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

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Not For Resale www.SmallEngineDiscount.com 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque N·m kgf·m ft·lb Remarks Handlebar lower clamp nuts 34 3.5 25 Handlebar switch housing screws 3.4 0.35 30 in·lb Frame: Footpeg holder bolts 34 3.5 25 Muffler mounting bolts 29 3.0 22 Side stand bolt 44 4.5 33 Side stand switch bolt 8.8 0.9 78 in·lb Windshield screws 0.35 ∼ 0.50 0.035 ∼ 3 ∼ 4in·lb 0.050 Front fender bolts 3.9 0.4 34.7 in·lb L Electrical System: Spark plugs 13 1.3 115 in·lb Alternator rotor bolt 110 11 81 Stator coil bolts 11 1.1 95 in·lb Alternator lead holding plate bolt 11 1.1 95 in·lb L Engine ground cable terminal bolt 9.8 1.0 87 in·lb Alternator cover bolts 11 1.1 95 in·lb Crankshaft sensor cover bolts 11 1.1 95 in·lb Crankshaft sensor bolts 5.9 0.6 53 in·lb Camshaft position sensor bolt 12 1.2 104 in·lb L Timing rotor bolt 39 4.0 29 Starter motor mounting bolts 11 1.1 95 in·lb Switch housing screws 3.4 0.35 30 in·lb Radiator fan switch 18 1.8 13 Water temperature sensor 25 2.5 18 SS Oil pressure switch 15 1.5 11 SS Oil pressure switch terminal bolt 1.5 0.15 13 in·lb G Neutral switch 15 1.5 11 Speed sensor bolt 6.9 0.7 62 in·lb Fuel level sensor bolts 6.9 0.7 62 in·lb Front brake light switch screw 1.2 0.12 11 in·lb Meter mounting screws 1.2 0.12 11 in·lb Tail/brake light mounting screws 1.2 0.12 11 in·lb License plate light mounting screws 1.2 0.12 11 in·lb Headlight mounting bolts 5.9 0.6 53 in·lb Starter lockout switch screw - - - L Starter motor clutch bolts 12 1.2 104 in·lb L Starter relay cable terminal bolts 3.9 0.4 35 in·lb L Regulator/rectifier bolts 6.9 0.7 62 in·lb Regulator/rectifier bracket bolts 6.9 0.7 62 in·lb Speed sensor cover bolts 6.9 0.7 62 in·lb L
Not For Resale www.SmallEngineDiscount.com Specifications PERIODIC MAINTENANCE 2-9 Item Standard Service Limit Fuel System: Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Idle speed 1 100 ± 50 r/min (rpm) Bypass screws (turn out) 2 ± 1/4 (for reference) ––– Engine vacuum 32.7 ± 1.333 kPa (245 ± 10 mm Hg) Air cleaner element Paper filter Cooling System: Coolant: Type (recommended) Permanent type of antifreeze Color Green Mixed ratio Soft water 50%, Coolant 50% Freezing point – 35°C (– 31°F) Total amount 2.9 L (3.1 US qt) Engine Top End: Valve clearance Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) Clutch: Clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Engine Lubrication System: Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 3.1 L (3.3 US qt, when filter is not removed) 3.3 L (3.5 US qt, when filter is removed) 3.8 L (4.0 US qt, when engine is completely disassembled and dry) Level Between upper and lower level lines (after idling or running) Tires: Tread depth: Front BRIDGESTONE 3.4 mm (0.13 in.) 1 mm (0.04 in.) 1.6 mm (0.063 in.) (DE, AT, CH) Rear BRIDGESTONE 5.8 mm (0.23 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 km/h (80 mph): 3 mm (0.12 in.)
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Page 19 and 20: General Specifications GENERAL INFO
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FUEL SYSTEM (DFI) 3-21 Troubleshoot
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DFI System Troubleshooting Guide FU
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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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