If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Disc Thickness Standard:
Front 5.3 
5.7 mm (0.21
0.22 in.)
Rear 4.8 
5.2 mm (0.19
0.20 in.)
Service Limit:
Front 5.0 mm (0.20 in.)
Rear 4.5 mm (0.18 in.)
Brake Disc Installation
Brake Disc Warp InspectionExternal 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 spring [C] is damaged in any way, replace it.
If the shift mechanism arm [D] is damaged in any way,
replace the shaft.
Check the s ...
External Shift Mechanism Removal
Remove:
Shift Lever (see Shift Pedal Removal)
Oil Pump Drive Gear (see Oil Pump Drive Gear Removal/
Installation in the Engine Lubrication System
chapter)
Circlip [A]
Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144
Remove:
Shift Shaft Assembly [A]
Washer [B] ...
Exploded View
10. US, CA, CAL and AU Models
11. ZX1000JD/KD
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
1. US, CA and CAL Models
2. ZX1000J Model
3. ZX1000K Model
4. AU Model
5. Face the large diameter side re ...