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

More documents

Recommendations

Info

Not For Resale www.SmallEngineDiscount.com 15-18 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 Electrical System Parts Location.................................... 16-3 Exploded View................................... 16-4 Specifications .................................... 16-10 Special Tools and Sealant ................. 16-11 Wiring Diagram (U.S.A. and Canada) 16-12 Wiring Diagram (Australia) ................ 16-14 Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)... 16-16 Wiring Diagram (Malaysia) ................ 16-18 Precautions........................................ 16-20 Electrical Wiring................................. 16-22 Wiring Inspection ......................... 16-22 Battery ............................................... 16-23 Battery Removal .......................... 16-23 Battery Installation ....................... 16-23 Electrolyte Filling.......................... 16-23 Initial Charge................................ 16-25 Precautions .................................. 16-26 Interchange.................................. 16-27 Charging Condition Inspection..... 16-27 Refreshing Charge....................... 16-27 Charging System............................... 16-29 Alternator Cover Removal............ 16-29 Alternator Cover Installation......... 16-29 Stator Coil Removal..................... 16-29 Stator Coil Installation .................. 16-30 Alternator Rotor Removal ............ 16-30 Alternator Rotor Installation ......... 16-30 Alternator Inspection .................... 16-32 Regulator/Rectifier Inspection...... 16-33 Charging Voltage Inspection........ 16-35 Ignition System.................................. 16-37 Crankshaft Sensor Removal........ 16-37 Crankshaft Sensor Installation..... 16-38 Crankshaft Sensor Inspection...... 16-38 Crankshaft Sensor Peak Voltage Inspection.................................. 16-39 Timing Rotor Removal ................. 16-39 Timing Rotor Installation .............. 16-39 Camshaft Position Sensor Removal.................................... 16-40 Camshaft Position Sensor Installation................................. 16-40 Camshaft Position Sensor Inspection.................................. 16-40 Table of Contents Camshaft Position Sensor Peak Voltage Inspection..................... 16-41 Stick Coil (Ignition Coil together with Spark Plug Cap) Removal . 16-41 Stick Coil (Ignition Coil together with Spark Plug Cap) Installation ................................. 16-42 Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection 16-43 Stick Coil Primary Peak Voltage .. 16-43 Spark Plug Removal .................... 16-44 Spark Plug Installation ................. 16-44 Spark Plug Cleaning and Inspection.................................. 16-44 Spark Plug Gap Inspection .......... 16-44 Interlock Operation Inspection ..... 16-45 IC Igniter Inspection ..................... 16-46 Electric Starter System...................... 16-49 Starter Motor Removal................. 16-49 Starter Motor Installation.............. 16-49 Starter Motor Disassembly........... 16-49 Starter Motor Assembly ............... 16-50 Brush Inspection .......................... 16-51 Commutator Cleaning and Inspection.................................. 16-51 Armature Inspection..................... 16-51 Brush Lead Inspection ................. 16-52 Brush Plate and Terminal Bolt Inspection.................................. 16-52 Starter Relay Inspection............... 16-52 Lighting System................................. 16-54 Headlight Beam Horizontal Adjustment ................................ 16-54 Headlight Beam Vertical Adjustment ................................ 16-54 Headlight Bulb Replacement ....... 16-55 Headlight Removal/Installation .... 16-56 City Light Bulb Replacement (European Model) ..................... 16-56 Turn Signal Light Bulb Replacement............................. 16-59 Turn Signal Relay Inspection ....... 16-61 Tail/Brake Light (LED) Removal... 16-61 Tail/Brake Light (LED) Installation 16-62 Radiator Fan System......................... 16-63 Fan System Circuit Inspection ..... 16-63 Not For Resale www.SmallEngineDiscount.com 16
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:
Page 319 and 320:
Page 321 and 322:
Page 323 and 324:
Page 325 and 326:
Page 327 and 328:
Page 329 and 330:
Page 331 and 332:
Page 333 and 334:
Page 335 and 336:
Page 337 and 338:
Page 339 and 340:
Page 341 and 342:
Page 343 and 344:
Page 345 and 346:
Page 347 and 348:
Page 349 and 350:
Page 351 and 352:
Page 353 and 354:
Page 355 and 356: Not For Resale www.SmallEngineDisco
Page 405: Not For Resale www.SmallEngineDisco
Page 445 and 446: Ignition System ELECTRICAL SYSTEM 1
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 ...

Create successful ePaper yourself

Delete template?

Save as template?