Мануал для кавасаки z800

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• 548, 15-24 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation • Applygreasetotheslidingarea[A]ofthesidestand[B]. • Replace the side stand nut [C] with a new one. • Tighten the side stand bolt [D] first, and then the side …

• 256, 5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Side Fairings (see Side Fairing Removal in the Frame chapter) • Disconnect the hose [A]. • Remove: Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem c hapter) Air Suction Valve Cover Bolts [A] (Both Sides) •…

• 144, Kawasaki Z800 ABS 3-58 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor Circuit 1. Water Proof Joint 1 2. Water Proof Joint 2 3. Intake Air Pressure Sensor 4. ECU
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• 352, 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance w ith the inside diam- eter. Crankcase Main Bearing Inside Diameter Marks: “ ○ ”or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). NOTE ○ The mark already on the upper crankcase half should almost…

• 605, ELECTRICAL SYSTEM 16-53 Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). • Slide back the rubber cap [A]. • Remove the starter motor cable terminal nut [B]. • Remove the mounting bolts [C]. • Pull out the starter motor [D]. Starter …

• 445, BRAKES 12-51 Anti-Lock Brake System (Equipped Models) Service Code Table Service Code Yellow ABS Indicator Light (LED) Problems Light State – Stays on* (Error function after the ignition switch turned on) Main harness, meter unit, wheel rotation sensor(s) or ABS unit abnormal ON – Does not go on (When the ignition switch turned on) Main harness, meter unit or ABS unit abnormal OFF 13 Rear intake solenoid valve trouble (wiring …

• 356, 9-28 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the springs [C] are damaged in any way, replace them. If the shift mechanism arm [D] is damaged in any way, replace the shaft. • Check the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the t…

• 482, 13-18 SUSPENSION Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special Tool — Fork Piston Rod Puller, M12 × 1.25: 57001 -1289 • Pull the puller up above the outer tube top. • Install the spring seat [A] with the flat surface [B] facing upward. • Install the fork spring [C] with the smaller end [D] facing upward. • Install the collar [A] so that the cut side [B] faces down- ward. • Install the washer [C] o…

• 655, Kawasaki Z800 ABS ELECTRICAL SYSTEM 16-103 Immobilizer System • Tighten a new Torx bolt [A] until the bolt head [B] is broken [C]. • Run the leads correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). • Register the more than two ignition keys (see Key Regis- tration). Immobilizer Amplifier Replacement • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Re…

• 56, 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible. • Remove the right subframe cover (see S ubframe Cover Removal in the Frame chapter). • Slide the dust cover [A] a…

• 481, SUSPENSION 13-17 Front F ork • Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Recommended Oil KHL15-10 or equivalent Amount (Per Side): When changing oil: Approx. 405 mL (13.7 US oz.) After disassembly and completely dry: Right Front For k 464 ±4 mL (15.7 ±0.135 US oz.) Left Front Fork 469 ±4 mL (15.9 ±0.135 US oz.) If necessary, measure the oil lev…

• 291, Kawasaki Z800 ABS CLUTCH 6-1 6 Clutch Table of Contents Exploded View………………………………………………………………………………………………………… 6-2 Specifications …………………………………………………………………………………………………………. 6-4 Special Tool and Sealant ………………………………………………………………………………………….. 6-5 Clutch Lever and Cable…………………….…

• 501, Kawasaki Z800 ABS SUSPENSION 13-37 Rear Shock Absorber • Remove: Bolts [A] Screw [B] • To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame. Special Tool — Hook Wrench T = 3. 2 R37: 57001-1539 If the spring action feels too soft or too stiff, adjust it. Spring Adjustment Adjuster Position Damping Force Setting Load Road Speed 1…

• 312, 7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation • Refer to the Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○ Inspect the valve in its assembled state. Disassembly and assembly…

• 245, ENGINE TOP END 5-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Suction Valve Cover Bolts 9.8 1.0 87 in·lb 2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb S 3 Camshaft Cap Bolts (L = 45 mm) 12 1.2 106 in·lb S 4 Camshaft Cap Bolts (L = 40 mm) 12 1.2 106 in·lb S 5 Spark Plugs 13 1.3 115 in·lb 6 Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18 7 Cylinder Head Bolts (M10) See the text ← ← MO, S 8 Cylinder Head Jacket …

• 503, SUSPENSION 13-39 Rear Shock Absorber • Remove the upper shock absorber nut and bolt [A]. • Remove the shock absorber [B] from downside. Rear Shock Absorber Installation • Replace the rear shock absorber nuts (upper and lower) and tie-rod nut with new ones. • Tighten: Torque — Rear Shock Absorber Nuts (Upper and Lower): 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Sh…

• 169, FUEL SYSTEM (DFI) 3-83 Exhaust Butterfly Valve Actuator Sensor (Service Co de 34, ZR800A/B M odels) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal). Exhaust Butterfly Valve Actuator Sensor Input Voltage I nspection NOTE ○ Be sure the battery is fully char…

• 298, 6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft. • Install the washer [B] and spring [C]. • Insert the release shaft straight into the upper hole of the clutch cover. NOTICE When inserting …

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