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.
If the ratchet [A], pawls [B], pins [C] or springs [D] are damaged in any way, replace them.
If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m, 21 ft·lb)
If the lever or spring are damaged in any way, replace them.
If they are badly worn or if they show any damage, replace it.
External Shift Mechanism Installation
Wheels/TiresRear Fender Front Removal
Remove:
Flap and Rear Fender Rear (see Flap and Rear Fender
Rear Removal)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Exhaust Butterfly Valve Actuator (see Exhaust Butterfly
Valve Actuator Remova ...
Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Brake Hose Fitting Bolt [A]
Brake Hose Banjo Bolts [B]
Bolt [C]
Clamp ...
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 ...