Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013 – PDF Download

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Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013

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Kawasaki Z1000 / 1000 ABS Workshop Service & Repair Manual 2010-2013

LANGUAGE:ENGLISH
PAGES:745
DOWNLOADABLE:YES
FILE TYPE:PDF

KAWASAKI Z1000 / 1000 ABS WORKSHOP SERVICE & REPAIR MANUAL 2010-2013 – PDF DOWNLOAD:

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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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