NOTE
Be sure the transmission and external shift mechanism are good condition.

When changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the rear wheel by hand.
Internal Circuit [C]
[1] LG Lead [2] G/R Lead [3] BK Lead
Special Tool - Hand Tester: 57001-1394

Gear Position Switch Resistance

If the tester reading is not as specified, replace the gear position switch with a new one.
Gear Position Switch Installation
Relay BoxExploded View
11. ZX1000JD/KD
AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening
torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
Specifications
...
Shift Fork/Gear Groove Wear Inspection
Measure the thickness of the shift fork ears [A], and measure
the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm ...
Battery Removal
Turn off the ignition switch.
Remove the front seat (see Front Seat Removal in the
Frame chapter).
Slide the red cap [A].
Disconnect the negative (–) cable [B] and then positive
(+) cable [C].
NOTICE
Be sure to disconnect the negative (–) cable first.
Remove the band [D] ...