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Kawasaki 2013 Z1000 User Manual
Page 421
Kawasaki 2013 Z1000
User Manual - Page 421
For 2013 Z1000.
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General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures
Fuel System (DFI)
Throttle Control System Inspection
Engine Vacuum Synchronization Inspection
Idle Speed Inspection
Idle Speed Adjustment
Fuel Hose Inspection (fuel leak, damage, installation condition)
Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Inspection
Cooling System
Coolant Level Inspection
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Air Suction System Damage Inspection
Clutch
Clutch Operation Inspection
Wheels/Tires
Air Pressure Inspection
Wheel/Tire Damage Inspection
Tire Tread Wear Inspection
Wheel Bearing Damage Inspection
Final Drive
Drive Chain Lubrication Condition Inspection
Drive Chain Slack Inspection
Drive Chain Slack Adjustment
Wheel Alignment Inspection
Wheel Alignment Adjustment
Drive Chain Wear Inspection
Chain Guide Wear Inspection
Brakes
Brake Fluid Leak (Brake Hose and Pipe) Inspection
Brake Hose and Pipe Damage and Installation Condition Inspection
Brake Operation Inspection
Brake Fluid Level Inspection
Brake Pad Wear Inspection
Brake Light Switch Operation Inspection
Suspension
Front Forks/Rear Shock Absorber Operation Inspection
Front Fork Oil Leak Inspection
Rear Shock Absorber Oil Leak Inspection
Rocker Arm Operation Inspection
Tie-Rod Operation Inspection
Steering
Steering Play Inspection
Steering Play Adjustment
Steering Stem Bearing Lubrication
Electrical System
Lights and Switches Operation Inspection
Headlight Aiming Inspection
Headlight Aiming Adjustment
Sidestand Switch Operation Inspection
Engine Stop Switch Operation Inspection
Others
Chassis Parts Lubrication
Bolts, Nuts and Fasteners Tightness Inspection
Replacement Parts
Air Cleaner Element Replacement
Fuel Hose Replacement
Coolant Change
Radiator Hose and O-ring Replacement
Engine Oil Change
Oil Filter Replacement
Brake Hose Replacement
Brake Fluid Change
Master Cylinder Rubber Parts Replacement
Caliper Rubber Parts Replacement
Spark Plug Replacement
Fuel System (DFI)
Exploded View
DFI System
DFI Parts Location
Specifications
Special Tools and Sealant
DFI Servicing Precautions
DFI Servicing Precautions
Troubleshooting the DFI System
Outline
Inquiries to Rider
DFI System Troubleshooting Guide
Self-Diagnosis
Self-diagnosis Outline
Self-diagnosis Procedures
Service Code Reading
Service Code Erasing
Backups
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Removal/Adjustment
Main Throttle Sensor Input Voltage Inspection
Main Throttle Sensor Output Voltage Inspection
Main Throttle Sensor Resistance Inspection
Intake Air Pressure Sensor #1 (Service Code 12)
Intake Air Pressure Sensor #1 Removal
Intake Air Pressure Sensor #1 Installation
Intake Air Pressure Sensor #1 Input Voltage Inspection
Intake Air Pressure Sensor #1 Output Voltage Inspection
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Removal/Installation
Intake Air Temperature Sensor Output Voltage Inspection
Intake Air Temperature Sensor Resistance Inspection
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Output Voltage Inspection
Water Temperature Sensor Resistance Inspection
Intake Air Pressure Sensor #2 (Service Code 16)
Intake Air Pressure Sensor #2 Removal
Intake Air Pressure Sensor #2 Installation
Intake Air Pressure Sensor #2 Input Voltage Inspection
Intake Air Pressure Sensor #2 Output Voltage Inspection
Crankshaft Sensor (Service Code 21)
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Resistance Inspection
Crankshaft Sensor Peak Voltage Inspection
Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation
Speed Sensor Input Voltage Inspection
Speed Sensor Output Voltage Inspection
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Vehicle-down Sensor Input Voltage Inspection
Vehicle-down Sensor Output Voltage Inspection
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Removal/Adjustment
Subthrottle Sensor Input Voltage Inspection
Subthrottle Sensor Output Voltage Inspection
Subthrottle Sensor Resistance Inspection
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation
Oxygen Sensor Inspection
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
Exhaust Butterfly Valve Actuator Sensor Removal/Installation
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
Immobilizer Amplifier (Service Code 35, Equipped Models)
Antenna Resistance Inspection
Amplifier Input Voltage Inspection
Blank Key Detection (Service Code 36, Equipped Models)
User Key (Ignition Key) Inspection
ECU Communication Error (Service Code 39)
ECU Communication Line Inspection
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
Stick Coil Removal/Installation
Stick Coil Primary Winding Resistance Inspection
Stick Coil Input Voltage Inspection
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
Radiator Fan Relay Inspection
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Removal
Subthrottle Valve Actuator Inspection
Subthrottle Valve Actuator Resistance Inspection
Subthrottle Valve Actuator Input Voltage Inspection
Exhaust Butterfly Valve Actuator (Service Code 63)
Exhaust Butterfly Valve Actuator Removal
Exhaust Butterfly Valve Actuator Installation
Exhaust Butterfly Valve Actuator Inspection
Exhaust Butterfly Valve Actuator Resistance Inspection
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
Air Switching Valve Inspection
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Removal/Installation
Oxygen Sensor Heater Resistance Inspection
Oxygen Sensor Heater Power Source Voltage Inspection
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
Oxygen Sensor Removal/Installation
Oxygen Sensor Inspection
Warning Indicator Light (LED)
Light (LED) Inspection
ECU
ECU Identification
ECU Removal
ECU Installation
ECU Power Supply Inspection
DFI Power Source
ECU Fuse Removal
ECU Fuse Installation
ECU Fuse Inspection
ECU Main Relay Removal/Installation
ECU Main Relay Inspection
Fuel Line
Fuel Pressure Inspection
Fuel Flow Rate Inspection
Fuel Pump
Fuel Pump Removal
Fuel Pump Installation
Fuel Pump Operation Inspection
Fuel Pump Operating Voltage Inspection
Pressure Regulator Removal
Pump Screen, Fuel Filter Cleaning
Fuel Pump Relay Removal/Installation
Fuel Pump Relay Inspection
Fuel Injectors
Fuel Injector Removal/Installation
Fuel Injector Audible Inspection
Fuel Injector Resistance Inspection
Fuel Injector Power Source Voltage Inspection
Fuel Injector Output Voltage Inspection
Fuel Injector Fuel Line Inspection
Throttle Grip and Cables
Free Play Inspection
Free Play Adjustment
Cable Installation
Cable Lubrication
Throttle Body Assy
Idle Speed Inspection/Adjustment
Synchronization Inspection/Adjustment
Throttle Body Assy Removal
Throttle Body Assy Installation
Throttle Body Assy Disassembly
Throttle Body Assy Assembly
Air Cleaner
Air Cleaner Element Removal/Installation
Air Cleaner Element Inspection
Air Cleaner Oil Draining
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank and Cap Inspection
Fuel Tank Cleaning
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)
Parts Removal/Installation
Hose Inspection
Separator Inspection
Separator Operation Test
Canister Inspection
Cooling System
Exploded View
Coolant Flow Chart
Specifications
Special Tools
Coolant
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Cooling System Flushing
Coolant Reserve Tank Removal/Installation
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Water Pump Impeller Disassembly/Assembly
Water Pump Impeller Inspection
Water Pump Housing Disassembly
Water Pump Housing Assembly
Mechanical Seal Inspection
Radiator
Radiator and Radiator Fan Removal
Radiator and Radiator Fan Installation
Radiator Inspection
Radiator Cap Inspection
Radiator Filler Neck Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hose and Pipes
Hose Installation
Hose Inspection
Water Temperature Sensor
Water Temperature Sensor Removal/Installation
Water Temperature Sensor Inspection
Engine Top End
Exploded View
Exhaust System Identification
Specifications
Special Tools and Sealant
Clean Air System
Air Suction Valve Removal
Air Suction Valve Installation
Air Suction Valve Inspection
Air Switching Valve Removal
Air Switching Valve Installation
Air Switching Valve Operation Test
Air Switching Valve Unit Test
Clean Air System Hose Inspection
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft, Camshaft Chain
Camshaft Removal
Camshaft Installation
Camshaft, Camshaft Cap Wear Inspection
Camshaft Runout Inspection
Cam Wear Inspection
Camshaft Chain Removal
Camshaft Chain Installation
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp Inspection
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Cylinder, Pistons
Cylinder Removal
Cylinder Installation
Piston Removal
Piston Installation
Cylinder Wear Inspection
Piston Wear Inspection
Piston Ring, Piston Ring Groove Wear Inspection
Piston Ring Groove Width Inspection
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection
Throttle Body Assy Holder
Throttle Body Assy Holder Removal
Throttle Body Assy Holder Installation
Muffler
Muffler Body Removal
Muffler Body Installation
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust Butterfly Valve Cable Removal
Exhaust Butterfly Valve Cable Installation
Clutch
Exploded View
Specifications
Special Tool and Sealant
Clutch Lever and Cable
Clutch Lever Free Play Inspection
Clutch Lever Free Play Adjustment
Clutch Cable Removal
Clutch Cable Installation
Clutch Cable Lubrication
Clutch Lever Assembly Installation
Clutch Cover
Clutch Cover Removal
Clutch Cover Installation
Release Shaft Removal
Release Shaft Installation
Clutch Cover Disassembly
Clutch Cover Assembly
Clutch
Clutch Removal
Clutch Installation
Clutch Plate Assembly Inspection
Clutch Plate Assembly Adjustment
Clutch Plate, Wear, Damage Inspection
Clutch Plate Warp Inspection
Clutch Spring Free Length Measurement
Clutch Housing Finger Inspection
Clutch Housing Spline Inspection
Engine Lubrication System
Exploded View
Engine Oil Flow Chart
Specifications
Special Tools and Sealants
Engine Oil and Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
Oil Pan
Oil Pan Removal
Oil Pan Installation
Oil Screen
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pump Drive Gear Removal
Oil Pump Drive Gear Installation
Oil Cooler
Oil Cooler Removal
Oil Cooler Installation
Oil Pressure Measurement
Oil Pressure Measurement
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
Engine Removal/Installation
Exploded View
Special Tool
Engine Removal/Installation
Engine Removal
Engine Installation
Crankshaft/Transmission
Exploded View
Specifications
Special Tools and Sealants
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Crankshaft and Connecting Rods
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection
Connecting Rod Big End Side Clearance Inspection
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Crankshaft Side Clearance Inspection
Crankshaft Runout Inspection
Crankshaft Main Bearing Insert/Journal Wear Inspection
Balancer
Balancer Removal
Balancer Installation
Balancer Adjustment
Balancer Damper Inspection
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
Starter Motor Clutch Inspection
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly
External Shift Mechanism
Shift Pedal Removal
Shift Pedal Installation
External Shift Mechanism Removal
External Shift Mechanism Installation
External Shift Mechanism Inspection
Transmission
Transmission Shaft Removal
Transmission Shaft Installation
Transmission Shaft Disassembly
Transmission Shaft Assembly
Shift Drum and Fork Removal
Shift Drum and Fork Installation
Shift Drum Disassembly
Shift Drum Assembly
Shift Fork Bending Inspection
Shift Fork/Gear Groove Wear Inspection
Shift Fork Guide Pin/Drum Groove Wear Inspection
Gear Dog and Gear Dog Hole Damage Inspection
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
Ball and Needle Bearing Wear
Oil Seal Inspection
Wheels/Tires
Exploded View
Specifications
Special Tools
Wheels (Rims)
Front Wheel Removal
Front Wheel Installation
Rear Wheel Removal
Rear Wheel Installation
Wheel Inspection
Axle Inspection
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Tires
Air Pressure Inspection/Adjustment
Tire Inspection
Tire Removal
Tire Installation
Tire Repair
Hub Bearing
Hub Bearing Removal
Hub Bearing Installation
Hub Bearing Inspection
Hub Bearing Lubrication
Final Drive
Exploded View
Specifications
Special Tools
Drive Chain
Drive Chain Slack Inspection
Drive Chain Slack Adjustment
Wheel Alignment Inspection/Adjustment
Drive Chain Wear Inspection
Drive Chain Lubrication
Drive Chain Removal
Drive Chain Installation
Drive Chain Replacement
Sprocket, Coupling
Engine Sprocket Cover Removal
Engine Sproket Cover Installation
Engine Sprocket Removal
Engine Sprocket Installation
Rear Sprocket Removal
Rear Sprocket Installation
Coupling Installation
Coupling Bearing Removal
Coupling Bearing Installation
Coupling Bearing Inspection
Coupling Bearing Lubrication
Coupling Damper Inspection
Sprocket Wear Inspection
Rear Sprocket Warp Inspection
Brakes
Exploded View
Specifications
Special Tools
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Brake Pedal Removal
Brake Pedal Installation
Calipers
Front Caliper Removal
Rear Caliper Removal
Caliper Installation
Front Caliper Disassembly
Front Caliper Assembly
Rear Caliper Disassembly
Rear Caliper Assembly
Caliper Fluid Seal Damage Inspection
Rear Caliper Dust Boot and Friction Boot Damage Inspection
Caliper Piston and Cylinder Damage Inspection
Rear Caliper Holder Shaft Wear Inspection
Brake Pads
Front Brake Pad Removal
Front Brake Pad Installation
Rear Brake Pad Removal
Rear Brake Pad Installation
Brake Pad Wear Inspection
Master Cylinder
Front Master Cylinder Removal
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Brake Disc
Brake Disc Removal
Brake Disc Installation
Brake Disc Wear Inspection
Brake Disc Warp Inspection
Brake Fluid
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Bleeding
Brake Hose
Brake Hose Removal/Installation
Brake Hose and Pipe Inspection
Anti-Lock Brake System (Equipped Models)
Parts Location
ABS Servicing Precautions
ABS Troubleshooting Outline
Inquiries to Rider
Self-diagnosis Outline
Self-diagnosis Procedures
Service Code Clearing Procedures
How to Read Service Codes
How to Erase Service Codes
ABS Indicator Light (LED) Inspection
Solenoid Coil Temperature Abnormal [High-Temperature] (Service Code 11)
Solenoid Valve Inspection (Service Code 13, 14, 17, 18)
ABS Solenoid Valve Relay Inspection (Service Code 19)
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
ABS Motor Relay Inspection (Service Code 35)
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)
Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52)
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)
ECU Inspection (Service Code 55)
Wheel Rotation Sensor Signal Abnormal [Too High Speed] (Service Code 93)
ABS Hydraulic Unit Removal
ABS Hydraulic Unit Installation
ABS Hydraulic Unit Inspection
Front Wheel Rotation Sensor Removal
Front Wheel Rotation Sensor Installation
Rear Wheel Rotation Sensor Removal
Rear Wheel Rotation Sensor Installation
Wheel Rotation Sensor Inspection
Wheel Rotation Sensor Air Gap Inspection
Wheel Rotation Sensor Rotor Inspection
ABS Solenoid Valve Relay Fuse (20 A) Removal
ABS Motor Relay Fuse (30 A) Removal
ABS ECU Fuse (10 A) Removal
Fuse Installation
Fuse Inspection
Suspension
Exploded View
Specifications
Special Tools
Front Fork
Rebound Damping Force Adjustment
Spring Preload Adjustment
Compression Damping Force Adjustment
Front Fork Removal (Each Fork Leg)
Front Fork Installation
Fork Oil Change
Front Fork Disassembly
Front Fork Assembly
Inner Tube, Outer Tube Inspection
Dust Seal Inspection
Spring Tension Inspection
Rear Shock Absorber
Rebound Damping Force Adjustment
Spring Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Rear Shock Absorber Bearing Removal
Rear Shock Absorber Bearing Installation
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Bearing Removal
Swingarm Bearing Installation
Swingarm Bearing, Sleeve Inspection
Swingarm Bearing Lubrication
Chain Guide Inspection
Tie-Rod, Rocker Arm
Tie-Rod Removal
Tie-Rod Installation
Rocker Arm Removal
Rocker Arm Installation
Tie-Rod and Rocker Arm Bearing Removal
Tie-Rod and Rocker Arm Bearing Installation
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
Rocker Arm/Tie-Rod Bearing Lubrication
Steering
Exploded View
Special Tools
Steering
Steering Inspection
Steering Adjustment
Steering Stem
Stem, Stem Bearing Removal
Stem, Stem Bearing Installation
Steering Stem Bearing Lubrication
Steering Stem Warp Inspection
Stem Cap Deterioration, Damage Inspection
Handlebar
Handlebar Removal
Handlebar Installation
Frame
Exploded View
Seats
Rear Seat Removal
Rear Seat Installation
Front Seat Removal
Front Seat Installation
Fairings
Lower Fairing Removal
Lower Fairing Installation
Rear Lower Fairing Removal
Rear Lower Fairing Installation
Center Fairing Removal
Center Fairing Installation
Windshield Removal
Windshield Installation
Upper Fairing Removal
Upper Fairing Disassembly
Upper Fairing Assembly
Upper Fairing Installation
Upper Fairing Bracket Removal
Upper Fairing Bracket Installation
Inner Fairing Removal
Inner Fairing Installation
Side Covers
Side Cover Removal
Side Cover Installation
Seat Covers
Seat Cover Removal
Seat Cover Installation
Fenders
Front Fender Removal
Front Fender Installation
Flap and Rear Fender Removal
Flap and Rear Fender Installation
Frame
Frame Inspection
Rear Frame Removal
Rear Frame Installation
Rear Frame Bracket Removal
Rear Frame Bracket Installation
Battery Case
Battery Case Removal
Battery Case Installation
Guard
Mud Guard Removal
Mud Guard Installation
Sidestand
Sidestand Removal
Sidestand Installation
Rear View Mirrors
Rear View Mirrors Removal (ZR1000DA/EA)
Rear View Mirrors Installation (ZR1000DA/EA)
Rear View Mirrors Removal (ZR1000DB â¼/EB â¼)
Rear View Mirrors Installation (ZR1000DB â¼/EB â¼)
Electrical System
Exploded View
Specifications
Special Tools and Sealant
Parts Location
Wiring Diagram (US and CA Models)
Wiring Diagram (Other than US and CA Models)
Wiring Diagram (ABS Equipped Models)
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Battery Activation
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Cover Removal
Alternator Cover Installation
Stator Coil Removal
Stator Coil Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Inspection
Regulator/Rectifier Inspection
Charging Voltage Inspection
Ignition System
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Timing Rotor Removal
Timing Rotor Installation
Stick Coil Removal
Stick Coil Installation
Stick Coil Inspection
Stick Coil Primary Peak Voltage Inspection
Spark Plug Removal
Spark Plug Installation
Spark Plug Condition Inspection
Interlock Operation Inspection
IC Igniter Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Lead Inspection
Right-hand End Cover Inspection
Starter Relay Inspection
Lighting System
Headlight Beam Horizontal Adjustment
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Headlight Removal/Installation
City Light Bulb Replacement
Tail/Brake Light (LED) Removal
Tail/Brake Light (LED) Installation
License Plate Light Bulb Replacement
Turn Signal Light Bulb Replacement
Turn Signal Relay Inspection
Air Switching Valve
Air Switching Valve Operation Test
Air Switching Valve Unit Test
Radiator Fan System
Fan Motor Inspection
Meter, Gauge, Indicator Unit
Meter Unit Removal/Installation
Meter Unit Disassembly
Meter Unit Assembly
Meter Unit Inspection
Immobilizer System (Equipped Models), ZR1000DA/EA
Operational Cautions
Key Registration
Immobilizer System Parts Replacement
Immobilizer System Inspection
Immobilizer System (Equipped Models), ZR1000DB â¼/EB â¼
Operational Cautions
Key Registration
Immobilizer System Parts Replacement
Immobilizer System Inspection
Immobilizer System (Equipped Models)
Switches and Sensors
Brake Light Timing Inspection
Brake Light Timing Adjustment
Switch Inspection
Water Temperature Sensor Inspection
Speed Sensor Removal
Speed Sensor Installation
Speed Sensor Inspection
Oxygen Sensor Removal (Equipped Models)
Oxygen Sensor Installation (Equipped Models)
Oxygen Sensor Inspection (Equipped Models)
Fuel Level Sensor Inspection
Relay Box
Relay Box Removal
Relay Circuit Inspection
Diode Circuit Inspection
Fuse
30 A Main Fuse Removal
Fuse Box Fuse Removal
15 A FI Fuse Removal
Fuse Installation
Fuse Inspection
Appendix
Cable, Wire, and Hose Routing
Troubleshooting Guide
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Contents
Table of Contents
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BRAKES
12-3
Exploded
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File type: PDF
File name: 12340301_2013-z1000.pdf
File size: 17.15 MB
File Language: English
Pages: 745
Author: Kawasaki
File created: 2012-05-24
Published: 2022-01-19
Updated: 2023-05-15
Download File
Table of Contents
×
General Information
11
Before Servicing
12
Model Identification
17
General Specifications
20
Unit Conversion Table
23
Periodic Maintenance
25
Periodic Maintenance Chart
27
Torque and Locking Agent
31
Specifications
36
Special Tools
38
Periodic Maintenance Procedures
39
Fuel System (DFI)
39
Throttle Control System Inspection
39
Engine Vacuum Synchronization Inspection
39
Idle Speed Inspection
43
Idle Speed Adjustment
44
Fuel Hose Inspection (fuel leak, damage, installation condition)
44
Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Inspection
45
Cooling System
46
Coolant Level Inspection
46
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)
46
Engine Top End
47
Valve Clearance Inspection
47
Valve Clearance Adjustment
48
Air Suction System Damage Inspection
52
Clutch
53
Clutch Operation Inspection
53
Wheels/Tires
54
Air Pressure Inspection
54
Wheel/Tire Damage Inspection
54
Tire Tread Wear Inspection
54
Wheel Bearing Damage Inspection
55
Final Drive
56
Drive Chain Lubrication Condition Inspection
56
Drive Chain Slack Inspection
56
Drive Chain Slack Adjustment
57
Wheel Alignment Inspection
57
Wheel Alignment Adjustment
57
Drive Chain Wear Inspection
58
Chain Guide Wear Inspection
58
Brakes
59
Brake Fluid Leak (Brake Hose and Pipe) Inspection
59
Brake Hose and Pipe Damage and Installation Condition Inspection
60
Brake Operation Inspection
60
Brake Fluid Level Inspection
60
Brake Pad Wear Inspection
61
Brake Light Switch Operation Inspection
62
Suspension
63
Front Forks/Rear Shock Absorber Operation Inspection
63
Front Fork Oil Leak Inspection
63
Rear Shock Absorber Oil Leak Inspection
63
Rocker Arm Operation Inspection
63
Tie-Rod Operation Inspection
64
Steering
64
Steering Play Inspection
64
Steering Play Adjustment
64
Steering Stem Bearing Lubrication
66
Electrical System
67
Lights and Switches Operation Inspection
67
Headlight Aiming Inspection
69
Headlight Aiming Adjustment
69
Sidestand Switch Operation Inspection
70
Engine Stop Switch Operation Inspection
71
Others
72
Chassis Parts Lubrication
72
Bolts, Nuts and Fasteners Tightness Inspection
74
Replacement Parts
75
Air Cleaner Element Replacement
75
Fuel Hose Replacement
75
Coolant Change
77
Radiator Hose and O-ring Replacement
80
Engine Oil Change
81
Oil Filter Replacement
81
Brake Hose Replacement
82
Brake Fluid Change
84
Master Cylinder Rubber Parts Replacement
85
Caliper Rubber Parts Replacement
86
Spark Plug Replacement
90
Fuel System (DFI)
91
Exploded View
94
DFI System
100
DFI Parts Location
106
Specifications
108
Special Tools and Sealant
110
DFI Servicing Precautions
112
DFI Servicing Precautions
112
Troubleshooting the DFI System
114
Outline
114
Inquiries to Rider
118
DFI System Troubleshooting Guide
121
Self-Diagnosis
126
Self-diagnosis Outline
126
Self-diagnosis Procedures
127
Service Code Reading
129
Service Code Erasing
130
Backups
131
Main Throttle Sensor (Service Code 11)
134
Main Throttle Sensor Removal/Adjustment
134
Main Throttle Sensor Input Voltage Inspection
134
Main Throttle Sensor Output Voltage Inspection
135
Main Throttle Sensor Resistance Inspection
137
Intake Air Pressure Sensor #1 (Service Code 12)
138
Intake Air Pressure Sensor #1 Removal
138
Intake Air Pressure Sensor #1 Installation
138
Intake Air Pressure Sensor #1 Input Voltage Inspection
139
Intake Air Pressure Sensor #1 Output Voltage Inspection
140
Intake Air Temperature Sensor (Service Code 13)
144
Intake Air Temperature Sensor Removal/Installation
144
Intake Air Temperature Sensor Output Voltage Inspection
144
Intake Air Temperature Sensor Resistance Inspection
145
Water Temperature Sensor (Service Code 14)
147
Water Temperature Sensor Removal/Installation
147
Water Temperature Sensor Output Voltage Inspection
147
Water Temperature Sensor Resistance Inspection
148
Intake Air Pressure Sensor #2 (Service Code 16)
149
Intake Air Pressure Sensor #2 Removal
149
Intake Air Pressure Sensor #2 Installation
149
Intake Air Pressure Sensor #2 Input Voltage Inspection
150
Intake Air Pressure Sensor #2 Output Voltage Inspection
151
Crankshaft Sensor (Service Code 21)
153
Crankshaft Sensor Removal/Installation
153
Crankshaft Sensor Resistance Inspection
153
Crankshaft Sensor Peak Voltage Inspection
153
Speed Sensor (Service Code 24, 25)
154
Speed Sensor Removal/Installation
154
Speed Sensor Input Voltage Inspection
154
Speed Sensor Output Voltage Inspection
155
Vehicle-down Sensor (Service Code 31)
157
Vehicle-down Sensor Removal
157
Vehicle-down Sensor Installation
158
Vehicle-down Sensor Input Voltage Inspection
158
Vehicle-down Sensor Output Voltage Inspection
159
Subthrottle Sensor (Service Code 32)
162
Subthrottle Sensor Removal/Adjustment
162
Subthrottle Sensor Input Voltage Inspection
162
Subthrottle Sensor Output Voltage Inspection
163
Subthrottle Sensor Resistance Inspection
165
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
166
Oxygen Sensor Removal/Installation
166
Oxygen Sensor Inspection
166
Exhaust Butterfly Valve Actuator Sensor (Service Code 34)
169
Exhaust Butterfly Valve Actuator Sensor Removal/Installation
169
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
169
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
170
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
171
Immobilizer Amplifier (Service Code 35, Equipped Models)
172
Antenna Resistance Inspection
172
Amplifier Input Voltage Inspection
173
Blank Key Detection (Service Code 36, Equipped Models)
174
User Key (Ignition Key) Inspection
174
ECU Communication Error (Service Code 39)
175
ECU Communication Line Inspection
175
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54)
176
Stick Coil Removal/Installation
176
Stick Coil Primary Winding Resistance Inspection
176
Stick Coil Input Voltage Inspection
176
Radiator Fan Relay (Service Code 56)
178
Radiator Fan Relay Removal/Installation
178
Radiator Fan Relay Inspection
178
Subthrottle Valve Actuator (Service Code 62)
179
Subthrottle Valve Actuator Removal
179
Subthrottle Valve Actuator Inspection
179
Subthrottle Valve Actuator Resistance Inspection
179
Subthrottle Valve Actuator Input Voltage Inspection
180
Exhaust Butterfly Valve Actuator (Service Code 63)
182
Exhaust Butterfly Valve Actuator Removal
182
Exhaust Butterfly Valve Actuator Installation
182
Exhaust Butterfly Valve Actuator Inspection
184
Exhaust Butterfly Valve Actuator Resistance Inspection
184
Air Switching Valve (Service Code 64)
186
Air Switching Valve Removal/Installation
186
Air Switching Valve Inspection
186
Oxygen Sensor Heater (Service Code 67, Equipped Models)
187
Oxygen Sensor Heater Removal/Installation
187
Oxygen Sensor Heater Resistance Inspection
187
Oxygen Sensor Heater Power Source Voltage Inspection
188
Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models)
190
Oxygen Sensor Removal/Installation
190
Oxygen Sensor Inspection
190
Warning Indicator Light (LED)
193
Light (LED) Inspection
193
ECU
194
ECU Identification
194
ECU Removal
194
ECU Installation
195
ECU Power Supply Inspection
195
DFI Power Source
198
ECU Fuse Removal
198
ECU Fuse Installation
198
ECU Fuse Inspection
198
ECU Main Relay Removal/Installation
198
ECU Main Relay Inspection
198
Fuel Line
199
Fuel Pressure Inspection
199
Fuel Flow Rate Inspection
200
Fuel Pump
202
Fuel Pump Removal
202
Fuel Pump Installation
203
Fuel Pump Operation Inspection
203
Fuel Pump Operating Voltage Inspection
204
Pressure Regulator Removal
204
Pump Screen, Fuel Filter Cleaning
205
Fuel Pump Relay Removal/Installation
205
Fuel Pump Relay Inspection
205
Fuel Injectors
207
Fuel Injector Removal/Installation
207
Fuel Injector Audible Inspection
207
Fuel Injector Resistance Inspection
207
Fuel Injector Power Source Voltage Inspection
208
Fuel Injector Output Voltage Inspection
209
Fuel Injector Fuel Line Inspection
210
Throttle Grip and Cables
212
Free Play Inspection
212
Free Play Adjustment
212
Cable Installation
212
Cable Lubrication
212
Throttle Body Assy
213
Idle Speed Inspection/Adjustment
213
Synchronization Inspection/Adjustment
213
Throttle Body Assy Removal
213
Throttle Body Assy Installation
215
Throttle Body Assy Disassembly
216
Throttle Body Assy Assembly
217
Air Cleaner
218
Air Cleaner Element Removal/Installation
218
Air Cleaner Element Inspection
218
Air Cleaner Oil Draining
218
Air Cleaner Housing Removal
218
Air Cleaner Housing Installation
219
Fuel Tank
220
Fuel Tank Removal
220
Fuel Tank Installation
224
Fuel Tank and Cap Inspection
225
Fuel Tank Cleaning
226
Evaporative Emission Control System (CAL, SEA-B1 and TH Models)
227
Parts Removal/Installation
227
Hose Inspection
227
Separator Inspection
227
Separator Operation Test
228
Canister Inspection
228
Cooling System
231
Exploded View
232
Coolant Flow Chart
234
Specifications
236
Special Tools
237
Coolant
238
Coolant Deterioration Inspection
238
Coolant Level Inspection
238
Coolant Draining
238
Coolant Filling
238
Pressure Testing
238
Cooling System Flushing
239
Coolant Reserve Tank Removal/Installation
239
Water Pump
240
Water Pump Removal
240
Water Pump Installation
240
Water Pump Inspection
242
Water Pump Impeller Disassembly/Assembly
242
Water Pump Impeller Inspection
242
Water Pump Housing Disassembly
242
Water Pump Housing Assembly
243
Mechanical Seal Inspection
243
Radiator
244
Radiator and Radiator Fan Removal
244
Radiator and Radiator Fan Installation
246
Radiator Inspection
246
Radiator Cap Inspection
247
Radiator Filler Neck Inspection
247
Thermostat
248
Thermostat Removal
248
Thermostat Installation
248
Thermostat Inspection
249
Hose and Pipes
250
Hose Installation
250
Hose Inspection
250
Water Temperature Sensor
251
Water Temperature Sensor Removal/Installation
251
Water Temperature Sensor Inspection
251
Engine Top End
253
Exploded View
254
Exhaust System Identification
258
Specifications
261
Special Tools and Sealant
263
Clean Air System
265
Air Suction Valve Removal
265
Air Suction Valve Installation
265
Air Suction Valve Inspection
266
Air Switching Valve Removal
266
Air Switching Valve Installation
267
Air Switching Valve Operation Test
267
Air Switching Valve Unit Test
267
Clean Air System Hose Inspection
267
Cylinder Head Cover
268
Cylinder Head Cover Removal
268
Cylinder Head Cover Installation
268
Camshaft Chain Tensioner
270
Camshaft Chain Tensioner Removal
270
Camshaft Chain Tensioner Installation
270
Camshaft, Camshaft Chain
271
Camshaft Removal
271
Camshaft Installation
272
Camshaft, Camshaft Cap Wear Inspection
276
Camshaft Runout Inspection
276
Cam Wear Inspection
276
Camshaft Chain Removal
277
Camshaft Chain Installation
277
Cylinder Head
278
Cylinder Compression Measurement
278
Cylinder Head Removal
279
Cylinder Head Installation
279
Cylinder Head Warp Inspection
281
Valves
282
Valve Clearance Inspection
282
Valve Clearance Adjustment
282
Valve Removal
282
Valve Installation
282
Valve Guide Removal
282
Valve Guide Installation
283
Valve-to-Guide Clearance Measurement (Wobble Method)
283
Valve Seat Inspection
284
Valve Seat Repair
284
Cylinder, Pistons
289
Cylinder Removal
289
Cylinder Installation
289
Piston Removal
290
Piston Installation
291
Cylinder Wear Inspection
291
Piston Wear Inspection
292
Piston Ring, Piston Ring Groove Wear Inspection
292
Piston Ring Groove Width Inspection
292
Piston Ring Thickness Inspection
293
Piston Ring End Gap Inspection
293
Throttle Body Assy Holder
294
Throttle Body Assy Holder Removal
294
Throttle Body Assy Holder Installation
294
Muffler
295
Muffler Body Removal
295
Muffler Body Installation
296
Exhaust Pipe Removal
298
Exhaust Pipe Installation
298
Exhaust Butterfly Valve Cable Removal
298
Exhaust Butterfly Valve Cable Installation
299
Clutch
301
Exploded View
302
Specifications
304
Special Tool and Sealant
305
Clutch Lever and Cable
306
Clutch Lever Free Play Inspection
306
Clutch Lever Free Play Adjustment
306
Clutch Cable Removal
306
Clutch Cable Installation
306
Clutch Cable Lubrication
306
Clutch Lever Assembly Installation
306
Clutch Cover
307
Clutch Cover Removal
307
Clutch Cover Installation
307
Release Shaft Removal
307
Release Shaft Installation
307
Clutch Cover Disassembly
308
Clutch Cover Assembly
308
Clutch
310
Clutch Removal
310
Clutch Installation
310
Clutch Plate Assembly Inspection
313
Clutch Plate Assembly Adjustment
313
Clutch Plate, Wear, Damage Inspection
314
Clutch Plate Warp Inspection
314
Clutch Spring Free Length Measurement
314
Clutch Housing Finger Inspection
314
Clutch Housing Spline Inspection
314
Engine Lubrication System
315
Exploded View
316
Engine Oil Flow Chart
318
Specifications
319
Special Tools and Sealants
320
Engine Oil and Oil Filter
321
Oil Level Inspection
321
Engine Oil Change
321
Oil Filter Replacement
321
Oil Pan
322
Oil Pan Removal
322
Oil Pan Installation
322
Oil Screen
324
Oil Screen Removal
324
Oil Screen Installation
324
Oil Screen Cleaning
324
Oil Pressure Relief Valve
325
Oil Pressure Relief Valve Removal
325
Oil Pressure Relief Valve Installation
325
Oil Pressure Relief Valve Inspection
325
Oil Pump
326
Oil Pump Removal
326
Oil Pump Installation
326
Oil Pump Drive Gear Removal
327
Oil Pump Drive Gear Installation
327
Oil Cooler
328
Oil Cooler Removal
328
Oil Cooler Installation
328
Oil Pressure Measurement
329
Oil Pressure Measurement
329
Oil Pressure Switch
330
Oil Pressure Switch Removal
330
Oil Pressure Switch Installation
330
Oil Pipe
331
Oil Pipe Removal
331
Oil Pipe Installation
331
Engine Removal/Installation
333
Exploded View
334
Special Tool
336
Engine Removal/Installation
337
Engine Removal
337
Engine Installation
340
Crankshaft/Transmission
345
Exploded View
346
Specifications
350
Special Tools and Sealants
352
Crankcase Splitting
353
Crankcase Splitting
353
Crankcase Assembly
354
Crankshaft and Connecting Rods
360
Crankshaft Removal
360
Crankshaft Installation
360
Connecting Rod Removal
360
Connecting Rod Installation
361
Crankshaft/Connecting Rod Cleaning
364
Connecting Rod Bend Inspection
364
Connecting Rod Twist Inspection
365
Connecting Rod Big End Side Clearance Inspection
365
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
365
Crankshaft Side Clearance Inspection
367
Crankshaft Runout Inspection
368
Crankshaft Main Bearing Insert/Journal Wear Inspection
368
Balancer
370
Balancer Removal
370
Balancer Installation
370
Balancer Adjustment
371
Balancer Damper Inspection
371
Starter Motor Clutch
372
Starter Motor Clutch Removal/Installation
372
Starter Motor Clutch Inspection
372
Starter Motor Clutch Disassembly
372
Starter Motor Clutch Assembly
372
External Shift Mechanism
373
Shift Pedal Removal
373
Shift Pedal Installation
373
External Shift Mechanism Removal
373
External Shift Mechanism Installation
374
External Shift Mechanism Inspection
375
Transmission
377
Transmission Shaft Removal
377
Transmission Shaft Installation
377
Transmission Shaft Disassembly
377
Transmission Shaft Assembly
378
Shift Drum and Fork Removal
382
Shift Drum and Fork Installation
382
Shift Drum Disassembly
382
Shift Drum Assembly
382
Shift Fork Bending Inspection
382
Shift Fork/Gear Groove Wear Inspection
383
Shift Fork Guide Pin/Drum Groove Wear Inspection
383
Gear Dog and Gear Dog Hole Damage Inspection
383
Ball Bearing, Needle Bearing, and Oil Seal
384
Ball and Needle Bearing Replacement
384
Ball and Needle Bearing Wear
384
Oil Seal Inspection
384
Wheels/Tires
385
Exploded View
386
Specifications
388
Special Tools
390
Wheels (Rims)
391
Front Wheel Removal
391
Front Wheel Installation
391
Rear Wheel Removal
392
Rear Wheel Installation
394
Wheel Inspection
395
Axle Inspection
395
Balance Inspection
396
Balance Adjustment
396
Balance Weight Removal
396
Balance Weight Installation
396
Tires
398
Air Pressure Inspection/Adjustment
398
Tire Inspection
398
Tire Removal
398
Tire Installation
398
Tire Repair
400
Hub Bearing
401
Hub Bearing Removal
401
Hub Bearing Installation
401
Hub Bearing Inspection
402
Hub Bearing Lubrication
402
Final Drive
403
Exploded View
404
Specifications
406
Special Tools
407
Drive Chain
408
Drive Chain Slack Inspection
408
Drive Chain Slack Adjustment
408
Wheel Alignment Inspection/Adjustment
408
Drive Chain Wear Inspection
408
Drive Chain Lubrication
408
Drive Chain Removal
408
Drive Chain Installation
409
Drive Chain Replacement
409
Sprocket, Coupling
413
Engine Sprocket Cover Removal
413
Engine Sproket Cover Installation
413
Engine Sprocket Removal
414
Engine Sprocket Installation
414
Rear Sprocket Removal
414
Rear Sprocket Installation
415
Coupling Installation
415
Coupling Bearing Removal
415
Coupling Bearing Installation
416
Coupling Bearing Inspection
416
Coupling Bearing Lubrication
416
Coupling Damper Inspection
416
Sprocket Wear Inspection
417
Rear Sprocket Warp Inspection
417
Brakes
419
Exploded View
421
Specifications
428
Special Tools
429
Brake Lever, Brake Pedal
430
Brake Lever Position Adjustment
430
Brake Pedal Position Inspection
430
Brake Pedal Position Adjustment
430
Brake Pedal Removal
430
Brake Pedal Installation
431
Calipers
432
Front Caliper Removal
432
Rear Caliper Removal
432
Caliper Installation
433
Front Caliper Disassembly
433
Front Caliper Assembly
433
Rear Caliper Disassembly
433
Rear Caliper Assembly
433
Caliper Fluid Seal Damage Inspection
434
Rear Caliper Dust Boot and Friction Boot Damage Inspection
434
Caliper Piston and Cylinder Damage Inspection
434
Rear Caliper Holder Shaft Wear Inspection
435
Brake Pads
436
Front Brake Pad Removal
436
Front Brake Pad Installation
436
Rear Brake Pad Removal
437
Rear Brake Pad Installation
437
Brake Pad Wear Inspection
437
Master Cylinder
438
Front Master Cylinder Removal
438
Front Master Cylinder Installation
438
Rear Master Cylinder Removal
438
Rear Master Cylinder Installation
439
Front Master Cylinder Disassembly
439
Rear Master Cylinder Disassembly
439
Master Cylinder Assembly
439
Master Cylinder Inspection (Visual Inspection)
440
Brake Disc
441
Brake Disc Removal
441
Brake Disc Installation
441
Brake Disc Wear Inspection
441
Brake Disc Warp Inspection
441
Brake Fluid
442
Brake Fluid Level Inspection
442
Brake Fluid Change
442
Brake Line Bleeding
442
Brake Hose
446
Brake Hose Removal/Installation
446
Brake Hose and Pipe Inspection
446
Anti-Lock Brake System (Equipped Models)
447
Parts Location
447
ABS Servicing Precautions
451
ABS Troubleshooting Outline
453
Inquiries to Rider
456
Self-diagnosis Outline
458
Self-diagnosis Procedures
458
Service Code Clearing Procedures
459
How to Read Service Codes
462
How to Erase Service Codes
462
ABS Indicator Light (LED) Inspection
464
Solenoid Coil Temperature Abnormal [High-Temperature] (Service Code 11)
464
Solenoid Valve Inspection (Service Code 13, 14, 17, 18)
464
ABS Solenoid Valve Relay Inspection (Service Code 19)
465
Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)
465
ABS Motor Relay Inspection (Service Code 35)
466
Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)
466
Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)
467
Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)
468
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)
468
Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52)
469
Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)
469
ECU Inspection (Service Code 55)
470
Wheel Rotation Sensor Signal Abnormal [Too High Speed] (Service Code 93)
470
ABS Hydraulic Unit Removal
470
ABS Hydraulic Unit Installation
472
ABS Hydraulic Unit Inspection
472
Front Wheel Rotation Sensor Removal
473
Front Wheel Rotation Sensor Installation
473
Rear Wheel Rotation Sensor Removal
474
Rear Wheel Rotation Sensor Installation
474
Wheel Rotation Sensor Inspection
475
Wheel Rotation Sensor Air Gap Inspection
475
Wheel Rotation Sensor Rotor Inspection
476
ABS Solenoid Valve Relay Fuse (20 A) Removal
476
ABS Motor Relay Fuse (30 A) Removal
476
ABS ECU Fuse (10 A) Removal
476
Fuse Installation
477
Fuse Inspection
477
Suspension
479
Exploded View
480
Specifications
484
Special Tools
485
Front Fork
487
Rebound Damping Force Adjustment
487
Spring Preload Adjustment
487
Compression Damping Force Adjustment
488
Front Fork Removal (Each Fork Leg)
488
Front Fork Installation
489
Fork Oil Change
489
Front Fork Disassembly
495
Front Fork Assembly
496
Inner Tube, Outer Tube Inspection
497
Dust Seal Inspection
497
Spring Tension Inspection
497
Rear Shock Absorber
498
Rebound Damping Force Adjustment
498
Spring Preload Adjustment
498
Rear Shock Absorber Removal
499
Rear Shock Absorber Installation
500
Rear Shock Absorber Inspection
500
Rear Shock Absorber Scrapping
500
Rear Shock Absorber Bearing Removal
501
Rear Shock Absorber Bearing Installation
501
Swingarm
502
Swingarm Removal
502
Swingarm Installation
503
Swingarm Bearing Removal
504
Swingarm Bearing Installation
504
Swingarm Bearing, Sleeve Inspection
505
Swingarm Bearing Lubrication
505
Chain Guide Inspection
505
Tie-Rod, Rocker Arm
506
Tie-Rod Removal
506
Tie-Rod Installation
506
Rocker Arm Removal
506
Rocker Arm Installation
506
Tie-Rod and Rocker Arm Bearing Removal
507
Tie-Rod and Rocker Arm Bearing Installation
507
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
508
Rocker Arm/Tie-Rod Bearing Lubrication
508
Steering
509
Exploded View
510
Special Tools
512
Steering
513
Steering Inspection
513
Steering Adjustment
513
Steering Stem
514
Stem, Stem Bearing Removal
514
Stem, Stem Bearing Installation
515
Steering Stem Bearing Lubrication
517
Steering Stem Warp Inspection
517
Stem Cap Deterioration, Damage Inspection
517
Handlebar
518
Handlebar Removal
518
Handlebar Installation
519
Frame
521
Exploded View
522
Seats
529
Rear Seat Removal
529
Rear Seat Installation
529
Front Seat Removal
529
Front Seat Installation
529
Fairings
530
Lower Fairing Removal
530
Lower Fairing Installation
530
Rear Lower Fairing Removal
530
Rear Lower Fairing Installation
531
Center Fairing Removal
531
Center Fairing Installation
531
Windshield Removal
532
Windshield Installation
532
Upper Fairing Removal
532
Upper Fairing Disassembly
533
Upper Fairing Assembly
533
Upper Fairing Installation
533
Upper Fairing Bracket Removal
533
Upper Fairing Bracket Installation
534
Inner Fairing Removal
534
Inner Fairing Installation
534
Side Covers
535
Side Cover Removal
535
Side Cover Installation
535
Seat Covers
536
Seat Cover Removal
536
Seat Cover Installation
536
Fenders
537
Front Fender Removal
537
Front Fender Installation
537
Flap and Rear Fender Removal
538
Flap and Rear Fender Installation
539
Frame
540
Frame Inspection
540
Rear Frame Removal
540
Rear Frame Installation
540
Rear Frame Bracket Removal
540
Rear Frame Bracket Installation
540
Battery Case
541
Battery Case Removal
541
Battery Case Installation
541
Guard
542
Mud Guard Removal
542
Mud Guard Installation
542
Sidestand
543
Sidestand Removal
543
Sidestand Installation
543
Rear View Mirrors
544
Rear View Mirrors Removal (ZR1000DA/EA)
544
Rear View Mirrors Installation (ZR1000DA/EA)
544
Rear View Mirrors Removal (ZR1000DB â¼/EB â¼)
544
Rear View Mirrors Installation (ZR1000DB â¼/EB â¼)
545
Electrical System
547
Exploded View
550
Specifications
556
Special Tools and Sealant
557
Parts Location
559
Wiring Diagram (US and CA Models)
562
Wiring Diagram (Other than US and CA Models)
564
Wiring Diagram (ABS Equipped Models)
566
Precautions
568
Electrical Wiring
569
Wiring Inspection
569
Battery
570
Battery Removal
570
Battery Installation
570
Battery Activation
570
Precautions
573
Interchange
574
Charging Condition Inspection
574
Refreshing Charge
574
Charging System
576
Alternator Cover Removal
576
Alternator Cover Installation
576
Stator Coil Removal
577
Stator Coil Installation
577
Alternator Rotor Removal
577
Alternator Rotor Installation
578
Alternator Inspection
579
Regulator/Rectifier Inspection
581
Charging Voltage Inspection
583
Ignition System
585
Crankshaft Sensor Removal
585
Crankshaft Sensor Installation
586
Crankshaft Sensor Inspection
587
Crankshaft Sensor Peak Voltage Inspection
587
Timing Rotor Removal
588
Timing Rotor Installation
588
Stick Coil Removal
588
Stick Coil Installation
588
Stick Coil Inspection
589
Stick Coil Primary Peak Voltage Inspection
589
Spark Plug Removal
590
Spark Plug Installation
590
Spark Plug Condition Inspection
590
Interlock Operation Inspection
590
IC Igniter Inspection
591
Electric Starter System
594
Starter Motor Removal
594
Starter Motor Installation
595
Starter Motor Disassembly
595
Starter Motor Assembly
596
Brush Inspection
598
Commutator Cleaning and Inspection
598
Armature Inspection
599
Brush Lead Inspection
599
Right-hand End Cover Inspection
599
Starter Relay Inspection
599
Lighting System
602
Headlight Beam Horizontal Adjustment
602
Headlight Beam Vertical Adjustment
602
Headlight Bulb Replacement
602
Headlight Removal/Installation
603
City Light Bulb Replacement
604
Tail/Brake Light (LED) Removal
604
Tail/Brake Light (LED) Installation
604
License Plate Light Bulb Replacement
605
Turn Signal Light Bulb Replacement
607
Turn Signal Relay Inspection
608
Air Switching Valve
611
Air Switching Valve Operation Test
611
Air Switching Valve Unit Test
611
Radiator Fan System
613
Fan Motor Inspection
613
Meter, Gauge, Indicator Unit
615
Meter Unit Removal/Installation
615
Meter Unit Disassembly
615
Meter Unit Assembly
616
Meter Unit Inspection
616
Immobilizer System (Equipped Models), ZR1000DA/EA
625
Operational Cautions
625
Key Registration
625
Immobilizer System Parts Replacement
641
Immobilizer System Inspection
643
Immobilizer System (Equipped Models), ZR1000DB â¼/EB â¼
644
Operational Cautions
644
Key Registration
644
Immobilizer System Parts Replacement
662
Immobilizer System Inspection
664
Immobilizer System (Equipped Models)
665
Switches and Sensors
666
Brake Light Timing Inspection
666
Brake Light Timing Adjustment
666
Switch Inspection
666
Water Temperature Sensor Inspection
667
Speed Sensor Removal
667
Speed Sensor Installation
668
Speed Sensor Inspection
668
Oxygen Sensor Removal (Equipped Models)
668
Oxygen Sensor Installation (Equipped Models)
669
Oxygen Sensor Inspection (Equipped Models)
669
Fuel Level Sensor Inspection
669
Relay Box
670
Relay Box Removal
670
Relay Circuit Inspection
670
Diode Circuit Inspection
671
Fuse
673
30 A Main Fuse Removal
673
Fuse Box Fuse Removal
673
15 A FI Fuse Removal
673
Fuse Installation
673
Fuse Inspection
674
Appendix
675
Cable, Wire, and Hose Routing
676
Troubleshooting Guide
740
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