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

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Not For Resale www.SmallEngineDiscount.com 3-14 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: 57001–125 Fuel Pressure Gauge Adapter: 57001–1417 Carburetor Drain Plug Wrench, Hex 3: 57001–1269 Needle Adapter Set: 57001–1457 Fork Oil Level Gauge: 57001–1290 Throttle Sensor Setting Adapter: 57001–1538 Hand Tester: 57001–1394 Sensor Harness Adapter: 57001–1561 Throttle Sensor Setting Adapter: 57001–1400 Kawasaki Bond (Silicone Sealant): 56019–120
Not For Resale www.SmallEngineDiscount.com DFI Servicing Precautions FUEL SYSTEM (DFI) 3-15 There are a number of important precautions that should be followed servicing the DFI system. ○This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU. ○To prevent damage to the DFI parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running. ○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. ○When charging, remove the battery from the motorcycle. This is to prevent ECU damage by excessive voltage. ○Do not turn the ignition switch ON while any of the DFI electrical connectors are disconnected. The ECU memorizes service codes. ○Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring. Never water a vehicle with connectors unplugged because seals don’t work and terminals could corrode. ○If a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU. ○When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose. ○Do not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. ○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. ○When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. ○To prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals. ○Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. ○Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. ○When disconnecting the vehicle-down sensor connector, raise the lock of the connector. Push the lock of the other connectors.
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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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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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