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

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Not For Resale www.SmallEngineDiscount.com 16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one. Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resistance as shown. [A] Terminal Bolt and Positive Brush [B] Brush Plate and Negative Brush Special Tool - Hand Tester: 57001–1394 If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assembly and/or the brush holder assembly. Brush Plate and Terminal Bolt Inspection • Using the highest hand tester range, measure the resistance as shown. [A] Terminal Bolt and Brush Plate [B] Terminal Bolt and Right–hand End Cover Special Tool - Hand Tester: 57001–1394 If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short. Replace the brush holder assembly and the terminal bolt assembly. Starter Relay Inspection • Remove the battery negative (–) cable from the battery negative (–) terminal (see Battery Removal). Remove the right side cover. • Pull out the starter relay. Disconnect the connector [A] • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D]. CAUTION The battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) terminal even when the ignition switch off, so take care not to short the removed cable to chassis ground.
Not For Resale www.SmallEngineDiscount.com ELECTRICAL SYSTEM 16-53 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: Criteria: ×1Ω range When battery is connected → 0 Ω When battery is disconnected →∞Ω Electric Starter Circuit 1. Ignition Switch 2. Joint Connector D 3. Engine Stop Switch 4. Starter Button 5. Junction Box 6. Starter Circuit Relay 7. Ignition Fuse 10A 8. Side Stand Switch 9. Joint Connector A 10. Starter Lockout Switch 11. Neutral Switch 12. Diode (Rectifier) 13. Starter Motor 14. Starter Relay 15. Main Fuse 30A 16. Battery 12 V 8 Ah 17. Joint Connector B 18. Meter Ground 19. Frame Ground
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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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