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

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2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Adjust the steering.
Special Tool - Steering Stem Nut Wrench: 57001–1100 [B]
If the steering is too tight, loosen the stem nut [A] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
• Install the claw washer [A] so that its bent side [B] faces
upward, and engage the bent claws with the grooves of
stem locknut [C].
• Hand tighten the stem locknut until it touches the claw
washer.
• Tighten the stem locknut clockwise until the claws are
aligned with the grooves (ranging from 2nd to 4th) of stem
nut [D], and bend the 2 claws downward [E].
• Tighten:
Torque - Steering Stem Head Bolt:
108 N·m (11 kgf·m, 80 ft·lb)
Front Fork Clamp Bolts (Upper):
8.8 N·m (0.90 kgf·m, 78 in·lb)
13 N·m (1.3 kgf·m, 113 in·lb) ZR1000–A2 ∼
• Check the steering again.
If the steering is still too tight or too loose, repeat the adjustment.
Stem Bearing Lubrication
Remove the steering stem.
• Using a high flash-point solvent, wash the upper and
lower ball bearings in the cages, and wipe the upper and
lower outer races, which are press-fitted into the frame
head pipe, clean off grease and dirt.
• Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear or
damage.
• Pack the upper and lower ball bearings [A] in the cages
with grease, and apply a light coat of grease to the upper
and lower outer races.
• Install the steering stem, and adjust the steering.
Electrical System
Spark Plug Cleaning and Inspection
• Remove:
Fuel Tank (see Fuel System (DFI) chapter)