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

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Not For Resale www.SmallEngineDiscount.com 12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder. ○The distance from the grip to the lever is minimum at number 5 and maximum at number 1. Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. [B] Footpeg Pedal Position Standard: About 47 mm (1.85 in.) [C] below top of footpeg If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment NOTE ○Usually it is not necessary to adjust the pedal position, but always adjust it when the push rod locknut has been loosened. • Unscrew the bolts [A] and remove the guard bracket [B]. • Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] shown is 70 ± 1 mm (2.76 ± 0.04 in.), the pedal position will be within the standard range. • Tighten: Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m (1.8 kgf·m, 13.0 ft·lb) • Check the brake light switch operation (see Brake Light Timing Inspection/Adjustment in the Periodic Maintenance chapter).
Not For Resale www.SmallEngineDiscount.com Calipers BRAKES 12-9 Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage. • Unscrew the banjo bolt and remove the brake hose [E] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away any brake fluid that spills. NOTE ○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Front Caliper Disassembly). Rear Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away any brake fluid that spills. NOTE ○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Rear Caliper Disassembly).
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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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Crankcase Splitting • Apply liqui
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Crankshaft and Connecting Rods •
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Crankshaft and Connecting Rods CRAN
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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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