Z Motorcycle. Service Manual. All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, 25, (K) To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-. top > Search for Owner’s Manual (Motorcycle). How to use this service. , , , , , , , , , , , , , . KAWASAKI Z REPAIR MANUAL DOWNLOAD This is the COMPLETE factory service workshop repair manual printed for the KAWASAKI Z
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All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Kaqasaki alert for problems and non-scheduled correctly followed, could result in per- maintenance. It also precedes the text of a NOTE.
Technical Information — Air Inlet System To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter manua necessary.
Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Be sure to maintain proper alignment and use smooth movements when installing.
Download Manual: 2003 Kawasaki Z1000 — Owner’s Manual
Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Ro- tate the crankshaft to positive direction clockwise viewed from output side. Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
Overall length 2 mm Overall width mm Overall height 1 mm Wheelbase 1 mm Road clearance mm 5. Seat height mm However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. The subthrottle valve is built in the each throttle body. The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb more than 5 times longeruses lower voltage, expends lower wattage approx.
Drive Chain Slack Adjustment. The initial maintenance is vitally important and must not be neglected. Oil filler plug 0. Front axle clamp bolt Front axle Rear axle nut Final Drive: Pilot Screw Adjuster, C: If the free play is incorrect, adjust the throttle cable see below.
Tachometer [A] If the idle speed is out of the specified range, adjust it. This is to set the screw to its original position. If the separator has any cracks or damage, replace it with a new one. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.
Replace the shim with one of a different thickness. Measure the clearance when engine is cold. Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect.
This shim will give the proper clearance. Present shim is 2.
If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. Torque – Rear Axle Nut: If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Apply the oil to the O-rings so that the O-rings will be coated with oil. CAUTION To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment.
If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir. Air, however, is easily compressed. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
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Never reuse old brake fluid. Ownerss not use fluid from a container that has been left unsealed or that has been open for a long time. Replace or repair any defective parts, if necessary. Special Tool – Jack: The front wheel should swing fully left and right from the force of gravity janual the fork hits the stop.
If the steering is too loose, tighten the stem nut a fraction of a kawazaki. The plug may also be cleaned using a high-flash point solvent and a wire brush or other tool.
Also, check to see that each cotter pin is in place and in good condition. Fuel return hose left, red 2. Fuel tank breather hose right, blue 3. Right fitting of throttle body 2 8. Separator breather hose blue 4.
Turn Signal Relay F: Subthrottle Sensor DFI 1. Power Supply to Sensors inlet air pres- tery — Terminal sure, atmospheric pressure, and throttle Four barrel type Type Bore 38 mm 1.
Non-adjustable and non-removal 4. Throttle Sensor Setting Adapter: Kawasaki Bond Silicone Sealant: Do not use any other battery except for a 12 V sealed owneers as a power source. Be sure to install the oil filler plug [A] after filling the engine oil. In addition, the condition of the problem is stored in the memory of the ECU electronic control unit.
Silicone Sealant Kawasaki Bond: If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Kaaasaki of initial registration: Environment when problem occurred.
It is meant simply as a rough guide to assist the troubleshooting kawaswki some of the more common difficulties. Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the manul in neutral.
Cylinder head gasket damaged Replace see chapter 5. Cylinder head warped Inspect and replace see chapter 5. No valve clearance Adjust see chapter 2. Fuel pressure too low or too high Inspect see chapter 3.
Battery voltage low Inspect and charge see chapter Water temperature sensor trouble Inspect see chapter 3. Subthrottle valve actuator trouble Inspect see chapter 3. Atmospheric pressure sensor trouble Inspect see chapter 3. Too low fuel pressure Inspect see chapter 3. Fuel pump trouble Inspect see chapter 3. Symptoms or Possible Causes Actions chapter Firing incorrect: Clean spark plug and adjust plug gap see chapter Spark plug dirty, broken or maladjusted Spark plug cap trouble Inspect stick coil see chapter Stick coil trouble Inspect see chapter Water temperature sensor trouble Inspect and replace see chapter 3.
Inlet air temperature sensor trouble Inspect and replace maual chapter 3.
Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Main Throttle Sensor Resistance Connections: Such a shock to the part can damage it. Throttle Full Open Pv: