Used 1986-1990 Kawasaki ZG1000A Concours Service Manual

Description

This used 1986-1990 Kawasaki ZG1000A Concours Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1986-1990 Kawasaki ZG1000A Concours motorcycles. Includes general information about each model, fuel system, cooling system, engine top-end, clutch, engine lubrication system, engine removal, engine installation, crankshaft, transmission, wheels, tires, final drive, brakes, suspension, steering, frame, body, electrical system and complete wiring diagrams. Features 372 illustrated pages. This is the original manual used by Kawasaki factory trained technicians. This book will pay for itself the first time you use it.

Note: This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

Table of Contents

Chapter 1 General Information
Before Servicing, Model Identification, General Specifications, Periodic Maintenance Chart Torque and Locking Agent, Hose Routing, Wire Routing.

Chapter 2 Fuel System
Exploded View, Specifications, Special Tools, Throttle Grip and Cable (Throttle Grip Play Inspection, Throttle Cable Adjustment, Throttle Cable Lubrication, Throttle Cable Inspection), Choke Cable (Choke Cable Free Play Inspection, Choke Cable Adjustment, Choke Cable Lubrication, Choke Cable Inspection), Carburetors (Idle Speed Inspection, Idle Speed Adjustment, Carburetors Synchronization Inspection, Carburetors Synchronization, Fuel Level Inspection, Fuel Level Adjustment, Fuel System Cleanliness Inspection, Carburetors Assembly Removal/Installation Notes, High Altitude Performance Adjustment(US model), Carburetors Disassembly/Assembly Notes, Carburetors Separation/Assembly Notes, Carburetors Cleaning, Carburetors Inspection, Coolant Filter Cleaning), Air Cleaner (Air Cleaner Element Removal, Air Cleaner Element Installation, Air Cleaner Element Cleaning, Air Cleaner Element Inspection and Replacement), Fuel Tank (Fuel Tank Removal, Fuel Tank Installation, Fuel Tap Removal, Fuel Tap Installation, Fuel Tank and Tap Cleaning, Fuel Tap Inspection, Fuel Tank and Cap Inspection), Evaporative Emission Control System(US California Vehicle Only) (Parts Removal/Installation Notes, Hose Inspection, Separator Inspection, Separator Operation Test, Canister Inspection, Fuel Tank and Cap Inspection), Fuel Gauge and Lever Sensor.

Chapter 3 Cooling System
Exploded View, Specifications, Cooling System, Coolant (Coolant Deterioration, Coolant Level Inspection, Coolant Draining, Coolant Filling, Air Bleeding, Visual Leak Inspection, Cooling System Pressure Testing, Flushing, Coolant Filter Cleaning), Disassembly and Assembly Precautions, Water Pump (Pump Cover Removal/Installation, Pump Impeller Inspection, Water Pump Removal, Water Pump Installation Note), Radiator (Radiator Fan, Radiator/ Radiator Fan Removal Notes, Radiator/ Radiator Fan Installation Notes, Radiator Cleaning, Radiator Inspection, Radiator Cap Inspection, Radiator Hose, Reservoir Tank Hose Inspection, Radiator Hose, Pipe, Reservoir Tank Hose Installation, Thermostat (Thermostat Removal, Thermostat Inspection).

Chapter 4 Engine Top End
Exploded View, Specifications, Special Tools, Clean Air System (US model and, Swiss – ZG1000-A3 – model) (Air Suction Valve Installation, Vacuum Switch Valve Installation, Air Suction Valve Inspection,, Clean Air System Hose Inspection, Vacuum Switch Valve Test), Cylinder Head Cover (Cylinder Head Cover Removal, Installation Note), Cam Chain Tensioner (Chain Tensioner Removal, Chain Tensioner Installation, Replacement Chain Tensioner, Installation), Camshaft – Camshaft Chain – Rocker Shaft (Camshafts – Rocker Shafts – Removal Note, Camshafts – Rocker Shafts – Installation Notes, Chain Timing Procedure, Camshaft and Sprocket Assembly Notes, Camshaft Oil Clearance Inspection, Camshaft Chain Wear, Camshaft Chain Guide Wear), Oil Pipe (Oil Pipe Installation Note, Head Oil Pipe Installation Note, Main Oil Pipe Removal Note, Main Oil Pipe Installation Note), Cylinder Head (Compression Measurement, Cylinder Head Removal Notes, Cylinder Head Installation Notes, Cylinder Head Disassembly and Assembly (Valve Mechanism Removal and Installation), Cylinder Head Warp, Cylinder Head Cleaning), Valves (Valve Clearance Inspection, Valve Clearance Adjustment, Valve Seat Inspection, Valve Seat Repair, Measuring Valve-to-Guide Clearance, (Wobble method)), Cylinder – Piston (Piston Removal Notes, Piston Installation Note, Cylinder Block Installation Notes, Piston Ring, Piston Ring, Groove Wear, Piston Ring End Gap, Cylinder Inside Diameter, Piston Diameter, Boring, Honing), Carburetor Holder (Carburetor Holder Installation), Muffler (Muffler Removal Notes, Muffler Installation Notes).

Chapter 5 Clutch
Exploded View, Specifications, Special Tool, Clutch Fluid (Clutch Fluid Recommendation, Clutch Fluid Level Inspection, Clutch Fluid Changing, Clutch Line Air Bleeding), Clutch Master Cylinder (Master Cylinder Disassembly, Master Cylinder Assembly Note, Master Cylinder Installation, Inspection and Adjustment after Installation, Visual Inspection), Clutch Pipe (Installation Note), Clutch Slave Cylinder (Clutch Slave Cylinder Removal, Clutch Slave Cylinder Disassembly, Clutch Slave Cylinder Assembly), Clutch (Clutch Removal, Clutch Installation, Clutch Hub Disassembly/Assembly, Spring Plate Pusher Removal/Installation Note, Right Cover Installation Note, Right Cover Cleaning, Spring Plate Free Play Measurement, Spring Plate Free Play Adjustment, Clutch Plate Wear, Damage Inspection, Clutch Plate Warp Inspection, Clutch Housing Finger Inspection, Clutch Hub Spline Inspection, Cam Damper Inspection, Clutch Spring Free Length Measurement).

Chapter 6 Engine Lubrication System
Exploded View, Engine Oil Flow Chart, Specifications, Special Tools, Engine Oil and Oil Filter (Engine Oil Level Inspection, Engine Oil and/or Filter Change, Oil Filter and Bypass Valve Removal, Oil Filter and Bypass Valve Installation Notes, Bypass Valve Disassembly, Bypass Valve Assembly, Bypass Valve Cleaning and Inspection), Oil Pan (Oil Pan Removal, Oil Pan Installation Notes), Oil Pump and Relief Valve (Oil Pump and Relief Valve Removal, Oil Pump and Relief Valve Installation Notes, Oil Pump Disassembly, Oil Pump Assembly Notes, Oil Pump Drive Gear Removal, Oil Pump Drive Gear Installation, Oil Pump Gear Removal, Oil Pump Gear Installation Notes, Oil Pressure Measurement, Oil Pump Inspection, Relief Valve Inspection), Oil Screens (Oil Screen Removal, Oil Screen Installation Note, Oil Screen Cleaning and Inspection), Oil Pressure Switch.

Chapter 7 Engine Removal and Installation
Exploded View, Engine Removal, Engine Installation.

Chapter 8 Crankshaft and Transmission
Exploded View, Specifications, Special Tools, Sealant, Crankcase Splitting, Crankcase Assembly, Crankshaft/Connecting Rods (Removal/Installation, Crankshaft Removal, Crankshaft Installation Note, Connecting Rod Removal, Connecting Rod Installation Notes, Inspection/Maintenance, Crankshaft/Connecting Rod Cleaning, Connecting Rod Bend/Twist, Connecting Rod Big End Side Clearance, Connecting Rod Big End Bearing Insert/Crankpin Wear, Crankshaft Runout, Crankshaft Main Bearing Insert/Journal Wear, Crankshaft Side Clearance), Balancer (Removal, Installation Notes, Damper Inspection, Needle Bearing Wear), Alternator Shaft/Starter Motor Clutch (Chain Tensioner Removal, Chain Tensioner Installation Note, Chain and Sprocket Removal, Chain and Sprocket Installation Note, Alternator Shaft and Starter Clutch Removal, Alternator Shaft and Starter Clutch Installation Notes, Alternator Shaft Chain Wear, Chain Guide Wear, Damper Inspection, Starter Motor Clutch Inspection , Ball and Needle Bearing Wear), Transmission (External Shift Mechanism Removal, External Shift Mechanism Installation Notes, External Shift Mechanism Inspection, Transmission Shafts, Shift Drum, Forks, Transmission Removal/Disassembly, Transmission Shaft Removal, Transmission Shaft Installation, Transmission Shaft Disassembly, Transmission Shaft Assembly, Shift Drum and Fork Removal, Shift Drum and Fork Installation, Transmission Maintenance, Gear Backlash, Shift Fork Bending, Shift Fork/Gear Groove Wear, Shift Fork Guide Pin/Shift Drum Groove Wear, Gear Dog/Gear Dog Hole Damage, Ball and Needle Bearing Wear).

Chapter 9 Wheels/Tires
Exploded View, Specifications, Special Tools, Wheels (Rims) (Front Wheel Removal, Front Wheel Installation, Rear Wheel Removal, Rear Wheel Installation, Wheel Inspection, Axle Inspection, Wheel Balance), Tires (Removal, Installation, Inspection, Repair), Hub Bearings (Front Hub Bearing Removal, Front Hub Bearing Installation, Rear Hub Bearing Removal, Rear Hub Bearing Installation, Hub Bearing Inspection and Lubrication, Grease Seal Inspection and Lubrication), Speedometer Gear Housing (Disassembly, Assembly, Lubrication).

Chapter 10 Final Drive
Exploded View, Specifications, Special Tools, Final Gear Case Oil (Oil Level Inspection, Oil Change), Final Bevel Gears (Final Gear Case Removal, Final Gear Case Installation Notes, Final Gear Case Disassembly, Final Gear Case Assembly Notes, Pinion Gear Removal, Pinion Gear Installation, Pinion Gear Bearing Preload Adjustment, Final Gear Backlash and Tooth Contact Adjustment, Pinion Gear Joint Inspection, Bevel Gear Inspection, Oil Seal Inspection, Tapered Roller Bearing Inspection), Propeller Shaft (Removal, Installation, Inspection, Sliding Joint Inspection, Sliding Joint Lubrication), Front Bevel Gear (Case Removal, Case Installation, Case Disassembly, Case Assembly, Driven Shaft Bevel Gear Removal, Driven Shaft Bevel Gear Installation, Damper Cam Removal/Installation Notes, Front Driven Gear Bearing Preload Adjustment, Front Bevel Gear Backlash and Tooth Contact Adjustment, Bevel Gear Inspection, Oil Seal Inspection, Tapered Roller Bearing Inspection, Drive Gear Bearing Inspection, Damper Cam Inspection).

 

Chapter 11 Brakes
Exploded View, Specifications, Special Tool, Brake Adjustment (Front Brake, Rear Brake, Rear Master Cylinder Clevis Position Inspection, Rear Master Cylinder Clevis, Position Adjustment, Brake Pedal Position Inspection, Brake Pedal Position Adjustment, Calipers (Front Caliper Removal, Rear Caliper Removal, Caliper Installation Notes, Caliper Disassembly Notes, Caliper Assembly Notes, Fluid Seal Damage, Dust Seal and Cover Damage, Piston Cylinder Damage, Caliper Holder Shaft Wear), Brake Pads (Removal, Installation Note, Lining Wear), Master Cylinders (Front Master Cylinder Removal, Rear Master Cylinder Removal, Front Master Cylinder Installation Notes, Rear Master Cylinder Installation Notes, Front Master Cylinder Disassembly Notes, Rear Master Cylinder Disassembly Notes, Front Master Cylinder Assembly Notes, Rear Master Cylinder Assembly Notes, Master Cylinder Inspection (Visual Inspection), Reservoir Disassembly Notes, Reservoir Assembly Notes), Brake Pedal Removal/Installation, Disc (Wear, Cleaning, Warp), Brake Fluid (Level Inspection, Change, Bleeding the Brake Line), Brake Hoses (Inspection, Brake Hose Replacement).

Chapter 12 Suspension
Exploded View, Specifications, Special Tools, Front Fork (Air Pressure Adjustment, Fork Oil Change, Front Fork Removal, Front Fork Installation, Front Fork Disassembly, Front Fork Assembly, Inner Tube Inspection, Guide Bush Inspection, Oil Seal and Dust Seal Inspection, Spring Tension, Fork Oil Leak Inspection), Rear Suspension (Uni-Trak) (Rear Shock Absorber, Rear Shock Absorber Adjustment, Air Pressure Inspection, Damping Force Adjustment, Rear Shock Absorber Removal, Rear Shock Absorber Installation, Swing Arm, Swing Arm Removal, Swing Arm Installation and Alignment, Swing Arm Disassembly Notes, Swing Arm Assembly Note, Swing Arm Bearing Inspection, Swing Arm Lubrication, Tie-rod, Rocker Arm, Tie-rod/Rocker Arm Installation Notes, Tie-rod/Rocker Arm Needle Bearing Inspection, Tie-rod/Rocker Arm Sleeve Inspection, Uni-trak Linkage Lubrication).

Chapter 13 Steering
Exploded View, Special Tools, Steering Adjustment, Steering Inspection, Steering Removal/Installation, Steering Stem Removal, Steering Stem Installation, Steering Maintenance (Stem Bearing Lubrication, Bearing Wear, Damage, Grease Seal Deterioration and Damage, Steering Stem Warp), Handlebars (Left Handlebar Removal, Right Handlebar Removal, Installation Notes).

Chapter 14 Frame
Exploded View, Rear Frame (Removal, Installation), Fenders (Front Fender Removal, Front Fender Installation, Rear Fender Rear Section Removal/Installation, Rear Fender Front Section Removal, Rear Fender Front Section Installation), Fairings (Removal and Installation Precaution, Lower Fairing Removal, Lower Fairing Installation, Middle Fairing Removal, Middle Fairing Installation, Fairing Stay Removal, Fairing Stay Installation), Seat Cover Removal/Installation.

Chapter 15 Electrical System
Precautions, Wiring Diagram (US and Canada), Wiring Diagram (Other than US and Canada), Exploded View, Specifications, Special Tools, Battery (Precautions, Electrolyte, Electrolyte Level Inspection, Battery Charging, Battery Condition, Battery Initial Charging, Battery Ordinary Charging, Battery Test Charging), Alternator (Removal/Disassembly, Alternator Installation Notes, Alternator Assembly Notes), Alternator Troubleshooting (Test No 1-Battery Discharged, Test No2-Battery Overcharged, Test No3-Noise), Alternator Inspection (Ball Bearing Inspection, Stator Coil Inspection, Rotor Coil Inspection, Slip Ring Cleaning, Slip Ring Diameter, Carbon Brush Length, Rectifier Inspection, Regulator Inspection), Ignition System (Safety Instructions, Part Removal, Pickup Coil Removal/Installation Notes, Ignition Coil Removal/ Installation Notes, Spark Plug Removal/Installation Notes, Ignition System Troubleshooting, Ignition System Inspection, IC Igniter Inspection, Pickup Coil Inspection, Ignition Coil Inspection, Spark Plug Cleaning and Inspection, Spark Plug Gap), Electric Starter System (Parts Removal, Starter Motor Removal/ Installation Notes, Starter Motor Disassembly/Assembly, Inspection, Starter Relay Inspection, Brush Inspection, Brush Spring Inspection, Commutator Cleaning and Inspection, Armature Inspection, Brush Plate Inspection, Brush and Lead Assembly Inspection), Lighting System (Adjustment, Headlight Beam Horizontal Adjustment, Headlight Beam Vertical Adjustment, Parts Removal, Headlight Bulb Replacement Notes, Tail/Brake Light Bulb Replacement Notes, Tail/Brake Light Lens Removal/Installation Note, Turn Signal Light Bulb Replacement Note, License Plate Light Bulb Replacement Notes, Inspection, Headlight Reserve Lighting System Inspection), Cooling Fan System (Fan System Circuit Inspection, Fan Inspection, Cooling Fan Fuse Inspection), Meters and Gauges and Digital Clock (Parts Removal, Meter and Gauge Removal/Installation Note, Meter Replacement Notes, Bulb Replacement Notes), Inspection (Tachometer Inspection, Digital Clock Inspection, Fuel Gauge Operation Inspection, Water Temperature Gauge Operation Inspection), Switches and Sensors (Adjustment, Rear Brake Light Switch Inspection, Rear Brake Light Switch Adjustment, Parts Removal Removal Note, Switch Inspection, Fuel Level Sensor Inspection, Water Temperature Sensor Inspection), Junction Box (Fuse Removal, Fuse Installation Note, Fuse Inspection, Junction Box Fuse Circuit Inspection, Fan, Starter Circuit and Headlight Relay Inspection, Diode Circuit Inspection), Electrical Wiring (Wiring Inspection, Wiring Installation Note).

Appendix
Additional Considerations for Racing (Carburetor, Spark Plug, Spark Plug Inspection), Troubleshooting Guide, General Lubrication, Nut, Bolt, and Fastener Tightness, Tightness Inspection, Unit Conversion Table.

Supplement – 1989 Model

Supplement – 1990 Model

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