Category:
Sport Touring Motorcycle
Description:
The Kawasaki Concours (ZG1000) was a benchmark in the sport-touring segment, known for its comfortable ergonomics, substantial fairing for wind protection, and shaft drive for low maintenance. It was designed for long-distance touring with a passenger and luggage.
Competitors Era:
BMW K100LT/RS, Honda ST1100 Pan European, Yamaha FJ1200.
Engine:
1000cc inline-four cylinder engine.
Drivetrain:
Shaft drive for reduced maintenance.
Ergonomics:
Comfortable, upright riding position for long-distance comfort.
Aerodynamics:
Large, integrated fairing and windscreen for excellent wind and weather protection.
Luggage:
Standard integrated hard saddlebags.
Years Covered:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Regions Covered:
Global (assumed, based on typical manual distribution for major manufacturers)
Type:
Workshop Service Repair Manual
Primary Language:
English
Download Type:
Instant Download
Engine Mechanical:
Full engine disassembly, assembly, repair, and troubleshooting (including valve timing, piston/cylinder inspection, crankshaft, connecting rods).
Fuel System:
Carburetor system (identification, removal, installation, adjustment, troubleshooting), fuel pump, fuel lines, fuel tank.
Ignition System:
Ignition timing, CDI unit, ignition coils, spark plugs, wiring.
Transmission Drivetrain:
Clutch operation, transmission disassembly and assembly, gear shifting mechanism, final drive (shaft drive).
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat operation.
Electrical System:
Wiring diagrams, lighting system (headlights, taillights, turn signals), starter system, charging system (alternator, battery), instruments and controls.
Suspension System:
Front fork (disassembly, inspection, service, fluid replacement), rear suspension (shock absorber, linkage).
Braking System:
Front and rear brake systems (hydraulic), brake pad replacement, caliper service, brake fluid replacement and bleeding.
Chassis Frame:
Frame inspection, steering head bearing service, body panels (fairing, seats) removal and installation.
Wheels Tires:
Wheel bearing inspection and replacement, tire condition and pressure checks.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain/shaft drive lubrication, brake checks, tire pressure checks, general inspections.
Troubleshooting:
Diagnosis of common problems, electrical system troubleshooting, engine performance issues, starting problems, braking issues.
Repair Rebuild:
Detailed step-by-step procedures for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch lever adjustment, brake lever adjustment, suspension adjustments.
Technical Specifications:
Torque specifications for all fasteners, fluid capacities, electrical component specifications, wear limits.
Special Tools:
Identification and usage of special tools required for specific repair procedures.
Depth:
Comprehensive, covering basic to advanced repair and rebuilding procedures. Includes diagnostic information and detailed exploded views.
User Level:
Suitable for professional mechanics and experienced DIY enthusiasts.
Type:
Four-stroke, liquid-cooled, DOHC, inline-four cylinder
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
9.5:1 (typical, may vary slightly by year)
Starting System:
Electric starter
Horsepower Estimate:
Approx. 100-105 HP @ 8500 RPM (estimate, varies by year/tuning)
Torque Estimate:
Approx. 70-75 lb-ft @ 6500 RPM (estimate, varies by year/tuning)
Carburetion:
Four Keihin CVK32 constant velocity carburetors
Fuel Capacity:
6.1 US gallons (23 L)
Oil Change:
Every 3,000-4,000 miles or 6 months (refer to manual for exact intervals and oil type).
Valve Clearance Check:
Every 6,000-8,000 miles (critical for engine health).
Coolant Flush:
Every 2 years or specified mileage.
Engine Oil:
10W-40 API SG or higher (refer to manual for precise specification and capacity).
Coolant:
Ethylene glycol based coolant with distilled water (50/50 mix), specific type mentioned in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Final Drive Oil:
Hypoid gear oil, SAE 80 API GL-4 or GL-5 (refer to manual for capacity and specific type).
Cam Chain Tensioner:
Early models can have hydraulic cam chain tensioners that fail, leading to rattling noise and potential engine damage. Manual will cover inspection and replacement.
Charging System:
Stator and voltage regulator can be points of failure. Manual covers testing procedures.
Carburetor Issues:
Carburetor synchronization and cleaning are crucial. Clogged jets or vacuum leaks can affect performance. Manual provides detailed procedures.
Suspension Leaks:
Front fork seals can degrade over time, leading to leaks. Manual details fork seal replacement.
Wiring Harness Wear:
Aging wiring harnesses can develop corrosion or wear. Manual includes wiring diagrams for diagnosis.
Kawasaki Legacy:
Kawasaki has a long history of producing reliable and powerful motorcycles, particularly in the sportbike and sport-touring categories.
Zg1000 Development:
The Concours was developed as Kawasaki's answer to the burgeoning sport-touring market, aiming to combine the performance of a sportbike with the comfort and practicality of a touring machine.
Updates Over Years:
While the core design remained consistent, minor updates occurred throughout its production run, including cosmetic changes, improvements to suspension, and minor engine refinements. This manual covers the entire first generation, encompassing these variations.
Production Run:
1986-2003
Manufacturing Location:
Japan (primarily)
