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

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Not For Resale www.SmallEngineDiscount.com 16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage. • Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage Standard: 88 V or more • Repeat the test for the other stick coil. If the reading is less than the specified value, check the following. Stick Coils (see Stick Coil Inspection) Crankshaft Sensor (see Crankshaft Sensor Inspection) If the stick coils, and crankshaft sensor are normal, check the ECU (see Fuel System (DFI) chapter). Spark Plug Removal • Refer to the Electrical System in the Periodic Maintenance chapter. Spark Plug Installation • Refer to the Electrical System in the Periodic Maintenance chapter. Spark Plug Cleaning and Inspection • Refer to the Electrical System in the Periodic Maintenance chapter. Spark Plug Gap Inspection • Refer to the Electrical System in the Periodic Maintenance chapter.
Not For Resale www.SmallEngineDiscount.com Ignition System ELECTRICAL SYSTEM 16-45 Interlock Operation Inspection • Remove: Seats (see Frame chapter) Junction Box (see this chapter) ○Do not disconnect the connectors. 1st Check • Measure the terminal voltage of the G/BK lead in the junction box connector [A] in accordance with the following procedure. ○Insert the needle adapter [B] in the Green/Black lead terminal. ○Set the tester [C] to the 25 V DC range, connect it to the needle adapter and frame ground [D]. Connection: Tester (+) Terminal → G/BK Lead Terminal Tester (–) Terminal → Frame Ground Condition: Transmission Gear → 1st Position Clutch Lever → Release or Pulled In Side Stand → Down Special Tool - Needle Adapter Set: 57001–1457 ○Turn the ignition switch on. ○Read the voltage. Interlock Operation Voltage Standard: 4Vormore If the voltage is lower than the standard, inspect the side stand switch, starter lockout switch, and junction box. And their parts are normality, replace the ECU. If the voltage is standard, push the starter button to check as follows. ○If the starter motor does not turn, the ECU is good, and check the starter system circuit. ○If the starter motor turned, ECU is defective. Replace the ECU. 2nd Check Raise the rear wheel off the ground with a stand. • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Side Stand → Up • Set the side stand on the ground, then the engine will stop. If whichever may not be stopped, inspect the starter lockout switch, side stand switch and junction box. If their parts are normality, replace the ECU.
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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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MODEL APPLICATION Year Model Beginn
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