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...
SelfDiagnosis 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 14
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...
A Warning Csj
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...
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
All rights reserved. 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...
Stem Bearing Lubrication
Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. Visually check the outer races and the ball bearings. Replace the bearing assemblies if they show wear or damage. Pack the upper and lower ball bearings A in the cages with grease, and apply a light coat of grease to the upper and lower outer races. Install the steering stem, and adjust the...
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...
Selfdiagnosis Outline
The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection ignition starter motor operation. Dealer Mode 1 The FI indicator LED light emits service code s to show the problem s which the DFI...
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 1
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...
Periodic Maintenance Procedures Spy
Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode A and or side electrode B are corroded or damaged, or if the insulator C is cracked, replace the plug. Use the standard spark plug or its equivalent. Measure the gaps D with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode with...
Atmospheric Pressure Sensor Service Code 15
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...
Fuel System DFI 1
Exploded DFI Parts DFI Wiring Special DFI Servicing Troubleshooting the DFI System 3-17 Inquiries to DFI System Troubleshooting Guide 3-24 Self-diagnosis Self-diagnosis Service Code Clearing Procedures 3-34 How to Read Service Codes 3-36 How to Erase Service Codes 3-36 Service Code Input Voltage Output Voltage Resistance Code Input Voltage Output Voltage Inlet Air Temperature Sensor Service Code Output Voltage Sensor Resistance Inspection 3-49 Code Output Voltage Sensor Resistance Inspection...
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...
Outline
When an abnormality in the system occurs, the FI indicator LED Light Emitting Diode light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU electronic control unit . With the engine stopped and turned in the self-diagnosis mode, the service code A is indicated by the number of times the FI indicator LED light blinks. When due to a malfunction, the FI indicator LED light remains lit, ask the rider about the conditions B...
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...
Caution 1
Do not pry the connector part of the coil while removing the coil. Remove the stick coil subharness connector A from the Stick Coil Connector 4 B disconnect Stick Coil 4 C Stick Coil Connector 3 D disconnect Water Temperature Sensor Connector A Left Switch Housing Connector B Pull the main harness C upward and remove the stick coil 3 D .
Spark Plug Cleaning and Inspection
Fuel Tank see Fuel System DFI chapter Unscrew the thermostat bracket bolt A . OIf removing the spark plug 2 or 3. Pull out the stick coil 1 B . Take out the camshaft position sensor connector C from the bracket. Pull out the stick coil 2 D .
Special Tools
Carburetor Drain Plug Wrench, Hex 3 57001-1269 Throttle Sensor Setting Adapter 57001-1400 Fuel Pressure Gauge Adapter 57001-1417 Fuel Pressure Gauge Adapter 57001-1417 Carburetor Drain Plug Wrench, Hex 3 57001-1269 Throttle Sensor Setting Adapter 57001-1538 Throttle Sensor Setting Adapter 57001-1538 Kawasaki Bond Silicone Sealant 56019-120 Throttle Sensor Setting Adapter 57001-1400 Kawasaki Bond Silicone Sealant 56019-120 There are a number of important precautions that should be followed...
Fuel System DFI
OThe fuel hoses are designed to be used throughout the motorcycle's life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak A or the hose to burst. Remove the fuel tank see Fuel System DFI chapter and check the fuel hoses. Replace the hose if any fraying, cracks B or bulges C are noticed. Check that the hoses are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the...
Periodic Maintenance Procedures Jnt
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...
Cooling System
Radiator Hose and Connection Inspection OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks B or bulges C are noticed. Check that the hoses are securely connected and clamps are tightened correctly. Torque - Radiator Hose Clamp...
A Warning Vds
If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result. Wheel Alignment Inspection Adjustment Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment see Slack Adjustment . O Wheel alignment can be also checked using the straightedge or string method.
Clutch
Pull the clutch lever just enough to take up the free play A . Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard 2 3 mm 0.08 0.12 in. To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. 1 Turn the adjuster A so that 5 of threads are visible. Slide the dust cover A at the clutch...
Periodic Maintenance Procedures 1
Install the fuel tank see Fuel System DFI chapter . Start the engine and warm it up thoroughly. Tachometer A If the idle speed is out of the specified range, adjust it. Do not measure the idle speed by the tachometer of the meter unit. While idling the engine, inspect the engine vacuum, using the vacuum gauge B . Front C Engine Vacuum Standard 32.7 1.333 kPa 245 10 mmHg at Idle Speed 1 100 50 r min rpm If any vacuum is not within the specifications, first synchronize the 3 and 4 throttle...