Segment:
Sport Touring Motorcycle
Target Audience:
Long-distance touring riders, commuters seeking comfort and luggage capacity.
Key Competitors Era:
Honda ST1100 Pan European, BMW K1100LT/K1200LT, Yamaha FJ1200.
Touring Capability:
Shaft drive, large integrated luggage system (trunk and side cases), comfortable ergonomics, aerodynamic fairing.
Engine Type:
Liquid-cooled, inline-four cylinder, DOHC.
Drivetrain:
Shaft drive for low maintenance touring.
Owner Benefit:
Empowers owners to perform routine maintenance and repairs, saving money and extending the life of the motorcycle.
Professional Benefit:
Provides quick reference for specifications, procedures, and troubleshooting for workshop technicians.
Years Covered:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
Regions Covered:
North America, Europe, Japan (likely, based on standard manual distribution)
Estimated Page Count:
700+
Type:
Service and Repair Manual
Engine:
Complete overhaul, tuning, diagnostics, cooling system, lubrication system, fuel system (carburetor), ignition system, exhaust system.
Transmission:
Gearbox operation, clutch assembly, driveline, maintenance, repair, troubleshooting.
Brakes:
Hydraulic system, front and rear brake caliper service, master cylinder, brake fluid replacement, disc maintenance, ABS (if applicable to specific sub-models/years within the range).
Electrical:
Wiring diagrams, battery maintenance, charging system (alternator), starter motor, lighting, ignition coils, fuses, relays, instrument panel, troubleshooting.
Suspension:
Front fork service (oil replacement, seal replacement, spring rates), rear shock absorber maintenance, linkage lubrication, bearing service.
Frame And Body:
Frame inspection, fairing removal/installation, body panel repair, seat maintenance, luggage system (trunk, side cases) servicing.
Fuel System:
Carburetor synchronization, jetting specifications, float bowl cleaning, fuel pump operation, fuel line routing.
Cooling System:
Radiator, coolant type, coolant capacity, thermostat replacement, fan operation, bleed procedures.
Maintenance:
Scheduled maintenance, oil changes, filter replacements (oil, air), spark plug replacement, chain lubrication and adjustment, valve clearance checks and adjustment, coolant flush.
Repair:
Engine rebuild procedures, transmission overhaul, brake caliper rebuilding, fork seal replacement, electrical component replacement, starter clutch repair.
Troubleshooting:
Diagnostic flowcharts for common problems, electrical system fault finding, engine performance issues, starting problems.
Depth:
Comprehensive - covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures.
PDF Quality:
High-resolution, clear text and diagrams, searchable text.
Printable:
Yes, designed for printing specific sections or the entire manual.
Diagrams Clarity:
High-fidelity, detailed line drawings and exploded views.
Digital Format:
PDF (Portable Document Format)
Digital Media:
Downloadable file for digital access or local printing.
Engine Type:
Four-stroke, Liquid-cooled, DOHC, 16-valve, inline-four
Displacement:
997 cc (60.8 cu. in.)
Bore X Stroke:
72.0 x 61.0 mm (2.83 x 2.40 in.)
Horsepower Est:
95-100 hp @ 8,500 rpm (approximate, varies by year and market)
Torque Est:
60-65 lb-ft @ 6,000 rpm (approximate, varies by year and market)
Carburetion:
Four 32mm Keihin constant velocity carburetors
Fuel Capacity:
28 L (7.4 US gal)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition Type:
Electronic ignition (CDI) with electronic advance
Cooling Method:
Liquid-cooled
Oil Capacity W Filter:
4.5 L (4.8 US qt)
Oil Type Recommendation:
SAE 10W-40 API SG or SH
Transmission Type:
Constant mesh 6-speed sequential
Clutch Type:
Wet multi-disc
Final Drive:
Shaft drive, spiral bevel gear
Gear Ratios Overall:
Refer to manual for specific ratios (e.g., 1st: 2.733, 2nd: 2.056, 3rd: 1.600, 4th: 1.300, 5th: 1.074, 6th: 0.917)
Transmission Fluid Type:
API GL-4 SAE 80 hypoid gear oil
Transmission Fluid Capacity:
0.25 L (0.26 US qt)
Crash Test Ratings:
Not applicable to motorcycles in the same way as automobiles; manual focuses on mechanical safety.
Braking System:
Dual front disc brakes, single rear disc brake. Some later models may have ABS (Anti-lock Braking System) as an option or standard, verify specific model year.
Headlight System:
Dual Halogen headlights for improved nighttime visibility.
Frame Construction:
Steel diamond frame providing rigidity and rider protection.
Fairing Design:
Full fairing and windscreen for rider protection from elements and wind blast.
Lighting:
Full complement of front, rear, and indicator lighting for road legality and visibility.
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or 12 months.
Coolant Flush Replace:
Every 24,000 km (15,000 miles) or 24 months.
Drive Shaft Oil Change:
Every 12,000 km (7,500 miles) or 12 months.
Engine Oil Spec:
API SG or SH, SAE 10W-40
Coolant Type:
Ethylene glycol-based antifreeze coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Cam Chain Tensioner:
Some models may experience wear or failure of the automatic cam chain tensioner, leading to rattling noise. Manual covers inspection and replacement procedures.
Carburetor Issues:
Carburetor synchronization drift or clogging can affect performance. Manual provides detailed tuning and cleaning instructions.
Electrical Connector Corrosion:
In humid environments, electrical connectors can corrode, affecting lighting and ignition. Manual details locating and cleaning connectors.
Starter Clutch Wear:
Some owners report starter clutch wear over time. Manual provides diagnosis and repair procedures.
Fairing Vibration:
Minor fairing vibration issues can occur. Manual may offer insights into mounting and tightening procedures.
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries Motorcycle & Engine Company has a long history of innovation in motorcycle design and performance since the 1950s.
Concours 1000 Introduction:
Introduced in 1986 as the ZG1000 Concours, it was designed to compete in the growing sport-touring market.
Zg1000 Updates:
The first generation (ZG1000) received several minor updates throughout its production run (1986-2006 in most markets), with this manual covering the initial and mid-period iterations.
Concours 14 Transition:
The ZG1000 was eventually replaced by the more technologically advanced GTR1400 (Concours 14) in 2007.
Production Period Covered:
1986-2000
Manufacturing Locations:
Primarily Japan (for global export).
