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

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Not For Resale www.SmallEngineDiscount.com 14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Front Wheel (see Wheels/Tires chapter.) Handlebar (see Handlebar Removal.) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and Washer Steering Stem Head • Remove the brake hose clamp bolt [A] and take the hose [B] off the steering stem [C]. • Remove the front fork (see Suspension chapter). Bend the claw washer tabs [A]. • Pushing up the stem base, and remove the steering stem locknut [B] and claw washer [C]. Stem Cap [D] • Remove the steering stem nut [A]. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] Remove the stem cap. • Remove the upper stem bearing inner race.
Not For Resale www.SmallEngineDiscount.com Steering Stem • To remove the bearing outer races [C] pressed into the head pipe [B], insert a bar [A] into the recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE ○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones. STEERING 14-7 • Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into the head pipe at the same time. Special Tools - Bearing Driver Set: 57001–1129 [A] Replace the bearing inner races with new ones. • Drive the lower ball bearing inner race applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver: 57001–1344 [A] Steering Stem Bearing Driver Adapter: 57001–1345 [B]
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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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