Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013
FILE DETAILS:
Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013
LANGUAGE:ENGLISH
PAGES:745
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
- Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013
- This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
- Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area.
- Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
TABLE OF CONTENTS:
Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013
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 ∼/EB ∼).............................................544 Rear View Mirrors Installation (ZR1000DB ∼/EB ∼)........................................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 ∼/EB ∼.......................................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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