Tighten: Torque - Shift Pedal Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) [D] Footpeg Bracket [E] Shift Pedal [F] Oil Seals
Not For Resale www.SmallEngineDiscount.com Transmission Install the footpeg bracket [A]. • Apply a non-permanent locking agent to the footpeg bracket bolts [B]. • Tighten: Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Mounting Bolt and Nut [C]: 29 N·m (3.0 kgf·m, 22 ft·lb) CRANKSHAFT/TRANSMISSION 9-23 • Install the shift lever [A], aligning the mark (previously marked). • TIghten: Torque - Shift Lever Bolt: 6.9 N·m (0.7 kgf·m, 61 in·lb) • Install the shift pedal [B] as shown. [C] Right Angle (90°) ○To adjust the pedal position, loosen the front locknut [D] (left-hand threads) and rear locknut [E] and then turn the tie-rod [F]. ○Tighten: Torque - Tie-rod Locknuts: 6.9 N·m (0.7 kgf·m, 61 in·lb) External Shift Mechanism Removal • Remove: Engine Oil (drain, see Engine Lubrication System chapter) Shift Pedal (see Shift Pedal Removal) Clutch (see Clutch chapter) Oil Pipe Holder Bolts [A] Oil Pipe Holders [B], Oil Pipe [C] and O-ring • Remove the shift shaft assembly [A] while pulling the shift mechanism arm [B] to the direction of the arrow.
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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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