Z1000 (2003)
Z1000
Motorcycle
Service Manual
Quick Reference Guide
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General Information 1
Periodic Maintenance 2
Fuel System (DFI) 3
Cooling System 4
Engine Top End 5
Clutch 6
Engine Lubrication System 7
Engine Removal/Installation 8
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
Crankshaft/Transmission 9
Wheels/Tires 10
Final Drive 11
Brakes 12
Suspension 13
Steering 14
Frame 15
Electrical System 16
Appendix 17
Z1000
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products and Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2002 Kawasaki Heavy Industries, Ltd. Third Edition (1) : Aug. 25, 2003 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center
BBDC before bottom dead center Pa pascal(s)
BDC
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direc
F farad(s) TDC top dead center
°F degree(s) Fahrenheit
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
bottom dead center
t current
N
PS
rpm revolution(s) per minute
TIR total indicator reading
newton(s)
horsepower
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with a
only.
1. Crankcase Emission Control System
This s
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the f uel and air
suppl
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of th
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model m otorcycle manufactured primarily for sale in California includes
acat
3. Evaporative Em ission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
ste
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
com
(3)(A) for any person to remove or render inoperative any device or element of design installed
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
) and exhaust emission (2) control systems in compliance with applicable regulations of
pplicable regulations of the California Air Resources Board on vehicles sold in California
ystem eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
ied by the fuel injection system.
is motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
alytic converter system.
ad, fuel vapors are routed into the running engine to be burned, or stored in a canister when
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
monly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
r in a motor vehicle or motor vehicle engine in compliance with regulations under this
on o
title prior to its sale and delivery to the ultimate purchaser, or for any m anufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
e and delivery to the ultimate purchaser.
sal
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ly to remove or render inoperative any device or element of design installed on or in a
ing
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."
NOTE
The phrase "remove or render inoperative any device or element of design" has been generally
○
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or dura bility of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECO MMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT
EXCEEDING $10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to i ts sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in compliance
•
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
•
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
ined mechanics in a properly equipped shop.
tra
However, it contains enough detail and basic information to make it useful to the owner who de-
es to perform his own basic maintenance and
sir
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
res must be understood in order to carry out
du
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
ubts his ability to do the work, all adjust-
do
ments, maintenance, and repair should be carried out only by qualified mechanics.
n order to perform the work efficiently and
I
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
efore starting work, and then do the work care-
b
fully 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.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki Mo-
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information, for example, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick R eference
Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
to Use This Manual
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and convenient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components f ollows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Con tents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Technical Information – Air Inlet System ................................................................................ 1-11
Technical Information – New Ignition Interlock Sidestand ...................................................... 1-13
Technical Information – Tail/Brake Lights Employing LED ..................................................... 1-14
Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) ........... 1-16
Unit Conversion Table ............................................................................................................ 1-17
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
photographs, cautions, and detailed descriptions have been included in each chapter wherever
tions,
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Espec
Battery Ground
Before completing any service on the motorcycle, disconnect t
from accidentally turning over. Disconnect the ground wire
(−) first and then the positive (+). When completed with the
servi
terminal of the battery then the negative (−) wire to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
ially note the following:
he battery wires from the battery to prevent the engine
ce, first connect the positive (+) wire to the positive (+)
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
GENERAL INFORMATION 1-3
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
ied sequence to prevent case warpage or deformation
specif
which can lead to malfunction. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
nally.
diago
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice-initial
tightening and final tightening with torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, Oring
Hardening, shrinkage, or damage of both gaskets and
grease seals after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces
thoroughly so that no gasket material or other material remains. Install new gaskets and replace used grease seal
when re-assembling
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil passages and cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
GENERAL INFORMATION 1-5
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins t hat were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
of rotating direction will affect the adjustment. Ro-
Model Identification
ZR1000–A1 Left Side View:
GENERAL INFORMATION 1-7
ZR1000–A1 Right Side View:
1-8 GENERAL INFORMATION
General Specifications
Items ZR1000–A1 ∼
Dimensions:
Overall length 2 080 mm (81.9 in.)
Overall width 770 mm (30.3 in.)
Overall height 1 055 mm (41.5 in.)
Wheelbase
Road clearance 145 mm (5.7 in.)
Seat height 820 mm (32.3 in.)
Dry mass 198 kg (410.1 lb)
Curb mass:
Fuel tank capacity
Performance:
Minimum turning radius
Engine:
Type
Cooling system Liquid-cooled
Bore and stroke
Displacement 953 mL (58.15 cu in.)
Compression ratio
Maximum horsepower 93.4 kW (127 PS) @10 000 r/min (rpm),
Maximum torque 95.6 N·m (9.7 kgf·m, 71 ft·lb) @8 000 r/min (rpm),
Carburetion system FI (Fuel Injection) Keihin TTK38 × 4
Starting system
Ignition system Battery and coil (transistorized)
Timing advance
Ignition timing From 10° BTDC @1 100 r/min (rpm)
Spark plug NGK CR9EK or ND U27ETR
Cylinder numbering method Left to right, 1-2-3-4
Firing order 1-2-4-3
Valve timing:
Inlet Open 38° BTDC
Exhaust Open 57° BBDC
Front
Rear 111 kg (244.8 lb)
Close 66° ABDC
Duration 284°
Close 31° ATDC
Duration
1 420 mm (55.9 in.)
110 kg (242.6 lb)
18 L (5.0 US gal.)
2.8 m (9.2 ft)
4-stroke, DOHC, 4-cylinder
77.2 × 50.9 mm (3.0 × 2.0 in.)
11.2
(MY, AU) 90.5 kW (123 PS) @10 000 r/min (rpm)
(HR) 78.2 kW (106 PS) @10 000 r/min (rpm)
(US)---
(MY, AU) 92.7 N ·m (9.4 kgf·m, 68 ft·lb) @8 000 r/min (rpm)
(HR) 86.3 N·m (8.8 kgf·m, 64 ft·lb) @7 500 r/min (rpm)
(US)---
Electric starter
Electronically advanced(digital igniter)
to 36° BTDC @7 500 r/min (rpm)
268°
General Specifications
Items ZR1000–A1 ∼
Lubrication system
Engine oil:
Type API SE, SF or SG
Viscosity SAE10W-40
Capacity 3.8 L (4.0 US qt)
Drive Train:
Primary reduction system:
Type Gear
Reduction ratio 1.714 (84/49)
Clutch type Wet m ulti disc
Transmission:
Type
Gear ratios:
1st 2.571 (36/14)
2nd 1.941 (33/17)
3rd 1.555 (28/18)
4th 1.333 (28/21)
5th
6th
Final drive system:
Type Chain drive
Reduction ratio 2.625 (42/16)
Overall drive ratio 4.929 @Top gear
Frame:
Type Tubular, diamond
Caster (rake angle) 24°
Trail 101 mm (4.0 in.)
Front tire: Type Tubeless
Size 120/70 ZR17 M /C ( 58W)
Rear tire: Type Tubeless
Size 190/50 ZR17 M /C ( 73W)
Front suspension:
Type Telescopic fork (upside-down)
Wheel travel 120 mm (4.7 in.)
Rear suspension:
Type Swingarm (uni-trak)
Wheel travel
Brake Type: Front Dual discs
Rear
Electrical Equipment:
Battery 12 V 8 Ah
Headlight: Type Semi-sealed beam
Bulb
Forced
API SH or SJ with JASO MA
6-s
.200 (24/20)
1
1.095 (23/21)
138 mm (5.4 in.)
Single disc
12 V 55 W × 2/55 W (Hi/Lo)
lubrication (wet sump with cooler)
peed, constant mesh, return shift
GENERAL INFORMATION 1-9
1-10 GENERAL INFORMATION
General Specifications
Items ZR1000–A1 ∼
Tail/brake light 12 V 0.5/3.8 W (LED)
(US, CA, Cal) 12 V 0.5/5W (LED)
Alternator: Type
Rated output 24 A/ 14 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
(AU): Australia Model
(US): U.S.A. Model
(CA): Canada Model
(Cal): C alifornia M odel
(MY): Malaysia Model
(HR): with Honeycomb Catalytic Converter Model (Restricted model)
Three-phase AC
GENERAL INFORMATION 1-11
Technical Information – Air Inlet System
Subthrottle Control System
The ZR 1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden
changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly
valve in a large bore. Therefore two throttle valves are placed in each i nlet tract, the main throttle
valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main
throttle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise,
while the subthrottle valve is operated by a stepping motor controlled by the ECU. The subthrottle
valve automatically adjusts air inlet to more precisely match engine demand, so that when the main
throttle is opened quickly there is no hesitation or j erky response.
The subthrottle valves allow the fuel injection system to provide smooth t hrottle response, similar to
that of a constant velocity carburetor, no matter how quickly the throttle is opened.
A. Main Throttle Valve
B. Subthrottle Valve
C. Throttle Valve
D. Vacuum Piston
E. Inlet Air
1-12 GENERAL INFORMATION
Technical Information – Air Inlet System
Operation
The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a
ng motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle
steppi
body.
The subthrottle control system operates on the signal supplied from the ECU. The open/close operation o
to change the current direction into the motor of the subthrottle valve actuator.
the EC
from fully closed position to fully opened position. The ECU memorizes these positions and turns
back t
f the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU
The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and
U determines the subthrottle valve angle based on the operation map.
When turning the ignition switch ON, every time the ECU automatically drives the subthrottle valve
he subthrottle valve to the original point to confirm the subthrottle valve idling voltage.
bthrottle Valves
A. Su
B. Subthrottle Valve Actuator
C. Subthrottle Sensor
ain Throttle Sensor
D.M
U (Electric Control Unit)
E. EC
F. Air Cleaner Side
G. Crankshaft Sensor
peed Sensor
H.S
GENERAL INFORMATION 1-13
Technical Informatio n – New Ignition Interlock Sidestand
Outline
The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if
gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which
differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at
each condition.
New Ignition Interlock Sidestand System
Side Stand Gear Position Clutch Lever Engine Start Engine Run
A Up Neutral Released Starts C ontinue running
B Up Neutral Pulled in Starts Continue running
C Up In Gear Released Doesn’t start Continue running
D Up In Gear Pulled in Starts Continue running
E Down Neutral Released Starts Continue running
F Down Neutral Pulled in Starts Continue running
G Down In Gear Released Doesn’t start Stops
H Down In Gear Pulled in Doesn’t start Stops
Current Ignition Interlock Sidestand System
Side Stand Gear Position Clutch Lever Engine S tart Engine Run
A Up Neutral Released Starts Continue running
B Up Neutral Pulled in Starts Continue running
C Up In G ear Released Doesn’t start Continue running
D Up In G ear Pul led in Starts Continue running
E Down Neutral Released Starts Continue running
F Down Neutral Pulled in Starts Continue running
G Down In Gear Released Doesn’t start Stops
H Down In Gear Pulled in Start Continue running
1-14 GENERAL INFORMATION
Technical Information – Tail/Brake Lights Employing LED
Outline
This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits
lumino
(more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker
responsing.
Due Position of LED Installation
us beams over a longer life span than those emitted from a traditional electric heated bulb
esistors, the diodes, and the Zener diodes are
The r
mounted in the electronic circuits [A] of the LED, which
supplies the steady current and voltage to the light.
Light Emitting Diode (LED)
The Light Emitting Diode (LED) [A] is an element of semiconductor diode that converts applied voltage to light.
The LED emits luminous beams by the collision of negative charge electrons [A] and positive charge holes [B] when
applied the forward voltage and current to the PN junction
diode [C].
GENERAL INFORMATION 1-15
Technical Information – Tail/Brake Lights Employing LED
The emitting color differs according to the materials of
semi-conductors.
Materials of Semi-Conductor and Emitting Color
Materials of Semi-Conductor Emitting Color
GaAsP
GaAlAs
GaP Gree
GaN Blue
,
Red
n
Ga: Gallium
As: Arsenic
P: Phosphorus
N: Nitrogen
Al: Aluminum
1-16 GENERAL INFORMATION
Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM)
Since the emission regulations become more severe, Kawasaki has adopted a type of simplified
KLEEN, which have no catalyst protection system, according to each regulation of different countries.
The muf
not use leaded gasoline and do not coast with the ignition system OFF. Running the engine without
ignition damages catalyst.
Refer t
(theory, maintenance, and handling precautions), including the secondary air injection system.
Honeycomb Type Catalytic Converter
The converter is a three-way catalytic converter, and its surface is covered with alumina upon which
○
platinum and rhodium are applied, and has a cylindrical metalic honeycomb structure made by bend-
ing a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter. The
honeycomb structure is convenient for the catalytic converter because it has a large surface area
but small size to react effectively and has low exhaust resistance. In addition, its inherent strength
helps resist vibration, and has simple structure welded directly on the silencer.
Generally, the temperature of the exhaust gas must be higher than activation temperature, so the
○
converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is
still high. And, the converters will be activated even under low load conditions.
After t he exhasut gas is diluted with the secondary air injection, the catalytic converter works well
○
because of rich oxygen to reduce CO, HC, and NO
emission within regulation.
This type of converter works more efficiently as a three-way catalytic converter to reduce CO, HC,
○
and NO
fler with built-in catalyst has the same durability as the conventional muffller, however, do
o the ZX900E Service Manual (Part No. 99924-1255) for more information about the KLEEN
x. A ccordingly, we can keep the exhaust gas
x than the pipe type catalytic converter because of its more and denser catalysts.
1. Manifold
2. Silencer
3. Honeycomb Type Catalyst
4. Mark for Manifold
5. Mark for Silencer
Unit Conversion Table
GENERAL INFORMATION 1-17
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m ×0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 =
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L × 2.113 = pint (US)
L × 1.816 = pint (imp)
mL × 0.03381 =
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
gal (imp)
oz (US)
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m
kgf·m × 86.80 = in·lb
× 7.233 =
ft·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg
kgf/cm²
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
× 98.07 = kPa
Units of Speed:
km/h × 0.6214 = mph
Units of Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Temperature:
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Con tents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent................. 2-4
Specifications .................................... 2-9
Special Tools ..................................... 2-11
Periodic Maintenance Procedures..... 2-12
Fuel System (DFI)........................... 2-12
Fuel Hose and Connection
Inspection .................................. 2-12
Throttle Control System
Inspection .................................. 2-13
Idle Speed Inspection .................. 2-14
Idle Speed Adjustment................. 2-14
Engine Vacuum Synchronization
Inspection .................................. 2-15
Air Cleaner Element Cleaning...... 2-19
Evaporative Emission Control
System Inspection (CAL) .......... 2-20
Cooling System............................... 2-21
Radiator Hose and Connection
Inspection .................................. 2-21
Coolant Change ........................... 2-21
Engine Top End .............................. 2-23
Air Suction Valve Inspection ........ 2-23
Valve Clearance Inspection ......... 2-24
Valve Clearance Adjustment........ 2-25
Clutch.............................................. 2-28
Clutch Adjust Inspection .............. 2-28
Engine Lubrication System ............. 2-29
Engine Oil C hange....................... 2-29
Oil Filter Change .......................... 2-29
Wheels/Tires................................... 2-30
Tire Inspection ............................. 2-30
Air Pressure
Inspection/Adjustment............... 2-31
Final Drive....................................... 2-31
Drive Chain Slack Inspection ....... 2-31
2
Drive Chain Slack Adjustment ..... 2-31
Wheel Alignment
Inspection/Adjustment............... 2-32
Drive Chain Wear Inspection ....... 2-32
Drive Chain Lubrication................ 2-33
Brakes............................................. 2-34
Brake Pad Wear Inspection ......... 2-34
Rear Brake Light Switch
Inspection/Adjustment............... 2-34
Caliper Fluid Seal Damage .......... 2-35
Caliper Dust Seal/Friction Boot
Damage..................................... 2-35
Master Cylinder Inspection (Visual
Inspection)................................. 2-36
Level Inspection ........................... 2-37
Brake Fluid Change ..................... 2-37
Brake Line Bleeding..................... 2-39
Brake Hoses and Connections
Inspection .................................. 2-41
Suspension..................................... 2-42
Front Fork Oil Leak Check ........... 2-42
Rear Shock Absorber Oil Leak
Check ........................................ 2-42
Swingarm Pivot Lubrication ......... 2-42
Uni-trak Linkage Lubrication ........ 2-42
Steering .......................................... 2-43
Steering Inspection ...................... 2-43
Steering Adjustment..................... 2-43
Stem Bearing Lubrication............. 2-44
Electrical System ............................ 2-44
Spark Plug Cleaning and
Inspection .................................. 2-44
General Lubrication ........................ 2-47
Lubrication ................................... 2-47
Nut, Bolt, and Fastener Tightness .. 2-48
Tightness Inspection.................... 2-48
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance m ust be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever 1 000 km *ODOMETER
READING
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
36 000 km
(24 000 mile)
•
OPERATION
Spark plug (e) - clean and gap †
Valve clearance (e) - inspect †
Air suction valve (e) - inspect †
Air cleaner element (e) - clean† #
Throttle control system (e) - inspect †
Idle speed (e) - inspect †
Engine vacuum synchronization (e) inspect †
comes (600 mile)
first
→ (4 000 mile)
↓ 12 000 km
Every
6 000 km
( 7 500 mile)
• • • • • •
• • • • • •
• • •
• • • • • • •
• • • •
• • •
Fuel hoses, connections - inspect †
Engine oil - change # year
Oil filter - replace
Evaporative emission control system (e)
(CAL) - inspect †
Drive chain wear - inspect †#
Brake pad wear - inspect †#
Brake light switch - inspect †
Steering - inspect †
Rear shock absorber oil leak - inspect †
Front fork oil leak - inspect †
Tire wear - inspect †
Swingarm pivot, Uni-trak linkage lubricate
General lubrication - perform
Nut, bolt, and fastener tightness - inspect
†
Drive chain - lubricate # 600 km
Drive chain slack - inspect †# 1000 km
Brake hoses, connections - inspect †
Brake fluid level - inspect † month
• • • • • •
• • • •
• • • •
• • • • • • •
• • • • • •
• • • • • •
• • • • • • •
• • • • • • •
• • •
• • •
• • • • • •
• • •
• • •
• • • •
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• • • • • • •
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