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

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Not For Resale www.SmallEngineDiscount.com
Not For Resale www.SmallEngineDiscount.com BRAKES 12-1 Brakes Table of Contents Exploded View................................... 12-2 Specifications .................................... 12-6 Special Tool ....................................... 12-7 Brake Lever, Brake Pedal.................. 12-8 Brake Lever Position Adjustment. 12-8 Brake Pedal Position Inspection .. 12-8 Brake Pedal Position Adjustment. 12-8 Calipers ............................................. 12-9 Front Caliper Removal................. 12-9 Rear Caliper Removal.................. 12-9 Caliper Installation ....................... 12-10 Front Caliper Disassembly........... 12-10 Front Caliper Assembly................ 12-11 Rear Caliper Disassembly ........... 12-12 Rear Caliper Assembly ................ 12-13 Caliper Fluid Seal Damage .......... 12-13 Caliper Dust Seal/Friction Boot Damage..................................... 12-13 Caliper Piston and Cylinder Damage..................................... 12-14 Caliper Holder Shaft Wear ........... 12-14 Brake Pads........................................ 12-15 Front Brake Pad Removal............ 12-15 Front Brake Pad Installation......... 12-15 Rear Brake Pad Removal ............ 12-15 Rear Brake Pad Installation ......... 12-16 Brake Pad Wear Inspection ......... 12-16 Master Cylinder ................................. 12-17 Front Master Cylinder Removal ... 12-17 Front Master Cylinder Installation 12-17 Rear Master Cylinder Removal.... 12-18 Rear Master Cylinder Installation. 12-18 Front Master Cylinder Disassembly.............................. 12-18 Rear Master Cylinder Disassembly.............................. 12-19 Master Cylinder Assembly ........... 12-19 Master Cylinder Inspection (Visual Inspection)................................. 12-19 Brake Disc ......................................... 12-20 Brake Disc Removal .................... 12-20 Brake Disc Installation ................. 12-20 Brake Disc Wear .......................... 12-20 Brake Disc Warp .......................... 12-20 Brake Fluid ........................................ 12-21 Brake Fluid Level Inspection........ 12-21 Brake Fluid Change ..................... 12-21 Brake Line Bleeding..................... 12-21 Brake Hose........................................ 12-22 Brake Hose Removal/Installation. 12-22 Brake Hose Inspection................. 12-22 12
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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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• Install the engine ground cable
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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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