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Kawasaki Z1000 - User Manual

Kawasaki Z1000
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Z1000
Z1000 ABS
Motorcycle
Service Manual

Table of Contents

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Summary

General Information

Before Servicing

Precautions and procedures for general parts removal and reinstallation.

General Specifications

Technical specifications for dimensions, engine, drive train, frame, and electrical components.

Unit Conversion Table

Table for converting units of length, mass, volume, force, pressure, speed, power, and torque.

Periodic Maintenance

Periodic Maintenance Chart

Scheduled maintenance intervals and procedures for optimal motorcycle condition.

Torque and Locking Agent

Tightening torques and recommended locking agents for major fasteners.

Specifications

Standard and service limit specifications for various motorcycle systems.

Fuel System (DFI)

DFI System

Overview and schematic of the Digital Fuel Injection system.

Specifications

Standard specifications for DFI system components like sensors and actuators.

DFI Servicing Precautions

Important precautions to follow when servicing the DFI system.

Troubleshooting the DFI System

Guidance on diagnosing and resolving DFI system problems.

Cooling System

Specifications

Standard specifications for coolant, radiator cap, and thermostat.

Coolant

Inspection, draining, filling, and pressure testing procedures for the coolant system.

Water Pump

Procedures for water pump removal, installation, inspection, and disassembly.

Radiator

Procedures for radiator and fan removal, installation, and inspection.

Engine Top End

Specifications

Technical specifications for camshafts, cylinder head, valves, and pistons.

Camshaft Chain Tensioner

Procedures for removing and installing the camshaft chain tensioner.

Camshaft, Camshaft Chain

Procedures for camshaft and chain removal and installation, including wear inspection.

Cylinder Head

Procedures for cylinder head removal, installation, and warp inspection.

Clutch

Specifications

Standard and service limit specifications for clutch components.

Clutch Lever and Cable

Procedures for clutch lever free play inspection, adjustment, cable removal, installation, and lubrication.

Clutch Cover

Procedures for clutch cover removal, installation, and disassembly/assembly.

Clutch

Procedures for clutch removal, installation, and plate assembly inspection/adjustment.

Engine Lubrication System

Specifications

Specifications for engine oil type, viscosity, capacity, level, and oil pressure.

Engine Oil and Oil Filter

Procedures for oil level inspection, engine oil change, and oil filter replacement.

Oil Pan

Procedures for oil pan removal, installation, and gasket application.

Oil Pump

Procedures for oil pump removal, installation, and drive gear removal/installation.

Engine Removal;Installation

Engine Removal

Step-by-step procedures for removing the engine from the motorcycle.

Engine Installation

Step-by-step procedures for installing the engine into the motorcycle.

Crankshaft;Transmission

Specifications

Specifications for crankcase, crankshaft, connecting rods, and transmission components.

Crankcase Splitting

Procedures for splitting the crankcase and assembling it with new gaskets.

Crankshaft and Connecting Rods

Procedures for crankshaft and connecting rod removal, installation, and inspection.

Balancer

Procedures for balancer removal, installation, adjustment, and inspection.

Wheels;Tires

Specifications

Specifications for wheel rim runout, balance, size, and tire specifications.

Wheels (Rims)

Procedures for front and rear wheel removal, installation, and inspection.

Tires

Procedures for tire inspection, removal, installation, and repair.

Hub Bearing

Procedures for hub bearing removal, installation, inspection, and lubrication.

Final Drive

Drive Chain

Inspection, adjustment, lubrication, removal, installation, and replacement of the drive chain.

Sprocket, Coupling

Procedures for rear sprocket installation, coupling installation, bearing removal/installation/inspection, and damper inspection.

Brakes

Specifications

Specifications for brake lever, pedal, pads, discs, fluid, and ABS system components.

Calipers

Procedures for front and rear caliper removal, installation, disassembly, and assembly.

Brake Pads

Procedures for front and rear brake pad removal, installation, and wear inspection.

Master Cylinder

Procedures for master cylinder removal, installation, disassembly, assembly, and inspection.

Suspension

Specifications

Specifications for front fork and rear shock absorber settings.

Front Fork

Adjustments and procedures for front fork removal, installation, oil change, and disassembly.

Rear Shock Absorber

Adjustments and procedures for rear shock absorber removal, installation, inspection, and scrapping.

Swingarm

Procedures for swingarm removal, installation, bearing inspection, and lubrication.

Steering

Special Tools

List of special tools required for steering system maintenance.

Steering Stem

Procedures for steering stem and bearing removal, installation, lubrication, and inspection.

Handlebar

Procedures for handlebar removal and installation, including switch housing and throttle grip.

Frame

Fairings

Procedures for removing and installing lower, rear, center, and upper fairings.

Sidestand

Procedures for sidestand removal, installation, and switch inspection.

Rear View Mirrors

Procedures for removing and installing rear view mirrors for different models.

Electrical System

Specifications

Specifications for battery, charging system, ignition system, and starter system.

Ignition System

Procedures for crankshaft sensor, timing rotor, stick coil, spark plug, and interlock inspections.

Battery

Procedures for battery removal, installation, activation, and charging inspections.

Charging System

Procedures for alternator cover, stator coil, and rotor removal/installation/inspection.

Appendix

Cable, Wire, and Hose Routing

Illustrations and descriptions for routing various cables, wires, and hoses on the motorcycle.

Troubleshooting Guide

A guide to diagnose and solve common motorcycle problems.

Summary

General Information

Before Servicing

Precautions and procedures for general parts removal and reinstallation.

General Specifications

Technical specifications for dimensions, engine, drive train, frame, and electrical components.

Unit Conversion Table

Table for converting units of length, mass, volume, force, pressure, speed, power, and torque.

Periodic Maintenance

Periodic Maintenance Chart

Scheduled maintenance intervals and procedures for optimal motorcycle condition.

Torque and Locking Agent

Tightening torques and recommended locking agents for major fasteners.

Specifications

Standard and service limit specifications for various motorcycle systems.

Fuel System (DFI)

DFI System

Overview and schematic of the Digital Fuel Injection system.

Specifications

Standard specifications for DFI system components like sensors and actuators.

DFI Servicing Precautions

Important precautions to follow when servicing the DFI system.

Troubleshooting the DFI System

Guidance on diagnosing and resolving DFI system problems.

Cooling System

Specifications

Standard specifications for coolant, radiator cap, and thermostat.

Coolant

Inspection, draining, filling, and pressure testing procedures for the coolant system.

Water Pump

Procedures for water pump removal, installation, inspection, and disassembly.

Radiator

Procedures for radiator and fan removal, installation, and inspection.

Engine Top End

Specifications

Technical specifications for camshafts, cylinder head, valves, and pistons.

Camshaft Chain Tensioner

Procedures for removing and installing the camshaft chain tensioner.

Camshaft, Camshaft Chain

Procedures for camshaft and chain removal and installation, including wear inspection.

Cylinder Head

Procedures for cylinder head removal, installation, and warp inspection.

Clutch

Specifications

Standard and service limit specifications for clutch components.

Clutch Lever and Cable

Procedures for clutch lever free play inspection, adjustment, cable removal, installation, and lubrication.

Clutch Cover

Procedures for clutch cover removal, installation, and disassembly/assembly.

Clutch

Procedures for clutch removal, installation, and plate assembly inspection/adjustment.

Engine Lubrication System

Specifications

Specifications for engine oil type, viscosity, capacity, level, and oil pressure.

Engine Oil and Oil Filter

Procedures for oil level inspection, engine oil change, and oil filter replacement.

Oil Pan

Procedures for oil pan removal, installation, and gasket application.

Oil Pump

Procedures for oil pump removal, installation, and drive gear removal/installation.

Engine Removal;Installation

Engine Removal

Step-by-step procedures for removing the engine from the motorcycle.

Engine Installation

Step-by-step procedures for installing the engine into the motorcycle.

Crankshaft;Transmission

Specifications

Specifications for crankcase, crankshaft, connecting rods, and transmission components.

Crankcase Splitting

Procedures for splitting the crankcase and assembling it with new gaskets.

Crankshaft and Connecting Rods

Procedures for crankshaft and connecting rod removal, installation, and inspection.

Balancer

Procedures for balancer removal, installation, adjustment, and inspection.

Wheels;Tires

Specifications

Specifications for wheel rim runout, balance, size, and tire specifications.

Wheels (Rims)

Procedures for front and rear wheel removal, installation, and inspection.

Tires

Procedures for tire inspection, removal, installation, and repair.

Hub Bearing

Procedures for hub bearing removal, installation, inspection, and lubrication.

Final Drive

Drive Chain

Inspection, adjustment, lubrication, removal, installation, and replacement of the drive chain.

Sprocket, Coupling

Procedures for rear sprocket installation, coupling installation, bearing removal/installation/inspection, and damper inspection.

Brakes

Specifications

Specifications for brake lever, pedal, pads, discs, fluid, and ABS system components.

Calipers

Procedures for front and rear caliper removal, installation, disassembly, and assembly.

Brake Pads

Procedures for front and rear brake pad removal, installation, and wear inspection.

Master Cylinder

Procedures for master cylinder removal, installation, disassembly, assembly, and inspection.

Suspension

Specifications

Specifications for front fork and rear shock absorber settings.

Front Fork

Adjustments and procedures for front fork removal, installation, oil change, and disassembly.

Rear Shock Absorber

Adjustments and procedures for rear shock absorber removal, installation, inspection, and scrapping.

Swingarm

Procedures for swingarm removal, installation, bearing inspection, and lubrication.

Steering

Special Tools

List of special tools required for steering system maintenance.

Steering Stem

Procedures for steering stem and bearing removal, installation, lubrication, and inspection.

Handlebar

Procedures for handlebar removal and installation, including switch housing and throttle grip.

Frame

Fairings

Procedures for removing and installing lower, rear, center, and upper fairings.

Sidestand

Procedures for sidestand removal, installation, and switch inspection.

Rear View Mirrors

Procedures for removing and installing rear view mirrors for different models.

Electrical System

Specifications

Specifications for battery, charging system, ignition system, and starter system.

Ignition System

Procedures for crankshaft sensor, timing rotor, stick coil, spark plug, and interlock inspections.

Battery

Procedures for battery removal, installation, activation, and charging inspections.

Charging System

Procedures for alternator cover, stator coil, and rotor removal/installation/inspection.

Appendix

Cable, Wire, and Hose Routing

Illustrations and descriptions for routing various cables, wires, and hoses on the motorcycle.

Troubleshooting Guide

A guide to diagnose and solve common motorcycle problems.

Kawasaki Z1000 Specifications

General IconGeneral
Compression Ratio11.8:1
IgnitionDigital
Front Tire120/70ZR17M/C (58W)
Rear Tire190/50ZR17M/C (73W)
Final DriveSealed chain
Displacement1043 cc
Bore x Stroke77.0 x 56.0 mm
Fuel SystemFuel injection: ΓΈ38 mm x 4 (Keihin)
Transmission6-speed, return
Front Suspension41 mm inverted fork with stepless rebound damping and spring preload adjustability
Rear SuspensionHorizontal back-link with stepless rebound damping and spring preload adjustability
Front BrakeDual 300 mm petal discs with dual 4-piston calipers
Rear BrakeSingle 250 mm petal disc with single-piston caliper
Overall Length2045 mm
Overall Width790 mm
Overall Height1055 mm
Wheelbase1435 mm
Seat Height815 mm
Curb Mass221 kg
Fuel Capacity17 liters
Maximum Power104.5 kW {142 PS} / 10, 000 rpm
Maximum Torque111 Nm @ 7, 300 rpm
Engine Type4-stroke, liquid-cooled, DOHC, 4-cylinder

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