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

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Not For Resale www.SmallEngineDiscount.com 14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] • Remove the handlebar holders [F] and then pull out the handlebar [G]. Remove the cotter pins [A]. • Unscrew the mounting nuts [B] and remove the handlebar lower clamps [C]. Handlebar Installation • Install the handlebar lower clamps [A], noting the letters “L” [B] and “R” [C]. • Tighten: Torque - Handlebar Lower Clamp Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) • Align the punch mark [A] on the handlebar and the corner edge [B] on the lower clamp. • Tighten the front clamp bolts first, and then the rear clamp bolts. There will be a gap [A] at the rear part of the clamp after tightening. Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Not For Resale www.SmallEngineDiscount.com Handlebar STEERING 14-11 Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to remove the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of spanners. Disassembly of this area is Not Available. Non-permanent locking agent [D] is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay [C]. Rear View Mirrors Installation • Screw the mounting area of the right rear view mirror into the holder all the way, and tighten the lower hexagonal area for tightening securely. [A] Lower Hexagonal Area for Tightening [B] Upper Hexagonal Area (Adapter) [C] Rear View Mirror (Right)
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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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