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

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Not For Resale www.SmallEngineDiscount.com 12-20 BRAKES Brake Disc Brake Disc Removal Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out. • Apply a non-permanent locking agent to the threads of the front and rear brake disc mounting bolts [B]. • Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Disc Wear • Measure the thickness of each disc [A] at the point where it has worn the most. If the disk has worn past the service limit, replace it. [B] Measuring Area Front Disc Thickness Standard: 4.8 ∼ 5.1 mm (0.19 ∼ 0.20 in.) Service Limit: 4.5 mm (0.18 in.) Rear Disc Thickness Standard: 4.8 ∼ 5.1 mm (0.19 ∼ 0.20 in.) Service Limit: 4.5 mm (0.18 in.) Brake Disc Warp • Jack up the motorcycle so that the wheel is off the ground (see Wheels/Tires chapter). Special Tool - Jack: 57001–1238 ○For front disc inspection, turn the handlebar fully to one side. • Set up a dial gauge against the disc [A] as shown and measure disc runout, while turning [B] the wheel by hand. If runout exceeds the service limit, replace the disc. Disc Runout Standard: Service Limit: Special Tool - Jack: 57001–1238 Not more than 0.2 mm (0.008 in.) 0.3 mm (0.012 in.)
Not For Resale www.SmallEngineDiscount.com Brake Fluid BRAKES 12-21 Brake Fluid Level Inspection • Refer to the Brake Fluid Level in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brake Line Bleeding in the Periodic Maintenance chapter.
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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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Transmission CRANKSHAFT/TRANSMISSIO
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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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Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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