Type:
Sport Touring Motorcycle
Segment:
Competed in the large-displacement sport-touring segment, offering comfort for long distances with sporty handling.
Engine Configuration:
Liquid-cooled, DOHC, 16-valve inline-four engine.
Aerodynamics:
Full fairing with adjustable windscreen for rider comfort and wind protection.
Cargo Capacity:
Integrated hard saddlebags for ample luggage carrying capability.
Engine:
Complete disassembly, assembly, inspection, and adjustment procedures for the 1000cc inline-four engine.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding; fuel pump inspection; fuel tank and lines.
Transmission:
Gearbox disassembly, inspection, and assembly; clutch operation and adjustment; driveshaft and final drive.
Suspension:
Front fork (telescopic) service, including seal replacement, oil level, and spring inspection; rear shock absorber and linkage service.
Brakes:
Hydraulic brake system service, including caliper overhaul, master cylinder inspection, brake fluid replacement, pad/shoe replacement, and bleeding procedures.
Electrical System:
Ignition system testing and adjustment; charging system (alternator, regulator/rectifier); lighting system; starting system; wiring diagrams and troubleshooting.
Cooling System:
Radiator, thermostat, water pump, and coolant replacement procedures.
Chassis And Bodywork:
Frame inspection, body panel removal/installation, fairing service, seat, and luggage system.
Maintenance:
Detailed periodic maintenance schedules, lubrication points, and routine checks.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.
Repair:
Step-by-step instructions for the removal, disassembly, inspection, repair, and reassembly of all major components and systems.
Adjustments:
Precise procedures for adjusting carburetor synchronization, valve clearances, clutch free play, and other critical settings.
Installation:
Guidance on the correct installation of replacement parts and accessories.
Depth:
Comprehensive, covering everything from basic fluid changes and adjustments to complete engine and transmission overhauls. Includes factory specifications, tolerances, and diagnostic procedures.
Quality:
High-resolution PDF, ensuring clear readability of text and diagrams.
Printable:
Yes, all 310 pages are printable for on-demand use.
Digital Binding:
N/A (Digital Download)
Digital Paper Type:
N/A (Digital Download)
Operating Systems:
Compatible with Windows, Mac, and Linux operating systems.
Software Requirement:
Adobe Reader or compatible PDF viewer required.
Type:
Inline-four cylinder, four-stroke
Displacement:
998 cc (60.9 cu. in.)
Bore X Stroke:
74.0 mm x 58.0 mm (2.91 in x 2.28 in)
Valve Train:
DOHC, 16 valves (4 per cylinder)
Cooling System:
Liquid-cooled
Horsepower Estimate:
Approximately 90-100 HP (varies by region and specific tuning).
Torque Estimate:
Approximately 70-80 lb-ft (varies by region and specific tuning).
Carburetion:
Four Keihin CVK (Constant Velocity) carburetors, 36mm.
Fuel Tank Capacity:
Approximately 6.3 US gallons (24 liters).
Length:
Approximately 90.7 inches (2305 mm)
Width:
Approximately 33.7 inches (855 mm)
Height:
Approximately 54.3 inches (1380 mm)
Dry Weight:
Approximately 637 lbs (289 kg)
Wet Weight:
Approximately 683 lbs (310 kg) (with all fluids).
Oil Change:
Recommended every 3,000-4,000 miles (4,800-6,400 km) or 6 months.
Valve Clearance Check:
Recommended every 7,500-10,000 miles (12,000-16,000 km).
Spark Plug Replacement:
Typically every 7,500-10,000 miles (12,000-16,000 km).
Engine Oil:
SAE 10W-40 API SG or higher. Capacity: Approximately 3.5 liters (3.7 US quarts) with filter change.
Coolant:
Permanent type antifreeze solution (ethylene glycol based), typically a 50/50 mix with distilled water. Capacity: Approximately 2.2 liters (2.3 US quarts).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Final Drive Oil:
API GL-5, SAE 80W-90 hypoid gear oil. Capacity: Approximately 160 ml.
Cam Chain Tensioner:
Some early models could develop noise from the automatic cam chain tensioner; manual replacement or adjustment might be necessary.
Carburetor Sync:
Carburetors can drift out of sync over time, affecting smooth running and fuel efficiency. Regular synchronization is crucial.
Charging System:
The regulator/rectifier unit can be a point of failure; proper diagnosis is important for maintaining battery charge.
Suspension Seals:
Front fork seals can eventually wear and leak, requiring replacement.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and reliability.
Zg1000 Concours:
The ZG1000 Concours was introduced in 1986 as a robust sport-touring machine, building on the success of the Voyager series. The A9 model represents a specific iteration within its production run.
Production Years:
1986-2006 (with various model codes and minor updates).
