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Manuals
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Kawasaki Manuals
Motorcycle
Z1000SX ABS
Service manual
Specifications - Kawasaki Z1000SX Service Manual
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Also See for Z1000SX
Owner's manual
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Page
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739
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
Page 31 - Torque and Locking Agent
Page 32
Page 33
Page 34
Page 35
Page 36
Page 37 - Specifications
Page 38
Page 39 - Special Tools
Page 40
Page 41 - Periodic Maintenance Procedures
Page 42
Page 43
Page 44
Page 45 - Idle Speed Inspection
Page 46 - Idle Speed Adjustment
Page 47 - Evaporative Emission Control System (CAL...
Page 48 - Cooling System
Page 49
Page 50 - Valve Clearance Adjustment
Page 51
Page 52
Page 53 - Air Suction System Damage Inspection
Page 54 - Clutch
Page 55 - Wheels/Tires
Page 56 - Wheel Bearing Damage Inspection
Page 57 - Final Drive
Page 58 - Drive Chain Slack Adjustment
Page 59 - Drive Chain Wear Inspection
Page 60 - Brakes
Page 61 - Brake Hose and Pipe Damage and Installat...
Page 62 - Brake Pad Wear Inspection
Page 63 - Brake Light Switch Operation Inspection
Page 64 - Suspension
Page 65 - Tie-Rod Operation Inspection
Page 66
Page 67 - Steering Stem Bearing Lubrication
Page 68 - Electrical System
Page 69
Page 70 - Headlight Aiming Inspection
Page 71 - Sidestand Switch Operation Inspection
Page 72 - Engine Stop Switch Operation Inspection
Page 73 - Others
Page 74
Page 75 - Bolts, Nuts and Fasteners Tightness Insp...
Page 76 - Replacement Parts
Page 77
Page 78 - Coolant Change
Page 79
Page 80 - Radiator Hose and O-ring Replacement
Page 81 - Engine Oil Change
Page 82 - Brake Hose Replacement
Page 83 - Brake Fluid Change
Page 84
Page 85 - Master Cylinder Rubber Parts Replacement
Page 86 - Caliper Rubber Parts Replacement
Page 87
Page 88
Page 89
Page 90 - Spark Plug Replacement
Page 91
Page 92
Page 93
Page 94 - Exploded View
Page 95
Page 96
Page 97
Page 98
Page 99
Page 100 - DFI System
Page 101
Page 102
Page 103
Page 104
Page 105
Page 106 - DFI Parts Location
Page 107
Page 108 - Specifications
Page 109
Page 110 - Special Tools and Sealant
Page 111
Page 112 - DFI Servicing Precautions
Page 113
Page 114 - Troubleshooting the DFI System
Page 115
Page 116
Page 117
Page 118 - Inquiries to Rider
Page 119
Page 120
Page 121 - DFI System Troubleshooting Guide
Page 122
Page 123
Page 124
Page 125
Page 126 - Self-Diagnosis
Page 127 - Self-diagnosis Procedures
Page 128
Page 129
Page 130 - Service Code Reading
Page 131 - Service Code Erasing
Page 132 - Backups
Page 133
Page 134
Page 135 - Main Throttle Sensor (Service Code 11)
Page 136 - Main Throttle Sensor Output Voltage Insp...
Page 137
Page 138 - Main Throttle Sensor Resistance Inspecti...
Page 139 - Intake Air Pressure Sensor #1 (Service C...
Page 140 - Intake Air Pressure Sensor #1 Input Volt...
Page 141 - Intake Air Pressure Sensor #1 Output Vol...
Page 142
Page 143
Page 144
Page 145 - Intake Air Temperature Sensor (Service C...
Page 146 - Intake Air Temperature Sensor Resistance...
Page 147
Page 148 - Water Temperature Sensor (Service Code 1...
Page 149 - Water Temperature Sensor Output Voltage ...
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 - Speed Sensor (Service Code 24, 25)
Page 157 - Speed Sensor Output Voltage Inspection
Page 158
Page 159 - Vehicle-down Sensor (Service Code 31)
Page 160 - Vehicle-down Sensor Installation
Page 161 - Vehicle-down Sensor Output Voltage Inspe...
Page 162
Page 163
Page 164 - Subthrottle Sensor (Service Code 32)
Page 165 - Subthrottle Sensor Output Voltage Inspec...
Page 166
Page 167 - Subthrottle Sensor Resistance Inspection
Page 168 - Oxygen Sensor - not activated (Service C...
Page 169
Page 170
Page 171 - Exhaust Butterfly Valve Actuator Sensor ...
Page 172 - Exhaust Butterfly Valve Actuator Sensor ...
Page 173 - Exhaust Butterfly Valve Actuator Sensor ...
Page 174 - Immobilizer Amplifier (Service Code 35, ...
Page 175 - Amplifier Input Voltage Inspection
Page 176 - Blank Key Detection (Service Code 36, Eq...
Page 177 - ECU Communication Error (Service Code 39...
Page 178 - Stick Coils #1, #2, #3, #4 (Service Code...
Page 179
Page 180 - Radiator Fan Relay (Service Code 56)
Page 181 - Subthrottle Valve Actuator (Service Code...
Page 182 - Subthrottle Valve Actuator Input Voltage...
Page 183
Page 184 - Exhaust Butterfly Valve Actuator (Servic...
Page 185
Page 186 - Exhaust Butterfly Valve Actuator Inspect...
Page 187
Page 188 - Air Switching Valve (Service Code 64)
Page 189 - Oxygen Sensor Heater (Service Code 67, E...
Page 190 - Oxygen Sensor Heater Power Source Voltag...
Page 191
Page 192 - Oxygen Sensor - Incorrect Output Voltage...
Page 193
Page 194
Page 195 - Warning Indicator Light (LED)
Page 196 - ECU
Page 197 - ECU Power Supply Inspection
Page 198
Page 199
Page 200 - DFI Power Source
Page 201 - Fuel Line
Page 202 - Fuel Flow Rate Inspection
Page 203
Page 204 - Fuel Pump
Page 205 - Fuel Pump Installation
Page 206 - Fuel Pump Operating Voltage Inspection
Page 207 - Pump Screen, Fuel Filter Cleaning
Page 208
Page 209 - Fuel Injectors
Page 210 - Fuel Injector Power Source Voltage Inspe...
Page 211 - Fuel Injector Output Voltage Inspection
Page 212 - Fuel Injector Fuel Line Inspection
Page 213
Page 214 - Throttle Grip and Cables
Page 215 - Throttle Body Assy
Page 216
Page 217 - Throttle Body Assy Installation
Page 218 - Throttle Body Assy Disassembly
Page 219 - Throttle Body Assy Assembly
Page 220 - Air Cleaner
Page 221 - Air Cleaner Housing Installation
Page 222 - Fuel Tank
Page 223
Page 224
Page 225 - Fuel Tank Installation
Page 226
Page 227 - Fuel Tank and Cap Inspection
Page 228 - Evaporative Emission Control System (CAL...
Page 229 - Separator Operation Test
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
Page 246 - Radiator and Radiator Fan Installation
Page 247 - Radiator Inspection
Page 248 - Radiator Filler Neck Inspection
Page 249 - Thermostat
Page 250 - Thermostat Inspection
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 Sealant
Page 263
Page 264 - Clean Air System
Page 265 - Air Suction Valve Inspection
Page 266 - Clean Air System Hose Inspection
Page 267 - Cylinder Head Cover
Page 268 - Cylinder Head Cover Installation
Page 269
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
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 - Piston Wear Inspection
Page 294 - Piston Ring Thickness Inspection
Page 295 - Throttle Body Assy Holder
Page 296 - Muffler
Page 297 - Muffler Body Installation
Page 298
Page 299 - Exhaust Pipe Removal
Page 300 - Exhaust Butterfly Valve Cable Installati...
Page 301
Page 302
Page 303
Page 304 - Exploded View
Page 305
Page 306 - Specifications
Page 307 - Special Tool and Sealant
Page 308 - Clutch Lever and Cable
Page 309 - Clutch Cover
Page 310 - Release Shaft Installation
Page 311 - Clutch Cover Assembly
Page 312 - Clutch Removal
Page 313
Page 314
Page 315 - Clutch Plate Assembly Inspection
Page 316 - Clutch Plate, Wear, Damage Inspection
Page 317
Page 318 - Exploded View
Page 319 - Engine lubrication system
Page 320 - Engine Oil Flow Chart
Page 321 - Specifications
Page 322 - Special Tools and Sealants
Page 323 - Engine Oil and Oil Filter
Page 324 - Oil Pan
Page 325
Page 326 - Oil Screen
Page 327 - Oil Pressure Relief Valve
Page 328 - Oil Pump
Page 329 - Oil Pump Drive Gear Removal
Page 330 - Oil Cooler
Page 331 - Oil Pressure Measurement
Page 332 - Oil Pressure Switch
Page 333 - Oil Pipe
Page 334
Page 335
Page 336 - Exploded View
Page 337
Page 338 - Special Tool
Page 339 - Engine Removal/Installation
Page 340
Page 341
Page 342 - Engine Installation
Page 343
Page 344
Page 345
Page 346 - Exploded View
Page 347
Page 348
Page 349
Page 350 - Specifications
Page 351
Page 352 - Special Tools and Sealants
Page 353 - Crankcase Splitting
Page 354 - Crankcase Assembly
Page 355
Page 356
Page 357
Page 358
Page 359
Page 360 - Crankshaft and Connecting Rods
Page 361
Page 362
Page 363
Page 364 - Crankshaft/Connecting Rod Cleaning
Page 365 - Connecting Rod Big End Bearing Insert/Cr...
Page 366 - Crankshaft Side Clearance Inspection
Page 367 - Crankshaft Runout Inspection
Page 368
Page 369 - Balancer
Page 370 - Balancer Adjustment
Page 371 - Starter Motor Clutch
Page 372 - External Shift Mechanism
Page 373 - External Shift Mechanism Installation
Page 374 - External Shift Mechanism Inspection
Page 375
Page 376 - Transmission
Page 377 - Transmission Shaft Assembly
Page 378
Page 379
Page 380
Page 381
Page 382 - Shift Drum and Fork Removal
Page 383 - Shift Fork/Gear Groove Wear Inspection
Page 384 - Ball Bearing, Needle Bearing, and Oil Se...
Page 385
Page 386 - Exploded View
Page 387
Page 388 - Specifications
Page 389 - Special Tools
Page 390 - Wheels (Rims)
Page 391 - Rear Wheel Removal
Page 392
Page 393 - Rear Wheel Installation
Page 394 - Wheel Inspection
Page 395 - Balance Inspection
Page 396
Page 397 - Tires
Page 398
Page 399 - Tire Repair
Page 400 - Hub Bearing
Page 401 - Hub Bearing Inspection
Page 402
Page 403
Page 404 - Exploded View
Page 405
Page 406 - Specifications
Page 407 - Special Tools
Page 408 - Drive Chain
Page 409 - Drive Chain Installation
Page 410
Page 411
Page 412
Page 413 - Sprocket, Coupling
Page 414 - Engine Sprocket Removal
Page 415 - Rear Sprocket Installation
Page 416 - Coupling Bearing Installation
Page 417 - Sprocket Wear Inspection
Page 418
Page 419
Page 420
Page 421 - Exploded View
Page 422
Page 423
Page 424
Page 425
Page 426
Page 427
Page 428 - Specifications
Page 429
Page 430 - Brake Lever Position Adjustment
Page 431 - Brake Pedal Installation
Page 432 - Calipers
Page 433 - Caliper Installation
Page 434 - Caliper Fluid Seal Damage
Page 435 - Rear Caliper Holder Shaft Wear
Page 436 - Brake Pads
Page 437 - Rear Brake Pad Removal
Page 438 - Master Cylinder
Page 439 - Rear Master Cylinder Installation
Page 440 - Master Cylinder Inspection (Visual Inspe...
Page 441 - Brake Disc
Page 442 - Brake Fluid
Page 443
Page 444
Page 445
Page 446 - Brake Hose
Page 447 - Anti-Lock Brake System (Equipped Models)
Page 448
Page 449
Page 450
Page 451 - ABS Servicing Precautions
Page 452
Page 453 - ABS Troubleshooting Outline
Page 454
Page 455
Page 456 - Inquiries to Rider
Page 457
Page 458 - Self-diagnosis Outline
Page 459 - Service Code Clearing Procedures
Page 460
Page 461
Page 462 - How to Read Service Codes
Page 463
Page 464 - ABS Indicator Light (LED) Inspection
Page 465 - ABS Solenoid Valve Relay Inspection (Ser...
Page 466 - ABS Motor Relay Inspection (Service Code...
Page 467 - Front Wheel Rotation Sensor Wiring Inspe...
Page 468 - Rear Wheel Rotation Sensor Signal Abnorm...
Page 469 - Power Supply Voltage Abnormal (Low-Volta...
Page 470 - ECU Inspection (Service Code 55)
Page 471
Page 472 - ABS Hydraulic Unit Installation
Page 473 - Front Wheel Rotation Sensor Removal
Page 474 - Rear Wheel Rotation Sensor Removal
Page 475 - Wheel Rotation Sensor Inspection
Page 476 - Wheel Rotation Sensor Rotor Inspection
Page 477 - Fuse Installation
Page 478
Page 479
Page 480 - Exploded View
Page 481
Page 482
Page 483
Page 484 - Specifications
Page 485 - Special Tools
Page 486
Page 487 - Front Fork
Page 488 - Compression Damping Force Adjustment (Ri...
Page 489 - Front Fork Installation
Page 490
Page 491
Page 492
Page 493
Page 494
Page 495 - Front Fork Disassembly
Page 496 - Front Fork Assembly
Page 497 - Inner Tube, Outer Tube Inspection
Page 498 - Rear Shock Absorber
Page 499 - Rear Shock Absorber Removal
Page 500 - Rear Shock Absorber Inspection
Page 501 - Swingarm
Page 502 - Swingarm Installation
Page 503 - Swingarm Bearing Removal
Page 504 - Swingarm Bearing, Sleeve Inspection
Page 505 - Tie-Rod, Rocker Arm
Page 506 - Tie-Rod and Rocker Arm Bearing Removal
Page 507 - Rocker Arm/Tie-Rod Bearing, Sleeve Inspe...
Page 508
Page 509
Page 510 - Exploded View
Page 511
Page 512 - Special Tools
Page 513 - Steering Inspection
Page 514 - Steering Stem
Page 515 - Stem, Stem Bearing Installation
Page 516 - Steering Stem Bearing Lubrication
Page 517 - Steering Stem Warp
Page 518 - Handlebar
Page 519
Page 520
Page 521
Page 522 - Exploded View
Page 523
Page 524
Page 525
Page 526
Page 527
Page 528 - Seats
Page 529 - Fairings
Page 530 - Lower Fairing Installation
Page 531 - Lower Fairing Disassembly
Page 532 - Lower Fairing Assembly
Page 533 - Rear Lower Fairing Removal
Page 534 - Upper Fairing Installation
Page 535 - Upper Fairing Disassembly
Page 536 - Windshield Bracket Assembly
Page 537
Page 538 - Windshield Bracket Assembly Removal
Page 539 - Side Covers
Page 540 - Seat Covers
Page 541 - Fenders
Page 542 - Flap and Rear Fender Installation
Page 543 - Frame Inspection
Page 544 - Battery Case
Page 545 - Guard
Page 546 - Sidestand
Page 547
Page 548
Page 549 - Exploded View
Page 550
Page 551
Page 552
Page 553
Page 554
Page 555
Page 556 - Specifications
Page 557 - Special Tools and Sealant
Page 558
Page 559 - Parts Location
Page 560
Page 561
Page 562 - Wiring Diagram (US, CA and CAL Models)
Page 563
Page 564 - Wiring Diagram (Other than US, CA and CA...
Page 565
Page 566 - Wiring Diagram (CA with ABS Models)
Page 567
Page 568 - Wiring Diagram (Other than CA with ABS M...
Page 569
Page 570 - Precautions
Page 571 - Electrical Wiring
Page 572 - Battery
Page 573
Page 574
Page 575 - Precautions
Page 576 - Interchange
Page 577
Page 578 - Charging System
Page 579 - Stator Coil Removal
Page 580 - Alternator Rotor Installation
Page 581
Page 582 - Alternator Inspection
Page 583 - Regulator/Rectifier Inspection
Page 584
Page 585 - Charging Voltage Inspection
Page 586
Page 587 - Ignition System
Page 588 - Crankshaft Sensor Installation
Page 589 - Crankshaft Sensor Inspection
Page 590 - Timing Rotor Removal
Page 591 - Stick Coil Inspection
Page 592 - Spark Plug Removal
Page 593 - IC Igniter Inspection
Page 594
Page 595
Page 596 - Electric Starter System
Page 597 - Starter Motor Installation
Page 598 - Starter Motor Assembly
Page 599
Page 600 - Brush Inspection
Page 601 - Armature Inspection
Page 602
Page 603
Page 604 - Lighting System
Page 605 - Headlight Removal/Installation
Page 606 - City Light Bulb Replacement
Page 607 - License Plate Light Bulb Replacement
Page 608
Page 609 - Turn Signal Light Bulb Replacement
Page 610 - Turn Signal Relay Inspection
Page 611
Page 612
Page 613 - Air Switching Valve
Page 614
Page 615 - Radiator Fan System
Page 616
Page 617 - Meter, Gauge, Indicator Unit
Page 618 - Electronic Combination Meter Unit Inspec...
Page 619
Page 620
Page 621
Page 622
Page 623
Page 624
Page 625
Page 626
Page 627 - Fuel Level Sensor Line Self-Diagnosis Mo...
Page 628
Page 629 - Immobilizer System (Equipped Models)
Page 630
Page 631
Page 632
Page 633
Page 634
Page 635
Page 636
Page 637
Page 638
Page 639
Page 640
Page 641
Page 642
Page 643
Page 644
Page 645
Page 646
Page 647 - Immobilizer System Parts Replacement
Page 648 - Immobilizer System Inspection
Page 649
Page 650 - Switches and Sensors
Page 651 - Water Temperature Sensor Inspection
Page 652 - Speed Sensor Installation
Page 653 - Oxygen Sensor Installation (Equipped Mod...
Page 654 - Relay Box
Page 655 - Diode Circuit Inspection
Page 656
Page 657 - Fuse
Page 658 - Fuse Inspection
Page 659
Page 660
Page 661
Page 662
Page 663
Page 664
Page 665
Page 666
Page 667
Page 668
Page 669
Page 670
Page 671
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
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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
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Page 720
Page 721
Page 722
Page 723
Page 724
Page 725
Page 726
Page 727
Page 728
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Page 730
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739
Contents
Table of contents
Troubleshooting
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4-6 COOLING SYSTEM
Specifications
Item
Coolant Provided when Shipping
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Radiator Cap
Relief Pressure
Thermostat
Valve Opening Temperature
Valve Full Opening Lift
Permanent type of antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)
Green
Soft water 50%, coolant 50%
−35°C (−31°F)
2.9 L (3.1 US qt) (reserve tank full level, including radiator
and engine)
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
58 ∼ 62°C (136 ∼ 144°F)
8 mm (0.31 in.) or more at 75°C (167°F)
Standard
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Wheel Alignment Inspection
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Chapters
Table Of Contents
11
Periodic Maintenance
25
Fuel System (dfi)
91
Cooling System
231
Engine Top End
253
Clutch
303
Engine Lubrication System
317
Table Of Contents
335
Crankshaft/transmission
345
Wheels/tires
385
Final Drive
403
Brakes
419
Suspension
479
Steering
509
Frame
521
Electrical System
547
Table of Contents
Troubleshooting
Troubleshooting the DFI System
114
DFI System Troubleshooting Guide
121
ABS Troubleshooting Outline
453
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Kawasaki Z1000SX ABS Owner's Manual
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This manual is also suitable for:
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