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Kawasaki Manuals
Motorcycle
Z1000
Service manual
Replacement Parts; Air Cleaner Element Replacement - Kawasaki Z1000 Service Manual
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Page
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719
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
Page 20 - General Specifications
Page 21
Page 22
Page 23 - Unit Conversion Table
Page 24
Page 25 - Table Of Contents
Page 26
Page 27 - Periodic Maintenance Chart
Page 28
Page 29
Page 30 - Torque and Locking Agent
Page 31
Page 32
Page 33
Page 34
Page 35
Page 36 - Specifications
Page 37
Page 38 - Special Tools
Page 39 - Periodic Maintenance Procedures
Page 40 - Engine Vacuum Synchronization Inspection
Page 41
Page 42
Page 43 - Idle Speed Inspection
Page 44 - Idle Speed Adjustment
Page 45 - Evaporative Emission Control System (CAL...
Page 46 - Cooling System
Page 47 - Radiator Hose and Pipe Inspection (coola...
Page 48 - Valve Clearance Adjustment
Page 49
Page 50
Page 51
Page 52 - Exhaust Butterfly Valve Cable Inspection
Page 53 - Exhaust Butterfly Valve Cable Adjustment
Page 54
Page 55
Page 56 - Air Suction System Damage Inspection
Page 57 - Wheels/Tires
Page 58 - Wheel/Tire Damage Inspection
Page 59 - Wheel Bearing Damage Inspection
Page 60 - Drive Chain Slack Inspection
Page 61 - Wheel Alignment Inspection
Page 62 - Drive Chain Wear Inspection
Page 63 - Brakes
Page 64 - Brake Hose and Pipe Damage and Installat...
Page 65 - Brake Pad Wear Inspection
Page 66 - Brake Light Switch Operation Inspection
Page 67 - Front Fork Oil Leak Inspection
Page 68 - Steering
Page 69 - Steering Stem Bearing Lubrication
Page 70 - Electrical System
Page 71 - Lights and Switches Operation Inspection
Page 72
Page 73 - Headlight Aiming Inspection
Page 74 - Sidestand Switch Operation Inspection
Page 75 - Engine Stop Switch Operation Inspection
Page 76 - Others
Page 77
Page 78 - Bolts, Nuts and Fasteners Tightness Insp...
Page 79 - Replacement Parts
Page 80 - Fuel Hose Replacement
Page 81
Page 82 - Coolant Change
Page 83
Page 84 - Radiator Hose and O-ring Replacement
Page 85 - Oil Filter Replacement
Page 86 - Brake Hose and Pipe Replacement
Page 87
Page 88 - Brake Fluid Change
Page 89 - Master Cylinder Rubber Parts Replacement
Page 90 - Caliper Rubber Parts Replacement
Page 91
Page 92
Page 93 - Spark Plug Replacement
Page 94
Page 95
Page 96
Page 97
Page 98 - Exploded View
Page 99
Page 100
Page 101
Page 102
Page 103
Page 104 - DFI System
Page 105
Page 106
Page 107
Page 108
Page 109
Page 110
Page 111
Page 112 - DFI Parts Location
Page 113
Page 114 - Specifications
Page 115
Page 116 - Special Tools and Sealant
Page 117
Page 118 - DFI Servicing Precautions
Page 119
Page 120 - Troubleshooting the DFI System
Page 121
Page 122
Page 123
Page 124 - Inquiries to Rider
Page 125
Page 126
Page 127 - DFI System Troubleshooting Guide
Page 128
Page 129
Page 130
Page 131
Page 132 - Self-Diagnosis
Page 133 - Self-diagnosis Procedures
Page 134
Page 135
Page 136 - Service Code Reading
Page 137
Page 138 - Backups
Page 139
Page 140
Page 141 - Main Throttle Sensor (Service Code 11)
Page 142 - Main Throttle Sensor Output Voltage Insp...
Page 143 - Main Throttle Sensor Resistance Inspecti...
Page 144
Page 145 - Inlet Air Pressure Sensor (Service Code ...
Page 146 - Inlet Air Pressure Sensor Output Voltage...
Page 147
Page 148
Page 149
Page 150 - Inlet Air Temperature Sensor (Service Co...
Page 151 - Inlet Air Temperature Sensor Resistance ...
Page 152
Page 153 - Water Temperature Sensor (Service Code 1...
Page 154 - Water Temperature Sensor Resistance Insp...
Page 155 - Atmospheric Pressure Sensor (Service Cod...
Page 156 - Atmospheric Pressure Sensor Output Volta...
Page 157
Page 158
Page 159
Page 160 - Crankshaft Sensor (Service Code 21)
Page 161 - Camshaft Position Sensor (Service Code 2...
Page 162
Page 163 - Speed Sensor (Service Code 24, 25)
Page 164 - Speed Sensor Output Voltage Inspection
Page 165
Page 166 - Vehicle-down Sensor (Service Code 31)
Page 167 - Vehicle-down Sensor Input Voltage Inspec...
Page 168 - Vehicle-down Sensor Output Voltage Inspe...
Page 169
Page 170 - Subthrottle Sensor (Service Code 32)
Page 171 - Subthrottle Sensor Output Voltage Inspec...
Page 172
Page 173 - Subthrottle Sensor Resistance Inspection
Page 174 - Oxygen Sensor - not activated (Service C...
Page 175
Page 176
Page 177
Page 178 - Exhaust Butterfly Valve Actuator Sensor ...
Page 179 - Exhaust Butterfly Valve Actuator Sensor ...
Page 180 - Exhaust Butterfly Valve Actuator Sensor ...
Page 181 - Immobilizer Amplifier (Service Code 35, ...
Page 182 - Blank Key Detection (Service Code 36, Eq...
Page 183 - ECU Communication Error (Service Code 39...
Page 184 - Stick Coils #1, #2, #3, #4 (Service Code...
Page 185
Page 186 - Radiator Fan Relay (Service Code 56)
Page 187
Page 188 - Subthrottle Valve Actuator (Service Code...
Page 189 - Subthrottle Valve Actuator Input Voltage...
Page 190
Page 191 - Exhaust Butterfly Valve Actuator (Servic...
Page 192 - Exhaust Butterfly Valve Actuator Install...
Page 193 - Exhaust Butterfly Valve Actuator Inspect...
Page 194
Page 195 - Air Switching Valve (Service Code 64)
Page 196 - Oxygen Sensor Heater (Service Code 67, E...
Page 197 - Oxygen Sensor Heater Power Source Voltag...
Page 198
Page 199 - Oxygen Sensor - Incorrect Output Voltage...
Page 200
Page 201
Page 202 - Warning Indicator Light (LED)
Page 203 - ECU
Page 204 - ECU Installation
Page 205 - ECU Power Supply Inspection
Page 206
Page 207
Page 208 - DFI Power Source
Page 209 - Fuel Line
Page 210 - Fuel Flow Rate Inspection
Page 211
Page 212 - Fuel Pump
Page 213 - Fuel Pump Installation
Page 214 - Fuel Pump Operating Voltage Inspection
Page 215 - Pressure Regulator Removal
Page 216
Page 217 - Fuel Injectors
Page 218 - Fuel Injector Power Source Voltage Inspe...
Page 219 - Fuel Injector Output Voltage Inspection
Page 220 - Fuel Injector Fuel Line Inspection
Page 221
Page 222 - Throttle Grip and Cables
Page 223 - Throttle Body Assy
Page 224
Page 225
Page 226 - Throttle Body Assy Installation
Page 227 - Throttle Body Assy Disassembly
Page 228 - Throttle Body Assy Assembly
Page 229
Page 230 - Air Cleaner
Page 231 - Fuel Tank
Page 232
Page 233 - Fuel Tank Installation
Page 234
Page 235 - Fuel Tank Inspection
Page 236 - Evaporative Emission Control System (CAL...
Page 237 - Separator Operation Test
Page 238
Page 239
Page 240 - Exploded View
Page 241
Page 242 - Coolant Flow Chart
Page 243
Page 244 - Specifications
Page 245 - Special Tools
Page 246 - Coolant
Page 247 - Cooling System Flushing
Page 248 - Water Pump
Page 249 - Water Pump Housing Assembly
Page 250 - Radiator
Page 251 - Radiator and Radiator Fan Installation
Page 252 - Radiator Cap Inspection
Page 253 - Thermostat
Page 254 - Thermostat Inspection
Page 255 - Hose and Pipes
Page 256 - Water Temperature Sensor
Page 257
Page 258 - Exploded View
Page 259
Page 260
Page 261
Page 262 - Exhaust System
Page 263
Page 264 - Specifications
Page 265
Page 266 - Special Tools and Sealant
Page 267
Page 268 - Clean Air System
Page 269 - Air Switching Valve Removal
Page 270 - Cylinder Head Cover
Page 271 - Camshaft Chain Tensioner
Page 272 - Camshaft, Camshaft Chain
Page 273 - Camshaft, Camshaft Cap Wear Inspection
Page 274 - Camshaft Runout Inspection
Page 275 - Cylinder Head
Page 276 - Cylinder Head Removal
Page 277 - Cylinder Head Warp Inspection
Page 278 - Valves
Page 279 - Valve Guide Installation
Page 280 - Valve Seat Inspection
Page 281
Page 282
Page 283
Page 284
Page 285 - Cylinder, Pistons
Page 286 - Piston Removal
Page 287 - Cylinder Wear Inspection
Page 288 - Piston Ring, Piston Ring Groove Wear Ins...
Page 289 - Piston Ring End Gap Inspection
Page 290 - Throttle Body Holder
Page 291 - Muffler
Page 292 - Muffler Body Installation
Page 293 - Exhaust Pipe Removal
Page 294 - Exhaust Pipe Installation
Page 295 - Exhaust Butterfly Valve Cable Removal
Page 296 - Exhaust Butterfly Valve Cable Installati...
Page 297
Page 298
Page 299
Page 300
Page 301
Page 302 - Exploded View
Page 303
Page 304 - Specifications
Page 305 - Special Tool and Sealant
Page 306 - Clutch Lever and Cable
Page 307 - Clutch Cover
Page 308 - Clutch Cover Disassembly
Page 309 - Clutch Removal
Page 310
Page 311
Page 312 - Clutch Plate Assembly Inspection
Page 313 - Clutch Plate Assembly Adjustment
Page 314 - Clutch Spring Free Length Measurement
Page 315
Page 316 - Exploded View
Page 317
Page 318 - Engine Oil Flow Chart
Page 319 - Specifications
Page 320 - Special Tools and Sealant
Page 321 - Engine Oil and Oil Filter
Page 322 - Oil Pan
Page 323
Page 324 - Oil Pressure Relief Valve
Page 325 - Oil Pump
Page 326 - Oil Pump Drive Gear Removal
Page 327 - Oil Cooler
Page 328 - Oil Pressure Measurement
Page 329 - Oil Pressure Switch
Page 330
Page 331
Page 332 - Exploded View
Page 333
Page 334 - Special Tool
Page 335 - Engine Removal/Installation
Page 336
Page 337 - Engine Installation
Page 338
Page 339
Page 340
Page 341
Page 342 - Exploded View
Page 343
Page 344
Page 345
Page 346 - Specifications
Page 347
Page 348 - Special Tools and Sealant
Page 349 - Crankcase Splitting
Page 350 - Crankcase Assembly
Page 351
Page 352
Page 353 - Crankshaft and Connecting Rods
Page 354
Page 355
Page 356 - Crankshaft/Connecting Rod Cleaning
Page 357 - Connecting Rod Bend Inspection
Page 358 - Connecting Rod Big End Bearing Insert/Cr...
Page 359 - Crankshaft Side Clearance Inspection
Page 360 - Crankshaft Runout Inspection
Page 361
Page 362 - Starter Motor Clutch
Page 363 - Transmission
Page 364 - External Shift Mechanism Removal
Page 365 - External Shift Mechanism Installation
Page 366 - Transmission Shaft Removal
Page 367 - Transmission Shaft Assembly
Page 368
Page 369
Page 370 - Shift Drum and Fork Removal
Page 371 - Shift Fork Bending Inspection
Page 372
Page 373
Page 374 - Exploded View
Page 375
Page 376 - Specifications
Page 377 - Special Tools
Page 378 - Wheels (Rims)
Page 379 - Rear Wheel Removal
Page 380 - Rear Wheel Installation
Page 381
Page 382 - Wheel Inspection
Page 383 - Balance Inspection
Page 384 - Balance Weight Installation
Page 385
Page 386 - Tires
Page 387
Page 388 - Tire Repair
Page 389 - Hub Bearing
Page 390 - Hub Bearing Inspection
Page 391
Page 392 - Exploded View
Page 393
Page 394 - Specifications
Page 395 - Special Tools
Page 396 - Drive Chain
Page 397 - Drive Chain Installation
Page 398
Page 399
Page 400
Page 401 - Sprocket, Coupling
Page 402 - Rear Sprocket Removal
Page 403 - Coupling Bearing Removal
Page 404 - Coupling Bearing Inspection
Page 405
Page 406
Page 407
Page 408 - Exploded View
Page 409
Page 410
Page 411
Page 412
Page 413
Page 414
Page 415
Page 416 - Specifications
Page 417
Page 418 - Brake Lever Position Adjustment
Page 419 - Brake Pedal Installation
Page 420 - Calipers
Page 421 - Front Caliper Disassembly
Page 422 - Caliper Fluid Seal Damage
Page 423 - Caliper Piston and Cylinder Damage
Page 424 - Brake Pads
Page 425 - Rear Brake Pad Removal
Page 426 - Rear Brake Pad Installation
Page 427 - Master Cylinder
Page 428 - Rear Master Cylinder Installation
Page 429 - Brake Disc
Page 430 - Brake Fluid
Page 431
Page 432
Page 433
Page 434 - Brake Hose
Page 435 - Anti-Lock Brake System (Equipped Models)
Page 436
Page 437
Page 438 - ABS Servicing Precautions
Page 439
Page 440 - ABS Troubleshooting Outline
Page 441
Page 442
Page 443 - Inquiries to Rider
Page 444
Page 445 - Self-diagnosis Outline
Page 446 - Service Code Clearing Procedures
Page 447
Page 448
Page 449 - How to Read Service Codes
Page 450
Page 451 - ABS Indicator Light (LED) Inspection
Page 452 - ABS Indicator Light (LED) Lights (When t...
Page 453
Page 454 - Front, Rear Wheel Rotation Difference Ab...
Page 455 - Front Wheel Rotation Sensor Signal Abnor...
Page 456 - Front Wheel Rotation Sensor Wiring Inspe...
Page 457 - Rear Wheel Rotation Sensor Signal Abnorm...
Page 458 - Rear Wheel Rotation Sensor Wiring Inspec...
Page 459 - Power Supply Voltage Abnormal (Over-Volt...
Page 460 - ECU Inspection (Service Code 55)
Page 461
Page 462 - ABS Hydraulic Unit Installation
Page 463 - Front Wheel Rotation Sensor Removal
Page 464 - Rear Wheel Rotation Sensor Removal
Page 465 - Wheel Rotation Sensor Inspection
Page 466 - Wheel Rotation Sensor Rotor Inspection
Page 467 - Fuse Installation
Page 468
Page 469
Page 470 - Exploded View
Page 471
Page 472
Page 473
Page 474 - Specifications
Page 475 - Special Tools
Page 476
Page 477 - Front Fork
Page 478 - Front Fork Removal (Each Fork Leg)
Page 479
Page 480
Page 481
Page 482
Page 483
Page 484 - Front Fork Disassembly
Page 485 - Inner Tube, Outer Tube Inspection
Page 486 - Dust Seal Inspection
Page 487 - Rear Shock Absorber
Page 488 - Rear Shock Absorber Removal
Page 489 - Rear Shock Absorber Inspection
Page 490 - Swingarm
Page 491 - Swingarm Installation
Page 492 - Swingarm Bearing Removal
Page 493 - Swingarm Bearing, Sleeve Inspection
Page 494 - Swingarm Bearing Lubrication
Page 495 - Tie-Rod, Rocker Arm
Page 496 - Tie-Rod and Rocker Arm Bearing Removal
Page 497 - Rocker Arm/Tie-Rod Bearing, Sleeve Inspe...
Page 498
Page 499
Page 500 - Exploded View
Page 501
Page 502 - Special Tools
Page 503 - Steering Inspection
Page 504 - Steering Stem
Page 505 - Stem, Stem Bearing Installation
Page 506 - Steering Stem Bearing Lubrication
Page 507 - Steering Stem Warp
Page 508 - Handlebar
Page 509
Page 510
Page 511
Page 512 - Exploded View
Page 513
Page 514
Page 515
Page 516
Page 517 - Seats
Page 518 - Fairings
Page 519 - Center Fairing Installation
Page 520 - Upper Fairing Disassembly
Page 521 - Inner Cover Removal
Page 522 - Side Covers
Page 523 - Seat Covers
Page 524 - Seat Cover Installation
Page 525 - Fenders
Page 526 - Flap and Rear Fender Installation
Page 527 - Frame Inspection
Page 528 - Sidestand
Page 529 - Frame Cover
Page 530 - Rear View Mirrors
Page 531
Page 532
Page 533
Page 534 - Exploded View
Page 535
Page 536
Page 537
Page 538
Page 539
Page 540 - Specifications
Page 541
Page 542 - Special Tools and Sealant
Page 543 - Parts Location
Page 544
Page 545
Page 546 - Wiring Diagram (ZR1000B7F ~ B8F (US, CA ...
Page 547
Page 548 - Wiring Diagram (Other than ZR1000B7F ~ B...
Page 549
Page 550 - Wiring Diagram (ZR1000B9F)
Page 551
Page 552 - Wiring Diagram (ABS Equipped Models)
Page 553
Page 554
Page 555
Page 556 - Precautions
Page 557 - Electrical Wiring
Page 558 - Battery
Page 559 - Battery Activation
Page 560
Page 561
Page 562 - Precautions
Page 563 - Charging Condition Inspection
Page 564
Page 565 - Charging System
Page 566 - Alternator Cover Installation
Page 567 - Stator Coil Installation
Page 568 - Alternator Rotor Installation
Page 569 - Alternator Inspection
Page 570
Page 571 - Regulator/Rectifier Inspection
Page 572
Page 573 - Charging Voltage Inspection
Page 574
Page 575 - Ignition System
Page 576 - Crankshaft Sensor Installation
Page 577
Page 578 - Crankshaft Sensor Peak Voltage Inspectio...
Page 579 - Camshaft Position Sensor Removal
Page 580 - Camshaft Position Sensor Inspection
Page 581 - Stick Coil Removal
Page 582 - Stick Coil Inspection
Page 583 - Spark Plug Removal
Page 584 - IC Igniter Inspection
Page 585
Page 586
Page 587 - Starter Motor Removal
Page 588 - Starter Motor Disassembly
Page 589 - Brush Inspection
Page 590 - Commutator Cleaning and Inspection
Page 591 - Brush Plate and Terminal Bolt Inspection
Page 592
Page 593 - Lighting System
Page 594 - Headlight Removal/Installation
Page 595 - Tail/Brake Light (LED) Removal
Page 596
Page 597
Page 598 - Turn Signal Light Bulb Replacement
Page 599 - Turn Signal Relay Inspection
Page 600
Page 601 - Air Switching Valve
Page 602
Page 603 - Radiator Fan System
Page 604
Page 605 - Meter, Gauge, Indicator Unit
Page 606 - Electronic Combination Meter Unit Inspec...
Page 607
Page 608
Page 609
Page 610
Page 611
Page 612
Page 613
Page 614
Page 615
Page 616
Page 617 - Fuel Level Sensor Line Self-Diagnosis Mo...
Page 618
Page 619 - Immobilizer System (Equipped Models)
Page 620
Page 621
Page 622
Page 623
Page 624
Page 625
Page 626
Page 627
Page 628
Page 629
Page 630
Page 631
Page 632
Page 633
Page 634
Page 635 - Immobilizer System Parts Replacement
Page 636
Page 637
Page 638 - Immobilizer System Inspection
Page 639 - Switches and Sensors
Page 640 - Water Temperature Sensor Inspection
Page 641 - Speed Sensor Installation
Page 642 - Oxygen Sensor Installation (Equipped Mod...
Page 643
Page 644 - Relay Box
Page 645 - Diode Circuit Inspection
Page 646
Page 647 - Fuse
Page 648 - 10 A ECU Fuse Removal
Page 649
Page 650
Page 651
Page 652
Page 653
Page 654
Page 655
Page 656
Page 657
Page 658
Page 659
Page 660
Page 661
Page 662
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Page 719
/
719
Contents
Table of contents
Troubleshooting
Bookmarks
Advertisement
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
○
In dusty areas, the element should be replaced more
frequently than the recommended interval.
○
After riding through rain or on muddily roads, the ele-
ment should be replaced immediately.
If dirt or dust is allowed to pass through into the
throttle assy, the throttle may become stuck, possi-
bly causing accident.
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Bolts [A]
Fuel Tank Bracket [B]
•
Remove the air cleaner duct screws [A].
•
Remove the air cleaner duct [B] backward.
•
Discard the air cleaner element [A].
NOTE
WARNING
CAUTION
PERIODIC MAINTENANCE 2-55
Table of
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Emission control information
Before Servicing
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Chapters
Table Of Contents
11
Periodic Maintenance
25
Fuel System (dfi)
95
Cooling System
239
Engine Top End
257
Clutch
301
Engine Lubrication System
315
Table Of Contents
331
Crankshaft/transmission
341
Wheels/tires
373
Final Drive
391
Brakes
405
Suspension
469
Steering
499
Frame
511
Electrical System
531
Table of Contents
Troubleshooting
Troubleshooting the DFI System
120
DFI System Troubleshooting Guide
127
ABS Troubleshooting Outline
440
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This manual is also suitable for:
Z1000 abs
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