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

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Not For Resale www.SmallEngineDiscount.com 3-2 FUEL SYSTEM (DFI) ECU Installation ........................... 3-71 ECU Power Supply Inspection..... 3-72 DFI Power Source ............................. 3-74 ECU Fuse Removal ..................... 3-74 ECU Fuse Installation .................. 3-74 ECU Fuse Inspection ................... 3-74 ECU Main Relay Removal ........... 3-74 ECU Main Relay Inspection ......... 3-74 Fuel Line............................................ 3-75 Fuel Pressure Inspection ............. 3-75 Fuel Flow Rate Inspection ........... 3-76 Fuel Pump ......................................... 3-78 Fuel Pump Removal .................... 3-78 Fuel Pump Installation ................. 3-78 Operation Inspection.................... 3-79 Operating Voltage Inspection....... 3-79 Pressure Regulator Removal....... 3-80 Pump Screen, Fuel Filter Cleaning.................................... 3-80 Fuel Pump Relay Removal .......... 3-81 Fuel Pump Relay Inspection........ 3-81 Fuel Injectors..................................... 3-82 Removal/Installation..................... 3-82 Audible Inspection........................ 3-82 Power Source Voltage Inspection 3-82 Output Voltage Inspection............ 3-83 Injector Signal Test....................... 3-84 Injector Resistance Inspection ..... 3-85 Injector Unit Test .......................... 3-85 Injector Fuel Line Inspection........ 3-85 Throttle Grip and Cables ................... 3-88 Throttle Grip Play Inspection/Adjustment............... 3-88 Choke Lever Operation................ 3-88 Choke Lever Play Inspection ....... 3-88 Choke Lever Play Adjustment...... 3-88 Cable Removal/Installation .......... 3-88 Cable Lubrication and Inspection. 3-88 Throttle Body Assy ............................ 3-89 Idle Speed Inspection/Adjustment 3-89 Throttle Bore Cleaning................. 3-89 Engine Vacuum Synchronization Inspection/Adjustment............... 3-89 High Altitude Performance Adjustment ................................ 3-89 Throttle Body Assy Removal........ 3-89 Throttle Body Assy Installation..... 3-91 Throttle Body Assy Disassembly . 3-92 Throttle Body Assy Assembly ...... 3-93 Air Cleaner......................................... 3-94 Element Removal/Installation ...... 3-94 Air Cleaner Oil Draining ............... 3-94 Air Cleaner Housing Removal...... 3-94 Fuel Tank........................................... 3-95 Fuel Tank Removal ...................... 3-95 Fuel Tank Installation ................... 3-97 Fuel Tank and Cap Inspection ..... 3-98 Fuel Tank Cleaning ...................... 3-98 Evaporative Emission Control System............................................ 3-99 Parts Removal/Installation ........... 3-99 Canister Installation ..................... 3-99 Hose Inspection ........................... 3-99 Separator Inspection.................... 3-99 Separator Operation Test............. 3-100
Not For Resale www.SmallEngineDiscount.com Exploded View FUEL SYSTEM (DFI) 3-3 Clifornia Evaporative Emission Control System 1. Canister 2. Separator 3. Right fitting of throttle body #2 4. Right fitting of throttle body #3 5. Canister purge hose (green) 6. Fuel return hose (left, red) 7. Fuel tank breather hose (right, blue) 8. Separator breather hose (blue) 9. Separator vacuum hose (white)
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© 2002 Kawasaki Heavy Industries,
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General Specifications GENERAL INFO
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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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ELECTRICAL SYSTEM 16-1 Electrical S
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Ignition System ELECTRICAL SYSTEM 1
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Meter, Gauge, Indicator Unit ELECTR
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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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