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

• Screw the fork piston rod puller onto the end of the rod.
Special Tool - Fork Piston Rod Puller, M10 × 1.0:
57001–1298
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13-12 SUSPENSION
Front Fork
Oil Level (fully compressed, without spring)
Standard:
Rightforkleg 62±2mm(2.44±0.08in.)
Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.)
(from the top of the outer tube)
NOTE
○Fork oil level may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge: 57001–1290 [A]
○With the fork fully compressed and without fork spring,
insert the gauge tube into the inner tube [B] and position
the stopper across the top end [F] of the outer tube [C].
○Set the gauge stopper [D] so that its lower side shows the
oil level distance specified [E].
○Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
If no oil is pumped out, there is insufficient oil in the inner
tube. Pour in enough oil, then pump out the excess oil as
shown above.
Pull the piston rod [A] up above the inner tube top.
• Screw the rod nut [B] on to the piston rod with the chamfered
side down.
○Check that the visible thread length is 12.5 mm (0.492 in.)
[C].
• Install the fork spring [A] with the smaller end [B] facing
upward.
• Install the spacer.
○The right fork leg spacer [A] is shorter than the left fork
leg spacer [B].
• Install the slider [C] and washer.