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

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Not For Resale www.SmallEngineDiscount.com 13-10 SUSPENSION Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). ○Turn the spring preload adjuster [A] counterclockwise until the fully position. • Unscrew the top plug [B] out of the inner tube. • Avoiding the pins [A], set the front fork spring compressor set [B] on the washer [C]. Special Tool - Front Fork Spring Compressor: 57001–1338 • Compress the fork spring. • Holding the piston rod nut [A] with a wrench [B], remove the fork top plug from the piston rod. ○For the right fork leg, remove the fork top plug with the rebound damping adjuster rod [A]. • Remove: Washer [A] Slider [B] Spacer [C]
Not For Resale www.SmallEngineDiscount.com Front Fork Drain the fork oil into a suitable container. • Remove the fork spring [A]. ○Pump the piston rod [B] up and down at least ten times to expel the oil from the fork. SUSPENSION 13-11 • Hold the fork tube upright, press the inner tube and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Viscosity: Amount (Right fork leg) When changing oil: SHOWA SS-8 approx. 385 mL (13.01 US oz) After disassembly and completely dry: 450 ± 2.5 mL (15.21 ± 0.085 US oz) Amount (Left fork leg) When changing oil: approx. 400 mL (13.52 US oz) After disassembly and completely dry: 468 ± 2.5 mL (15.82 ± 0.085 US oz) If necessary, measure the oil level as follows. ○Hold the inner tube vertically in a vise. ○Pump the inner tube several times to expel air bubbles. ○Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil. Special Tool - Fork Piston Rod Puller, M10 ×1.0: 57001–1298 ○Wait until the oil level settles. ○With the fork fully compressed and the piston rod [B] fully pushed in, insert a tape measure or rod into the inner tube, and measure the distance from the top of the inner tube to the oil.
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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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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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