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

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Not For Resale www.SmallEngineDiscount.com 16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Spark Plugs 5. Stick Coils 6. Side Stand Switch 7. Crankshaft Sensor 8. Camshaft Position Sensor 9. Throttle Sensor 10. Neutral Switch 11. Junction Box 12. Ignition Fuse 10A 13. Starter Lockout Switch 14. Diode 15. ECU Main Relay 16. ECU Fuse 15A 17. Vehicle-down Sensor 18. Main Fuse 30A 19. Battery 12 V 8 Ah 20. ECU (Electrical Control Unit) 21. Joint Connector A 22. Joint Connector B 23. Joint Connector C 24. Joint Connector D
Not For Resale www.SmallEngineDiscount.com Electric Starter System ELECTRICAL SYSTEM 16-49 Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. Remove the mounting bolts [A]. • Pull out the starter motor [B]. Slide back the rubber cap [A]. • Remove the starter motor terminal nut [B]. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • When installing the starter motor, clean the starter motor legs [A] and crankcase [B] where the starter motor is grounded. Replace the O-ring [A] with a new one. • Apply a small amount of engine oil to the O–ring. • Tighten: Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Starter Motor Disassembly • Take off the starter motor through bolts [A] and remove both end covers [B] and pull the armature out of the yoke [C].
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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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Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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