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

More documents

Recommendations

Info

Not For Resale www.SmallEngineDiscount.com 13-16 SUSPENSION Front Fork Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: 282.7 mm (11.13 in.) Service Limit: 277 mm (10.91 in.)
Not For Resale www.SmallEngineDiscount.com Rear Shock Absorber SUSPENSION 13-17 Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position. ○The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 3/4 turns out of the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping Position Force Setting Load Road Speed 3 ∼ 4 Weak Soft Light Good Low ↑ ↑ ↑ ↑ ↑ ↑ STD 1 ↓ ↓ ↓ ↓ ↓ ↓ 0 Strong Hard Heavy Bad High Spring Preload Adjustment • Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal). • Loosen the locknut and turn out the adjusting nut to free the spring. Special Tools - Hook Wrenches: 57001–1539 • Measure the spring free length. Spring Free Length Standard: 198.2 mm (7.80 in.) • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. [C] Spring Length Spring Preload Setting Standard: Spring length 188.4 mm (7.42 in.) Usable Range: Spring length 193.4 ∼ 183.4 mm (7.61 ∼ 7.22 in.) (weaker to stronger) ○The standard adjusting nut setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is 188.4 mm (7.42 in.) spring length. If the spring action feels too soft or too stiff, adjust it. • Remove: Right Side Muffler Body (see Engine Top End chapter.) Chain Cover (see Drive Chain Removal in the Final Drive chapter.) Mud Guard (see Frame chapter.)
Page 1 and 2:
Not For Resale www.SmallEngineDisco
Page 3 and 4:
Page 5 and 6:
© 2002 Kawasaki Heavy Industries,
Page 7 and 8:
Page 9 and 10:
Page 11 and 12:
Page 13 and 14:
Page 15 and 16:
Page 17 and 18:
Page 19 and 20:
General Specifications GENERAL INFO
Page 21 and 22:
Page 23 and 24:
Page 25 and 26:
Page 27 and 28:
Page 29 and 30:
Page 31 and 32:
Page 33 and 34:
Torque and Locking Agent PERIODIC M
Page 35 and 36:
Torque and Locking Agent PERIODIC M
Page 37 and 38:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
Page 45 and 46:
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Periodic Maintenance Procedures •
Page 53 and 54:
Page 55 and 56:
Page 57 and 58:
Periodic Maintenance Procedures PER
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
FUEL SYSTEM (DFI) 3-1 Fuel System (
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
Page 85 and 86:
Page 87 and 88:
Page 89 and 90:
Page 91 and 92:
Page 93 and 94:
Page 95 and 96:
Page 97 and 98:
FUEL SYSTEM (DFI) 3-21 Troubleshoot
Page 99 and 100:
Page 101 and 102:
DFI System Troubleshooting Guide FU
Page 103 and 104:
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Page 119 and 120:
Inlet Air Pressure Sensor (Service
Page 121 and 122:
Page 123 and 124:
Page 125 and 126:
Page 127 and 128:
Page 129 and 130:
Page 131 and 132:
Page 133 and 134:
For Resale www.SmallEngineDiscount.
Page 135 and 136:
Page 137 and 138:
Page 139 and 140:
Page 141 and 142:
Page 143 and 144:
Subthrottle Valve Actuator (Service
Page 145 and 146:
Page 147 and 148:
Page 149 and 150:
Page 151 and 152:
Page 153 and 154:
Fuel Line • Open the fuel tank ca
Page 155 and 156:
Page 157 and 158:
Page 159 and 160:
Page 161 and 162:
Page 163 and 164:
Page 165 and 166:
Page 167 and 168:
Page 169 and 170:
Page 171 and 172:
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
Page 179 and 180:
Page 181 and 182:
Page 183 and 184:
Page 185 and 186:
Coolant COOLING SYSTEM 4-9 Pressure
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
Page 193 and 194:
Page 195 and 196:
Page 197 and 198:
Page 199 and 200:
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Camshaft, Camshaft Chain ENGINE TOP
Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
Page 221 and 222:
Page 223 and 224:
Page 225 and 226:
Cylinder, Pistons ENGINE TOP END 5-
Page 227 and 228:
Page 229 and 230:
Page 231 and 232:
Page 233 and 234:
Page 235 and 236:
Page 237 and 238:
Clutch Cover CLUTCH 6-7 Clutch Cove
Page 239 and 240:
Page 241 and 242:
Page 243 and 244:
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
Page 253 and 254:
Page 255 and 256:
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
Page 263 and 264:
Page 265 and 266:
Page 267 and 268:
• Install the engine ground cable
Page 269 and 270:
Page 271 and 272:
Page 273 and 274:
Page 275 and 276:
Page 277 and 278:
Page 279 and 280:
Page 281 and 282:
Crankcase Splitting • Apply liqui
Page 283 and 284:
Crankshaft and Connecting Rods •
Page 285 and 286:
Crankshaft and Connecting Rods CRAN
Page 287 and 288:
Page 289 and 290:
Page 291 and 292:
Page 293 and 294:
Page 295 and 296:
Transmission CRANKSHAFT/TRANSMISSIO
Page 297 and 298:
Page 299 and 300:
Page 301 and 302:
Page 303 and 304:
Page 305 and 306:
Page 307 and 308:
Page 309 and 310:
Page 311 and 312:
Page 313 and 314:
Page 315 and 316:
Page 317 and 318: Not For Resale www.SmallEngineDisco
Page 367: Not For Resale www.SmallEngineDisco
Page 407 and 408: ELECTRICAL SYSTEM 16-1 Electrical S
Page 419 and 420:
Page 421 and 422:
Page 423 and 424:
Page 425 and 426:
Page 427 and 428:
Page 429 and 430:
Page 431 and 432:
Page 433 and 434:
Page 435 and 436:
Page 437 and 438:
Page 439 and 440:
Page 441 and 442:
Page 443 and 444:
Page 445 and 446:
Ignition System ELECTRICAL SYSTEM 1
Page 447 and 448:
Page 449 and 450:
Page 451 and 452:
Page 453 and 454:
Page 455 and 456:
Page 457 and 458:
Page 459 and 460:
Page 461 and 462:
Page 463 and 464:
Page 465 and 466:
Page 467 and 468:
For Resale www.SmallEngineDiscount.
Page 469 and 470:
Page 471 and 472:
Page 473 and 474:
Page 475 and 476:
Page 477 and 478:
Meter, Gauge, Indicator Unit ELECTR
Page 479 and 480:
Page 481 and 482:
Page 483 and 484:
Page 485 and 486:
Page 487 and 488:
Page 489 and 490:
Page 491 and 492:
Page 493 and 494:
Page 495 and 496:
Page 497 and 498:
Page 499 and 500:
Page 501 and 502:
Page 503 and 504:
Page 505 and 506:
Page 507 and 508:
Page 509 and 510:
Page 511 and 512:
Page 513 and 514:
Page 515:
MODEL APPLICATION Year Model Beginn
show all

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

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?