Table of Contents

4-6 4-8 Water Water Pump Water Pump Water Pump Mechanical Seal Radiator Radiator Radiator Cap Radiator Filler Neck Thermostat Thermostat Thermostat Hose and Hose Hose Radiator Fan Switch, Water Temperature Radiator Fan Switch Radiator Fan Switch Radiator Fan Switch Water Temperature Sensor Water Temperature Sensor 21. Oil pump rotor G Apply grease. Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns...

Battery

Terminal Voltage 11.5 less than 12.6 V Standard Charge 0.9AX5 10 h Quick Charge 4.0 A x 1.0 h Battery Terminal Voltage (V) A Charge Time (h) B If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard charge later on. Terminal Voltage less than 11.5 V Charging Method 0.9 A x 20 h OIncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage...

Valveto Guide Clearance Measurement Wobble Method

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Move the stem back and forth C to measure valve valve guide clearance. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit,...

Battery Removal

Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Control Unit). Never reverse the connections of the battery, this could damage the ECU. Disconnect the negative (-) cable A . Slide out the positive (+) terminal cap B and then disconnect the positive (+) cable. Be sure to disconnect the negative (-) cable first.

Charging Condition Inspection

Battery charging condition can be checked by measuring battery terminal voltage. Remove the seats (see Frame chapter). Disconnect the battery (-) cables. Be sure to disconnect the negative (-) cable first. Measure the battery terminal voltage. OMeasure with a digital voltmeter A which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard 12.6V or more

Water Pump

Refer to Oil Pump Removal in the Engine Lubrication System chapter. Water Pump A Front B Remove the water pump body A (see Oil Pump Removal in the Engine Lubrication System chapter). Insert a metal rod B into the water pump body and tap evenly around the mechanical seal C until the seal comes off. Replace the mechanical seal with a new one. Using a thin-bladed screwdriver, pry out the oil seal D . Refer to Oil Pump Installation in the Engine Lubrication System chapter. Check the drainage...

Special Tools and Sealant

Valve Seat Cutter, 32 - 028 57001-1119 Valve Spring Compressor Assembly 57001-241 Valve Seat Cutter, 45 - 027.5 57001-1114 Valve Seat Cutter, 45 - 032 57001-1115 Valve Seat Cutter, 32 - 028 57001-1119 Valve Seat Cutter, 32 - 030 57001-1120 Valve Spring Compressor Assembly 57001-241 Valve Seat Cutter, 32 - 030 57001-1120 Valve Seat Cutter, 60 - 030 57001-1123 Valve Seat Cutter, 60 - 030 57001-1123 Valve Seat Cutter Holder Bar 57001-1128 Valve Seat Cutter, 45 - 027.5 57001-1114 Valve Seat Cutter...

Appendix

Cable, Wire, and Hose Troubleshooting 1. Fixes by the left side clamp of the tank. 2. Tank drain hose passes the side cover installation under the bracket. 8. Fixes by the right side clamps two places of the tank. 9. The outside of the frame passed 10. Fuel level sensor lead 3. Clamp (Ignition switch connector) 7. Fan motor connector (Connect the connector on the inlet air pressure sensor.) 10. To fuel level gauge and fuel reserve switch 11. To pickup coil and oil pressure switch 12. Insert the...

Clutch Lever Installation

Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B . Tighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp after tightening. Torque - Clutch Lever Holder Bolts 7.8 N m (0.80 kgf m, 69 inlb)

Service Code Table

Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor malfunction, wiring open or short Speed sensor malfunction, wiring open or short First 24 is displayed and then 25,...

Warning

If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safely, use only the standard chain. It is an endless type and should not be cut for installation. If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it...

Fuel System Dfi Fuel Injectors

Kawasaki Z1000r Fuel System Relay

Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with a high-pressure fuel hose C both ends connected with the clamps D as shown. Torque - Fuel Hose Clamp Screws 1.5 N-m 0.15 kgf-m, 13 inlb OApply soap and water solution to the areas E as shown. OWatching the pressure gauge, squeeze the pump lever F , and build up the pressure until the pressure reaches the maximum pressure. Injector Fuel Line...

Subthrottle Valve Actuator Service Code

57001 1394 Kawasaki

Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory. Never drop the actuator, especially on a hard surface. Such a shock to the actuator can damage it. OBe sure the battery is fully charged. Turn the ignition switch ON and ensure that the actuator valves open and close make light sounds several times within seconds, and then close at the idle throttle opening position. Turn the ignition switch OFF. If the actuator does not work as...

Subthrottle Valve Actuator Service Code 62

Speedtriple Led Indicator

OBe sure the battery is fully charged. Turn the ignition switch OFF. Remove the throttle body assy see Throttle Body Assy Removal . Connect the peak voltage adapter A and a digital meter B to the connector C , using the needle adapter set D . Recommended Tool - Peak Voltage Adapter Special Tool - Needle Adapter Set 57001-1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector I Meter BK BL lead 1 Meter - P BL lead 2 II Meter G lead 3 Meter - W BL lead 4 Measure the...

Troubleshooting the DFI System

Year of initial registration fine, cloudy, rain, snow, always, other hot, warm, cold, very cold, always street, highway, mountain road uphill, downhill , bumpy, pebble normal, high about 1 000 m 3 281 ft or more Motorcycle conditions when problem occurred. light up immediately after ignition switch ON, and goes off after 1 2 seconds normal lights blinks immediately after ignition switch ON, and stays on DFI problem lights up immediately after ignition switch...

Fuel System Dfi

If the rubber protector A is removed, install it. ECU B Visually inspect the terminals A of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise damaged. Replace the ECU if the terminals of the ECU connectors are cracked, bent, or otherwise damaged. With the ECU connectors A connected, check the following ground lead for continuity with the...

Speed Sensor Service Code 24

Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector. Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter Measure the sensor output voltage with the engine stopped, and with the connector joined. Turn the ignition switch ON. Speed Sensor Output Voltage at Sensor Connections to Adapter Meter Y W sensor Y lead C Meter - BK BL sensor BK lead D OIfyou rotate the engine...

Kawasaki 57001-1457

Z1000sx Switched Relay Seat

Special Tool - Needle Adapter Set 57001-1457 Check the ECU power source voltage with a digital meter A . OPosition the terminal in accordance with terminal numbers of ECU connectors B in this chapter figure. Battery C ECU Power Source Inspection Meter between Terminal 13 W Y and Ignition switch Terminal 13 W Y 0 V, OFF Terminal 43 W BK 12.6 V or more Ignition switch Both Battery Voltage 12.6 V or ON more If the meter does not read as specified, check the following Main Fuse 30 A see Electrical...

Fuel Injectors

Kawasaki Setting Adapter 57001 1457

Refer to the Throttle Body Assy Disassembly Assembly. Apply the tip of a screwdriver A to the injector C . Put the grip end onto your ear, and listen whether the injector is clicking or not. OA sound scope B can also be used. Do the same for the other injectors. If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection see Fuel Line section in this chapter . OThe click interval becomes shorter as...

Fuel System Dfi Subthrottle Sensor Service Code

Disconnect the subthrottle sensor connector. Connect a digital meter A to the subthrottle sensor connector B . Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections BL lead C lt gt BR BK lead D Standard 4 - 6 kQ If the reading is out of the range, replace the throttle body assy. If the reading is within the range, but the problem still exists, replace the ECU see this chapter . L. Subthrottle Valve Actuator m. Throttle Body Assy...

Inlet Air Temperature Sensor Service Code

Remove the inlet air temperature sensor see this section . Suspend the sensor A in a container of machine oil so that the heat-sensitive portion is submerged. Suspend a thermometer B with the heat-sensitive portion C located in almost the same depth with the sensor. OThe sensor and thermometer must not touch the container side or bottom. Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature. Using a digital...

DFI Power Source

Szr 660 Battery Connection

Refer to the Electrical System chapter for the ECU fuse removal. If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Electrical System chapter for the ECU fuse installation. Refer to the Electrical System chapter for the ECU Fuse Inspection. Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. Remove the seat cover see Frame chapter . Remove the ECU main...

Camshaft Position Sensor Service Code

Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the camshaft position sensor. In this case, turn off the ignition switch and turn it on again to enter the Dealer 2 mode. In this mode, the system tells all the troubles which the DFI system had in both static and dynamic conditions. Camshaft Position Sensor...

Vehiciedown Sensor Service Code

Kawasaki Sensor Vehicle Down

Connect a digital volt meter A to the connector with needle adapter set B . Special Tool - Needle Adapter Set 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Meter Y G lead D Meter - BK Y lead E Hold the sensor vertically. Turn the ignition switch ON, and measure the output voltage with the connector joined. OTilt the sensor 60 70 or more C right or left, then hold the sensor almost vertical with the arrow mark pointed up, and measure the...

Master Cylinder Inspection Visual Inspection

Master Cylinder Relief Port Harley

Disassemble the front and rear master cylinders. Check that there are no scratches, rust or pitting on the inner wall A of each master cylinder and on the outside of each piston B . If a master cylinder or piston shows any damage, replace them. Inspect the primary cup C and secondary cup D . If a cup is worn, damaged softened rotted , or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assembly should be replaced to...

Self Diagnosis Backups

OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0.2 4.8 V If the main throttle sensor system fails the signal is out of the usable range, wiring short or open , the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method. Also, the main throttle sensor system and inlet air pressure fails, the...

Water Temperature Sensor Service Code

Sensor Honda

Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Remove the fuel tank see Fuel Tank Removal . Drain the coolant about 200 mL 6.76 US oz . Disconnect the sensor connector, and unscrew the water temperature sensor A . Torque - Water Temperature Sensor 25 N-m 2.5 kgf-m, 18 ftlb Fill the engine with coolant and bleed the air from the cooling system see Coolant Change in the Periodic Maintenance chapter . OBe sure the battery is fully charged. Remove the...

Engine Doesnt Start Starting Difficulty

Ignition and engine stop switches not ON Starter lockout switch or neutral switch trouble Inspect and charge see chapter 16 . Starter relays not contacting or operating Inspect the starter relay see chapter 16 . Inspect and replace see chapter 16 . Starter system wiring open or shorted Inspect the wiring see chapter 16 . Inspect and replace see chapter 16 . Inspect and repair or replace see chapter 16 . Inspect and replace see chapter 16 . Starter motor rotating but engine doesn't turn over...

Read Owners Manual before operating

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control...

Specifications

Up to 180 kg 396 lb load 250 kPa 2.5 kgf cm2, 36 psi Up to 180 kg 396 lb load 290 kPa 2.9 kgf cm2, 41 psi 317.5 318.2 mm 12.50 12.53 in. ON after about 10 mm 0.39 in. of pedal travel AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany Steering Stem Nut Wrench 57001-1100 Spark Plug Wrench Owner's Tool 92110-1132

Motorcycle Service Manual

No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department Consumer Products and Machinery Company Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as...

Basic Torque for General Fasteners

Cam shaft position sensor rotor bolt Throttle body assy holder clamp bolts Cylinder head bolts M10 used bolts Front camshaft chain guide bolt upper Front camshaft chain guide bolt lower Camshaft chain tensioner mounting bolts Oil filter cartridge type, P No.16097-1070 Oil filter cartridge type, P No.16097-0002 Front brake hose joint bracket bolts Rear master cylinder push rod locknut Front fork clamp bolts Upper ZR1000-A2 Front fork clamp bolts Lower ZR1000-A2 Rear shock absorber nuts Upper and...

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following...

Technical Information Air Inlet System

The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body. The subthrottle control system operates on the signal supplied from the ECU. The open close operation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU to change the current direction into the motor of the subthrottle valve actuator. The...

Atmospheric Pressure Sensor Service Code

Intake Air Pressure Sensor Yamaha Fz6

Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring. Turn the ignition switch off. Remove the seat cover see Frame chapter . Remove the atmospheric pressure sensor A from the rubber damper in the frame. Disconnect the sensor connector. OBe sure the battery is fully charged. OThe inspection...

Poor Running or No Power at High Speed

Spark plug dirty, broken or maladjusted Clean spark plug and adjust plug gap see chapter 2 . Inspect stick coil see chapter 16 . Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 . Replace it with the correct plug see chapter 16 . Air cleaner clogged, poorly sealed or missing Clean element or inspect sealing see chapter 3 . Change fuel. Inspect and clean fuel system see chapter 3 . Fuel pump operates intermittently and often ECU fuse blows. Pump...

Diagnosis Kawasaki Z1000

Mode Diagnosis Kawasaki

OUse a fully charged battery when conducting self-diagnosis. Otherwise, the LED light blinks very slowly or doesn't blink. OKeep the self-diagnosis terminal grounded during self -diagnosis, with an auxiliary lead. Remove the rear and front seats see Frame chapter . Ground A the self-diagnossis terminal B yellow lead to the battery - terminal C or battery - lead connector, using a wire. Turn on the ignition switch. Connect an auxiliary lead E to the self-diagnosis terminal G for grounding. To...

Engine Lubrication System

Kawa 57001 1249

Situate the motorcycle so that it is vertical after warming up the engine. Remove the engine drain plug A to drain the oil. OThe oil in the oil filter can be drained by removing the filter Replace the drain plug gasket B with a new one if it is damaged. Torque - Engine Drain Plug 20 Nm 2.0 kgfm, 14.5 ftlb Pour in the specified type and amount of oil. API SH or SJ with JASO MA Viscosity SAE 10W-40 Amount 3.1 L 3.3 US qt when filter is not removed 3.3 L 3.5 US qt when filter is removed 3.8 L 4.0...

Periodic Maintenance Procedures

Yamaha Virago 250 Fuel Reserve Tank

Remove the fuel tank see Fuel System DFI chapter . Remove the radiator cap A in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. OThe coolant will drain from the radiator and engine. Front B 1 Remove Left Side Cover see Frame chapter Reserve Tank Screws A Turn over B the reserve tank, remove the cap C , and pour the coolant into a suitable container. 1 Install the reserve tank. Torque - Coolant Reserve...