Transmission Shaft Removal
Split the crankcase (see Crankcase Splitting). Remove the drive shaft A and output shaft B . Transmission Shaft Installation Check to see that the set pins A and set rings B are in place. Install the drive shaft and output shaft into the upper crankcase half. Apply engine oil to the sliding surfaces of the gears and bearings. OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races. When they are properly matched, there is no clearance A between...
Connecting Rod Big End Side Clearance
Measure connecting rod big end side clearance. OInsert a thickness gauge A between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard 0.13 0.38 mm (0.0051 0.0150 in.) Service Limit 0.58 mm (0.023 in.) If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If clearance is too large after connecting rod replacement, the crankshaft also must be replaced. Connecting Rod Big End Bearing...
Table of Contents
Exploded Rear Seat Rear Seat Front Seat Front Seat Side Side Cover Side Cover Windshield Windshield I nner Cover Inner Cover Fairing Fairing Faring Bracket Seat Seat Cover Seat Cover Mud Mud Guard Mud Guard Front Fender Front Fender Frame Frame Cover Battery Battery Case Battery Case Side Side Stand Side Stand Frame I
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,...
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
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,...
Fuel System Dfi Fuel Injectors
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...
Periodic Maintenance Procedures
Check the throttle bore for cleanliness as follows ORemove the throttle body assy see Fuel System DFI OCheck the main throttle valves and throttle bores A for carbon deposits by opening the main valves. If any carbon accumulates, wipe the carbon off the throttle bores and throttle valves, using a cotton pad B penetrated with a high-flash point solvent. Be careful not to remove molybdenum disulfide coat black C from the throttle valves and the bores. Do not rub these surfaces hard and do not...
Subthrottle Valve Actuator Service Code
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
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
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
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 Pump
Connect the hand tester 25 V DC to the fuel pump connector A with needle adapter set. Special Tools-Hand Tester 57001-1394 OMeasure the operating voltage with the engine stopped, and with the connector joined. Turn the ignition switch ON. OThe tester needle should indicate battery voltage for 3 seconds, and then 0 V. Pump Operating Voltage at Pump Connections to Pump Connectors Tester Y R Lead Tester - BK W Lead Operating Voltage at Pump Connector Standard Battery Voltage 12.6 V or more for 3...
DFI Power Source
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
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
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
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...
Warning
Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations like leaning over in a turn with the potential for an accident resulting in injury or death. Ensure that the down sensor is held in place by the sensor brackets. OBe sure the battery is fully charged. Connect a digital volt meter A to the connector of the vehicle-down sensor B with the needle adapter set C . Vehicle-down Sensor Power Source...
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...
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
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
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
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...
