After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident.
Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Cleaning Vehicle before Disassembly
Replacement PartsMeter Unit Circuit (ZX1000K Model)
1. Ignition Switch
2. Joint Connector F
3. Stop Watch Button
4. Oil Pressure Switch
5. Crankshaft Sensor
6. Water Temperature Sensor
7. Gear Position Switch
8. Intake Air Temperature Sensor
9. ESD ECU (ZX1000JD/KD)
10. ECU
11. Rear Wheel Rotation Sensor
12. Frame Ground 1
13. Engine ...
Connecting Rod Big End Side Clearance Inspection
Measure connecting rod big end side clearance.
Insert a thickness gauge [A] between the big end and either
crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard: 0.13 0.38 mm
(0.0051 0.0150 in.)
Service Limit: 0.58 mm (0.023 in.)
If the clearance exceeds ...
Throttle Grip and Cables
Free Play Inspection
Refer to the Throttle Control System Inspection in the Periodic
Maintenance chapter.
Free Play Adjustment
Refer to the Throttle Control System Inspection in the Periodic
Maintenance chapter.
Cable Installation
Install the throttle cables in accordance with the Cable,
...