Kawasaki Z1000SX - Service manual > Throttle Grip and Cables, Throttle Body Assy

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, Wire, and Hose Routing section in the Appendix chapter.
• Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip.
• After installation, adjust each cable properly (see Throttle Control System Inspection in the Periodic Maintenance chapter).

WARNING Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Be sure the cables are routed correctly and properly adjusted.

Cable Lubrication

• Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter.

Throttle Body Assy

Idle Speed Inspection/Adjustment

• Refer to the Idle Speed Inspection/Adjustment in the Periodic Maintenance chapter.

Synchronization Inspection/Adjustment

• Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter.

Throttle Body Assy Removal

WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTICE Never drop the throttle body assy, especially on a hard surface. Such a shock to the body assy can damage it.

• Remove:
  Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  Air Cleaner Housing (see Air Cleaner Housing Removal)
  Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter)
• Disconnect:
  Intake Air Pressure Sensor #1 Connector [A]
  Intake Air Pressure Sensor #2 Connector [B]
  Subthrottle Valve Actuator Connector [C]
• For California and Southeast AsiaModels, pull off the vacuum hose [D].

• Disconnect:
  Main Throttle Sensor Connector [A]
  Subthrottle Sensor Connector [B]

• Loosen the locknuts [A].
• Turn the adjusters [B] to give the more free play.

• Remove:
  Lower Side Fairing (see Lower Side Fairing Removal in the Frame chapter)
  Throttle Cable Holder Clamp [A]
  Throttle Cable Lower Ends [B]

• Loosen the throttle body assy holder clamp bolts [A].

Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269

• Remove the throttle body assy [A] from the throttle body assy holders.
• Disconnect the injector connectors [B].
• Remove the clamps [C].
• After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.

WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.

NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage will occur.

Throttle Body Assy Installation

• Be sure to position the throttle body assy holder clamp in original position (see Throttle Body Assy Holder Installation in the Engine Top End chapter).
• Connect the injector connectors [A].
• Install the throttle body assy to the throttle body assy holders.
• Install the clamps [B].
• Tighten:
  Torque - Throttle Body Assy Holder Clamp Bolts: 2.9 N*m (0.30 kgf*m, 26 in*lb)

Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269

• Apply a thin coat of grease to the throttle cable lower ends.
• Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley.
  • The accelerator cable has a clamp [C].
• Install the clamp securely.

• Turn the throttle grip and make sure that the throttle pulley moves smoothly and return by spring force.
• Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Adjust:
  Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)
  Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter)

Throttle Body Assy Disassembly

1. Subthrottle Valve Actuator
2. Subthrottle Sensor
3. Main Throttle Sensor
4. Throttle Body Assy
5. Fuel Injectors
6. Delivery Pipe Assy

NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

• Remove the throttle body assy (see Throttle Body Assy Removal).
• Remove the delivery pipe assy mounting screws [A] to pull out the fuel injectors [B] from the throttle body assy together with the delivery pipe assy [C].

NOTE

• Do not damage the insertion portions of the injectors when they are pulled out from the throttle body.

• Pull out the fuel injectors [A] from the delivery pipe assy [B].

NOTE

• Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy.

NOTICE Never drop the primary fuel injector, especially on a hard surface. Such a shock to the injector can damage it.

Throttle Body Assy Assembly

• Before assembling, blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air.
• Replace the O-rings [A] of each fuel injector [B] with new ones.
• Apply engine oil to the new O-rings, insert them to the delivery pipe assy [C] and confirm whether the injectors turn smoothly or not.

• Replace the dust seals [A] with new ones.
• Apply engine oil to the new dust seals.
• Install the fuel injectors along with the delivery pipe assy to the throttle body.
• Tighten:
  Torque - Delivery Pipe Assy Mounting Screws: 3.4 N*m (0.35 kgf*m, 30 in*lb)
• Install the throttle body assy (see Throttle Body Assy Installation).

See also: