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

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Not For Resale www.SmallEngineDiscount.com 12-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • When removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. • There are washers on each side of the brake hose fitting. Replace them with new ones when installing. • When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire and Hose Routing section in General Information chapter. • Tighten: Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Bleed the brake line after installing the brake hose (see Brake Line Bleeding in the Periodic Maintenance chapter). Brake Hose Inspection • Refer to the Brake Hoses and Connection Inspection in the Periodic Maintenance chapter.
Not For Resale www.SmallEngineDiscount.com SUSPENSION 13-1 Suspension Table of Contents Exploded View........................................................................................................................ 13-2 Specifications ......................................................................................................................... 13-6 Special Tools .......................................................................................................................... 13-7 Front Fork............................................................................................................................... 13-8 Rebound Damping Force Adjustment (Only Right Fork Leg) ........................................... 13-8 Spring Preload Adjustment ............................................................................................... 13-8 Front Fork Removal (each fork leg) .................................................................................. 13-9 Front Fork Installation ....................................................................................................... 13-9 Fork Oil Change................................................................................................................ 13-10 Front Fork Disassembly .................................................................................................... 13-13 Front Fork Assembly......................................................................................................... 13-14 Inner Tube, Outer Tube Inspection ................................................................................... 13-15 Dust Seal Inspection ......................................................................................................... 13-15 Spring Tension .................................................................................................................. 13-16 Rear Shock Absorber ............................................................................................................. 13-17 Rebound Damping Force Adjustment............................................................................... 13-17 Spring Preload Adjustment ............................................................................................... 13-17 Rear Shock Absorber Removal ........................................................................................ 13-18 Rear Shock Absorber Installation ..................................................................................... 13-19 Rear Shock Absorber Inspection ...................................................................................... 13-19 Rear Shock Absorber Scrapping ...................................................................................... 13-19 Swingarm................................................................................................................................ 13-20 Swingarm Removal........................................................................................................... 13-20 Swingarm Installation........................................................................................................ 13-21 Swingarm Bearing Removal ............................................................................................. 13-21 Swingarm Bearing Installation .......................................................................................... 13-22 Swingarm Bearing, Sleeve Inspection .............................................................................. 13-22 Swingarm Pivot Lubrication .............................................................................................. 13-22 Chain Slider Inspection ..................................................................................................... 13-22 Tie-Rod, Rocker Arm.............................................................................................................. 13-23 Tie-Rod Removal .............................................................................................................. 13-23 Tie-Rod Installation ........................................................................................................... 13-23 Rocker Arm Removal........................................................................................................ 13-23 Rocker Arm Installation..................................................................................................... 13-24 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection ............................................................. 13-24 Unit-track Linkage Lubrication .......................................................................................... 13-24 13
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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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