Kz1000 Service Manual Pdf Download

2
Quick Reference Guide
5
General Information
6
Before Servicing
7
Two-color Lead Identification
8
Model Identifications
9
Specifications for 1981 KZ650
11
Service Data
18
Torque and Locking Agent
21
Coarse Threads
21
Fine Threads
22
Special Tools
28
KZ650-D4 Wiring Diagram
29
KZ650-F2 Wiring Diagram
30
KZ650-H1 Wiring Diagram
31
Scheduled Maintenance
32
Periodic Maintenance Chart
34
Engine Oil Level Inspection
34
Engine Oil And/or Oil Filter Change
34
Spark Plugs Cleaning and Gapping
35
Ignition System Lubrication
35
Valve Clearance Inspection
36
Valve Clearance Adjustment Chart
37
Valve Clearance Adjustment
37
Air Suction Valves Inspection
38
Air Cleaner Cleaning
38
Air Cleaner Replacement
38
Throttle Grip Inspection
39
Carburetors
39
Throttle Grip Adjustment
39
Idle Speed Inspection
39
Idle Speed Adjustment
40
Synchronization Inspection
40
Synchronization Adjustment
41
Clutch Adjustment
42
Drive Chain Slack Adjustment
43
Drive Chain Wear Inspection
43
Drive Chain Tightening Torque
43
Drive Chain 20-Link Length
44
Front Brake Pedal Play Inspection
44
Front Brake Pedal Play Adjustment
44
Drive Chain Lubrication
44
Sprocket Teeth
45
Front Brake Cam Lever Angle Inspection
45
Front Brake Cam Lever Angle Adjustment
45
Disc Brake Pedal Play Inspection
45
Disc Brake Pedal Play Adjustment
46
Disc Brake Inspection
46
Drum Brake Inspection
46
Brake Fluid Level Inspection
46
Locknut Tightening
47
Changing Brake Fluid
47
Air Bleeding
47
Recommended Disc Brake Fluid
48
Brake Camshaft Lubrication
48
Filling Up the Brake Line
48
Bleeding the Brake Line
49
Steering Inspection
49
Brake Light Switches Inspection
49
Brake Light Switches Adjustment
49
Rubber Disc Brake Parts
50
Steering Adjustment
50
Steering Lubrication
51
Front Fork Cleaning
51
Front Fork Oil Change
51
Fork Oil
52
Tire Wear, Damage
52
Wheel Bearings and Speedometer Gear Lubrication and Inspection
52
Fork Oil Level Measurement
52
Tire Tread Depth
53
Spoke Tightness
53
Rim Runout
53
Standard Tire
54
Swing Arm Lubrication
54
Battery Electrolyte Level Inspection
54
Fuel System Inspection and Cleaning
55
General Lubrication
55
Fuel Hose Replacement
55
Brake Lever
55
Clutch Lever
56
Brake Pedal, Brake Rod Joints
56
Center Stand
56
Carburetor Choke Link Mechanism
56
THrottle Grip
57
Bolt and Nut Tightening
59
Non-scheduled Maintenance - Engine
60
Fuel Tank, Fuel Tap, Tank Cap Inspection
60
Mixture Trouble Symptoms
61
Carburetors Wear Inspection
61
Service Fuel Level Measurement
61
Carburetor Specifications
62
Service Fuel Level Adjustment
62
Accelerator Pump System Inspection
62
Float Height
63
Accelerator Pump System Cleaning and Replacement
63
Vacuum Switch Valve Inspection
63
Camshafts Cam Wear Inspection
63
Cam Height
64
Journal, Bearing Wear Inspection
64
Cam Height Measurement
64
Camshaft Journal/Camshaft Cal Clearance
64
Camshaft Bearing Inside Diameter
65
Camshaft Runout Measurement
65
Camshaft Chain Wear Inspection
65
Chain Guide Wear Inspection
65
Chain Tensioner Inspection
66
Cylinder Head, Cylinder Block, Pistons Compression Measurement
66
Cylinder Head Cleaning
66
Cylinder Head Warp Inspection
67
Cylinder Head Combustion Volume Measurement
67
Combustion Chamber Volume
67
Measuring Plastic Plate
68
Valve Inspection
68
Valve Heat Thickness
68
Valve Shape
68
Valve Stem Bend
69
Valve Guide Inspection
69
Valve Seat Inspection
69
Valve Seat Repair
69
Valve Guide Inside Diameter
70
Valve Installed Height Inspection
70
Valve and Valve Seat
70
Cutting Valve Seat
70
Lapping Valve Seat
71
Valve Stem Installed Height Procedure
71
Valve Spring Tension Inspection
72
Valve Spring Squareness Inspection
72
Oil Seal Inspection
72
Piston Cleaning
72
Cylinder, Piston Wear Inspection
73
Piston/Cylinder Clearance
73
Boring, Honing
73
Cylinder Inside Diameter Measurement
74
Piston/Cylinder Seizure
74
Piston Ring, Piston Ring Groove Wear Inspection
74
Piston Ring End Gap Inspection (Top, Second)
74
Piston, Piston Pin, Connecting Rod Wear Inspection
75
Connecting Rod Bend, Twist Inspection
75
Connecting Rod Bend Measurement
76
Connecting Rod Bearing Insert/Journal Wear Inspection
76
Connecting Rod Bearing Insert Replacement
76
Connecting Rod Twist Measurement
77
Connecting Rod Side Clearance Inspection
77
Crankshaft Runout Inspection
77
Crankshaft Bearing Insert/Journal Wear Inspection
78
Crankshaft Bearing Insert Replacement
78
Upper Crankcase Marking
79
Crankshaft Side Clearance Inspection
79
Oil Passage Cleaning
79
Primary Chain Drive Sprocket Damage Inspection
80
Secondary Sprocket Damage Inspection
80
Damper Inspection
80
Primary Chain Wear Inspection
80
Chain Trouble
81
Spring Tension Inspection
81
Friction Plate Wear, Damage Inspection
81
Clutch Plate Warp Inspection
81
Friction Plate/Clutch Housing Clearance Inspection
82
Clutch Housing Gear/Secondary Shaft Gear Backlash Inspection
82
Clutch Housing/Drive Shaft Sleeve Wear Inspection
82
Clutch Hub Damage Inspection
82
Clutch Release Gear Wear Inspection
83
Neutral Switch Inspection
83
External Shift Mechanism Inspection
84
Gear Backlash Inspection
84
Shift Fork Bending Inspection
84
Shift Fork/Gear Groove Wear Inspection
84
Shift Fork Guide Pin/Shift Drum Groove Wear Inspection
85
Engine Lubrication
85
Gear Dog, Gear Dog Hole, Gear Dog Recess Damage Inspection
85
Gear/Shaft Clearance Inspection
85
Shaft/Needle Bearing Outer Race Wear Inspection
86
Oil Pressure Measurement
86
Oil Pressure Switch Operation
86
Relief Valve Opening Pressure
87
Engine Oil Flow Chart
88
Relief Valve Inspection
88
Outer Rotor/Inner Rotor Clearance
88
Outer Rotor/Pump Body Clearance
88
Rotor Side Clearance
89
Ball Bearing Wear, Damage Inspection
89
Needle Bearing Wear, Damage Inspection
89
Oil Seal Damage Inspection
89
Muffler Inspection
91
Non-scheduled Maintenance - Chassis
92
Tire Pressure Adjustment
92
Wheel Balance Inspection
92
Wheel Balancing
92
Tire Air Pressure
93
Tubeless Tires
93
Balance Weight Installation
94
Tubeless Tire Repair
96
Drive Train
96
Cast Rims
96
Rim Runout Measurement
96
Rim Damage Inspection
97
Rear Sprocket Warp Inspection
97
Drive Chain Cleaning
97
Brake Pedal Position
98
Pedal Position Inspection
98
Pedal Position Adjustment
98
Master Cylinder Part Wear Inspection
99
Caliper Part Inspection
100
Disc Warp, Wear Inspection
100
Disc Cleaning
100
Brake Line Damage Inspection
100
Brake Drum Wear Inspection
101
Brake Shoe Lining Wear Inspection
101
Brake Shoe Spring Tension Inspection
101
Camshaft, Shaft Hole Wear Inspection
102
Steering Stem Warp Inspection
102
Bearing Wear, Damage Inspection
102
Grease Seal Deterioration, Damage Inspection
102
Suspension Adjustment
103
Front Fork Air Pressure
103
Front Fork Load/Compression Stroke Relationship (KZ650-D)
103
Front Fork Load/Compression Stroke Relationship (KZ650-F)
103
Front Fork Load/Compression Stroke Relationship (KZ650-H)
104
Rear Shock Absorber Spring Force Inspection
104
Rear Shock Absorber Spring Force Adjustment
104
Shock Absorber Spring Force (KZ650-D)
104
Shock Absorber Spring Force (KZ650-F)
105
Rear Shock Absorber Damping Force Inspection
105
Rear Shock Absorber Damping Force Adjustment
105
Front Fork Spring Tension Inspection
105
Front Fork Inner Tube Damage Inspection
106
Front Fork Oil Seal, Dust Seal Inspection
106
Rear Shock Absorbers Inspection
106
Swing Arm Sleeve Wear Inspection
106
Swing Arm Needle Bearing Inspection
107
Non-scheduled Maintenance - Electrical
108
Battery
108
Electrolyte
108
Specific Gravity/Battery Charge Relationship
109
Battery Initial Charging
109
Battery Ordinary Charging
109
Battery Troubleshooting Guide
110
Charging System
110
Battery Test
110
Charging System Initial Inspection
110
Charging Circuit
111
Operational Inspection of Charging System
111
Alternator Inspection
111
Charging Voltage
111
Alternator Output Voltage
112
Regulator/Rectifier Inspection
113
Ignition System Troubleshooting Guide
114
Ignition Circuit
114
Dynamic Ignition Timing Test
115
Ignition Coil Inspection
115
Ignition Coil Test
116
Operational Inspection of the Ignition System
116
Pickup Coil Inspection
116
Ignition Coil Resistance
116
Pickup Coil Resistance
117
Ignition System Wiring Check
117
IC Igniter Out of Circuit Test
117
Ignition Switch Test
117
Wiring Inspection
118
Electric Starter Motor Circuit
118
Electric Starter Relay Test
119
Starter Lockout Switch Test
119
Starter Button Test
119
Starter Motor Carbon Brush Wear Inspection
119
Brush Spring Inspection
120
Field Coil Inspection
120
Starter Motor Clutch Inspection
120
Commutator Groove
121
Lighting System
121
Headlight Beam Horizontal Adjustment
121
Headlight Beam Vertical Adjustment
122
Headlight Circuit for US and Canadian Models
122
Headlight Circuit for Other Than US and Canadian Models
123
Brake Light Circuit
123
Headlight Switch, Dimmer Switch, Passing Button Inspection
123
Front Brake Light Switch Inspection
124
Rear Brake Light Switch Inspection
124
Brake Light Failure Indicator Switch Inspection
125
Turn Signal and Hazard Circuit
125
Turn Signal Trouble
126
Automatic Turn Signal Cancelling System
127
Distance Sensor Inspection
127
Turn Signal Switch and Selector Switch Inspection
127
Selector Switch Internal Connections
128
Hazard Circuit Test
129
Low Fuel Warning System
129
Horn Adjustment
129
Horn Trouble
130
Warning System Trouble
131
Disassembly - Engine
133
Flow Chart
134
Fuel Tank Removal
134
Fuel Tap, Fuel Level Sensor Removal
135
Fuel Tank Installation
135
Fuel Tap Disassembly
135
Fuel Tap Assembly
135
Ignition Coil Removal
136
Vacuum Switch Valve Installation
136
Ignition Coil Installation
136
Carburetor Removal
137
Air Cleaner Element Removal

Kz1000 Service Manual Free

2
Quick Reference Guide
3
General Information Table of Contents
4
Before Servicing
5
Model Identification
7
KZ/Z1000-J1 Specifications
9
KZ/Z1000-K1, KZ/Z1000-M1 Specifications
11
Torque and Locking Agent
11
Engine Part Tightening Torque
12
Chassis Part Tightening Torque
13
Brake Part Tightening Torque
15
Special Tools
20
Service Data
27
KZ1000-J1 Wiring Diagram
28
Z1000-J1 Wiring Diagram
29
KZ1000-K1 Wiring Diagram
30
Z1000-K1 Wiring Diagram
31
KZ1000-M1 Wiring Diagram
32
Scheduled Maintenance Table of Contents
33
Periodic Maintenance Chart
35
Engine Oil Level Inspection
35
Oil And/or Oil Filter Change
36
Valve Clearance
36
Spark Plugs Cleaning and Gapping
36
Ignition System Lubrication
37
Valve Clearance Inspection
37
Valve Clearance Measurement
38
Valve Clearance Adjustment
38
Valve Lifter Holder
39
Valve Adjustment Chart
40
Air Suction Valves Inspection
40
Air Cleaner Cleaning
41
Air Cleaner Replacement
41
Throttle Grip Inspection
41
Throttle Grip Adjustment
41
Carburetors
42
Idle Speed Inspection
42
Idle Speed Adjustment
42
Synchronization Inspection
42
Synchronization Adjustment
43
Adjusting Screws for Synchronization
43
Clutch Adjustment
44
Drive Chain Slack Inspection
44
Drive Chain Slack Adjustment
45
Drive Chain Wear Inspection
45
Drive Chain 20-Link Length
46
Brake Adjustment
46
Brake Wear
46
Brake Fluid Level
46
Drive Chain Lubrication
47
Brake Fluid Change
47
Front Brake Fluid Reservoir
47
Rear Brake Fluid Reservoir
47
Recommended Disc Brake Fluid
48
Air Bleeding
48
Rubber Disc Brake Parts
48
Filling Up Brake Line
48
Bleeding Brake Line
49
Brake Light Switches Inspection
49
Brake Light Switches Adjustment
49
Steering Inspection
49
Steering Adjustment
50
Torquing Stem Locknut
51
Steering Lubrication
51
Front Fork Cleaning
51
Front Fork Oil Change
52
Wheels
52
Tire Wear, Damage
52
Fork Oil
52
Oil Level Measurement
53
Wheel Bearings Lubrication
53
Tire Tread Depth
54
Spoke Tightness
54
Rim Runout
54
Swing Arm Lubrication
55
Battery Electrolyte Level Inspection
55
Fuel System Inspection and Cleaning
56
General Lubrication
56
Fuel Hose Replacement
59
Bolt and Nut Tightening
61
Non-scheduled Maintenance - Engine
62
Fuel Tank, Fuel Tap
62
Mixture Trouble Symptoms
62
Carburetor Specifications
63
Service Fuel Level Measurement and Adjustment
63
Valve Needle
63
Jet Needle
64
Float Height Measurement
64
Service Fuel Level
64
Float Height
65
Camshafts
65
Cam Wear
65
Journal, Bearing Wear
65
Cam Height Measurement
66
Camshaft Runout
66
Camshaft Chain Wear
66
Chain Guide Wear
66
Chain Tensioner Inspection
67
Cylinder Head Cleaning
67
Cylinder Head Warp
67
Combustion Chamber Volume Measurement
67
Plastic Measuring Plate
68
Valve Inspection
68
Valve Stem Grinding
68
Valve Head Thickness
69
Valve Guide Inside Diameter
69
Valve Stem Bend Measurement
70
Valve Seat Inspection
70
Valve Seat Repair
70
Valve/Valve Guide Clearance
70
Valve Seating Surface
71
Valve Installed Height
71
Lapping Valve Seat
72
Valve Springs
72
Spring Tension Measurement
73
Kawasaki Clean Air System (US Model)
73
Air Section Valves
73
Spring Squareness
73
Oil Seal Inspection
74
Cylinder Block, Pistons
74
Vacuum Switch Valve Inspection
74
Vacuum Switch Valve Operation
75
Compression Measurement
75
Cylinder Diameter
76
Piston Diameter
76
Piston/Cylinder Clearance
76
Boring, Honing
76
Piston/Cylinder Seizure
77
Piston Ring, Piston Ring Groove Wear
77
Piston Ring End Gap
77
Piston Ring/Groove Clearance
77
Piston Ring Thickness
78
Crankshaft, Connecting Rods
78
Piston, Piston Pin, Connecting Rod Wear
78
Connecting Rod Bending or Twisting
78
Connecting Rod Big End Radial Clearance
79
Connecting Rod Side Clearance
79
Crankshaft Runout
80
Clutch
80
Main Bearing Inspection
80
Bearing Outer Race Side Clearance
80
Spring Tension
81
Friction Plate Thickness, Damage
81
Friction and Steel Plate Warp
81
Friction Plate/Clutch Housing Clearance
81
Clutch Housing Gear Inspection
82
Transmission, Shift Mechanism
82
Clutch Housing, Bearing Collar Diameter
82
Clutch Hub Damage
82
Clutch Release Inspection
83
External Shift Mechanism Inspection
83
Shift Drum, Shift Fork, Shift Rod Inspection
84
Neutral Switch Inspection
84
Transmission Gear Backlash
84
Width of Shift Fork Grooves On Gears
85
Engine Lubrication System
85
Gear Dog and Gear Dog Recess Damage
85
Gear/Shaft Clearance
85
Oil Pressure Measurement
87
Engine Oil Pump
87
Oil Pressure Switch Inspection
87
Pump Gear/Pump Body Clearance
87
Oil Screen Inspection
88
Non-scheduled Maintenance - Chassis
89
Wheel Balance
89
Construction of Tires
89
To Check the Wheel Balance
90
Tires Payload and Tire Pressure
90
Balance Weight Installation
91
Tubeless Tire Repair
91
Tire Air Pressure
93
Rim Sizes
94
Rim Damage
94
Axle Runout
94
Grease Seal Inspection
94
Wheel Bearings Inspection
95
Sprocket Diameter
95
Rear Sprocket Warp
95
Brake Pedal Position
96
Pedal Position Adjustment
96
Master Cylinders
96
Visual Inspection
97
Front and Rear Master Cylinders
97
Calipers Pad Wear
98
Fluid Seal Damage
98
Dust Seal and Cover Damage
98
Piston, Cylinder Wear
99
Caliper Holder Shaft Wear
99
Brake Discs
99
Disc Warp
99
Disc Cleaning
100
Front Fork
100
Steering Stem Warp
100
Bearing Wear, Damage
100
Grease Seal Deterioration, Damage
101
Air Pressure Adjustment
101
Inner Tubes, Guide Bushes
101
Front Fork Air Pressure
101
Fork Spring Free Length
102
Inner Tube Damage
102
Guide Bush Damage
102
Oil Seals, Dust Seals
102
Rear Shock Absorber Inspection
103
Rear Shock Absorber Spring Force
104
Spring Force Adjustment
104
Damping Force Adjustment
104
Rear Shock Absorber Setting
105
Swing Arm Sleeve Wear
105
Swing Arm Bearing Damage
105
Pivot Shaft Runout
105
Drive Chain Cleaning
106
Non-scheduled Maintenance - Electrical
107
Battery
107
Electrolyte
107
Hydrometer
107
Specific Gravity/Battery Charge Relationship
108
Battery Charging
108
Initial Charge
108
Ordinary Charge
109
Charging System
109
Test Charging
109
Battery Troubleshooting Guide
110
Regulator/Rectifier
110
Charging System Inspection
110
Alternator Construction
111
Operational Inspection of Charging System
111
Alternator Inspection
111
Regulator/Rectifier Output Voltage
111
Alternator Output Voltage
112
Regulator/Rectifier Inspection
112
Stator Coil Resistance
113
Ignition System
114
Main Component Parts
115
Safety Instructions
115
Ignition System Troubleshooting Guide
117
Timing Marks
117
Arcing Distance Measurement
119
Spark Plugs
119
Operational Inspection of Ignition System
120
Electric Starter System
120
Starter Relay Test
120
Spark Plug Specifications
121
Starter Lockout Switch Test
121
Starter Switch Test
121
Starter Motor Circuit
121
Starter Relay Switch Test
122
Carbon Brushes
122
Starter Motor Construction
123
Brush Spring
123
Commutator
123
Field Coils
124
Ignition Switch
124
Starter Clutch Inspection
124
Starter Clutch Operation
125
Testing Switch
125
Headlight Beam
125
Headlight Horizontal Adjustment
125
Headlight Vertical Adjustment
126
Checking Reserve Lighting System
126
Headlight Circuit and Reserve Lighting System
127
Headlight Circuit (US, Canada Model KZ1000-J and K)
127
Headlight Circuit (US, Canada Model KZ1000-M)
128
Headlight, Dimmer Switch Inspection
128
Headlight Circuit (European Model KZ1000-J and K)
129
Reserve Lighting System Wiring Inspection
129
Turn Signal Circuit
129
Turn Signal Trouble
130
Turn Signal Circuit, Automatic Canceling System, and Hazard Warning Circuit (KZ/Z1000-K)
130
Turn Signal and Hazard Warning Circuit
130
Turn Signal Circuit (West German, UK and Italian Model Z1000-J)
131
Automatic Turn Signal Canceling System (KZ/Z1000-K)
131
Distance Sensor Inspection
132
Turn Signal Switch Inspection
132
Wiring Inspection
132
Distance Sensor Pulse
132
Turn Signal Switch Connections
133
Tail/Brake Light
133
Testing the Hazard Warning Circuit
134
Tail/Brake Light Circuit (US, Canadian Models)
134
Tail/Brake Light Circuit (European Model)
135
Front Brake Light Switch Inspection
135
Rear Brake Light Switch Inspection
135
Horn Adjustment
135
Tail/Brake Light Trouble
136
Fuel Gauge
136
Horn Trouble
137
Gauge Circuit Check
137
Fuel Level Sender Inspection
137
Fuel Gauge Check
137
Wiring Check
138
Electric Speedometer, Tachometer and Odometer
138
Electric Meter System Troubleshooting Guide
139
Description of Each Test Procedure
139
Speed-Sensor, Power Supply Lead Voltage
139
Odometer, Power Supply Lead Voltage
139
Pulses for Speedometer
140
Pulse Transmit-Circuit in Odometer
140
Speedometer, Power Supply Lead Voltage
140
Ignition Coil Signal Lead
140
Tachometer, Power Supply Lead Voltage
141
Neither Odometer Not Speedometer Operates at All

Kz1000 Service Manual Pdf Download Free

KZ1000 REPAIR MANUAL download now kz1000 kz1100 fours 81-85 service repair workshop manual instant 1978 kawasaki kz1000 service manual. Related title This is the complete repair manual for the 1981/1982 Kawasaki KZ1000/1100 LTD. Classic Kawasaki OEM Parts & Shop Manuals. Repair & Shop Manual Add to cart $8.95 is a 163 pages. It also contains color wiring diagrams, periodic maintenance, timing and tune-up references, picture history of the H1, exploded parts view with part numbers. Download PDF Manual: 1979-80 Kawasaki KZ1000 E. View and Download Kawasaki KZ1100 service manual online. KZ1100 Motorcycle pdf manual download. Also for: Kz1000.