2015 Kawasaki Z1000 Service Manual
. Z1000 Z1000 ABS Motorcycle Service Manual. Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix. 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 Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan. LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current. EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
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 its 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. Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance.
venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and. Indicates a procedural step or work to be testers that are necessary when servicing done. GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.Model Identification.
General Specifications.1-10 Unit Conversion Table.1-13. 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit.
Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact 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. 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation.
Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. GENERAL INFORMATION 1-7 Model Identification ZR1000DA (United States and Canada) Left Side View ZR1000DA (United States and Canada) Right Side View Frame Number Engine Number. 1-8 GENERAL INFORMATION Model Identification ZR1000DA (Europe) Left Side View ZR1000DA (Europe) Right Side View. GENERAL INFORMATION 1-9 Model Identification ZR1000EA Left Side View ZR1000EA Right Side View. 1-10 GENERAL INFORMATION General Specifications ZR1000DA ∼ DD/EA ∼ ED Items Dimensions Overall Length 2 095 mm (82.48 in.) Overall Width 805 mm (31.7 in.) Overall Height 1 085 mm (42.72 in.) Wheelbase 1 440 mm (56.69 in.) Road Clearance 140 mm (5.51 in.) Seat Height 815 mm (32.1 in.). GENERAL INFORMATION 1-11 General Specifications ZR1000DA ∼ DD/EA ∼ ED Items Duration 276° Exhaust: Open 58° BBDC Close 18° ATDC Duration 256° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity.
1-12 GENERAL INFORMATION General Specifications ZR1000DA ∼ DD/EA ∼ ED Items Rear Suspension: Type Swingarm Wheel Travel 138 mm (5.43 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb 12 V 55 W ×. GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 Nm ×. PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart.Torque and Locking Agent. 2-12 Special Tools. 2-14 Periodic Maintenance Procedures.2-15 Fuel System (DFI).
2-15 Throttle Control System Inspection. 2-15 Engine Vacuum Synchronization Inspection.2-15 Idle Speed Inspection. 2-2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication. 2-42 Electrical System. 2-43 Lights and Switches Operation Inspection.
2-43 Headlight Aiming Inspection. 2-45 Headlight Aiming Adjustment. 2-45 Sidestand Switch Operation Inspection.2-46 Engine Stop Switch Operation Inspection. 2-47 Others. PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must 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. Periodic Inspection FREQUENCY Whichever. ODOMETER READING comes ×.
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever. ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Final Drive Drive chain lubrication condition - Every 600 km (400 mile) 2-32 inspect # Drive chain slack - inspect #. PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.: For higher odometer readings, repeat at the frequency interval established here. 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever. ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element # - replace Every 18 000 km (11 250 mile) 2-51 Fuel hose - replace 5 years. PERIODIC MAINTENANCE 2-7 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease. 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Front Camshaft Chain Guide Bolt (Upper) Plugs 19.6 Rear Camshaft Chain Guide Bolt Spark Plugs 115 inlb Throttle Body Assy Holder Bolts 106 inlb Upper Camshaft Chain Guide Bolts 106 inlb Exhaust Butterfly Valve Actuator Bolts 0.44. PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Breather Side Plate Bolt 0.60 52 inlb ← ← Connecting Rod Big End Nuts see the text Breather Plate Bolts 87 inlb Shift Drum Bearing Holder Bolts 106 inlb Oil Passage Plugs Oil Passage Plug. 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Nuts Upper Front Fork Clamp Bolts.
PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Meter Unit Mounting Screws 0.12 11 inlb Oxygen Sensor (Equipped Models) Switch Housing Screws 0.36 31 inlb Alternator Cover Bolts (Engine No. ∼ 87 inlb ZRT00DE013356) Alternator Cover Bolts 106 inlb Alternator Lead Holding Plate Bolt 106 inlb. 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –. PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.56 in.) Length) Standard Chain: Make. 2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 Steering Stem Nut Wrench: Vacuum Gauge: Jack: Throttle Sensor Setting Adapter: Oil Filter Wrench: Fuel Hose: Attachment Jack: Jack Attachment:. PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection. Check that the throttle grip A moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage. 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Plug the vacuum hose end A.
Connect a vacuum gauge (special tool) and hoses A to the fittings on the throttle body. Special Tool - Vacuum Gauge:. Connect a highly accurate tachometer B to one of the stick coil primary leads. PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures. Start the engine and warm it up thoroughly. Check the idle speed, using a highly accurate tachometer A.
Idle Speed Standard: 1 100 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment). 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws A. Special Tool - Pilot Screw Adjuster, A B:. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures.
Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment. Start the engine and warm it up thoroughly.
Turn the adjusting screw A until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range. PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Evaporative Emission Control System (CAL, SEA-B1 and TH Models) Inspection. Inspect the canister as follows. ○ Remove the front seat (see Front Seat Removal in the Frame chapter). ○ Remove the canister A, and disconnect the hoses from the canister. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature).
Clear the clutch cable A from the clamp B. Check the coolant level in the reserve tank C with the motorcycle held perpendicular (Do not use the side- stand.). PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (room temperature). Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter). 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve A ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders. PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance.
Adjustment Shims Thickness 3.225 mm. 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold).
Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm. PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1.
Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Clutch Clutch Operation Inspection.
Pull the clutch lever just enough to take up the free play A. Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection.
2015 Kawasaki Z1000 Specs
Remove the air valve cap. Measure the tire air pressure with an air pressure gauge A when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).