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

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10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals Circlips • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Please blocks under the wheel so that the disc does not touch the ground. Special Tools - Bearing Remover Shaft, 13: 57001–1377 [B] Bearing Remover Head, 25 × 28: 57001–1346 [C] Hub Bearing Installation • Before installing the wheel bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. • Replace the bearings with new ones. NOTE ○Install the bearings so that the marked side faces out. • Install the bearings by using the bearing driver set which does not contact the bearing inner race. • Press in each bearing [A] right until they are bottomed. Special Tool - Bearing Driver Set: 57001–1129 [B] Replace the circlips with new ones. Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface flush [B] with the end of the hole. ○Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001–1129 [C] Hub Bearing Inspection Since the hub bearings are made to extremely close tolerances, the clearance cannot normally be measured. NOTE ○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones. • Turn each bearing in the hub back and forth [A] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing. Not For Resale www.SmallEngineDiscount.com
Not For Resale www.SmallEngineDiscount.com FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................................................................................................................ 11-2 Specifications ......................................................................................................................... 11-4 Special Tools .......................................................................................................................... 11-5 Drive Chain............................................................................................................................. 11-6 Drive Chain Slack Inspection ............................................................................................ 11-6 Drive Chain Slack Adjustment .......................................................................................... 11-6 Wheel Alignment Inspection/Adjustment .......................................................................... 11-6 Drive Chain Wear Inspection ............................................................................................ 11-6 Drive Chain Lubrication..................................................................................................... 11-6 Drive Chain Removal........................................................................................................ 11-6 Drive Chain Installation ..................................................................................................... 11-6 Drive Chain Replacement ................................................................................................. 11-6 Sprocket, Coupling ................................................................................................................. 11-10 Engine Sprocket Removal ................................................................................................ 11-10 Engine Sprocket Installation ............................................................................................. 11-10 Rear Sprocket Removal.................................................................................................... 11-11 Rear Sprocket Installation................................................................................................. 11-11 Coupling Bearing Removal ............................................................................................... 11-11 Coupling Bearing Installation ............................................................................................ 11-11 Coupling Installation.......................................................................................................... 11-12 Coupling Bearing Inspection............................................................................................. 11-12 Coupling Bearing Lubrication............................................................................................ 11-12 Coupling Damper Inspection............................................................................................. 11-12 Sprocket Wear Inspection................................................................................................. 11-13 Rear Sprocket Warp Inspection ........................................................................................ 11-13 11
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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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