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

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ELECTRICAL SYSTEM 16-1<br />

Electrical System<br />

Parts Location.................................... 16-3<br />

Exploded View................................... 16-4<br />

Specifications .................................... 16-10<br />

Special Tools and Sealant ................. 16-11<br />

Wiring Diagram (U.S.A. and Canada) 16-12<br />

Wiring Diagram (Australia) ................ 16-14<br />

Wiring Diagram (Other than U.S.A.,<br />

Canada, Australia, and Malaysia)... 16-16<br />

Wiring Diagram (Malaysia) ................ 16-18<br />

Precautions........................................ 16-20<br />

Electrical Wiring................................. 16-22<br />

Wiring Inspection ......................... 16-22<br />

Battery ............................................... 16-23<br />

Battery Removal .......................... 16-23<br />

Battery Installation ....................... 16-23<br />

Electrolyte Filling.......................... 16-23<br />

Initial Charge................................ 16-25<br />

Precautions .................................. 16-26<br />

Interchange.................................. 16-27<br />

Charging Condition Inspection..... 16-27<br />

Refreshing Charge....................... 16-27<br />

Charging System............................... 16-29<br />

Alternator Cover Removal............ 16-29<br />

Alternator Cover Installation......... 16-29<br />

Stator Coil Removal..................... 16-29<br />

Stator Coil Installation .................. 16-30<br />

Alternator Rotor Removal ............ 16-30<br />

Alternator Rotor Installation ......... 16-30<br />

Alternator Inspection .................... 16-32<br />

Regulator/Rectifier Inspection...... 16-33<br />

Charging Voltage Inspection........ 16-35<br />

Ignition System.................................. 16-37<br />

Crankshaft Sensor Removal........ 16-37<br />

Crankshaft Sensor Installation..... 16-38<br />

Crankshaft Sensor Inspection...... 16-38<br />

Crankshaft Sensor Peak Voltage<br />

Inspection.................................. 16-39<br />

Timing Rotor Removal ................. 16-39<br />

Timing Rotor Installation .............. 16-39<br />

Camshaft Position Sensor<br />

Removal.................................... 16-40<br />

Camshaft Position Sensor<br />

Installation................................. 16-40<br />

Camshaft Position Sensor<br />

Inspection.................................. 16-40<br />

Table of Contents<br />

Camshaft Position Sensor Peak<br />

Voltage Inspection..................... 16-41<br />

Stick Coil (Ignition Coil together<br />

with Spark Plug Cap) Removal . 16-41<br />

Stick Coil (Ignition Coil together<br />

with Spark Plug Cap)<br />

Installation ................................. 16-42<br />

Stick Coil (Ignition Coil together<br />

with Spark Plug Cap) Inspection 16-43<br />

Stick Coil Primary Peak Voltage .. 16-43<br />

Spark Plug Removal .................... 16-44<br />

Spark Plug Installation ................. 16-44<br />

Spark Plug Cleaning and<br />

Inspection.................................. 16-44<br />

Spark Plug Gap Inspection .......... 16-44<br />

Interlock Operation Inspection ..... 16-45<br />

IC Igniter Inspection ..................... 16-46<br />

Electric Starter System...................... 16-49<br />

Starter Motor Removal................. 16-49<br />

Starter Motor Installation.............. 16-49<br />

Starter Motor Disassembly........... 16-49<br />

Starter Motor Assembly ............... 16-50<br />

Brush Inspection .......................... 16-51<br />

Commutator Cleaning and<br />

Inspection.................................. 16-51<br />

Armature Inspection..................... 16-51<br />

Brush Lead Inspection ................. 16-52<br />

Brush Plate and Terminal Bolt<br />

Inspection.................................. 16-52<br />

Starter Relay Inspection............... 16-52<br />

Lighting System................................. 16-54<br />

Headlight Beam Horizontal<br />

Adjustment ................................ 16-54<br />

Headlight Beam Vertical<br />

Adjustment ................................ 16-54<br />

Headlight Bulb Replacement ....... 16-55<br />

Headlight Removal/Installation .... 16-56<br />

City Light Bulb Replacement<br />

(European Model) ..................... 16-56<br />

Turn Signal Light Bulb<br />

Replacement............................. 16-59<br />

Turn Signal Relay Inspection ....... 16-61<br />

Tail/Brake Light (LED) Removal... 16-61<br />

Tail/Brake Light (LED) Installation 16-62<br />

Radiator Fan System......................... 16-63<br />

Fan System Circuit Inspection ..... 16-63<br />

Not For Resale<br />

www.<strong>Small</strong><strong>Engine</strong>Discount.com<br />

16

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