Kawasaki ZG1000 Concours 1986-2004 M409
Includes Color Wiring Diagrams.
This repair manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the Kawasaki Concours Series motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual, making it an indispensable part of your tool box
Models:
ZG1000 Concours / GTR1000 (1986-2004)
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine noises / Engine lubrication / Engine leakdown test / Clutch / Fuel system / Gearshift linkage / Transmission / Final drive / Electrical testing / Charging system / Ignition system / Starting system / Cooling system / Front suspension and steering / Brakes
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Spark plugs / Engine compression test / Ignition timing / Valve clearance / Engine oil and filter / Air filter / Throttle and choke cable / General lubrication / Emission control system / Specifications
CHAPTER FOUR / ENGINE TOP END
Servicing engine in the frame / Cylinder head cover / Cam chain tensioner / Camshaft / Cam chain and chain guides / Rocker arm assembly / Cylinder head / Valves and valve components / Cylinder block / Pistons / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Alternator chain assembly / Starter clutch and alternator shaft / Oil cooler / Oil pan / Oil pump / Oil pressure switch / Crankcase / Crankshaft / Connecting rods / Balancer / Specifications
CHAPTER SIX / CLUTCH
Clutch system bleeding and draining / Clutch cover / Clutch master cylinder / Clutch slave cylinder / Clutch hose / Specifications
CHAPTER SEVEN / TRANSMISSION, BEVEL GEARCASE AND SHIFT MECHANISM
Shift pedal / Shift pedal bracket / External shift mechanism / Internal shift mechanism / Bevel gear assembly / Specifications
CHAPTER EIGHT / AIR/FUEL, EMISSION AND EXHAUST SYSTEM
Fuel tank / Fuel level sensor / Fuel valve / Air filter housing / Secondary air system / Evaporative emission control system / Carburetor / Throttle cable / Exhaust system / Specification
CHAPTER NINE / ELECTRICAL SYSTEM
Battery terminal / Charging system / Alternator / Ignition system / Starting system / Lighting system / Meter assembly / Gauges / Wiring and connectors / Switches / Junction box / Fuses / Specifications
CHAPTER TEN / COOLING SYSTEM
Hose clamps / Flushing the system / Water pump / Thermostat assembly / Coolant temperature sensor / Coolant reservoir / Coolant manifold / Radiator / Cooling fan motor / Fan switch / Radiator bracket / Specifications
CHAPTER ELEVEN / WHEELS AND TIRES
Bike stand / Brake rotor protection / Front wheel / Front hub / Rear wheel / Rear hub / Wheel balance / Tire repairs / Tire changing / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front fork / Handlebars / Handlebar left grip replacement / Steering head / Lower bearing replacement / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear suspension linkage / Swing arm / Driveshaft / Final gearcase / Specifications
CHAPTER FOURTEEN / BRAKES
Bleeding and draining brake fluid / Brake pads / Front rear brake calipers / Front rear brake master cylinder / Brake pedal footpeg assembly / Brake disc / Brake hose replacement / Specifications
CHAPTER FIFTEEN / BODY AND FRAME
Side covers / Footpegs / Lower fairing / Middle fairing / Front fairing / Fairing bracket / Tail cover / Front fender / Rear fender / Seat / Tool box / Rear frame
INDEX
COLOR WIRING DIAGRAMS
