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

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9-28 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 2. 2nd Gear 3. 3rd Gear 4. 4th Gear 5. 5th Gear 6. 6th (Top) Gear 7. Toothed Washer, 31 mm (1.22 in.) 8. Thrust Washer, 30 mm (1.18 in.) 9. Circlip 10. Circlip 11. Bushing 12. Bushing 13. Needle Bearing 14. Needle Bearing 15. Bearing Outer Race 16. Steel Ball 17. Nut 18. Bushing 19. Bushing 20. Circlip 21. Ball Bearing 22. Collar Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts External Shift Mechanism (see External Shift Mechanism Removal) Bolt [A] and Screw [B] Shift Drum Bearing Holder [C] Pull out the shift rods [D], and take off the shift forks. • Pull out the shift drum [E]. Not For Resale www.SmallEngineDiscount.com 23. Washer 24. Toothed Washer 25. Oil Seal 26. Thrust Washer, 31 mm (1.22 in.) 27. Thrust Washer, 33 mm (1.30 in.) 28. Toothed Washer 29. Toothed Washer 30. Toothed Washer, 35 mm (1.38 in.)
Not For Resale www.SmallEngineDiscount.com Transmission CRANKSHAFT/TRANSMISSION 9-29 Shift Drum and Fork Installation • Install the shift rods [A], noting the groove position. The rods are identical. • Position the one with shortest ears [B] on the drive shaft and place the pin in the center groove in the shift drum [C]. ○The two forks [D] on the output shaft are identical. Install the forks as shown. • Apply a non-permanent locking agent to the threads of the shift drum bearing holder bolt and screw, and tighten them. Torque - Shift Drum Bearing Holder Bolt: 13 N·m (1.3 kgf·m, 113 in·lb) Shift Drum Bearing Holder Screw: 5.4 N·m (0.55 kgf·m, 48 in·lb) Shift Drum Disassembly • Remove the shift drum (see Shift Drum and Fork Removal). • While holding the shift drum with a vise, remove the shift drum cam holder bolt. [A] Shift Drum Cam Holder Bolt [B] Dowel Pin Shift Drum Assembly Be sure to install the dowel pin. • Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt, and tighten it. Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A]
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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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