
If any of the cylinder inside diameter measurements exceeds the service limit, replace the crankcase.
10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B]
Cylinder (Upper Crankcase) Inside Diameter
Standard: 75.994
76.006 mm
(2.9919
2.9924 in.)
Service Limit: 76.09 mm (2.996 in.)

Piston Installation
Piston Wear InspectionStarter Clutch Inspection
Remove:
Torque Limiter Cover (see Torque limiter Removal)
Turn the torque limiter [A] by hand. The torque limiter
should turn forward freely [B], but should not turn backward.
If the starter clutch does not operate as it should or if it
makes noise, go to the next step.
Disassem ...
Front Master Cylinder Installation
Apply silicone grease to the sliding surface of the brake
lever pivot bolt.
Tighten:
Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11
in·lb)
Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m,
52 in·lb)
Assemble the reservoir [A] and the bracket [B] as shown
in the figu ...
Exploded View
7. US, CA and CAL Models
8. Immobilizer System Equipped Models
9. ZX1000JD/KD
AD: Apply adhesive.
L: Apply a non-permanent locking agent.
R: Replacement Parts
13. Other than US, CA and CAL Models
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a ...