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

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Not For Resale www.SmallEngineDiscount.com 9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) Service Limit: 5.8 mm (0.228 in.) If the gear groove is worn over the service limit, the gear must be replaced. Gear Groove Width Standard: 6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.) Service Limit: 6.25 mm (0.246 in.) Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.) Service Limit: 6.8 mm (0.268 in.) If any shift drum groove is worn over the service limit, the drum must be replaced. Shift Drum Groove Width Standard: 7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.) Service Limit: 7.3 mm (0.287 in.) Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
Not For Resale www.SmallEngineDiscount.com WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................................................................................................................ 10-2 Specifications ......................................................................................................................... 10-4 Special Tools .......................................................................................................................... 10-5 Wheels (Rims)........................................................................................................................ 10-6 Front Wheel Removal ....................................................................................................... 10-6 Front Wheel Installation .................................................................................................... 10-6 Rear Wheel Removal........................................................................................................ 10-7 Rear Wheel Installation..................................................................................................... 10-8 Wheel Inspection .............................................................................................................. 10-9 Axle Inspection.................................................................................................................. 10-10 Balance Inspection............................................................................................................ 10-10 Balance Adjustment.......................................................................................................... 10-10 Balance Weight Removal.................................................................................................. 10-10 Balance Weight Installation............................................................................................... 10-11 Tires........................................................................................................................................ 10-13 Air Pressure Inspection/Adjustment.................................................................................. 10-13 Tire Inspection .................................................................................................................. 10-13 Tire Removal..................................................................................................................... 10-13 Tire Installation.................................................................................................................. 10-13 Tire Repair ........................................................................................................................ 10-15 Hub Bearing............................................................................................................................ 10-16 Hub Bearing Removal....................................................................................................... 10-16 Hub Bearing Installation.................................................................................................... 10-16 Hub Bearing Inspection..................................................................................................... 10-16 10
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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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