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

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Not For Resale www.SmallEngineDiscount.com 13-22 SUSPENSION Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal and Bearing Remover: 57001–1058 [A] Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer’s marks face in. • Install the ball bearing so that the manufacturer’s marks faces out. Special Tool - Bearing Driver Set: 57001–1129 [A] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. • Inspect the needle bearings [A] and ball bearing [B] installed in the swingarm, ○The rollers and ball in bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage. If the needle bearing, ball bearing, and sleeve show any sings of abnormal wear, discoloration, or damage. replace them as a set. Swingarm Pivot Lubrication • Refer to Swingarm Pivot Lubrication in the Periodic Maintenance chapter. Chain Slider Inspection • Visually inspect the chain slider [A]. Replace the chain slider if it shows any signs of abnormal wear or damage.
Not For Resale www.SmallEngineDiscount.com Tie-Rod, Rocker Arm SUSPENSION 13-23 Tie-Rod Removal Remove the muffler bodies (see Engine Top End chapter.) Remove the side stand (see Frame chapter.) • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Squeeze the brake lever slowly and hold it with a band [A]. • Remove: Lower Rear Shock Absorber Bolt and Nut [A] Upper and Lower Tie-Rod Bolts and Nuts [B] Tie-Rods [C] Tie-Rod Installation • Apply grease to the inside of the needle bearings and grease seals. • Install the tie-rods so that the marked side faces the bolts and nuts. • Tighten: Torque - Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Rocker Arm Removal • Remove the right side muffler body (see Engine Top End chapter.) • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 Squeeze the brake lever slowly and hold it with a band. • Remove: Lower Rear Shock Absorber Bolt and Nut [A] Lower Tie-Rod Bolt and Nut [B] Rocker Arm Bolt and Nut [C] Rocker Arm [D]
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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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