1986-2006 Kawasaki Concours Clymer Motorcycle Repair Manual

Description

This 1986-2006 Kawasaki Concours Clymer Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1986-2006 Kawasaki ZG1000 Concours motorcycles.

1986 1987 1988 1989
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
2000 2001 2002 2003 2004 2005 2006

This manual features 450 pages, hundreds of digitally produced photographs, hundreds of original pieces of artwork and easy to use color wiring diagrams.

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
Fuel requirements , Maintenance intervals , Cylinder numbering and firing order , Engine rotation , Tune-up , Spark plugs , Engine compression test , Ignition timing , Valve clearance , Engine oil and filter , Clutch , Air filter , Carburetor , Throttle cable , Choke cable , Control cable lubrication , General lubrication , Emission control system , Battery , Cooling system , Tires and wheels , Steering head bearings , Front suspension , Rear suspension , Final gearcase , Brakes , Fasteners , Specifications

CHAPTER FOUR , ENGINE TOP END
Servicing engine in 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
Servicing engine in frame , Engine , 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 , Brake fluid draining , Clutch cover , Clutch , Clutch master cylinder , Clutch slave cylinder , Clutch hose replacement , Specifications

CHAPTER SEVEN , TRANSMISSION, BEVEL GEARCASE AND SHIFT MECHANISM
Shift pedal , Shift pedal bracket , External shift mechanism , Internal shift mechanism , Transmission , 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
Electrical component replacement , Electrical connectors , Negative 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 , Cooling system checks , 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
Motorcycle 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
Brake service , Preventing brake fluid damage , Brake bleeding tips , Bleeding the brakes , Brake fluid draining , Brake pad replacement , Front brake calipers , Front brake master cylinder , Rear brake caliper , 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

WIRING DIAGRAMS