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

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Front Fork
• Check the O-ring on the top plug and replace it with a new
one if damaged.
• For the right fork leg, check the distance [C] between the
bottom end [A] of the top plug and rebound damping adjuster
[B] with a pair of vernier caliper.
[C] 20 mm (0.79 in.)
SUSPENSION 13-13
• Holding the top plug [A] with a wrench [B], tighten the
piston rod nut [C] against the top plug.
Torque - Piston Rod Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)
○For the right fork leg, the top plug has the rebound damping
adjuster rod.
Raise the outer tube and screw the top plug into it.
• Install the front fork (see Front Fork Installation).
Front Fork Disassembly
Remove the front fork (see Front Fork Removal).
Hold the fork leg with a vise [A].
Loosen the Allen bolt [B] and tighten it loosely.
• Drain the fork oil (see Fork Oil Change).
• Unscrew the Allen bolt, then take the bolt and gasket out
of the bottom of the inner tube.
• Take the cylinder unit and centring plate out of the inner
tube.
○Do not disassemble the cylinder unit.
Cylinder Unit [A] and Center Ring Plate [C] for Right Fork
Leg
Cylinder Unit [B] and Center Ring Plate [C] for Left Fork
Leg
• Separate the inner tube from the outer tube as follows.
○Slide up the dust seal [A].
○Remove the retaining ring [B] from the outer tube.