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Kawasaki Manuals
Motorcycle
Z1000
Service manual
Kawasaki Z1000 Service Manual Page 389
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Go
Page 1
Page 2
Page 3 - GENERAL INFORMATION
Page 4
Page 5
Page 6
Page 7 - Emission control information
Page 8
Page 9 - How to use this manual
Page 10
Page 11
Page 12 - Before Servicing
Page 13
Page 14
Page 15
Page 16
Page 17 - Model Identification
Page 18
Page 19 - General Specifications
Page 20
Page 21
Page 22 - Unit Conversion Table
Page 23 - Table Of Contents
Page 24
Page 25 - Periodic Maintenance Chart
Page 26
Page 27 - Torque and Locking Agent
Page 28
Page 29
Page 30
Page 31
Page 32
Page 33 - Specifications
Page 34
Page 35 - Special Tools
Page 36 - Periodic Maintenance Procedures
Page 37 - Idle Speed Inspection
Page 38 - Engine Vacuum Synchronization Inspection
Page 39
Page 40
Page 41 - Fuel System
Page 42 - Fuel Hose Replacement
Page 43
Page 44 - Evaporative Emission Control System Insp...
Page 45 - Cooling System
Page 46
Page 47
Page 48 - Water Hose and O-ring Replacement
Page 49 - Engine Top End
Page 50 - Valve Clearance Adjustment
Page 51
Page 52
Page 53
Page 54 - Air Suction System Damage Inspection
Page 55 - Clutch
Page 56 - Engine Lubrication System
Page 57 - Oil Filter Replacement
Page 58 - Wheel Bearing Damage Inspection
Page 59 - Final Drive
Page 60 - Drive Chain Slack Inspection
Page 61 - Wheel Alignment Adjustment
Page 62 - Chain Guide Wear Inspection
Page 63 - Brake Operation Inspection
Page 64 - Brake Fluid Change
Page 65
Page 66 - Brake Hose and Pipe Replacement
Page 67
Page 68
Page 69
Page 70 - Master Cylinder Rubber Parts Replacement
Page 71 - Caliper Rubber Parts Replacement
Page 72
Page 73
Page 74 - Brake Pad Wear Inspection
Page 75 - Brake Light Switch Operation Inspection
Page 76 - Suspension
Page 77 - Steering
Page 78
Page 79 - Steering Stem Bearing Lubrication
Page 80 - Electrical System
Page 81
Page 82 - Headlight Aiming Inspection
Page 83 - Side Stand Switch Operation Inspection
Page 84 - Engine Stop Switch Operation Inspection
Page 85 - Spark Plug Replacement
Page 86 - Condition of Bolts, Nuts and Fasteners T...
Page 87
Page 88
Page 89
Page 90
Page 91
Page 92 - Exploded View
Page 93
Page 94
Page 95
Page 96
Page 97
Page 98 - DFI System
Page 99
Page 100
Page 101
Page 102
Page 103
Page 104
Page 105
Page 106
Page 107
Page 108 - DFI Parts Location
Page 109
Page 110
Page 111 - Specifications
Page 112
Page 113 - Special Tools and Sealant
Page 114
Page 115 - DFI Servicing Precautions
Page 116
Page 117 - Troubleshooting the DFI System
Page 118
Page 119
Page 120
Page 121 - Inquiries to Rider
Page 122
Page 123
Page 124 - DFI System Troubleshooting Guide
Page 125
Page 126
Page 127 - Poor running or no power at high speed
Page 128
Page 129 - Self-Diagnosis
Page 130 - Self-Diagnosis Procedures
Page 131
Page 132 - Service Code Reading
Page 133 - Backups
Page 134
Page 135
Page 136 - Main Throttle Sensor (Service Code 11)
Page 137 - Main Throttle Sensor Resistance Inspecti...
Page 138
Page 139
Page 140 - Intake Air Pressure Sensor #1 (Service C...
Page 141 - Intake Air Pressure Sensor #1 Input Volt...
Page 142 - Intake Air Pressure Sensor #1 Output Vol...
Page 143
Page 144
Page 145
Page 146 - Intake Air Temperature Sensor (Service C...
Page 147 - Intake Air Temperature Sensor Resistance...
Page 148
Page 149 - Water Temperature Sensor (Service Code 1...
Page 150 - Water Temperature Sensor Resistance Insp...
Page 151 - Intake Air Pressure Sensor #2 (Service C...
Page 152 - Intake Air Pressure Sensor #2 Input Volt...
Page 153 - Intake Air Pressure Sensor #2 Output Vol...
Page 154
Page 155 - Crankshaft Sensor (Service Code 21)
Page 156 - Rear Wheel Rotation Sensor Signal (Servi...
Page 157
Page 158
Page 159 - Front Wheel Rotation Sensor Signal (Serv...
Page 160
Page 161 - Vehicle-down Sensor (Service Code 31)
Page 162 - Vehicle-down Sensor Installation
Page 163 - Vehicle-down Sensor Output Voltage Inspe...
Page 164
Page 165
Page 166 - Subthrottle Sensor (Service Code 32)
Page 167 - Subthrottle Sensor Output Voltage Inspec...
Page 168
Page 169 - Subthrottle Sensor Resistance Inspection
Page 170 - Oxygen Sensor - not activated (Service C...
Page 171
Page 172
Page 173 - Exhaust Butterfly Valve Actuator Sensor ...
Page 174 - Exhaust Butterfly Valve Actuator Sensor ...
Page 175 - Exhaust Butterfly Valve Actuator Sensor ...
Page 176 - Immobilizer Amplifier (Service Code 35, ...
Page 177 - Blank Key Detection (Service Code 36, Eq...
Page 178 - ECU Communication Error (Service Code 39...
Page 179 - Stick Coils #1, #2, #3, #4 (Service Code...
Page 180
Page 181 - Radiator Fan Relay (Service Code 56)
Page 182 - Subthrottle Valve Actuator (Service Code...
Page 183 - Subthrottle Valve Actuator Input Voltage...
Page 184
Page 185 - Exhaust Butterfly Valve Actuator (Servic...
Page 186
Page 187 - Air Switching Valve (Service Code 64)
Page 188 - Oxygen Sensor Heater (Service Code 67, E...
Page 189 - Oxygen Sensor Heater Power Source Voltag...
Page 190
Page 191 - Oxygen Sensor - Incorrect Output Voltage...
Page 192
Page 193
Page 194 - Purge Valve (Service Code 3A) (CAL, SEA-...
Page 195
Page 196 - Warning Indicator Light (LED)
Page 197 - ECU
Page 198 - ECU Installation
Page 199
Page 200
Page 201 - DFI Power Source
Page 202 - Fuel Line
Page 203 - Fuel Flow Rate Inspection
Page 204
Page 205 - Fuel Pump
Page 206 - Fuel Pump Installation
Page 207 - Fuel Pump Operating Voltage Inspection
Page 208 - Pressure Regulator Removal
Page 209
Page 210 - Fuel Injectors
Page 211 - Fuel Injector Power Source Voltage Inspe...
Page 212 - Fuel Injector Output Voltage Inspection
Page 213 - Fuel Injector Fuel Line Inspection
Page 214
Page 215
Page 216 - Throttle Grip and Cables
Page 217 - Throttle Body Assy
Page 218
Page 219 - Throttle Body Assy Installation
Page 220 - Throttle Body Assy Disassembly
Page 221 - Throttle Body Assy Assembly
Page 222 - Air Cleaner
Page 223 - Air Cleaner Housing Installation
Page 224 - Fuel Tank
Page 225
Page 226 - Fuel Tank Installation
Page 227 - Fuel Tank and Cap Inspection
Page 228 - Fuel Tank Cleaning
Page 229 - Evaporative Emission Control System (CAL...
Page 230
Page 231
Page 232 - Exploded View
Page 233
Page 234 - Coolant Flow Chart
Page 235
Page 236 - Specifications
Page 237 - Special Tools
Page 238 - Coolant
Page 239 - Cooling System Flushing
Page 240 - Water Pump
Page 241
Page 242 - Water Pump Inspection
Page 243 - Water Pump Housing Assembly
Page 244 - Radiator
Page 245 - Radiator and Radiator Fan Installation
Page 246 - Radiator Inspection
Page 247 - Radiator Filler Neck Inspection
Page 248 - Thermostat
Page 249 - Thermostat Inspection
Page 250
Page 251 - Hose and Pipes
Page 252 - Water Temperature Sensor
Page 253
Page 254 - Exploded View
Page 255
Page 256
Page 257
Page 258 - Exhaust System Identification
Page 259
Page 260 - Specifications
Page 261
Page 262 - Special Tools and Sealants
Page 263
Page 264
Page 265 - Clean Air System
Page 266 - Air Suction Valve Installation
Page 267 - Air Suction Valve Inspection
Page 268 - Clean Air System Hose Inspection
Page 269 - Cylinder Head Cover
Page 270
Page 271 - Camshaft Chain Tensioner
Page 272 - Camshaft, Camshaft Chain
Page 273 - Camshaft Installation
Page 274
Page 275
Page 276 - Camshaft, Camshaft Cap Wear Inspection
Page 277 - Cam Wear Inspection
Page 278 - Cylinder Head
Page 279 - Cylinder Head Removal
Page 280 - Cylinder Head Installation
Page 281 - Cylinder Head Warp Inspection
Page 282 - Valves
Page 283 - Valve Guide Installation
Page 284 - Valve-to-Guide Clearance Measurement (Wo...
Page 285 - Valve Seat Repair
Page 286
Page 287
Page 288
Page 289
Page 290 - Cylinder, Pistons
Page 291 - Piston Removal
Page 292 - Piston Installation
Page 293 - Cylinder Wear Inspection
Page 294 - Piston Ring Thickness Inspection
Page 295 - Throttle Body Assy Holder
Page 296 - Muffler
Page 297
Page 298 - Muffler Body Installation
Page 299
Page 300
Page 301 - Exhaust Pipe Removal
Page 302
Page 303 - Exhaust Butterfly Valve Cable Installati...
Page 304 - Exhaust Butterfly Valve Actuator Removal
Page 305 - Exhaust Butterfly Valve Actuator Install...
Page 306 - Exhaust Butterfly Valve Actuator Adjustm...
Page 307
Page 308 - Exploded View
Page 309
Page 310 - Specifications
Page 311 - Special Tool and Sealant
Page 312 - Clutch Lever and Cable
Page 313 - Clutch Lever Installation
Page 314 - Clutch Cover
Page 315 - Release Shaft Installation
Page 316 - Clutch Cover Assembly
Page 317 - Clutch Removal
Page 318
Page 319
Page 320 - Clutch Plate Assembly Inspection
Page 321 - Clutch Plate, Wear, Damage Inspection
Page 322
Page 323
Page 324 - Exploded View
Page 325
Page 326 - Engine Oil Flow Chart
Page 327 - Specifications
Page 328 - Special Tools and Sealants
Page 329 - Engine Oil and Oil Filter
Page 330 - Oil Pan
Page 331
Page 332 - Oil Screen
Page 333 - Oil Pressure Relief Valve
Page 334 - Oil Pump
Page 335 - Oil Pump Drive Gear Removal
Page 336 - Oil Cooler
Page 337 - Oil Pressure Measurement
Page 338 - Oil Pressure Switch
Page 339 - Oil Pipe
Page 340
Page 341
Page 342 - Exploded View
Page 343
Page 344 - Special Tool
Page 345 - Engine Removal/Installation
Page 346
Page 347
Page 348 - Engine Installation
Page 349
Page 350
Page 351
Page 352
Page 353
Page 354 - Exploded View
Page 355
Page 356
Page 357
Page 358 - Specifications
Page 359
Page 360 - Special Tools and Sealants
Page 361 - Crankcase Splitting
Page 362 - Crankcase Assembly
Page 363
Page 364
Page 365
Page 366
Page 367 - Crankshaft and Connecting Rods
Page 368 - Connecting Rod Installation
Page 369
Page 370
Page 371 - Crankshaft/Connecting Rod Cleaning
Page 372 - Connecting Rod Bend Inspection
Page 373 - Connecting Rod Big End Bearing Insert/Cr...
Page 374 - Crankshaft Side Clearance Inspection
Page 375 - Crankshaft Runout Inspection
Page 376
Page 377
Page 378 - Balancer
Page 379 - Balancer Adjustment
Page 380 - Starter Motor Clutch
Page 381 - External Shift Mechanism
Page 382 - External Shift Mechanism Removal
Page 383 - External Shift Mechanism Inspection
Page 384
Page 385 - Transmission
Page 386 - Transmission Shaft Assembly
Page 387
Page 388
Page 389
Page 390 - Shift Drum and Fork Removal
Page 391 - Shift Fork Bending Inspection
Page 392 - Ball Bearing, Needle Bearing, and Oil Se...
Page 393
Page 394 - Exploded View
Page 395
Page 396 - Specifications
Page 397 - Special Tools
Page 398 - Wheels (Rims)
Page 399 - Rear Wheel Removal
Page 400
Page 401 - Rear Wheel Installation
Page 402 - Wheel Inspection
Page 403 - Balance Inspection
Page 404
Page 405 - Tires
Page 406
Page 407 - Tire Repair
Page 408 - Hub Bearing
Page 409 - Hub Bearing Inspection
Page 410
Page 411
Page 412 - Exploded View
Page 413
Page 414 - Specifications
Page 415 - Special Tools
Page 416 - Drive Chain
Page 417
Page 418
Page 419
Page 420 - Sprocket, Coupling
Page 421 - Engine Sprocket Cover Disassembly
Page 422 - Rear Sprocket Removal
Page 423 - Coupling Bearing Removal
Page 424 - Coupling Bearing Inspection
Page 425 - Rear Sprocket Warp Inspection
Page 426
Page 427
Page 428
Page 429 - Exploded View
Page 430
Page 431
Page 432
Page 433
Page 434
Page 435
Page 436 - Specifications
Page 437 - Special Tools
Page 438 - Brake Lever, Brake Pedal
Page 439 - Brake Pedal Installation
Page 440 - Calipers
Page 441 - Front Caliper Assembly
Page 442 - Rear Caliper Dust Boot and Friction Boot...
Page 443 - Brake Pads
Page 444 - Rear Brake Pad Installation
Page 445 - Master Cylinder
Page 446 - Rear Master Cylinder Installation
Page 447 - Master Cylinder Inspection (Visual Inspe...
Page 448 - Brake Disc
Page 449 - Brake Disc Warp Inspection
Page 450 - Brake Fluid
Page 451
Page 452
Page 453
Page 454 - Brake Hose
Page 455 - Anti-Lock Brake System (Equipped Models)
Page 456
Page 457
Page 458
Page 459 - ABS Servicing Precautions
Page 460
Page 461 - ABS Troubleshooting Outline
Page 462
Page 463
Page 464 - Inquiries to Rider
Page 465
Page 466 - Self-diagnosis Outline
Page 467 - Service Code Clearing Procedures
Page 468
Page 469
Page 470 - How to Read Service Codes
Page 471 - Service code table
Page 472
Page 473 - Yellow ABS Indicator (LED) Inspection
Page 474 - Front, Rear Wheel Rotation Difference Ab...
Page 475 - ABS Motor Relay Inspection (Service Code...
Page 476 - Front Wheel Rotation Sensor Wiring Inspe...
Page 477 - Rear Wheel Rotation Sensor Wiring Inspec...
Page 478 - Power Supply Voltage Abnormal [Over-Volt...
Page 479 - Output Fluid Pressure Sensor (Front Brak...
Page 480
Page 481 - ABS Hydraulic Unit Installation
Page 482 - Front Wheel Rotation Sensor Removal
Page 483 - Rear Wheel Rotation Sensor Removal
Page 484 - Wheel Rotation Sensor Inspection
Page 485 - Wheel Rotation Sensor Rotor Inspection
Page 486 - Fuse Inspection
Page 487
Page 488 - Exploded View
Page 489
Page 490
Page 491
Page 492 - Specifications
Page 493 - Special Tools
Page 494
Page 495 - Front Fork
Page 496 - Spring Preload Adjustment
Page 497
Page 498 - Front Fork Oil Change
Page 499
Page 500
Page 501
Page 502
Page 503
Page 504
Page 505
Page 506 - Front Fork Disassembly
Page 507 - Inner Tube Inspection
Page 508 - Spring Tension Inspection
Page 509 - Rear Shock Absorber
Page 510 - Rear Shock Absorber Removal
Page 511 - Rear Shock Absorber Installation
Page 512 - Rear Shock Absorber Bearing Removal
Page 513 - Swingarm
Page 514 - Swingarm Installation
Page 515 - Swingarm Bearing Removal
Page 516 - Swingarm Bearing, Sleeve Inspection
Page 517 - Tie-Rod, Rocker Arm
Page 518 - Rocker Arm Installation
Page 519 - Tie-Rod and Rocker Arm Bearing Removal
Page 520 - Rocker Arm/Tie-Rod Bearing, Sleeve Inspe...
Page 521
Page 522 - Exploded View
Page 523
Page 524 - Special Tools
Page 525 - Steering Inspection
Page 526 - Steering Stem
Page 527 - Stem, Stem Bearing Installation
Page 528
Page 529 - Steering Stem Bearing Lubrication
Page 530 - Handlebar
Page 531
Page 532
Page 533
Page 534 - Exploded View
Page 535
Page 536
Page 537
Page 538
Page 539
Page 540 - Seats
Page 541 - Fairings
Page 542 - Upper Fairing Installation
Page 543 - Upper Fairing Assembly
Page 544 - Middle Fairing Removal
Page 545 - Middle Fairing Disassembly
Page 546 - Ignition Switch Cover Removal
Page 547 - Side Covers
Page 548 - Seat Covers
Page 549
Page 550 - Fenders
Page 551
Page 552 - Frame Inspection
Page 553 - Rear Frame Bracket Installation
Page 554 - Battery Case
Page 555 - Guard
Page 556 - Side Stand
Page 557 - Rear View Mirrors
Page 558
Page 559
Page 560
Page 561
Page 562 - Exploded View
Page 563
Page 564
Page 565
Page 566
Page 567
Page 568 - Specifications
Page 569 - Special Tools and Sealant
Page 570
Page 571 - Parts Location
Page 572
Page 573
Page 574 - Wiring Diagram (SEA-B1 Model)
Page 575
Page 576 - Wiring Diagram (Other than SEA-B1 Model)
Page 577
Page 578 - Wiring Diagram (ABS Equipped Models: US,...
Page 579
Page 580 - Wiring Diagram (ABS Equipped Models: SEA...
Page 581
Page 582 - Wiring Diagram (ABS Equipped Models: Oth...
Page 583
Page 584 - Precautions
Page 585 - Electrical Wiring
Page 586 - Battery
Page 587
Page 588
Page 589 - Precautions
Page 590 - Interchange
Page 591
Page 592 - Charging System
Page 593 - Stator Coil Installation
Page 594 - Alternator Rotor Installation
Page 595
Page 596 - Charging Voltage Inspection
Page 597
Page 598 - Regulator/Rectifier Removal
Page 599
Page 600
Page 601 - Ignition System
Page 602 - Crankshaft Sensor Installation
Page 603 - Crankshaft Sensor Inspection
Page 604 - Crankshaft Sensor Peak Voltage Inspectio...
Page 605 - Stick Coil Removal
Page 606 - Spark Plug Removal
Page 607 - Spark Plug Condition Inspection
Page 608 - IC Igniter Inspection
Page 609
Page 610
Page 611 - Electric Starter System
Page 612 - Starter Motor Assembly
Page 613 - Brush Inspection
Page 614 - Brush Lead Inspection
Page 615
Page 616 - Lighting System
Page 617 - City Light (LED) Removal
Page 618 - City Light (LED) Installation
Page 619 - Tail/Brake Light (LED) Installation
Page 620
Page 621 - Turn Signal Light Bulb Replacement
Page 622
Page 623
Page 624 - Air Switching Valve
Page 625
Page 626 - Radiator Fan System
Page 627 - Meter, Gauge, Indicator Unit
Page 628 - Meter Unit Disassembly
Page 629
Page 630 - Meter System Inspection
Page 631 - Meter Unit Inspection
Page 632
Page 633
Page 634
Page 635
Page 636
Page 637
Page 638
Page 639 - Fuel Level Sensor Line Self-Diagnosis Mo...
Page 640
Page 641
Page 642 - Immobilizer System (Equipped Models)
Page 643
Page 644
Page 645
Page 646
Page 647
Page 648
Page 649
Page 650
Page 651
Page 652
Page 653
Page 654
Page 655
Page 656
Page 657
Page 658
Page 659
Page 660 - Immobilizer System Parts Replacement
Page 661
Page 662
Page 663 - Immobilizer System Inspection
Page 664
Page 665 - Switches and Sensors
Page 666 - Water Temperature Sensor Inspection
Page 667 - Oxygen Sensor Installation (Equipped Mod...
Page 668 - Relay Box
Page 669 - Diode Circuit Inspection
Page 670
Page 671 - Fuse
Page 672
Page 673
Page 674
Page 675
Page 676
Page 677
Page 678
Page 679
Page 680
Page 681
Page 682
Page 683
Page 684
Page 685
Page 686
Page 687
Page 688
Page 689
Page 690
Page 691
Page 692
Page 693
Page 694
Page 695
Page 696
Page 697
Page 698
Page 699
Page 700
Page 701
Page 702
Page 703
Page 704
Page 705
Page 706
Page 707
Page 708
Page 709
Page 710
Page 711
Page 712
Page 713
Page 714
Page 715
Page 716
Page 717
Page 718
Page 719
Page 720
Page 721
Page 722
Page 723
Page 724
Page 725
Page 726
Page 727
Page 728
Page 729 - Troubleshooting guide
Page 730
Page 731 - Gear shifting faulty
Page 732 - Exhaust smokes excessively
Page 733
Page 734
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734
Contents
Table of contents
Troubleshooting
Bookmarks
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Transmission
1. Output Shaft
2. Collar
3. Ball Bearings
4. Bushing
5. 2nd Gear (39 T)
6. Washer ( 34 × 28.1)
7. Circlips ( 33 × 25.9)
8. Top Gear (31 T)
9. Toothed Washer ( 34)
10. 4th Gear (25 T)
11. Bushings
12. Toothed Washer ( 40.5)
13. Toothed Washer ( 37)
14. 3rd Gear (24 T)
15. Steel Balls
16. 5th Gear (26 T)
17. Low Gear (39 T)
18. Washers ( 31 × 20.5)
19. Races
20. Needle Bearings
21. Circlips ( 22.2 × 18.7)
22. Needle Bearing
23. Low Gear (15 T) (Drive Shaft)
24. Bushing
25. 5th Gear (21 T)
26. Toothed Washers ( 31)
27. Circlips ( 29 × 22.6)
28. 3rd/4th Gear (15 T/18 T)
29. Bushing
30. Top Gear (28 T)
31. Toothed Washer ( 34.2)
32. Toothed Washer ( 32)
33. 2nd Gear (20 T)
34. Washer ( 30 × 20.5)
CRANKSHAFT/TRANSMISSION 9-37
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Emission control information
Before Servicing
Periodic Inspection
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Cooling System
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Chapters
Table Of Contents
11
Periodic Maintenance
23
Fuel System (dfi)
89
Cooling System
231
Engine Top End
253
Clutch
307
Engine Lubrication System
323
Table Of Contents
341
Crankshaft/transmission
353
Wheels/tires
393
Final Drive
411
Brakes
427
Suspension
487
Steering
521
Frame
533
Electrical System
559
Table of Contents
Troubleshooting
Troubleshooting the DFI System
117
DFI System Troubleshooting Guide
124
ABS Troubleshooting Outline
461
troubleshooting guide
729
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This manual is also suitable for:
Z1000 abs
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